N 1500SJ JLG Service Manual English

Service and Maintenance Manual
Model
1500SJ
3121262
May 24, 2019 - Rev N
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.
3121262 A-1
INTRODUCTION
REVISON LOG
Original Issue A - September 12, 2011

Revised B - November 9, 2011
Revised C - March 26, 2012
Revised D - May 16, 2012
Revised E - January 10, 2013
Revised F - February 20, 2013
Revised G - May 22, 2013
Revised H - September 30, 2015
Revised I - March 7, 2016
Revised J - November 8, 2016
Revised K - May 23, 2017
Revised L - May 30, 2018
Revised M - June 29, 2018 - Revised Covers
Revised N - May 24, 2019
A-2 3121262
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
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
3121262 i
TABLE OF CONTENTS

SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Axle Limit Switch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Steering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6 Drive/Steering Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.7 Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.8 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Swing Envelope Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.9 Oscillating Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.10 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.11 Wheel Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.12 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.13 Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Installation of the Wheel Drive on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Start Up and Running In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Connecting the Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Filling-up the Gearbox with Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Gearbox Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Changing the Lubricating oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Disassembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Inspection of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Final Test and Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3.14 Drive Hub - Reggiana Riduttori. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Symbol Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
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3.15 Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Roll and Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Hub-Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Hub-Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Motor Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.16 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3.17 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Disassembly and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.18 Procedure For Setting Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.19 Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3.20 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
Turntable/Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
Turntable/Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
3.21 Swing Speed Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3.22 Chassis Tilt Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3.23 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
3.24 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.25 Engine (Deutz 2011). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
Changing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
Cleaning the Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3.26 Deutz Engine - Td2.9l4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Check Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Replacing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
Replacing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
Replacing the Primary Fuel Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
Replacing the Fuel Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
Water in Fuel Sensing System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
Draining Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
Auxiliary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
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3.27 Deutz 2.9 L4 (Guo Iii) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
3.28 Deutz Td2011 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
3.29 Deutz 2.9l4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
3.30 Deutz EMR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
3.31 Bio Fuel in Deutz Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158
3.32 Deutz Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159
3.33 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-206
SECTION 4 - BOOM & PLATFORM
4.1 Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Broken Cable Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Platform Control Enable System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drive/Steer – Boom Function Interlock System (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Jib Stow System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Envelope Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Moment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom Control System (BCS) Functional Check (Push to Test) System . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2 Boom/Jib System Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Main Lift/Jib Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Jib Leveling During Automatic/Manual Envelope Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Jib Lift Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Jib Telescope Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Jib Swing Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Jib Swing Stow Sequence (Jib Pin Unlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Jib Swing Deploy Sequence (Jib Pin Lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Jib Lock Pin Lamp Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Swing/Axle Extend Retract Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Dual Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Jib Control During Over/Under Moment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Boom Recovery Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.3 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Platform/Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Platform/Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.4 Rotator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.5 Boom Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.6 Boom Disassembly/Assembly & Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.7 Load Sensing Pin Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
4.8 Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.9 Boom Lubrication Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
4.10 Platform Leveling Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
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4.11 Jib Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4.12 Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.13 Jib Straight Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
4.14 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4.15 Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4.16 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
One Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Two Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4.17 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Additional Inspection Required If:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
12 Year or 7000 Hour Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Additional Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4.18 Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Boom Section Re-Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
4.19 Broken Boom Cable Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Adjusting the Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
4.20 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
4.21 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Greasing Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Testing the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
4.22 Jib Rotator Torquing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108
4.23 Skyguard® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110
Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110
SkyGuard Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110
Diagnostics & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111
4.24 Bolt-on External Fall Arrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Axle Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Jib Level Cylinder (SN 0300209000 through 0300239990) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Jib Level Cylinder (SN 0300239991 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Platform Level Cylinder (SN 0300209000 through 0300239674) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
Platform Level Cylinder (SN 0300239675 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Boom Lift Cylinder (SN 0300209000 through 0300239990) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Boom Lift Cylinder (SN 0300239991 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
Jib Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
Jib Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
Main Boom Telescope Cylinder (SN 0300209000 through 0300244704). . . . . . . . . . . . . . . . . . . . . . . . . 5-127
Main Boom Telescope Cylinder (SN 0300244705 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133
5.4 Cylinder Length Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
5.5 Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
5.6 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-152
Set Up of the Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-152
Adjustments made at the Main Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-153
Adjustments Made at the Frame Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-153
Adjustments Made at the Platform Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-158
Adjustments Made at the Jib Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-159
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5.7 Drive Pumps (Rexroth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-165
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-165
Charge Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-168
Mechanical Centering of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-169
Hydraulic Centering of Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-169
High Pressure Relief Valve Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-170
Removal and inspection of charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-170
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-171
Removal and Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-173
5.8 Function Pump (Rexroth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-174
Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-174
Sealing the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-175
Disassembly and Assembly of the Complete Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-176
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-179
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-180
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-180
Pump Control Disassembly For Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-182
5.9 Drive Pumps (Sauer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-184
Port Locations and Gauge Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-184
Initial Startup Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-187
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-187
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-191
Removing The Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-195
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-195
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-195
Electric Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196
Shaft, Seal, and Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-197
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-198
Charge Check / HPRV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
Charge Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-201
Control Cutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-202
5.10 Function Pump (Sauer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-205
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-205
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-207
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-210
5.11 Gear pump (Sauer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-214
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-214
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-217
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-224
5.12 Drive & Function Pump Start Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-225
Start-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-225
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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
6.2 Machine Personality Settings and Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.3 Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Test Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.4 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.6 Control System Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Sensor #1 -Moment Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Sensor #2 - Main Boom Angle Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Sensor #3 - Main Boom Length Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Sensor #4 - Main Boom Cylinder Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Sensor #5 - Main Boom Transport Length Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Sensor #6 - Jib Level Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Sensor #7 - Jib Lock Pin Switch with both normally open and normally closed outputs . . . . . . . . . 6-52
Sensor #8 - Jib Stow Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Sensor #9 - Jib Lift Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Sensor #10 - Dual Capacity / Jib Transport Length Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Sensor #11 - Platform Level Cylinder Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Sensor #12 - Platform Level Angle Gravity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Sensor #13 - Turntable Swing Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
6.7 Jib Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6.8 CAN Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6.9 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
6.10 Calibrating Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
6.11 Calibrating Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
6.12 LSS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
6.13 Resetting The MSSO System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
6.14 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Platform Leveling Fault Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Fault Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
6.15 Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
STEP 2: BLEEDING THE PLATFORM VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS . . . . . . . . . . . . . 6-93
6.16 Calibrating Lift Crack Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
6.17 Calibrating Telescope Crack point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
6.18 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
6.19 Jib Sensor Calibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Calibrating the Jib Level Up and Down Valve Crackpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
6.20 Calibrating the Boom Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
Boom Control System Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
viii 3121262
TABLE OF CONTENTS

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
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
1500SJ ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
3121262 ix
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-2. Deutz Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
2-1. Engine Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-2. Hydraulic Oil Operating Temperature Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
3-1. Axle Limit Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Conventional Two Wheel Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Crab Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-4. Coordinated Steer Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-5. Chassis Component Location - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-6. Chassis Component Location - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-7. Turntable Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-8. Turntable Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-9. Oscillating Axle - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-10. Oscillating Axle - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-11. Fixed Axle - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-12. Fixed Axle - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-13. Axle Loctite Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-14. Steering Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-15. Wheel Drive Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-16. Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-17. Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-18. Drive Hub Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-19. Hub Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-20. Gearbox engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-21. Gearbox Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-22. Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-23. Drive Hub Special Tools - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3-27. Bearing Track Spacer Mounting C016117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-28. Oil Seal Spacer Mounting C125049 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-29. Bearing Spacer Mounting CO16117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-30. Assembly Diagram 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-31. Wrench For Ring Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-32. Anti-rotation Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-33. Anti-rotation Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-34. Anti-rotation Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-35. Assembly Diagram 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-36. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3-37. Reggiana Riduttori Hub - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3-38. Reggiana Riduttori Hub - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3-39. Swing System (SN 030020900 through 0300254531). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-40. Swing System (SN 0300254532 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3-41. Swing Drive - Motor Control Valve Disassembly (SN 030020900 through 0300254531) . . . . . . . . . . . . . . . . 3-68
3-42. Swing Drive - Motor and Brake Disassembly (SN 030020900 through 0300254531) . . . . . . . . . . . . . . . . . . . 3-69
3-43. Swing Drive - Main Disassembly(SN 030020900 through 0300254531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3-44. Swing Drive - Hub Shaft Disassembly(SN 030020900 through 0300254531). . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3-45. Swing Drive - Carrier Disassembly (SN 030020900 through 0300254531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3-46. Swing Drive (SN 0300254532 to Present)- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3-47. Swing Drive (SN 0300254532 to Present)- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3-48. Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
x 3121262
LIST OF FIGURES

3-49. Swing Brake 8 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3-50. Swing Brake 12 Spring Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3-51. Swing Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
3-52. Swing Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-53. Swing Drive Ports (SN 0300209000 through 0300254531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3-54. Swing Drive Lubrication (SN 0300209000 through 0300254531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3-55. Swing Drive Ports (SN 0300254532 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
3-56. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
3-57. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
3-58. Swing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
3-59. Swing Bearing Removal - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
3-63. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3-64. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
3-65. Auxiliary Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3-67. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
3-69. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
3-70. Location of the oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
3-71. Location of the Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
3-72. Location of Fuel Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
3-73. Components of Fuel Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
3-74. Components of Auxiliary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
3-75. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
3-76. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139
3-77. Detuz TD2011 L040 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
3-78. Detuz TCD2.9L4 Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
3-79. Detuz TCD2.9L4 Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
3-80. EMR 2 Engine Side Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
3-81. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
3-82. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
3-83. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148
3-84. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
3-85. EMR 2 Engine Plug Pin Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
3-86. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
3-87. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152
3-92. Counterweight Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-206
4-1. Boom Component Location - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2. Boom Component Location - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3. Location of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-4. Rotator Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-5. Boom Assembly - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-12. Boom Assembly Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4-13. Locations for Threadlocker Application - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
3121262 xi
LIST OF FIGURES

4-17. Load Pin Removal Tool, JLG PN 4846765 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4-18. Jib Assembly - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4-21. Jib Straight Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4-22. Powertrack Hosing - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4-25. Wire Rope Wire Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4-26. Wire Rope Kink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4-27. Sheave Groove Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4-28. Torque Sequence for Fly Extend Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
4-29. Wire Rope Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
4-30. Outer Mid Boom Extend/Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
4-31. Fly Boom Extend/Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
4-32. Wire Rope Adjustment Tools (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
4-33. Broken Boom Cable Proximity Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
4-34. Actuator Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
4-35. Rotary Actuator - Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
4-36. Rotary Actuator - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
4-37. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
4-38. JIb Rotator Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108
4-39. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109
4-40. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
4-41. Bolt-On External Fall Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114
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. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-16. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-17. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-18. Axle Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5-19. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5-20. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-21. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-22. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-23. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-24. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-25. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-26. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-27. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5-28. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
xii 3121262
LIST OF FIGURES

5-31. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5-32. Axle Lockout Cylinder (SN 0300209000 through 0300239674) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-33. Axle Lockout Cylinder (SN 0300239675 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5-34. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-36. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-37. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-38. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-39. Installation of Head Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-40. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-41. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-42. Hydrolock Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-43. Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-45. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-48. Jib Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-61. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
5-63. Jib Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5-64. Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5-65. Piston Seal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5-66. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5-67. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
5-69. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5-71. Cylinder Head Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5-74. Platform Level Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5-86. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
3121262 xiii
LIST OF FIGURES

5-88. Platform Level Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5-90. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
5-92. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5-93. Cylinder Head Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5-94. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5-97. Cylinder Head Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5-101. Boom Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5-110. Hydrolock Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5-111. Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5-116. Boom Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
5-117. Piston Diassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
5-120. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5-121. Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
5-125. Jib Lift Cylinder (SN 0300209000 through 0300239990) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5-126. Jib Lift Cylinder (SN 0300239991 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
5-135. Hydrolock Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5-136. Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5-138. Cylinder Barrel support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5-139. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5-141. Jib Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
xiv 3121262
LIST OF FIGURES

5-145. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5-147. Cylinder Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
5-149. Steer Cylinder (SN 0300209000 through 0300238017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
5-150. Steer Cylinder (SN 0300238018 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118
5-155. Jib Telescope Cylinder (SN 0300209000 through 0300213726) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
5-156. Jib Telescope Cylinder (SN 0300213727 through 0300244704) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-123
5-157. Jib Telescope Cylinder (SN 0300244705 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
5-158. Jib Telescope Cylinder Head Gland Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126
5-159. Jib Telescope Piston Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126
5-163. Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
5-177. Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
5-178. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135
5-181. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-136
5-182. Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
5-183. Cylinder Length Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5-184. Platform Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
5-185. Platform Valve Torque and Resistance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-142
5-186. Platform Valve Fitting Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-143
5-187. Jib Control Valve Identification - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-144
5-188. Jib Control Valve Identification - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
5-189. Jib Control Valve Torque and Resistance Specifications - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
5-190. Jib Control Valve Torque and Resistance Specifications - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-147
5-191. Jib Control Valve Fitting Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-148
5-192. Main Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-149
5-193. Main Valve Cartridge Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-150
5-194. Oil Sampling Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
5-195. Steer Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155
5-196. Function Pump - Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-174
5-197. Function Pump, Pressure and Flow Control - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-181
5-200. Piston Pump Cross Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-184
3121262 xv
LIST OF FIGURES

5-201. Port locations - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-185
5-202. Port locations - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-186
5-203. Charge Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-191
5-204. Control Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-192
5-205. Servo and System Pressure Gauge Port Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-194
5-206. Control Module And Solenoid Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196
5-207. Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-197
5-208. Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199
5-209. Charge Check / HPRV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
5-210. Charge Check / HPRV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-201
5-211. Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-202
5-212. Control Cutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-203
5-213. Fastener and Plug Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-204
5-214. Hydraulic Schematic - Sheet 1 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-228
5-223. Hydraulic Schematic - Sheet 10 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-237
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Control System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6-3. Analyzer Flow Chart - Sheet 1 of 5 (Software Version P7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-5. Analyzer Flow Chart - Sheet 3 of 5 (Software VersionP 7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6-8. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6-9. Ground Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-10. Platform Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6-11. Chasis Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6-12. BLAM Control Module (SN 030020900 through 0300248621). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-13. BLAM Control Module (SN 0300248622 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6-14. Jib Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-15. Analyzer Connecting Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6-16. Control System Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6-17. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
6-18. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
6-19. Boom Sensor Calibration Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
6-28. Boom Sensor Calibration Position 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
6-29. Fault Code Light Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131
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
xvi 3121262
LIST OF FIGURES

7-6. Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-7. Brad-Harrison M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-8. Phoenix Contact M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
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. Jib Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-26. Chassis Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-27. Chassis Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7-28. Turntable Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-29. Turntable Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-30. Console Box Harness (Without Skyguard) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7-31. Console Box Harness - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7-32. Console Box Harness-With Skugurad (SN 0300220152 through 0300234293) . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7-33. Console Box Harness - With Skyguard (SN 0300234294 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-34. Platform Valve Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7-35. Jib Valve Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7-38. Boom Length and Angle Harness - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7-39. Boom Length and Angle Harness - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7-40. Main Terminal Box Harness - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
7-41. Main Terminal Box Harness - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
7-42. Turntable Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
7-43. Turntable Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
7-44. Pump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
7-45. Chassis Harness - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
7-46. Chassis Harness - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
7-47. BLAM Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7-48. Beacon Light Harness- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
7-49. Beacon Harness- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
7-50. Platform Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
3121262 xvii
LIST OF FIGURES

7-51. Engine Harness - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
7-58. Ground Control Box Wiring Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7-59. Ground Control Box Wiring Diagram - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
7-60. Electrical Schematic - Sheet 2 of 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
7-68. Electrical Schematic - Sheet 10 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
xviii 3121262
LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-5 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-6 Deutz TCD2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Deutz TD2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-9 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-10 Mobil DTE 10 Excel 32 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-11 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-12 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-13 Mobil EAL 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-14 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-15 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-16 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2 Steering Assembly Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-3 Brake Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-4 Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade . . . . . . . . . . . . . . . . . . . . . . 3-24
3-5 Drive Hub Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-7 Engine Fault Codes TCD2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159
4-2 SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111
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
xix 3121262
LIST OF TABLES
TABLE NO. TITLE PAGE NO.

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 Platform Valve Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-142
5-34 Fitting Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-143
5-35 Jib Control Valve Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-147
5-36 Fitting Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-148
5-37 Cartridge Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-150
5-38 Torque Specs for Relief Valves into Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-170
5-39 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-180
5-40 Port information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-184
5-41 Electrical troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-188
5-42 Neutral difficult or impossible to find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-188
5-43 System operating hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-188
5-44 System will not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-189
5-45 System noise or vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-189
5-46 Sluggish system response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-190
5-47 Displacement Limiter Adjustment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-192
5-48 Fastener Size and Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-203
5-49 Plug Size and Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-203
6-1 Analyzer Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2 Machine Configuration Programming Information (Software Version P7.29). . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-3 Machine Configuration Programming Settings (Software Version P7.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-4 Machine Personality Settings and Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6-6 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
6-7 Machine Diagnostics Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
6-8 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
6-9 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
6-10 SkyGlazier Capacity Reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
6-11 Pipe Rack Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
6-12 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
6-13 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
3121262 xx
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA
Table 1-1. Operating Specifications Table 1-2. Dimensional Data
Capacity - ANSI Turning Radius (Axles Retracted)

Unrestricted 500 lbs (227 kg) Outside 22 ft. 6 in. (6.8 m)
Restricted 1000 lbs (454 kg) Inside 14 ft. 5 in. (4.4 m)
Capacity - CE & Australia Turning Radius (Axles Extended)

Unrestricted 500 lbs (230 kg) Inside 8 ft. (2.4 m)
Restricted 1000 lbs (450 kg) Outside 19 ft. 4 in. (5.9 m)
Maximum Travel Grade, stowed 40% Machine Height (stowed) 9 ft. 11 in. (3.04 m)
Position (Gradeability)
Machine Length (stowed) 61 ft. 8-5/8 in. (18.81 m)
Maximum Travel Grade, stowed 5°
Position (Side Slope) Platform Height
Unrestricted Capacity 150 ft. 1 in. (45.75 m)
Maximum Drive Speed 3.0 mph (4.8 kph) Restricted Capacity 130 ft. 2 in. (39.67 m)
Gross Machine Weight - Approximate 48000 lbs. (21772 kg) Horizontal Reach from centerline of rota-
tion
Ground Bearing Pressure - Maximum 113 psi (7.94 kgcm2) Unrestricted Capacity 80 ft. (24.38 m)
Restricted Capacity 64 ft. 11 in. (19.79 m)
Maximum Wind Speed 28 mph (12.5 m/s)
Horizontal Reach over end
Maximum Manual Force 90 lbs (400 N) Unrestricted Capacity 72 ft. 4 in. (24.38 m)
Maximum System Voltage 12 volts
Horizontal Reach over side
Maximum Main Relief Hyd. Pressure 4600 psi (317 Bar)
Unrestricted Capacity 73 ft. 9 in. (22.48 m)
Overall Width
Axles Retracted 8 ft. 2 in. (2.49 m)
Axles Extended 12 ft. 6 in. (3.8 m)
Wheelbase 12ft. 6in. (3.81 m)
Tailswing 5ft. 5-7/8 in. (1.6 m)
Ground Clearance (Axle) 12 in. (30.4 cm)
Ground Clearance (Chassis) 25.5 in. (64.7 cm)
3121262 1-1
1.3 CAPACITIES 1.5 ENGINE DATA

Table 1-3. Capacities
Deutz
Hydraulic Oil Tank 55 gal. (208 L) Table 1-5. Deutz TD2011L4 Specifications
Fuel Tank - Standard 31 gal. (117 L) Type Diesel
Fuel Tank - Optional 52.8 gal. (200 L) Number of Cylinders 4
Bore 3.7 in. (94 mm)
Drive Hub
Stroke 4.4 in. (112 mm)
Bonfiglioli 2.1 quarts (2 liters) ± 10%
Reggiana Riduttori 0.5 quarts (0.5 liters) ± 10% Total Displacement 190 cu. in. (3108 cm³)
Compression Ratio 17.5:1
Firing Order 1-3-4-2
1.4 TIRES
Output 75hp (56 kW)
Table 1-4. Tire Specifications Oil Capacity
Cooling System 5 Quarts (4.5 L)
Size 445/50D710
w/Filter 11 Quarts (10.5 L)
Load Range J Total Capacity 16 Quarts (15 L)
Ply Rating 18 Average Fuel Consumption 1.2 gph (4.1 lph)
Foam Fill Polyurethane HD (55 Durometer) Foam Idle Engine RPM 1200
Diameter 46.45 in. (117.9 cm) Mid Engine RPM 1800
Width 18 in. (45.7 cm) High Engine RPM 2475
Rim Size 15x28
Tire & Wheel Weight 867 lbs. (393 kg)
Max Tire Load 28600 lbs. (12973 kg) Table 1-6. Deutz TCD2.9L4 Specifications
Size 445/65-24 Type Diesel
Type Solid or Solid Non-Marking Number of Cylinders 4
Diameter 45.3 in. (115.1 cm) Bore 3.6 in. (92 mm)
Width 17.3 in. (43.9 cm) Stroke 4.3 in. (110 mm)
Rim Size 12.00-24 Total Displacement 178 cu. in. (2925 cm³)
Tire & Wheel Weight - Solid 960 lbs. (435.4 kg) Firing Order 1-3-4-2
Tire & Wheel Weight - Solid Non- 990 lbs. (449 kg) Output 74.2hp (55.4 kW)
Marking
Oil Capacity 2.4 Gallon (8.9 L)
Max Tire Load 28600 lbs. (12973 kg)
Coolant Capacity (System) 0.79 Gallon (3 L)
Average Fuel Consumption 1.2 gph (4.1 lph)
Min. Low Engine RPM 900
Mid Engine RPM 1800
Max. High Engine RPM 2500
High RPM set 2500 ± 50 rpm
Low RPM set 1200 ± 50 rpm
1-2 3121262
Table 1-9. Mobilfluid 424 Specs

Table 1-7. Deutz TD2.9L4 Specifications
SAE Grade 10W-30
Type Diesel
Gravity, API 29.0
Number of Cylinders 4
Density, Lb/Gal. 60° F 7.35
Bore 3.6 in. (92 mm)
Pour Point, Max -46° F (-43° C)
Stroke 4.3 in. (110 mm)
Flash Point, Min. 442° F (228° C)
Total Displacement 177 cu. in. (2900 cm³)
Viscosity
Output 74.2hp (55.4 kW)
Brookfield, cP at -18° C 2700
Oil Capacity 2.11 Gallon (8.0 L)
at 40° C 55 cSt
Coolant Capacity (System) 0.92 Gallon (3.5 L)
at 100 ° C 9.3 cSt
Average Fuel Consumption TBD
Viscosity Index 152
Min. Low Engine RPM 900
Mid Engine RPM 1800
Max. High Engine RPM 2600 Table 1-10. Mobil DTE 10 Excel 32 Specs
High RPM set 2500 ± 50 rpm
ISO Viscosity Grade #32
Low RPM set 1200 ± 50 rpm
Gravity API
Pour Point, Max -65° F (-54° C)
1.6 HYDRAULIC OIL
Flash Point, Min. 482° F (250° C)
Viscosity
Table 1-8. Hydraulic Oil
at 40° C 32.7cSt
Hydraulic System at 100° C 6.63 cSt
S.A.E. Viscosity
Operating
Grade at 100° F 32.7 cSt
Temperature Range
at 210° F 6.63 cSt
+0° to + 180° F 10W
(-18° to +83° C) cp at -30° F
+0° to + 210° F 10W-20, 10W30 Viscosity Index 164
(-18° to +99° C) Density (kg/l) @ 15° C 0.8468
+50° to + 210° F 20W-20 Density (lb/in3) @ 60° F 0.0305
(+10° to +99° C
NOTE: Hydraulic oils require anti-wear qualities at least API Ser- Table 1-11. UCon Hydrolube HP-5046
vice Classification GL-3, and sufficient chemical stability
for mobile hydraulic system service. Type Synthetic Biodegradable
NOTE: Aside from JLG recommendations, it is not advisable to Specific Gravity 1.082
mix oils of different brands or types, as they may not con- Pour Point, Max -58° F (-50° C)
tain the same required additives or be of comparable vis- pH 9.1
cosities.
Viscosity
at 0° C (32° F) 340 cSt (1600 SUS)
at 40° C (104° F) 46 cSt (215 SUS)
at 65° C (150° F) 22 cSt (106 SUS)
Viscosity Index 170
3121262 1-3
1.7 MAJOR COMPONENT WEIGHTS

Table 1-12. Mobil EAL H 46 Specs
Type Synthetic Biodegradable

ISO Viscosity Grade 46 DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT
WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT-
Density at 15° C 0.874
FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Pour Point -49° F (-45° C) Table 1-15. Component Weights
Flash Point 500° F (260° C)
Components LBS. KG.
Operating Temp. -20 to 200° F (-29 to 93° C)
7.64 lb/gal Counterweight 9500 4309
Weight
(0.9 kg/L)
Tire and Wheel 867 393
Viscosity
at 40° C 48.8 cSt Drive Hub & Motor 275.5 123
at 100° C 7.8 cSt Swing Drive 290 132

Viscosity Index 145
Engine Assembly 1275 579
Table 1-13. Mobil EAL 46 Specs Complete Boom (including jib) 12513 5676
Type Synthetic Biodegradable Platform 36 x 96 245 111
ISO Viscosity Grade 46 Platform 36 x 72 195 89

Density at 15 °C 0.93 Axle Extension Cylinder 92 42
Pour Point -27° F (-33° C)
Axle Lockout Cylinder 74 33.75
Flash Point 568 °F (298° C)
Jib Level Cylinder 146.8 66.6
Operating Temp. -20 to 200° F (-29 to 93° C)
7.64 lb/gal Platform Level 76 34
Weight
(0.9 kg/L) Boom Lift Cylinder 787 357
Viscosity
Jib Lift Cylinder 186 84
at 40° C 43.3 cSt
at 100° C 7.7 cSt Jib Lock Cylinder 22.3 10.1
Viscosity Index 149 Steer Cylinder 49 22
Table 1-14. Exxon Univis HVI 26 Specs Jib Telescope Cylinder 130.5 59
Specific Gravity 32.1 Boom Telescope Cylinder 1432 650

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.
1-4 3121262
16A,16B
12,14
15
19
9B
5
4
4
13
7 10A,10B,11
8
9A
17
2,3
1
4 4
18
Figure 1-1. Maintenance and Lubrication Diagram
3121262 1-5
1.8 OPERATOR MAINTENANCE 2. Swing Gearbox

a. Swing Gearbox (SN 030020900 through
NOTE: The following numbers correspond to those in Figure 1-1.,
0300254531)
Maintenance and Lubrication Diagram.
Table 1-16. Lubrication Specifications.
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API
CC/CD class, MIL-L-2104B/MIL-L-2104C
Super Synthetic-Based Oil, Non-Flammable. Withstands temperatures within -
Lube® 45° to 450°F (-43° to 232° C). JLG PN 3020042.
b. Swing Gearbox (SN 0300254532 to Present)
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-

MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
FREQUENCIES MUST BE INCREASED ACCORDINGLY.
1. Swing Bearing - Remote Lube
MAE36090
Lube Point(s) - 2 Grease Fitting
Capacity - A/R
Lube - MPG Lube Point(s) - Fill Plug
Interval - Every 3 months or 150 hours of operation. Capacity - 79 ounces (2.3 L)
Lube - GL-5
Interval - Check level every 150 hrs/Change every
1200 hours of operation. Fill to cover ring gear.
1-6 3121262
3. Swing Brake 4. A. Wheel Drive Hub - Bonfiglioli

a. Swing Brake (SN 030020900 through 0300254531)
Lube Point(s) - Level/Fill Plug

Capacity - 2.1 quarts (2 liters) ± 10%
Lube - EPGL
Interval - Change after first 150 hours then every
1200 hours of operation
b. Swing Brake (SN 0300254532 to Present)
Comments - Place Fill port at 12 o’clock position and
Check port at 8 o’clock position. Pour lubricant into fill
port until it just starts to flow out of check port.
B: Wheel Drive Hub - Reggiana Riduttori
Lube Point(s) - Level/Fill Plug

Capacity - 0.5 quarts (0.5 liters) ± 10%
Lube - EPGL
Interval - Change after first 150 hours then every
MAE36100 1200 hours of operation
Comments - Place Fill port at 12 o’clock position and
Lube Point(s) - Fill Plug Check port at 3 o’clock position. Pour lubricant into fill
Capacity - 2.7 ounces (80 ml) port until it just starts to flow out of check port.
Lube - DTE24
Interval - Check level every 150 hrs/Change every
1200 hours of operation.
3121262 1-7
5. Hydraulic Return Filter 7. Hydraulic Oil
FULL LEVEL (HOT OIL)

Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and every FULL LEVEL (COLD OIL)
300 hours thereafter or as indicated by condition
indicator.
6. Hydraulic Charge Filter
Lube Point(s) - Fill Cap

Capacity - Standard 31 gallons (117 liters)
Optional 52.8 gallons (200 liters)
Lube - HO
Interval - Check level daily. Change every 2 years or
1200 hours of operation.
8. Suction Strainers (In Tank)

Interval - Change after first 50 hours and every 300
hours thereafter or as indicated by condition
indicator.
Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation.
Remove and clean at time of hydraulic oil change.
1-8 3121262
9. A. Oil Change w/Filter - Deutz 2011
MINIMUM OIL
LEVEL
MAXIMUM OIL
LEVEL
MINIMUM LEVEL,
OIL HOT
Lube Point(s) - Fill Cap/Spin-on Element MAXIMUM LEVEL,
OIL HOT
Capacity -
5 Quarts (4.5 L) Cooling System
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L) Total Capacity MINIMUM LEVEL,
OIL COLD
Lube - EO MAXIMUM LEVEL,
OIL COLD
Interval - Check level daily; change every 500 hours or
six months, whichever comes first. Adjust final oil level NOTE: Hot oil checks should not be made until the engine
has been shut down for a period of 5 minutes.
by mark on dipstick. Refer to Figure 1-2., Deutz Engine
Dipstick.
Figure 1-2. Deutz Engine Dipstick
10. A. Fuel Filter - Deutz 2011
B. Oil Change w/Filter - Deutz TCD2.9

Interval - Every year or 600 hours of operation.
Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 2.4 Gallon (8.9 L)
Lube - EO
six months, whichever comes first. Adjust final oil level
by mark on dipstick.
3121262 1-9
B. Fuel Filter - Deutz TCD2.9 12. Fuel Pre-Filter TCD2.9

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

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

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

1-10 3121262
14. A. Air Filter - DEUTZ 2011 15. Platform Filter

Interval - Every 6 months or 300 hours of operation or as Lube Point(s) - Replaceable Element
indicated by the condition indicator. Interval - Change after first 50 hours and then every year
or 600 hours of operation thereafter.
B. Air Filter - Deutz TCD2.9
16. Boom
Lube Point(s) - Apply to wear pad contact paths

Lube - Super Lube®
Interval - As needed. Refer to the Section 4 - Boom for
detailed procedures.
17. Optional Fuel Filter/Water Separator

Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator
Comments - Check Dust Valve daily.

Interval - Drain water daily; Change every year or 600
hours of operation.
3121262 1-11
Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
1-12 3121262
To rqu e
Torqu e
Torq ue
Tor que
Torq ue
3121262 1-13
Torq ue
Tor que
Torqu e
Torq ue
Cl amp L oa d
To rqu e
To rque
1-14 3121262
To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
3121262 1-15
To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue
Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
1-16 3121262
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.
3121262 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 Annually, no later than 13 months from the date of Owner, Dealer, or User Factory-Trained Service Service and Maintenance Manual
Inspection 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.
NOTE: Inspections forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
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
Your safety, and that of others, is the first consideration when parts should remain in their containers until they are
engaging in the maintenance of equipment. Always be con- ready to be used.
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 3121262
SECTION 2 - GENERAL
Component Disassembly and Reassembly Bolt Usage and Torque Application

When disassembling or reassembling a component, complete
the procedural steps in sequence. Do not partially disassemble
or assemble one part, then start on another. Always recheck SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
your work to assure that nothing has been overlooked. Do not LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
make any adjustments, other than those recommended, with-
out obtaining proper approval. 1. Always use new replacement hardware when installing
locking fasteners. Use bolts of proper length. A bolt
Pressure-Fit Parts which is too long will bottom before the head is tight
against its related part. If a bolt is too short, there will
When assembling pressure-fit parts, use a molybdenum disul- not be enough thread area to engage and hold the part
fide base compound or equivalent to lubricate the mating sur- properly. When replacing bolts, use only those having
face. the same specifications of the original, or one which is
equivalent.
Bearings
2. Unless specific torque requirements are given within the
1. When a bearing is removed, cover it to keep out dirt and text, standard torque values should be used on heat-
abrasives. Clean bearings in nonflammable cleaning sol- treated bolts, studs, and steel nuts, in accordance with
vent and allow to drip dry. Compressed air can be used recommended shop practices. (See Torque Chart Sec-
but do not spin the bearing. tion 1.)
2. Discard bearings if the races and balls (or rollers) are pit-
ted, scored, or burned. Hydraulic Lines and Electrical Wiring
3. If bearing is found to be serviceable, apply a light coat of Clearly mark or tag hydraulic lines and electrical wiring, as well
oil and wrap it in clean (waxed) paper. Do not unwrap as their receptacles, when disconnecting or removing them
reusable or new bearings until they are ready to install. from the unit. This will assure that they are correctly rein-
stalled.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer or
bore, apply pressure to the outer race. If the bearing is to
Hydraulic System
be installed on a shaft, apply pressure to the inner race. 1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
Gaskets flush the entire system.
Check that holes in gaskets align with openings in the mating 2. Disassemble and reassemble parts on clean work sur-
parts. If it becomes necessary to hand-fabricate a gasket, use face. Clean all metal parts with non-flammable cleaning
gasket material or stock of equivalent material and thickness. solvent. Lubricate components, as required, to aid
Be sure to cut holes in the right location, as blank gaskets can assembly.
cause serious system damage.
Lubrication
Service applicable components with the amount, type, and
grade of lubricant recommended in this manual, at the speci-
fied intervals. When recommended lubricants are not avail-
able, consult your local supplier for an equivalent that meets
or exceeds the specifications listed.
Battery
Clean battery using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After cleaning,
thoroughly dry battery and coat terminals with an anti corro-
sion compound.
Lubrication and Servicing

Components and assemblies requiring lubrication and servic-
ing are shown in the Lubrication Chart in Section 1.
3121262 2-3
SECTION 2 - GENERAL
2.3 LUBRICATION AND INFORMATION Hydraulic Oil

Hydraulic System 1. Refer to Section 1 for recommendations for viscosity
ranges.
1. The primary enemy of a hydraulic system is contamina-
tion. Contaminants enter the system by various means, 2. JLG recommends Mobilfluid 424 hydraulic oil, which has
e.g., using inadequate hydraulic oil, allowing moisture, an SAE viscosity of 10W-30 and a viscosity index of 152.
grease, filings, sealing components, sand, etc., to enter
when performing maintenance, or by permitting the NOTE: Start-up of hydraulic system with oil temperatures below -
pump to cavitate due to insufficient system warm-up or 15 degrees F (-26 degrees C) is not recommended. If it is
leaks in the pump supply (suction) lines. necessary to start the system in a sub-zero environment, it
will be necessary to heat the oil with a low density, 100VAC
2. The design and manufacturing tolerances of the compo- heater to a minimum temperature of -15 degrees F
nent working parts are very close, therefore, even the (-26 degrees C).
smallest amount of dirt or foreign matter entering a sys-
tem can cause wear or damage to the components and
3. The only exception to the above is to drain and fill the
generally results in faulty operation. Every precaution
system with Mobil DTE 13 oil or its equivalent. This will
must be taken to keep hydraulic oil clean, including
allow start up at temperatures down to -20 degrees F
reserve oil in storage. Hydraulic system filters should be
(- 29 degrees C). However, use of this oil will give poor
checked, cleaned, and/or replaced as necessary, at the
performance at temperatures above 120 degrees F (49
specified intervals required in the Lubrication Chart in
degrees C). Systems using DTE 13 oil should not be oper-
Section 1. Always examine filters for evidence of metal
ated at temperatures above 200 degrees F
particles.
(94 degrees C) under any condition.
3. Cloudy oils indicate a high moisture content which per-
mits organic growth, resulting in oxidation or corrosion. Changing Hydraulic Oil
If this condition occurs, the system must be drained,
flushed, and refilled with clean oil. 1. Filter elements must be changed after the first 50 hours
4. It is not advisable to mix oils of different brands or types, of operation and every 300 hours (unless specified oth-
as they may not contain the same required additives or erwise) thereafter. If it is necessary to change the oil, use
be of comparable viscosities. Good grade mineral oils, only those oils meeting or exceeding the specifications
with viscosities suited to the ambient temperatures in appearing in this manual. If unable to obtain the same
which the machine is operating, are recommended for type of oil supplied with the machine, consult local sup-
use. plier for assistance in selecting the proper equivalent.
Avoid mixing petroleum and synthetic base oils.
NOTE: Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing components. 2. Use every precaution to keep the hydraulic oil clean. If
the oil must be poured from the original container into
another, be sure to clean all possible contaminants from
the service container. Always clean the mesh element of
the filter and replace the cartridge any time the system
oil is changed.
3. While the unit is shut down, a good preventive mainte-

nance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a
functional check of each system, before placing the
machine back in service.
Lubrication Specifications
Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however, multi-pur-
pose greases usually have the qualities which meet a variety of
single purpose grease requirements. Should any question
arise, regarding the use of greases in maintenance stock, con-
sult your local supplier for evaluation. Refer to Section 1 for an
explanation of the lubricant key designations appearing in the
Lubrication Chart.
2-4 3121262
SECTION 2 - GENERAL
2.4 CYLINDER DRIFT Cylinder Leakage Test

Cylinder oil must be at stabilized ambient temperature before
Theory 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.
3121262 2-5
SECTION 2 - GENERAL
2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT
GUIDELINES NOTE: This instruction applies to repairs, or modifications to the
Filament wound bearings. machine and to welding performed from the machine on
an external structure, or component,
1. Pinned joints should be disassembled and inspected if
the following occurs:
Do the Following When Welding on JLG 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
the following is observed: • Ground only to structure being welded.
a. Frayed or separated fibers on the liner surface. Do NOT Do the Following When Welding on JLG
b. Cracked or damaged liner backing. Equipment
c. Bearings that have moved or spun in their housing.
• Ground on frame and weld on any other area than the
d. Debris embedded in liner surface. chassis.
3. Pins should be replaced if any of the following is • Ground on turntable and weld on any other area than the
observed (pin should be properly cleaned prior to turntable.
inspection):
• Ground on the platform/support and weld on any other
a. Detectable wear in the bearing area. area than the platform/support.
b. Flaking, pealing, scoring, or scratches on the pin sur- • Ground on a specific boom section and weld on any other
face. area than that specific boom section.
c. Rusting of the pin in the bearing area.
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
4. Re-assembly of pinned joints using filament wound valves, electrical wiring, or hoses to be between the
bearings. grounding position and the welded area.
a. Housing should be blown out to remove all dirt and
debris bearings and bearing housings must be free
of all contamination. FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
b. Bearing / pins should be cleaned with a solvent to PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
remove all grease and oil filament wound bearing RING, BOOM WIRE ROPES ETC.)
are a dry joint and should not be lubricated unless
otherwise instructed (i.e. sheave pins).
c. Pins should be inspected to ensure it is free of burrs,
nicks, and scratches which would damage the bear-
ing during installation and operation.
2-6 3121262
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Pre-Delivery1 Annual3

or Frequent2 (Yearly)
Inspection Inspection
Boom Assembly
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Boom Assembly 14
Platform Assembly
Platform 1,2
Railing 1 1,2
Gate 1 1,5
Floor 1 1,2
Rotator 15 15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly
Swing Bearing 1,2,14 1,2,3,13,14
Oil Coupling
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly
Tires 16,17,18 16,17,18
Wheel Nuts/Bolts 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Extendable Axle Systems 5,8 5,8
Steer Components
Spindle Thrust Bearing/Washers 1,2
Drive Hubs 11 11
3121262 2-7
SECTION 2 - GENERAL
INTERVAL

Functions/Controls
Platform Controls 6 6
Ground Controls 6 6
Function Control Locks, Guards, or Detents 5 5
Footswitch 5 5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems 5 5
Drive Brakes 5 5
Swing Brakes 5 5
Auxiliary Power 5 5
Power System
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 11 11
Air/Fuel Filter 7 7
Exhaust System 9 9
Batteries 19
Battery Fluid 11 11
Battery Charger 5
Fuel Reservoir, Cap, and Breather 1,5 1,5
Hydraulic/Electric System
Hydraulic Pumps 1,2,9 1,2,9
Hydraulic Cylinders 1,2,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,2 1,2
Hydraulic Hoses, Lines, and Fittings 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1,5 1,5
Hydraulic Filter 7 7
Hydraulic Fluid 7,11 7,11
Electrical Connections 20 20
Instruments, Gauges, Switches, Lights, Horn 5,23
General
Operation and Safety Manuals in Storage Box 21 21
ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only) 21
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
2-8 3121262
SECTION 2 - GENERAL
INTERVAL

Annual Machine Inspection Due 21 21

No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to each sale, lease, or delivery
2 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
3 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
3121262 2-9
SECTION 2 - GENERAL
1001159163-B
Figure 2-1. Engine Operating Temperature Specifications - Deutz
2-10 3121262
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
3121262 2-11
SECTION 2 - GENERAL
NOTES:
2-12 3121262
SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES AND WHEELS 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
Tire Inflation with a lug wrench, then immediately have a service garage or
The air pressure for pneumatic tires must be equal to the air dealer tighten the lug nuts to the proper torque. Over-tighten-
pressure that is stenciled on the side of the JLG product or rim ing will result in breaking the studs or permanently deforming
decal for safe and proper operational characteristics. the mounting stud holes in the wheels.
The proper procedure for attaching wheels is as follows:
Tire Damage
1. Start all nuts by hand to prevent cross threading. DO
For pneumatic tires, JLG Industries, Inc. recommends that NOT use a lubricant on threads or nuts.
when any cut, rip, or tear is discovered that exposes sidewall or
tread area cords in the tire, measures must be taken to remove 2. Tighten nuts in the following sequence:
the JLG product from service immediately. Arrangements
must be made for replacement of the tire or tire assembly.
For polyurethane foam filled tires, JLG Industries, Inc. recom-

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

inches (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies which

exceeds 1 inch (2.5 cm) in any direction
• any punctures which exceed 1 inch in diameter
• any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria, the

tire must be inspected on a daily basis to insure the damage
hasn’t propagated beyond the allowable criteria.
3. The tightening of the nuts should be done in stages. Fol-
Wheel and Tire Replacement lowing the recommended sequence, tighten nuts per
wheel torque chart.
The rims installed on each product model have been designed
for stability requirements which consist of track width, tire Table 3-1. Wheel Torque Chart
pressure, and load capacity. Size changes such as rim width,
TORQUE SEQUENCE
center piece location, larger or smaller diameter, etc., without
written factory recommendations, may result in an unsafe 1st Stage 2nd Stage 3rd Stage
condition regarding stability. 45 ft. lbs. 100 ft. lbs. 180 ft. lbs.
(60 Nm) (140 Nm) (252 Nm)
Wheel Installation
It is extremely important to apply and maintain proper wheel 4. Wheel nuts should be torqued before first road use and
mounting torque. after each wheel removal. Check and torque every 3
months or 150 hours of operation.
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE

TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS
MATCHED TO THE CONE ANGLE OF THE WHEEL.
3121262 3-1
3.2 AXLE EXTENSION SYSTEM will be automatically limited to +/- 25 degrees anytime the
axles are not fully extended. If the wheel angle is more than
NOTE: The boom must be oriented between the rear wheels to +/- 25 degrees when the axle retract command is engaged,
extend or retract the axles. the control system will automatically reduce the wheel angle
to 25 degrees during axle retraction.
The Axle Extension System allows each of the four axles to be NOTE: For more detailed information concerning system adjust-
extended and retracted together while maintaining full steer- ment and operation, refer to Section 6 - JLG Control Sys-
ing control as the machine is driven. The system allows the tem.
axles to extend or retract only while the boom is in the trans-
port position and in order to minimize wheel scrubbing during
axle movement, a minimum drive speed must be attained 3.3 AXLE LIMIT SWITCH ADJUSTMENT PROCEDURE
before axle extension/retraction will be permitted. The system
1. Fully extend the axles.
uses four limit switches (one at each axle) to sense when the
axles are fully extended. If any of the switches are not made, 2. Initially position the limit switch arm straight.
the control system considers the axles retracted. To extend/
retract the axles, the user engages the axle extend/retract 3. Select the mounting plate bolt pattern to position the
switch on the platform console and the drive control at the switch roller within 0.125 inches (3.1 mm) from the edge
same time. The axle set indicator will be off when the axles are of the axle cutout. It may be necessary to reposition the
not fully extended and the axle extend/retract switch is not switch arm ±10° to accomplish this.
engaged. It will flash while the axles are extending or retract- 4. Ensure the arm will clear the axle (without bottoming
ing and will be on constantly when the axles are fully out to 70° stroke of the switch) in the retracted position.
extended. With the axles not fully extended, the boom is
restricted to operation within the transport position. If a signal 5. Check for proper operation. Axle set light is to deacti-
from any axle extend sensing switch is lost when the boom vate when the axle is retracted 0.625 inches (16 mm)
beyond the transport position, the axle set indicator will flash maximum from fully extended.
and drive/steer functions will be disabled until the boom is
brought back into the transport position. The steering angle
Figure 3-1. Axle Limit Switch Adjustment
3-2 3121262
3.4 DRIVE SYSTEM

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

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

ment and operation, refer to Section 6 - JLG Control Sys-
tem.
Figure 3-3. Crab Steer Mode
3121262 3-3
3.6 DRIVE/STEERING SPEED CONTROL enabled, the DOS indicator will be illuminated continuously
and a 3-second enable timer will be started and will continue
The Drive/Steering Speed Control system uses the steering for 3 seconds after the end the last drive/steer command. If the
sensors from the steering control system to increase operator timer expires, the DOS override switch must be re-engaged to
control and comfort by reducing the effect of turning the enable drive/steer.
chassis on the resulting lateral platform speed. The system
proportionally varies the drive speed based on the predicted Swing Envelope Service Mode
turning radius of the chassis for conventional two wheel steer
modes. The tighter the turn the slower the allowable drive NOTE: If the axles are in the retracted position, boom swing is
speed. As crab steer does not steer on a radius, low speed restricted to between the rear wheels (40 degrees).
drive is maintained regardless of steer angle.
The Swing Envelope Service Mode is used if the boom is
NOTE: For more detailed information concerning system adjust- swung past the rear tires with the axles retracted, there is a dis-
ment and operation, refer to Section 6 - JLG Control Sys- agreement fault between the DOS proximity switch and the
tem. turntable angle sensors, or there is a failed turntable angle
sensor. (Drive and swing are disabled during these events.)
This allows swing and drive functions to enable turntable
3.7 TRACTION CONTROL SYSTEM swing in the correct direction to return the boom between the
The traction control system uses the steering sensors from the rear wheels in the event the boom is beyond the swing enve-
steering control system to optimize the performance of the lope when the axles are retracted.
drive system. This is especially important due to the disparity Swing Envelope override is accessible in Access Level 1. Using
of wheel speeds generated between the inside and outside
wheels of the extended axle chassis with large steering angle
capability. The steering sensors are used to predict the rolling the Left and Right arrow keys until the screen
path and therefore the required wheel speed of each wheel as shown below is reached.
the steering angles change and steering modes change. The
control system can then command the ideal flow from each of
the two drive pumps, one for the right side of the machine and
one for he left side. Two flow dividers, one for the right side
front to back and one for the left side front to back absorb the
variation in wheel speed front to back.

tem.
3.8 DRIVE ORIENTATION SYSTEM

The Drive Orientation System (DOS) is intended to indicate to
the operator conditions that could make the direction of
movement of the chassis different than the direction of move-
ment of the drive/steer control handle. The system indicates to
the operator the need to match the black and white direc-
tional arrows on the platform control panel to the arrows on
the chassis. The system uses a proximity switch mounted on
the hydraulic swivel, an indicator light and an override switch
on the platform display panel. The proximity switch trips when
the turntable is swung +/- 45 degrees off center of the normal
driving position. This occurs roughly when the boom is swung
past a rear tire. When the turntable is in the normal drive posi-
tion with the boom between the rear tires, no indications or
interlocks are made. When the machine is actively driving
when the turntable is swung past the switch point, the system
is ignored until drive/steer is released. When drive is initiated
with the boom swung past the switch point, the DOS indicator
will flash and the drive/steer functions will be disabled. The
operator must engage the DOS override switch to enable
Drive/steer (high drive will remain disabled). When the DOS is
3-4 3121262
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 , the screen should read:
Swing and drive functions can now be used to swing the turn-
table in the correct direction to return the boom between the
rear wheels in the event the boom is beyond the swing enve-
lope when the axles are retracted.

tem.
3121262 3-5
1
15
14
17
13
12
4
16
7
10
8
11
9
1001119385-D
Figure 3-5. Chassis Component Location - Sheet 1 of 2
3-6 3121262
1. Axle Limit Switch (Right Front) 10. Steer Angle Sensor (Left Rear)
2. Steer Angle Sensor (Right Front) 11. Chassis Module
3. Steer Valve (Front) 12. Swivel/Collector Ring
4. Axle Lockout Valve 13. Axle Lockout Pressure Switch
5. Traction Valve 14. Steer Angle Sensor (Left Front)
6. Steer Valve (Rear) 15. Axle Limit Switch (Left Front)
7. Steer Angle Sensor (Right Rear) 16. Brake Valve
8. Axle Limit Switch (Right Rear) 17. Two Speed Valve
9. Axle Limit Switch (Left Rear)
Figure 3-6. Chassis Component Location - Sheet 2 of 2
3121262 3-7
2
1
28
27 4
5
26 25
6
7
8
10 9
23 22 11
24 12
13
21 14
20
15
16
19
18
17
1001119385-C
Figure 3-7. Turntable Component Location - Sheet 1 of 2
3-8 3121262
1. Ground Control Box 15. Starter Relay

2. Headlight 16. Glow Plug Relay
3. Deutz EMR2 Module & Diagnostic Connector 17. Swivel
4. 110V / 220V Generator 18. Alarm
5. 110V / 220V Generator Control Box 19. Main Control Valve
6. Alternator 20. Auxiliary Power Pump
7. Throttle Actuator 21. Auxiliary Power Relay
8. Oil Temperature Switch 22. Horn
9. Oil Pressure Switch 23. Head & Tail Light Relay
10. Intake Heaters 24. Ignition Relay
11. In-Head Glow Plugs 25. Lift Cylinder Pivot Pin
12. Engine Speed Sensor 26. Fuel Level Sensor
13. Starter 27. Strobe
14. Drive Pumps 28. Headlight
Figure 3-8. Turntable Component Location - Sheet 2 of 2
3121262 3-9
3
1 DETAIL A
6 * AXLE STOP SHIMMING PROCEDURE:

2 1. ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL
SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME.
2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST
SHIM.
DETAIL B
Figure 3-9. Oscillating Axle - Sheet 1 of 2
3-10 3121262
9
3
11,12,B,G
6
11,12,A,G
8
10
11,12,C,G DETAIL A
11,12,D,G
11,12,E,G
11,12,F,G
2
4
A - Assemble to Axle Box Mid Plate; Typical 8 Places
B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 DETAIL B
inches (12.7 ± 1.587 mm) thread engagement.
C - Assemble to Side Plates of Axle Weldments; Typical 16 Places.
D - Assemble to Front and Rear Plates of Axle Boxes; Typical 8 Places.
E - Assemble to Top Plate of Axle Weldment; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5
±0.062 inches (12.7 ± 1.587 mm) thread engagement.
F - Assemble to Bottom Plate of Axle Box Weldment; Typical 8 Places.
G - See Axle Stop Shimming Procedure on Sheet 1
1. Axle Oscillation Cylinder 5. Axle Pivot Pin 9. Hose Clamp

2. Axle 6. Axle Limit Switch 10. Stop Block
3. Axle Powertrack 7. Axle Stop Pin 11. Wear Pad
4. Extension Cylinder 8. Rubber Pad 12. Shim
Figure 3-10. Oscillating Axle - Sheet 2 of 2
3121262 3-11
SEE DETAIL A
AXLE STOP SHIMMING PROCEDURE:

1) ALL 4 WHEELS OF THE MACHINE SHOULD
BE ON A LEVEL SURFACE WITH THE
TURNTABLE SQUARE TO THE FRAME.
2) SHIM AXLE STOPS TO WITHIN THE
THICK NESS OF THE THINNEST SHIM.
1 3 6
SEE DETAIL B
AXLE AND AXLE BOX FRONT PLATES -ASSEMBLE TO TOP PLATE OF AXLE WELDMENT
5
-TYP 4 PLACES, 4 AXLES
-TORQUE GRADE 8 PER JLG SPEC 5000059
-SELECT APPROPRIATE BOLT (ITEM #15 OR #16)
TO ENSURE 1/2" 1/16" THREAD ENGAGEMENT
1001173914-I
MAE35940I
Figure 3-11. Fixed Axle - Sheet 1 of 2
3-12 3121262
3 -ASSEMBLE TO TOP PLATE OF

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

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

PLATES OF AXLE BOXES
TYP 8 PLACES, 2 AXLE BOXES
ASSEMBLE TO BOTTOM PLATE

OF AXLE BOX WELDMENT
1 TYP 8 PLACES, 2 AXLE BOXES
9
8
DETAIL A
2
DETAIL B
5 1001173914-I
MAE35950I
1. Axle 5. Extension Cylinder

2. Axle Power Track 6. Axle Pivot Weldment
3. Axle Limit Switch 7. Axle Stop Pin
4. Axle Pivot Pin 8. Rubber Pad
Figure 3-12. Fixed Axle - Sheet 2 of 2
3121262 3-13
Figure 3-13. Axle Loctite Application
3-14 3121262
Table 3-2. Steering Assembly Notes
A Apply JLG Threadlocker PN 0100011
B Apply JLG Threadlocker PN 0100019
C Apply Loctite #222
D Preload Torque 100-300 ft. lb. (140-420 Nm)

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

2. Angle Sensor Assembly 5. King Pin
3. Steer Cylinder 6. Axle
Figure 3-14. Steering Installation
3121262 3-15
3.9 OSCILLATING AXLE SYSTEM 3.10 OSCILLATING AXLE BLEEDING PROCEDURE AND
The oscillating front axle is attached to the frame by a pivot
LOCKOUT TEST
pin, which allows all four wheels to remain on the ground
when traveling on rough terrain. The oscillating axle also Lockout Cylinder Bleeding
incorporates two lockout cylinders connected between the To start the test, the axle must be fully oscillated in one direc-
frame and the axle. The lockout cylinders permit axle oscillation. Start with oscillating the axle so that the left lock-out cyl-
tion when the boom is in the transport position and drive is inder is fully retracted (left front tire up), and the right lock-out
commanded. The lockout cylinders will lock and hold the axle cylinder Is fully extended (right front tire down).
when drive is not commanded or when the boom is outside
the transport position. The cylinders unlock when pilot pres-
sure is applied to the holding valves mounted on the cylinders
and lock when pilot pressure is removed. Pilot pressure is avail- ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CENTERED OVER REAR
able from brake pressure and is controlled by a solenoid oper- AXLE PRIOR TO BEGINNING BLEEDING PROCEDURE. MAKING SURE MACHINE
IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED, BRAKE WIRE IS
ated NC lockout valve mounted in the frame. To ensure the
DISCONNECTED.
lockout valve is functioning correctly, a NO pressure switch is
mounted between the lockout valve and the holding valves.
The system is “healthy” when pressure trips the pressure 1. Making sure machine is on a level surface and rear
switch when the lockout valve is commanded to be open and wheels are blocked, machine is in transport mode.
conversely is healthy when the lack of pressure resets the pres-
2. Disengage the drive hubs.
sure switch when the lockout valve is commanded to be
closed. Failures in the oscillating axle system will cause the 3. Use suitable container to catch any residual hydraulic
control system to disallow main lift up and main and jib tele- fluid, place container under the lockout cylinder.
scope out when the boom is within the transport position and
will disallow drive/steer, main lift up and main and jib tele- 4. With the left lock-out cylinder retracted, open the
bleeder on top of the cylinder, then have an operator
scope out when the boom is beyond the transport position.
from the platform (on high engine) feather drive. Acti-
vate drive fully.
ment and operation, refer to Section 6 - JLG Control Sys- 5. Close the bleeder when there is a steady stream of oil
tem. and not air.
6. With the axle in the same position, go to the right lock-

out cylinder and open the bleeder at the rod end. Acti-
vate drive in the same manner and close when all air has
been purged.
7. Close the bleeder when there is a steady stream of oil

and not air.
8. Oscillate the axle the other direction, left lock-out cylin-

der extended (tire down), right lock-out cylinder
retracted (tire up). Use the same procedure for the
bleeder in the rod end of the left lock-out cylinder, Then
the piston end of the right lock-out cylinder then close.
9. Repeat this process one more time to ensure that all air
has been purged from the system.
10. Perform oscillating axle lockout test.
11. If necessary, repeat steps 1 thru 9.
NOTE: Bleeding of the oscillating axles is an infrequent operation

performed after hydraulic line failure and or lock-out cylin-
der repair.
3-16 3121262
Oscillating Axle Lockout Test 11. Telescope the boom out of the transport position.
The front axles will oscillate when the boom is in the transport 12. Drive machine off of block and ramp back onto the level
position (i.e. when the boom is less than 6° above horizontal surface.
and not extended beyond 12" [30.4 cm] and drive is selected.
13. Have an assistant check to see that right front wheel
remains locked in position off of ground.
14. Retract the boom back in to the transport position. Acti-
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- vate drive and the lockout cylinders should release.
TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
SUSPECTED. 15. If lockout cylinders do not function properly, have quali-
fied personnel correct the malfunction prior to any fur-
ther operation.
NOTE: Ensure boom is fully retracted, lowered, and centered
between drive wheels prior to beginning lockout cylinder
test. The axles must also be fully extended.
1. Place a 6 .in (15.2 cm) high block with ascension ramp in

front of left front wheel.
2. From platform control station, activate machine hydrau-

lic system.
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/

TORQUE SELECT control switches to their respective
LOW positions.
4. Place DRIVE control lever to FORWARD position and

carefully drive machine up ascension ramp until left
front wheel is on top of block.
5. Telescope the boom out of the transport position.
6. Drive machine off of block and ramp back onto the level
surface.
7. Have an assistant check to see that left front wheel

remains locked in position off of ground.
8. Retract the boom back in to the transport position. Acti-

vate drive and the lockout cylinders should release.
9. Place the 6 .in (15.2 cm) high block with ascension ramp
in front of right front wheel.
10. Place DRIVE control lever to FORWARD and carefully

drive machine up ascension ramp until right front wheel
is on top of block.
3121262 3-17
3.11 WHEEL DRIVE ASSEMBLY 2. Remove hardware securing wheel and remove wheel
assembly.
Removal 3. Place a wheel assembly on Clean area.
NOTE: The drive motor can be removed through the axle flange as Installation
part of the wheel drive assembly or they can be removed
1. Place blocking strong enough to support the weight of
separately through the bottom of the frame while leaving
the machine under the frame and remove the jack.
the torque hub bolted to the axle.
2. Using adequate support, install wheel into wheel
1. Use a jack to lift the frame enough so the tire and wheel assembly and secure with bolts and washers.
assembly is off the ground. Place blocking strong NOTE: Torque the bolts to 180 ft. lbs. (244 Nm).
enough to support the weight of the machine under the
frame and remove the jack.
NOTE: The solid tire & wheel assembly weighs approximately

960 lbs. (435 kg). The foam-filled tire & wheel assembly
weighs approximately 867 lbs. (393 kg).
WHEEL
WASHER
BOLT
MAE35900
Figure 3-15. Wheel Drive Removal and Installation
3-18 3121262
3.12 DRIVE MOTOR Installation

1. Make sure that the pump shaft is properly aligned.
Removal
NOTE: The drive motor weighs approximately 34 lbs. (15.4 kg).
1. Place machine on the firm level surface.
2. Disconnect the battery power and all electrical connec- 2. Install the drive motor to the drive hub and secure using
tions from the drive motor. bolts and washers.
NOTE: The drive motor weighs approximately 34 lbs. (15.4 kg).
3. Remove hardware attached drive motor to the drive INCORRECT SHAFT ALIGNMENT MAY RESULT IN DAMAGE TO DRIVE SHAFT,
hub. BEARINGS, OR SEAL WHICH CAN CAUSE EXTERNAL OIL LEAKAGE.
4. Remove the drive motor from machine and place in a 3. Reconnect all electrical connections to the drive motor.
clean work area.
4. Start the machine and check the motor for proper func-
tioning.
BOLT
WASHER
DRIVE MOTOR
DRIVE HUB
BOLT
WASHER
MAE37610
Figure 3-16. Drive Motor Removal and Installation
3121262 3-19
5
4
6
3
1
9
3 10
11
2 7 12
13
8
14
15
20 16
17
18
19 21
22
23
24
26
30
25
27
31
29
28
32
33
34
35
36
34
MAE37590B
1. Bolt 9. Snap ring 17. Cylinder Piston 25. Gasket 33. Snap ring
2. End cap motor 10. Spring Retainer 18. Piston Ring 26. Plug 34. Snap ring
3. Locating pin 11. Spring 19. O- ring 27. O-ring 35. Seal
4. O- ring 12. Washer 20. Piston 28. Plug 36. Washer
5. Plug 13. Cylinder block 21. Spring 29. O- ring
6. Dower pin 14. Slipper Pin 22. Pin 30. Housing
7. Needle Bearing 15. Guide 23. Swash Plate 31. Shaft
8. Valve Plate 16. Slip Retainer 24. Kit Bearing 32. Bearing
Figure 3-17. Drive Motor Assembly
3-20 3121262
3.13 DRIVE HUB Installation of the Wheel Drive on the Machine

NOTE: Machines may be built with either Bonfiglioli or Reggiana 1. Clean the mating surfaces from oils or paint and fit the
Riduttori wheel drive hubs. See Section 3.14, Drive Hub - wheel drive on the machine frame.
Reggiana Riduttori. Do not use different hubs on the same
2. Attach the gearbox to the machine frame with the
machine.
mounting bolts and torque to 178 ft.lbs. (241 Nm).
Product Identification Start Up and Running In

The identification data of the hub is shown on a name plates on
the hub. Figure 3-18., Drive Hub Identification Plate shows If new hubs are being installed, it is advised to follow the
how the information is displayed. measures given below:
1. Bleed air from every part of the hydraulic and add oil in
The informations stamped on the name plates must always be the tank if necessary.
readable. Use the identification data (at least serial number)
for spare part enquiries, information and service, etc.
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL BE REC-
Hydraulic Motor Installation OGNIZED BY THE PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A
The mating areas and the pilot diameter of the gearbox JERKING OF THE MOTOR AS WELL AS EXCESSIVE NOISE COMING FROM THE
where the motor is to be mounted must be clean and without MOTOR AND THE VALVES.
burrs.
2. Start the gearmotor at a low speed and gradually
Before assembling the hydraulic motor, verify by a depth slide increase it after having verified that it is functioning cor-
gauge the correct assembly of the unit checking the axial dis- rectly without any noises or vibrations.
tance as shown in the scheme below as shown in the scheme
below.
1. Fit the O-ring seal, supplied with the gearbox, in its seat DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN
in the hydraulic motor, and assemble it to the gearbox FILTERED TO ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.
being careful not to damage the seal already fitted.
NOTE: During the running-in stage follow the steps given
2. Torque the bolts to 63.5 ft.lbs. (86 Nm) torque.
below.
3. Check the correct revolution and direction of rota-

tion.
4. Make sure that the functioning is regular and without

any excessive noises and vibrations.
5. Make sure that the oil temperature does not exceed

values listed previously.
Figure 3-18. Drive Hub Identification Plate
3121262 3-21
After having finished running-in the gearbox, follow the steps Connecting the Brake
given below. The gearbox is fitted with a negative multi disk safety brake
6. Check that there are no oil leaks. If leaks are present, with hydraulic control release (parking brake). For information
fix them before proceeding. regarding the characteristics of the brake refer to the installa-
tion drawing.
7. Check the level of oil in the gearmotor.
Table 3-3. Brake Technical Data
8. It possible that the presence of air in the system
during the first start up could cause the application of Brake Release Pressure 232 psi (16 bar)
the brake to be slowed down. It is advised to Maximum Operating Pressure Brake 725 psi (50 bar)
repeat the application and release functions of the
Braking Torque 195 ft.lbs. (265 Nm) ± 10%
brake to purge air from the brake.
9. Check that there are no other problems in general.
Filling-up the Gearbox with Lubricating Oil
The motor and the gearbox have separate lubrication. The
General Information gearbox is lubricated by oil splashing. The recommended type
The gearbox is designed and built for wheel drive. of oil is SAE 80W/90 or SAE 85W/140 with EP features comply-
ing with MIL-L-2105 C & API GL5. Refer to Table 3-4, Suggested
The unit includes planetary gearbox, 3 stages, rotating hous-
Lubricants According SAE 80W/90 and SAE 85W/140 API GL5
ing type.
Grade.
The illustrations show the parts and the main functions of the
NOTE: During operation the oil temperature must not exceed
gearbox.
185-194° F (85-90° C) intermittent.
A strict and consistent compliance with the specifications of
this technical manual ensure the minimum operating costs
and a longer unit life.
Photographic documentation and drawings are supplied for
educational purposes, so as to safely and properly carry out
maintenance operations.
Minor deviations from pictures of this manual may appear on
the actual gearbox. However, these discrepancies are not rele-
vant to the main parameters, or maintenance functions.
3-22 3121262
1= M18x1,5..........................Filling, draining and oil level plugs

2= 7/16" - 20 UNF - 2B..........Brake port
Figure 3-19. Hub Assembly
3121262 3-23
Table 3-4. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade
Ambient temperature -20°C / +30°C +10°C / +45°C

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

Gearbox Disengagement
below. The gearbox is supplied with mechanical disengagement.
1. Check that the gearbox axis is horizontal. Rotate the

gearbox housing until the drain plug (A) is on the bot-
tom on the vertical axis of the end cover. THE DISENGAGEMENT OPTION MUST BE CONNECTED OR DISCONNECTED ONLY
WHEN THE GEARBOX IS STOPPED ON FLAT GROUND.
2. Unscrew the fill and level oil plug (B).
3. Fill from the hole until the lubricant flows out.
3-24 3121262
3. Take out the cap nut (5).
THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25
REV/MIN.
4. Turn the cap nut (5) upside down. As result the pin (3)
will be pushed inside in order to permit disengagement
of the gearbox.
Figure 3-20. Gearbox engaged
1. Unscrew the 2 socket head screws M8x16 (4), grade 8.8,

of the end cover (7) with a male hex head wrench.
5. Rotate the cap nut (5).
2. Rotate the cap nut (5).
3121262 3-25
6. Tighten the 2 socket head screws M8x16 (4) with a male Should irregularities in function arise, it will be necessary to
hex head torque wrench at 18.4 ft.lbs. (25 Nm) torque. consult the troubleshooting checklist to find the most ade-
quate solution.
If unsuccessful, it may be necessary to partially or completely

disassemble the gearbox.
Table 3-5. Drive Hub Maintenance Schedule
Inspection Frequency Action

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

1. Check that the gearbox axis is horizontal. Rotate the
gearbox housing until the drain plug is on the bottom of
the vertical axis of the end cover.
Figure 3-21. Gearbox Disengaged
7. Repeat the above steps to engage the gearbox again.
Operation:
a. Engaged gearbox
At this condition the motion is transmitted from the
2. Unscrew the both plugs (Fill and Drain) and let the oil
hydraulic motor to the gearbox.
flow in a large enough container; in order to facilitate
b. Disengaged gearbox draining the oil must still be warm.
3. Wait a few minutes until all the oil is drained and then
proceed to screw on the plugs.
AT THIS CONDITION THE HYDRAULIC MOTOR AND THE BRAKE ARE DISCON-
NECTED TO THE GEARBOX: THE WHEEL IS IDLE. 4. Proceed with the oil fill-up. Refer to Filling-up the Gear-
box with Lubricating Oil.
Maintenance Information
NOTE: Never mix mineral oils with synthetic oils and vice versa.
PERIODIC MAINTENANCE
The gearbox only requires the scheduled maintenance proce-

dures set out by the manufacturer (see Table 3-5).
DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT. BE CAREFUL TO
Good maintenance will ensure an ongoing functioning in time ELIMINATE IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS
as well as maximum reliability. THAT GOVERN LOCALLY.
3-26 3121262
Troubleshooting
The following table is provided to help locate problems in the
gearbox.
Table 3-6. Troubleshooting
Symptom Causes Remedies

External oil leakage:
From the lifetime seal a) Lifetime seal damaged a) Replace lifetime seal
From the end cover a) O-ring seal damaged a) Replace O-ring seals
From the plugs a) Plug seal damaged a) Replace plug seal
b) Plugs or screws loose b) Tighten the plugs/screws
Too much noise:
Hydraulic noise (during the slowing down a) Hydraulic circuit malfunctioning a) Verify hydraulic circuit
of the motor speed)
Inside the gearmotor (reductions) a) Internal damage a) Check the gearbox
Other:
Overheating a) Insufficient oil level a) Check the oil level and refill if necessary
b) Hydraulic oil too warm b) Check the hydraulic circuit
c) Brake not fully released c) Check brake release pressure
Parking brake malfunctioning
Insufficient braking torque a) Brake discs worn a) Replace brake disc pack
b) Damaged parts b) Check brake components
Wheel Locked a) Parking brake locked a) Check the complete brake release
b) Mechanical components damaged b) Replace damaged parts
Disassembly Information 2. Making sure that the coupling surfaces are not dam-
aged.
It is also important that this procedure is undertaken in a
workshop that is equipped with the proper tools. As well as 3. Handle with care so as to be sure that there are no risks
normal workshop tools it will be necessary to use special tools for personnel safety and to guarantee the reliability of
that can be made (see special tools attachment) or may be the gearbox.
requested from the manufacturer.
4. Making available a work area that is in line with work
Special Tools: and health safety in the workplace guidelines.
Puller...............................................Code/: 6689960240 Disassembly Procedure

Tool for lifetime seal assembly........Code/: 6689960300
NOTE: Below are all the steps to follow during Disassembly and
Puller for brake disassembly..........Code/: 6689960310 Assembly. Numbers in brackets in the text correspond to
the references in the exploded view.
Torque multiplier............................Code/: ATZ.09.016.0
Initial inspection can be made without disassembling the hub
To be able to produce these special tools refer to Figure 3-23. from the machine. Before wheel drive disassembling, make
thru Figure 3-26. sure that the oil is drained from the hub.
It is important to strictly adhere to all the procedures for disas- Unscrew and remove the nos. 2 screws M12, grade 8,8, and
sembling and reassembling the gearbox. Proceed with these remove the hydraulic motor and its O-ring seal (48).
instructions using all the necessary safety measures, for exam-
ple:
1. Plug all the Hydraulic ports on the gearbox to avoid the

introduction of any foreign particles in the circuit and
the gearbox.
3121262 3-27
1. Install the special tool (6689960310) on the flanged hub 4. Mark the position of the springs (45) as a reference for
(31) and turn the screw until it compresses the springs the reassembly.
(45).
5. Remove the springs (45) from their seats in the brake

2. Remove the circlip (47) and remove the special tool. piston (44).
3. Remove the spring retainer disc (46). 6. By using pliers remove the circlip (36) from its seat in the
brake shaft (35).
3-28 3121262
1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring
2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring
3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43. Backup Ring
4. Screw 14. Splined Shaft 24. Bearing 34. Spacer 44. Brake Piston
5. Cap Nut 15. Disengagement Shaft 25. Spacer 35. Brake Shaft 45. Springs
6. Oil Plug 16. 1st Reduction Assembly 26. Spacer 36. Circlip 46. Retainer Disc
7. End Cover 17. 2nd Stage Sun Gear 27. O-ring 37. Backup Ring 47. Circlip
8. Pad 18. 2nd Reduction Assembly 28. Spacer 38. O-ring 48. O-ring
9. O-ring 19. Circlip 29. Half Seal 39. Spacer
10. 1st Stage Sun Gear 20. 3rd Reduction Assembly 30. Seal Ring 40. Backup Ring
Figure 3-22. Drive Hub
3121262 3-29
7. By using a puller remove, at the same time, the brake 10. Remove the external O-Ring seal (38) and the backup
piston (44), the spacer (39) and the brake shaft (35). ring (37) from their seat in the spacer (39).
11. Remove the O-ring seal (42) and the backup ring (43)
from their seats in the flanged hub (31).
8. Remove the spacer (39) from the brake piston (44).
12. Remove brake discs pack (32-33).

9. Remove the internal O-Ring seal (41) and the backup
ring (40) from their seat in the spacer (39).
3-30 3121262
13. Remove the disengagement shaft kit (15). 16. By using pliers remove the elastic ring (11) from the
splined shaft (14).
14. Place the disengagement shaft kit (15) inside the special
tool (6689960240). 17. Remove the special tool and remove the spring (13) and
the washers (12).
15. Tighten the 2 screws M5x16, grade 8.8, of the cover by a

torque wrench to 18.4 ft.lbs. (25 Nm). 18. Turn the gearbox upside down and unscrew the 2
screws M8x16 (4), grade 8.8, of the end cover (7).
3121262 3-31
19. Remove the cap nut (5). 22. Unscrew the draining-filling-level oil plugs (6) by a male
hex head wrench.
20. Remove the pin (3).

23. Unscrew the 10 screws M10X25 (1), grade 12,9, from the
end cover (7).
21. Remove the O-ring seal (2) from its seat in the end cover
(7).
24. Remove the end cover (7).
3-32 3121262
25. Remove the O-ring seal (9) from its seat in the end cover 28. Remove the 2nd stage sun gear (17).
(7).
29. Remove the 2nd reduction assembly (18).

26. Remove the 1st stage sun gear (10).
30. By using pliers remove the circlips (19) from their seats
27. Remove the 1st reduction assembly (16). in the flanged hub's pins (31).
3121262 3-33
31. By using a puller remove the planet assemblies of the 34. By using a tackle place the torque multiplier
3rd reduction (20). (ATZ.09.016.0) on the ring nut (22).
35. By using the torque multiplier (ATZ.09.016.0) loosen the

32. Remove the spacer (21) from their seats in the pins of
ring nut (22).
the flanged hub (31).
36. Take out the ring nut (22).

NOTE: In order to proceed with the gearbox disassembly, it is now
necessary to remove it from the machine and bring it to a
properly equipped workshop.
33. By using a drill remove the caulkings on the ring nut

(22).
3-34 3121262
37. By using a puller and a metal stopper, remove the 40. By using a screwdriver, remove the 1st half-seal (29)
flanged hub (31) from the gearbox housing (23). from the flanged hub (31).
38. By using a tackle remove the gearbox housing (23) from 41. By using a screwdriver, remove the 2nd half-seal (29)
the flanged hub (31). from the gearbox housing (23).
39. Remove the seal ring (30) from its seat in the flanged
hub (31). NOTE: The gearbox disassembly ends with the above operation.
All items are now available for the necessary inspections.
Inspection of Parts
The pieces that are subject to general wear and tear are the
following:
- Gears.
- Bearings.
- All the seals
Replace the used or irregular parts using the following steps:
1. Remove dirt, and in particular properly clean the seals,

bearings and locking rings seating.
NOTE: In case of oil leaks, it may be necessary to check and even- 2. Lubricate the parts before connecting them.
tually replace the lifetime seal (29), which means both the
metal rings parts and the O-ring seals. 3. In the case of damaged gears, for example a planetary,
do not proceed to replace the individual gear but the
entire reduction assembly.
3121262 3-35
4. When reassembling a part always replace all the seals c. Carefully clean the lapped surface (D) of metal rings
involved. Add some grease on the seats and on the new (E) and remove dust or fingerprints. Then lubricate
seals to make reassembly easier. them with a thin oil film, taking care not to oil the
other components.
5. Replace all the damaged parts with original spare parts.
2. Assemble the half seal (29) on the tool (6689960300).
Assembly
Apply grease TECNOLUBE SEAL GS730 on the gearbox hous-
ing (23).
3. Assemble the 1st half seal (29) on the gearbox housing

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

assembly:
a. Carefully clean the seats (A and B) using, if neces-

sary, metallic brushes or solvent (surfaces in contact
with or (C) must be perfectly clean and dry).
4. Using the same tool (6689960300), assemble the 2nd

half seal (29) on the flanged hub (31).
b. Make sure that sealing surfaces (D) of metal rings (E)

are free from scratches, dinges or foreign sub-
stances; metallic ring surfaces must be perfectly
clean and dry. We suggest to dip the metallic rings
in volatile solvent or industrial degreasing alcohol.
3-36 3121262
5. Carefully clean the metallic faces of the lifetime seal (29) 8. By using a hoist, place the gearbox housing (23) on the
and lube the surfaces with oil. flanged hub (31).
6. Insert the seal ring (30) in its seat in the flanged hub (31). 9. By using a press and a metallic stopper, push the gear-
box housing (23) against the shoulder on the flanged
hub (31) until assembling of the unit is complete.
7. Apply grease TECNOLUBE SEAL GS730 on the seal ring

(30).
SCREW THE NUT (22) ON PARTIALLY IN ORDER TO PREVENT THE FLANGED

HUB (31) FROM COMING OUT OF THE GEARBOX HOUSING (23) DURING THE
FOLLOWING STEPS.
AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL (29)
3121262 3-37
10. By using a hoist place the torque multiplier NOTE: Stake Ø 4+5 mm (depth 1+1,5 mm).
(ATZ.09.016.0) on the ring nut (22).
13. Assemble correctly the spacers (21) on the pins of the

11. By using the multiplier (ATZ.09.016.0), tighten the ring
flanged hub (31).
nut (22), using a torque wrench with an input multiplier
torque of 71 ± 3 ft.lbs.(96,5 ± 4, 5 Nm) corresponding to
an output multiplier torque of 3688 ± 184 ft.lbs. (5000 ±
250 Nm).
14. Place the 5 planet assemblies of the 3rd reduction (20) in

the flanged hub's pin (31).
12. Stake the ring nut (22) near 2 seats at 180° of the flanged
hub (31) on the right side.
3-38 3121262
15. By using a rubber hammer and a metal stopper push the 18. Insert the 2nd stage sun gear (17).
planet assemblies of the 3rd reduction (20) against the
shoulder until assembly is complete.
19. Assemble the 1st reduction assembly (16).
16. By using pliers, assemble the circlips (19) in the flanged

hub pin seats (31).
20. Insert the 1st stage sun gear (10).
17. Assemble the 2nd reduction assembly (18).
3121262 3-39
21. Assemble the O-ring seal (9) into its seat in the end 24. Insert the plugs (6) into the oil draining-filling holes of
cover (7). the end cover (7). Torque the plugs to 52 ± 7 ft.lbs.
(70±10 Nm).
22. Place the end cover (7) on the gearbox housing (23).
25. Assemble the O-ring seal (2) into its seat in the end
cover (7).
23. Tighten the 10 socket head screws M10x25 (1),grade

12,9, by a torque wrench at 62.7 ft.lbs. torque (85 Nm).
26. Protect the seat and the pin (3) with grease type
MOLYKOTE G6000. Wait 15 minutes for it to completely
dry. Insert the pin (3) in its seat in the end cover (7).
3-40 3121262
27. Assemble the cap nut (5). 30. Insert the spring (13) in the splined shaft (14).
28. Torque the 2 screws M8x16 (4) grade 8.8, to 18.4 ft.lbs. 31. Insert the splined shaft (14) in the equipment
(25 Nm). (6689960240).
29. Insert the 1st washer (12) in the splined shaft (14). 32. Insert the 2nd washer (12) correctly in the splined shaft
(14).
3121262 3-41
33. Torque the 2 screws M5x16, grade 8.8, of the cover to 35. Insert the disengagement shaft kit (15) in the flanged
18.4 ft.lbs. (25 Nm). hub (31).
34. By using pliers, assemble the elastic ring (11) into its seat 36. By using pliers assemble the circlip (36) into its seat in
in the splined shaft (14). the brake shaft (35).
37. Turn the gearbox upside down and assemble the brake
shaft (35) inside the flanged hub (31).
3-42 3121262
38. Assemble the brake discs package according to the fol- 41. Fit the external O-ring seal (38) and the backup ring (37)
lowing order: first, insert one sintered bronze disc with into their seats in the spacer (39).
external teeth (33).
42. Insert the spacer (39) inside the flanged hub (31), paying
39. Then insert an internally toothed steel disc (32). Repeat attention not to damage the seals already fitted.
the operation until all 5 sintered bronze discs and 4 steel
discs have been assembled.
43. By using a rubber hammer and a metal stopper push the

spacer (39) against the flanged hub (31), paying atten-
40. Fit the internal O-ring seal (41) and the backup ring (40) tion not to damage the seals already fitted.
into their seats in the spacer (39).
3121262 3-43
44. Lube the seal seats into the flanged hub (31) and assem- 45. Insert the brake piston (44) inside the flanged hub (31),
ble the O-ring seal (42) and the backup ring (43). paying attention not to damage the seals already fitted.
NOTE: The O-ring seals (A) and backup rings (B) must be fitted in 46. By using a rubber hammer and a metal stopper push the
the seats according the mutual position as shown in the brake piston (44) against the flanged hub (31), paying
scheme. attention not to damage the seals already fitted.
3-44 3121262
47. Insert the springs (45) into the holes in the brake piston 49. Install the special tool (6689960310) on the flanged hub
(44) marked previously. (31) and turn the screw until it compresses the springs
(45).
48. Insert the spring retainer disc (46).

50. Assemble the circlip (47) in its seat and remove the spe-
cial tool.
NOTE: Before assembling the hydraulic motor, verify by a depth

slide gauge the correct assembly of the unit checking the
axial distance as shown below.
3121262 3-45
Final Test and Reinstallation 2. Open the flow valve and release the brake with the pilot
pressure of 50 bar.
Check the product by remounting it to the machine.
3. Close the flow valve and keep the brake released 3 min-
Check the function of the drive hub following all the checks utes or longer.
shown in Startup and Running In. 4. Using the manometer, check that the pressure remains
constant.
If work on the brake was undertaken, it is important to check
that there are no oil leaks. Follow the procedure below: NOTE: If the pressure drops it may mean that the brake seals are
not tight and consequently they must be replaced or it may
1. Connect the pressure pilot line with the manometer mean that the reassembling was not completed properly.
(with a base scale of 100 bars) to the brake release port.
5. After having reassembled the gearbox, install the
hydraulic motor.
6. Fill the gearmotor with the lubricant oil.
3-46 3121262
Figure 3-23. Drive Hub Special Tools - Sheet 1 of 4
3121262 3-47
3-48 3121262
3121262 3-49
3-50 3121262
3.14 DRIVE HUB - REGGIANA RIDUTTORI 9. Socket wrench for M6 hexagonal screw.
NOTE: After SN 0300134389 machines may be built with either

Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec-
tion 3.13, Drive Hub. Do not use different hubs on the same M- 1326
machine.
Ø240
Symbol Nomenclature Ø130
Ø30 5x45°
35
°
15
R5
= ADHESIVE
Ø224
10
5
Ø233
Ø240
60°
= LUBRICANT
60
60
°
A A
= GREASE
N° 6 Hole to 120° Ø30
Figure 3-27. Bearing Track Spacer Mounting C016117

= TORQUE WRENCH
M- 1537
Ø249
= DISPOSAL Ø130
Ø30
Tools N° 4 Hole to 90° Ø30
Tools required for assembling and disassembling the wheel

29.5
gear RRTD1701TB
1. Hammer;
Ø210
14.5
10
2. Clamps for inner retention rings; Ø219

3. Clamps for outer retention rings;
4. Electric or pneumatic screwdriver; Figure 3-28. Oil Seal Spacer Mounting C125049
5. Special spacer mounting;
6. Torque wrench;
7. Hydraulic press;
8. Wrench for M6, M8, M10 socket head screws and
1/4" G plug.
3121262 3-51
Ø210
5x45°
Ø130
25
Ø30
M- 1321
LOCTITE 2701
N° 4 Hole to 90° Ø40
110
M- 1320
Ø197.5
Ø210
Figure 3-29. Bearing Spacer Mounting CO16117
Figure 3-30. Assembly Diagram 1
3-52 3121262
M- 1316 M- 1020
30
Ø34 35 35
10
10 10
M- 1317
45°
45°
8 M- 1317
N° 4 R
35
45°
45°
70
A A
35
50
M- 1317
70
50
216.5
Ø
12
10
Ø11
Ø230
20
M- 1316 10x45°
60
Ø16 90
70
Ø17
55
38
11
M- 1317
M- 1317
M- 1317 Figure 3-33. Anti-rotation Block
16 n° 8 Routing to 45°
Ø205
Figure 3-31. Wrench For Ring Nut

M- 1126
Ø20
Ø12
M- 1125 T.U.9
Ø180
n° 12 Fori a 30° Ø35
Ø80
30
50
Ø20 H7 (+0.021) n°12 Hole to 30°
10.5
0
20
n° 12 Hole to 30° Ø6.5

M6
32
n° 12 Spot-facing to 30° Ø10.5

T.U.15
Figure 3-34. Anti-rotation Pin

6.5
n° 4 Hole to 90° M10

Ø50
Ø275
Ø305
30° 30°
0
°
30
3
°
30°
30°
A A
Figure 3-32. Anti-rotation Flange
3121262 3-53
M- 1126 M- 1126
M- 1125 VTCEI M6X12 n°12
M- 1020
VTCEI M10X60 n°4
Figure 3-35. Assembly Diagram 2
3-54 3121262
Ø105 M- 1546 M- 1548

Ø93.5
+0.1
Ø48
Ø20+0.2 Ø46
5
5
9
80
70
50
8.5
20
Ø8.5
Ø13.5 Ø40.5
5
Ø46
M- 1547
2.5x15°
Ø39.5
t.u. 12
88.5
0
3.5
M8
Ø20 -0.1
VTCEI M8X16 n°1
Figure 3-36. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram
3121262 3-55
Disassembly 3. Release the screws from the release cover and pull the
pin out.
1. Remove the plugs and pour the lubricant in a container.
4. Remove the BR250 ring and pull the cover out avoiding
to damage the O-Ring.
2. Release the screws to disassemble the motor flange tak-

ing care not to damage the O-Ring.
5. Pull the reduction gears out.
3-56 3121262
3121262
Figure 3-37. Reggiana Riduttori Hub - Sheet 1 of 2
3-57
3-58
1. Screw 13. Iron Brake Disc 25. Tapered Roller Bearing 37. O-ring
2. Motor Support 14. Plastic Plug 26. Bearing Support 38. Crown Gear
3. O-ring 15. Spindle 27. Ring Nut 39. Crown Gear Screw
4. Inner Retention Ring 16. Planet Wheel 28. Sphere 40. O-ring
5. Brake Spring Spacer 17. Bearing 29. Screw 41. Support Tablet
6. Brake Spring 18. Outer Retention Ring 30. Pinion 42. O-ring
7. Brake Piston 19. Input Shaft 31. Reduction Gears 43. Cover
8. Parbak 20. Input Shaft Bearing 32. Outer Retention Ring 44. Steel Plug
9. O-ring 21. Ring 33. Pinion 45. Cover Retaining Ring
10. O-ring 22. Disengagement Spring 34. Reduction Gears 46. Disengagement Stud
11. Parbak 23. Disengagement Shaft 35. Outer Retention Ring 47. Disengagement Cap
12. Sintered Brake Disc 24. Spindle Oil Seal 36. Pinion 48. Disengagement Screw
Figure 3-38. Reggiana Riduttori Hub - Sheet 2 of 2
3121262
6. Loosen the M10x25 flathead socket screws and remove 9. Loosen the M6x6 socket headless screws and also
the planetary ring without damaging the O-Ring. remove the 3/16" balls.
7. Remove the release joint together with the spring. 10. Loosen the ring nut using the special wrench.
8. Disassemble the Ø40 outer snap rings and using an 11. Remove the hub support together with the roller bear-
extractor remove the planetary gears from the spindle ing inner track.
pins.
3121262 3-59
12. Disassemble the Ø160 inner snap ring and pull the Assembly
spring holder spacer out. Remove the springs and using
a compressed air jet in the brake control hole pull the 1. Make sure all the component parts of the wheel gear are
piston out of the spindle. devoid of burrs, machining residues and that they are
correctly washed.
2. Fit the ball bearing in the input shaft and lock with a Ø40
outer snap ring.
13. Remove the brake discs and seals.

3. Mount the motor shaft in the spindle and lock with BR68
ring. Lubricate the bearing.
14. Fit the ball bearing into the input shaft and lock it with a
Ø40 outer snap ring. Then mount the motor shaft in the
spindle and lock with a BR68 ring. Lubricate the bearing.
3-60 3121262
4. Fit the brake sealing rings O-Ring and PARBAK (lubri- 6. Prepare the hub support, mounting on it the two roller
cated with grease) in the respective spindle seats. Place bearing outer tracks. Place the first roller bearing inner
the brake discs making sure to centre them on the spin- track.
dle and on the input shaft.
7. Fit the oil seal lubricated with grease onto the support
5. Insert the brake piston and place the springs into the
with the special spacer mounting (see figure A).
piston holes. Close the brake fitting the spring holder
plate, then lock with the Ø160 inner snap ring. Check the
brake leakage, if any, as well as the static torque and Fig.A
minimum opening pressure.
8. Place the hub support already assembled on the spindle

making sure that the first roller bearing inner track goes
correctly against it; then fit the second roller bearing
inner track by means of the spacer mounting. Tighten
the ring nut.
3121262 3-61
9. Now check the unit roll torque and proceed in the fol- 11. Using the special tool and hammer make four dents on
lowing order: the spindle thread by the M6 holes of the ring nut.
10. By keeping the spindle locked, apply a setting preload
by tightening the ring nut at 40daNm, turn completely
the hub support twice using the special wrench to
recover any bearing cage misalignments. Release and
tighten the ring nut at the final torque of 30daNm (alter-
nate tightening and some setting turns). Check the roll
torque with seal which must be within 1÷1,5 daNm.
12. Fit the 4 3/16" balls and tighten with LOCTITE 243 the 4
M6x6 socket headless screws at the torque of 1daNm.
NOTE: Place the ring nut with its convex part facing the roller
bearing as shown below.
3-62 3121262
13. Fit the bearings onto the 3rd stage planetary gears and 15. Place the hub onto the support making the two holes
using a spacer mounting mount everything on the spin- coincide for tightening the M10x25 flathead socket
dle pins. Lock with a ÿ40 outer snap ring. Lubricate the screws at the torque of 5daNm.
bearings.
16. Fit the reduction gears and the pinion in the unit.
14. Using a marking pen, make a mark between the snap

ring and the bearing. Fit the greased spring and the
release joint. Use grease to fit the O-Ring 2-275 in the
hub support seat.
3121262 3-63
17. Prepare the closing cover fitting the O-ring 5-582 suit- 19. Fit the O-Ring 2-163 suitably greased, onto the motor
ably greased and lock it with the shimming ring. Lubri- coupling flange S-D LC/KC. Mount the flange on the
cate the bearings. spindle with 6 M8x25 socket cap screws at the torque of
2.4daNm with LOCTITE 243 Insert the pin and carry out
the rotation test according to PGQ-22 standard.
18. Fit the O-Ring 2-177 suitably greased, mount the cover
locking it with the BR250 ring.
20. Mount the release cover fastening it with 2 M6x20 hex-
agonal screws at the torque of 1daNm. Mount the 1/
4"GAS plugs on the cover at the torque of 1daNm.
3-64 3121262
1. Swing Drive 4. Outer Race Bearing Bolt

2. Inner Race Bearing Bolt 5. Turntable Lock Pin
3. Swing Bearing 6. Remote Bearing Lubrication Fittings
Figure 3-39. Swing System (SN 030020900 through 0300254531)
3121262 3-65
4
MAE36280
1. Swing Drive 4. Outer Race Bearing Bolt

2. Inner Race Bearing Bolt 5. Turntable Lock Pin
3. Swing Bearing 6. Remote Bearing Lubrication Fittings
Figure 3-40. Swing System (SN 0300254532 to Present)
3-66 3121262
3.15 SWING DRIVE Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
should be taken to ensure that the bolts are not tightened
Roll and Leak Testing beyond their specified torque.
Torque-Hub units should always be roll and leak tested before
The following steps describe how to tighten and torque bolts
disassembly and after assembly to make sure that the unit's
or socket head cap screws in a bolt circle.
gears, bearings and seals are working properly. The following
information briefly outlines what to look for when performing
these tests.
NOTE: The brake must be released before performing the roll test.
This can be accomplished by either pressure testing using
the Brake Leak Test procedure below or by tightening the
12 bolts into the piston through the end plate (See Brake
Disassembly Procedure)
NOTE: Bolts must be removed while performing brake release test
Roll Test
The purpose of the roll test is to determine if the unit's gears

are rotating freely and properly. You should be able to rotate
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con-
cerned if the gears in your unit seem to roll hard as long as
they roll with consistency. 1. Tighten (but do not torque) bolt “A" until snug.
LEAK TEST (MAIN UNIT) 2. Go to the opposite side of the bolt circle and tighten
bolt "B" until equally snug.
The purpose of a leak test is to make sure the unit is air tight.
You can tell if your unit has a leak if the pressure gauge read- 3. Crisscross around the bolt circle and tighten remaining
ing on your air checker starts to fall after the unit has been bolts.
pressurized and allowed to equalize. Leaks will most likely 4. Now use a torque wrench to apply the specified torque
occur at the pipe plugs, the main seal or wherever o-rings or to bolt "A".
gaskets are located. The exact location of a leak can usually be
detected by brushing a soap and water solution around the 5. Using the same sequence, crisscross around the bolt cir-
main seal and where the o-rings or gaskets meet on the exte- cle and apply an equal torque to the remaining bolts.
rior of the unit, then checking for air bubbles. If a leak is
detected in a seal, o-ring or gasket, the part must be replaced,
and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20 min-
utes.
3121262 3-67
Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36)
and remove fittings from Brake (26) and Motor Control
1. Place unit on bench with the motor end up. Valve (32).
2. Remove O-ring Plug (1J) and drain the oil from the gear- 5. Remove O-ring Plugs (21) from Motor Control Valve (32).
box.
6. Remove Motor Control Valve (32) from Motor (10) by
3. Remove Hydraulic Tubing Assembly (35) by loosening removing the four Bolts (34) and washers (33).
fittings on both ends of tube with a wrench.
1J. O-Ring Plug 32. Motor Control Valve

10. Hydraulic Motor 33. Lockwasher
21. Plug 34. Hex Bolt
24. ID Plate 35. Hydraulic Tubing
25. Drive Screw 36. Elbow
26. Hydraulic Brake
Figure 3-41. Swing Drive - Motor Control Valve Disassembly

(SN 030020900 through 0300254531)
3-68 3121262
Motor and Brake Disassembly 3. Remove Gasket (31) from between Brake (26) and Motor
(10).
1. With unit resting on bench with Motor (10) end up, 4. Remove Brake (26) from Main Torque-Hub Assembly
loosen Hex Bolts (29) and remove Lift Lugs (28) from the and dump oil out of Brake (26).
Motor (10).
5. Remove O-ring (27) from between Motor (10) and Brake
2. Pull Motor (10) straight up and remove Motor (10) from (26).
Brake (26).
10. Hydraulic Motor 28. Lift Lug

26. Hydraulic Brake 29. Bolt
27. O-Ring 31. Gasket
Figure 3-42. Swing Drive - Motor and Brake Disassembly

(SN 030020900 through 0300254531)
3121262 3-69
Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15)
from between Input Cover (6) and Carrier (3A) Subas-
1. With the unit resting on the Output Shaft (Pinion) (1A), sembly.
remove the eight Bolts (17), four Shoulder Bolts (18) and
7. Remove Ring Gear (4) from Housing (1G).
four Lock Washers (19) from the Input Cover (6).
8. Remove O-ring (5) from between Ring Gear (4) and
2. Thread either 1/2-13 UNC eye bolts or motor mounting Housing (1G).
Bolts (29) into threaded holes in Input Cover (6) and pull
Input Cover (6) off on the main assembly. 9. Remove Carrier (3A) Subassembly.
3. Remove O-ring (5) from between Input Cover (6) and 10. Remove Thrust Washers (16) and Thrust Bearing (15)
Ring Gear (4). from between Carrier (3A) Subassembly and Internal
Gear (2).
4. Remove Thrust Washer (8) from end of Sun Gear (13).
11. Remove Internal Gear (2).
5. Remove Sun Gear (13).
2. Internal Gear 15. Thrust Bearing

4. Ring Gear 16. Thrust Washer
5. O-Ring 17. Hex Bolt
6. Input Cover 18. Shoulder Bolt
8. Hex Bolt 19. Lockwasher
13. Sun Gear 20. Pipe Plug
Figure 3-43. Swing Drive - Main Disassembly

(SN 030020900 through 0300254531)
3-70 3121262
Hub-Shaft Disassembly 4. Remove the Bearing Cone (1F) from the Housing (1G).
5. Invert the Housing (1G) and remove the Lip Seal (1B) if
1. Using retaining ring pliers, remove Retaining Ring (1I)
not already removed when Output Shaft (1A) was
from groove in Output Shaft (1A) and discard.
pressed out of Housing (1G).
6. Remove the Bearing Cone (1D).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 7. Bearing Cups (1C & 1E) will remain in Housing (1G).
2. Remove Thrust Washer (1H). NOTE: If bearing replacement is necessary, the Bearing Cups (1C &
1E) can be removed with a slide hammer puller or driven
3. While supporting the Housing (1G) on the Output Shaft out with a punch.
(1A) end, press the Output Shaft (1A) out of the Housing
(1G).
NOTE: The Lip Seal (1B) may or may not be pressed out of the
Housing (1G) by the Bearing Cone (1D) during this step.
1A. Output Shaft 1F. Tapered Bearing Cone

1B. Lip Seal 1G. Housing
1C. Tapered Bearing Cup 1H. Thrust Washer
1D. Tapered Bearing Cone 1I. Retaining Ring
1E. Tapered Bearing Cup 1J. O-Ring Plug
Figure 3-44. Swing Drive - Hub Shaft Disassembly

(SN 030020900 through 0300254531)
3121262 3-71
Carrier Disassembly 3. Slide the Planet Gear (3F), two Ball-Indented Thrust
Washers (3H) and the two Thrust Washers (3B) out of the
1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G) which Carrier (3A).
holds the Planet Shaft (3E) in the Carrier (3A) down into
4. Remove both rows of Needle Bearings (3C) and the
the Planet Shaft (3E) until it bottoms.
Spacer (3D) from the bore of the Planet Gear (3F).
NOTE: Make sure that the Roll Pin has bottomed. Otherwise, dam-
5. Repeat Steps 1 thru 4 for the remaining two Cluster
age to the carrier could occur when the Planet Shaft is
Gears(3F).
removed.
2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a
small punch to remove the Roll Pin (3G) from the Planet
Shaft (3E).
3A. Carrier 3E. Planet Shaft

3B. Tanged Thrust Washer 3F. Cluster Gear
3C. Needle Bearing 3G. Roll Pin
3D. Thrust Washer 3H. Ball Indented Washer
Figure 3-45. Swing Drive - Carrier Disassembly

(SN 030020900 through 0300254531)
3-72 3121262
Hub-Shaft Sub-Assembly Carrier Sub-Assembly

NOTE: Refer to Figure 3-44., Swing Drive - Hub Shaft Disassembly NOTE: Refer to Figure 3-45., Swing Drive - Carrier Disassembly (SN
(SN 030020900 through 0300254531). 030020900 through 0300254531).
1. Press Bearing Cone (1D) onto Shaft (1A).
1. Apply a liberal coat of grease to the bore of Cluster Gear
2. Press Bearing Cup (1C) into Housing (1G), take care to (3F). This will enable the Needle Rollers (3C) to be held in
insure cup starts square with bore of Hub (1G). place during assembly.
3. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing
1G). 2. Install the first row of 14 Needle Rollers (3C) into the
bore of Cluster Gear (3F).
4. Press or tap Seal (1B) into the counterbore of Housing
(1G) to the point where it becomes flush with the Hous- 3. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of
ing (1G) face. Care should be taken to insure Seal (1B) is the Needle Rollers (3C).
being correctly installed (smooth face up).
4. Place second row of Needle Rollers (3C) into bore of
5. Invert Hub (1G) and press Bearing Cup (1E) into counter-
Cluster Gear (3F) against Spacer (3D) and remove Planet
bore of Housing (1G).
Shaft (3E).
6. Carefully lower Housing (1G) onto the Output Shaft (1A).
5. Place Carrier (3A) into tool fixture so that one of the roll
7. Start the Bearing Cone (1F) onto the Output Shaft (1A). pin holes is straight up.
8. Press or tap the Bearing Cone (1F) onto the Output Shaft
(1A) until it is seated in the Bearing Cup (1E). 6. Start Planet Shaft (3E) through the hole in Carrier (3A).
Using ample grease to hold it in position, slide one
9. Install Bearing Spacer (1H) onto Output Shaft (1A) and Thrust Washer (3B) over the Planet Shaft (3E) with the
against Bearing Cone (1F). tang resting in the cast slot of the Carrier (3A). Place Ball-
10. Install Retaining Ring (1I) into the groove in the Output Indented Thrust Washer (3H) on the Planet Shaft (3E)
Shaft (1A). This Retaining Ring (1I) should never be with the indents against the first washer.
reused in a repair or rebuild.
7. With large end of Cluster Gear (3F) facing the roll pin
hole in the carrier, place the cluster gear into position in
Carrier (3A) and push Planet Shaft (3E) through the Clus-
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. ter Gear (3F) without going all the way through.
11. Tap the Retaining Ring (1I) with a soft metal punch to 8. Slide the second Thrust Washer (3E) between the Cluster
ensure that the Retaining Ring (1I) is completely seated Gear (3F) and the Carrier (3A) with the tang of the
in the groove of the Output Shaft (1A). washer located in the cast slot of the Carrier (3A). Slide
ball-indented Thrust Washer (3H) onto the end of the
Planet Shaft with the indents against the second thrust
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. Washer. Finish sliding the Planet Shaft (3E) through the
Thrust Washers (3H) & (3B) and into the Carrier (3A).
12. Install O-ring Plug (1J) and torque 23 to 24 ft-lbs.
(32 - 33.5 Nm). 9. Position the non-chamfered side on the Planet Shaft (3E)
roll pin hole so that it is in line with the hole in the Car-
rier (3A) using a 1/8" (3 mm) diameter punch.
10. After using a 3/16" (5 mm) punch to align the two roll
pin holes. Drive the Roll Pin (3G) through Carrier (3A)
and into the Planet Shaft (3E) until the Roll Pin (3G) is
flush with the bottom of the cast tang slot in the Carrier
(3A). Use a 1/4" (6 mm) pin punch to make sure the Roll
Pin (3G) is flush in the slot.
11. Repeat Steps 1 thru 10 for the remaining two Cluster

Gears(3F).
3121262 3-73
Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
NOTE: Refer to Figure 3-43., Swing Drive - Main Disassembly (SN with the Internal Gear (2) and Input Gear (13). On the
030020900 through 0300254531). Ring Gear (4) locate the hole marked "X", or punch
marked, over one of the marked counter-bored holes
1. With the Hub Shaft Sub-Assembly resting on the Shaft (Step 5) in Hub (1G). Check timing through the slots in
(1A) install Internal Gear (2). The spline of the Internal the carrier. Rotate carrier in assembly to check for free-
Gear (2) bore will mesh with the spline of the Output dom of rotation.
Shaft (1A).
NOTE: If gears do not mesh easily or Carrier Assembly does not
2. Inspect the location of the Internal Gear (2) on the Out- rotate freely, then remove the Carrier and Ring Gear and
put Shaft (1A). The portion of the Output Shaft (1A), check the Cluster Gear timing
which does not have full spline, should protrude
through the Internal Gear (2) bore. 10. Install Thrust Washer (15) Thrust Bearing (16) set into the
counter-bore in the face of the carrier. Use grease to
3. Install two Thrust Washers (15) and one Thrust Bearing
hold in place.
(16) on the portion of Output Shaft (1A) which protrudes
through Internal Gear (2). 11. Place O-ring (5) into Cover (6) counter-bore. Use grease
4. Center the Input Gear (13) on the end of the Output to hold O-Ring in place.
Shaft (1A) opposite the gear with the large diameter
down.
5. Place O-ring (5) into Hub counter-bore. Use grease to CAUTION: BEWARE OF SHARP EDGES OF THE COUNTER-BORE WHILE SEATING
hold O-ring in place. THIS O-RING.
12. Using sufficient grease to hold in place, install Thrust

Washer (8) into the counter-bore of the interface of the
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE SEATING THIS O- Cover (6).
RING.
13. The Cover (6) is now installed, taking care to correctly
6. Also at this time locate and mark the four counter align Pipe Plug hole (20) with those in the Hub (1J).
reamed holes in the face of the Hub (1G). This is for iden- Check timing sheet.
tification later in the assembly.
14. Locate the 4 counter-bored holes in Hub (1G) [marked in
7. Place Carrier (3A) Subassembly on bench with the large Step 5] and install 4 Shoulder Bolts (18) with Lockwash-
end of Cluster Gears (3F) up with one at the 12 o clock ers (19). Start the shoulder bolts by hand.
position. Find the punch marked tooth on each gear at
the large end and locate at 12 o'clock (straight up) from 15. Install Grade 8 Bolts (17) with Lockwashers (19) into
each planet pin. Marked tooth will be located just under remaining holes.
the Carrier on upper two gears. Check the timing 16. Torque Shoulder Bolts (18) 43 to 47 ft.-lbs. (60 to 65 Nm)
through the slots in the carrier. and Grade 8 Bolts (17) to 43 to 47 ft.-lbs. (60 to 65 Nm).
8. With large shoulder side of Ring Gear (4) facing down, Roll and leak test the assembly.
place Ring Gear (4) over (into mesh with) large end of 17. With gearbox standing on the pinion end fill gearbox
gears. Be sure that punch marks remain in correct loca- with GEAROIL 80W90, to bottom of plug hole in cover at
tion during Ring Gear (4) installation. The side of the Pipe Plug (20).
Ring Gear (4) with an "X" or punch mark stamped on it
should be up. 18. Install Pipe Plug (20) into Cover (6) using thread sealant.
3-74 3121262
Motor and Brake Assembly

NOTE: Refer to Figure 3-42., Swing Drive - Motor and Brake Disas-
sembly (SN 030020900 through 0300254531).
1. Place O-ring (27) onto end of Brake (26) and locate brake
into pilot of cover.
2. Place Gasket (31) onto the brake face and line up the
holes.
3. Place Motor (10) into Brake pilot against the Gasket (31).
4. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble
Hex Bolts (29) with Lift Lugs through the Motor (10) and
Brake (26) against the motor flange. Torque to 35 ft-lbs.
5. Fill Brake (26) with 2.7 oz. (80cc) of BRAKOILVG32
(DTE24).
Motor Control Valve Assembly

NOTE: Refer to Figure 3-41., Swing Drive - Motor Control Valve Dis-
assembly (SN 030020900 through 0300254531).
1. Lay assembly down with motor ports facing up. Remove

the two plastic plugs in the motor ports, being careful
not to loose the O-ring in each port. Assemble the Motor
control Valve (32) onto the Motor (10) with Bolt (34) and
Lock Washers (33). Torque Bolts (33) 23 to 27 ft-lbs. (32 to
38 Nm).
NOTE: Be sure to align the holes in the control valve with the
motor ports.
2. Install Elbow Fittings (36) into Brake (26) and torque 13

to 15 ft-lbs. (18 to 21 Nm).
3. Install Elbow Fittings (36) into Motor Control Valve (32)
and torque to 13 to 15 ft-lbs. (18 to 21 Nm).
4. Assemble Tube (35) into Elbow Fittings (36) and torque

13 to 15 ft-lbs. (18 to 21 Nm).
5. Install O-ring Plugs (21) into Motor Control Valve (32)
and torque 30 to 31 ft-lbs. (42 to 43 Nm).
6. Pressure test brake, tube and control valve connections
by applying 3000 psi (207 bar) pressure to the brake
bleed port and holding for 1 minute. Check for leaks at
the control-valve-motor interface and the tube connec-
tions. Release pressure.
7. Place I.D. Plate (24) onto Housing (1G) with two Drive
Screws (25). I.D. Plate (24) is to be inline with O-ring Plug
(1J) as shown on assembly print.
3121262 3-75
15
11
9 10
12
13
17
12
14
16
8
5 6
4
4
3
2 7 40
30
6 27
1
26
25
20
18 28
19
29
18
24 7
27
23
22
21 49
20 48
18
19
18 43 47
46
45
44
42
41
31
32
39
38
37
36
35
32
31
34
33 1001228488-B
MAE37600B
Figure 3-46. Swing Drive (SN 0300254532 to Present)- Sheet 1 of 2
3-76 3121262
1. Shaft 11. Spacer 21. Pinion 31. Seal 41. O-ring

2. Ring 12. O-Ring 22. Ring 32. O-Ring 42. Cover
3. Oil Seal 13. Planetory Gear 23. Spacer 33. Steel Disc 43. Screw
4. Bearing 14. Spacer 24. Spacer 34. Disc 44. O-ring
5. Support 15. O-Ring Plug 25. Pinion 35. Disc 45. Motor
6. O-ring Plug 16. Spring 26. Ring 36. Seal 46. Lung Lifting
7. O- ring Plug 17. Capscrew 27. Washer 37. O-ring 47. Capscrew
8. Nut Ring 18. O-ring 28. Brake Housing 38. Piston Brake 48. Brake valve adapter
9. Reduction Gear 19. Planetory Ring 29. Plug 39. Spring Brake 49. Valve
10. Pinion 20. Reduction Gear 30. Capscrew 40. Shaft Input
Figure 3-47. Swing Drive (SN 0300254532 to Present)- Sheet 2 of 2
3121262 3-77
3.16 SWING BRAKE HYDRAULIC/MECHANICAL

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

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

2. Housing 10. Deep Groove Ball Bearing 18. Backing Ring
3. Inner Friction Plate 11. Internal Retaining Ring 19. Dowel Pin
4. Pressure Plate 12. Rotary Shaft Seal 20. Hexagon Plug
5. Gasket 13. Socket Head Cap Screw 21. Plastic Plug
6. Outer Plate 14. Shakeproof Washer 21A. Socket Pressure Plug
7. Gasket 15. O-Ring 22. Spring (Natural)
8. Cylinder 16. Backing Ring 23. Spring (Blue)
Figure 3-48. Swing Brake
3-78 3121262
Installation 6. Remove springs (8). Take note of quantity and orienta-

tion of springs.
Position 1-off gasket (5) over male pilot on brake housing (4).
Locate brake shaft (1) and secure brake in position using 2-off 7. Should it be necessary to replace ball bearing (10) or
1/2” UNC mounting bolts in the through mounting (fixing) shaft seal (12), reverse remainder of brake sub-assembly,
holes provided. supporting on face “c” of housing (2).
Connect hydraulic pressure supply to brake pressure inlet
8. Remove internal retaining ring (11).
port. Ensure that the hydraulic pressure is set to the required
level up to a maximum of 3000 psi (200 bar) and check that the 9. Using arbor press or similar to break Loctite seal, remove
brake disengages and re-engages correctly. brake shaft (1) from housing (2) and lay aside.
10. Reverse housing (2) and press out ball bearing (10).
Maintenance Shaft seal (12) can also be removed if necessary.
The brake is required to be kept in good working order and
must be included in the planned maintenance program for the Examination
equipment to which the brake is installed. All components can now be examined and inspected, paying
This must include torque testing together with inspection and particular attention to the following.
replacement of the working parts such as friction plates (3 & 6)
and, springs (22 & 23). The frequency of inspection depends 1. Inspect friction plates (3 & 6) and friction surface on
on the duty demanded of the brake. pressure plate (4) for wear or damage.
2. Examine friction plates (3) and brake shaft (1) for wear or
Disassembly damage to splines.
To remove brake from its installed position, reverse procedure
3. Examine input and output splines of brake shaft (1) for
previously described in the installation instructions.
wear or damage.
Place the complete brake assembly on a clean, dry work
bench. 4. Examine compression springs (22 & 23) for damage or
fatigue.
Remove external gasket (5) as necessary.
5. Check ball bearing (10) for axial float or wear.
NOTE: Refer to Diagrams for the following. 6. Examine O-ring seals (15 & 17) and backing rings
(16 & 18) for damage.
1. Supporting brake face “A”, remove the six socket head
7. Obtain replacement parts as required.
cap screws and washers (items 13 & 14) in equal incre-
ments to ensure the spring pressure within the brake is
reduced gradually and evenly.
Alternatively, if press is available, the cylinder housing
(8) can be restrained on face “B” while removing the six
socket head cap screws and washers (13 & 14).
The brake assembly can now be fully dismantled and
parts examined.
2. Remove cylinder housing (8) and piston (9) subassembly

and dismantle if required, removing O-ring seals
(15 & 17) and backing rings (16 & 18) as necessary.
3. Remove gasket (7) from housing (2).
4. Remove friction plates (3 & 6) and pressure plate (4).
5. Remove 2-off dowel pins (19).
3121262 3-79
Assembly
Clean all parts thoroughly.
Reverse procedure previously outlined in Dismantling instruc-
tions taking particular care with.
a. Assembly of shaft seal (12).

b. Assembly of bearing (10).
c. Quantity and orientation of springs (8).
d. Assembly sequence of friction plates (3 & 6).
1. Lightly lubricate rotary shaft seal (12) and assemble to
housing (2) taking care not to damage seal lip.
2. Apply ring of Loctite 641 or equivalent adhesive to full
circumference of housing (2) bearing recess adjacent to
shoulder.
Apply complete coverage of Loctite 641 to outside
diameter of bearing (10) and assemble fully in housing
(2), retaining with internal retaining ring (11). Remove
excess adhesive with clean cloth. Figure 3-50. Swing Brake 12 Spring Orientation
Press shaft (1) through bearing (10), ensuring bearing
inner ring is adequately supported. 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or
3. Assemble correct quantity of springs (8) in orientation equivalent) silicone grease and assemble together with
required. Refer to (See Figure 3-54.) and backing rings (16 & 18) to piston (9). To ensure correct
(See Figure 3-55.). brake operation, it is important that the backing rings
are assembled opposite to the pressurized side of piston
(9).
5. Correctly orientate piston (9) aligning spaces with the
two dowel pin holes and, assemble into cylinder hous-
ing (2) taking care not to damage seals and carefully lay
aside.
6. Loctite 2-off pins (19) in housing (2) followed by pres-
sure plate (4) and friction plates i.e. an inner (3) followed
by an outer (6) in correct sequence.
7. Position gasket (7) in correct orientation.
8. Align two holes in cylinder with dowel pins (19) and
assemble piston & cylinder sub-assembly to remainder
of brake securing with 6-off socket head cap screws and
washers (13 & 14). Torque to 55ft-lbs. (75 Nm).
NOTE: The use of a suitable press (hydraulic or arbor) Pressing

down on cylinder end face “B” will ease assembly of the
socket head cap screws (13).
Figure 3-49. Swing Brake 8 Spring Orientation
3-80 3121262
1. Brake Shaft 8. Cylinder 15. O-Ring

2. Housing 9. Piston 16. Backing Ring
3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring
4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring
5. Gasket 12. Rotary Shaft Seal 19. Dowel Pin
6. Outer Plate 13. Socket Head Cap Screw 20. Hexagon Plug
7. Gasket 14. Shakeproof Washer 21. Plastic Plug
21A. Socket Pressure Plug
Figure 3-51. Swing Brake Assembly
3121262 3-81
3.17 SWING MOTOR
Disassembly and inspection

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

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

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

the exploded view to determine the end cover construction
being serviced.
3-82 3121262
1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing

2. End Cover 8C. Vane 16. Seal
3. Seal Ring-Commutator 8D. Stator Half 17. Back-up Washer
4. Seal Ring 9. Wear Plate 18. Housing
5. Commutator Ring 10. Drive Link 18A. O-Ring
6. Commutator Ring 11. Not Used 19. Bearing/Bushing, Outer
7. Manifold 12. Coupling Shaft 20. Dirt & Water Seal
8. Rotor Set 13. Bearing/Bushing, Inner 21. Plug
8A. Rotor 14. Thrust Washer
Figure 3-52. Swing Drive Motor
5. If the end cover (2) is equipped with shuttle valve com-

ponents, remove the two previously loosened plugs
(21). BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS
THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE
REMOVED.
NOTE: The insert and if included the orifice plug in the end cover
(2) must not be removed as they are serviced as an integral
part of the end cover.
3121262 3-83
6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal
blow dry. Be sure the end cover valve apertures, includ- ring from commutator, using an air hose to blow air into
ing the internal orifice plug, are free of contamination. ring groove until seal ring is lifted out and discard seal
Inspect end cover for cracks and the bolt head recesses ring. Inspect commutator for cracks or burrs, wear, scor-
for good bolt head sealing surfaces. Replace end cover ing, spalling or brinelling. If any of these conditions exist,
as necessary. replace commutator and commutator ring as a matched
set.
NOTE: A polished pattern (not scratches) on the cover from rota-

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

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

ing, brinelling or spalling. Replace manifold if any of
these conditions exist. A polished pattern on the ground
surface from commutator or rotor rotation is normal.
Remove and discard the seal rings (4) that are on both
sides of the manifold.
3-84 3121262
NOTE: The manifold is constructed of plates bonded together to

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

normal.
11. Place rotor set (8) and wear plate (9) on a flat surface
and center rotor (8A) in stator (8B) such that two
rotor lobes (180 degrees apart) and a roller vane
(8C) centerline are on the same stator centerline.
Check the rotor lobe to roller vane clearance with a
feeler gage at this common centerline. If there is
more than 0.005 inches (0.13 mm) of clearance,
replace rotor set.
NOTE: The rotor set (8) components may become disassembled

during service procedures. Marking the surface of the rotor
and stator that is facing UP, with etching ink or grease pen-
cil before removal from Torqlink™ will ensure correct reas-
sembly of rotor into stator and rotor set
intoTorqlink™.Marking all rotor components and mating
spline components for exact repositioning at assembly will
ensure maximum wear life and performance of rotor set
andTorqlink™.
NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets
of seven vanes (8C & 8E) as shown in the alternate con-
struction TG rotor set assembly view, check the rotor lobe
to roller vane clearance at both ends of rotor.
3121262 3-85
12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output
not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur-
link for cracks and worn or damaged splines. No percep- faces for spalling, nicks, grooves, severe wear or corro-
tible lash (play) should be noted between mating spline sion and discoloration. Inspect for damaged or worn
parts. Remove and discard seal ring (4) from housing internal and external splines or keyway. Replace cou-
(18). pling shaft if any of these conditions exist.
13. Remove thrust bearing (11) from top of coupling shaft

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

0.020 inches (0.51 mm) diametrically, replace coupling
shaft.
14. Check exposed portion of coupling shaft (12) to be sure
you have removed all signs of rust and corrosion which
might prevent its withdrawal through the seal and bear- NOTE: A slight “polish” is permissible in the shaft bearing areas.
ing. Crocus cloth or fine emery paper may be used. Anything more would require coupling shaft replacement.
16. 16. Remove and discard seal ring (4) from housing (18).
3-86 3121262
17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and
Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is
ment of retained rollers. required.
18. Remove seal (16) and back up washer (17) from Small 20. Inspect housing (18) assembly for cracks, the machined
Frame, housing (18). Discard both. surfaces for nicks, burrs, brinelling or corrosion. Remove
burrs that can be removed without changing dimen-
sional characteristics. Inspect tapped holes for thread
damage. If the housing is defective in these areas, dis-
card the housing assembly.
3121262 3-87
21. If the housing (18) assembly has passed inspection to NOTE: The depth or location of bearing/bushing (13) in relation to
this point, inspect the housing bearings/bushings (19) the housing wear plate surface and the depth or location
and (13) and if they are captured in the housing cavity of bearing/bushing (19) in relation to the beginning of
the two thrust washers (14) and thrust bearing (15). The bearing/bushing counter bore should be measured and
bearing rollers must be firmly retained in the bearing noted before removing the bearings/ bushings. This will
cages, but must rotate and orbit freely. All rollers and facilitate the correct reassembly of new bearings/bushings.
thrust washers must be free of brinelling and corrosion.
The bushing (19) or (13) to coupling shaft diameter
clearance must not exceed 0.010 inch (0.025 mm). A
bearing, bushing, or thrust washer that does not pass
inspection must be replaced. If the housing has passed
this inspection the disassembly of the Torqlink™ is com-
pleted.
22. If the bearings, bushing or thrust washers must be

replaced use a suitable size bearing puller to remove
bearing/bushings (19) and (13) from housing (18) with-
out damaging the housing. Remove thrust washers (14)
and thrust bearing (15) if they were previously retained
in the housing by bearing (13).
3-88 3121262
Assembly
Replace all seals and seal rings with new ones each time you
reassemble the Torqlink™ unit. Lubricate all seals and seal rings
with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a complete seal

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

before assembly.
NOTE: Bearing mandrel must be pressed against the lettered end
Wash all parts in clean petroleum-based solvents before of bearing shell. Take care that the housing bore is square
assembly. Blow them dry with compressed air. Remove any with the press base and the bearing/bushing is not cocked
when pressing a bearing/bushing into the housing.
paint chips from mating surfaces of the end cover, commuta-
tor set, manifold rotor set, wear plate and housing and from
port and sealing areas.
IF THE BEARING MANDREL SPECIFIED IN THE “TOOLS AND MATERIALS
REQUIRED FOR SERVICING” SECTION IS NOT AVAILABLE AND ALTERNATE
METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE
SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADE-
SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR QUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COM-
DEATH. PONENTS WHEN ASSEMBLED.
BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX-
HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE
IMUM AIR PRESSURE REQUIREMENTS.
REUSED.
1. If the housing (18) bearing components were removed

for replacement, thoroughly coat and pack a new outer
bearing/bushing (19) with clean corrosion resistant
grease recommended in the material section. Press the
new bearing/bushing into the counterbore at the
mounting flange end of the housing, using the appro-
priate sized bearing mandrel, which will control the
bearing/ bushing depth.
Torqlink™ housings require the use of bearing mandrel
to press bearing/ bushing (19) into the housing to a
required depth of 0.151/0.161 inches (3.84/4.09 mm)
from the end of the bearing counterbore.
3121262 3-89
2. The Torqlink™ inner housing bearing/bushing (13) can

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

until its flange is flush against the housing.
3-90 3121262
4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15)
the coupling shaft bore down, clamping against the that was removed from the Torqlink™.
mounting flange.
NOTE: Torqlinks™ require one thrust washer (14) with thrust bear-
5. On the Torqlinks™ assemble a new backup washer (17)
ing (15).The coupling shaft will be seated directly against
and new seal (16) with the seal lip facing toward the
inside of Torqlink™, into their respective counterbores in the thrust
housing (18) if they were not assembled in procedure 2.
7. Apply masking tape around splines or keyway on shaft
(12) to prevent damage to seal.
8. Be sure that a generous amount of clean corrosion resis-

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

BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A
NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).
3121262 3-91
9. Apply a small amount of clean grease to a new seal ring

(4) and insert it into the housing (18) seal ring groove.
THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC
FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED
GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT
#K-70M.
NOTE: Mobil Mobilith SHC ® 460
NOTE: A 102Tube (PN 406010) is included in each seal kit.
NOTE: The coupling shaft (12) will be flush or just below the hous-
ing wear plate surface on Torqlinks™ when properly seated.
The coupling shaft must rotate smoothly on the thrust
bearing package.
NOTE: One or two alignment studs screwed finger tight into hous-
ing (18) bolt holes, approximately 180 degrees apart, will
facilitate the assembly and alignment of components as
required in the following procedures.The studs can be
made by cutting off the heads of either 3/8-24 UNF 2A or 5/
16-24 UNF 2A bolts as required that are over 0.5 inch (12.7
mm) longer than the bolts (1) used in the Torqlink™.
10. Install drive link (10) the long splined end down into the
coupling shaft (12) and engage the drive link splines
into mesh with the coupling shaft splines.
NOTE: Use any alignment marks put on the coupling shaft and
drive link before disassembly to assemble the drive link
splines in their original position in the mating coupling
shaft splines.
3-92 3121262
11. Assemble wear plate (9) over the drive link (10) and NOTE: The rotor set rotor counterbore side must be down against
alignment studs onto the housing (18). wear plate for drive link clearance and to maintain the
original rotor-drive link spline contact. A rotor set without
a counterbore and that was not etched before disassembly
can be reinstalled using the drive link spline pattern on the
rotor splines if apparent, to determine which side was
down.The rotor set seal ring groove faces toward the wear
plate (9).
14. Apply clean grease to a new seal ring (4) and assemble it
in the seal ring groove in the rotor set contact side of
manifold (7).
12. Apply a small amount of clean grease to a new seal ring

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

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

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

Assembly Procedure.”
3121262 3-93
16. Apply grease to a new seal ring (4) and insert it in the
seal ring groove exposed on the manifold.
19. If shuttle valve components items #21, were removed

17. Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one
onto the manifold. end of the valve cavity in the end cover. A 3/16 inch
Allen wrench is required.
20. Assemble a new seal ring (4) into end cover (2) and
assemble end cover over the alignment studs and onto
the commutator set. If the end cover has only 5 bolt
holes be sure the cover holes are aligned with the 5
threaded holes in housing (18).The correct 5 bolt end
cover bolt hole relationship to housing port bosses.
18. Assemble a new seal ring (3) flat side up, into commuta-
tor (5) and assemble commutator over the end of drive
link (10) onto manifold (7) with seal ring side up.
3-94 3121262
NOTE: If the end cover has a valve (24) or has five bolt holes, use
the line you previously scribed on the cover to radially align
the end cover into its original position.
21. Assemble the 5 or 7 special bolts (1) and screw in finger

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

cover assembly to 45-55 ft. lbs. (61-75 Nm) if cover is so
equipped.
3121262 3-95
One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read-
A disassembled rotor (8A) stator (8B) and vanes (8C) that can- ily assemble into the stator vane pockets.
not be readily assembled by hand can be assembled by the
following procedures.
1. Place stator (8B) onto wear plate (9) with seal ring (4)
side down, after following Torqlink™ assembly proce-
dures 1 through 13. Be sure the seal ring is in place.
EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD
SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.
2. If assembly alignment studs are not being utilized, align 5. Grasp the output end of coupling shaft (12) with locking
stator bolt holes with wear plate and housing bolt holes pliers or other appropriate turning device and rotate
and turn two bolts (1) finger tight into bolt holes coupling shaft, drive link and rotor to seat the rotor and
approximately 180 degrees apart to retain stator and the assembled vanes (8C) into stator (8B), creating the
wear plate stationary. necessary clearance to assemble the seventh or full
complement of seven vanes. Assemble the seven vanes
3. Assemble the rotor (8A), counterbore down if applica-
ble, into stator (8B), and onto wear plate (9) with rotor using minimum force.
splines into mesh with drive link (10) splines.
NOTE: If the manifold side of the rotor was etched during Torqlink
disassembly, this side should be up. If the rotor is not
etched and does not have a counterbore, use the drive link
spline contact pattern apparent on the rotor splines to
determine the rotor side that must be against the wear
plate.
6. Remove the two assembled bolts (1) if used to retain sta-

tor and wear plate.
3-96 3121262
3.18 PROCEDURE FOR SETTING GEAR BACKLASH 5. Pre-torque the capscrews (shown below) to 90 ft-lbs
(122 Nm) with JLG Threadlocker PN 0100019.
1. Set backlash to 0.010 to 0.015" using the following pro-
cedure.
2. Place shim (JLG PN 4071041) between pinion and bear-
ing on the bearing high spot. The bearing high spot
should be stamped with an "X" on the surface below the
teeth and marked with yellow paint in the tooth space.
3. Torque the shoulder screw (shown below) to 660 ft-lbs 6. Tighten the setscrew (shown below) until the pinion is
(896 Nm) with JLG Threadlocker PN 0100019. completely snug against the shim and bearing and then
back off the setscrew.
4. Remove the turntable lock pin.

7. Torque the setscrew to 50 ft-lbs (68 Nm).
3121262 3-97
8. Tighten the jam nut (shown below) with JLG Thread- The Swing Gearbox is to be filled with 79 ounces (2.3 L) of API
locker PN 0100019. Service Classification GL-5 Extreme Pressure Gear Lube. Fill to
cover the ring gear.
1.195 in. (30.35 mm) TOP OF HOUSING TO TOP

OF RING GEAR. TO BE FILLED TO COVER RING
GEAR.
9. Torque the capscrews shown in step 5 to 660 ft-lbs

(896 Nm).
10. Remove shim and discard.
Figure 3-54. Swing Drive Lubrication

3.19 SWING DRIVE LUBRICATION (SN 0300209000 through 0300254531)
The Swing Brake is to be filled half full, 2.7 ounces (80 ml), with
DTE24 oil.
1 Brake Bleed Port

2 Brake Fill Port
3 Gearbox Fill Port
4 Gearbox Drain Port
Figure 3-53. Swing Drive Ports

(SN 0300209000 through 0300254531)
3-98 3121262
MAE37630
1 Swing Gearbox/Brake Fill Port

2 Swing Gearbox/Brake Drain Port
Figure 3-55. Swing Drive Ports (SN 0300254532 to Present)
The brake on swing drive uses same oil cavity as gearbox.

Remove the swing gearbox/brake fill plug and fill the unit with
105 ounces (3.1 L) of ISO VG 150 oil, until oil reaches halfway of
the plug opening. Close the swing gearbox/brake fill port (1)
immediately. Drain oil through the swing gearbox/brake drain
port (2).
3121262 3-99
3.20 SWING BEARING 2. Check the turntable to bearing attach bolts as follows:
a. Elevate the fully retracted main boom to full eleva-
Turntable Bearing Mounting Bolt Condition tion.
b. At the position indicated on Figure 3-58. try to insert
Check 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
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL boom.
LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE d. At the position indicated on Figure 3-57., try and
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE insert the 0.0015” feeler gauge between the bolt
SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. head and hardened washer at the arrow indicated
position.
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.
1. Check the frame to bearing attach bolts as follows:
a. Fully elevate the main boom. (See Figure 3-56.).

b. At the position indicated on Figure 3-56., try to
insert a 0.0015" feeler gauge between the bolt and
hardened washer at the arrow indicated position.
c. Ensure that the 0.0015” feeler gauge will not pene-
trate under the bolt head to the bolt shank.
d. Swing the turntable 90 degrees, and check some
selected bolts at the new position.
e. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in
all quadrants.
3-100 3121262
Figure 3-56. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2
3121262 3-101
3-102
Figure 3-57. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2
3121262
3. If the measurement is greater than 0.094 in. (2.387 mm),

the swing bearing should be replaced.
4. If the measurement is less than 0.094 in. (2.387 mm), and
any of the following conditions exist, the bearing should
be removed, disassembled, and inspected for the fol-
lowing:
a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation.
5. If bearing inspection shows no defects, reassemble and
Figure 3-58. Swing Bolt Feeler Gauge Check return to service.
Wear Tolerance
1. From the underside of the machine, at rear center, with

the main boom fully elevated and fully retracted, as
shown in Figure 3-56., Swing Bearing Tolerance Boom
Placement - Sheet 1 of 2, set up a magnetic base dial
indicator as shown below and set the indicator to 0
(zero).
2. Next, position the main boom fully extended and hori-

zontal as shown in Figure 3-57., Swing Bearing Tolerance
Boom Placement - Sheet 2 of 2. Read the measurement
recorded on the dial indicator gauge.
3121262 3-103
Turntable/Swing Bearing Removal It may be necessary to disconnect additional lines to

gain access to certain fittings. Cap or plug all openings.
The following procedure was accomplished using two over-
head cranes with the jib assembly and the boom removed
prior to un-decking the turntable. For un-decking information
concerning lifting the entire upperstructure as a unit, or
removing the boom and jib assembly together refer to Section
4 - Boom & Platform.
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.
5. Remove the valve from the boom.
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.
3-104 3121262
3121262
Figure 3-59. Swing Bearing Removal - Sheet 1 of 4
3-105
3-106
287” (729 cm)
CENTER
OF
GRAVITY
Boom & Jib Assembly - 20,650 lbs. (9,370 kg)
Main Boom Pivot
3121262
3121262
Boom Assembly - 10,791 lbs. (4,895 kg)
227” (576.5 cm)
CENTER
OF
GRAVITY
Main Boom Pivot
3-107
3-108
Turntable - 12,850 lbs. (5,825 kg)
Note: Attach Lifting Device to

Turntable Cutouts Closest to
This Side of Turntable
C
L ROTATION
3121262
6. Lay the jib control valve aside on the jib. Secure it in 8. Remove the bolt and keeper pin securing the jib level
place so it does not fall. cylinder pivot pin and remove the pin. Place blocking or
a soft material under the cylinder rod to protect the rod
surface from being scratched.
7. Disconnect the jib protractor sensor linkage from the

boom.
NOTE: The jib and platform assembly weighs approximately

2100 lbs. (953 kg.).
3121262 3-109
9. Attach an adequate supporting device to the jib to sup- 11. At the rear of the turntable, tag and disconnect all wir-
port its weight. Remove the bolt and keeper pin securing harnesses that run from the powertrack to the
ing the jib pivot pin and remove the pin. ground control station. The connector inside the ground
control box will have to be removed from the wires to
allow the harness to be pulled out of the control box. It
will simplify installation if a diagram of the wiring run-
ning into the connector is made at this time.
10. Remove the jib and platform assembly from the boom.

residual hydraulic fluid. Disconnect the pressure line
going into the platform filter, taking care to slowly bleed
off hydraulic pressure. Cap or plug all openings..
3-110 3121262
13. Have a container or absorption material ready to catch 15. Remove the cover from the rear of the boom and dis-
residual hydraulic fluid. Disconnect the telescope hoses connect the wiring harnesses and hoses running from
from the bottom of the hydraulic control valve. Cap or the turntable to the boom.
plug all openings. Pull the hoses out so the can be lifted
away from the machine with the boom.
16. Disassemble the end of the turntable-to-boom

powertrack from the turntable. Use a lifting device to
14. Have a container or absorption material ready to catch pull the powertrack up so the hydraulic hoses and wir-
residual hydraulic fluid. Disconnect the pressure hose ing harnesses can be pulled out from the turntable.
from the end of the main control valve. Cap or plug all
openings.
3121262 3-111
17. Using the Main Lift Crackpoint option under the Calibra- NOTE: To assist in determining when the lift cylinder is properly
tions menu on the JLG Analyzer, lift the boom enough to supported, use the JLG Analyzer and select Diagnostics >
access the boom lift cylinder rod pivot pin. Refer to Sec- Moment > Actual Moment and get a reading as close to
tion 6 - JLG Control System for additional analyzer zero (0) as possible.
instructions.
20. Remove the bolt and keeper pin securing the boom lift
cylinder rod pivot pin and drive out the pivot pin.
NOTE: The boom assembly weighs approximately 10,800 lbs.

(4,900 kg.). 21. Lower the lift cylinder until it rests on the turntable.
18. Using an adequate lifting device, support the weight of 22. Attach an adequate lifting device to support the pivot
the boom. end of the boom.
19. Attach a lifting device to support the weight of the

boom lift cylinder.
23. Remove the bolt and keeper pin securing the boom
pivot pin and remove the pivot pin. Remove the boom
from the machine and place it on adequate supports.
3-112 3121262
24. Disconnect the negative battery terminal from the bat- 27. Remove the attaching hardware securing the side of the
tery. hood.
25. Place a container under the machine to catch escaping 28. Remove the attaching hardware securing the top of the
hydraulic fluid. hood.
NOTE: The hood assembly weighs approximately 72 lbs. (33 kg). 29. Remove the front hood from the machine.
26. Attach an adequate lifting device to the rear hood

assembly.
30. Repeat steps 4, 5, and 6 for the front hood on the other
side of the machine.
3121262 3-113
31. Tag and disconnect the hoses from the top of the swivel. NOTE: The complete swing drive assembly weighs approximately
Cap or plug all openings. Use a tie strap to secure the 290 lbs. (132 kg).
hoses together.
34. Remove the hardware securing the swing drive to the
turntable and remove the swing drive.
32. Tie off the bundle of hydraulic hoses to the center sup-
port to prevent any damage to the hoses during the
remainder of the procedure.
NOTE: Remove the shoulder/pivot bolt last.
33. Remove the hardware securing the swing brake to the

swing drive and lay the swing brake and motor to the
side.
3-114 3121262
NOTE: The turntable assembly weighs approximately 20,650 lbs. 37. Lift the turntable assembly off of the swing bearing and
(9370 kg). place it on adequate supports.
35. Using the lifting lugs and the center support, attach a
lifting device to the front and rear of the turntable to
support its weight.
36. Remove the swing bearing inner race bolts. Remove the
bolts on the inside of the turntable first, leaving 3-4
bolts on both sides of the outside of the turntable to be
removed last.
38. Remove the remote grease lines from the bearing.
NOTE: The turntable assembly weighs approximately 20,650 lbs.

(9370 kg).
39. Remove the outer race bearing bolts from the underside
of the frame.
3121262 3-115
40. Install lifting eyes into the swing bearing for removal. Turntable/Swing Bearing Installation
1. Remove the attaching hardware securing the swivel and
lay it off to the side.
NOTE: The swing bearing weighs approximately 300 lbs. (136 kg).
41. Attach an adequate lifting device to the swing bearing

and remove it from the frame.
2. Thoroughly clean the bearing mounting surface and

mounting holes.
3-116 3121262
3. Locate the high spot on the swing bearing. This will be 7. Install grease fittings into the bearing and also install
marked by blue paint and two X’s on the bearing teeth. two pins to facilitate turning the bearing by hand and
for alignment of the turntable.
4. Place the new bearing onto the frame orienting the high
spot as close as possible to where the swing drive gear 8. Using the pins, turn the bearing slowly by hand while an
will be. assistant applies grease to the fitting. Apply grease until
the bearing is adequately greased around the entire cir-
cumference of the bearing.
9. Place the swivel back into position and secure in place
with the mounting hardware.
10. Line up the two grease holes in the bearing perpendicu-
lar to the chassis and install the remote grease lines.
5. Once the bearing is positioned on the frame, start the

outer race bolts by hand until they are all installed.
6. Tighten all the outer race bearing bolts until snug and
then torque them according to the torquing procedures
in this section.
11. Clean the bearing mounting surface on the bottom of

the turntable. If necessary, run a tap through the swing
drive mounting holes to clean the threads.
3121262 3-117
12. Lift the turntable into place on the bearing using the 15. Connect the hoses to the top of the swivel as tagged
previously installed guide pins for alignment. during removal. Secure the hoses together with a tie
strap as shown.
13. Install all of the inner race bearing bolts hand tight.
Remove the guide pins to install the last two bolts. After
all of the bolts are installed, tighten them until snug. Dis-
connect the front lifting device at the front of the turnta-
ble (leaving the rear lifting device in place) to gain full
access to all bolts and torque the bolts according to the
torquing procedures in this section.
16. Using an adequate lifting device, set the swing drive in

place on the turntable. Make sure the swing bearing
high spot is still aligned with the swing drive gear. If nec-
essary, swing the turntable slightly to align the mark
with the gear.
14. After all swing bearing bolts are torqued, the rear lifting
device can be disconnected.
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17. Position the swing drive mounting bolts and backlash 19. Lift the boom from its supports.
adjusting shim, JLG PN 4071041. Set backlash following
the procedures in this section.
18. Attach the swing bearing remote lubrication lines to the

turntable.
3121262 3-119
20. While lifting the boom into position, begin to route the 22. Raise the boom enough to gain access to the lift cylin-
hoses into position so they can be inserted into the der rod pivot fitting.
powertrack.
23. Attach a lifting device to the lift cylinder barrel. Lift the
lift cylinder up to align the lift cylinder rod pivot fittings.
21. Line up the boom pivot fittings and install the boom
pivot pin. Apply JLG Threadlocker PN 0100019 to the
bolt threads and secure the pin in place with the keeper
pin and bolt. Torque the bolt to 285 ft.lbs. (388 Nm). 24. Install the lift cylinder rod pivot pin. Apply JLG Thread-
locker PN 0100019 to the bolt and secure the pivot pin
in place with the keeper pin and bolt. Torque the bolt to
285 ft.lbs. (388 Nm).
3-120 3121262
25. Connect the hoses to the main valve and pressure filter 29. Place something under the front of the jib that will allow
as tagged during removal. it to slide or move along the ground easily. Attach a lift-
ing device to the rear of the jib, allowing the front to
pivot on the ground.
26. Reconnect the negative battery terminal.
30. Lift the jib into position on the boom fly section and
install the jib pivot pin. Apply JLG Threadlocker PN
0100019 to the bolt and secure the pivot pin in place
with the keeper pin and bolt. Torque the bolt to
165 ft.lbs. (224 Nm).
27. Using auxiliary power, lower the boom to horizontal.

28. Attach an adequate lifting device to the jib and position
it in front of the boom.
3121262 3-121
31. Attach a lifting device to the front of the jib and align 33. Install the wiring harnesses and hydraulic hoses on the
the jib level cylinder attachment fittings. Install the pivot jib valve as tagged during removal.
pin. Apply JLG Threadlocker PN 0100019 to the bolt and
secure the pivot pin in place with the keeper pin and
bolt. Torque the bolt to 165 ft.lbs. (224 Nm).
34. Install the jib valve protection plate.

35. Connect all electrical harnesses as tagged during
removal. Reinstall the wiring into the connector plug in
the ground control box as tagged during removal.
32. Place the mounting bracket on the jib valve and bolt the
jib valve to the fly boom section.
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36. Position the hoods in place on the turntable and secure Swing Bearing Torque Values
in place with the mounting hardware.
1. Outer Race - 190 ft. lbs. (258 Nm) w/Loctite.
2. Inner Race - 190 ft. lbs. (258 Nm) w/Loctite.
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.
37. Cycle test the machine and check for leakage and
proper operation.
38. Perform a boom calibration as described in Section 6

under Calibrating the Boom Sensors.
3121262 3-123
NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races.
Figure 3-63. Swing Bearing Torque Sequence
3.21 SWING SPEED PROPORTIONING Version P7.29) The 5.0° omni directional angle is used for the
purpose of warning the operator by means of the chassis tilt
Swing Speed Proportioning uses the boom length and angle
light in the platform display panel. Additionally when used in
sensors to improve the comfort, speed and control of the turn-
table swing function. Turntable swing speed is increased as conjunction with the Beyond Transport - Drive Speed Cutback
the distance of the platform to the center of rotation is System, the tilt sensor will cause an alarm to sound, and auto-
decreased. This results in approximately constant platform matically put all functions in the creep speed mode. With the
speeds regardless of boom position. Swing speed proportion- exception of the speed cutback, this is a warning system only
ing is disabled with any envelope sensors failure. Disabling of indicating to the operator the machine has reached the out of
swing speed proportioning will default to the slowest swing level limit. The machine will continue to function. The operator
speed setting.
is responsible to prevent the machine from attaining an unsta-
NOTE: For more detailed information concerning system adjust- ble position. The 3.0° side tilt setting is used in conjunction
ment and operation, refer to Section 6 - JLG Control Sys- with the main boom length and when exceeded, imposes the
tem. same functionality as the 5.0° omni directional setting. The
side tilt setting is ignored when the main boom length is less
3.22 CHASSIS TILT INDICATOR SYSTEM than its 65° maximum length regardless of boom angle
(1367.0 inches in the 500 lb mode or 1245.0 inches in the 1000
The Chassis Tilt Indicator System measures the turntable angle
lb mode).The 8.0 degree angle is used exclusively for the pur-
with respect to level ground. The tilt sensor (which is an inte-
pose of automatically shifting the drive motors to the maxi-
gral part of the ground module) has three settings; 3.0° side
tilt, 5.0° omni directional tilt and an 8.0° omni directional tilt. mum displacement position (slow speed). The control system
The tilt angle is dependent on market, Refer Table 6-2, responds to indicated angle readings 0.5° smaller than the
Machine Configuration Programming Information (Software required angles to account for calibration and sensor variation.
3-124 3121262
NOTE: For more detailed information concerning system adjust- Every 500 hours
tem. Every 500 hours of operation, service the generator brushes
and slip rings. Hostile environments may require more fre-
3.23 GENERATOR quent service.
Every 250 hours

Every 250 hours of operation, check the drive belt for proper
tension.
1/2 in. Every 500 hours of service, blow out the inside of the genera-
(13 mm) tor. If operating in a hostile environment, clean monthly.
3121262 3-125
Overload Protection Inspecting Brushes, Replacing Brushes, and

Cleaning Slip Rings
Refer to Figure 3-64., Inspecting Generator Brushes, Replacing
STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Brushes, and Cleaning Slip Rings.
BREAKER.
INSPECTING BRUSH POSITION
The circuit breaker protects the generator windings from over- Inspect brush alignment with slip rings. View alignment
load. If the circuit breaker opens, generator output stops. If the through the air vents in the stator barrel. The brushes must
circuit breaker continues to open, check for faulty equipment ride completely on the slip rings.
connected to the platform receptacles.
INSPECTING BRUSHES
Remove the end panel. Inspect the wires. Remove the brush
holder assembly. Pull the brushes from the holders.
Replace the brushes if damaged, or if the brush is at or near

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

the belt to turn the shaft by hand for cleaning.
Clean the rings with 220 grit emery paper. Remove as little
material as possible. If the rings are deeply pitted and do not
clean up, consult generator factory service.
Reinstall the belt, brush holder assembly, and end panel.
3-126 3121262
Brush Position On Slip Rings
2
3
Acceptable Unacceptable
Brushes must ride
completely on slip
rings
1/4 in (6 mm)
Or Less - Replace
7/16 in - 1/2 in
2 (11 - 12 mm) New
1. Brush Holder Assembly

2. Brushes
3. Slip Rings
Figure 3-64. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3121262 3-127
3.24 AUXILIARY POWER SYSTEM ity. The auxiliary power lift down function supplies pilot pres-
sure to the lift cylinder allowing gravity to lower the boom.
The auxiliary power system is intended as a secondary means The system redirects discharge oil from the lift cylinder to
of moving the boom in the event of primary power loss. This retract the telescope cylinder. When the boom is retracted to
system uses an electric motor/pump unit powered by a 12V the transport length, the telescope in valve is dropped out and
battery capable of operating all functions except drive, con- lift down is operated alone allowing the platform to reach the
trolled arc, controlled boom angle, and envelope tracking. ground. This not only greatly reduces the power required for
During lift up or down functions, no other functions are per- these functions but also lowers the boom within the envelope
mitted and during lift up functions, automatic platform level- regardless of starting position. Envelope control and moment
ing is not active. To reduce the demand on the battery and control remain active during the auxiliary power function.
therefore extend the run time of the system, the auxiliary
power functionality differs from the primary power functional-
1. Auxiliary Pump
2. Power Relay
3. Battery
Figure 3-65. Auxiliary Pump Installation
3-128 3121262
3.25 ENGINE (DEUTZ 2011) Check the oil level, and if necessary, top the oil level up
to the MAX mark with an approved grade and type of oil
NOTE: Refer to the engine manufacturer’s manual for detailed as outlined in the engine manufacturer’s operator’s
operating and maintenance instructions. manual. Refer to Figure 3-66., Deutz Engine Dipstick.
Glow Plugs MINIMUM OIL

LEVEL
If the glow plug option is enabled in the JLG Control System,
the glow plug and indicator lamp will be energized when the
Power/Emergency Stop switch is pulled on if the ambient air
temperature is less than 50° F (10° C) and the engine coolant
temperature is less than 140° F (60° C). This determination will
occur one second after the Power/Emergency Stop switch has MAXIMUM OIL
LEVEL
been pulled on. The lamp and glow plugs will remain ener-
gized for the period of time specified by the setting in the JLG
Control System. Engine start shall be disabled during this
period. On Deutz engines, the glow plugs will continue (post
glow) after the engine has started for three times the machine
digit setting.
MINIMUM LEVEL,
Checking Oil Level OIL HOT
MAXIMUM LEVEL,
OIL HOT
1. Switch the engine off before checking oil level.
2. Make sure the machine and engine are level.

MINIMUM LEVEL,
3. Remove the oil dipstick. OIL COLD
MAXIMUM LEVEL,
OIL COLD
4. Wipe the dipstick with non-fibrous, clean cloth.
NOTE: Hot oil checks should not be made until the engine
5. Insert the dipstick to the stop and remove again. has been shut down for a period of 5 minutes.
Figure 3-66. Deutz Engine Dipstick

6. Replace the dipstick making sure that it is fully seated in
the dipstick tube to seal off the crankcase.
3121262 3-129
Changing Engine Oil 8. Pour in new engine oil. Refer to Section 1 for capacity
and refer to Figure 3-67., Engine Oil Viscosity for the
1. Allow the engine to warm up. The engine oil should proper grade.
reach approximately 176° F (80° C).
2. Make sure the machine and engine are level.
3. Switch off the engine.
4. Place an oil tray under the engine.
5. Open the oil drain valve.
Figure 3-67. Engine Oil Viscosity
Changing the Oil Filter
WHEN DRAINING HOT ENGINE OIL THERE IS A RISK OF SCALDING.
DO NOT LET USED OIL RUN INTO THE SOIL; COLLECT THE USED OIL IN A CON-
TAINER SUITABLE FOR DISPOSAL OR RECYCLING. DISPOSE OF THE USED
ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.
6. Drain the oil.

7. Close the oil drain valve.
1. Wipe the area around the filter to clean any dirt from the
area.
3-130 3121262
2. Using a suitable oil filter removal tool, loosen the lube oil Replacing the Fuel Filter
filter cartridge and spin off.
3. Catch any escaping oil.
4. Clean any dirt from the filter carrier sealing surface.
5. Lightly oil the rubber gasket on the new oil filter. WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE
FUEL SYSTEM.
area.
2. Undo the fuel filter cartridge and spin off.
3. Catch any escaping fuel.
4. Clean any dirt from the filter carrier sealing surface.
5. Apply a light film of oil or diesel fuel to the rubber gas-
ket of the new filter cartridge.
6. Manually screw in the new filter until the gasket is flush.
6. Manually screw in the new filter until the gasket is flush. 7. Tighten the fuel filter cartridge with a final half-turn.
8. Open the fuel shut-off valve.
9. Check for leaks.
7. Tighten the filter another half-turn.
8. Check the oil level.
9. Check the oil pressure.
10. Check the oil filter cartridge and make sure there are no
leaks.
3121262 3-131
Cleaning the Fuel Strainer 3.26 DEUTZ ENGINE - TD2.9L4

NOTE: Refer to engine manufacturer's manual for detailed oper-
ating and maintenance instructions. Limited engine main-
tenance items are presented here for convenience but
detailed engine maintenance items and schedule are
included in the engine manufacturer's manual.
Glow Plugs
If the glow plug option is enabled in the JLG Control System,
the glow plug and indicator lamp will be energized when the
Power/Emergency Stop switch is pulled on if the ambient air
temperature is less than 50° F (10° C) and the engine coolant
temperature is less than 140° F (60° C). This determination will
occur one second after the Power/Emergency Stop switch has
been pulled on. The lamp and glow plugs will remain ener-
gized for the period of time specified by the setting in the JLG
Control System. Engine start shall be disabled during this
period. On Deutz engines, the glow plugs will continue (post
WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN glow) after the engine has started for three times the machine
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE digit setting.
FUEL SYSTEM.
Check Oil Level
1. Unscrew the hexagonal nut (1).
1. Make sure machine and engine are level and switch
engine OFF before checking oil level.
2. Remove oil dipstick and wipe with clean cloth.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level as shown in figure below
with an approved grade and type of oil outlined in
engine manufacturer’s operator’s manual.
2. Remove the fuel strainer cover (2).

3. Clean the fuel strainer with diesel fuel, replace if neces-
sary. Figure 3-68. Deutz Engine Dipstick
4. Place the seal (3) in position.
5. Replace dipstick until fully seated.
5. Install the fuel strainer cover (2) in position and tighten
the hexagonal screw (1).
6. Check for leaks.
3-132 3121262
Replacing Engine Oil Replacing the Oil Filter

1. Allow engine to warm up. Engine oil should reach
approximately 176° F (80° C).
2. Make sure machine and engine are level.
3. Switch off engine.
4. Place oil tray under engine.
HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
DRAINING.
Figure 3-70. Location of the oil filter

COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.
DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU- 1. Wipe area around filter to clean any dirt from area.
LATIONS.
2. Using a suitable oil filter removal tool, loosen lube oil fil-
5. Open oil drain valve and drain oil. ter element and spin off.
6. Close oil drain valve.

7. Pour in new engine oil. Refer to Section 1 for capacity
and Figure 3-75., Engine Oil Viscosity.
3. Catch any escaping oil.

4. Clean any dirt from filter carrier sealing surface.
5. Lightly coat new oil filter rubber gasket with clean oil.
6. Screw in new filter by hand until gasket is flush.
7. Hand-tighten filter another half-turn.
Figure 3-69. Engine Oil Viscosity
8. Check oil level.

9. Check oil pressure.
10. Check oil filter cartridge for leaks.
3121262 3-133
Replacing the Primary Fuel Filters 7. Screw in new filter by hand until gasket is flush. Hand-
tighten filter another 3/4 turn.
8. Check for leaks.

Figure 3-71. Location of the Primary Fuel Filter
Replacing the Fuel Pre-Filter
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON THE FUEL SYSTEMS.
1. Wipe area around filter to clean any dirt from area.
2. Fuel supply from the fuel tank may need to be blocked
to prevent flow from the fuel tank.
3. Remove fuel filter cartridge.
Figure 3-72. Location of Fuel Pre-Filter
NOTE: Refer Figure 3-74., Components of Fuel Pre-Filter.
5. Clean dirt from filter carrier sealing surface.

6. Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.
3-134 3121262
Water in Fuel Sensing System (Optional)

6 The Water in Fuel Sensing System detects when there is an
excessive amount of water in the fuel and sets a DTC code in
the JLG Control System to alert the operator and/or service
technician.
When Water in Fuel condition occurs, the machine will
respond in the following way:
• The engine will shut down automatically.
• The JLG Control System will set DTC 4375 - Water in Fuel.
• An alarm will sound from the active control station (ground
or platform).
• If in platform mode, the Low Fuel Indicator will flash.
• Engine Restart will be permitted after the machine senses
the Water in Fuel condition, but will only run for 2 minutes
and the engine will shut down again. This restart process
will continue until the Water in Fuel condition is corrected.
Draining Water
1. Fuel Supply Flow to the Pump 4. Drain Plug
Frequency of water draining is determined by the contamina-
2. Venting Screw 5. Filter Element
tion level of the fuel. Inspect or drain the collection bowl of
3. Electrical Connection for Water 6. Fuel Inlet from the Fuel Tank
water daily or as necessary. The collection bowl must be
Level Sensor
drained before contaminants reach the top of the turbine or
Figure 3-73. Components of Fuel Pre-Filter when the Water Detection Module (optional) indicates it’s
time to drain water.
Pressure Applications / Installations:

WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE 1. Open the drain plug on the bottom of the bowl to evac-
FUEL SYSTEM. uate water and contaminants with a suitable collection
container in place.
1. Switch off the engine.
2. Close the drain after all the water and contaminants
2. Fuel supply from the fuel tank may need to be blocked have been evacuated.
to prevent fuel flow from the tank.
NOTE: Do not leave the drain open too long as it may completely
3. Place suitable collecting container under drain plug. drain the entire filter assembly of water and fuel.
4. Disconnect electrical connections from water sensor.
5. Loosen drain plug and drain liquid.
6. Remove filter element.
8. Clean any dirt of the sealing surfaces of the new filter
element and opposite side of filter head.
9. Wet the sealing surfaces of new filter element slightly
with fuel.
10. Install new filter onto the filter head in clockwise direc-
tion. Torque to 12.5-13.3 ft. lbs. (17-18 Nm).
11. Install the drain plug and tighten to torque 1-1.4 ft. lbs.
(1.3-1.9 Nm).
12. Connect electrical connection to water sensor.
13. Check for leaks after starting engine.
3121262 3-135
Auxiliary Fuel Filter NOTE: Do not use any tool for removal and installation of T-han-
dle.
PRIMING OF AUXILIARY FUEL FILTER

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

6. Correct as necessary with engine off and pressure
relieved from filter assembly.
DRAINING WATER
Frequency of water draining is determined by the contamina-
tion level of the fuel. Inspect or drain the collection bowl of
1. T-handle 3. Lid water daily or as necessary. The collection bowl must be
2. Filter Element 4. Drain Plug drained before contaminants reach the top of the turbine or
when the Water Detection Module (optional) indicates it’s
Figure 3-74. Components of Auxiliary Fuel Filter
time to drain water.
Pressure Applications / Installations:
WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN 1. Open the self-venting drain plug on the bottom of the
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE bowl to evacuate water and contaminants with a sui
FUEL SYSTEM. able collection container in place. Head pressure will
push any water and contaminants out of the drain while
ELEMENT REPLACEMENT keeping the filter primed.
Frequency of element replacement is determined by the con-
tamination level of the fuel. Replace the elements every 500 2. Close the drain after all the water and contaminants
hours, if power loss is noticed or annually, which ever comes have been evacuated.
first. 3. If necessary, follow priming of auxiliary fuel filter.
1. Switch off the engine. NOTE: Do not leave the drain open too long as it may completely
2. Fuel supply from the fuel tank may need to be blocked drain the entire filter assembly of water and fuel.
to prevent fuel flow from the tank.
area.
4. Remove the T-handle and lid.
5. Remove the element by holding the bail handles and
slowly pulling upward with a twisting motion. Dispose
of properly.
6. Replace old lid gasket and T-handle O-ring with new
seals (supplied with new element). Lubricate both seals
with motor oil or diesel fuel before installation.
7. Refer to Priming of auxiliary fuel filter or fill the unit with
clean fuel, then replace the lid and T-handle then
tighten snugly by hand only.
3-136 3121262
This Page Left Blank Intentionally
3121262 3-137
3.27 DEUTZ 2.9 L4 (GUO III) ENGINE
8
4
7
1001221259-C
MAE35970C
Figure 3-75. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 1 of 2
3-138 3121262
8
7
1
6
5
1001221259-C
MAE36230C
1. Generator Mount 5. Air Filter

2. Lower Radiatpr Hose 6. Coolant Level Sensor
3. Air Intake Hose 7. Upper Radiator Hose
4. Air Filter Indicator 8. Pipe Flex Assembly
Figure 3-76. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 2 of 2
3121262 3-139
3.28 DEUTZ TD2011 ENGINE
4
16
8
19
15
1
5
17 11
18 2
12
14
10
13
20
1001116015-D
MAE35960D
1. Fan 6. Oil Cooler 11. Oil Drain 16. Muffler Bracket

2. Rod 7. Muffler 12. Lanyard 17. Motor Mount
3. Exhaust 8. Air Cleaner Assembly 13. Front Engine Mounting Plate 18. Generator Mount
4. Air Intake 9. Pump Assembly 14. Rear Engine Mounting Plate 19. Pump Coupling Kit
5. Heater 10. Cooler 15. Pulley 20. Engine Tray
Figure 3-77. Detuz TD2011 L040 Engine Installation
3-140 3121262
3121262 3-141
3.29 DEUTZ 2.9L4 ENGINE
3 4
1001141744-L
MAE36140L
1. Fan 5. Muffler
2. Fuel Tank 6. Engine Mount
3. Alternator 7. Radiator
4. Air Fuel Filter
Figure 3-78. Detuz TCD2.9L4 Engine Installation - Sheet 1 of 2
3-142 3121262
1
1001141744-L
MAE36270L
1. Air Filter 5. Sensor Coolant Level

2. Air Intake 6. Generator Mount
3. Fuel Filter Service Indicator 7. Heater Enfine Block
4. Pipe Exhaust 8. Engine Tray
Figure 3-79. Detuz TCD2.9L4 Engine Installation - Sheet 2 of 2
3121262 3-143
3.30 DEUTZ EMR 2

The EMR2 consists of the sensors, the control unit and the
actuator. Engine-side controls as well as the JLG Control Sys-
tem are connected by means of separate cable harnesses to
the EMR control unit.
The sensors attached to the engine provide the electronics in
the control unit with all the relevant physical parameters In
accordance with the information of the current condition of
the engine and the preconditions (throttle position etc.), the
EMR2 controls an actuator that operates the control rod of the
injection pump and thus doses the fuel quantity in accordance
with the performance requirements.
The exact position of the regulating rod is reported back and,
if necessary, is corrected, by means of the control rod travel
sensor, situated together with the rotation magnets in a hous-
ing of the actuator.
The EMR2 is equipped with safety devices and measures in the
hardware and software in order to ensure emergency running
(Limp home) functions.
In order to switch the engine off, the EMR2 is switched in a de-
energized fashion over the ignition switch. A strong spring in
the actuator presses the control rod in the de-energized con-
dition into the zero position. As a redundancy measure, an
additional solenoid serves for switching off and this, indepen-
dently of the actuator, also moves the control rod in the de-
energized condition into the zero position.
After the programming, that is carried out over the ISO9141
interface, the EMR2 is possesses a motor-specific data set and
this is then fixedly assigned to the engine. Included in this are
the various application cases as well as the customer’s wishes
regarding a particular scope of function.
Each EMR2 module is matched by serial number to the engine.
Modules cannot be swapped between engines.
3-144 3121262
CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY
COOLANT TEMPERATURE FLYWHEEL SPEED

SENSOR SENSOR
JLG SYSTEM HANDLES ENGINE START/STOP; EMR2

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

OIL PRESSURE TO CONTROL THE ENGINE & FAULT REPORTING.
SENSOR
Figure 3-80. EMR 2 Engine Side Equipment
3121262 3-145
3-146
Deutz EMR2;
Fails to Start/
Runs Abnormally
Does the machine Add fuel or

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

Laptop to Replace/Repair
use Deutz indicate a Deutz the faulty
Diagnostic NO fault code YES wiring/
Software number? component(s)
YES
Does the
diagnostic software
indicate a problem?
Figure 3-81. Deutz EMR 2 Troubleshooting Flow Chart
3121262
3121262
Figure 3-82. Deutz EMR 2 Vehicle Side Connection Diagram
3-147
3-148
Figure 3-83. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
3121262
3121262
Figure 3-84. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3-149
Figure 3-85. EMR 2 Engine Plug Pin Identification
3-150 3121262
Figure 3-86. EMR 2 Vehicle Plug Pin Identification
3121262 3-151
3-152
Figure 3-87. EMR2 Fault Codes - Sheet 1 of 5
3121262
3121262
3-153
3-154
3121262
3121262
3-155
3-156
3121262
3.31 BIO FUEL IN DEUTZ ENGINES The use of US bio-diesel based on soy oil methylester is only
permissible in mixtures with diesel fuel with a bio-diesel part of
a max. 20 weight-%. The US bio-diesel used for the mixture must
General
comply with the ASTM D6751-07a (B100) standard.
Use of bio fuels is permitted for the compact engines made by
DEUTZ. APPROVED ENGINES
The 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and
Distillate fuels with residue oil percentages or mixed fuels may
513 series are approved for bio-diesel from year of manufac-
not be used in DEUTZ compact engines.
ture 1993 under compliance with the basic conditions speci-
The DEUTZ vehicle engines are designed for diesel fuels in fied below.
accordance with EN 590 with a cetane number of at least 51.
DEUTZ engines for mobile machinery are designed for a cetane BASIC CONDITIONS TO BE OBSERVED
number of at least 45. When using fuels of a low cetane num- • A power loss of 5-9 % in relation to diesel fuel in accor-
ber, disturbing white smoke and ignition misfires are to be dance with EN 590 is possible due to the lower heating
expected under some circumstances. value. Blocking of the fuel injector is not allowed.
A cetane number of at least 40 is permissible for the US market, • The lubricating oil quality must correspond to TR 0199-
therefore special engine models have been developed to 99-3002. The lubricating oil change interval must be
avoid starting difficulties, extreme white smoke or increased halved in relation to operation with diesel fuel in accor-
hydrocarbon emissions (EPA specification - US EPA REGULA- dance with EN 590.
TIONS FOR LARGE NONROAD COMPRESSION-IGNITION
ENGINES). • Standstills of longer than 4 to 6 weeks must be avoided
with bio-diesel. Otherwise the engine must be started and
If the white smoke behavior is unacceptable when using a very
stopped with diesel fuel.
low cetane number, the use of ignition improvers is to be rec-
ommended as a later remedial measure. • Bio-diesels can be mixed with normal diesel fuel but the
basic conditions described in this subsection apply for mix-
The certification measurements for compliance with the legal
tures. Mixtures with up to 5 % (m/m) bio-diesel (B5) which
emission limits are carried out with the test fuels prescribed by
have recently been on sale at European fuel stations are
law. These correspond to the diesel fuels in accordance with
excepted. These fuels must be treated like normal diesel
EN 590 and ASTM D 975. No emission values are guaranteed
fuels because EN 590 expressly permits adding up to 5 %
with the other fuels described. It is the obligation of the owner
(m/m) bio-diesel in accordance with EN 14214.
to check the permission for use of the fuels in accordance with
regional regulations. • Approx. 30-50 hours after changing over from diesel fuel to
bio-diesel, the fuel filter should be changed as a preventive
Bio Fuel measure to avoid a drop in performance due to clogged fuel
filters. Deposited fuel ageing products are dissolved by bio-
PERMITTED BIO-DIESEL FUELS diesel and transported into the fuel filter. They should not
Originally only rape seed oil methylester (RME) was sold as a be changed immediately but after approx. 30 to 50 hours
bio-diesel fuel in Europe but fatty acid methylester (FAME) because the dissolving of dirt takes a certain amount of
based on other oils have come onto the market increasingly in time.
recent years. However, with the latter there is a risk that the limit
values of EN 14214 are not kept in the field. Anyone who uses
bio-diesel fuel in DEUTZ engines must therefore choose his
supplier very carefully and have him guarantee compliance
with the EN 14214 limit values. Since experience has shown
that rape seed oil methylester (RME) exceeds the limit values
less often that other esters, it is expressly recommended to use
only rape seed oil methyester. DEUTZ customers in Germany
can additionally ensure the quality by buying bio-diesel fuel
with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Man-
agement Biodiesel e.V.).
3121262 3-157
PLANT OIL PREVENTIVE MEASURES

• Keep the storage tank clean, regular cleaning of the tank
by specialist companies
PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS • Installation of fuel pre-filters with water traps, especially in
BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPER- countries with frequently fluctuating fuel qualities and high
ATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH percentage of water.
VISCOSITY, POOR EVAPORATION BEHAVIOR.
If the fuel system and storage tank have already been attacked
by micro-organisms. The biocide must be dosed according to
The conversion of DEUTZ engines to rape seed oil fuel opera-
the manufacturer's specifications.
tion with conversion kits and modified tanks systems of vari-
ous manufacturers is not allowed and leads to loss of warranty • Avoid direct exposure of the storage tank to sunlight
rights.
• Use smaller storage tanks with corresponding low dwell
times of the stored fuel
Biological Contamination In Fuels
FUEL ADDITIVES
SYMPTOMS The use of fuel additives is not permitted. The flow improvers
The following symptoms may indicate that a fuel tank is con- mentioned above are an exception. Use of unsuitable additives
taminated by micro-organisms: will result in loss of warranty.
• Internal tank corrosion,

• Filter blockage and the associated loss of power due to gel-
like deposits on the fuel filter (especially after long stand-
stills)
CAUSE
Micro-organisms (bacteria, yeasts, funguses) can form bio-
sludge under unfavorable conditions (favoured particularly by
heat and water).
Penetration by water is usually caused by condensation of the

water in the air. Water does not dissolve in fuel so that the pene-
trating water collects at the bottom of the tank. The bacteria and
funguses grow in the watery phase, at the phase boundary to
the fuel phase, from which they draw their nutrition. There is an
increased risk especially with bio-diesel (FAME).
3-158 3121262
3.32 DEUTZ ENGINE FAULT CODES
Table 3-7. Engine Fault Codes TCD2.9L4
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
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.
29 3 932 1-2-6 Diagnostic fault check of short circuit to sup- The signal exceeds the applicatable threshold; If the signal is below the applicatable threshold
ply voltage signal range violation APP_uRawSRCHiHTLIS_C, the signal
(signal range check high) of acceleration range violation is reset
pedal signal. after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal is below the threshold
APP_uHTLISCCPHi[1], a signal range violation
is reset
after debouncing.
29 4 937 1-2-6 Diagnostic fault check of short circuit to The signal is below the applicatable threshold; If the signal exceeds the applicatable threshold
ground (signal range check low) of accelera- signal range violation APP_uRawSRCLoHTLIS_C, the signal
tion pedal signal range violation is reset
after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal exceeds the threshold
APP_uHTLISCCPLo[1], a signal range violation
is reset
after debouncing.
91 3 935 2-2-6 Analog accelerator pedal sensor 1 or double Sensor defect. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- Short cut to battery or open loop. and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it.
compared with the position of the second If the signal is below the applicatable threshold
pedal APP_uRaw1SRCHigh_C, the signal
range violation is reset after
the healing debouncing.
91 4 940 2-2-6 Analog accelerator pedal sensor 1 or double Short circuit to ground. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it
compared with the position of the second If the signal exceeds the applicatable threshold
pedal APP_uRaw1SRCLow_C, the signal
range violation is reset after the
healing
3121262 3-159
Deutz Blink
Code Code
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 it,
check connection cable and if necessary repair
or replace it.
When the PWM period APP_tiPWMPer is in
between APP_tiSRCLoPWMPer_C and
APP_tiSRCHiPWMPer_C .
94 1 474 216 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Check low fuel pressure system (fuel feed
culated by ECU is underneath the target pump, relay , fuse, wiring, sensor) and if
range; the ECU activates a system reaction necessary repair or replace it.
94 3 472 216 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range Short cut to battery or open loop connection cable and if necessary repair or
replace it
94 4 473 216 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range short cut to ground connection cable and if necessary repair or
replace it
97 3 464 228 Fuel filter water level sensor: the voltage of Sensor not connected or sensor defect. Check of wiring and water in fuel sensor.
sensor measured by ECU is out of the target Check cabling, if charge Water in Fuel sensor is
range not working, check sensor and if
necessary replace it,
or replace it.
97 4 465 228 Fuel filter water level sensor: the voltage of cable break or short circuit, sensor defective, Check sensor and if necessary replace it, check
sensor measured by ECU is out of the target connection cable damaged. connection cable
range. Short cut to ground. and if necessary repair or replace it.
97 12 1157 228 Fuel filter water level sensor: the maximum Water level in fuel pre-filter reservoir over limit Measure Voltage at Water in Fuel Sensor and
level is exceeded (bad fuel quality) renew harness if needed.
100 1 736 231 Oil pressure is below the target range (warn- Oilpressure too low (pressure below warning Threshold for error detection is an internal ECU
ing threshold) threshold) threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value
100 1 737 231 Oil pressure is below the target range (shut Oilpressure too low (pressure below shut off Threshold for error detection is an internal ECU
off threshold) threshold). threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value.
100 3 732 224 Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiring
measured by ECU is out of the target range Check cabling. If sensor not working, check sen-
sor and if necessary replace it,
or replace it.
3-160 3121262
Deutz Blink
Code Code
100 4 733 224 Oil pressure sensor: the voltage of sensor Short circuit to ground The sensed raw voltage value Oil_uRawPSwmp
measured by ECU is out of the target range is above Oil_SRCPSwmp.uMin_C
Check cabling, if sensor not working, check sen-
sor and if necessary replace it, check
connection cable and if necessary repair or
replace it
No detail informationen!
102 1 774 223 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 2 88 223 Charge air pressure messured by sensor is Charged air cooler pressure below threshold. Check waste gate system if necessary replace
above the shut off threshold. TC,
check CAC if all channels are clean,check charge
air piping if nececery.
102 2 89 223 Charge air pressure messured by sensor is Charge air pressure above shut off threshold Check waste gate system if necessary replace
above the warning threshold TC, check CAC if all channels are clean,
check charge air piping if necessery.
102 2 772 223 Deviation between sensed intake manifold deviation between ambient pressure sensor 1) Exchange boost pressure sensor
pressure is not plausible compared to envi- and charge air pressure sensor at not 2) Exchange ECU
ronment pressure. Which sensor is not okay running engine to high
can not be said.
102 3 776 223 Charge air pressure sensor: the measured The Sensor Voltage is above the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and if necessary replace it, check connection
cable and if necessary repair or replace it.
102 4 777 223 Charge air pressure sensor: the measured The Sensor Voltage is below the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and
if necessary replace it, check connection cable
and if necessary repair or replace it
105 0 996 233 Charge air temperature downstream calcu- Charge air temperature (downstream) over Check CAC system and clean it. Check fan func-
lated by ECU is above the target range. warning threshold. tionality.
The ECU activates a system reaction. Check cooling perfomance with temperature
measurement.
105 0 997 233 Charge air temperature downstream calcu- Charge air temperature (downstream) over the Check CAC system and clean it. Check fan func-
lated by ECU is under the shut down thresh- low threshold. tionality. Check cooling perfomance
old. with temperature measurement.
The ECU activates a system reaction.
105 1 992 128 Charged Air cooler down stream tempera- Sensed temperature within intake air manifold actual temperature below -40°C?
ture. < threshold. exchange sensor
Temperature below lower physical thresh-
old.
105 3 994 128 Charge air temperature sensor: the voltage Short circuit to battery. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage > limit age) > Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it.
3121262 3-161
Deutz Blink
Code Code
105 4 995 128 Charge air temperature sensor: the voltage Short circuit to ground or open load. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage < limit. age) is below Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it
107 0 752 136 Air filter differential pressure: the pressure Pressure loss above target range with system Check airfilter and if necessary clean or renew it,
difference of the intake air between the filter reaction, air filter clogged or defective, check cabling, check sensor and if
inlet and outlet calculated by ECU is above sensor not working, connection cable damaged necessary replace it, check connection cable
the target range and the ECU activates a Pressure value above warning threshold and if necessary repair or replace it
system reaction
110 0 98 232 Coolant temperature: the coolant tempera- Cooling temperature too high. Coolant temper- Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target ature above warning threshold level, check cooling system in general,
range; the ECU activates a system reaction check thermostat function, check water pump
110 0 99 232 Coolant temperature: the coolant tempera- Coolant temperature above shut off threshold. Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target level, check cooling system in general,
range. check thermostat function, check water pump
The ECU activates a system reaction
110 1 93 225 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 96 225 Coolant temperature sensor: the voltage of Short cut to battery or open load. Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- connection cable and if necessary
get range repair or replace it.
110 4 97 225 Coolant temperature sensor: the voltage of Voltage Surveillance has found shortcut to Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- Ground at Coolant Temperatur Sensor. connection cable and if necessary
get range repair or replace it
Measure Voltage at Coolant Temperature Sen-
sor and renew harness if needed.
111 1 101 235 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
157 3 877 147 Rail pressure sensor: the voltage of sensor Short cut to battery. Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. Damaged rail pressure sensor. necessary replace it,
or replace it.
157 4 878 147 Rail pressure sensor: the voltage of sensor Check cabling, check rail pressure sensor and if Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. necessary replace it, necessary replace it,
check connection cable and if necessary repair check connection cable and if necessary repair
or replace it. or replace it.
164 2 1381 839 Rail pressure safety function is not executed Rail pressure is still above threshold. Threshold for error detection is an internal ECU
correctly threshold.
Reset the fault and at reappearance check ECU
and injection system
168 0 1180 318 Battery voltage: the voltage measured by Battery voltage over limit Check alternator, regulator of alternator and if
ECU is out of the target range necessary replace it, check wiring and
voltage of alternator
168 1 1181 318 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
3-162 3121262
Deutz Blink
Code Code
168 2 47 318 Battery voltage: the voltage measured by If Batteryvoltage (Ubatt_U) > 17V or 31V for Check wiring harness and connected alternator.
ECU is out of the target range, system reac- mor than =0.5sec a warning is generated
tion is initiated Battery voltage above warning threshold
168 3 45 318 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 46 318 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
171 3 417 312 Sensor error SCR-System environment tem- open loop to sensor Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check high and if necessary replace it, check connection
cable and if necessary repair or replace it.
171 4 418 312 Sensor error SCR-System environment tem- short circuit to Ground Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check low and if necessary replace it, check connection
cable and if necessary repair or replace it
172 0 1425 226 sensed intake air temperature at air filter > sensed intake air temperature at air filter > Check outside conditions:
physical high limit physical high limit Temperature > Threshold within the intake air
system of the engine?
E.G: engine sucks in air from hot asphalt out of
paver bucket
Sensor positioned within black air filter housing
above engine lid at hot environmental
conditions and idling or similar?
=> if yes check with application team to adapt
limits
if not check sensor and wiring harness
exchange sensor
172 1 1183 226 sensed air temperature within air intake sensed air temperature within air intake path of Cold start and ambient temperature < thresh-
path of engine below physical low limit engine below physical low limit old
Check wiring harness to AFST-sensor
Exchange AFST-sensor
190 0 389 214 Engine speed: the engine speed calculated Overspeed monitoring during 1 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over Limit.
190 2 421 213 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 8 419 212 Camshaft speed sensor: the ECU receives no When disturbed camshaft signal detected. Threshold for error detection is an internal ECU
signal and uses the signal from crankshaft Error in sensor or wiring. threshold, occurs by disturbed
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
Check Camshaft Sensor or wiring.
3121262 3-163
Deutz Blink
Code Code
190 8 422 212 Sensor crankshaft speed; disturbed signal Error in sensor or wiring. Threshold for error detection is an internal ECU
Crankshaft sensor defect. threshold, occurs by disturbed
crankshaft signal.
Check increment wheel position, clean and
Check Crankshaft Sensor or wiring.
190 11 390 214 Engine speed: the engine speed calculated Overspeed monitoring during 2 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over limit.
190 12 420 212 Camshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
Threshold: adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
190 12 423 212 Crankshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the Crankshaft signal.
engine speed. Check increment wheel position, clean and
adjust if necessary, check Crankshaft
sensor postition or wiring.
190 14 391 214 Engine speed: the engine speed calculated Overspeed monitoring during ORC (Override check powertrain settings regarding overspeed
by ECU is above the target range; the ECU conditions) if engine speed was over
activates a system reaction 2900rpm
190 14 1222 2-1-2 Camshaft- and Crankshaft speed sensor sig- Sensors for engine speed are defect. Threshold for error detection is an internal ECU
nal not available on CAN or defect. threshold.
Check wiring, check cabels and repair or replace
if necessary.
411 0 791 693 delta pressure across venturi in EGR line sensed value of venturi difference pressure > Threshold for error detection is an internal ECU
above physical high limit high limit threshold.
EGR-Valve blocked open
EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect
411 1 792 693 delta pressure across venturi in EGR line sensed value of venturi difference pressure < Threshold for error detection is an internal ECU
below physical low limit low limit threshold.
Check correct mounting of difference pressure
sensor at venturi tube
Exchange difference pressure sensor broken
411 3 795 693 The sensed raw voltage EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the maxi- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
411 4 381 693 Range check cannot be done or interrupted. EGR or wiring defect Check wiring harness and connected EGR.
3-164 3121262
Deutz Blink
Code Code
411 4 796 693 The sensed raw voltage value EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the mini- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
411 11 793 693 DFC is stored in EEPROM and status kept until deviation between desired O2 concentration in Threshold for error detection is an internal ECU
check is allowed intake air manifold threshold.
to be carried out again and the real O2-concentration within intake air EGR-Valve mechanically blocked open or closed
DFC can be reset by service routine 216 manifold > limit EGR-pipe blocked with metall plate instead
sealing downstream EGR-Valve
EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
412 3 1007 682 EGR downstream temperature sensor: the Short circuit to battery. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage > limit Exchange TEGR-sensor.
the target range.
412 4 1008 682 EGR downstream temperature sensor: the Short circuit to ground or open load. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage < limit Exchange TEGR-sensor.
the target range.
630 12 376 281 Internal hardware monitoring: the ECU finds Section could not be erased Threshold for error detection is an internal ECU
an error during the access to its EEPROM threshold.
memory or works with an alternative value There is no healing possible for the error. In the
every new initialization phase, the
debounce level is set to zero.
If not programmed, EEPROM is defect --> ECU is
defect, reprogramm ECU and if
necessary replace it.
630 12 377 281 Internal hardware monitoring: the ECU finds Minimum 3 blocks could not be readed, There is no healing possible for the error. In the
an error during the access to its EEPROM EEPROM has Checksum Error every new initialization phase, the
memory or works with an alternative value debounce level is set to zero.
If not programmed, EEPROM is defect -->ECU is
necessary replace it
630 12 378 281 Internal hardware monitoring: the ECU finds Block could not be written for minimum 3 times Threshold for error detection is an internal ECU
an error during the access to it's EEPROM threshold.
memory or works with an alternative value If not programmed, EEPROM is defect --> ECU is
necessary replace it.
639 14 84 271 CAN bus 0: the ECU is not allowed to send CAN BusOff error; CAN 0 (Customer CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold.
detected. BusOff bit for CAN A node is set.
Check wiring of CAN bus and if necessary repair
it, check connection cable and if
necessary repair or replace it, check resistance in
CAN lines (120 Ohm)
3121262 3-165
Deutz Blink
Code Code
651 3 580 154 Injector cyl. 1: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 1 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
damaged test for diagnosis.
651 5 568 154 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 necessary
repair/replace it.
repair/replace it.
repair/replace it.
test for diagnosis.
repair/replace it.
test for diagnosis.
repair/replace it.
test for diagnosis.
3-166 3121262
Deutz Blink
Code Code
repair/replace it.
676 11 543 263 Cold start aid relay error. Relay defect or wire harness problem Threshold for error detection is an internal ECU
threshold.
check wire harness, replace relay
676 11 544 263 Cold start aid relay open load Relay or wire harness Threshold for error detection is an internal
threshold.
check wire harness, replace relay
677 3 956 512 Start relay (high side power stage): the cur- Short cut HighSide-output to battery. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the tar- threshold.
get range. Check cabling and start relay and if necessary
replace it,
or replace it.
677 3 960 512 Start relay (low side power stage): the cur- Shortcut LowSide-Output to battery. Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- threshold.
replace it,
or replace it.
677 4 957 512 Start relay (high side power stage): Shortcut HighSide-output to ground. Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold.
the target range. Check cabling and start relay and if necessary
replace it,
or replace it.
677 4 961 512 Start relay (low side power stage): the cur- Shortcut LowSide-Output to ground. Threshold for error detection is an internal ECU
replace it,
check connection cable of terminal 50 and if
677 5 958 512 Start relay (low side power stage): the cur- Open circuit/disconnection LowSide-Output. Threshold for error detection is an internal ECU
get range Check cabling and start relay and if necessary
replace it,
or replace it.
677 12 959 512 Start relay (low side power stage): the cur- Temperature over limit. Threshold for error detection is an internal ECU
replace it,
or replace it.
691 8 928 928 Supply module heater: PWM time periode PWM signal for temperature readout from sup- The Time period of the received PWM signal
out of valid range. ply module to the control unit is out of SCR_tiSMPerPwm is within the specified
range. range of150ms to 250ms
Supply modul defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
3121262 3-167
Deutz Blink
Code Code
729 3 549 263 wiring to the intake air heater device is Intake Air Heater Device: overload, short-circuit Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, Check wiring to the intake air
heater device.
729 4 551 263 wiring to the air intake heater is faulty Relay (for cold start aid) cable break or short to Threshold for error detection is an internal ECU
ground: threshold.
Electrical error, check wiring to the air intake
heater.
729 5 545 263 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 12 547 263 The cold start aid relay is overheated, which High temperature around the cold start relay. Check the functionality of relay and replace it if
causes this error needed.
Check the temperature around the cold start
relay during worst case operation.
898 9 305 118 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
- active short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
1079 13 946 282 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of the Pin A19: DEF press / Exh.PressBeforeTurb (P3) / working voltage and if necessary correct
power supply voltage of sensor output 1. Air Pump Press it,
/BrnFuelPressAfterDV2 Pin K19: Fan Speed Sen- check connection cable and if necessary repair
sor or replace it,
Pin A21: LDF6T / OilPress / LowFuelPress Pin if error is not removable, change ECU.
A17: Rail Pressure Sensor
Suspected components EDC17cv54
Pin A21: CAM speed Pin K44: Delta Press Venturi
/ Poti EGR or Inlet Throttle
Pin A24: LDF6T / OilPress / LowFuelPressPin
K43: Reserve 5V Sensor Supply
Pin A09: second footpedal
Pin A21: Cam speed Pin K44: DEF press / Air Fil-
terDiffPress
Pin A24: LDF6T / OilPress / LowFuelPress Pin
K43: second footpedal
Pin A09: Delta Press Venturi
detects a deviation of the target range of the Pin K16: second footpedal working voltage and if necessary correct
power supply voltage of sensor output 2. Pin A20: Exh.PressAfterTurb/DPFDiffPress/ it, check connection cable and if necessary
BrnDV1Press/HCIPressDV1DV2 repair or replace it, if error is not removable,
Suspected components EDC17cv54 change ECU.
Pin K45: DPF Diff Press / Exh. Press After Turb /
Fan Speed Sensor
Pin A46: first footpedal
Pin A22: Fan Speed Sensor
Pin K45: Position EGR or Intake throttle flap
Pin K46: First footpedal
3-168 3121262
Deutz Blink
Code Code
1109 2 121 341 Request of engine shut off: the operator Engine Shut Off demand has been ignored by Depending on error requested a shut off.
ignores the engine shut off request within an the user
allowed period.
1136 0 1398 681 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
1231 14 85 271 CAN bus 1: the ECU is not allowed to send CAN BusOff error; CAN 1 (Diagnostic CAN) Threshold for error detection is an internal ECU
detected BusOff bit for CAN B node is set.
Warning, no diagnostic with SERDIA2010 Check wiring of CAN bus and if necessary repair
possible it, check connection cable and if
CAN lines (120 Ohm)
1235 14 86 271 CAN bus 2: the ECU is not allowed to send CAN BusOff error; CAN 2 (Engine CAN) Threshold for error detection is an internal ECU
detected. BusOff bit for CAN C node is set.
Warning, depends on engine, EAT. Check wiring of CAN bus and if necessary repair
it, check connection cable and if
CAN lines (120 Ohm)
1237 2 747 145 Override switch switch: the ECU receives a Switch is blocked, taster locked, connection If the Block Button is pressed shorter than the
permanent signal. cable damaged Maximum Plausible pressing Time.
plausbility error "override switch > 250ms Check cabling, if sensor is not working, check
pressed". switch and if necessary replace it, check
replace it.
1761 0 1593 129 The urea tank level sensor detects a value Suspected components: Check level sensor and float gauge
higher than the maximum allowed thresh- Urea Quality Sensor defect
old mechanical defect at the float gauge
1761 1 1594 129 The DEF tank level sensor detects a value Suspected components: Check level sensor and float gauge
lower than the minimum allowed threshold Urea Quality Sensor defect
mechanical defect at the float gauge
1761 14 1655 138 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <5% below applicable threshold 5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
SCRUTnk_rVol_mp must change.
Exchange DEF level sensor, if no change of value
or it's implausible.
1761 14 1656 138 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <2.5% below 2.5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
Exchange DEF level sensor, if no change of value
or it's implausible.
3121262 3-169
Deutz Blink
Code Code
1761 14 1880 138 The DEF tank level is below the threshold. actual DEF tank level SCRUTnk_rVol_mp [%] is Check DEF level => if empty, refill
below the threshold Check DEF level sensor.
If there is urea in the tank loose the sensor and
move it. The floater must be free and
move if you lift the sensor body.
Compare SCRUTnk_rVol_mp to:
1 = SCR_rawUTnkLvl
2 = SCR_rAdapUtnkLvl
3 = SCRUTnk_rActTnkVol
*SCRUTnk_facVolPer_mp
In case of malfunction, exchange DEF level sen-
sor.
2791 0 1763 415 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.
2791 2 1753 415 corrupted CAN communication with actua- CAN bus error or faulty EGR actuator. Threshold for error detection is an internal ECU
tor. threshold.
Check other CAN bus components. If no mes-
sage is sent, fix the wiring.
If o.k. exchange EGR actuaror.
2791 3 1758 415 Overvoltage at EGR actuator. High voltage from the battery Check battery voltage.
2791 4 1759 415 Undervoltage at EGR actuator. Low voltage from the battery. Check battery voltage.
2791 6 1757 415 Overcurrent to EGR actuator. High voltage from battery. Check battery voltage. Check if EGR is blocked or
EGR actuator is blocked or moving very hard. not running smoothly.
If everything is o.k. change EGR actuator.
2791 7 1752 415 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 7 1761 415 EGR actuator spring broken. mechanical damage of spring due to overstress. Threshold for error detection is an internal ECU
threshold.
Exchange EGR actuator.
2791 12 1755 415 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 1754 415 EGR actuator can not learn stop positions. Error detection during the learning process. Threshold for error detection is an internal ECU
Possibly only second failure if other EGRTV threshold.
failures occure. Start Serdia Usecase to reset EGR actuator.
Check EGR valve and mounting situation. If o.k.
change EGR actuator.
2791 13 1756 415 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 13 1760 415 Stop positions of EGR valve not o.k. Mechanical damage of EGR actuator. Threshold for error detection is an internal ECU
EGR valve is blocked or moving very hard. threshold.
Start Serdia Usecase to reset EGR actuator.
2791 16 1762 415 Internal actuator temperature above thresh- overheating of EGR actuator Let EGR actuator cool down, check heat accu-
old. mulation during worst case operation.
3-170 3121262
Deutz Blink
Code Code
2797 4 1337 565 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
2797 4 1339 565 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 0 Note: affected injector has to be evaluated
2798 4 1338 566 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 1 threshold.
Note: affected injector has to be evaluated
2798 4 1340 566 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 1 Note: affected injector has to be evaluated
3031 0 1135 669 The urea tank temperature sensor detects a Sensed urea tank temperature > physical range Case "CANBUS sensor":
value above the maximum allowed thresh- high limit Check urea tank temperature: really hot?
old Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Tank heater permantly on?
Check wiring of DEF-quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really hot?
Check urea tank temperature SCR_tSensUTnkT
Compare urea tank temperature to EnvT_t or to
SCR_tSMT (the urea temperature
inside the supply module) identical?
Tank heater permantly on?
Check wiring of analog DEF T & Level sensor
3031 1 1136 669 The urea tank temperature sensor detects a sensed urea tank temperature < physical range Case "CANBUS sensor":
value lower than the minimum allowed low limit Check ambient temperature EnvT_t => About
threshold. -40 °C? If yes Error could be plausible
Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Check wiring of DEF-quality sensor
Check quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really that cold?
Check ambient temperature EnvT_t =>
About -40 °C? If yes Error could be plausible
Check urea tank temperature SCR_tSensUTnkT
Check wiring of analog DEF T & Level sensor
Check analog DEF T & Level sensor
3224 2 129 596 DLC Error of CAN-Receive-Frame AT1IG1Vol Not Used Threshold for error detection is an internal ECU
NOX Sensor (SCR-system upstream cat; DPF- threshold.
system downstream cat); length of frame Check Nox-Sensor and the wiring from CAN-
incorrect BUS.
3121262 3-171
Deutz Blink
Code Code
3224 9 130 597 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 2 138 114 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 9 139 117 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)
3361 3 1077 677 Urea dosing valve (low side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range See substitute function
Check the wiring
3361 3 1078 677 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the target range Check the wiring
3361 4 1079 677 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 677 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the target range Check the wiring
3361 6 1075 677 Urea dosing valve: the current measured Fault in the wiriing Check wiring
value by ECU at the end of the injection is too Defect urea dosing injection valve Check the urea dosing injection valve
high
3519 3 1898 277 The integrated diagnostic of the tempera- Wrong diagnostic of the short circuits logic Check the wiring to the suction unit in the DEF
ture sensor of the Urea Quality Sensor recog- inside the temperature sensor of the UQS tank.
nized a short circuit to battery. CAN Communication corrupted Check the CAN bus communication of the suc-
The UQS Sensor is an combined sensor of tion unit. In case the communication is
tank temperature, filling grade and DEF corrupt, exchange the suction unit.
quality and it is also an CAN sensor --> no
PIN
3519 4 1899 277 The integrated diagnostic of the tempera- DEF quality sensor in the suction unit of the DEF Check the wiring to the suction unit of the DEF
ture sensor of the Urea Quality Sensor recog- tank is defect tank.
nized a short circuit to ground CAN Communication corrupted Check the CAN bus communication from the
suction unit. In case the signal is corrupt,
exchange the suction unit in the DEF tank.
3-172 3121262
Deutz Blink
Code Code
3519 12 1895 277 The integrated temperature sensor of the Temperature sensor inside the UQS defect. Check the temperature sensor signal for plausi-
Urea Quality Sensor measures higher tem- CAN Communication corrupted. bility. In case of improper signal,
perature than threshold Overheating of the DEF tank due to malfunction exchange the suction unit in the tank.
of the heating valve. Check CAN bus communication for proper sig-
Flow direction is of coolant is wrong due to nal. In case of improper signal, exchange
mixed up the hoses routed to the heating the suction unit in the tank.
valve. Check the function of heating valve and routing
Overheating of the DEF tank due to heat transfer of the hoses. The coolant flow through
from neighbor parts. the heating valve must be observed according
to the shown arrow.
In case all actions above are OK, check the real
temperature in the DEF tank during
worst case condition and improve the installa-
tion of the DEF tank.
3519 13 1908 277 Temperature at UQS out of range the speci- Suspected Components Check temperature system and/or DEF quality
fied thresholds; invalid quality of the tem- Tank heater sensor
perature DEF sensor
3520 2 1904 2-7-8 Measured DEF Quality from UQS is too low. Suspected components: Check that there is liquid urea of known quality
Quality value received from UQS is < 22 % for Urea quality sensor defect in the tank first
a certain time and a certain number or for Wrong installation (measuring air) Check urea tank level. Add urea until level is at
measuring conditions not observed for a cer- Urea level sensor defect least 10 cm above sensor.
tain time. Non urea filled in tank Ensure that urea is not frozen / sufficient urea is
CANBUS problems liquid
Evaluation conditions for new quality check not Check Sensor: Are urea tank temperature and
fulfilled after one previous mal detection level displayed? Changes the level if you
refill urea?
Check electrical connection
Check CANBus
New quality detection is carried out if urea re-
fill is detected or if an quality evaluation
was triggered and was not finished success-
fully: To provoke a quality measurement: refill
urea, at least 10 % of tank volume
Wait until quality evaluation was carried out,
can take up to 30 minutes => check value.
It should be about 33 %
Exchange quality sensor
3520 3 1896 278 The integrated diagnostic of the Urea Quality wiring harness of UQS corrupted Threshold for error detection is an internal ECU
Sensor recognized a short circuit to battery CAN Communication corrupted threshold.
Check the wiring harness from the ECU to the
suction unit of the DEF tank
Check the CAN bus communication. If the signal
is corrupt, then exchange the suction
unit.
3520 4 1897 278 The integrated diagnostic of the Urea Quality wiring harness to the suction unit in the DEF Threshold for error detection is an internal ECU
Sensor recognized a short circuit to ground. tank is corrupted threshold.
CAN Communication corrupted Check the wiring to the suction unit in the DEF
tank.
Check the CAN bus communication. In case the
communication is corrupt, exchange
the suction unit in the DEF tank.
3121262 3-173
Deutz Blink
Code Code
3520 13 1907 278 Urea quality at UQS out of range the speci- Suspected components Check DEF quality and/or DEF quality sensor
fied thresholds; invalid quality of the urea DEF quality sensor
qualiy DEF
3532 3 1911 127 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or sensor.
greater than the maximum physical range UQS defect
threshold
Comment: tank temperature is measured by
the UQS sensor
3532 4 1912 127 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or Sensor.
lower than the minimum physical range UQS defect
threshold.
3711 12 1455 711 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC
DPF temperature < Threshold 1 temperature, is below or above Exh_tSensOxiCatUs within Stand-still: > 450
Temperature Phy_tPfWgh, the weighted the target temperature towards the end of the °C? If
DPF temperature > Threshold 2 stand-still main phase. not:
towards the end of the stand-still main => Check air path of engine: EGR-Valve,
phase. Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
Check temperature difference across DOC by
Exh_tSensOxiCatDs -
Exh_tSensOxiCatUs within Stand-still: <
100°C? If not:
Check exhaust pipe downstream turbo charger
for oil?
check injectors: is an injector got stuck?
Too many hydrocarbons in exhaust? White
smoke (at hot EAT system, not at cold
start)?
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check exhaust gas temperature sensors within
EAT-system: T upstream DOCC, T
downstream DOC & T upstream SCR catalyst
all three of them can influence Phy_tPfWgh
3936 14 1917 2-8-6 Standstill escalation by time. In case the Stand-still request ignored by the operator. Perform Stand-still. If soot load level of DPF has
standstill request will not be released within Display / stand-still request lamp broken. increased too high already call service
50 h by the driver this fault code will be set. to perform stand-still.
In case the DPF soot load level remove DPF =>
Exchange DPF.
4334 0 1122 665 The absolute pressure value of the urea Suspected Components: Check the urea pump
pump is greater than an applicable maximal Urea pump defect Check the supply module pressur sensor
filtered pressure threshold Supply module pressure sensor defect Clean the urea pump (filter)
Pump contains dirty parts
4334 1 1123 665 Urea supply module pressure sensor: The Check the urea pump Check the urea pump
absolute pressure value of the urea pump is Check the supply module pressur sensor Check the supply module pressur sensor
less than an applicable minimal filtered Clean the urea pump (filter) Clean the urea pump (filter)
pressure threshold
3-174 3121262
Deutz Blink
Code Code
4334 2 1866 665 absolute difference of sensed urea pump absolute difference of sensed urea pump pres- Check environment pressure sensor (EnvP_p)
pressure (SCR_pAbsSensUPmpP) and ambi- sure (SCR_pAbsSensUPmpP) and => plausible value?
ent pressure (EnvP_p) > limit ambient pressure (EnvP_p) > limit Engine shut-off and immediately re-started?
abs(UPmpP_pDiffPmpEnv_mp) > abs(UPmpP_pDiffPmpEnv_mp) > => Shut-off again. Wait until afterun of
UPmpP_pDiffPmpEnv_C (250 hPa) UPmpP_pDiffPmpEnv_C ECU has finished, re-Start engine
Back-flow line free? Does the urea pump pres-
sure show values < 1000 hPa in SCR
state emptying (64)?
Check revision valve => Does the urea pump
pressure show values < 1000 hPa in SCR
state emptying (64)? => exchange supply
module
Supply module pressure sensor defect =>
exchange supply module
4341 3 1104 675 Urea heater supply line: the current drain electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
Check wire harness
Check supply line
Check wire harness
Check supply line
4343 3 1096 673 Urea pressure line heater: 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
a result error: KWP 1089 Check wiring
broken heating element in pressure line Check heating element
4343 4 1097 673 Urea pressure line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
Short cut to ground or broken wiring, broken Check heating element
heating element in pressure line
4343 5 1094 673 Urea pressure line heater: the current drain Open load Threshold for error detection is an internal ECU
Broken wiring, broken heating element in pres- Check heating element
sure line
4345 3 1092 674 Urea backflow line heater: the current drain Shortcut to battery Threshold for error detection is an internal ECU
Short cut to battery or broken wiring, broken Check heating element
heating element in backflow line
4345 4 1093 674 Urea backflow line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
Short cut to ground or broken wiring, broken Check heating element
heating element in backflow line
3121262 3-175
Deutz Blink
Code Code
4345 5 1090 674 Urea backflow line heater: the current drain Open load Threshold for error detection is an internal ECU
Broken wiring, broken heating element in back- Check heating element
flow line
4360 0 1069 668 The filtered urea cat upstream temperature Sensed temperature upstream SCR > physical Check temperature difference across DOC
is greater than an applicable maximum tem- high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at higher
perature threshold engine load => high difference > 100 K?
If yes, the engine emitts too many Hydrocar-
bons => check injectors: is an injector got
stuck?
=> Check EGR Valve
If difference normal the exhaust out of the engie
itself is too hot:
=> Check air path of engine: EGR-Valve,
Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
If that error was set while stand-still operation
the error source could be exothermal
soot burn off in DPF (which should not happen)
=> Dismount DPF and check it visually
exchange temperature sensor upstream SCR
4360 1 1070 668 The filtered temperature before urea cat is Sensed temperature upstream SCR catalyst < Cold start and ambient temperature < Thresh-
less than an applicable minimum tempera- than physical low limit old? Missdetection?
ture threshold Check wiring harness to UCatUsT-sensor
Exchange UCatUsT-sensor
4360 2 1865 668 Error at static plausibility check: Error at static plausibility check: Check whether temperature sensor upstream of
absolut temperature difference of sensed absolut temperature difference of sensed tem- SCR catalyst is physically mounted
temperature upstream SCR catalyst and perature upstream SCR catalyst and within exhaust pipe
ambient temperature > as static plausibility ambient temperature > as static plausibility If cold start condition can be made sure (engine
limit limit was off for at least 8 h) compare
at engine cold start (engine was off for at at engine cold start (engine was off for at least 8 values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
least 8 h), temperature upstream of SCR cat- h), temperature upstream of SCR Exh_tOxiCatDs and
alyst is expected to be identical to ambient catalyst is expected to be identical to ambient SCR_tSensUCatUsT at ignition on, without
temperature => see enable conditions for temperature => see enable conditions for starting the engine. All identical?
details. details. Compare values of Exh_TOxiCatUs,
Error at dynamic plausibility check: Error at dynamic plausibility check: Exh_tOxiCatDs and SCR_tSensUCatUsT after 15
temperature difference of sensed tempera- temperature difference of sensed temperature min in constant operation point: show all simi-
ture upstream SCR catalyst and ambient upstream SCR catalyst and ambient lar values (30 K tolerance width). Are
temperature < as dynamic plausibility limit temperature < as dynamic plausibility limit ambient temperature and (EnvT_t), cooling
dynamic check is blocked if static plausibility dynamic check is blocked if static plausibility water temperature (EngDa_tEng) plausible?
check is already faulty check is already faulty Sensor coated with urea crystalls? Dismount
=> Temperature upstream SCR catalyst => Temperature upstream SCR catalyst must urea injector and inspect temperature
must be by 40°C higher than ambient tem- be by 40°C higher than ambient sensor upstream SCR catalyst visually
perature if engine runs and a certain delay temperature if engine runs and a certain delay Check wiring of sensor
time has expired. time has expired. Replace sensor
4361 3 1072 668 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst > maximum limit Check wiring
of the target range Short circuit to battery Replace UCatUsT-sensor
4361 4 1073 668 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst < minimum limit Check wiring
of the target range Short circuit to ground Replace UCatUsT-sensor
3-176 3121262
Deutz Blink
Code Code
4365 2 1137 6-6-9 Signal error in case of Urea tank temperature CAN message is not send properly. Check sensor connector
trnasmitted via CAN-signal Com_tUTnkT. Check CANbus
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.
range. The Sensed raw voltage value SCR_uRawUTnkT
is below SCR_SRCUTnkT.uMax_C.
Check wiring.
4365 3 1914 669 Internal error of DEF qualitysensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF qualitysensor
Wiring harness
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.
range. The sensed raw voltage value SCR_uRawUTnkT
is above SCR_SRCUTnkT.uMin_C.
Check wiring.
4365 4 1915 6-6-9 Internal error of DEF qualitysensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF qualitysensor
Wiring harness
4366 3 1112 671 Urea tank heating valve: the current drain Shortcut to battery Threshold for error detection is an internal ECU
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
4366 4 1113 671 Urea tank heating valve: the current drain Shortcut to ground Threshold for error detection is an internal ECU
4366 5 1110 671 Urea tank heating valve: the current drain Open load Threshold for error detection is an internal ECU
4375 3 1120 666 Urea supply module pump: the current drain Shortcut to battery Threshold for error detection is an internal ECU
a result error: KWP 1089 The hardware detects absence of any short cir-
Broken wiring cuit to battery on the PWM output power
Pump in urea supply module defect stage for the urea pump module actuator
Check wiring
Check pump in the urea supply module
4375 4 1121 666 Urea supply module pump: the current drain Shortcut to ground Threshold for error detection is an internal ECU
a result error: KWP 1089 The hardware detects a short circuit to ground
Broken wiring error on the PWM output power stage
Pump in urea supply module defect for the UreaPump Module Motor Actuator. The
error is updated by setting bit 1 of
measuring point UPmp-
Mot_stPrevTstRslt_mp
Check wiring
3121262 3-177
Deutz Blink
Code Code
4375 5 1118 666 Urea supply module pump: the ECU can not Open load Threshold for error detection is an internal ECU
measure any reaction during pump control Broken wiring threshold
Pump in urea supply module defect The hardware detects the presence of load on
the PWM output power stage for the
urea pump module actuator.
Check wiring
4376 3 1131 667 Urea supply module reversal valve: the cur- Shortcut to battery Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- Fault in the wiring threshold
get range Reversal valve in the urea supply module defect Check wiring
Check urea supply modul
4376 4 1132 667 Urea supply module reversal valve: the cur- Shortcut to ground Threshold for error detection is an internal ECU
4376 5 1129 667 Urea supply module reversal valve: the cur- Open load Threshold for error detection is an internal ECU
4765 0 1039 683 The exhaust temperature value from the sensed temperature upstream DOC > shut-off Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle,
is above an applicable upper shutoff thresh- Check Turbocharger and Piping each for leakage
old and correct function
TOxiCatUs_tShOffThresHiAds_C = Thresh- Check injectors: is an injector got stuck?
old 1 in Normal and Exchange temperature sensor upstream DOC
Heatmodes
(TOxiCatUs_tShOffThresHiRgn_C = Thresh-
old 2
in stand-still)
4765 0 1040 683 The exhaust temperature value from the Sensed temperature upstream DOC > warning Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle, Turbocharger and Piping each
is above an applicable upper warning for leakage and correct function
threshold Check injectors: is an injector got stuck?
TOxiCatUs_tWarnThresHi_C = Threshold Exchange temperature sensor upstream DOC
3-178 3121262
Deutz Blink
Code Code
4768 2 1036 683 Static plausibility check: Static plausibility check: Check ambient temperature => value plausi-
The exhaust temperature value from the The exhaust temperature value from the sensor ble?
sensor before DOC, the exhaust temperature before DOC, the exhaust temperature upstream DOC sensor mounted within exhaust
value from the sensor after DOC, the temper- value from the sensor after DOC, the tempera- line?
ature value from the sensor before ture value from the sensor before T upstream DOC sensor physically mounted in
SCR-Cat, the environment temperature and SCR-Cat, the environment temperature and the correct position upstream DOC? (not
the coolant engine temperature their ratios coolant engine temperature their ratios upstream SCR or downstream DOC?)
to each other exceed their related thresh- to each other exceed their related thresholds. Check T upstream DOC sensor
olds. (difference between temperature after DOC and Check other T-sensors within EAT-system
Dynamic plausibility check with environ- temperature before DOC > Threshold 1 (Exh_tOxiCatDs & UCatUsT_tFlt_mp show
ment temperature sensor value: difference between temperature befor DOC and plausible values? No errors on them?
The exhaust temperature value from the before SCR > Threshold 2
sensor before DOC is lower than an applica- difference between temperature after DOC and
ble environment temperature threshold before SCR < Threshold 3
difference between temperature after DOC and
ambinet temperature < Threshold 4
differnece between temperatur ambient tem-
perature and engine temperature <
Threshold 5)
Dynamic plausibility check with environment
temperature sensor value:
The exhaust temperature value from the sensor
before DOC is lower than an applicable
environment temperature threshold (< envi-
ronmental temperature + Threshold 6)
4768 2 1881 683 At engine cold start conditions the sensed Difference temperature of exhaust gas temper- Check whether all exhaust gas temperature
exhaust gas temperature downstream DOC ature downstream DOC and fixed sensors within the EAT system are
(Exh_tSensTOxiCatDs) ambient temperature at ignition on exceeds a mounted properly: Within the exhaust line and
has exceeded the sum of ambient tempera- certain limit earlier than the difference at correct positions.
ture (EnvT_t) + offset (40°C) earlier than the temperature of exhaust gas temperature Check the position of the sensor upstream SCR
sensed exhaust gas upstream DOC and fixed ambient temperature which might be physically mounted in
temperature upstream of DOC at ignition on. the wrong position.
(Exh_tSensTOxiCatUs). If cold start condition can be made sure (engine
The check is only performed once each igni- was off for at least 8 h) compare
tion cycle and only if the start is judged a cold values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
start. Exh_tOxiCatDs and
Error status is frozen for that ignition cycle. SCR_tSensUCatUsT at ignition on, without
No healing possible. starting the engine. All identical? Then the
sensors itself are okay.
Check exhaust piping for leakage.
Check wiring of sensors
Replace sensors
Check DOC => physicallly intact?
4768 3 1044 683 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is above upstream DOC
ECU is out of the target range Exh_SRCTOxiCatUs.uMax_C Exchange temperature sensor upstream DOC
Shortcut to battery
4768 4 1045 683 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is upstream DOC
ECU is out of the target range below Exh_SRCTOxiCatUs.uMin_C Exchange temperature sensor upstream DOC
Shortcut to ground
3121262 3-179
Deutz Blink
Code Code
5763 3 1024 594 Actuator of the external EGR valve: the ECU Short cut to battery or open loop. Check cabling, actuator defect, check actuator
detects a short circuit to battery or open and if necessary replace it, check
load. connection cable and if necessary repair or
replace it.
5763 3 1226 594 Actuator EGR-valve: short cut to battery is Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
detected threshold.
Check repair with SerDia 2010 use case
5763 3 1227 594 Actuator EGR-valve: short cut to battery on Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
ECU pin is detected threshold.
5763 4 1025 594 Actuator of the external EGR valve: the ECU Short cut to ground Check cabling, actuator defect, check actuator
detects a short circuit to ground. and if necessary replace it, check
replace it.
5763 4 1228 594 Actuator EGR-valve: short cut to ground on Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
5763 4 1229 594 Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal ECU
5763 4 1232 5-9-4 Actuator error EGR-Valve (2.9;3.6) or Throt- Monitoring for CY146 Under Voltage. Threshold for error detection is an internal ECU
tle-Valve (4.1;6.1;7.8); Voltage below threshold.
threshold Check wiring, component
3.6) Drosselklappe (4.1;6.1;7.8); Voltage
below threshold;
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 6 1014 594 Actuator error EGR-Valve. Short cut to batterie. Check wiring and repair or replace if necessary,
Signal range check high. check actuator with SERDIA test for
EGR and if necessary replace it.
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
replace it.
5763 6 1223 594 Actuator EGR-Valve: Open load on ECU out- Open circuit on component wiring Threshold for error detection is an internal ECU
put is detected threshold.
5763 6 1224 594 Actuator EGR-valve: too high curent is going Overload on component wiring Threshold for error detection is an internal ECU
into the actuator. Output is switched off threshold.
3-180 3121262
Deutz Blink
Code Code
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 7 1016 594 Actuator position for EGR valve is not plausi- Position error of throttle flap (deviation > 7%). Threshold for error detection is an internal ECU
ble, internal error, angular misalignement of threshold.
the flap. Threshold for error detection, deviation from
setpoint > 7%.
Troubleshooting with SERDIA 2010 Use Case
"EGR Diagnostic".
5763 11 1231 5-9-4 Power stage overtemperature due to high Temperature dependent Over Current Threshold for error detection is an internal ECU
current. threshold.
Check wiring, component
520521 5 1015 594 Actuator error EGR-Valve. Short cut to ground. Check wiring and repair or replace if necessary,
Signal range check low. check actuator with SERDIA test for
EGR and if necessary replace it.
523009 9 825 253 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.
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.
523212 9 171 3-3-3 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer devices
ComEngPrt; Engine Protection
523240 9 179 527 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
range.
523350 4 565 151 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.
repair/replace it.
523352 4 566 152 Injector cylinder bank 2: the current drop Short circuit injection bank 2 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
repair/replace it.
523354 12 567 153 Internal hardware monitoring: the ECU Defective powerstage in ECU Threshold for error detection is an internal ECU
detects an error of its injector high current threshold.
output. Chip of CY33x defect power stage If error is not removable, change ECU.
components
523450 4 839 1-4-3 Diagnostic fault check for min error of COM The sensed raw value is less than the threshold. Check cabling, check sensor and if necessary
message. replace it,
or replace it.
523470 2 826 146 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
523470 2 827 146 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
3121262 3-181
Deutz Blink
Code Code
523470 7 876 146 Rail pressure is out of the expected average Rail pressure is out of the expected average (A) Check railpressure relief valve and replace if
range. range. necessary.
PRV can not be opened. (B) Check high pressure pumps, pressure relief
valve and metering unit.
(C) Change components if necessary
523470 11 831 146 Rail pressure relief valve can not be opened Railpressure out of tolerance range (PRV can not Threshold for error detection is an internal ECU
due to the railpressure. be opened by a pressure peak in this threshold.
operating point) Check railpressure, check rail pressure sensor for
plausibility, check FCU.
523470 11 832 146 Rail pressure is out of the expected average Averaged rail pressure is outside the expected Threshold for error detection is an internal ECU
range. tolerance range. threshold.
The PRV can not be opened at this operating Check PRV and replace if necessary.
point with a pressure shock.
523470 12 828 146 Rail pressure relief valve: is open. Shut Off after PRV Open Threshold for error detection is an internal ECU
Shutoff conditions. threshold.
Check PRV opening counter and if necessary
replace PRV,
check rail-pressure sensor for plausibility and if
check FCU and if necessary replace it.
523470 12 829 146 Rail pressure relief valve is open. Warning PRV open Threshold for error detection is an internal ECU
Warning conditions. threshold.
replace PRV,
523470 14 830 146 Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal ECU
threshold.
Only after ECU reset.
replace it,
523550 12 980 515 Terminal 50 was operated for more than 2 Startinformation to Starter (T50-switch) Threshold for error detection is an internal ECU
minutes. This may happen due to short to erratic/defect. threshold.
battery or wrong usage of Terminal 50. Check cabling, if sensor not working, check start
Starter control is disabled until this error is switch and if necessary replace it,
healed. check connection cable and if necessary repair
or replace it.
detects a deviation of the target range of the Pin A18: DeltaPressVenturi / Position intake working voltage and if necessary correct
power supply voltage of sensor output 3. throttle flap it,
Pin K20: First footpedal check connection cable and if necessary repair
Pin K21: Air FilterDiffPress or replace it,
Suspected components EDC17cv54 and cv56 if error is not removable, change ECU.
Pin A07: Rail pressure
523612 3 644 555 supply voltage too high not used Threshold for error detection is an internal ECU
threshold.
3-182 3121262
Deutz Blink
Code Code
523612 4 646 555 supply voltage too low not used Threshold for error detection is an internal ECU
threshold.
523612 12 387 555 Internal hardware monitoring: the CPU of Injector shut off demand for the ICO coordinator Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- System responses: threshold.
nally; no item will be created in error mem- not Caution ! Sequence error, check error memory
ory for other errors.
523612 12 612 555 Internal hardware monitoring: the CPU of Plausibility check failed (MoCADC_uNTP_mp is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- higher than MoCADC_uNTPMax_C). threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory.
523612 12 613 555 Internal hardware monitoring: the CPU of Analysis of test voltage (Value is out of the tar- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- get -> ECU internal error) threshold.
nally; no item will be created in error mem- Check wiring, check connected sensors actua-
ory tors.
If error is still present, exchange ECU.
523612 12 614 555 Internal hardware monitoring: the CPU of Analysis of the ratiometric correction (Value is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- out of the target -> ECU internal error) threshold.
nally; Check wiring, check connected sensors actua-
no item will be created in error memory tors.
523612 12 615 555 Internal hardware monitoring: the CPU of Error report due to an error in the plausbility of Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Function Coordination(FC) and threshold.
nally; Monitoring Modul(MM)(ECU internal error) If error is still present, exchange ECU.
no item will be created in error memory
523612 12 616 555 Internal hardware monitoring: the CPU of Error report due to an interrupted SPI communi- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- cation (ECU internal error) threshold.
ory
523612 12 617 555 Internal hardware monitoring: the CPU of multiple error in complete ROM-test during Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- postdrive detected (ECU internal error) threshold.
ory
523612 12 618 555 Internal hardware monitoring: the CPU of Too less bytes received by monitoring memory Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- from CPU as response (ECU internal threshold.
nally; no item will be created in error mem- error). Loss of synchronization sending bytes to If error is still present, exchange ECU.
ory the monitoring memory from CPU
523612 12 619 555 Internal hardware monitoring: the CPU of Suspected components: Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Injector threshold.
nally; no item will be created in error mem- ECU If error is still present, exchange ECU.
ory wiring harness/connector
523612 12 620 555 Internal hardware monitoring: the CPU of Error trying to set MM Response time (ECU Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- internal error) threshold.
ory
523612 12 621 555 Internal hardware monitoring: the CPU of Error detected in the internal ECU communica- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- tion, Too many SPI errors during threshold.
nally; no item will be created in error mem- MoCSOP execution If error is still present, exchange ECU.
ory
3121262 3-183
Deutz Blink
Code Code
523612 12 623 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- under voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in undervoltage monitoring
523612 12 624 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- monitoring module (ECU internal error). threshold.
ory
523612 12 625 555 Internal hardware monitoring: the CPU of Time out error trying to set or cancelling the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- alarm task (ECU internal error). Failure threshold.
nally; no item will be created in error mem- setting the alarm task period If error is still present, exchange ECU.
ory
523612 12 627 555 Internal hardware monitoring: the CPU of Error in time monitoring of the shut-off path Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- test (ECU internal error). Diagnostic fault threshold.
nally; no item will be created in error mem- check to report the timeout in the shut If error is still present, exchange ECU.
ory off path test
523612 12 628 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- over voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in overvoltage monitoring
523612 12 629 555 The two voltage values (ADC_VAL1, Defect pedal or wiring Threshold for error detection is an internal ECU
ADC_VAL2), detected by threshold.
the accelerator pedal, are not plausible to Check Pedal, repair or exchange the Pedal.
each other. Check wiring.
523612 12 630 555 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.
523612 12 631 555 Diagnostic fault check to report the plausi- Implausible injection energizing time for either Threshold for error detection is an internal ECU
bility error between level 1 energizing time PiIx or MI1 or PoIx. threshold.
and level 2 information If error is still present, exchange ECU.
523612 12 632 555 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.
523612 12 633 555 Error in the plausibility of the energising The energising times of the zero fuel quantity Threshold for error detection is an internal ECU
times of the zero fuel quantity calibration calibration ZFC is out of the target. (-> threshold.
ECU internal error) If error is still present, exchange ECU.
523612 12 634 555 Error in the plausibility of PoI2 efficiency. Error in the plausibility of PoI2 efficiency. Threshold for error detection is an internal ECU
threshold.
523612 12 635 555 Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an internal ECU
threshold.
523612 12 636 555 Error in the plausibility of PoI3 efficiency. Error in the plausibility of PoI3 efficiency. Threshold for error detection is an internal ECU
threshold.
3-184 3121262
Deutz Blink
Code Code
523612 12 637 555 Engine speed: the engine speed calculated Error in the plausibility of current energising Threshold for error detection is an internal ECU
by ECU is above the target range; the ECU time with maximum permitted energising threshold.
activates a system reaction time. Diagnostic fault check to report the error If error is still present, exchange ECU.
due to Over
Run
523612 12 638 555 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.
523612 12 639 555 Plausibility error of the Rail pressure sensor In case the gradient of rail pressure is larger than Threshold for error detection is an internal ECU
the max threshold or lesser than the threshold.
min threshold. Check metering unit or cable.
Rail metering unit defect. Check Rail pressure. Check the Rail System of
Leakge in the Rail System. leakage.
523612 12 640 555 Error in the torque comparison between per- Error in the torque comparison between the Threshold for error detection is an internal ECU
missible engine torque and current actual permissible inner engine torque and the threshold.
torque current plausible actual torque. If error is still present, exchange ECU.
523612 12 641 555 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.
523612 12 642 555 Diagnosis of lead path limitation forced by The setpoint path of the air system is limited by Threshold for error detection is an internal ECU
ECU monitoring level 2 the limitation torque of the functional threshold.
control unit monitoring. If error is still present, exchange ECU.
523612 12 643 555 Diagnosis of set path limitation forced by If the quantity setpoint is exceeds the limit of Threshold for error detection is an internal ECU
ECU monitoring level 2. the torque function. threshold.
523612 12 714 555 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 12 715 555 Error report "ABE wire is active" due to The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
undervoltage detection electrical system voltage (defective threshold.
autobattery) Software reset.
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage
recognition.
523612 12 716 555 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 12 717 555 Error report "ABE/WDA active" due to an The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
unknown reason electrical system voltage (defective threshold.
autobattery) Software reset.
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage
recognition.
523612 12 1170 555 Internal hardware monitoring: the CPU of Error during positive test (ECU internal error). Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Diagnostic fault check to report that the threshold.
nally; no item will be created in error mem- positive test failed Reflash ECU. If error is still activ replace ECU.
ory
3121262 3-185
Deutz Blink
Code Code
523612 12 1857 555 Fault in the monitoring during the engine wiring is not according DEUTZ requirements Threshold for error detection is an internal ECU
start. Start requested in level 1, but not engine start conditions are not observed threshold.
released in level 2 which leads to no fuel low battery voltage during start check other active errors and fix them.
injection. malfunction of starter check all needed engine start conditions, e.g.
neutral switch.
check the engine speed during starting of the
engine. If it's too low, then check the
battery voltage and then check the starter for
malfunction.
523612 14 973 555 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 14 974 555 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
nally;
no item will be created in error memory.
523612 14 975 555 Internal hardware monitoring: the CPU of Visibility of SoftwareResets in DSM Threshold for error detection is an internal ECU
nally; If possible the software update has to be done.
no item will be created in error memory Replace the ECU.
523613 0 856 134 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 0 857 134 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 0 858 134 Rail pressure: the fuel pressure in rail calcu- leakage is detected based on fuel quantity bal- Threshold for error detection is an internal ECU
lated by ECU is above the target range which ance. threshold.
is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
523613 0 859 134 Rail pressure: the fuel pressure in rail calcu- Maximum negative rail pressure deviation with Threshold for error detection is an internal ECU
lated by ECU is above the target range which metering unit on lower limit is exceeded. threshold.
is dependant on the engine speed. (A) Check backflow pressure
tor) if necessary
523613 0 862 134 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.
3-186 3121262
Deutz Blink
Code Code
523613 1 861 134 Rail pressure: the fuel pressure in rail calcu- Rail pressure falls below the limiting value Threshold for error detection is an internal ECU
lated by ECU is below the target range based on the engine speed. threshold.
which is dependant on the engine speed. (A) Check backflow pressure
tor) if necessary
523613 2 864 134 Rail pressure metering unit, Setpoint of Pressure pump delivery quantity in overrun Threshold for detection is an internal ECU
metering unit in overrun mode not plausi- exceeds the threshold based on the threshold.
ble. pressure. (A) Check backflow pressure
(B) Check pressure relief valve and metering
unit.
523615 3 594 135 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 unit if nec-
essary repair/replace it.
523615 3 596 135 Fuel metering unit: the current drain mea- short circuit to battery low side Threshold for error detection is an internal ECU
523615 4 595 135 Fuel metering unit: the current drain mea- short circuit to ground high side Threshold for error detection is an internal ECU
523615 4 597 135 Fuel metering unit: the current drain mea- short circuit to ground low side Threshold for error detection is an internal ECU
523615 5 592 135 Detecting an open load fault in the metering wiring harness defective, cable break Threshold for error detection is an internal ECU
unit threshold.
523615 12 593 135 powerstage of metering unit is overheated over temperature Threshold for error detection is an internal ECU
threshold.
Check functionality of metering unit and
replace it if needed.
Check temperature of metering unit and
improve the installation in case of overheating.
523632 3 1127 665 Urea supply module pressure sensor: the Shortcut to battery Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
523632 4 1128 665 Urea supply module pressure sensor: the Shortcut to ground Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
The sensed raw voltage value
SCR_uRawUPmpP is above
SCR_SRCUPmpP.uMin_C
523632 11 1117 666 Urea supply module pump: the current drain When the pump motor does not switch to pump Threshold for error is an internal ECU threshold
measured by ECU is above the target range actuation mode after temperature
measurement has
been carried out.
3121262 3-187
Deutz Blink
Code Code
523698 11 122 591 Shut off request from supervisory monitor- Engine Shut Off due to supervisory function Threshold for error detection is an internal ECU
ing function threshold.
Check error memory for additional errorcode to
find root cause.
Depending on additional error follow the docu-
mented "Take action for repair".
523718 3 1100 676 Urea heater relay: the current drain mea- Shortcut to battery Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase it threshold
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
523718 4 1101 676 Urea heater relay: the current drain mea- Shortcut to ground Threshold for error detection is an internal ECU
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
523718 5 1098 676 Urea heater relay: the current drain mea- Open load Threshold for error detection is an internal ECU
is a result error: KWP 1089 Test SCR main relay
Broken wiring Check cabling, if necessary replace relay.
broken relay
523719 4 1109 672 Urea supply module heater: the current Shortcut to ground Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply mod-
Heating element in supply module defect ule
523719 5 1106 672 Urea supply module heater: the current Open load Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase is threshold
range a result error: KWP 1089 Check wiring
523720 8 925 148 Supply module heater: Duration of switch on uty cycle for temperature readout from supply When the received supply module heater tem-
is too long. module heater to the control unit is out perature duty cycle SCR_rSMT is out of
of range; Supply modul defect, fault in the wir- the failurerange (SCR_rSMFailMax_C <
ing. SCR_rSMHtrT < SCR_rSMFailMin_C)
Supply module check and replace if necessary.
Check the wiring.
523720 8 926 148 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply When the received supply module heater duty
over error threshold. module heater to the control unit is not cycle SCR_rSMHtrT is in the valid range
valid. (SCR_r-
Check the wiring.
523721 8 930 689 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply Supply module check and replace if necessary.
over error threshold. module to the control unit is out of Check the wiring.
range.
Supply modul defect, fault in the wiring.
3-188 3121262
Deutz Blink
Code Code
523721 8 931 689 Supply module heater: Dutycycle timing out Duty cycle for temperature readout from supply When the received supply module duty cycle
of valid range. module to the control unit is not valid. SCR_rSMT is in the valid range
Supply modul defect, fault in the wiring. (SCR_rSMTVld-Min_C <= SCR_rSMT <=
SCR_rSMTVldMax_C), OR in the failure
range (SCR_rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C)
Check wiring.
523721 11 927 689 Supply module heater: temperature mea- Duty cycle for temperature readout from supply Threshold for detection is an internal ECU
surement not available. module heater to the control unit is not threshold.
available. No erasing in the current driving cycle.
Check the wiring.
523722 8 929 691 Supply module heater: Faulty PWM signal PWM Signal for temperature readout from sup- Threshold for error detection is an internal ECU
from supply module. ply module to the control unit is not valid. threshold.
Supply modul defect, fault in the wiring. When valid Sync followed by temperature
information signal is received AND valid sync
and temperaturesignal for both information is
received one after the other.
Check the wiring.
523776 9 291 119 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Threshold for error detection is an internal ECU
- active threshold.
Check CAN Bus cabling (Bus sheduling, polarity,
short circuit, power interrupt), test
range.
523777 9 292 119 Message TSC1-TE has been missing (passive) Passive timeout Error (Missing CAN Bus mes- Check CAN Bus cabling (Bus scheduling, polar-
sage) ity, short circuit, power interrupt), test
range, check actuator
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.
order). Check correct injector adjustment value (IMA).
Use SERDIA UseCase to check it.
programming (IMA) injector 2 (in firing cyl. 2 threshold.
order). check dataset and flash correct injector adjuste-
ment value (IMA). Use SERDIA
UseCase to check it.
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.
3121262 3-189
Deutz Blink
Code Code
523912 4 73 7-2-2 @ engines < 4l: The sensed raw voltage value is below the mini- The sensed raw voltage value
Throttle valve error, Open Load or Short cut mum threshold. DPM_uRawBrnDVDsP is above the minimum
to Battery, blocked valve or wrong control threshold
signal for valve. DPM_SRCBrnDVDsP.uMin_C
@ engines with Burner T4i: @ CRT < 4l: check throttle valve
Pressure Sensor error after valve (DV2), @ engines with Burner T4i: check back-pressure
lower limit reached valve
523924 4 42 167 Overload at Pins O_V_RH2x: A01, K74, K91. Suspected components: Threshold for error detection is an internal ECU
Components on A01, K74, K91 cannot be 1- Pin K91: threshold.
activated. Clutch switch, Brake switch, Engine brake Check wiring harness and connected loads on
Internal ECU power stage switched off. demand, Regeneration activation, Parking pins A01, K74, K91 and/or reflash ECU.
brake, Gearbox N, Fan control 1 If error is still present, exchange ECU.
2- Pin K74:
Boost air cooler bypass or electrical fuel pump
relay, Fan control 2/fuel valve for flame
star
523925 3 38 731 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A88, K57 cannot be 1- Lamps K57: Warn Ash Charge, Diagnostic, pins A88, K57.
activated. Warn Coolant Temp/Level, Warn Oil,
Internal ECU power stage switched off. Warn Boost Air, Warn Air Filter, Warn Water in
Fuel, SCR, Regeneration, Engine
Running.
2- Relay Preheat A88
3- Exhaust Flap A88
523925 4 43 731 Short circuit to ground actuator relais 3 Suspected components: Threshold for error detection is an internal ECU
Overload at Pins O_V_RH3x: A88, K57 1- Pin A88: threshold.
Preheat relay, Exhaust flap Check wiring harness and connected loads on
2- Pin K 57: pinsA88, K57.
- control lamps: If error is still present, exchange ECU.
- OBD, preheat lamp, warning temp., warning
oil, maintenance lamp, regeneration
indicator, alternator management, engine run-
ning, diagnostic
523926 4 44 732 Short circuit to ground aktuator relais 4. Suspected components:Fan, Wiring harness Threshold for error detection is an internal ECU
Overload at Pins O_V_PCV: A90 threshold.
Check wiring harness and connected loads on
pin A90.
523927 3 40 733 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A04, A05 cannot be 1- Urea Pump A04 pins A04, A05.
activated. 2- SCR Heater A05
Internal ECU power stage switched off.
523935 12 168 763 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 12 169 764 Timeout Error of CAN-Transmit-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
EEC3VOL2; Engine send messages
3-190 3121262
Deutz Blink
Code Code
523938 9 133 766 Timeout Error (BAM to packet) for CAN- Failure of the CAN Bus message NOX sensor and sensor connection check
Receive-Frame AT1IGCVol1 information;
factors & Sensorcalibration for NOX Sensor
(SCR-system upstream cat; DPF-system
downstream cat)
523939 9 134 766 Broadcast Announce Message of the calibra- Defective Nox sensor, faulty parameterization NOX sensor and sensor connection check
tion message
of the upstream catalytic NOx sensor has
failed.
Timeout Error (BAM to BAM) for CAN-
Receive-Frame AT1IGCVol1 information.
(SCR-system upstream cat, DPF-system
downstream cat).
523940 9 135 766 Timeout Error (PCK2PCK) for CAN-Receive- Failure of the CAN Bus message NOX sensor and sensor connection check
Frame AT1IGCVol1 information; factors &
Sensorcalibration for NOX Sensor (SCR-sys-
tem upstream cat; DPF-system
downstream cat)
523941 9 140 767 Timeout Error (BAM to packet) for CAN- Timeout Error (Missing CAN Bus message) NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information; check
(SCR-system downstream cat; DPF-system
downstream cat)
523942 9 141 767 Timeout Error (BAM to BAM) for CAN- Defective Nox sensor, faulty parameterization. NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information, check.
Calibration message 1 of the after catalyst
NOx sensor has failed.
Factors & Sensorcalibration for NOX Sensor
(SCR-system downstream cat, DPF-system
downstream cat)
523943 9 142 767 Timeout Error (PCK2PCK) for CAN-Receive- The fault is detected when a timeout error in NOX downstream sensor and sensor connection
Frame AT1OGCVol2 information; factors & packet 2 of NOxSenVol2Rx frame occurs. check
Sensorcalibration for NOX Sensor (SCR-sys-
tem downstream cat; DPF-system
downstream cat)
523960 0 1011 771 Physical range check high for EGR cooler Sensed temperature downstream EGR-cooler EGR-Valve blocked open
downstream temperature. > limit. EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
523960 1 1012 771 Physical range check low for EGR cooler sensor voltage > lower limit EGR-Valve blocked open
downstream temperature. EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
3121262 3-191
Deutz Blink
Code Code
523982 0 360 737 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not high. to too high battery voltage. repair or replace if necessary.
523982 1 361 737 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not low. to too low battery voltage. repair or replace if necessary.
523984 3 1239 788 Actuator relay 5: the voltage measured by Short-Circuit to battery to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
523986 4 1241 176 Actuator relay 4: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
523987 4 1242 791 Actuator relay 5: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
524050 11 1434 8-3-6 CAN; not used not used not used
524051 11 1435 8-3-7 CAN; not used not used not used
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
524063 3 1558 869 SCR heater mainrelay; short circuit to battery Short-Circuit to battery on wiring to component Check wiring, component
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 4 1559 869 Connection between heating valve (Y31) on Faulty wiring, faulty heater relay (K27-K31), Disconnect plug from heating valve (Y31) and
the control unit Pin A:92 and defective heating valve (Y31), reset fault.
Load side SCR heater main relay (K31) is a broken element in heating. If fault is still present you have to look in the wir-
short cut to ground. ing of Y31 to the control unit Pin A:92.
Threshold 1 < If error is no longer present, you have to check
SCRHtr_rUHtrMeasRatio_mp < Threshold the wiring of Y31 via relay K31
2 and possibly the heating cables and relay (K27-
K30).
524063 5 1555 869 Urea backflow line heater: broken wiring Open Load on wiring to component Check wiring, component
detected
Threshold 1 <
2
524063 5 1556 869 Urea main relay: broken wiring detected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
524063 5 1557 869 Urea pressure line heater: broken wiring Open load on wiring to component Check wiring, component
detected
Threshold 1 <
2
524063 5 1560 869 SCR relay for suction line not connected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
3-192 3121262
Deutz Blink
Code Code
524063 5 1561 869 Open load on wiring to component Open load on wiring to component Check wiring, component
Threshold 1 <
2
524063 5 1562 869 SCR heater tank; open load Open load on wiring to component Check wiring, component
524063 12 1646 869 SCR supply module temperature is not Suspected components: Check
reaching a threshold before a calibratable Enviroment temperature sensor defect Environment temperature sensor
time is exceeded. SCR supply module temperature sensor defect SCR supply module temperature sensor
Corresponding to the environmental Tem- SCR supply module electrical heater defect SCR supply module electrical heater
perature a specific defrosting time is given.
After starting the defrosting a clock counter
is starting. Does the counter reach the given
defrosting time limit, an error will be
detected. Is the temperature reached in time
the clock counter will be reset
Example: by using the calibrated tempera-
ture/time curve --> environmental temper-
ature 0°C --> defrosting time limit 6000s --
> if the clock counter reaches 6000s the error
will
be detected
524065 0 1565 892 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check for crystallisation in exhaust line
from the urea cat upstream cal high range limit f(exhaust volume upstream SCR and dwnstream of urea injector
sensor is greater than an applicable maxi- flow) Check correct connection from exhaust line to
mum pressure threshold UCatUsP_pRelFlt_mp > UCatUsP_pMax_mp pressure sensor upstream SCR catalyst:
syphons?, water in tube?, water in sensor?
Check that exhaust pipe outlet is free (down-
stream SCR catalyst)
Check wiring of pressure sensor upstream SCR
catalyst
Check pressure sensor upstream SCR catalyst:
sensor has no connection to vehicle body? =>
Ensure that sensor is free
Does sensor oscillate heavely at engine low idle
/ high idle? => try to supress the
oscillating
Exchange pressure sensor upstream SCR cata-
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
3121262 3-193
Deutz Blink
Code Code
524065 1 1566 892 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check correct connection from exhaust line to
from the urea cat upstream sensor is less cal high range limit f(exhaust volume pressure sensor upstream SCR catalyst:
than an applicable minimum pressure flow) leakage?
threshold UCatUsP_pRelFlt_mp < UCatUsP_pMin_mp Check electric connector: 4h pin open / new
connector type used? pressure exchange
from inside electrical connector with the envi-
ronemt possible
Check exhaust line: any leakages upstream of
SCR catalyst?
catalyst
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
524065 2 1598 892 Comparison of urea cat upstream exhaust absolut value of difference between sensed Check electric connector: 4h pin open / new
gas- and environment pressure, the differ- pressure upstream SCR catalyst and connector type used?
ence should not exceed a certain limit environmental pressure > limit pressure exchange from inside electrical con-
abs(UCatUsP_pDiffEnvCat_mp) > Thresh- abs(UCatUsP_pDiffEnvCat_mp) > Threshold nector with the environemt possible?
old water in sensor?
sensor frozen?
catalyst
lyst
Check intake manifold pressure sensor
(Air_pCACDs)
Check ambient pressure sensor (EnvP_p)
524065 3 1569 892 voltage of pressure sensor upstream SCR > voltage of pressure sensor upstream SCR > volt- Check wiring of pressure sensor upstream SCR
voltage high limit age high limit catalyst
Check pressure sensor upstream SCR catalyst
lyst
524065 4 1570 892 voltage of pressure sensor upstream SCR < voltage of pressure sensor upstream SCR < volt- Check wiring of pressure sensor upstream SCR
voltage low limit age low limit catalyst. Check pressure sensor
upstream SCR catalyst. Exchange pressure sen-
sor upstream SCR catalyst
3-194 3121262
Deutz Blink
Code Code
524067 0 1581 894 Filtered urea supply module heater temper- sensed temperature of supply module heater > Compare SCR_tSMT with SCR_tSMHtrT. Both
ature value is above an applicable maximum physical high range limit show the same value?
heater temperature threshold of the supply Check urea tank temperature
module (SCR_tAdapUTnkT). Very hot (> 70°C), urea
The temperature is read out via the PWM sig- tank heater
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module heater temperature sensor
defect
Supply module heater defect
Supply module defect
524067 0 1585 894 Filtered urea supply module temperature sensed temperature of urea within supply mod- Compare SCR_tSMT with SCR_tSMHtrT. Both
value (SCR_tSMT) is above an applicable ule > physical high range limit show the same value?
maximum temperature threshold of the Check urea tank temperature
supply module (SCR_tAdapUTnkT). Very hot (> 70°C), ure tank
The temperature is read out via the PWM sig- heater
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module temperature sensor defect
Supply module heater defect
Supply module defect
524067 1 1582 894 Filtered urea supply module heater temper- sensed temperature of supply module heater < Check ambient temperature EnvT_t < Thresh-
ature value is below an applicable minimum threshold old?
heater temperature threshold of the supply Compare SCR_tSMT with SCR_tSMHtrT
module Check wiring with regard to supply modul
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module heater temperature sensor
tion was switched on. When that state is defect
left the sensed temperature value is frozen. Supply module defect
524067 1 1586 894 Filtered urea supply module temperature sensed temperature of urea within supply mod- Check ambient temperature EnvT_t < thresh-
(SCR_tSMT) value is below an applicable ule < physical low range limit old?
minimum temperature threshold of the sup- Compare SCR_tSMT with SCR_tSMHtrT
ply module Check wiring with regard to supply modul
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module temperature sensor defect
tion was switched on. When that state is Supply module defect
left the sensed temperature value is frozen.
3121262 3-195
Deutz Blink
Code Code
524067 2 1867 894 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module heater temperature and supply module heater temperature and and CEngTds_t and
ambient temperature ambient temperature SCR_tAdapUTnkT => All identical? If not:
UPmpT_tDiffPmpHtrAmb_mp > threshold UPmpT_tDiffPmpHtrAmb_mp > threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Problem at Supply module unit (broken?) =>
524067 2 1868 894 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module temperature and ambient supply module temperature and ambient and CEngTds_t and
temperature > threshold temperature UPmpT_tDiffPmpAmb_mp > SCR_tAdapUTnkT => All identical? If not:
threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Problem at Supply module unit (broken?) =>
524074 9 1533 246 Open load sensor internally at NOx-sensor Open load sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
dismounting. => If water inside, replace sen-
sor.
Check mounting position of sensor and judge it
regarding condense water formation /
agglomeration.
Check wiring harness
Exchange sensor
524075 11 1534 247 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
sor.
agglomeration? Rearrange if critical and possi-
ble
Exchange sensor
3-196 3121262
Deutz Blink
Code Code
524076 9 1535 248 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
sor.
agglomeration.
Exchange sensor
524077 11 1536 249 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
sor.
agglomeration.
Exchange sensor
524078 9 1537 255 Lambda value of NOx-Sensor downstream sensed lambda value of Nox-sensor down- Check whether NOx-sensor downstream SCR
SCR is out of range. stream SCR catalyst is > physical high limit catalyst is physically mounted within the
When the filtered Lambda concentration ComRxSCR_rCanLamDs_mp > threshold exhaust line
value at the sensor Check Lambda values of NOx-sensor down-
(ComRxSCR_rFltLamDs_mp) is greater than stream SCR catalystat at idle conditions,
the physical range check max. lambda ComRxSCR_rCanLamDs_mp > threshold?
threshold Compare to ComRxSCR_rCanLamUs_mp. Val-
ues must be almost identical
Check CANBus of NOx-sensor downstream SCR
catalyst
Check NOx-sensor downstream SCR catalyst
wiring
itself
Replace NOx-sensor downstream SCR catalyst
3121262 3-197
Deutz Blink
Code Code
524079 9 1538 256 sensed lambda value of NOx-sensor down- sensed lambda value of NOx-sensor down- Compare to ComRxSCR_rCanLamUs_mp.
stream SCR catalyst is < physical low limit stream SCR catalyst is < physical low limit ComRxSCR_rCanLamDs_mp must be
ComRxSCR_rCanLamDs_mp < threshold ComRxSCR_rCanLamDs_mp < threshold almost identical!
If almost identical,
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check injection system of engine. Injector
stuck?
if sensed lambda upstream SCR higher
(ComRxSCR_rCanLamUs_mp) : Diesel in
Urea-tank?
Check CANBus of NOx-sensor downstream SCR
catalyst
wiring
itself
524080 9 1539 257 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check whether NOx-sensor upstream SCR cata-
upstream SCR catalyst is > physical high SCR catalyst is > physical high limit lyst is physically mounted within the
limit ComRxSCR_rCanLamUs_mp > Threshold exhaust line
ComRxSCR_rCanLamUs_mp > Threshold Check Lambda values of NOx-sensor upstream
SCR catalystat at idle conditions,
ComRxSCR_rCanLamUs_mp < Threshold?
Compare to ComRxSCR_rCanLamDs_mp. Must
be almost identical
Check CANBus of NOx-sensor upstream SCR cat-
alyst
Check NOx-sensor upstream SCR catalyst wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
524081 9 1540 258 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check air path of engine: EGR-Valve, Intake-
upstream SCR catalyst is < physical low limit SCR catalyst is < physical low limit Throttle, Turbocharger and Piping each
ComRxSCR_rCanLamUs_mp < Threshold ComRxSCR_rCanLamUs_mp < Threshold for leakage and correct function
Check injection system of engine. Injector
stuck?
Check CANBus of NOx-sensor upstream SCR cat-
alyst
524083 9 1542 261 sensed NOx-value of NOx-sensor down- sensed Nox-value of Nox-sensor downstream Check CANBus of NOx-sensor downstream SCR
stream SCR catalyst < Threshold SCR catalyst < physical low limit catalyst
wiring
itself
3-198 3121262
Deutz Blink
Code Code
524085 9 1544 912 sensed Nox-value of Nox-sensor upstream sensed Nox-value of Nox-sensor upstream SCR Check CANBus of NOx-sensor upstream SCR cat-
SCR catalyst < Threshold catalyst < physical low limit alyst
524100 9 1666 924 Timeout error of CAN-Transmit-Frame Com- Open load on CANBUS wiring. Check wiring, component.
DPFHisDat.
524104 9 1676 928 Timeout error of CAN-Receive-Frame Com- Time out of Check CANBUS EAT Control Receive Threshold for error detection is an internal ECU
RxDPFCtl. CM1 Module Customer Recieve Message, PGN65348. threshold.
Message. The message is not received. Check CANBUS EAT Control Receive Message,
PGN65348.
CM1 Module Customer Recieve Message.
524118 9 1672 9-4-2 Timeout error of CAN-Receive-Frame If the frame CM1 message is not transmitted Check CAN Bus cabling (Bus sheduling, polarity,
ComRxCM1 successfully short circuit, power interrupt), test
range.
524121 9 1683 9-4-5 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
RxTrbChActr short circuit, power interrupt), test
range.
524125 9 1687 9-4-9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
TxTrbChActr short circuit, power interrupt), test
range.
524141 7 1827 192 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
524141 7 1858 192 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
3121262 3-199
Deutz Blink
Code Code
524147 13 1639 966 No proper urea pressure level could be build This error shows up, if no proper urea pressure Make sure that frozen lines, pump or tank can be
up within the SCR system state "Fill Lines" level could be build up within the SCR excluded!
=> SCRCo_stStatus_mp = 1 within some system state "Fill Lines" => Check whether there is urea in the urea tank
miuntes SCRCo_stStatus_mp = 1 within some minutes Check urea lines:
Once the urea pump pressure has exceeded the All lines connected? The right lines connected to
threshold the error is declared as the correct places?
okay. Suction line blocked?
Suspected components: No leakage? Not also urea to the outside but also
Suction line blocked air into the lines, especially in the
PWM Powerstage has a defect and a default suction line!
value which leads not to a rising pressure Perform service routine "pressure test":
Pump Pressure sensor defect Does the urea pump work? => check wiring
pump filter contains dirty parts harness & PWM signal for pump
reverting valve continously open Does the urea pressure rise?
DFC already healed?
If all unsuccessful so far:
Check urea pressure sensor: At ignition on and
SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
Check reverting valve => see
DFC_SCRCoRevVlvBlk
Check pump filter: dirt inside?
Suspected components:
Urea pump broken
Reverting valve continously open
Urea suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
Pump Pressure sensor broken
524152 2 1874 971 CAN message is not received fora definite CAN message is not received for a definite time Check eletrical connection oif urea quality sen-
time => error is set. As soon as the message => error is set. As soon as the sor
is received the error heals. message is received the error heals. Check engine CAN bus
Check urea quality sensor itself
Exchange urea quality sensor
524153 2 1875 997 CAN message is not reseived for a definite CAN message is not reseived for a definite time Check eletrical connection of suction unit sen-
time => error is set. As soon as the message => error is set. As soon as the sor (combined sensor with tank level and
is received the error heals. message is received the error heals. tank temperature)
Check engine CAN bus
Check level sensor itself
Exchange suction unit
524156 9 1705 972 Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
ComRxEBC2 from wheel speed sensor. Defect on wheel speed sensor. short circuit, power interrupt), test
range.
Replace the wheel speed sensor.
3-200 3121262
Deutz Blink
Code Code
524177 7 1863 995 The error shows up, if no proper urea presure This error shows up, if no proper urea presure Make sure that DEF lines, pump and tank are not
could be build up within the SCR system could be build up within the SCR system frozen.
state "Fill Lines" => SCRCo_stStatus_mp = state "Fill Lines" => SCRCo_stStatus_mp = 1. Check for DEF level in the tank.
1. 3 cases can lead to the error: Check DEF lines:
Case A: increasing pressure is detected within Are all DEF lines connected?
15s the check has passed => no error Is the suction line blocked?
Case B: The pressure threshold was not reached Is ther any leakage? Not only urea to the outside
within the 60s but case A was not but also air into the lines, especially in
positiv. the suction line!
Case C: The minimum pressure of 3000 hPa was Perform SERDIA usecase "pressure test":
not reached within the 60s. Does the DEF pump work? => check wiring har-
ness & PWM signal for pump.
Does the urea pressure increase?
All errors are already healed?
If still unsuccessful so far:
Check urea pressure sensor: At ignition on and
Check DEF pump filter: Is any dirt inside?
Suction line
PWM Powerstage has a defect and a default
value which leads not to a rising pressure
DEF pump pressure sensor defect
DEF pump filter contains dirty parts
3121262 3-201
Deutz Blink
Code Code
524178 7 1864 996 The urea pump is not able to control the urea The urea pump controller is not able to control Make sure that DEF lines, pump and tank are not
pressure between 9bar and 11 bar. the urea pressure between 9bar and 11 frozen.
bar due to malfunction in the SCR system. Check for DEF level in the tank
Suspected components: Check DEF lines:
- DEF pump broken All lines connected? The right lines connected to
- Reverting valve continously open the correct places?
- Urea suction line, backflow line broken or con- Suction line blocked?
nection swapped Is there any leakage? Not also urea to the out-
- PWM Powerstage has a defect side but also air into the lines, especially
- Pump Pressure sensor broken in the suction line!
Perform SERDIA usecase "pressure test":
Does the DEF pump work properly? => check
wiring harness & PWM signal for pump
Does the DEF pressure rise?
Is the error healed?
If still unsuccessful so far:
- Check DEF pressure sensor: At ignition on and
- Check reverting valve
- Check DEF pump filter: dirt inside?
DEF pump broken
Reverting valve continously open
DEF suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
DEF pump pressure sensor broken
524190 14 1891 272 Not enough urea in tank or low urea quality Low DEF tank level Check DEF level in tank. If there is no DEF, refill
or hardware tampering failure is detected or Low DEF quality up to volume above the warning
hardware failure is detected Hardware Tampering is active threshold.
Hardware Failure is active Check the DEF quality in the tank. If wrong fluid
is filled, refill with proper DEF.
Check other errors based on hardware malfunc-
tions.
524191 14 1892 273 A low DEF tank level or a low DEF quality is Low DEF tank level Threshold for error detection is an internal ECU
detected or hardware tampering(system Low DEF quality threshold.
components are pinched off) or hardware Hardware Tampering is active Check the DEF level in tank. If there is no DEF,
failures as shortcut to battery, shortcut to Hardware Failure is active refill up above the warning level.
ground Check DEF quality filled in the tank.
etc. are detected. Check other errors based on hardware tamper-
ing or failure.
3-202 3121262
Deutz Blink
Code Code
524193 8 1893 275 The total time in standstill-regeneration Stand-still mode is very often aborted by the Read out stand-still statistics => see service
mode exceeds the long-limit threshold operator. manual:
within last 500h total engine run time. Stand-still mode does not reach required tem- Stand-still operation finished or often inter-
The error is activated if the engine runs to perature level and regeneration level is rupted by driver / engine shut-off? => Run
many times in Standstill regeneartion. therefore reached after a short time again stand-still and instruct operator
Stand-still operation required often by soot
load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPf allow it:
Perform Stand-still and check reached temper-
ature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min
stand-still main phase 590°C are reached?
Temerature traces are steady and even?
Temperature downstream DOC higher than
upstream DOC but difference does not
exceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C downstream
DOC are not reached) => exchange DOC
Very big difference (>100 K after 25 min stand-
still main phase, 590 °C downstream
DOC exceeded) => check injection system of
engine & engine air path
3121262 3-203
Deutz Blink
Code Code
524194 8 1894 276 The total time in standstill-regeneration Stand-still mode is aborted / interrupted too Read out stand-still statistics => see service
mode exceeds the long-limit threshold: 2,5h often by the operator manual:
stand-still operation within 50h total motor Stand-still is required too often due to miscalcu- Stand-still operation finished or often inter-
run time. lation in the soot model rupted by driver / engine shut-off? => Run
The error is activated if the engine runs to Stand-still mode does not reache temperature stand-still and instruct operator
much time in short Standstill regeneartion. level and regeneration level is therefore Stand-still operation required often by soot
reached after a short time again. load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPF allows it:
Perform Stand-still and check reached temper-
ature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min
stand-still main phase 590°C are reached?
Temerature traces are steady and even?
Temperature downstream DOC higher than
upstream DOC but difference does not
exceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C downstream
DOC are not reached) => exchange DOC
Very big difference (>100 K after 25 min stand-
still main phase, 590 °C downstream
DOC exceeded) => check injection system of
engine & engine air path
3-204 3121262
Deutz Blink
Code Code
524195 14 1900 279 The standstill request of detected crystalli- Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line and
zation is ignored for more than reached a level which indicates inspect visually the injector and the
5h(>300min) crystallisation inside of exhaust line. exhaust line for urea crystallisation upstream of
This will be activated if there is a standstill The error detection depends on the sensed pres- SCR catalyst:
request activated by Crystalisation Monitor- sure upstream of the SCR catalyst and If crystallisation can be clearly seen, then stand-
ing. the calculated exhaust volume flow through still must be processed.
the mixer pipe. Has the engine been operated in low load for
In case of error is set, but no crystallisation can longer time? If yes, then it could be the
be found in the mixing pipe, a possible reaoson for crystallisation.
reason can be the defect sensors: Does the NOx-Sensors work properly? Compare
- exhaust pressure & temperature upstream of ComRxSCR_rNOxUs to
the SCR catalyst, ComRxSCR_rNOxDs, when
- the ambient pressure ComRxSCR_stNOxRdyUs = 1 &
- the exhaust mass flow => Check air path sys- ComRxSCR_stNOxRdyDs = 1 (Warm engine
tem at the engine. and EAT-system,
SCRT_tCatAvrgExhGs_mp > 250°C,
SCR_stStatus = "Dosing" = 8): sensed NOx
upstream of SCR catalyst must be higher than
downstream of SCR catalyst.
Go to idle and wait until SCR system enters sta-
tus "stand-by" (no dosing),
SCRT_tCatAvrgExhGs_mp < 225°C:
ComRxSCR_rNOxUs = ComRxSCR_rNOxDs
Clean urea injector: rinse it thourougly under
water
Check EGR-Path: difference pressure sensor at
venturi tube, EGR cooler, EGR-Valve,
Reed-Valve, Intake throttle regarding function
and leakage. Does the EGR-cooler leak
water in the exhaust?
Check air path for leakage
Check turbocharger
No crystallisation can be seen in the mixing
pipe:
Check exhaust pressure sensor upstream of SCR
catalyst (SCR_pSensUCatUsP):
tube, water in sensor?
Check environmental pressure sensor
(EnvP_p): plausible?
Check exhaust temperature sensor upstream of
SCR-catalyst (SCR_tSensUCatUsT):
plausible compared to Exh_tOxiCatUs &
Exh_tOxiCatDs e.g. when engine has idled for
20 minutes?
=> Run stand-still to remove crystallisation
and to reset the DFC
5232719 3 1108 672 Urea supply module heater: the current Short circuit to battery Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error:KWP 1089 Check wiring
3121262 3-205
3.33 COUNTERWEIGHT
If the counterweight has been removed, ensure the retaining
bolts are torqued to the proper value as shown in Figure 3-92.,
Counterweight Bolt Torque.
APPLY THREADLOCKER P/N 0100019

TO BOLT AND THREADS IN COUNTERWEIGHT.
TORQUE TO 400 FT LBS (542 Nm).
Figure 3-92. Counterweight Bolt Torque
3-206 3121262
SECTION 4. BOOM & PLATFORM
4.1 BOOM SYSTEMS Transport Position Sensing System

The transport position sensing system uses the main boom
NOTE: For more detailed information concerning system adjust- angle sensors, the main boom length sensor mounted in the
ment and operation, refer to Section 6 - JLG Control Sys- pivot end of the main base boom in addition to the boom
tem. length switch mounted on the platform end of the main base
boom and transport proximity switches mounted to the jib fly
Broken Cable Indicator System boom to sense when the main boom and jib boom are in the
position associated with high speed travel. Above transport
The boom on this model is a 4 section proportionally driven angle is recognized when the main boom cylinder angle sen-
telescopic boom. The inner mid boom is driven directly by the sor reads more than 6º with respect to the turntable and resets
telescope cylinder. The outer mid and fly booms are each to within transport position when both main boom angle sen-
driven by separate wire rope systems. Each rope system con- sors read less than 4º with respect to the turntable. Transport
tains redundant ropes that are capable of allowing the opera- length is recognized when the main boom length switch and
tor to unknowingly continue use of the machine with a single main boom length sensor read less than 1 ft extension for the
rope failure. These kinds of failures with the extend ropes are main boom. Transport position is also determined when the
self revealing to the operator so proper action can be taken. jib boom length switches indicate the jib is fully retracted with
Failures within the fly extend ropes are self revealing as they the jib and below 5 degrees with respect to the main boom.
are exposed on the exterior of the boom where a broken rope During failures of either the main boom length switch or the
would be obvious. Failures within the outer mid ropes require main boom length sensor the main boom transport length
will be determined by the remaining sensor or switch. In addi-
the addition of the Broken Cable Indicator System in order to
tion for a failure either jib boom length switch, jib length will
be self-revealing to the operator. This system uses a proximity
be determined by the remaining switch.
sensor to detect excessive movement of the sensed rope as
would be expected with a rope failure. A broken rope detec- This system is used to control the following systems:
tion results in illuminating the Cable Break indicator on the
platform control panel. No restrictions are made to the func- • Beyond Transport - Drive Speed Cutback System
tionality of the control system. It is the responsibility of the
operator to take the appropriate action. • Drive/Steer - Boom Function Interlock System (CE Only)
• Jib Stow System

Platform Control Enable System
• Axle Extension System
The platform controls make use of a time dependent enable
circuit to limit the time availability of “live” or enabled controls. • Oscillating Axle System
To operate any directional function, the foot-switch must be
depressed before activation of the function. When the foot- Beyond Transport - Drive Speed Cutback System
switch is depressed, the controls are enabled and the operator
has 7 seconds to operate any function. The controls will When boom is positioned beyond the Transport Position, the
remain enabled as long as the operator continues to use any drive motors are automatically restricted to their maximum
function and will remain enabled 7 seconds after the last func- displacement position (slow speed).
tion has been used. While the controls are “live”, the enabled
light will be illuminated in the platform display panel. When
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 machine the controls must be re-enabled to start the timer
system over again. This is done by releasing all functions, then
releasing and re-depressing the foot-switch.
3121262 4-1
4 3 2
1
1. Boom Angle Sensor #1 (Right)

2. Boom Cable Proximity Sensor
3. Boom Length Sensor
4. Boom Angle Sensor #2 (Left)
5. Boom Length & Angle Module
6. Lift Cylinder Pivot Pin
1001119385 D
Figure 4-1. Boom Component Location - Sheet 1 of 2
4-2 3121262
16
15
9 14
13
10
12
11
7. Jib Level Rotary Sensor 12. Platform Level Sensor #1 (Right-Primary)

8. Lock Pin Proximity Sensor (Bottom Side) 13. Jib Transport Proximity Sensors
9. Jib Control Module 14. Jib Swing Rotary Sensor (Bottom Side)
10. Platform Level Sensor #2 (Left-Secondary) 15. Jib Control Valve
11. Platform Control Valve 16. Main Boom Transport Limit Switch
1001119385 D
Figure 4-2. Boom Component Location - Sheet 2 of 2
3121262 4-3
Drive/Steer – Boom Function Interlock System (CE Envelope Tracking System

ONLY) The Envelope Tracking System uses the envelope control sen-
The Drive/Steer – Boom Function Interlock System uses the sors to enhance the control of the boom within the working
Transport Position Sensing System to sense when the boom envelope. Due to the shape of the working envelope, the max-
and jib are out of the transport position. All controls are simul- imum boom angle varies with telescope length. To maintain
taneously functional when the booms are within the transport unrestricted operation of the boom, the lift down function is
position as on the standard machine. When the boom/jib are automatically introduced while telescoping in only when the
beyond the transport position, the control functions are inter-
boom is on the rearward edge of the envelope. This only
locked to prevent simultaneous operation of any boom func-
occurs when telescoping in along the rearward edge and is
tion with drive/steer. The first function set to be operated in
this mode, becomes the master function set. In other words, not used elsewhere within the envelope or when telescoping
while operating drive/steer functions the boom functions are out. Envelope tracking is disabled with any envelope or
inoperable. Likewise, while operating boom functions drive/ moment violations or failures. The envelope tracking function-
steer functions are inoperable. ality and be turned off using the manual position of the boom
control select switch.
Jib Stow System
The machines stowed length can be reduced to facilitate Moment Control System
transportation on standard trailers by swinging the jib to the
The Moment Control System is the secondary means of con-
right using the hydraulic power of the jib stow rotator. The
trolling the stability of the machine. This system uses a load
control system will prevent swinging the jib unless the axles
are retracted, the boom and jib are in the transport position. If cell pin to attach the lift cylinder of the main boom to the turn-
the transport criteria are met and the operator commands jib table. This pin is instrumented with gauges allowing the forces
swing right via the jib swing function switch. The control sys- in the pin to be monitored. These forces are used to compare
tem will retract the jib lock pin and begin to swing the jib into the actual boom moment (force at a distance) to a predeter-
the stowed position. When the jib is stowed, automatic plat- mined allowable boom moment. In controlling the boom
form leveling is disabled, the boom is restricted to the trans- moment, the position and load of the boom is controlled. The
port position, and axle extension is disabled. This system is
moment control system will detect moments larger than
functional only in the 500# mode of the Dual Capacity System.
Jib telescope function will resume when the jib is fully stowed expected as well as those smaller than expected. This effec-
along side the main boom. Conversely, the jib must be tively controls the forward and rearward positions of the
retracted into the transport position before the jib is allowed boom. The moment control system varies the maximum
to swing left into the locked position. Once the jib reaches the allowable moment based on ground slope. On level ground
in-line position, and the operator is maintaining the jib swing and with rated load in the platform, the allowable moments
left function switch the control system will attempt to lock the establish a working envelope slightly larger than the Envelope
jib lock pin. If successful, the jib lock pin lamp will illuminate
Control System’s envelope to minimize interaction of the sys-
continuously after the operator releases jib swing function
switch. tems. With increasing ground slopes and rated load in the
platform, the allowable moments may establish a working
envelope smaller than the Envelope Control System’s enve-
lope and may result in moment violations at the extreme plat-
form positions. Violations of the moment control systems
allowable moment will result in reduced function speeds, BCS
warning light illumination, and restriction of functions. The
platform alarm will sound and the BCS light will flash with
attempts to operate restricted functions. The restricted func-
tions due to moment system violations related to forward
reach are disallowing jib functions, lift down, telescope out,
swing, drive and steer. The restricted functions due to moment
system violations related to backward reach are disallowing jib
functions, lift up, telescope in, swing, drive and steer. Recog-
nized failures within this system will result in control by the
Envelope Control System, reduced function speeds, BCS warn-
ing light illumination. The boom will be restricted from leaving
the transport position until the failure is resolved.
4-4 3121262
Boom Control System (BCS) Functional Check Jib Leveling During Automatic/Manual Envelope
(Push to Test) System Control
The machine is equipped with a system for the operator to
There are no function switches in the platform or ground con-
daily verify the proper functioning of the Boom Control Sys-
trols to manually adjust the jib level function. During auto-
tem (Envelope Control System and the Moment Control Sys-
matic or manual main lift control, jib level maintains its angle
tem). The operator is instructed to position the boom in the
in relation to the main boom position.
position described by the instruction decal and to then verify
the control system cut out the main telescope movement at Jib Level Up/Down can be manually overriden using the ana-
the correct length. When the operator pushes the push button lyzer. The control system only allows this under certain condi-
mounted on the ground control panel, the control system tions and it should only be performed by an authorized JLG
compares the current moment reading in the moment system service technician. When accessed, jib level can be adjusted
to the moment expected for this position. If the current using the Jib Lift Up/Down function switch.
moment is within allowable tolerance for the test position, the
Jib Level override is accessible in Access Level 1. Using the Left
green BCS indicator will illuminate indicating the system is
working properly. If the current moment is not within the
allowable tolerance for the test position, the red BCS indicator and Right arrow keys until the screen shown
will illuminate indicating the machine requires service by JLG below is reached.
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-
bility to take proper action. The machine can be in either
capacity mode of the dual capacity system for this system
check.
4.2 BOOM/JIB SYSTEM FUNCTIONALITY

Main Lift/Jib Velocity Control
To improve the control of the main boom, platform leveling,
and main lift/jib functions' end of stroke dampening, the fol-
lowing angle sensors are utilized:
• Jib lift cylinder angle - CAN based in-cylinder length sen-
sor.
• Platform level cylinder angle - CAN based in-cylinder
length sensor.
• Jib level angle - Dual output analog angle sensor whose
signal is processed by the Jib Control Module.
• Jib rotate angle - Dual output analog angle sensor whose
signal is processed by the Jib Control Module.
• Main boom cylinder angle - Dual output analog angle sen-
sor (to be processed by the BLAM)
3121262 4-5
Press ENTER , the screen should read: Press ENTER , the screen should read:
To enable the level override mode 58237 must be entered as

the code. When the code is entered, the screen will show:
Using the UP and DOWN arrow keys will toggle
the override from off to on. Once turned on, operating the jib
lift function will cause jib level to be activated.
NOTE: Using this override may set the JIB LEVELING SYSTEM FAULT
depending on how far out of level the jib is moved. (See Jib
Leveling section)
Escaping out of this override will not turn it off, reset is

achieved by cycling power to the machine or re-entering the
override code and manually turning it off.
4-6 3121262
Attempts to lift the main boom while this override is on will Jib Telescope Functionality
result in a JIB LEVELING SYSTEM FAULT because during the
override automatic jib leveling is disabled. To adjust the jib Jib Telescope out will only be allowed if the axles are
back to level go into override mode for the jib leveling. Turn it extended, and the capacity control is in the 500# mode and
on, escape out of the Service Modes menu, and go to DIAG- the jib is locked inline with the main boom, or if the machine is
in the stowed state.
NOSTICS/BOOM SENSORS menu. Use the RIGHT arrow
key go until you get to the following screen. Jib Swing Functionality
The jib swing function is only used to stow the jib for trans-
port, and taking the jib out of the stowed position for use. This
function is only permitted when the main boom is in the trans-
port state.
Jib Swing Stow Sequence (Jib Pin Unlock)

If the machine is in the transport mode and the operator
attempts jib swing right, the control system attempts to
unlock the jib lock pin. If successful, (determined by the jib
lock pin proximity sensor) the control system continues to
command the jib lock pin unlock output on and control the jib
swing right function until the operator releases the jib swing
function, or the jib reaches the jib stowed position. Once the
operator releases the jib swing function the control system
shall command the jib lock pin unlock output to off. If the jib
lock pin does not unlock, the control system continues to try
to unlock the jib pin when the operator commands a jib swing
right function. The control system allows jib swing left to jog
the jib in the instance the pin is pinched by the jib structure.
Jib Lock Pin control can be manually overriden using the ana-
Adjust the jib level using the jib lift up and down function lyzer. The control system only allows this under certain condi-
switch until the jib level control angle reads zero. Cycle power tions and it should only be performed by an authorized JLG
and operate the main boom to verify that jib level is working. service technician. When accessed, the jib lock pin can be
manually extended or retracted. To use this service mode the
Jib Lift Functionality technician must be in platform and in platform mode because
the footswitch is required to activate the jib lock pin.
The ground module controls the jib control valve using an out-
put on the ground. Simultaneous main lift and jib lift function
is not possible. The first function activated will have priority
over the other. Manual override of the platform leveling func-
tion will be allowed during all functions. If there is a failure in
which the jib functions cannot be controlled from the Jib Con-
trol Module, the ground module will control the jib control
valve and also override the jib lift up and down valve with out-
puts out of the ground module.
3121262 4-7
Jib Lock Pin override is accessible in Access Level 1. Using the

Press ENTER , the screen should read:
Left and Right arrow keys until the screen shown
below is reached.

code. When the code is entered, the screen will show:
4-8 3121262
Use the Left or Right arrow key until you see: Using the Up and Down arrow keys will allow the
following modes:
• OFF
• EXTEND
• RETRACT
Once the desired mode is selected, stepping into the foot-

switch with the machine running will perform extension or
retraction of the jib lock pin. 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 turn-
ing it off. When the service mode is used to retract the jib lock
pin for servicing, attempts to lift or telescope out of transport
will result in a JIB UNLOCKED OUT OF TRANSPORT – HYDRAU-
LICS SUSPENDED fault and the boom will be trapped into
transport.
Jib Swing Deploy Sequence (Jib Pin Lock)

If the machine is in the stowed state and the operator
attempts to swing the jib left, the control system will first
check the position of the jib telescope. If the jib is in the trans-
port position, the control system will unlock the jib lock pin
and jib swing left until the jib is in line with the main boom
Press ENTER , the screen should read:
(determined by the jib swing angle sensor). If the jib is in line
the control system will attempt to lock the jib lock pin. If the
attempt fails, the control system will allow the operator to jib
swing right or left.
Jib Lock Pin Lamp Operation

On machine power-up the control system will energize the
lamp based on the current state of the jib lock pin as deter-
mined by the jib lock proximity sensor. While attempting to
stow or deploy the jib, the control system shall flash the jib
lock pin lamp while the operator is activating the jib swing
function switch. If the jib lock pin is in the locked position the
lamp will be energized. If the jib lock pin is in the unlocked
position the lamp will be de-energized. If the jib lock pin is in a
fault state (i.e. the jib is deployed and the jib lock pin is
unlocked) or the jib is in the stowed state and the jib lock pin is
in the locked state, attempts of disallowed functions results in
the jib lock pin lamp being flashed.
NOTE: Attempts to move the boom out of transport when the pin
is unlocked will be disallowed and a fault code will be regis-
tered.
3121262 4-9
Swing/Axle Extend Retract Restrictions Boom Recovery override is accessible in Access Level 1. Using
In addition to the Direction Of Steer proximity switch in the the Left and Right arrow keys until the screen
chassis, a 360 degree dual rotary sensor is also used to calcu- shown below is reached.
late the turntable rotation angle. These sensors are used
together to restrict swing when the machine is in the trans-
port state. If the machine is in the transport state and the oper-
ator is attempting to swing the boom, the control system shall
allow swing until the angle is at approx. +/- 40 Degrees from
the transport position or the DOS proximity switch is tripped.
At this point the control system will use the turntable rotary
angle sensor to determine which swing function is allowed to
return the boom between the rear wheels. Attempts to con-
tinue swinging in the wrong direction causes the DOS indica-
tor light to flash. If the machine is in the transport state with
the exception of the axles being extended and the operator
has the boom outside of the rear wheels, the control system
disallows axle retract until the boom is again within the rear
wheels. Faults within this system override DOS functionality.
Dual Capacity
The position of the jib telescope is integrated into the dual
capacity logic and the logic relating to the jib swing control
and dual capacity will be removed since the jib is restricted
from swinging in all cases except when the machine is in the
transport state. In order to switch from the 500# capacity Press ENTER , the screen should read:
mode to 1000# capacity mode the jib will have to be fully
retracted, (determined by the two proximity switches
mounted on the side of the jib) and the operating envelope
will have to be in the 1000# envelope in order to switch capac-
ity modes. The jib transport/dual capacity proximity sensors
are mounted in line so one should switch before the other. The
control system monitors the proximity sensors changing state
in relation to jib telescope in versus jib telescope out.
Jib Control During Over/Under Moment

During an overmoment condition the control system limits
the jib functions to jib telescope in only. During an undermo-
ment condition the control system disables all jib functions.
Boom Recovery Mode

Boom Recovery Mode allows the boom to be lifted down and
telescoped in, in the event CAN bus communication is lost to
both the Jib Control Module and the Platform Module.
Boom Recovery Override is only available in the event the

ground module loses CAN communication with both the Jib
Control Module and the Platform module, in the case of a sev-
ered boom cable for example. This mode allows the boom to
be lifted down and telescoped in.
4-10 3121262

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.
Use the Left or Right arrow key until you see:
3121262 4-11
4.3 PLATFORM 5. Using a suitable device, support the platform support.

6. Remove the bolts and locknuts securing the support to
the rotator.
Platform/Support Removal
CENTER BOLT
BOLT
ROTATOR
LOCKNUT
MAF09600
MAF09580
7. Using a suitable brass drift and hammer, remove the
Figure 4-3. Location of Components center bolt and locknut.
1. Disconnect electrical cable from platform control con-

sole.
2. Tag and disconnect the hydraulic lines from the rotator.

Use suitable container to retain any residual hydraulic
fluid. Cap hydraulic lines and ports.
3. Remove the bolts securing the platform to the platform

support, then remove the platform.
4. Remove the bolts securing the platform to the platform

support, then remove the platform.
MAF09610
MAF09590
NOTE: The platform support weighs approximately 125 lbs.

(56.8 kg).
4-12 3121262
Platform/Support Installation 5. Position the platform on the platform support and

install the bolts securing the platform to the platform
1. Using a suitable lifting device, support the platform sup- support. See Figure 4-2. and Figure 4-3.
port and position it on the rotator.
NOTE: The platform support weighs approximately 125 lbs.

(56.8 kg).
2. Install the rotator center bolt and locknut.
MAF09590
6. Connect the electrical cable to the platform control

console.
7. Remove tag and uncap the hydraulic lines and ports.
MAF09610 8. Connect the hydraulic lines to the rotator.
3. Apply JLG Threadlocker PN 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.
3121262 4-13
4.4 ROTATOR Installation

NOTE: The rotator approximately weighs 230 lbs. (104 kg).
Removal
1. Remove the Platform and Platform Support. Refer to 1. Supporting the rotator and jib lift cylinder, align rotator
Section 4.3 - Platform. with jib lift cylinder and jib. Using a suitable brass drift
and hammer install pin (1) to the jib assembly. Install
2. Tag and disconnect hydraulic lines from rotator. Use hardware securing pin (1).
suitable container to retain any residual hydraulic fluid.
Cap or plug all openings of hydraulic lines and ports. 2. Using a soft head mallet install pin (2) to jib assembly
and install the rotator. Install hardware securing pin (2).
NOTE: The rotator approximately weighs 230 lbs. (104 kg).
3. Install the platform and platform support. Refer to Sec-
tion 4.3 - 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.
JIB LIFT CYLINDER
ROTATOR
MAF09640
Figure 4-4. Rotator Removal/Installation
4-14 3121262
4.5 BOOM REMOVAL AND INSTALLATION 4. Disconnect the telescope hoses from the bottom of the
hydraulic control valve. Pull the hoses out so that can be
lifted away from the machine with the boom.
Removal
1. Remove the Jib Assembly. Refer to Section 4.8 - Jib.
2. At the rear of the turntable, tag and disconnect all wir-
ing harnesses that run from the powertrack to the
ground control station. The connector inside the ground
control box will have to be removed from the wires to
allow the harness to be pulled out of the control box.

residual hydraulic fluid. Disconnect the pressure hose
from the end of the main control valve. Cap or plug all
openings.

residual hydraulic fluid. Disconnect the pressure line
going into the platform filter, taking care to slowly bleed
off hydraulic pressure. Cap or plug all openings.
3121262 4-15
6. Remove the cover from the rear of the boom and dis- 8. Using the Main Lift Crackpoint option under the Calibra-
connect the wiring harnesses and hoses running from tions menu, lift the boom enough to access the boom
the turntable to the boom. lift cylinder rod pivot pin.
7. Disassemble the end of the turntable to boom pow- NOTE: The boom assembly weighs approximately 10,800 lbs.
ertrack from the turntable. Use a lifting device to pull (4,900 kg.).
the powertrack up so the hydraulic hoses and wiring
harnesses can be pulled out from the turntable. 9. Using an adequate lifting device, support the weight of
the boom.
10. Attach a lifting device to support the weight of the

boom lift cylinder.
NOTE: To assist in determining when the lift cylinder is properly

supported, use the JLG Analyzer and select Diagnostics >
Moment > Actual Moment and get a reading as close to
zero as possible.
4-16 3121262
11. Remove the bolt and keeper pin securing the boom lift Installation
cylinder rod pivot pin and drive out the pivot pin.
1. Lift the boom from its supports.
12. Lower the lift cylinder until it rests on the turntable.

13. Attach an adequate lifting device to support the rear of
the boom.
14. Remove the bolt and keeper pin securing the boom
pivot pin and remove the pivot pin. Remove the boom
from the machine and place it on adequate supports.
3121262 4-17
2. While lifting the boom into position, begin to route the 4. Raise the boom enough to gain access to the lift cylin-
hoses into position so they can be inserted into the der rod pivot fitting.
powertrack.
5. Attach a lifting device to the lift cylinder barrel. Lift the

lift cylinder up to align the lift cylinder rod pivot fittings.
3. Line up the boom pivot fittings and install the boom

pivot pin. Apply JLG Threadlocker PN 0100019 to the
6. Install the lift cylinder rod pivot pin and secure it in place
bolt threads and secure the pin in place with the keeper
with the keeper pin and bolt.
pin and bolt. Torque the bolt to 285 ft.lbs. (388 Nm).
4-18 3121262
7. Connect the hoses to the main valve and pressure filter 11. Position the hoods in place on the turntable and secure
as tagged during removal. in place with the mounting hardware.
8. Reconnect the negative battery terminal. 12. Cycle test the machine and check for leakage and
proper operation.
9. Using auxiliary power, lower the boom to horizontal.
10. Connect all electrical harnesses as tagged during
removal. Reinstall the wiring into the connector plug in
the ground control box as tagged during removal.
3121262 4-19
4.6 BOOM DISASSEMBLY/ASSEMBLY & CABLE 6. Remove the bolt and keeper pin securing the jib pivot
pin and remove the pin.
REPLACEMENT
It is not necessary to completely remove the entire boom
assembly from the machine to replace the cables. In the fol-
lowing procedure, the base boom section will remain on the
machine.
Disassembly
NEVER HANDLE WIRE ROPE WITH BARE HANDS.

1. Position the boom so that it is horizontal. If the boom is
below horizontal, ensure that the boom is not on the
boom rest.
2. Use an appropriate lifting device to support the weight
of the jib and platform assembly. 7. Remove the jib and platform assembly from the boom.
3. Tag and disconnect the hoses and electrical harnesses

that run to the platform. Cap or plug all openings.
4. Pull the hoses and harnesses through the jib and lay
them off to the side of the boom.
5. Remove the bolt and keeper pin securing the platform
level pivot pin and remove the pin.
4-20 3121262
8. Attach a lifting device to the powertrack for support and 9. Remove the lower powertrack tube from the outer mid
remove the upper powertrack tube from the fly boom. boom section and the mounting bracket from the inner
Pull the disconnected tube back to allow boom to dis- mid boom section.
connect the lower tube.
10. Attach a strap or other similar device around the pow-

ertrack and boom to keep the powertrack secure
throughout the cable replacement procedure.
3121262 4-21
4-22
B 1 2 3 4
B
A
MAF10920C
1001140107-C
1. Boom Base
2. Boom Inner Mid
3. Boom Outer Mid
4. Boom Fly
Figure 4-5. Boom Assembly - Sheet 1 of 7
3121262
3121262
1
4
8
7
6
SECTION A-A SECTION B-B
5
MAF10930C
1001140107-C
1. Outer Mid Extend Block 4. Retract Rope Retainer Plate 7. Retract Rope Retainer Plate
2. Outer Mid Retract Sheave 5. Rope Retainer Block 8. Lock Plate
3. Rope Retainer Block 6. Fly Retract Sheave 9. Tele Cylinder Wear Pads
4-23
1,2
4-24
3
4
7
5,6
8,9
MAF10940C
1001140107-C
1. Upper Rear Wear Pad 6. Shim
2. Shim 7. Tele Cylinder Pulley Assembly
3. Telescope Cylinder 8. Bottom Rear Wear Pad
4. Trunnion Keeper Block 9. Shim
5. Lower Rear Wear Pad
3121262
3121262
5 7
4
3
6 8
MAF10950C
1001140107-C
1. Sheave Deflector 6. Rope Retainer Block
2. Sheave Deflector 7. Level Cylinder
3. Rope Retainer Block 8. Front Lower Wear Pad
4. Fly Extension Sheave 9. Lock Plate
5. Rope Retainer Block
4-25
4-26
1,2 SECTION 4 - BOOM & PLATFORM
3,4
1.375 ± .062
1.125 ± .062
1.438 ± .062
MAF10960C
1001140107-C
1. Front Upper Wear Pad 4. Shim
2. Shim 5. Lock Plate
3. Front Side Wear Pad
3121262
3121262
8.000 .500
9.500 .500
3.563 .500
4 3
2
5 4 3
6
MAF10970C
1001140107-C
1. Outer Mid Extend Rope 4. Outer Mid Retract Rope
2. Fly Extend Rope 5. Proximity Switch Spring
3. Fly Retract Rope 6. Switch Adjustment Block
4-27
A
4-28
D
D
A
1.374 ±.062
1.375 ± .062 1.125 ± .062
1.125 ± .062
1.438 ± .062
1.438 ± .062
SECTION D-D
SECTION A-A
MAF10980C
1001140107-C
3121262
11. Remove the bolts securing the side wear pads to the 13. Remove the cover over the boom length limit switch at
front of the base boom and remove the pads and shims. the front of the boom base section. Remove the switch.
12. Remove the boom length plate.
14. Remove the rear boom cover.
3121262 4-29
15. Tag and disconnect the wiring harness running to the 18. Remove the keepers for the outer mid retract cable
boom length sensor. Remove all the bolts and washers adjustment nuts at the front of the boom base section.
securing the sensor, including those that secure the
measuring cable to the telescope cylinder, and remove
the length sensor.
19. Loosen and remove the outer mid retract cable adjust-
16. Tag and disconnect the hydraulic hoses from the tele-
ment nuts.
scope cylinder. Cap or plug all openings.
20. Remove the adjustment bolt keepers for the outer mid
extend cable adjustment nuts at the rear of the boom.
17. Remove the front side, top, and lower wear pads from
the boom base section.
4-30 3121262
21. Remove the adjustment nuts for the for the outer mid 23. Remove the cover plate from the bottom of the boom
extend cables along with the Broken Cable proximity and remove the sheave blocks.
switch, spring, and adjustment plate.
22. Remove the cable mounting plate.
24. Remove the trunnion blocks that secure the telescope

cylinder rod to the boom base section.
3121262 4-31
25. Remove the outer mid retract cables from the attach- 27. Pull the inner mid, outer mid, and fly boom sections out
ment fixtures at the front of the boom base section. of the base boom section. Use additional lifting devices
and reposition any lifting straps as necessary as the sec-
tions are withdrawn. It will be helpful during this step to
pull the outer mid retract cable out from the front of the
base section as the other sections are being pulled out.
This will prevent the cables from tangling as the sections
are withdrawn.
26. Attach an auxiliary hydraulic power source to the tele-

scope cylinder and extend the cylinder rod enough to
turn the trunnion in a vertical position.
4-32 3121262
28. Remove the trunnion blocks that secure the telescope 30. Remove the hardware attaching the outer mid extend
cylinder barrel to the inner mid boom section. block and remove the block and outer mid extend
cables.
29. Attach a lifting device to the telescope cylinder and pull

the cylinder, along with the outer mid extend cables out 31. Remove the cable retainer plate, cable retainer block,
of the inner mid boom section. Reposition the lifting bushing, and sheave.
device as necessary to balance the cylinder.
3121262 4-33
32. Remove the rear bottom wear pad. 34. Pull the fly boom extend cables from their mounting
receptacles.
33. Remove the lock plates from the fly boom retract cable
adjustment nuts and remove the adjustment nuts from
the fly boom retract cables and from the fly boom
extend cables at the front of the inner mid boom sec-
tion.
35. Remove the top, side, and bottom wear pads from the
front of the inner mid boom sections.
4-34 3121262
36. Attach a strap to pull the outer mid and fly boom sec- NOTE: When pulling the outer mid and fly boom sections out of
tions out of the inner mid boom section. Secure the rear the inner mid boom section, make sure the outer mid
of the inner mid boom section so it doesn’t move as the retract cables do not catch at the rear of the boom section.
other sections are withdrawn.
38. Pull the sections the rest of the way out of the inner mid
boom section, pulling the fly boom retract cables out at
the same time.
39. Remove the outer mid retract cables from the rear of the
inner mid boom section.
37. Pull the sections out enough to allow easy removal of

the cable retainer blocks and sheave blocks for the fly
boom retract cables at the front of the inner mid boom
section.
3121262 4-35
40. Remove the cable retract retainer plates, cable retainer 42. Remove the upper rear wear pads from the fly boom
blocks, sheaves, and bushings from the rear of the outer section.
mid boom section.
43. Remove the cable retainer blocks and shims.
41. Remove the front wear pads from the outer mid boom
section.
4-36 3121262
44. Pull the fly boom extend cables out enough to have NOTE: When pulling the fly boom section out of the outer mid
clearance to remove the sheave, and remove the retain- boom section, make sure the fly boom retract cables do not
ing bolt, keeper pin, pin, bushings, and sheave from the catch at the rear of the boom section.
front of the outer mid boom section.
45. Attach a lifting device to the fly boom section and pull
the section and fly boom extend cables from the outer
mid boom section. Secure the rear of the outer mid
boom section so it doesn’t move when the fly boom sec-
tion is withdrawn.
3121262 4-37
46. Remove the tape from the fly boom section and remove Assembly
the fly boom retract cables.
NEVER HANDLE WIRE ROPE WITH BARE HANDS.
NOTE: Moderately apply Super Lube JLG Part No. 3020042 to all
four inner surfaces of both ends of each boom section to a
minimum depth of 3 to 4 feet (1 to 1.25 m). The fly boom
section only needs Super Lube applied to the insertion end.
Super Lube is also to be moderately applied to all outer sur-

faces of interior wear pads after they are installed to the
insertion end of boom sections. Care should be taken to
avoid application on exposed painted surfaces of the fully
extended boom. Refer to Section 4.9 - Boom Lubrication
Application.
47. Remove the fly boom extend cables from the bottom of
the fly boom section. WIRE ROPE NUTS ARE CLOSE IN SIZE AND CAN BE SWITCHED. REFER TO THE
JLG PARTS MANUAL. OUTER MID RETRACT NUTS, LOCATED ON BOTTOM OF
BASE BOOM, WILL BE BLACK IN COLOR.
48. Thoroughly clean the boom sections.
4-38 3121262
3. Install the fly retract wire rope button ends into the slots
in the side of the fly boom, coil the remaining lengths of
TAKE EXTRA CARE NOT TO CROSS ANY WIRE ROPES DURING THE ASSEMBLY wire rope and place them into the fly boom, tape the
PROCEDURE. slots to keep the rope from jumping out.
1. Install the fly extend wire rope button ends into the slots
on the bottom of the fly boom section. Place tape over
the wire ends to keep them in place during assembly.
2. Fabricate a special fixture as shown below to keep four

extend wire ropes from crossing over each other.
3121262 4-39
Ft-Lbs. Nm
A 165 224
B 165 224
C 35 49
D 50 70
Figure 4-12. Boom Assembly Torque Values
4-40 3121262
#0100019
#0100011
#0100011
#0100019
#0100019
#0100011
#0100011
SECTION A-A
Figure 4-13. Locations for Threadlocker Application - Sheet 1 of 4
3121262 4-41
#0100011
#0100011
#0100011
#0100011
#0100011
4-42 3121262
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
3121262 4-43
#0100011
#0100011
#0100011
4-44 3121262
4. Install the fly boom section partially into the outer mid 7. Install the sheave, bushings, pin, keeper pin, and retain-
boom section. ing bolt to the front of the outer mid boom section.
DO NOT ALLOW THE FLY BOOM TO REST ON THE FOUR EXTEND WIRE ROPES
8. Install the cable retainer blocks and shims.
WHILE INSERTING IT INTO THE OUTER MID BOOM.
5. Apply JLG Threadlocker PN 0100011 to the bolts and

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

install the front upper, and side wear pads on the outer
mid boom section as marked during disassembly.
Torque the bolts to 50 ft.lbs. (68 Nm).
6. Install the fly boom section most of the way into the
outer mid boom section, leaving enough of the fly out
so there is adequate slack in the fly boom extend cables
to allow for installation of the front sheave.
3121262 4-45
10. Apply JLG Threadlocker PN 0100011 to the bolts and 12. Apply a thin coat of moly paste lubricant to the inside
install the rear upper and side wear pads on the outer diameter of the sheave composite bearings. Install the
mid boom section as marked during disassembly. fly retract sheaves and bushings while guiding the wire
Torque the bolts to 50 ft.lbs. (68 Nm). ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply JLG Threadlocker
PN 0100019 to the sheave retaining bolts and torque to
165 ft.lbs. (224 Nm). Install the cable retract retainer
plates and cable retainer blocks.
11. Uncoil the fly retract wire ropes from the fly boom.
Route the threaded ends of the wire ropes through the
holes in the outer mid boom plates at the retract sheave
locations.

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

install the side and upper wear pads on the rear of the
inner mid boom section. Torque the bolts to 50 ft.lbs. (68
Nm).
15. Lubricate the wear surfaces on the inside of the inner
mid boom section with Super Lube.
4-46 3121262
16. Feed the fly boom retract cable into the inner mid boom 18. Attach the fly boom retract cables in the inner mid
section from the front. boom section to the receptacles at the rear of the outer
mid boom section.
19. Put tape over the holes to keep the cable ends from
jumping out.
17. Using an adequate lifting device, align the outer mid

boom section with the inner mid boom section.
20. Push the outer mid assembly part way into the inner
mid boom section. Apply JLG Threadlocker PN 0100011
to the bolts and install the front bottom wear pad into
the inner mid boom section. Torque the bolts to
50 ft.lbs. (68 Nm).
3121262 4-47
21. Push the outer mid assembly into the inner mid while 23. Push the outer mid assembly almost completely into the
pulling the boom cables out the back fo the inner mid inner mid boom section.
section at the same time. Leave 3 to 4 feet of the outer
mid section sticking out of the inner mid section.
24. Install the cable retainer blocks over the fly boom retract
cables and insert the fly boom extend cable into the
22. Push the retract cable ends into the mounting recepta- mounting receptacles.
cles and install the cable sheaves and adjustment nuts.
4-48 3121262
25. Apply JLG Threadlocker PN 0100011 to the bolts and 27. Apply a thin coat of moly paste lubricant to the inside
install the side and top wear pads into the inner mid diameter of the sheave composite bearings. Install the
boom section. Torque the bolts to 50 ft.lbs. (68 Nm). retract sheaves and bushings while guiding the wire
ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply JLG Threadlocker
PN 0100019 to the sheave retaining bolts and torque to
165 ft.lbs. (224 Nm). Install the cable retainer blocks and
cable retainer plates.
26. Put moly paste on the sheave mounts at the rear of the
inner mid boom section and install the sheaves.

install the rear bottom wear pad on the rear of the inner
mid boom section. Torque the bolts to 50 ft.lbs. (68 Nm).
3121262 4-49
29. Install a new sheave on the telescope cylinder. 32. Route the cables around the sheave on the cylinder and
install the cable retainer block.
30. Install the outer mid extend cables into the cable pulley
at the rod end of the telescope cylinder. 33. Using an adequate lifting device, insert the cylinder and
cables part way into the inner mid boom.
31. Install the other end of the outer mid extend cables into
the cable guide block.
4-50 3121262
34. Apply JLG Threadlocker PN 0100019 to the bolts and 37. Using Super Lube®, lubricate all wear surfaces on the
attach the cable guide to the inner mid boom section inside of the boom base section and the outside of the
with the mounting hardware. Torque the bolts to inner mid boom section.
165 ft.lbs. (224 Nm).
38. Insert the inner mid boom section part way into the
boom base section enough to be able to pull the outer
mid retract cables out through the hole at the bottom
front of the boom base section.
35. Push the cylinder the rest of the way into the inner mid
boom assembly.
36. Install the cylinder trunnion blocks and shims.

install the front lower wear pads into the boom base
3121262 4-51
40. Push the inner mid boom assembly the rest of the way 46. Install the outer mid retract cable adjustment nuts at the
into the boom base section, adjusting the lifting device front of the boom base section.
as necessary to keep the weight balanced.
install the side and upper wear pads into the boom base
42. Install the boom transport length sensor on the side of
the boom base section.
43. Attach the powertrack tubes.
44. If necessary, attach a source of auxiliary hydraulic power
and retract the boom enough to allow installation of the
cable adjustment plate at the rear of the base boom sec-
tion and install the plate.
47. Install the boom length sensors and angle sensors as

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

49. Adjust the boom cables. Refer to Section 4.18 - Wire

Rope Tensioning Adjustment.

4-52 3121262
4.7 LOAD SENSING PIN REMOVAL AND 6. Use the Load Pin Removal Tool (JLG PN 4846765) to pre-
vent the pin from being damaged, and use a hammer to
INSTALLATION remove the pin. To make the tool refer to Figure 4-17.,
1. Place the machine on a firm, level surface. Load Pin Removal Tool, JLG PN 4846765. If the Load Pin
Removal Tool is not available, use an arbor of the proper
NOTE: Replacing the load sensing pin requires the boom sensors size (as shown below). If excessive force is necessary to
be re-calibrated. Make sure the machine is in an area move the pin, it may be necessary to carefully activate
where this can be accomplished after installation of the lift using the auxiliary power switch to relieve lift cylin-
new pin. der weight from the load sensing pin.
2. Swing the engine tray out to gain access to the sensing

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

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

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

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

installed. Secure the pin in place with the retaining pin
and retaining pin bolt.
5. Disconnect the wiring harness from the strain relief con-
nector at the opposite side of the load sensing pin.
DO NOT TAP ON THE CENTER OF THE PIVOT PIN.
9. Connect the wiring harness to the strain relief connector

and re-calibrate the boom sensors.
3121262 4-53
Figure 4-17. Load Pin Removal Tool, JLG PN 4846765
4-54 3121262
4.8 JIB It may be necessary to disconnect additional lines to

gain access to certain fittings. Cap or plug all openings.
Removal
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.
5. Remove the valve from the boom.
3. Remove the jib valve protection plate.
6. Lay the jib control valve aside on the jib. Secure it in

place so it does not fall.

residual hydraulic fluid. Tag and disconnect the hydrau-
lic hoses that run from the boom to the jib control valve.
3121262 4-55
7. Disconnect the jib protractor sensor linkage from the NOTE: The jib and platform assembly weighs approximately
boom. 2100 lbs. (953 kg.).
9. Attach an adequate supporting device to the jib to sup-

port its weight. Remove the bolt and keeper pin secur-
ing the jib pivot pin and remove the pin.
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
protect the rod from being scratched.
10. Remove the jib and platform assembly from the boom.
4-56 3121262
Installation 3. Lift the jib into position on the boom fly section and
install the jib pivot pin. Secure the pin in place with the
1. Attach an adequate lifting device to the jib and position keeper pin and bolt.
it in front of the boom.
2. Place something under the front of the jib that will allow
it to slide or move along the ground easily. Attach a lift-
ing device to the rear of the jib, allowing the front to
pivot on the ground.
3121262 4-57
4. Attach a lifting device to the front of the jib and align 5. Place the mounting bracket on the jib valve and bolt the
the jib level cylinder attachment fittings. Install the pivot jib valve to the fly boom section.
pin. Apply JLG Threadlocker PN 0100019 to the bolt 6. Install the wiring harnesses and hydraulic hoses on the
threads and secure the pin in place with the keeper pin jib valve as tagged during removal.
and bolt. Torque the bolt to 165 ft.lbs. (224 Nm).
7. Install the jib valve protection plate.

4-58 3121262
JIB
ROTARY
JIB LIFT CYLINDER ACTUATOR
PLATFORM LEVEL CYLINDER
PLATFORM ROTARY ACTUATOR
JIB BASE BOOM
JIB LOCK CYLINDER
JIB POWER TRACK

JIB FLY BOOM
PLATFORM ROTARY ACTUATOR
1001118868-A
Figure 4-18. Jib Assembly - Sheet 1 of 3
3121262 4-59
PIN
KEEPER
BOLT
*
TORQUE 120 FT.LBS. (163 Nm)
PIN
KEEPER
PLATFORM BUSHING
ROTARY PIN
ACTUATOR KEEPER
BOLT
*
BOLT
*
HEX HEAD TORQUE 700 FT.LBS. (950 Nm)
*
CAPSCREW
** BOLT
JIB
PIVOT
BEARING
JIB
BOLT
KEEPER
*
JIB LIFT
* BOLT
KEEPER CYLINDER * BOLT
ROTATE
ACTUATOR
PIN
KEEPER TORQUE 165 FT.LBS. (224 Nm)
PIN
PIN
INSERT SHIMS
BETWEEN JIB PIVOT AND
JIB ROTATE ACTUATOR
ADJUST QTY OF SHIMS A/R

TO MINIMIZE GAP BETWEEN
JIB PIVOT AND
JIB ROTATE ACTUATOR
* JLG Threadlocker PN# 0100011
** JLG Threadlocker PN# 0100019

1001118868-A
4-60 3121262
BOLT
LOCKPIN CYLINDER CAP
ALIGN CUTOUT IN CAP
INWARD AS SHOWN
(SEE SECTION A-A BELOW) ALIGN LOCK CYL WITH
PROTRUSIONS CAP
(SEE SECTION A-A BELOW)
JIB LOCK CYLINDER
LOCKNUT
LOCK PIN
CYLINDER ALIGN CUTOUT IN CAP
AS SHOWN
CAP
ALIGN HOLES IN LOCK CYL
WITH PROTRUSIONS
IN CAP AS SHOWN
INTERNALS OF ACTUATOR
NOT SHOWN FOR CLARITY
JIB PIVOT
BEARING HOUSING
BEARING
* (PRESS FIT)
FLANGE BEARING
* (PRESS FIT)
JIB ROTATOR
BEARING HOUSING
BEARING
* (PRESS FIT)
JIB PIVOT
BEARING HOUSING
* Loctite RC 609 Threadlocker
SECTION A-A
1001118868-A
3121262 4-61
4.9 BOOM LUBRICATION APPLICATION 4.10 PLATFORM LEVELING CYLINDER

This procedure applies to booms after assembly or during Removal
annual application using Super Lube® lubricant (JLG PN
3020042). 1. Ensure the platform is supported by blocking or an ade-
quate lifting device.
1. Position the boom on the boom rest using the 500lb
capacity setting. 2. Remove the bolt and keeper pin securing the retaining
pin that secures the cylinder rod to the platform assem-
2. Telescope main boom section as far as it will extend at bly and remove the pin.
this position, approximately 3 ft. (0.9 m).
3. From the front of the machine (boom pivot end), moder-

ately apply lubricant to the interior surfaces of the base
boom, inner mid boom, and outer mid boom. To pre-
vent misdiagnosis of hydraulic leaks, take care to pre-
vent excessive application of lubrication.
4. At the rear of the machine, apply lubricant to the side,

top and bottom surfaces of the fly boom, outer mid, and
inner mid specifically to wear pad contact paths. To pre-
vent misdiagnosis of hydraulic leaks, take care to pre-
vent excessive application of lubrication.
5. After application of the lubricant is complete, cycle the

boom through its full range of travel 2 times.
3. Tag and disconnect the hydraulic hoses from the plat-

form level cylinder. Cap or plug all openings. Tag and
disconnect the electrical harness running to the cylin-
der.
4-62 3121262
4. Lift the platform to allow enough room for removal of Installation

the cylinder.
1. Attach a lifting or jacking device to the platform and
position the platform to provide adequate room to
install the platform leveling cylinder.
2. Coat the retaining pin holes with an anti-seize com-

NOTE: The platform level cylinder weighs approximately 79 lbs.
pound to lubricate the holes and prevent rust.
(36 kg.).
5. Ensure the cylinder is supported so it will not move

when the rear retaining pin is removed. Remove the bolt
and keeper pin securing the retaining pin at the rear of
the cylinder and remove the pin.
3. Lift the cylinder into place.

4. Line up the rear pivot hole and insert the pivot pin.
6. Carefully lift the cylinder from the machine.
3121262 4-63
5. Secure the pivot pin in place with the keeper pin. 4.11 JIB TELESCOPE CYLINDER
Loosely install the bolt, but do not tighten it at this time.
Removal
1. Remove the guide pad at the rear of the jib to provide
more room for cylinder removal.
6. Thread the length sensor harness around the cylinder

and up to the platform box. Connect the harness to the
connector under the platform box.
7. Route the hydraulic hoses around the cylinder. Connect 2. Extend the jib enough to gain access to the pins that
the hoses to the cylinder as tagged during removal. secure the jib telescope rod to the jib fly boom section.
8. Extend the cylinder to align the front pivot pin hole. It
may be necessary to lower the platform to help align the
components.
9. Install the retaining pin and keeper pin.
install the bolts to secure the keeper pins. Torque the
bolt at the rod end of the cylinder to 40 ft. bs. (55 Nm)
and the bolt at the barrel end cylinder to 95 ft.lbs.
(130 Nm).
11. Function check the cylinder to ensure it operates prop-
erly and there is no leakage.
3. Lower the boom so the platform base is on the ground

or supported by blocking.
4-64 3121262
4. Remove the retaining rings securing the retaining pins 8. Tag and disconnect the hoses going to the jib telescope
on the powertrack side of the jib and remove the pins. cylinder.
5. Attach a strap or similar device between the jib base

boom and the jib fly boom to ensure the jib fly boom 9. Place blocking underneath the cylinder to prevent it
will not extend inadvertently when the jib is raised. from falling when the retaining bolts are removed.
Remove the retaining bolts securing the jib telescope
cylinder to the jib base boom.
NOTE: The platform level cylinder weighs approximately 130 lbs.

(59 kg.).
10. Attach an adequate lifting device to the cylinder and lift

the cylinder from the jib. Adjust the device as necessary
as the cylinder is withdrawn to balance the weight of
the cylinder.
6. Raise the jib to horizontal.
7. Retract the jib telescope cylinder.
3121262 4-65
4. Connect the hydraulic hoses to the cylinder as tagged

during removal.
Installation
5. Lower the jib enough to enable easier access to the
1. If installing a new cylinder, test fit the retaining pins that attachment holes in the jib fly boom.
secure the jib telescope rod to the jib fly boom to ensure
they fit properly. Apply an anti-seize compound to the 6. Extend the cylinder enough to align the attachment
attachment holes in the cylinder rod. holes in the jib fly boom with those in the end of the cyl-
inder rod.
2. Lift the cylinder into place, adjusting the lifting device as
necessary to maintain balance. 7. Install the retaining pins and secure them in place with
the retaining rings.
3. Fasten the cylinder barrel to the jib base boom with the
attaching bolts. Do not tighten the bolts at this time.
8. Apply JLG Threadlocker PN 0100011 to the bolts secur-
ing the cylinder barrel to the jib base boom and torque
the bolts to 95 ft.lbs. (130 Nm).
4-66 3121262
4.12 JIB LIFT CYLINDER 3. Remove the bolt and keeper pin that secure the jib lift
cylinder barrel pivot pin. Remove the jib lift cylinder bar-
rel pin.
Removal
1. Ensure the weight of the jib is fully supported.
4. Lower the cylinder enough to tag and disconnect the

cylinder length sensor harness. Readjust the lifting
2. Place a strap or similar device in place to support the device as necessary to balance the weight of the cylin-
weight of the cylinder. der.
3121262 4-67
5. Remove the bolt and keeper pin that secure the jib lift Installation
cylinder rod pivot pin. Remove the jib lift cylinder rod
pivot pin. 1. If installing a new cylinder, test fit the pivot pins in the
cylinder to ensure they fit properly. Apply an anti-seize
compound to the attachment holes in the cylinder rod
and barrel.
1. Lift the cylinder into position to install the jib lift rod
pivot pin. Install the pivot pin.
2. Secure the pin in place with the keeper pin. Apply JLG
Threadlocker PN 0100011 to the retaining bolt. Install
the retaining bolt to secure the keeper pin and torque to
165 ft.lbs. (224 Nm).
6. Lower the cylinder from the machine, readjusting the

lifting device as necessary to balance the weight of the
cylinder.
3. Reposition the lifting device as necessary to keep the

cylinder balanced. Raise the cylinder enough to allow
the length sensor harness to be connected and connect
the harness as tagged during disassembly.
4-68 3121262
4. Raise the cylinder into position to allow the jib lift barrel 4.13 JIB STRAIGHT SHIMMING PROCEDURE
pivot pin to be installed and install the pin.
See Figure 4-21., Jib Straight Shimming.
5. Secure the pin in place with the keeper pin. Apply JLG
Threadlocker PN 0100011 to the retaining bolt. Install 1. Install the jib lock cylinder and fully extend the rod
through the bearing housings in the jib rotator and jib
the retaining bolt to secure the keeper pin and torque to
pivot.
165 ft.lbs. (224 Nm).
2. Align the jib pivot straight with the jib assembly.
3. Insert shims (16 gauge and 20 gauge) between the wear
pad and pivot pad mount.
4. Add shims as required to align bearings.
5. Bearing alignment must be checked by rotating against
shimmed stop with hydraulic pressure from power unit.
6. Check alignment by installing locking cylinder.
7. Remove hydraulic pressure by rotating with hydraulic
power unit.
8. When shimmed properly, the jib pivot and jib assembly
should line up straight as shown below.
ALIGN JIB PIVOT STRAIGHT
WITH JIB ASSEMBLY AS SHOWN
6. Remove the lifting device supporting the cylinder and

the lifting device supporting the jib.

3121262 4-69
PIVOT PAD MOUNT
JIB ROTATOR
BOTTOM PLATE
WEAR PAD
SHIMS
(NOMINAL QTY SHOWN)
Figure 4-21. Jib Straight Shimming
4-70 3121262
4.14 BOOM CLEANLINESS GUIDELINES 4. The first attempt to remove debris from inside the boom
must be to utilize pressurized air to blow the debris
The following are guidelines for internal boom cleanliness for toward the nearest exiting point from the boom. Make
machines that are used in excessively dirty environments. sure that all debris is removed before operating the
machine.
1. JLG recommends the use of the JLG Hostile Environment
5. If pressurized air cannot dislodge the debris, then water
Package if available to keep the internal portions of a
with mild solvents applied via a pressure washer can be
boom cleaner and to help prevent dirt and debris from
used. Again the method is to wash the debris toward the
entering the boom. This package reduces the amount of
nearest exiting point from the boom. Make sure that all
contamination which can enter the boom but does not
debris is removed, that no “puddling” of water has
eliminate the need for more frequent inspections and
occurred, and that the boom internal components are
maintenance when used in these types of environ- dry prior to operating the machine. Make sure you com-
ments. ply with all federal and local laws for disposing of the
wash water and debris.
2. JLG recommends that you follow all guidelines for ser-
vicing your equipment in accordance with the instruc- 6. If neither pressurized air nor washing of the boom dis-
tions outlined in the JLG Service & Maintenance Manual lodges and removes the debris, then disassemble the
for your machine. Periodic maintenance and inspection boom in accordance to the instructions outlined in the
is vital to the proper operation of the machine. The fre- JLG Service & Maintenance Manual to remove the
quency of service and maintenance must be increased debris.
as environment, severity and frequency of usage
requires. 4.15 HOSE ROUTING
3. Debris and foreign matter inside of the boom can cause For proper hose routing, refer to Figure 4-22., Figure 4-23., and
premature failure of components and should be Figure 4-24. It is important to periodically inspect hoses, wraps
removed. Methods to remove debris should always be and clamps for proper slack adjustments and clamping integ-
done using all applicable safety precautions outlined in rity (pull check). Any changes as a result of inspection should
the JLG Service & Maintenance Manuals. be verified by performing full strokes of boom functions espe-
cially lift, telescope, jib, and platform rotate.
3121262 4-71
4-72
TELESCOPE RETRACT HOSE
(OUTSIDE OF BEND RADIUS)
TELESCOPE TANK HOSE
(INSIDE OF BEND RADIUS)
HARNESS BUNDLE
TELESCOPE EXTEND HOSE
HOSES AND CABLES SHOULD NOT BE HOSES AND CABLES SHOULD BE AGAINST
PULLED TIGHT AGAINST THE INSIDE THE OUTSIDE RADIUS OF THE POWER TRACK
RADIUS OF THE POWERTRACK
INCORRECT CORRECT
Figure 4-22. Powertrack Hosing - Sheet 1 of 3
3121262
3121262
4-73
4-74
3121262
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.
3121262 4-75
5. Slide the poly roller off of the round bar. 7. Slide the flat bar out.
6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket.
9. Remove the snap ring from the other side of the bracket.
4-76 3121262
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.
3121262 4-77
4. Hold the flat bar and remove the screws. 7. Slide the link out.
5. Remove the snap rings and pins. Snap Rings and Screws
WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO

DISCARD AND REPLACE ALL OLD SCREWS.
Make sure screws are tight and installed properly.
6. Remove the screws from the bar. Remove the snap ring
and pin. LOOSE SCREW TIGHT SCREW
4-78 3121262
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.
3121262 4-79
4.17 WIRE ROPE 5. Inspect sheaves for condition of flanges. (See Dimension
Of Sheaves for proper dimension.)
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. NOTE: Check groove so that it may be clearly seen if gauge con-
tour matches sheave groove contour.
Each day before using the machine:
1. Raise the main boom to approximately horizontal.
2. Extend and retract the boom sections.
3. Check for delayed movement of the fly section, which

indicates loose wire ropes.
IF DELAYED MOVEMENT IS DETECTED IN WIRE ROPE OPERATION, LOWER

PLATFORM TO STOWED POSITION, SHUT DOWN MACHINE, AND HAVE WIRE
Figure 4-27. Sheave Groove Wear
ROPES INSPECTED/SERVICED BY A QUALIFIED JLG MECHANIC. LOOSE OR MIS-
ADJUSTED WIRE ROPES COULD RESULT IN SERIOUS INJURY OR DEATH.
7. Ropes passing inspection should be lubricated with wire
rope lubricant before reassembly.
Inspection
NOTE: The pictures in this paragraph are just samples to show the
Three Month Inspection
replacement criteria of the rope. 1. Remove boom covers and visually (with flashlight)
inspect the ropes for rust, broken wires, frays, abuse, or
1. Inspect ropes for broken wires, particularly valley wire any signs of abnormalities.
breaks and breaks at end terminations.
2. Check rope tension by deflecting the ropes by hand
NOTE: Flexing a wire rope can often expose broken wires hidden properly tensioned ropes should have little or no move-
in valleys between strands. ment.
Additional Inspection Required If:

a. Machine is exposed to hostile environment or
conditions.
b. Erratic boom operation or unusual noise exists.
Figure 4-25. Wire Rope Wire Breaks c. Machine is idle for an extended period.
d. Boom is overloaded or sustained a shock load.
e. Boom exposed to electrical arc. Wires may be fused
2. Inspect ropes for corrosion. internally.
3. Inspect ropes for kinks or abuse
12 Year or 7000 Hour Replacement
NOTE: A kink is caused by pulling down a loop in a slack line
during improper handling, installation, or operation.. 1. Mandatory wire rope and sheave replacement.
Figure 4-26. Wire Rope Kink
4. Inspect sheaves for condition of bearings/pins. (See

Dimension Of Sheaves for proper dimension.)
4-80 3121262
Additional Replacement Criteria

1. Rusted or corroded wire ropes. PROPER BOOM POSITIONS DO NOT MEAN THAT THE WIRE ROPE TENSIONS
ARE CORRECT.
2. Kinked, “bird caged”, or crushed ropes.
3. Ropes at end of adjustment range. If the measurements do not fall within the tolerances in Figure
4-29., Wire Rope Tensioning, adjust the booms using the re-
4. Sheaves failing wearout gage inspection. positioning procedures that follow.
5. Ropes with 6 total broken wires in one rope lay, 3 in one
strand in one rope lay, 1 valley break, or 1 break at any INNER MID BOOM SECTION REPOSITIONING
end termination. The inner mid section of the boom is positioned by the
hydraulic cylinder. No adjustments can be made to this sec-
4.18 WIRE ROPE TENSIONING ADJUSTMENT tion. The wire ropes within the assembly only control the
movement of the Outer Mid Boom and Fly Boom sections.
ANY TIME THE WIRE ROPE TENSIONING HAS BEEN ADJUSTED, BOOM CALI- OUTER MID BOOM SECTION REPOSITIONING
BRATION SHOULD BE PERFORMED IMMEDIATELY AFTERWARD. If the Outer Mid Boom falls within the dimension and toler-
ance of Figure 4-29., Wire Rope Tensioning, proceed to the Fly
Before adjusting wire rope tension, the boom sections must Boom Section Positioning procedure in this section. If the
be in the proper position as shown in Figure 4-29., Wire Rope
Outer Mid Boom section is outside of the tolerance as shown,
Tensioning. This is so the wire ropes are equalized on both
sides of the sheaves and are seated properly in the sheave perform the following procedure.
grooves. This is necessary for proper tensioning of the wire
ropes. 1. Extend the boom assembly so the platform moves 5 to 6
feet (1.5 to 1.8 m) from the fully retracted position.
This section covers the two major operations in tensioning the
wire ropes which are as follows: 2. Remove any covers necessary to access the wire rope
adjustment nuts.
• Positioning the boom sections (so that proper tensioning
can be achieved).
• Tensioning the wire rope.
Boom Section Re-Positioning

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

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

assembly in the fully retracted position.
3. Take preliminary measurements of the position of each

boom section and compare them to Figure 4-29., Wire
Rope Tensioning. If the measurements fall within the tol-
erances in the figure, proceed to Wire Rope Tensioning
in this section.
3121262 4-81
3. Remove the lock plates and nylon collar locknuts from 7. Verify that the exposed boom section dimensions meet
the wire rope adjustment nuts. the dimensions and tolerances of Figure 4-29., Wire
Rope Tensioning.
a. If the Outer Mid Boom still does not fall within the
dimension and tolerance of Figure 4-29., repeat the
Outer Mid Boom positioning procedure.
b. If the Outer Mid Boom falls within the dimension
and tolerance of Figure 4-29., proceed to the Fly
Boom Section Positioning procedure in this section.
NOTE: Because the Outer Mid Boom is used to control the move-
ment of the Fly Boom, any repositioning of the Outer Mid
Boom Section will also affect the position of the Fly Boom
section. After repositioning the Outer Mid Boom, always
check the Fly Boom position per Figure 4-29.
Outer Mid Retract Adjusting
Nuts and Lock Plates FLY BOOM SECTION REPOSITIONING
If the Fly Boom section location and the Outer Mid Boom sec-
tion location are both within the dimensions and tolerances in
Figure 4-29., proceed to the Wire Rope Tensioning Procedure
in this section.
If the Fly Boom section is outside of the tolerance as shown in

Figure 4-29. while the boom assembly is fully retracted, per-
form the following procedure:
1. Extend the boom assembly such that the platform

moves 4 feet (1.3 m) from the fully retracted position.
2. Remove the lock plates and nylon collar locknuts from

Outer Mid Extend Adjusting
the wire rope adjustment nuts.
Nuts and Lock Plates
3. If the Fly Boom needs to be retracted farther in:
4. If the Outer Mid Boom needs to be retracted:
a. Loosen the Fly Boom Extend Adjustment Nuts by an
a. Loosen the Outer Mid Boom Extend Adjustment amount equal to twice the distance the boom needs
Nuts by an amount equal to twice the distance the to move to be in tolerance.
boom needs to move to be in tolerance.
b. Fully retract the boom.
c. To remove the slack caused by the previous step,

tighten the Outer Mid Boom Extend Adjustment
Nuts until they just contact the plate.
5. If the Outer Mid Boom needs to be extended out:
a. Loosen the Outer Mid Boom Retract Adjustment

Nuts by an amount equal to twice the distance the
boom needs to move to be in tolerance
Fly Boom Extend Adjusting
b. Extend the boom 3-4 feet (1-1.5m). Nuts and Lock Plates

b. Fully retract the boom.
tighten the Outer Mid Boom Retract Adjustment
Nuts until they just contact the plate. c. To remove the slack caused by the previous step,
tighten the Fly Boom Extend Adjustment Nuts until
6. Fully retract the boom sections. they just contact the plate.
4-82 3121262
4. If the Fly Boom needs extended:

a. Loosen the Fly Boom Retract Adjustment Nuts by an IF THE BOOMS HAVE BEEN PROPERLY POSITIONED AND THERE IS NOT
amount equal to twice the distance the boom needs ENOUGH ADJUSTMENT REMAINING ON THE WIRE ROPES TO ACHIEVE TORQUE,
to move to be in tolerance. THE SERVICE LIFE OF THE WIRE ROPES HAS BEEN CONSUMED. DO NOT PRO-
CEED WITH THE REMAINDER OF THIS PROCEDURE. REPLACE THE WIRE ROPES
AND SHEAVES.
1. Remove any covers necessary to access the wire rope

adjustment nuts.
Fly Boom Retract Adjusting

b. Extend the boom 3-4 feet (1-1.5m).
tighten the Fly Boom Retract Adjustment Nuts until
they just contact the plate.
d. Fully retract the boom sections.
5. Verify that the exposed boom section dimensions meet
the dimensions and tolerances of Figure 4-29., Wire
Rope Tensioning.
a. If the Fly Boom still does not fall within the dimen-
sion and tolerance of Figure 4-29., repeat the Fly
Boom Section Repositioning procedure.
b. If the Fly Boom falls within the dimension and toler-
ance of Figure 4-29., proceed to the Wire Rope Ten-
sioning Procedure.
Wire Rope Tensioning Procedure

NOTE: Verification of the rope tension should be determined by 2. If not already done, remove the lock plates and nylon
proper function of the boom assembly and by the dimen- collar locknuts from the wire rope adjustment nuts.
sions and tolerances of Figure 4-29., Wire Rope Tensioning. 3. Position the boom so that it is horizontal within ±5°. If
the boom is below horizontal, ensure that the boom is
not on the boom rest.
REPEAT WIRE ROPE TENSIONING PROCEDURE ONLY AS NECESSARY TO 4. Extend the boom so the platform moves 4 feet (1.3 m)
ACHIEVE PROPER TENSION. from the fully retracted position. This is done to position
the boom so the ropes to be tensioned are not under
load.
5. When extending the boom in the previous step, if the
boom reaches the end of travel and then automatically
retracts a small amount, the ropes may still be under
load. If so, perform the following steps:
a. Note where the boom hits the end of stroke.
b. Retract 3-4 feet (1-1.3 m).
c. Extend the boom and stop just before the boom
hits the end of stroke.
3121262 4-83
6. Using tool JLG PN 4120043, torque the Outer Mid Boom 9. Using tool JLG PN 4120043, torque the Outer Mid Boom
Retract Adjustment Nuts to 80 ft-lb (108 Nm), alternat- Extend Adjustment Nuts to 80 ft-lb (108 Newton
ing between the two ropes until both maintain the meters), alternating between the two ropes until both
required torque. maintain the required torque.
Outer Mid Extend Adjusting

Outer Mid Retract Adjusting
Nuts and Lock Plates 10. Using tool JLG PN 4120040, torque the Fly Extend
Adjustment Nuts to 10 ft-lb (13.5 Nm), starting with the
7. Using tool JLG PN 4120043, torque the Fly Boom Retract inside ropes and doing the outside ropes last. Refer to
Adjuster Nuts to 80 ft-lb (108 Nm), alternating between Figure 4-28., Torque Sequence for Fly Extend Rope.
the two ropes until both maintain the required torque. Alternate between the four ropes until all maintain the
required torque.
Fly Boom Retract Adjusting

Nuts and Lock Plates Fly Boom Extend Adjusting
8. Retract the boom 2-3 feet (0.6-1.0 m). Do not fully retract
or bottom out the booms.
3 1 2 4
Figure 4-28. Torque Sequence for Fly Extend Rope
4-84 3121262
11. Repeat the following boom movement steps three 18. Install all covers.
times. This is to ensure that the wire rope tension has
equalized on both sides of the sheaves and the ropes are
seated properly in the sheave grooves.
a. Fully retract the boom.
b. Extend the boom such that the platform moves 4
feet (1.3 m) from fully retracted position.
12. Verify the Fly Boom and Outer Mid Boom Retract wire
rope torques.
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step.
13. Retract the boom 2-3 feet (0.5-1 m). Do not fully retract
or bottom out the boom.
14. Verify the Fly Boom and Outer Mid Boom Extend wire
rope torques.
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step.
15. Check for proper function of the boom assembly. When
properly torqued and positioned, all three moving
boom sections will move simultaneously.
16. Install new nylon collar locknuts to the Fly Boom Extend
wire rope fittings. Do not re-use the old nylon collar lock
nuts. Torque the locknuts to 10 ft-lb (13.5 Nm)
17. Reinstall the lock plates to the remaining adjuster nuts.
3121262 4-85
9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
FLY BOOM
BASE BOOM OUTER MID BOOM
INNER MID BOOM
NOTE: Boom shown in fully retracted position.
Figure 4-29. Wire Rope Tensioning
4-86 3121262
3121262
Figure 4-30. Outer Mid Boom Extend/Retract Cables
4-87
4-88
Figure 4-31. Fly Boom Extend/Retract Cables
3121262
1. 2" Socket
2. 3/4” Socket
3. Retaining Bolt
Figure 4-32. Wire Rope Adjustment Tools (Optional)
3121262 4-89
4.19 BROKEN BOOM CABLE PROXIMITY SWITCH To avoid damaging the proximity switch, install and adjust
after assembling the switch block, compression spring, and
This system uses a proximity switch to detect excessive move- torquing the wire ropes.
ment of the cable block. If movement is detected the Cable
Break indicator will illuminate in the platform control panel.
No restrictions are made to the functionality of the control sys-
Adjusting the Proximity Switch
tem. It is the responsibility of the operator to take immediate
action. 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.
3. Tighten the jam nut.
Figure 4-33. Broken Boom Cable Proximity Switch Location
4.20 ELECTRONIC PLATFORM LEVELING PRIMARY AND SECONDARY TILT SENSOR

INTERACTION
NOTE: For more detailed information concerning system adjust- The secondary tilt sensor is used as a backup to the primary tilt
ment and operation, refer to Section 6 - JLG Control Sys- sensor. Any time a tilt set point is reset, a value from each sen-
tem.
sor shall be set.
Description If a fault occurs with the primary sensor, control will revert to
the secondary sensor. (This is discussed in more detail in the
Electronic platform leveling replaces the conventional hydrau-
Error Response section in Section 6 - JLG Control System.)
lic method of platform leveling.
Because of the mounting orientation of the tilt sensors, the
To control electronic platform leveling the platform is
equipped with a pair of tilt sensors, one primary and one sec- primary tilt sensor will output ascending voltage values with
ondary, mounted to the non-rotating portion of the platform increases in positive platform tilt angle. The backup or second-
rotator. The tilt sensors are monitored regularly and the plat- ary tilt sensor will output descending voltage values with
form level up and down valves are automatically controlled to increases in positive platform angle.
maintain set point as the machine is operated.
4-90 3121262
PLATFORM VALVES In order to obtain acceptable performance while performing

The platform specific valves are located in a manifold at the all hydraulic functions, five sets of parameters are used. These
platform. “zones” allow compensation for differences in how the basket
level changes when doing different functions. These zones are
There are individual proportional control valves that control as follows:
each of the four platform functions; Platform Level, Platform
Rotate, Jib Lift, and Jib Swing. 1. Lift up
There is also a Platform Dump Valve, located in the platform
2. Lift down
valve manifold, which is used to hydraulically isolate the con-
trol valves and to improve hydraulic response. 3. Other boom functions
The Ground Module controls this valve to provide manual
4. Drive
platform leveling in the event that the Platform Module is
inoperable.
5. Auxiliary
In ground mode, the platform dump valve is turned on when-
ever any platform or jib valve output is turned on. Whenever The other boom functions zone includes Swing, Telescope, Jib
all platform and jib valves are turned off, the platform dump swing (It is not necessary to level with jib lift, since the
valve is turned off. mechanical linkage keeps the basket level).
In platform mode, the platform dump valve is turned on These zones are prioritized when multiple functions are active.
whenever the footswitch is depressed. The priorities are as follows.
1. Auxiliary power and any other function, zone = auxiliary

Normal Operation
power
AUTOMATIC LEVELING 2. Drive and any other function, zone = Drive
Two tilt sensors, mounted on either side of the platform sup-
port, are used to measure the incline of the platform with 3. Lift up and any other function, zone = Lift up
respect to gravity and control the automatic leveling function,
one is used as the primary sensor and one as a secondary back 4. Lift down and any other function, zone = Lift down
up sensor.
5. Other boom functions, zone = Other boom functions
The level system shall assume a new fixed set point (fixed
incline of the platform with respect to gravity) each time the During the power-up procedure, function enable, in both Plat-
control system is powered up (cycling of the EMS). form and Ground Mode, is delayed during the 1.5 second
startup lamp test. During this 1.5 second startup period, the
Automatic platform leveling only functions while operating
basket level up valve will be energized at 100% duty cycle for
drive, telescope, lift or swing. It does not operate while operat-
ing any other function (e.g. rotate, jib, or steer). 0.5 second, and then the basket level down valve energized at
100% duty cycle for 0.5 second. This will help to keep the
The proportional control for these valves varies. This is depen- valves from sticking.
dant on the tilt variance from target as well as on the impact
coil temperature is having on the current to the valves. PLATFORM LEVEL MANUAL OVERRIDE
If a command from the Platform Level Up and Down toggle In addition to automatic leveling the operator is able to manu-
switch on either the platform or the ground is received, auto- ally adjust the platform level position by means of the level
matic platform leveling will cease and the appropriate output override switches located at the platform and ground control
will be commanded to turn on. positions (similar to a Master/Slave hydraulic system).
When the toggle switch is released, after ¼ second, the current The level system assumes a new set point after a level over-
filtered value of tilt angle will be taken as the new set point.
ride switch is operated. In other words the operator can chose
a platform level incline other than level with gravity and the
system will maintain this set point during automatic leveling.
3121262 4-91
4.21 ROTARY ACTUATOR As hydraulic pressure is applied, the piston is displaced axially
within the housing - similar to the operation of a hydraulic cyl-
Each actuator is individually serial numbered. The serial num- inder - while, simultaneously, the splines cause the shaft to
ber is a five or six digit number and must be provided before rotate. When the control valve is closed, oil is trapped inside
parts and/ or service issues can be addressed. the housing, preventing piston movement and locking the
shaft firmly in position.
The serial number can be found on the Identification (ID) Tag The shaft is supported radially by the large upper radial bear-
that is affixed to all actuators. The tag is a thin, silver colored, ing and the lower radial bearing (see drawings on pages 8 and
plastic material with a self-adhesive backing. Information is 9). Axially, the shaft is separated from the housing by the
imprinted in black. The tag is located either on the side plate upper and lower thrust washers. The end cap is adjusted for
or on the housing tube of the actuator. axial clearance and locked in position by set screws or pins.
Configurations of parts may be slightly different depending on
Additionally, the serial number of the actuator is stamped model.
onto the side plate or the housing tube. It may be necessary to
remove paint to expose the serial number. Many actuators are equipped with counterbalance valves,
which performs four major functions.
Theory of Operation • Protects the actuator in the event of overload
The rotary actuator is a simple mechanism that uses Helac’s • Enables the actuator to hold position without drifting
sliding spline technology which converts axial piston motion when external loads are applied
into powerful shaft rotation. As seen in the illustration below • Reduces hydraulic backlash by pressuring the hydraulic
left, each actuator is composed of a housing with an integral fluid
ring gear (1) and only two moving parts: the central shaft (2),
• Provides a constant controlled rate of rotation in over-cen-
and the annular piston sleeve (3). Note the actuator shaft fea-
ter load conditions
tures an integral mounting flange and bearing which are not
shown in the illustration. Applying fluid pressure will displace the piston axially while
the helical gearing causes the piston and shaft to rotate simul-
Helical spline teeth machined on the shaft engage matching taneously. The double helix design compounds rotation: shaft
splines on the inside diameter of the piston. The outside diam- rotation is about twice that of the piston. Applying pressure to
eter of the piston carries a second set of splines, of opposite the opposite port will return the piston and shaft to their orig-
hand, which engage the matching splines of the housing’s ring inal starting positions.
gear.
Bars indicate starting positions of piston and shaft. Arrows indicate direction Applying fluid pressure will displace the piston axially while the helical gearing
they will rotate. The housing with integral ring gear remains stationary. For clar- causes the piston and shaft to rotate simultaneously. The double helix design
ity, the shaft flange, bearings, and end cap are not shown. compounds rotation: shaft rotation is about twice that of the piston. Applying
pressure to the opposite port will return the piston and shaft to their original
starting positions.
Figure 4-34. Actuator Theory of Operation
4-92 3121262
Tools Required 9. PLASTIC MANDREL
10. PRY BAR

Removal of end cap and manual rotation of shaft.
11. FELT MARKER

Highlights timing marks and outlines troubled areas.
Permanent ink is recommended.
12. T-HANDLE SCREW EXTRACTOR
13. HEX WRENCH SET

Removal and replacement of port plugs and set screws
(106,110).
14. SEAL TOOLS

Removal and installation of seals and wear guides.
Several basic tools are required for the disassembly and reas-
Directions on making a seal tool are provided at bottom
sembly of the actuator. The tools and their intended functions
are outlined below: 15. PUNCH
1. PIPE VISE 16. DOWEL PINS
Removal and installation of end cap.
2. HEXWRENCH
Removal and replacement of port plugs and set screws. MAKING A SEAL TOOL
3. ASSORTED SCREWS
4. SAFETY GLASSES
5. END CAP REMOVAL TOOLS

(provided with seal kit)
6. DRILL The seal tool is merely a customized standard flat head screw-
driver.
7. FLASHLIGHT
Helps in locating and examining timing marks, compo- 1. Heat the flat end with a torch until it glows.
nent failure and overall condition. 2. Secure the heated end of the screwdriver in a vise and
8. RUBBER MALLET bend the heated end to a slight radius.
Removal and installation of shaft and piston sleeve 3. Round off all sharp edges of the heated screwdriver to a
assembly. polished finish. The tool may be modified slightly to
your own personal preference.
TO AVOID INJURY BE CAREFUL WHEN HANDLING THE SCREWDRIVER WHEN

HOT.
3121262 4-93
Disassembly 4. Remove the lock pins using a screw extracting tool such
as an "Easy Out" (a size #2 is shown).
Inspect the actuator for corrosion prior to disassembly. Severe
corrosion can make it difficult to remove the lock pins (109) If the pin cannot be removed with the screw extractor,
and unthread the end cap (04). If corrosion is evident, soak the use a 5/16" bit to drill out the entire pin. Do not drill
lock pins and end cap with penetrating oil for several hours deeper than 1/2" (12.7 mm).
before disassembling.
Disassembly is easier if the actuator is firmly secured to a work

bench. A pipe vise or mounting fixture works well for this pur-
pose.
5. Install the end cap removal tools provided with the seal
kit. (1/4-20)
1. Remove port plugs (106.1) (106.2) and drain oil. Inspect

oil for signs of contamination, i.e. water, metal shavings.
6. Using a metal bar or similar tool, unthread the end cap

(4) by turning it counterclockwise.
2. Remove the cap screws (113) that cover the end cap lock
pins (109).
3. Using a 1/8" (3 mm) drill bit, drill a hole in the center of

each lock pin to a depth of approximately 3/16" (5 mm).
4-94 3121262
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-35. Rotary Actuator - Assembly Drawing
3121262 4-95
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 401 Counterbalance Valve
3. Piston Sleeve 106.1. Port Plug 204. O-ring
4. End Cap 106.2. Port Plug 205. Cup Seal
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Exclusion Seal
Figure 4-36. Rotary Actuator - Exploded View
4-96 3121262
7. Remove the end cap (4) and carefully set aside for later
inspection.
8. Remove the stop tube (400) if the actuator is equipped

with one. The stop tube is an available option that limits
the rotation of the actuator.
9. Every actuator has two sets of small punched timing 10. Prior to removing the shaft (2), use a felt marker to
marks that indicate timing between the gear sets. The clearly indicate the timing between shaft and piston
location and appearance of the marks can vary slightly sleeve (3). This will greatly simplify timing when the
between models. One set indicates the timing between actuator is reassembled.
the piston sleeve (3) and the housing (1) (upper photo),
the second set between the piston and the shaft (lower
photo). To ensure correct rotation and accurate end
positions, it is essential that the actuator be correctly
timed when it is reassembled. The punched timing
marks can be used, but it is easier to highlight punched
marks with a marker before disassembly as outlined in
the steps below.
3121262 4-97
11. Remove the shaft (2) by rotating counterclockwise. As 14. At the point when the piston gear teeth come out of
the shaft is rotated, it will disengage from the piston engagement with the housing gear teeth, mark the pis-
sleeve (3) and can be removed. It may be necessary to ton and housing with a marker as shown.
strike the threaded end of the shaft with a rubber mallet.
15. Remove the O-ring (204) and backup ring (207) from
12. As in step 9, before removing the piston (3), mark the end cap (4).
housing (1) ring gear in relation to the piston outside
diameter gear. There should now be timing marks on
the housing (1) ring gear, the piston (3) and the shaft (2).
13. To remove the piston (3) use a rubber mallet and a plas- TO AVOID DAMAGE TO MACHINED PARTS CAREFULLY REMOVE SEALS USING
tic mandrel so the piston and housing bore are not dam- REMOVAL TOOLS WITH ROUNDED EDGES.
aged.
16. Remove the wear guide (302) from the end cap (4) and
shaft (2).
4-98 3121262
17. Remove the main pressure seal (205). 20. Remove the outside diameter piston seal (202) from the
piston.
18. Remove the thrust washer (304) from the end cap (4)
and shaft (2). 21. Remove the inside diameter piston seal (200).
19. Remove the O-ring (304.1) from its groove in the end
cap (4) and shaft (2). Inspection
PRIOR TO ASSEMBLY OF ACTUATOR, THESE STEPS MUST BE CLOSELY FOL-

LOWED TO ENSURE PROPER OPERATION OF THE ACTUATOR.
1. Clean all parts in a solvent tank and dry with com-

pressed air prior to inspecting.
2. Carefully inspect all critical areas for any surface finish
abnormalities: Seal grooves, bearing grooves, thrust sur-
faces, shaft surface, housing bore and gear teeth.
SMALL OR MINOR SURFACE SCRATCHES CAN BE CAREFULLY POLISHED.
3121262 4-99
Assembly 4. Using a seal tool install the main pressure seal (205) onto
shaft (2) and end cap (4). Use the seal tool in a circular
1. Gather all the components and tools into one location motion.
prior to re-assembly. Use the cut away drawing to refer-
ence the seal orientations.
5. Install the wear guide (302) on the end cap (4) and
shaft (2).
2. Coat the thrust washers (304) with a generous amount
of Lithium grease. Install the thrust washer (304) onto
shaft (2) and end cap (4).
6. Install the O-ring (204) and back-up ring (207) into the
inner seal groove on the end cap (4).
3. Install the exclusion seal (304.1) into the appropriate

grooves on the shaft (2) and end cap (4) around the out-
side edge of the thrust washer (304).
4-100 3121262
7. Install the inner T-seal (200) into the appropriate groove 8. Insert the piston (3) into the housing (1) as shown, until
in the piston (3). Use a circular motion to ensure the seal the outer piston seal (202) contacts the inside housing
is correctly seated in the groove. bore.
Install the outer T-seal (202) by stretching it around the
groove in a circular motion.
9. Looking into the housing bore from the shaft flange

end, rotate the piston (3) until the marks you put on the
Each T-seal has 2 back-up rings (see Assembly Drawing piston and the housing (1) during disassembly align as
for orientation). Beginning with the inner seal (200) shown. Using a rubber mallet, tap the piston into the
insert one end of backup ring in the lower groove and housing until the gear teeth contact.
feed the rest in using a circular motion. Make sure the
wedged ends overlap correctly.
Insert the other back up ring in upper groove.
Repeat both of these steps for the outer seal (202).
3121262 4-101
10. Looking into the bore from the opposite end of the 12. Looking at the actuator from the end opposite the shaft
housing (1) be sure the timing marks align correctly. flange, use the existing timing marks to align the gear
Rotate the piston as necessary until aligned, then gently teeth on the shaft (2) with the gear teeth on the inside of
tap the piston (3) into the housing until the gear teeth the piston (3). When the marks align, gently tap the
mesh together. Tap the piston into the housing until it flange end of the shaft with a rubber mallet until the
completely bottoms out against the ring gear. gear teeth engage.
13. Install two bolts in the threaded holes in the flange.

Using a metal bar, rotate the shaft in a clockwise direc-
11. Insert the shaft (2) into the piston (3). Be careful not to tion until the wear guides are seated inside the housing
damage the piston seals. Do not engage the piston gear bore.
teeth yet.
AS THE SHAFT IS ROTATED, BE CAREFUL NOT TO DISENGAGE THE PISTON AND

HOUSING GEARING.
4-102 3121262
14. Install the stop tube (400) onto the shaft end if neces- 17. Tighten the end cap (4) using a metal bar. In most cases
sary. Stop tubes are an available option to limit the rota- the original holes for the lock pins will align.
tion of an actuator.
15. Coat the threads on the end of the shaft with anti-seize 18. Insert the lock pins (109) provided with the Helac seal kit
grease to prevent galling. into the holes with the dimple side up. Then, using a
punch, tap the lock pins to the bottom of the hole.
16. Thread the end cap (4) onto the shaft (2). Make sure the
wear guide remains in place on the end cap as it is 19. Insert the set screws (113) over the lock pins. Tighten to
threaded into the housing (1).
25 in-lbs. (2.8 Nm).
3121262 4-103
Greasing Thrust Washers Installing Counterbalance Valve

Refer to Figure 4-37., Rotator Counterbalance Valve.
1. After the actuator is assembled but before it is put into
service, the thrust washer area must be packed with 1. Make sure the surface of the actuator is clean, free of any
Lithium grease. contamination and foreign debris including old Loctite.
2. Make sure the new valve has the O-rings in the counter-
There are two grease ports located on both the shaft bores of the valve to seal it to the actuator housing.
flange and the end cap. They are plugged with cap
screws (113) or set screws. Remove the grease port 3. The bolts that come with the valve are grade 8 bolts.
screws from the shaft flange and end cap. (See exploded New bolts should be installed with a new valve. JLG
view) Threadlocker PN 0100011 should be applied to the
shank of the three bolts at the time of installation.
4. Torque the 1/4-inch bolts 110 to 120 inch pounds
(12.4 to 13.5 Nm). Do not torque over 125 inch pounds
(14.1 Nm). Torque the 5/16-inch bolts 140 inch pounds
(15.8 Nm). Do not torque over 145 inch pounds
(16.3 Nm).
Testing the Actuator

If the equipment is available, the actuator should be tested on
a hydraulic test bench. The breakaway pressure — the pres-
sure at which the shaft begins to rotate — should be approxi-
mately 400 psi (28 bar). Cycle the actuator at least 25 times at
3000 psi (210 bar) pressure. After the 25 rotations, increase the
pressure to 4500 psi (315 bar) to check for leaks and cracks.
Perform the test again at the end of the rotation in the oppo-
site direction.
IF A HYDRAULIC TEST BENCH IS NOT AVAILABLE, THE ACTUATOR CAN BE
TESTING THE ACTUATOR FOR INTERNAL LEAKAGE
ROTATED BY HAND, OPEN THE PRESSURE PORTS AND USE A PRY BAR WITH
If the actuator is equipped with a counterbalance valve, plug
CAP SCREWS INSERTED INTO THE SHAFT FLANGE TO TURN THE SHAFT IN THE
the valve ports. Connect the hydraulic lines to the housing
DESIRED DIRECTION.
ports. Bleed all air from the actuator (see Installation and
Bleeding) Rotate the shaft to the end of rotation at 3000 psi
Insert the tip of a grease gun into one port and apply (210 bar) and maintain pressure. Remove the hydraulic line
grease to the shaft flange. Continue applying until from the non-pressurized side.
grease flows from the opposite port. Cycle the actuator
five times and apply grease again. Repeat this process Continuous oil flow from the open housing port indicates
on the end cap. Insert the cap screws into the grease internal leakage across the piston. Replace the line and rotate
ports and tighten to 25 in-lbs. (2.8 Nm). the shaft to the end of rotation in the opposite direction.
Repeat the test procedure outlined above for the other port. If
there is an internal leak, disassemble, inspect and repair.
4-104 3121262
Figure 4-37. Rotator Counterbalance Valve
3121262 4-105
Installation and Bleeding 1. Connect a 3/16" inside diameter x 5/16" outside diame-
ter x 5 foot clear, vinyl drain tube to each of the two
After installation of the actuator on the equipment, it is impor- bleed nipples. Secure them with hose clamps. Place the
tant that all safety devices such as tie rods or safety cables are vinyl tubes in a clean 5-gallon container to collect the
properly re-attached. purged oil. The oil can be returned to the reservoir after
this procedure is completed.
To purge air from the hydraulic lines, connect them together
to create a closed loop and pump hydraulic fluid through
them. Review the hydraulic schematic to determine which
hydraulic lines to connect. The linear feet and inside diameter
of the hydraulic supply lines together with pump capacity will
determine the amount of pumping time required to fully
purge the hydraulic system.
Bleeding may be necessary if excessive backlash is exhibited

after the actuator is connected to the hydraulic system. The
following steps are recommended when a minimum of two
gallons (8 liters) is purged.
TYPICAL CONFIGURATION OF ACTUA-

TOR
2. With an operator in the platform, open both bleed nip-

ples 1/4 turn. Hydraulically rotate the platform to the
end of rotation (either clockwise or counterclockwise),
and maintain hydraulic pressure. Oil with small air bub-
bles will be seen flowing through the tubes. Allow a 1/2
gallon of fluid to be purged from the actuator.
3. Keep the fittings open and rotate the platform in the

opposite direction to the end position. Maintain hydrau-
lic pressure until an additional 1/4 gallon of fluid is
pumped into the container.
4. Repeat steps 2 & 3. After the last 1/2 gallon is purged,

close both bleed nipples before rotating away from the
end position.
4-106 3121262
Troubleshooting
Problem Cause Solution

1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s
pressure specifications. Load may be above maximum
capacity of the actuator.
b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic lines for
restrictions and leaks.
c. Control or counterbalance valve has internal leak c. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate the actuator through housing ports
(do not exceed OEM’s operating pressure). The valve must
be replaced if a steady flow of fluid is seen coming from the
valve ports.
d. Piston and/or shaft seal leak d. Remove the plug and the housing’s valve ports. Operate
the actuator through the housing ports. Conduct the inter-
nal leakage test as described in the Testing section on page
24 of this manual.
e. Corrosion build-up on the thrust surfaces e. Re-build the actuator. Remove all rust then polish.
Replacement parts may be needed.
f. Swollen seals and composite bearings caused by incom- f. Re-build the actuator. Use fluid that is compatible with
patible hydraulic fluid seals and bearings.
2. Operation is erratic or not responsive a. Air in actuator a. Purge air from actuator. See bleeding procedures.
3. Shaft will not fully rotate a. Twisted or chipped gear teeth a. Check for gear binding. Actuator may not be able to be re-
built and may need to be replaced. Damage could be a result
of overload or shock.
b. Port fittings are obstructing the piston b. Check thread length of port fittings. Fittings should dur-
ing stroke not reach inside the housing bore.
4. Selected position cannot be maintained a. Control or counterbalance valve has internal leak a. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate the actuator through housing ports
(do not exceed OEM’s operating pressure). The valve must
be replaced if a steady flow of fluid is seen coming from the
valve ports.
b. Piston and/or shaft seal leak b. Remove the plug and the housing’s valve ports. Operate
the actuator through the housing ports. Conduct the inter-
nal leakage test as described in the Testing section on page
24 of this manual.
c. Air in actuator c. Purge air from actuator. See bleeding procedures
3121262 4-107
4.22 JIB ROTATOR TORQUING PROCEDURE 3. Torque the top bolts in a crossing star pattern to
300 ft.lbs. (410 Nm).
See Figure 4-38., JIb Rotator Torque
4. Torque the center bolt to a final torque of 700 ft.lbs.
1. Torque the center bolt to 350 ft.lbs. (475 Nm). (950 Nm).
2. Torque the bottom bolts in a crossing star pattern to
170 ft.lbs. (230 Nm).
Figure 4-38. JIb Rotator Torque
4-108 3121262
NOTE: If any rotator bolts are replaced, all bolts on the

rotator should be retorqued.
A Torque to 40 ft.lbs. (55 Nm)

B JLG Threadlocker PN 0100011
C Torque 85 ft. lbs. (116 Nm)
D Torque 586ft. lbs. (795 Nm)
E Check torque every 150 hours of operation
Figure 4-39. Platform Support Torque Values
3121262 4-109
4.23 SKYGUARD® Function Test
Operation SkyGuard Only

SkyGuard provides enhanced control panel protection. When Perform this function test if SkyGuard only is selected in
the SkyGuard sensor is activated, functions in use at the time machine setup (refer to Table 6-2).
of actuation will reverse or cutout. The SkyGuard Function
Table provides more details on these functions. From the Platform Control Console in an area free from
obstructions:
Consult the following illustrations to determine which type of
SkyGuard the machine is equipped with. Regardless of the 1. Operate the telescope out function, then activate Sky-
type, SkyGuard function according to the SkyGuard Function Guard sensor.
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:
NOTE: Machine will treat Soft Touch/SkyGuard override switch as

if it is a Soft Touch and SkyGuard switch.
0"%
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.
4. Disengage SkyGuard sensor, release controls, and recy-

0"$
cle footswitch. Ensure sure normal operation is available.
SkyGuard SkyEye™
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.
4-110 3121262
SOFT TOUCH ONLY Engage the SkyGuard sensor and observe the Analyzer to
If Soft Touch only is selected in machine setup (refer to Table determine if the switch/relay closes.
6-2), machine will treat the Soft Touch/SkyGuard override If the status of the switch/relay remains OPEN while the Sky-
switch as if it is a Soft Touch switch. Guard sensor is actively engaged, it is possible the sensor has
failed and should be replaced immediately.
SKYGUARD NOT SELECTED IN MACHINE SETUP
If the SkyGuard system is installed on the machine, but no If the status of the switch/relay remains CLOSED while the Sky-
option is selected in the machine setup (refer to Table 6-2), Guard sensor is actively engaged, a power or ground wire may
SkyGuard sensor status will be ignored. No function cutout or not be making good contact or may be loose or broken. Addi-
reversal will be implemented. tionally, there is a low probability that both relays may have
failed.
Diagnostics & Troubleshooting If the switch/relay status is in disagreement, then one may
If SkyGuard does not function when the sensor is engaged, have failed or is not installed correctly. In this case, the
first verify the configuration under the machine will be inoperable.
MACHINE SETUP: SKYGUARD OPTION menu using the hand-
held Analyzer. Ensure the selected configuration matches the FAULT CODES
actual system installed on the machine. If not, select the cor- Refer to Table 6-13 for more fault code information
rect configuration, then verify operation. • 0039 - SkyGuard switch activation fault
Additionally, use the handheld analyzer to navigate to the • 2563 - switch disagreement fault
DIAGNOSTICS: FEATURES SKYGUARD INPUTS menu to deter-
mine additional SkyGuard fault information.
Table 4-2. SkyGuard Function Table
Boom
Drive Drive Boom Boom Boom Jib Basket Basket
Steer Swing Lift Jib Lift Jib Tele
Forward Reverse Lift Up Tele Out Tele In Swing Level Rotate
Down
R*/C** R C R R R R C C C C C 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.
3121262 4-111
4.24 BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands,
kinks, or any signs of corrosion.
The Bolt-On External Fall Arrest system is designed to provide
a lanyard attach point while allowing the operator to access GAP
GAPSHOWING:
SHOWING:
areas outside the platform. Exit/Enter the platform through INCORRECT
INCORRECT
the gate area only. The system is designed for use by one per-
son.
Personnel must use fall protection at all times. A full body har-
ness is required with lanyard not to exceed 6 ft. (1.8 M) in
length, that limits the maximum arrest force to 900 lbs.
(408 kg). NO GAP:
NO GAP: CORRECT
CORRECT
Bolt-On External Fall Arrest System capacity is 310 lb (140 kg) -
one (1) person maximum.
Do not move the platform during use of the Bolt-On External

Fall Arrest system.
DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM.

BE CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION. Figure 4-40. 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
OR IS OTHERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND • Attachment Ring: No cracks or signs of wear are accept-
THE PLATFORM FULLY INSPECTED BEFORE RETURNING TO SERVICE. REFER TO able. Any signs of corrosion requires replacement.
THE SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES.
• Attaching Hardware: Inspect all attaching hardware to
THE BOLT-ON EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL ensure there are no missing components and hardware is
INSPECTION AND CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICA- properly tightened.
TION MUST BE PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER.
• Platform Rails: No visible damage is acceptable.
Inspection Before Use
The Bolt-On External Fall Arrest system must be inspected
Installation
before each use of the aerial work platform. Replace compo-
nents if there are any signs of wear or damage. 1. Install the retaining hardware (bolts, nuts, and washers)
and secure the brackets to the platform rail. Tighten the
Before each use, perform a visual inspection of the following nuts but do not torque them yet.
components:
BOLT
WASHER
WASHER
NUT
4-112 3121262
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
nuts onto the cable finger tight so the mark on the cable
does not move.
WASHER
BELLEVILLE
NUT 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
cable has not rotated during tightening.
3121262 4-113
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 4-41. Bolt-On External Fall Arrest System
4-114 3121262
SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS

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

prior to assembly.
Cup and Brush

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

• Small paint brush 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring is
coated with hydraulic oil.
1. Hold the fitting in one hand while using the brush with
the other hand to dip into the container. Remove excess
hydraulic oil from the brush so an even film of oil is
applied on the o-ring.
3121262 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 3121262
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
3121262 5-3
Straight Thread Types, Port Connections Flange Connection Types

ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162
MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162
6149, DIN 3852
Figure 5-10. ORB-MPP Thread
Tightening Methods
Torque = Application of a twisting force to the applicable con-
Figure 5-8. ORB-MPP Thread nection by use of a precise measurement instrument (i.e.
torque wrench).
MFF = metric flat face port per ISO 9974-1
Finger Tight = The point where the connector will no longer
BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852- thread onto the mating part when tightened by hand or fin-
2 gers. Finger Tight is relative to user strength and will have
some variance. The average torque applied by this method is 3
ft-lbs [4 N-m] Also referred to as ‘Hand Tight.’
TFFT = Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by hand (fin-
gers) and applying an additional rotation counted by a
defined number of turns by use of a tool.
FFWR = Flats from Wrench Resistance; Application of a pre-
load to a connection by tightening to the point of initial
wrench resistance and turning the nut a described number of
‘flats’. A ‘flat’ is one side of the hexagonal tube nut and
equates to 1/6 of a turn. Also referred to as the ‘Flats Method.’
Figure 5-9. MFF-BSPP Thread
5-4 3121262
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.
3121262 5-5
Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS
TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED
Thread Tapered (NPTF) Connections. TURNS AND USE THE LAST TURN FOR ALIGNMENT.
1. Inspect components to ensure male and female port
threads are free of rust, splits, dirt, foreign matter, or 5. Rotate male fitting the number of turns per Table 5-1,
burrs. NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT
procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to
the male pipe threads if not already applied. Ensure the NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
first 1 to 2 threads are uncovered to prevent system con- applicable for the following material configurations:
tamination.
• STEEL fittings with STEEL mating components
3. Assemble connection hand tight.
• STEEL fittings with ALUMINUM or BRASS mating compo-
4. Mark fittings, male and female. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE
PIPE FITTING AND DAMAGE TO THE JOINING FITTING, • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
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
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
OMPONENTS
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 3121262
Assembly Instructions for British Standard Pipe TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED
TURNS AND USE THE LAST TURN FOR ALIGNMENT.
Thread Tapered (BSPT) Connections
1. Inspect components to ensure male and female port 5. Rotate male fitting the number of turns per Table 5-2,
threads are free of rust, splits, dirt, foreign matter, or BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT
burrs. procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to NOTE: TFFT values provided in Table 5-2, BSPT Pipe Thread are
the male pipe threads if not already applied. Ensure the applicable for the following material configurations:
first 1 to 2 threads are uncovered to prevent system con-
tamination. • STEEL fittings with STEEL mating components
3. Assemble connection hand tight. • STEEL fittings with ALUMINUM or BRASS mating compo-
nents
4. Mark fittings, male and female.
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
PIPE FITTING AND DAMAGE TO THE JOINING FITTING, mating components.
FLANGE OR COMPONENT MAY OCCUR.
NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS
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

6 3/8 - 19 0.66 16.66 2 to 3
STEEL, ALUMINUM, OR BRASS
8 1/2 - 14 0.83 20.96 2 to 3

12 3/4 - 14 1.04 26.44 2 to 3
MATING COMPONENTS
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.
3121262 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 configuration of the connection.
INTO ALIGNMENT. IT 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:
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRI-
CATED OR OILY FITTINGS. NO LUBRICATION OR SEALANT
nents
IS REQUIRED. THE LUBRICATION WOULD CAUSE
INCREASED CLAMPING FORCE AND CAUSE FITTING DAM- • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
AGE. mating components.
5-8 3121262
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 --
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --

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

8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
* ØA and ØB thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121262 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 COMPONENTS; UN-LUBRICATED THREADS
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
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 3121262
3121262 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 ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
THE JOINT EVENTUALLY LEADING TO 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 LUBRI-
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
CATED OR OILY FITTINGS. NO LUBRICATION OR SEALANT
IS REQUIRED. THE LUBRICATION WOULD CAUSE mating components.
INCREASED CLAMPING FORCE AND CAUSE FITTING DAM-
AGE.
5-12 3121262
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.
3121262 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-
replace fitting or adapter. uration of the connection.
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING

COMPONENTS’ indicate either the following material configu-
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID rations:
ADDING OIL TO THE THREADED CONNECTION OF THE FIT-
TING. THE LUBRICATION WOULD CAUSE INCREASED • STEEL fittings with ALUMINUM or BRASS mating compo-
CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
• ALUMINUM or BRASS fittings with ALUMINUM or
4. Place the tube assembly against the fitting body so that
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
STEEL MATING COMPONENTS;
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4

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

12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
5-14 3121262
Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass
Flats from Wrench

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

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

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

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

12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
** See FFWR and TFFT Methods for FFWR procedure requirements.
3121262 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 3121262
Table 5-9. DIN 24°Cone (MBTL & MBTS)
DIN 24° CONE FLARELESS BITE FITTING

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

MATERIAL
ØA* ØB* C* ØD* Wrench

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

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

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

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

FFWR is the recommended
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
method of fitting assembly.
12 M20 x 1.5 18.50 20.00 7.50 12.20 1.5 to 1.75
14 M22 x 1.5 20.50 22.00 8.00 14.20 Torque values are application 1.5 to 1.75
16 M24 x 1.5 22.50 24.00 8.50 16.20 specific due to variability in the 1.5 to 1.75
fitting supplier, coating,
20 M30 x 2 27.90 30.00 10.50 20.20 lubrication, and other physical 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 characteristics of the connection. 1.5 to 1.75
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
Refer to the specific procedure
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
in the
* ØA, ØB, C, & ØD thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121262 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 3121262
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
6 11/16-16 25 27 28 34 37 38
O-RING FACE SEAL (ORFS)
8 13/16-16 55 58 61 75 79 83
BULKHEAD FITTING
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
3121262 5-19
Table 5-11. Bulkhead Fittings (BH) - METRIC
FASTENING JAM NUT

for Bulkhead Connectors
Connecting Torque
Thread M Size
MATERIAL TYPE Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
DIN 24° CONE FLARELESS BITE
(MBTL) BULKHEAD FITTING
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
STEEL FITTINGS
Connecting Torque
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING
Thread M Size
Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
14 M22 x 1.5 44 47 50 60 64 68
16 M24 x 1.5 70 75 80 95 102 108
20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
5-20 3121262
3121262 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 • STEEL fittings with ALUMINUM or BRASS mating compo-
ADDING OIL TO THE THREADED CONNECTION OF THE FIT- nents
TING. THE LUBRICATION WOULD 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 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
Assembly for proper assembly.
5-22 3121262
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
COMPONENTS; UN-LUBRICATED THREADS
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
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.
3121262 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 3121262
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
3121262 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 3121262
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
3121262 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 3121262
3121262 5-29
Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18,
Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5-
Metric (MFF) Fittings 23 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the Metric port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the Metric port.
2. If O-ring is not pre-installed, install proper size, taking b. Torque values provided in Table 5-18, Table 5-19,
care not to damage it. See O-ring Installation (Replace- Table 5-20, Table 5-21, Table 5-22, and Table 5-23
ment) for instructions. are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
nents
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
5-30 3121262
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
3121262 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 3121262
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
3121262 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 3121262
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
3121262 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 3121262
3121262 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 FIT- • ALUMINUM or BRASS fittings with STEEL mating compo-
TING. THE LUBRICATION WOULD CAUSE INCREASED nents
CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
3. Pre-lubricate the O-ring with Hydraulic Oil.
7. Inspect to ensure the O-ring is not pinched and the
4. For Non-Adjustable Fittings and Plugs, thread the fitting washer is seated flat on the counter bore of the port.
by hand until contact.

5-38 3121262
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
3121262 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
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
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 3121262
3121262 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.
2. If O-ring is not preinstalled, install proper size, taking b. Torque values provided in Table 5-25, Table 5-26,
care not to damage it. See O-ring Installation (Replace- Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are
ment) for instructions. segregated based on the material configuration of
the connection. ‘ALUMINUM/BRASS FITTINGS OR
nents
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
5-42 3121262
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
3121262 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 3121262
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

3121262 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 3121262
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

3121262 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
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 Service Manual.
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
Connecting
Thread G
Size
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 Service Manual.
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499

5-48 3121262
3121262 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 3121262
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.
3121262 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 3121262
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
3121262 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 3121262
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.
3121262 5-55
5.3 HYDRAULIC CYLINDERS 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
inder head retainer capscrews, and remove capscrews
Axle Extension Cylinder from cylinder barrel.
DISASSEMBLY
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED

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

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

RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
SURE.
Figure 5-16. Cap Screw Removal
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable. 6. Attach a suitable pulling device to the cylinder rod end.
3. Remove the sequence valves from the cylinder port

block. Discard o-rings.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
4. Place the cylinder barrel into a suitable holding fixture. CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
ROD SUPPORT PISTON AND CYLINDER BARREL SURFACES.
PROTECTED ROD CLAMP
7. With the barrel clamped securely, carefully withdraw the
complete rod assembly from the cylinder barrel.
BARREL CLAMP
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
Figure 5-15. Cylinder Barrel Support
Figure 5-17. Cylinder Rod Support
8. Using suitable protection, clamp the cylinder rod in a

vise or holding fixture as close to the piston as possible.
5-56 3121262
1
18
4* 17
8
9
14
4
18
17
13
15 11
16
15
12
10
3
6
5
7
4**
* Torque 9 ft.lbs. (12 Nm)

1684102-E
** Torque 35ft.lbs. (47 Nm) 1001228020-D
MAF10990
1. Barrel 6. Seal 11. Wear Ring 16. T-Seal

2. Rod 7. Washer Ring 12. O-ring 17. O-ring
3. Head 8. Tapered Bushing 13. Backup Ring 18. Holding Valve
4. Capscrew 9. Piston 14. O-ring
5. Wiper 10. Backup Ring 15. Wear Ring
Figure 5-18. Axle Extension Cylinder
3121262 5-57
9. Loosen and remove the capscrew which attach the CLEANING AND INSPECTION
tapered bushing to the piston.
1. Clean all parts thoroughly in an approved cleaning sol-
vent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or

other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage.

Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring

or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress

threads as necessary.
6. Inspect piston surface for damage and scoring and for

Figure 5-19. Tapered Bushing Removal distortion. Dress piston surface or replace piston as nec-
essary.
10. Insert the capscrews in the threaded holes in the outer
piece of the tapered bushing. Progressively tighten the 7. Inspect threaded portion of piston for damage. Dress
capscrews until the bushing is loose. threads as necessary.
11. Remove the tapered bushing from the piston. 8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
12. By hand, screw the piston counterclockwise and remove
it from cylinder rod. 9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace as
13. Remove and discard the piston o-rings, seal rings, and necessary.
backup rings.
10. Inspect threaded portion of head for damage. Dress
14. Remove the rod from the holding fixture. Remove the threads as necessary.
cylinder head gland and washer ring. Discard all seals on
the cylinder head. 11. Inspect seal and o-ring grooves in head for burrs and
5-58 3121262
12. Inspect cylinder head outside diameter for scoring or ASSEMBLY

other damage and ovality and tapering. Replace as nec-
essary. NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
13. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to
assembly.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt,
etc. to facilitate bearing installation. 1. A special tool is used to install a new rod seal into the
applicable cylinder head gland groove.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
NOTE: Install pin into the composite bearing dry. Lubrication is

not required with nickel plated pins and bearings.
Figure 5-21. Rod Seal Installation
WHEN INSTALLING NEW S EALS, ENSURE SEALS ARE

INSTALLED PROPERLY. IMPROPER SEAL INSTALLATION
COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER
Figure 5-20. Composite Bearing Installation CYLINDER OPERATION.
14. Inspect travel limiting collar or spacer for burrs and

sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding

valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other

damage. Replace as necessary.
Figure 5-22. Cylinder Head Seal Installation
3121262 5-59
2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating
der head gland groove. Install a new wear ring into the end of rod must be free of oil.
cylinder head gland groove.
8. 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.
Figure 5-23. Wiper Seal Installation
3. Place a new “O-ring and backup ring in the outside

diameter groove of the cylinder head.
Figure 5-25. Tapered Bushing Installation
9. Tighten the capscrews evenly and progressively in rota-

tion to 9 ft.lbs. (12 Nm).
10. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4" in diameter) as follows;
a. Place the shaft against the cylinder rod and in con-

tact with the bushing in the spaces between the
capscrews.
Figure 5-24. Installation of Head Seal Kit b. Tap each space once; this means the tapered bush-
ing is tapped 3 times as there are 3 spaces between
4. Install washer ring onto rod, carefully install the head the capscrews.
gland on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the
rod to the rod end.
5. Place a new O-ring and backup rings in the inner piston

diameter groove.

vise or similar holding fixture as close to the piston
threads as possible.
7. Carefully thread the piston on the cylinder rod hand

tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.
Figure 5-26. Seating the Tapered Bearing
11. Retorque the capscrews evenly and progressively in

rotation to 9 ft.lbs. (12 Nm).
5-60 3121262
12. Remove the cylinder rod from the holding fixture. 17. Secure the cylinder head gland using the washer ring,
JLG Threadlocker PN 0100011 and socket head bolts.
13. Place a new t-seal and wear rings in the outer piston
diameter grooves. (A tube, with I.D. slightly larger than Torque to 35 ft.lbs. (47 Nm).
the O.D.of the piston is recommended to install the seal.)
Figure 5-28. Rod Assembly Installation
18. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the
reinstallation of any valves.
Figure 5-27. Piston Seal Kit Installation 19. Install the counterbalance valves in the rod port block.
14. Position the cylinder barrel in a suitable holding fixture.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE

CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
PISTON AND CYLINDER BARREL SURFACES.
15. With barrel clamped securely, and while adequately sup-

porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston t-seal is not damaged or
dislodged.
16. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
3121262 5-61
Axle Lockout Cylinder 6. Mark cylinder head and barrel with a center punch for
DISASSEMBLY inder head retainer capscrews, and remove capscrews
from cylinder barrel.



SURE.

Adequately support the cylinder rod, if applicable. Figure 5-30. Cap Screw Removal
3. Remove the counterbalance valves from the cylinder

7. Attach a suitable pulling device to the cylinder rod end.
port block. Discard o-rings.
4. If necessary, remove the bleeder valve.
5. Place the cylinder barrel into a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
ROD SUPPORT ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
PROTECTED ROD CLAMP
BARREL CLAMP complete rod assembly from the cylinder barrel.
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
5-62 3121262
9
6****
20***
24
9
1
10
8**
4
3
8** 15
16
12
5
14
13 11 19
18
13 21
21
7*
2
9
* Torque to 85 ft.lbs.(115 Nm)

**Torque to 9 ft.lbs.(12 Nm)
***Torque to 12-15 ft.lbs. (16-20 Nm) 1684081-F
****Torque to 30-35 ft.lbs. (41-48 Nm) MAF11000F
1. Barrel 6. Counterbalance Valve 11. Wear Ring 16. O-ring 21. Washer Ring
2. Rod 7. Capscrew 12. Backup Ring 17. Wiper
3. Piston 8. Bolt 13. Lock Ring 18. Seal
4. Bushing 9. Bearing 14. Backup Ring 19. Rod Seal
5. Head 10. Plug 15. O-ring 20. Bleeder Valve
Figure 5-32. Axle Lockout Cylinder (SN 0300209000 through 0300239674)
3121262 5-63
19
20
17****
18*** 18
1
19
14
20
9
15**
13
12
13
11
6
10
11 7
8
3 5
4
16*
2
19
19
* Torque to 85 ft.lbs.(115 Nm)
**Torque to 9 ft.lbs.(12 Nm)
***Torque to 12-15 ft.lbs. (16-20 Nm)
1001228019-B
****Torque to 30-35 ft.lbs. (41-48 Nm) MAF11010B
1. Barrel 6. Wear Ring 11. Lock Ring 16. Capscrew

2. Rod 7. O-ring 12. O-ring 17. Cartridge Valve
3. Piston 8. Backup Ring 13. Backup Ring 18. Bleeder Valve
4. Wiper 9. Piston 14. Bushing 19. Bearing
5. Rod Seal 10. Seal 15. Bolt 20. O-ring plug
Figure 5-33. Axle Lockout Cylinder (SN 0300239675 to Present)
5-64 3121262
9. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
10. Loosen and remove the capscrews which attach the vent.




distortion. Dress piston surface or replace piston as nec-
essary.
7. Inspect threaded portion of piston for damage. Dress

Figure 5-34. Tapered Bushing Removal
8. Inspect seal and o-ring grooves in piston for burrs and

piece of the tapered bushing. Progressively tighten the
capscrews until the bushing is loose. 9. Inspect cylinder head inside diameter for scoring or
12. Remove the tapered bushing from the piston. necessary.
13. By hand, screw the piston counterclockwise and remove 10. Inspect threaded portion of head for damage. Dress
it from cylinder rod. threads as necessary.
14. Remove and discard the piston o-rings, seal rings, and 11. Inspect seal and o-ring grooves in head for burrs and
backup rings.
15. Remove the rod from the holding fixture. Remove the
the cylinder head.
3121262 5-65

assembly.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
be replaced.

WHEN INSTAL LING NEW S EALS, ENSURE SEALS ARE




5-66 3121262



capscrews.
rod to the rod end.

diameter groove.



3121262 5-67
12. Remove the cylinder rod from the holding fixture. 14. Position the cylinder barrel in a suitable holding fixture.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTA- ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
TION. IMPROPER SEAL INSTALLATION COULD RESULT IN PISTON AND CYLINDER BARREL SURFACES.
CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERA-
TION.
inder. Ensure that the piston seals are not damaged or
dislodged.
17. Secure the cylinder head gland using the washer ring,
Torque to 85 ft.lbs. (115 Nm).
Figure 5-42. Hydrolock Piston Seal Installation
13. Place new hydrolock seals in the outer piston diameter

grooves. (A tube, with I.D. slightly larger than the O.D.of
the piston is recommended to install the seal.)
19. Install the counterbalance valves in the rod port block.

Torque 30-35 ft.lbs. (41-48 Nm).
20. If removed, install the bleeder valve. Torque

12 to 15 ft.lbs. (16 to 20 Nm).
Figure 5-43. Piston Seal Installation
5-68 3121262
Jib Level Cylinder (SN 0300209000 through 5. Mark cylinder head and barrel with a center punch for
0300239990) inder head retainer capscrews, and remove capscrews
DISASSEMBLY



SURE.
2. Operate the hydraulic power source and extend the cyl- Figure 5-46. Cap Screw Removal
Adequately support the cylinder rod, if applicable.
PROTECTED ROD CLAMP

ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
3121262 5-69
21** 22
19
19
20**
22
10* 18
9
14 17
13 3
17
18
15
16
12
11
4
5
6
7 2
8***
19 ** Torque 50-55 ft.lbs. (68-75 Nm)
*** Torque 170 ft.lbs. (230 Nm)
1001118142-C
1001139998-B
MAF11020
1. Barrel 7. Washer Ring 13. O-ring 19. Bushing

2. Rod 8. Capscrew 14. Backup ring 20. Holding Valve
3. Piston 9. Tapererd Bushing 15. O-ring 21. Counterbalance Valve
4. Head 10. Bolt 16. Spacer 22. Plug
5. Rod Seal 11. Wear Ring 17. Seal
6. Rod Wiper 12. Backup Ring 18. Guide Ring
Figure 5-48. Jib Level Cylinder
5-70 3121262
CLEANING AND INSPECTION

vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Loosen and remove the capscrews which attach the
tapered bushing to the piston. 2. Inspect the cylinder rod for scoring, tapering, ovality, or




essary.

Figure 5-49. Tapered Bushing Removal threads as necessary.

10. Insert the capscrews in the threaded holes in the outer sharp edges. Dress applicable surfaces as necessary.
11. Remove the tapered bushing from the piston.
necessary.
it from cylinder rod.
13. Remove and discard the piston o-rings, seal rings, and
11. Inspect seal and o-ring grooves in head for burrs and
backup rings.
14. Remove the piston spacer from the rod.
the cylinder head.
3121262 5-71

assembly.
be replaced.





5-72 3121262



capscrews.
rod to the rod end.
5. Push the spacer onto the rod.
diameter groove.

3121262 5-73
WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
TION. IMPROPER SEAL INSTALLATION COULD RESULT IN
TION.
dislodged.

5-74 3121262
Jib Level Cylinder (SN 0300239991 to Present) 5. Unscrew cylinder head with hook spanner wrench.
DISASSEMBLY
CYLINDER BARREL
SPANNER NUT

HOOK SPANNER
ROD
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING
PRESSURE.
MAF07790

Figure 5-61. Cylinder Head Removal
6. Attach a suitable pulling device to the cylinder rod port-
block end or cylinder rod end, as applicable.
4. Place the cylinder barrel into a suitable holding fixture.
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND
CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN
ROD SUPPORT REMOVING CYLINDER ROD, HEAD, AND PISTON.
PROTECTED ROD CLAMP
7. Clamp barrel securely. Unscrew cylinder head and pull
rod assembly from barrel.
BARREL CLAMP
8. Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
3121262 5-75
19
18* 17 17
19 19
19
18*
13
12
16
14 15
7
8
9
11
3**
5
6
10 4
2 *Torque to 50-55 ft.lbs. (68-75 Nm)

17 **Torque to 835-84 ft.lbs.(1138-114 Nm)
17
1001228043-B
MAF11030B
1. Barrel 7. Wear Ring 13. Piston Seal 19. Plug

2. Rod 8. O-ring 14. O-ring
3. Head 9. Backup Ring 15. Setscrew
4. Rod Wiper 10. Retainer Ring 16. Steel ball
5. Rod Seal 11. O-ring 17. Bushing
6. Backup Ring 12. Piston 18. Counterbalance Valve
Figure 5-63. Jib Level Cylinder
5-76 3121262
9. Using suitable protection, clamp cylinder rod in a vise or 14. Remove rod from holding fixture and remove cylinder
similar holding fixture as close to piston as possible. head (3).
10. Loosen and remove the setscrew (16) and Steel ball (15) 15. Remove and discard wear ring (7), wiper seals (4),
which attaches the piston to the rod. retainer ring (10), backup ring (6) and rod seal (5) from
inside of cylinder head (3).
11. Screw the piston (12) counterclockwise and remove the
piston from cylinder rod (2). 16. Remove and discard O-ring (8), backup ring (9) and
O-ring (11) from outside groves of cylinder head (3).
ROD
PISTON
8
9 7
5
6
STEEL BALL 3
SETSCREW 11 4
MAF07710
10
MAF07730
Figure 5-64. Piston Removal
Figure 5-66. Cylinder Head Disassembly
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY.

DO NOT USE A KNIFE, SHARP OBJECT, OR SCREW DRIVER.
MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING
FOR PROPER INSTALLATION.
12. Remove and discard the piston seal (13) from outside
grooves of piston (12).
13. Remove and discard the o-ring (14) from inside grooves
of piston (12).
12
13
14
MAF07720
Figure 5-65. Piston Seal Disassembly
3121262 5-77
1. Clean parts thoroughly with approved cleaning solvent.
2. Inspect cylinder rod for scoring, tapering, ovality, or



Figure 5-67. Bushing Installation
14. Inspect spacer for burrs and sharp edges. If necessary,
5. Inspect threaded portion of barrel for damage. Dress dress inside diameter surface with Scotch Brite or equiv-
threads as necessary. alent.
15. Inspect port block fittings and holding valves. Replace
6. Inspect piston surface for damage, scoring, or distortion. as necessary.
Dress piston surface or replace piston as necessary.
16. Inspect oil ports for blockage or presence of dirt or other
7. Inspect threaded portion of piston for damage. Dress foreign material. Repair as necessary.
8. Inspect seal and O-ring grooves in piston for burrs and

sharp edges. Dress surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring or

other damage, and for ovality and tapering. Replace as
necessary.

11. Inspect seal and O-ring grooves in head for burrs and-
12. Inspect cylinder head outside diameter for scoring,

damage, ovality, and tapering. Replace as necessary.
13. Inspect rod and barrel bearings for signs of correct

excessive wear or damage. Replace as necessary.

etc. to facilitate bearing installation.

be replaced.

d. Press bushing in barrel or rod bushing with correct

size arbor.
NOTE: Lubrication is not required with nickel plated pins and

bearings. Install pin in composite bushing dry.
5-78 3121262
ASSEMBLY 4. Install o-ring (8), backup ring (9) and o-ring (11) in out-
side groves of cylinder head (3).
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER

LEAKS AND IMPROPER CYLINDER OPERATION.
NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
NOTE: Apply a light film of hydraulic oil to all components before 8

assembly. 9 7
5
1. A special tool is used to install a new rod seal into the 6
applicable cylinder head groove. 3
11 4
10
WHEN INSTALLING NE W SEALS, ENSUR E S EALS ARE MAF07730
COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER Figure 5-69. Cylinder Head Assembly
CYLINDER OPERATION.
5. Carefully install the cylinder head (3) on the rod (2),
2. Use a soft mallet to tap a new wiper seal into the appli- ensuring that the wiper seal (4), wear ring (7), backup
cable cylinder head groove. Install a new bearing into rings (6), rod seal (5) and backup rings (9) are not dam-
the applicable inside diameter of the cylinder head aged or dislodged. Push the head (3) along the rod (2) to
groove. the rod end, as applicable.
6. Using suitable protection, clamp the cylinder rod (2) in a
vise or similar holding fixture as close to piston as
WEAR
RING
possible.
7. Place new o-ring (14) in the inside diameter of the
piston (12).
WIPER
SEAL 8. Carefully thread the piston (12) on the cylinder rod (2),
CYLINDER
MALLET HEAD
ensuring that the o-ring (14) and seal (13) are not dam-
aged or dislodged.
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
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 cylin-
der head (3).
3121262 5-79
11. Place new piston seal (13) in the outer diameter of pis- 16. After the cylinder has been reassembled, the rod should
ton (12) groove. (A tube, with I.D. slightly larger than the be pushed all the way in (fully retracted) prior to the
O.D. of the piston is recommended to install the solid reinstallation of any plugs.
seal).
17. Install the plugs (19) in the cylinder ports.
18. Install two counterbalance valves (3) with new O-rings in
12 valve block. Torque to 50-55 ft-lb (68-75 Nm).
13
14
MAF07720

CYLINDER ROD, HEAD AND PISTON. AVOID PULLING THE
13. With barrel clamped secured and adequately support-

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.
der head can be inserted into the barrel cylinder.
15. Screw the cylinder head into the barrel using a hook
spanner wrench. Torque to 835-84 ft.lbs (1138-114 Nm).
HOOK SPANNER
ROD
CYLINDER
BARREL
SAPANNER NUT
Figure 5-71. Cylinder Head Tightening
5-80 3121262
Platform Level Cylinder (SN 0300209000 through 7. Using a spanner wrench, unscrew the cylinder head
from the barrel.
0300239674)
DISASSEMBLY

1. Connect a suitable auxiliary hydraulic power source to 9. With the barrel clamped securely, carefully withdraw the
the cylinder port block fitting. complete rod assembly from the cylinder barrel.
ROD SUPPORT
SUPPORT TABLE
SURE.

3. Remove the cylinder length sensor from the cylinder.

See Section 5.4, Cylinder Length Sensor.

ROD SUPPORT
PROTECTED ROD CLAMP
BARREL CLAMP
SUPPORT TABLE
6. Remove the self-tapping screw from cylinder barrel.
3121262 5-81
22
23
25
18 28 24
26
27
26
21
1
20 20
19**
18
20
20
19
12*
11
13
14
4
14
13
15
16
15 8
17 9
10
3
5
6
7
18
* Torque to 9 ft.lbs. (12 Nm)

**Torque to 30 -35 ft.lbs. (41-48 Nm)
2
18
1001139999-D
MAF11040D
1. Barrel 7. Rod Wiper 13. Lock Ring 19. Counterbalance Valve 25. Sensor Magnet
2. Rod 8. Backup Ring 14. Seal 20. Plug 26. Spacer Sleeve
3. Head 9. O-rings 15. Backup Ring 21. Setscrew 27. Magnet Sensor
4. Piston 10. O-ring 16. O-ring 22. Capscrew 28. Internal Retaining Ring
5. Wear Ring 11. Tapered Bushing 17. Spacer 23. Retainer cap
6. Rod Seal 12. Bolt 18. Bushing 24. Cylinder length Sensor
Figure 5-74. Platform Level Cylinder
5-82 3121262




essary.
Figure 5-75. Tapered Bushing Removal 7. Inspect threaded portion of piston for damage. Dress
12. Insert the capscrews in the threaded holes in the outer 8. Inspect seal and o-ring grooves in piston for burrs and
piece of the tapered bushing. Progressively tighten the sharp edges. Dress applicable surfaces as necessary.
capscrews until the bushing is loose.
13. Remove the tapered bushing from the piston. other damage and for ovality and tapering. Replace as
necessary.
it from cylinder rod.
backup rings.
16. Remove the piston spacer from the rod.
17. If necessary, remove the retaining ring, sensor magnet,

and spacer sleeve from the cylinder rod.
cylinder head gland and discard all seals on the cylinder
head.
3121262 5-83

assembly.
be replaced.





5-84 3121262



capscrews.
rod to the rod end.
diameter groove.

3121262 5-85
13. If removed, install the spacer sleeve, sensor magnet, and 16. Position the cylinder barrel in a suitable holding fixture.
retaining ring.
14. Remove the cylinder rod from the holding fixture.

WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE PISTON AND CYLINDER BARREL SURFACES.
SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK
PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTA- 17. With barrel clamped securely, and while adequately sup-
TION. IMPROPER SEAL INSTALLATION COULD RESULT IN porting the rod, insert the piston end into the barrel cyl-
CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERA- inder. Ensure that the piston seals are not damaged or
TION. dislodged.
19. Screw the cylinder head gland into the barrel using a
spanner wrench.
Figure 5-83. Hydrolock Piston Seal Installation Torque 30 to 35 ft.lbs. (41-48 Nm).
22. Install the cylinder length sensor. See Section 5.4, Cylin-
der Length Sensor.
5-86 3121262
Platform Level Cylinder (SN 0300239675 to 6. Unscrew cylinder head with hook spanner wrench.
Present)
DISASSEMBLY CYLINDER BARREL
SPANNER NUT
HOOK SPANNER
cylinder port fitting.
ROD
D O N OT F U L LY E X T E N D C YL I N D E R TO T H E E N D O F
STROKE.RETRACT CYLINDER SLIGHTLY TO AVOID TRAP- MAF07850
PING PRESSURE.
Figure 5-86. Cylinder Head Installation
2. Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately 7. Attach a suitable pulling device to the cylinder rod end.
support cylinder rod, if applicable.
See Section 5.4, Cylinder Length Sensor. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
4. Remove the counterbalance valves from the cylinder ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
port block. Discard o-rings. PISTON AND CYLINDER BARREL SURFACES.
5. Place cylinder barrel in a suitable holding fixture.
8. Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
ROD SUPPORT 9. Protect cylinder rod from damage and clamp in a vise or
PROTECTED ROD CLAMP
BARREL CLAMP ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
3121262 5-87
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 ft.lb. (13 Nm)
**Torque to 30-35 ft.lb.(41-47 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 5-88. Platform Level Cylinder Assembly
5-88 3121262
10. Loosen and remove Capscrews (13) from tapered bush-

ing (14) and piston (17).
15
11. Insert capscrews (13) in threaded holes in outer piece of 16
tapered bushing (14). Progressively tighten capscrews
15
(13) until tapered bushing (14) is loose. Remove tapered
bushing (14) from piston (17).
TAPERED BUSHING
17
18
19
ROD 18
20
Figure 5-90. Piston Disassembly

PISTON
15. Remove cylinder rod (28) from holding fixture. Remove

CAPSCREWS cylinder head (24).
MAF09940 16. Remove and discard backup ring (21), O-ring (22), O-ring
Figure 5-89. Tapered Bushing Removal (23), rod wiper (27), seal (26), and two wear rings (25),
from cylinder head (24).
12. Screw piston (17) counter-clockwise by hand and
remove from cylinder rod (28).

DO NOT USE A KNIFE, SHARP OBJECT, OR SCREW DRIVER.
FOR PROPER INSTALLATION. 21
22
13. Remove and discard two guidelock ring (15), lock rings
(16), backup rings (18), O-ring (19) from piston (17). 23
14. Remove piston spacer (20) from cylinder rod (28).

24
25
26
27 MAF08020
Figure 5-91. Cylinder Head Disassembly
3121262 5-89
CLEANING AND INSPECTION NOTE: Lubrication is not required with nickel plated pins and



Figure 5-92. Composite Bushing Installation
threads as necessary. 15. Inspect port block fittings and holding valve. Replace as
necessary.
6. Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary. 16. Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.
threads as necessary. ASSEMBLY
JLG Parts Manual.
Apply a light film of hydraulic oil to all components before
assembly.
necessary.
10. Inspect threaded portion of head for damage. Dress IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER
threads as necessary. LEAKS AND IMPROPER CYLINDER OPERATION.
11. Inspect seal and O-ring grooves in head for burrs and 1. Install O-ring (23), O-ring (22), and backup ring (21) in
sharp edges. Dress applicable surfaces as necessary. outside diameter grooves of cylinder head (24).
12. Inspect cylinder head outside diameter for scoring, 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.
14. Inspect rod and barrel bearings for signs of excessive

wear or damage. Replace as necessary.


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

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

rect size arbor.
5-90 3121262
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
8. Thread piston (17) on cylinder rod (28) until it aligns with

spacer (20) end and install tapered bushing (14).
9. Apply JLG Threadlocker PN 0100011 or equivalent to
tapered bushing capscrews (13) and assemble the
21 tapered bushing (14) loosely into the piston (17. Insert
22 capscrews (13) through the drilled holes in the tapered
bushing (14) and into the tapped holes in the piston
23 (17). Insert capscrews (13) through the drilled holes in
the tapered bushing (14) and into the tapped holes in
24 the piston (17).
25
26
27 MAF08020
Figure 5-93. Cylinder Head Seal Kit Installation
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 10. Tighten the capscrews (13) evenly and progressively in
rotation to 9 ft. lbs. (13 Nm).
15
capscrews.
b. Tap each space once; this means the tapered bush-
the capscrews.
17
18
19
18
20
Figure 5-94. Piston Seal Kit Installation
6. Using suitable protection, clamp cylinder rod (28) in a

vise or similar holding fixture as close to piston (17) as
possible.
7. Thread piston (17) on cylinder rod (28) hand tight.

Ensure O-ring and back-up rings are not damaged or
dislodged.
3121262 5-91
HOOK SPANNER
SAPANNER NUT
CYLINDER
BARREL
ROD
12. Retorque the capscrews evenly and progressively in Figure 5-97. Cylinder Head Tightening
rotation to 9 ft. lbs. (13 Nm).
19. Install the plugs (12) in the cylinder ports.
13. Install two counterbalance valves (2) with new O-rings in
valve block. Torque to 30-35 ft-lb (41-47 Nm).
14. If removed, install the cylinder length sensor. See Sec-
tion 5.4, Cylinder Length Sensor.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND

INSTALLING CYLINDER ROD, HEAD, AND PISTON.
15. Clamp barrel (3) securely and support cylinder rod (28).
16. Insert piston (17) end into cylinder barrel (3). Do not
damage or dislodge piston loading O-ring and seal ring.
17. Continue pushing cylinder rod (28) into cylinder
barrel (3) until cylinder head (24) gland can be inserted
into cylinder barrel (3).
18. Tighten cylinder head with hook spanner wrench.
5-92 3121262
Boom Lift Cylinder (SN 0300209000 through 5. Mark cylinder head and barrel with a center punch for
0300239990) inder head retainer capscrews, and remove capscrews
DISASSEMBLY



SURE.
3. Remove the check valve, counterbalance valve, and
pressure regulator valve from the cylinder port block.
Discard o-rings.
PROTECTED ROD CLAMP

BARREL CLAMP
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
3121262 5-93
19
22***
19
1
21*
20***
7**
23 18
13
12
17
16
12
13
14
15
14
11
15
10
9
8
3
5
4 2
6
7****
* Torque 25-27 ft.lbs. (34-37 Nm)

19 ** Torque to 60 ft.lbs. (81 Nm)
*** Torque 30-35 ft.lbs. (41-47 Nm)
**** Torque 300 ft.lbs. (410 Nm)
19
1001118442-D
MAF11060D
1. Barrel 7. Capscrew 13. Lock Ring 19. Bushing

2. Rod 8. Wear Ring 14. Backup Ring 20. Check Valve
3. Head 9. Backup Ring 15. O-ring 21. Pressure Regulator Valve
4. Wiper 10. O-ring 16. Wear Ring 22. Cartridge Valve
5. Rod Seal 11. Spacer 17. Piston 23. O-ring
6. Ring Washer 12. Guide Ring 18. Tapered Bushing
Figure 5-101. Boom Lift Cylinder
5-94 3121262

vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Loosen and remove the capscrews which attach the
tapered bushing to the piston. 2. Inspect the cylinder rod for scoring, tapering, ovality, or




essary.

necessary.
it from cylinder rod. 10. Inspect threaded portion of head for damage. Dress
backup rings. 11. Inspect seal and o-ring grooves in head for burrs and
14. Remove the piston spacer from the rod. Remove and sharp edges. Dress applicable surfaces as necessary.
discard the o-ring inside the piston spacer.
the cylinder head.
3121262 5-95

assembly.
be replaced.





5-96 3121262
3. Place a new O-ring and backup ring in the outside diam-

eter groove of the cylinder head.


capscrews.
rod to the rod end.
5. Place a new O-ring into the spacer and push the spacer
onto the rod.
diameter groove.

3121262 5-97
TION.
dislodged.

20. Install the check valve in the rod port block. Torque
30-35 ft.lbs. (41-47 Nm).
21. Install the counterbalance valve in the rod port block.
22. Install the pressure regulator valve in the rod port block.
5-98 3121262
Boom Lift Cylinder (SN 0300239991 to Present) .
DISASSEMBLY
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEM-

BLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE
WORK AREA.

cylinder port block fitting.

SURE. Figure 5-114. Cap Screw Removal
2. Operate hydraulic power source and extend cylinder.

Shut down and disconnect power source. Adequately
support cylinder rod, if applicable. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND
3. If applicable, remove cartridge-type counterbalance CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN
valve and fittings from cylinder port block. Discard REMOVING CYLINDER ROD, HEAD, AND PISTON.
Orings.
6. Clamp barrel securely. Unscrew cylinder head and pull
4. Place cylinder barrel in a suitable holding fixture. Tap rod assembly from barrel.
around outside of cylinder head retainer with a suitable
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. Mark cylinder head and barrel with center punch marks
for later realignment. Remove cylinder head cap screws
3121262 5-99
19
20
9 9
9 21
1
9 9 19
22
15 17 18
16
15
6
4
10
13 12
14
3
10
7 11
8*
19 2
19 1001228045-B
MAF11070B
1. Barrel 7. Washer 13. O-ring 19. Bushing

2. Rod 8. Capscrew 14. Backup Ring 20. Cartridge Valve
3. Head 9. O-ring Plug 15. Wear Ring 21. Pressure Regulator Valve
4. Piston 10. Wear Ring 16. Piston Seal 22. Check Valve
5. Spacer 11. Wiper 17. Backup Ring
6. Screw 12. Rod Seal 18. O-ring
Figure 5-116. Boom Lift Cylinder
5-100 3121262
8. Using suitable protection, clamp cylinder rod in a vise or

similar holding fixture as close to piston as possible.
9. Remove setscrews attaching piston to cylinder rod.
10. Screw the piston counterclockwise by hand and remove 10
piston from cylinder rod.
12
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. 13

DO NOT USE A KNIFE, SHARP OBJECT, OR SCREW DRIVER. 14
FOR PROPER INSTALLATION.
3
11. Remove and discard piston seal (16) and wear ring (15) 10
from outside grooves of piston (4).
11
MAF11970
12. Remove spacer (5) from rod (2).
13. Remove and discard backup ring (17) and o-ring (18) Figure 5-118. Cylinder Head Disassembly
from inside of piston (4).
16. Remove and discard o-ring (13) and backup ring (14)
17 18 from outside of cylinder head (3).
15
16 CLEANING AND INSPECTION
15
6
4 other damage. If necessary, dress rod with Scotch Brite



MAF11960 threads as necessary.
Figure 5-117. Piston Diassembly
14. Remove rod (2) from holding fixture. Remove cylinder
head (3) from rod (2).
15. Remove and discard wear ring (10), wiper (11) and rod
seal (12) from inside of cylinder head (3). 8. Inspect seal and O-ring grooves in piston for burrs and

necessary.

11. Inspect seal and O-ring grooves in head for burrs and
12. Inspect cylinder head outside diameter for scoring,

3121262 5-101
13. Inspect rod and barrel bearings for signs of correct ASSEMBLY
a. Thoroughly clean hole, (steel bushing) of burrs, dirt JLG Parts Manual.
b. Inspect steel bushing for wear or other damage. If Apply a light film of hydraulic oil to all components before
steel bushing is worn or damaged, rod/barrel must assembly.
be replaced.
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER
NOTE: Lubrication is not required with nickel plated pins and LEAKS AND IMPROPER CYLINDER OPERATION.
1. Install o-ring (13) and backup ring (14) on outside of cyl-
d. Press bushing into barrel or rod bushing with cor- inder head (3).
rect size arbor.
2. Install wear ring (10), wiper (11) and rod seal (12) in
10
12
13
Figure 5-119. Bushing Installation 14
14. Inspect port block fittings and holding valves. Replace 3

as necessary. 10
15. Inspect oil ports for blockage or presence of dirt or other 11
MAF11970
Figure 5-120. Cylinder Head Assembly
3. Carefully install cylinder head assembly (3) on rod (2). Do

not damage or dislodge wiper and rod seals. Push head
along rod to rod end.
4. Install O-ring (18) and backup ring (17) into the spacer
(5) and Carefully slide spacer (5) onto rod (2) with O-ring
(18) end facing cylinder head. Ensure that O-ring not
damage and dislodge.
5. Install wear ring (15) and piston seal (16) on outside of
piston(4) groove.
5-102 3121262
15 17 18
16 CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN
INSTALLING CYLINDER ROD, HEAD AND PISTON.
15
6
8. Clamp barrel (1) securely and support rod (2). Insert pis-
4 ton (4) end in barrel. Do not damage or dislodge piston
O-rings or seal rings.
9. Continue pushing rod in barrel until cylinder head (3)
can be inserted in barrel.
10. Install cylinder head (3) until tight and marks made dur-
ing disassembly are aligned.
11. Secure cylinder head assembly (3) to barrel (1) with cap-
screws (8). Torque to 356 ft-lb (483-Nm).
MAF11960
Figure 5-121. Piston Assembly
6. Install the setscrew on the piston (10) and attach the pis-
ton (10) on the rod (2).
7. Position cylinder barrel (1) in a suitable holding fixture.
3121262 5-103
Jib Lift Cylinder 6. Mark cylinder head and barrel with a center punch for
DISASSEMBLY inder head retainer capscrews, and remove capscrews



SURE.

Adequately support the cylinder rod, if applicable. Figure 5-123. Cap Screw Removal

See Section 5.4, Cylinder Length Sensor.
4. Remove the counterbalance valve and holding valve
from the cylinder port block. Discard o-rings. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
PROTECTED ROD CLAMP 8. With the barrel clamped securely, carefully withdraw the
BARREL CLAMP
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
5-104 3121262
21
19
22 25 23
7 24
29
21 28
18 26
27
26
1
19
21
20
9
4
13
14
11
14
13
15
16
15
16
12
17 10
3
5
6
7
8
9
19
19
1001140104-D
MAF11080D
1. Barrel 8. Washer Ring 15. Backup Rings 22. Setscrew 29. Cylinder Length Sensor
2. Rod 9. Capscrew 16. O-ring 23. Bolt
3. Head 10. Backup Ring 17. Spacer 24. Retainer Cap
4. Tapered Bushing 11. Piston 18. Counterbalance Valve 25. Screw
5. Wear Ring 12. O-ring 19. Bushing 26. Sleeve Spacer
6. Rod Seal 13. Lock Ring 20. Holding valve 27. Magnet Sensor
7. Rod Wiper 14. Spacer Sleeve 21. Plug 28. Retainer Ring
Figure 5-125. Jib Lift Cylinder (SN 0300209000 through 0300239990)
3121262 5-105
20
24 25 15
21 22
20 28 23
20 26
18 20 26 27
1
21
19
20
15
14
11
10
9
10
13 11
12
13
12
16
7
8
3
6
5
4
17
15
21
21
1001228058-B
MAF11090B
1. Barrel 8. Backup Ring 15. Capscrew 22. Retainer Cap

2. Rod 9. Piston 16. Spacer 23. Sensor Cylinder Length
3. Head 10. Lock Ring 17. Washer Ring 24. Compound Locking
4. Wiper 11. Guide Ring 18. Counter Balance Valve 25. Bolt
5. Rod Seal 12. O-ring 19. Holding Valve 26. Sleeve Spacer
6. Wear Ring 13. Backup Ring 20. Plug 27. Magnet Sensor
7. O-ring 14. Tapered Bushing 21. Bushing 28. Retainer Ring
Figure 5-126. Jib Lift Cylinder (SN 0300239991 to Present)
5-106 3121262




essary.
Figure 5-127. Tapered Bushing Removal 7. Inspect threaded portion of piston for damage. Dress
necessary.
it from cylinder rod. 10. Inspect threaded portion of head for damage. Dress
backup rings. 11. Inspect seal and o-ring grooves in head for burrs and
15. Remove the piston spacer from the rod. Remove and
discard the o-ring inside the piston spacer.
16. If necessary, remove the retaining ring, sensor magnet,

and spacer sleeve from the cylinder rod.
the cylinder head.
3121262 5-107

assembly.
be replaced.





5-108 3121262


tion.

capscrews.
rod to the rod end.
5. Place a new O-ring into the spacer and push the spacer
onto the rod.
diameter groove.

rotation.
3121262 5-109
TION.
dislodged.

20. Install the holding valve and counterbalance valve in the
rod port block.
21. Install the cylinder length sensor. See Section 5.4, Cylin-
der Length Sensor.
5-110 3121262
Jib Lock Cylinder

DISASSEMBLY


. .
SURE. Mark For Reassembly

Figure 5-139. Cylinder Head Removal
ROD SUPPORT
PROTECTED ROD CLAMP

BARREL CLAMP CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE

ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
Figure 5-138. Cylinder Barrel support
4. Using a spanner wrench, unscrew the cylinder head

from the barrel.
3121262 5-111
8. Using suitable protection, clamp the cylinder rod in a 6. Inspect seal and o-ring grooves on piston for burrs and
vise or holding fixture as close to the piston as possible. sharp edges. Dress applicable surfaces as necessary.
9. Remove and discard the piston wear ring and t-seal. 7. Inspect cylinder head inside diameter for scoring or
necessary.
cylinder head gland and discard all seals on the cylinder
head. 8. Inspect threaded portion of head for damage. Dress
1. Clean all parts thoroughly in an approved cleaning sol- sharp edges. Dress applicable surfaces as necessary.
vent.
10. Inspect cylinder head outside diameter for scoring or
2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage and ovality and tapering. Replace as nec-
other damage. If necessary, dress rod with Scotch Brite essary.
3. Inspect inner surface of cylinder barrel tube for scoring or other foreign material. Repair as necessary.
ovality. Replace if necessary. 12. If applicable, inspect piston rings for cracks or other
distortion. Dress piston surface or replace piston and
rod assembly as necessary.
5-112 3121262
10
11
7
8
9
3
5
6
1001119313-C
1001228046-B
MAF11100
1. Barrel 4. Wear Ring 7. O-ring 10. Wear Ring

2. Rod 5. Seal 8. Backup Ring 11. Seal
3. Head 6. Rod Wiper 9. O-ring
Figure 5-141. Jib Lock Cylinder
3121262 5-113
ASSEMBLY 3. Place a new O-rings and backup ring in the outside

diameter groove of the cylinder head and new wear
NOTE: Prior to cylinder assembly, ensure that the proper cylinder rings and polyseal in the inside diameter grooves of the
seal kit is used. See your JLG Parts Manual. cylinder head.
4. Carefully install the head gland on the rod, ensuring that
Apply a light film of hydraulic oil to all components prior to
the wiper and rod seals are not damaged or dislodged.
assembly.
Push the head along the rod to the rod end.
1. A special tool is used to install a new rod seal into the 5. Place a new wear ring and t-seal in the outer piston
applicable cylinder head gland groove. diameter grooves. (A tube, with I.D. slightly larger than
WHEN I NSTALLI NG NEW SEALS, ENSURE SEALS ARE Figure 5-144. Piston Seal Installation
COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER 6. Position the cylinder barrel in a suitable holding fixture.
CYLINDER OPERATION.
2. Use a soft mallet to tap a new wiper seal into the cylin-
der head gland groove. Install a new wear ring into the
5-114 3121262


dislodged.
. .
Figure 5-145. Cylinder Head Installation
9. Apply anti-seize lubricant to the threads and screw the

cylinder head gland into the barrel using a spanner
wrench.
3121262 5-115
Steer Cylinder 4. Mark cylinder cap and barrel with a center punch for
easy realignment. Unscrew the cylinder cap from the
DISASSEMBLY barrel.



SURE.

inder. Shut down and disconnect the power source. Figure 5-147. Cylinder Cap Removal
ROD SUPPORT
PROTECTED ROD CLAMP
BARREL CLAMP PISTON AND CYLINDER BARREL SURFACES.

ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
5-116 3121262
15
1
15
10
11
5* 10
6
4
3
14 12
13
9
8
7
15
* Torque to 401 ft.lbs. (545 Nm) 15 1684314-F

MAF11110F
1. Barrel 6. Wiper 11. Piston

2. Rod 7. Piston Seal 12. O-ring
3. Cylinder Cap 8. Backup Ring 13. Wear Ring
4. Head 9. O-ring 14. O-ring
5. Nut 10. Wear Ring 15. Bushing
Figure 5-149. Steer Cylinder (SN 0300209000 through 0300238017)
3121262 5-117
15
15 1
16
11* 12
16
10
5
7
13 14
9
6
2 15
15
* Torque to 401 ft.lbs. (545 Nm) 1001228031-A

MAF11120A
1. Barrel 5. Wiper 9. Backup Ring 13. Wear Ring

2. Rod 6. Rod Seal 10. Piston 14. O-ring
3. Head 7. Wear Ring 11. Nut 15. Bushing
4. Cylinder Cap 8. O-ring 12. Piston Seal 16. Plug
Figure 5-150. Steer Cylinder (SN 0300238018 to Present)
5-118 3121262
8. Using suitable protection, clamp the cylinder rod in a c. Lubricate inside of the steel bushing with WD40
vise or holding fixture as close to the piston as possible. prior to bearing installation.
9. Loosen and remove the lock nut that secures the piston d. Using an arbor of the correct size, carefully press the
to the cylinder rod. bearing into steel bushing.
10. Remove the piston from the cylinder rod. NOTE: Install pin into the composite bearing dry. Lubrication is
11. Remove and discard the piston o-rings, seal rings, and t-
seal.
cylinder head. Discard all seals on the cylinder head.

vent.
or equivalent. Replace rod if necessary. Figure 5-151. Composite Bearing Installation

Dress threads as necessary. 14. Inspect the oil ports for blockage or the presence of dirt
or other damage. Check inside diameter for tapering or 15. If applicable, inspect piston rings for cracks or other
ovality. Replace if necessary. damage. Replace as necessary.
5. Inspect threaded portion of barrel for damage. Dress ASSEMBLY

NOTE: Prior to cylinder assembly, ensure that the proper cylinder
6. Inspect piston surface for damage and scoring and for seal kit is used. See your JLG Parts Manual.
essary. Apply a light film of hydraulic oil to all components prior to
assembly.
1. A special tool is used to install a new rod seal into the
8. Inspect seal and o-ring grooves in piston for burrs and applicable cylinder head gland groove.
necessary.
12. Inspect cylinder head outside diameter for scoring or
essary.
correct excessive wear or damage. Replace as necessary. Figure 5-152. Rod Seal Installation

be replaced.
3121262 5-119
10. Place a new wear ring and t-seal in the outer piston
diameter grooves. (A tube, with I.D. slightly larger than
WHEN I NSTALLI NG NEW SEALS, ENSURE SEALS ARE the O.D.of the piston is recommended to install the seal.)
CYLINDER OPERATION.

2. Use a soft mallet to tap a new wiper seal into the cylin- EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
der head gland groove. Install new wear rings into the CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
cylinder head gland groove. ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
3. Place a new O-ring and backup ring in the outside diam- PISTON AND CYLINDER BARREL SURFACES.
4. Place the cylinder cap over the rod and carefully install porting the rod, insert the piston end into the barrel cyl-
the head gland on the rod, ensuring that the wiper and inder. Ensure that the piston seals are not damaged or
rod seals are not damaged or dislodged. Push the head dislodged.
along the rod to the rod end.
5. Place a new O-ring and backup rings in the inner piston der head gland can be inserted into the barrel cylinder.
diameter groove.
14. Secure the cylinder head using JLG Threadlocker
6. Using suitable protection, clamp the cylinder rod in a PN 0100035 and the cylinder cap.
threads as possible. 15. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted).
7. Install the piston on the cylinder rod hand tight, ensur-
ing that the o-ring and back-up rings are not damaged
or dislodged.
8. Carefully thread the lock nut onto the rod to secure the
piston in place. Torque to 401 ft.lbs. (545 Nm).
5-120 3121262
Jib Telescope Cylinder INSPECTION

1. Inspect all seals, backup rings, wipers, and wear rings for
tears, grooves, foreign matter, and excessive wear. Deep
grooves may be an indication of damage to the barrel
USE CARE IN REMOVAL OF ANY, AND ALL, COMPONENTS
bore, rod chrome, or the presence of large particle con-
AS COUNTERBALANCE VALVES MAY RETAIN CONSIDER-
tamination.
ABLE PRESSURE WITHIN THE CYLINDER ASSEMBLY. USE
EXTREME CARE REMOVING PLUGS, VALVES, AND/OR THE 2. Remove the seals, backup rings, wipers, and wear rings
ROD ASSEMBLY TO ENSURE THE INTERNAL CYLINDER using a soft metal tool (brass or aluminum) with
PRESSURE HAS BEEN RELIEVED. rounded edges. Use care not to nick or score the sur-
faces of any component, especially the seal grooves.
NOTE: The jib telescope cylinder weighs approximately 130.5 lbs. 3. Wipe all components clean with a lint-free cloth. Plug
(59.2 kg). the barrel opening with a lint-free cloth. Remove any
adhesive remnants from the head gland, barrel, rod, and
DISASSEMBLY piston threads (where applicable) using a soft wire
brush. Use care not to scratch or otherwise damage the
1. Retract cylinder and support equipment to allow for cyl- critical surfaces of any component including seal
inder removal. Relieve system pressure to the cylinder. grooves, barrel bore, rod chrome, etc.
Clean any debris from around both ports and remove
the hydraulic lines. Plug/cap both ports and remove cyl- 4. Inspect the piston and head gland for excessive wear,
inder from equipment. cracks, scoring, or any other damage. If wear is present
on the O.D. of the piston or the I.D. of the head gland,
2. The cylinder assembly should be secured in such a way check to ensure that the circularity of both dimensions
as to prevent movement of the barrel assembly while are within 0.007”. Beyond this limit the seal performance
removing the rod assembly. (Such as in a vise with pipe is compromised and the components must be replaced.
jaws.) Caution should be used to avoid damaging the
rod surface and to avoid excessive deformation of the 5. The stop tube should be inspected for cracking and
barrel, which could permanently damage the unit. Provi- excessive flaring of the ends.
sions must also be made to support the rod assembly 6. Closely inspect the chrome surface of the rod. Any nicks,
during its removal. gouges, or scratches that penetrate the chrome plating
or result in a sharp edge, which may damage seals, are
3. Remove all dirt, grease, and other contaminants from
cause for rod assembly replacement.
around the ports and the head gland. Drain all oil from
the unit. Extending and retracting the rod manually can 7. Flush the barrel and fluid tube (if equipped), drain, and
help purge the bulk of remaining oil. wipe dry with a lint-free cloth. Closely inspect bore for
nicks, gouges, or scratches. Replace barrel assembly if
4. Mark the orientation of the rod, gland, pad support, and any of these are present.
barrel with a permanent marker or paint pen. Do not
paint the chromed surface of the rod! Remove the cap
screws retaining the head gland from the cylinder
assembly.
NOTE: The threads are “locked” with a non-permanent thread

adhesive during assembly; a quick tug on the wrench may
be necessary to release the thread adhesive.
5. Remove the rod assembly from the barrel using care not
to damage the threads or any other components sur-
face.
6. Clamp the rod mount and support the rod assembly

with the chrome surface protected. Remove the piston
assembly by unthreading the piston itself from the rod
using a spanner wrench.
3121262 5-121
15
10
12
19
18
7
20
6
17
13
16
4
9
13
5
9 22
11 14
8 14 14 21
3
14
14
22
14
1
1001118663-F
MAF11130F
1. Barrel 7. Pad Support 13. Wear Ring 19. Nut

2. Rod 8. O-ring 14. Plug 20. Capscrew
3. Head 9. O-ring 15. Wear Ring 21. Shuttle Valve
4. Piston 10. Rod Seal 16. Piston Seal 22. Counterbalance Valve
5. Spacer 11. Backup Ring 17. Capscrew
6. Wear Pad 12. Rod Wiper 18. Lock washers
Figure 5-155. Jib Telescope Cylinder (SN 0300209000 through 0300213726)
5-122 3121262
12
14
16
23
22
17
21
18
24
10
11
13
10 21
8
9 4
8
15
7 19
6 6
3 6 6 20
5
6
6
19
7
1
1001121121-D
MAF11140D
1. Barrel 7. O-ring 13. Piston 19. Counterbalance Valve

2. Rod 8. Backup Ring 14. Rod Seal 20. Shuttle Valve
3. O-ring 9. O-ring 15. Spacer 21. Capscrew
4. Tapered 10. Wear Ring 16. Wiper Seal 22. Washer
5. Head 11. Seal 17. Bracket 23. Nut
6. Seal 12. Wear Ring 18. Wear Pad 24. Bolt
Figure 5-156. Jib Telescope Cylinder (SN 0300213727 through 0300244704)
3121262 5-123
8
7
6
4
5
18
20
16
19 13
12
17 13
11
21
19
14 23
23
22
15
9
10 24
9
23
8
3 23
21
1
1001228048-A
MAF11150A
1. Barrel 7. Backup Ring 13. Wear Ring 19. Capscrew

2. Rod 8. Wear Ring 14. O-ring 20. Nut
3. Head 9. O-ring 15. Spacer 21. Counterbalance Valve
4. Wiper 10. Backup Ring 16. Plate 22. Shuttle valve
5. Retaining Ring 11. Piston 17. Bracket 23. Plug
6. Rod Seal 12. Piston Seal 18. Setscrew
Figure 5-157. Jib Telescope Cylinder (SN 0300244705 to Present)
5-124 3121262
ASSEMBLY ROD, GLAND, PISTON ASSEMBLY
NOTE: Refer to Figure 5-158. and Figure 5-159. provided at the end 1. Lubricate I.D. of head gland assembly with hydraulic
of this procedure for the proper seal locations and orienta- fluid, and slide onto rod (rod wiper end first) using cau-
tions. Improper seal orientation will compromise perfor- tion not to damage rod wiper or seal on rod end.
mance! 2. Slide stop tube (with o-ring) onto rod. Do not scratch
rod chrome.
Inspect all components per above INSPECTION procedure.
3. For pistons with threaded I.D., apply Loctite #7471
Clean all components with a lint-free cloth. The barrel should
(Primer-T) to piston and rod threads. Allow primer to
be flushed out and drained. Compressed air may be used to
evaporate then apply two beads of Loctite #222 Thread
blow out the barrel bore and all ports. Lubricate all seals with
Adhesive axially across the threads of the piston I.D.
hydraulic fluid prior to assembly.
4. Install piston assembly onto threaded end of rod.
HEAD GLAND ASSEMBLY
Tighten piston onto rod end to 100 ft.lbs. An optional
1. Install rod seal; refer to Seal Detail for proper orientation. method for tightening threaded piston is to turn until
piston bottoms out; then set in place by hitting spanner
2. Install wear rings. wrench handle with a hammer; piston should rotate
3. Press in the rod wiper using a soft metal (brass or alumi- slightly while setting.
num) or nylon tool which contacts the wiper 360°. Make FINAL ASSEMBLY
sure the wiper remains perpendicular to the bore at all
times. 1. Make sure all rags, etc. are removed from barrel bore.
Lubricate barrel bore and piston assembly with hydrau-
4. Install the backup ring and o-ring with the backup ring lic fluid. Avoid getting any oil in barrel threads.
nearest the head gland flange.
2. Place pad support on rod assembly before installing into
PISTON ASSEMBLY barrel. Use care to avoid damaging wear rings, seals, and
rod chrome.
1. Install o-ring into groove in I.D. of piston.
3. Align rod with barrel assembly. Insert piston into barrel
2. Install one wear ring onto piston. opening. Use care to avoid damaging wear rings, seals,
3. Install piston seal into central groove on piston O.D. A and piston surface on barrel.
clean, small cross-section o-ring or a thin elastic band 4. Lubricate o-ring and backup on head gland using
may be wrapped around seal to help stretch it over pis- hydraulic fluid.
ton.
5. Align head gland with barrel assembly, position pad
4. Install remaining wear ring. support over head gland (avoid damaging the o-ring
and back-up with the pad support), and press head
gland into barrel assembly.
6. Apply a bead of Loctite #222 Thread Adhesive axially
cap screw threads.
7. Screw cap screws into head gland / barrel assembly.
3121262 5-125
Figure 5-158. Jib Telescope Cylinder Head Gland Detail
Figure 5-159. Jib Telescope Piston Detail
5-126 3121262
Main Boom Telescope Cylinder (SN 0300209000 5. Mark cylinder head and barrel with a center punch for
through 0300244704) inder head retainer capscrews, and remove capscrews
DISASSEMBLY



SURE.
3. Remove the check valves, counterbalance valves, and
relief valve from the cylinder port block. Discard o-rings.
PROTECTED ROD CLAMP

ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
3121262 5-127
24
23
22
21
22
23
24
19
20
9 14
21
9
17
11 16
18
11
13
15
12 6
9
4
5
7
8
10
2
1001119497-D
MAF11170D
1. Barrel 8. Flat Washer 15. O-Ring 22. Wear pad

2. Rod 9. Capscrew 16. Backup Ring 23. Flat Washer
3. Head 10. Valve Assembly 17. Spacer 24. Bolt
4. Rod Seal 11. Wear Ring 18. T-Seal
5. Rod Wiper 12. Backup Ring 19. Tapered Bushing
6. Bracket 13. Wear Ring 20. Piston
7. Retaining Ring 14. O-Ring 21. O-ring Plug
Figure 5-163. Boom Telescope Cylinder
5-128 3121262




essary.


11. Remove the tapered bushing from the piston. necessary.
12. By hand, screw the piston counterclockwise and remove 10. Inspect threaded portion of head for damage. Dress
it from cylinder rod. threads as necessary.
13. Remove and discard the piston o-rings, seal rings, and 11. Inspect seal and o-ring grooves in head for burrs and
backup rings.
the cylinder head.
3121262 5-129

assembly.
be replaced.





5-130 3121262

capscrews.
b. Tap each space once; this means the tapered bush-
the capscrews.
Figure 5-169. Installation of Head Seal Kit
4. Install washer ring onto rod, carefully install the head

rod to the rod end.

diameter groove.


tight, ensuring that the o-ring and back-up rings are not Figure 5-171. Seating the Tapered Bearing
3121262 5-131
12. Place a new t-seal and wear rings in the outer piston 16. Secure the cylinder head gland using the washer ring,
diameter grooves. (A tube, with I.D. slightly larger than JLG Threadlocker PN 0100011 and socket head bolts.
18. Install the check valves in the rod port block.
13. Position the cylinder barrel in a suitable holding fixture. 20. Install the relief valve in the rod port block.


dislodged.
5-132 3121262
Main Boom Telescope Cylinder (SN 0300244705 to

Present)
DISASSEMBLY


DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. Figure 5-175. Cap Screw Removal
SURE. 6. Attach a suitable pulling device to the cylinder rod end.
Adequately support the cylinder rod, if applicable. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
3. Remove the check valves, counterbalance valves, and ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
relief valve from the cylinder port block. Discard o-rings. PISTON AND CYLINDER BARREL SURFACES.
ROD SUPPORT
PROTECTED ROD CLAMP ROD SUPPORT
BARREL CLAMP
SUPPORT TABLE
SUPPORT TABLE
5. Mark cylinder head and barrel with a center punch for

easy realignment. Using an allen wrench, loosen the cyl- Figure 5-176. Cylinder Rod Support
inder head retainer capscrews, and remove capscrews
from cylinder barrel. 8. Protect cylinder rod from damage and clamp in a vise or
3121262 5-133
25
1
19
25
3
9
10
11
8 20
6
13 7
12
22
15 9
16 4
14
15 18 5
24
22 23
17
17
2
25
25
23
21
25
1001228047-B
MAF11180B
1. Barrel 8. O-ring 15. Wear Ring 22. Setscrew

2. Rod 9. Wear Ring 16. O-ring 23. Capscrew
3. Head 10. O-ring 17. Backup Ring 24. Washer
4. Wiper 11. Backup Ring 18. Spacer 25. O-ring Plug
5. Retaining Ring 12. O-ring 19. Wear Pad
6. Rod Seal 13. Piston 20. Bracket
7. Backup Ring 14. Piston Seal 21. Valve Assembly
Figure 5-177. Boom Telescope Cylinder
5-134 3121262
9. Loosen and remove the setscrew(22) which is attached

to the piston assembly.
10. Screw the piston(13) counterclockwise and remove the
piston from cylinder rod(2).
9
10
11
13 8
6
22 7
12
3
15
9
16 4
14 1
15
MAF11990
22 Figure 5-179. Cylinder Head Disassembly

17
17 15. Remove and discard retaining ring (5), rod seal (6),
MAF11980
backup ring (7) and o-ring (12) from inside of cylinder
Figure 5-178. Piston Disassembly head (3).
11. Remove and discard o-ring (16) and backup ring (17) 16. Remove and discard o-ring (10) and backup ring (11)
from inside of piston (13). from outside of cylinder head (3).
12. Remove and discard piston seal (14) and wear ring (15) CLEANING AND INSPECTION
from outside grooves of piston (13).
13. Remove spacer (18) from rod (2).
DO NOT USE A KNIFE,SHARP OBJECT, OR SCREW DRIVER. 3. Inspect threaded portion of rod for excessive damage.
MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING Dress threads as necessary.
FOR PROPER INSTALLATION. 4. Inspect inner surface of cylinder barrel tube for scoring
14. Remove and discard wear ring (9) and wiper (4) from ovality. Replace if necessary.
necessary.
11. Inspect seal and O-ring grooves in head for burrs and
3121262 5-135
12. Inspect cylinder head outside diameter for scoring, ASSEMBLY

13. Inspect rod and barrel bearings for signs of correct JLG Parts Manual.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt Apply a light film of hydraulic oil to all components before
etc. to facilitate bearing installation. assembly.

be replaced. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER
c. Lubricate inside of the steel bushing with WD40 LEAKS AND IMPROPER CYLINDER OPERATION.
1. Install rod seal (6), backup ring (7) and o-ring (12) inside
NOTE: Lubrication is not required with nickel plated pins and the cylinder head (3).
2. Install wear ring (9), wiper (4) and retaining ring (5)
d. Press bushing into barrel or rod bushing with cor- inside the cylinder head (3).
rect size arbor.
9
10
11
8
6
7
12
3
Figure 5-180. Bushing Installation 9
4
14. Inspect port block fittings and holding valves. Replace 1
as necessary. MAF11990
15. Inspect oil ports for blockage or presence of dirt or other

Figure 5-181. Cylinder Head Assembly
3. Install o-ring (10) and backup ring(11) on outside
grooves of the cylinder head (3).
4. Carefully slide the spacer (18) onto rod (2).
5. Install o-ring (16) and backup ring (17) inside the
piston (13).
6. Install Piston seal (14) and wear ring (15) on outside
grooves of the piston (13).
7. Using suitable protection, clamp cylinder rod (2) in a
vise or similar holding fixture as close to piston as
possible.
5-136 3121262
13
22
15
16
14
15
22
17
17
MAF11980
Figure 5-182. Piston Assembly
8. Carefully thread piston (13) on cylinder rod (2) hand

tight. Do not damaged or dislodge O-ring and backup
rings.
9. Install setscrew (22) on the piston (13) and attach piston
(13) to the rod (2).
10. Position cylinder barrel (1) in a suitable holding fixture.

INSTALLING CYLINDER ROD, HEAD, AND PISTON.
11. Continue pushing rod in barrel until cylinder head (3)

can be inserted into the barrel.
12. Secure the cylinder head gland using the washer ring
and socket head bolts.
reinstallation of any holding valve or valves.
3121262 5-137
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 5-183. 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.
5-138 3121262
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.
3121262 5-139
Installation 3. Apply lubricant JLG PN 3020039 to the setscrew and

install the setscrew. Torque the setscrew to 4 in. lbs.
1. Carefully insert the sensor into the cylinder. It may be (0.45 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.
5-140 3121262
Figure 5-184. Platform Valve Identification
3121262 5-141
Table 5-33. Platform Valve Specifications
Torque
# Item Ohms
ft.lbs. Nm
1 Pressure Check Port 17-18 23-24.5 --
2 Pressure Compensa- 25-30 34-41 --
tor
3 Relief Valve 25-30 34-41 --
4 Relief Valve 25-30 34-41 --
tor
6 Relief Valve 25-30 34-41 --
7 Inlet Valve 2-3 3-4 7.4
8 Platform Level Valve 16-20 22-27 9.8
9 Platform Rotate Valve 16-20 22-27 9.8
Figure 5-185. Platform Valve Torque and Resistance Specifications
5-142 3121262
Table 5-34. Fitting Torque Specifications
Torque
#
ft.lbs. Nm
1 24 32.5
2 24 32.5
3 40 54
4 15 20
Figure 5-186. Platform Valve Fitting Torque Specifications
3121262 5-143
Figure 5-187. Jib Control Valve Identification - Sheet 1 of 2
5-144 3121262
Figure 5-188. Jib Control Valve Identification - Sheet 2 of 2
3121262 5-145
Figure 5-189. Jib Control Valve Torque and Resistance Specifications - Sheet 1 of 2
5-146 3121262
Table 5-35. Jib Control Valve Specifications
Torque
# Item Ohms
ft.lbs. Nm
tor
tor
3 Jib Lift Valve 16-20 22-27 9.8
4 Jib Tele Valve 16-20 22-27 7.2
5 Jib Level Valve 16-20 22-27 9.8
6 Jib Swing Valve 16-20 22-27 9.8
7 Inlet Valve 29-37 39-50 7.4
8 Relief Valve 25-30 34-41 --
9 Relief Valve 25-30 34-41 --
10 Relief Valve 25-30 34-41 --
11 Relief Valve 25-30 34-41 --
12 Relief Valve 25-30 34-41 --
Figure 5-190. Jib Control Valve Torque and Resistance Specifications - Sheet 2 of 2
3121262 5-147
Table 5-36. Fitting Torque
Torque
#
ft.lbs. Nm
1 24 32.5
2 60 81
3 40 54
4 24 32.5
5 15 20
6 15 20
7 40 54
8 35 47.5
Figure 5-191. Jib Control Valve Fitting Torque Specifications
5-148 3121262
1. Aux Lift Down 5. Dump 9. Lift Up Relief 13. Tele Out Relief
2. Tele Out 6. Swing Relief 10. Lift Down Relief 14. Tele In Relief
3. Lift Up 7. Swing Left 11. Lift Flow 15. Tele Flow
4. Swing Right 8. Lift Down 12. Tele In 16. Lift Down/Aux Select
Figure 5-192. Main Valve Identification
3121262 5-149
Table 5-37. Cartridge Torque Values
Ft-Lbs. Nm Ft-Lbs. Nm
1 25-30 33.9-40.6 9 30-35 40.6-47.4
2 25-30 33.9-40.6 10 30-35 40.6-47.4
3 30-35 40.6-47.4 11 30 40.6
4 30-35 40.6-47.4 12 30-35 40.6-47.4
5 30-35 40.6-47.4 13 30-35 40.6-47.4
6 30-35 40.6-47.4 14 30-35 40.6-47.5
7 30-35 40.6-47.4 15 30-35 40.6-47.5
8 30 40.6
Figure 5-193. Main Valve Cartridge Torque Values
5-150 3121262
5.5 OIL SAMPLING 3. Locate the oil sampling valve on the front of the main
control valve.
See Figure 5-194., Oil Sampling Port. 4. Unscrew the knurled end which is attached to the chain.
5. Place a drip pan under the spout and push in for approx-
This machine is equipped with an oil sampling valve to
imately 10 seconds. This should flush out the valve.
allow for verification of hydraulic oil condition.
6. Open and place the sample bottle under the spout.
Procedure 7. Push in on the end of the valve and fill up the bottle.
1. Function the machine for approximately 15 minutes 8. Cap the bottle immediately.
operating all functions. 9. Thread the knurled cap back onto the valve.
2. Switch the select switch to the ground controls and start 10. The sample is complete.
the engine.
Figure 5-194.Oil Sampling Port
3121262 5-151
5.6 PRESSURE SETTING PROCEDURE

Cold temperatures have a significant impact on pressure read-
ings. JLG Industries Inc. recommends operating the machine
until the hydraulic system has warmed to normal operating
temperatures prior to checking pressures. JLG Industries Inc.
also recommends the use of a calibrated gauge. Pressure read-
ings are acceptable if they are within ± 5% of specified pres-
sures.
To ensure all pressures are set correctly, the following proce-

dures must be followed in order.
1. All applicable steps in Section 5.12, Drive & Function REXROTH PUMP
Pump Start Up Procedures must be followed.
2. Set up of the function pump.
3. Adjustments made at the main valve bank.
4. Adjustments made at the platform valve.
5. Adjustments made at the jib valve.
Set Up of the Function Pump

HIGH PRESSURE RELIEF
1. Install a high pressure gauge at the MP port of the main
valve block.
2. Using a screwdriver, remove the Din connector from the SAUER PUMP
lift down coil.
3. Activate lift down. The gauge should read 3400 psi 5. After adjusting the pressure, tighten the jam nut and the
(234.4 bar). cover nut if applicable. This is the maximum relief pres-
sure for all the functions governed by this pump.
4. To make an adjustment to this pressure on a Rexroth
pump, go to the engine compartment and locate the STAND BY PRESSURE OR LOW PRESSURE RELIEF
function pump which is the back pump. The high pres-
sure relief adjustment is the adjustment closest to the 1. Install a low pressure gauge at port MP of the main valve
pump. Using a 17 mm wrench, remove the cover nut. Be block capable of accurately reading 300 psi (20.6 bar).
careful not to lose the o-ring washer inside the cover
nut. Loosen the jam nut at the setscrew with the 17 mm 2. Start the engine, the gauge should read 300 psi
wrench. Using a 3 mm allen wrench, adjust clockwise to (20.6 bar).
increase, or counterclockwise to decrease pressure.
To make an adjustment to this pressure on a Sauer

pump, loosen the 4 mm setscrew towards the engine.
Using a 6 mm allen wrench, turn clockwise to increase
pressure and counterclockwise to decrease pressure.
5-152 3121262
3. To make an adjustment to this pressure, go to the SWING

engine compartment, locate the function pump. The
stand by adjustment is the adjustment outside adjust- NOTE: Left and right are done with one adjustment.
ment, closest to the turntable. Use the same tools that
were used in the High pressure adjustment procedure. 1. Install a high pressure gauge at port MS.
2. Lock the turntable pin.
3. Activate swing, the gauge should read 1500 psi (103.4

Bar). The adjustment cartridge is located below the MS
gauge port.
4. Turn clockwise to increase, counterclockwise to

decrease pressure.
TELESCOPE OUT
REXROTH PUMP 1. Install a high pressure gauge at the M8 port of the main
valve bank. Plug the telescope out hose either at the
valve bank (port #8) or at the inlet of the telescope cylin-
der (V1).
2. Activate telescope out. The gauge should read 3200 psi

(220.6 Bar).
3. The adjustment cartridge is located below the M8

gauge port. Turn clockwise to increase, counterclock-
wise to decrease pressure.
TELESCOPE IN
1. Install a high pressure gauge at the M7 port of the main

SAUER PUMP valve block. Plug the telescope in hose either at the
valve bank (port #7) or at the inlet of the telescope cylin-
der (V2).
Adjustments made at the Main Valve Bank
2. Activate Telescope In. The gauge should read 1800 psi
LIFT UP (124 Bar).
1. Install a high pressure gauge at the M5 port of the main 3. The adjustment cartridge is located to the left of the M7
valve block. Plug and cap the hose on port 5. gauge port. Turn clockwise to increase, counterclock-
2. Activate lift up. The gauge should read 2750 psi
(189.6 Bar).
Adjustments Made at the Frame Valve Bank
3. The adjustment cartridge is located below the M5
gauge port. Turn clockwise to increase, counterclock- AXLE EXTEND AND RETRACT, FRONT AND REAR
1. To extend the axles, drive the machine back and forth
LIFT DOWN until fully extended. A machine that cannot be driven
1. Install a high pressure gauge at the M4 port of the main must be jacked up.
valve block.
2. On both the front and rear frame valve banks, install a
2. Activate lift down to the end of the stroke. The gauge high pressure gauge on ports MA1 for extend and MA2
should read 2000 psi (137.9 Bar). for retract. The gauge should read 2500 psi (172.3 Bar) in
both directions.
3. The adjustment cartridge is located to the left of the M4
gauge port. Turn clockwise to increase, counterclock- 3. Turn clockwise to increase, counterclockwise to
wise to decrease pressure. decrease pressure.
3121262 5-153
STEERING, FRONT AND REAR 2. Install the Analyzer in the platform control box and scroll
menu’s to Access Level 2 and insert password (33271) to
NOTE: The following procedure requires 2 people to perform. One get into Access Level 1.
is needed for verifying / adjusting pressure readings and
wheel spindle alignment the other for operating the steer
functions and using the Analyzer from the platform.
The Analyzer is required to perform the pressure check proce-

dure through access of the calibration menu. The calibration
menu will allow for extending and retracting the steer cylin-
ders individually, verifying pressures, and proper steer sensor
calibration. Verification of the steer sensor calibration will
require one of two types of measuring methods; using a
square and ruler or using string as explained in Section 6 - JLG
Control System. The purpose of these measuring tools is to
assure that the wheel spindle is aligned “straight” with the
extended axle weldment.
1. Position the machine with both front and rear axles fully
extended.
3. Scroll to the calibration mode. Once in the calibration

mode, press “ENTER” and scroll to steer. Once in the
steer calibration mode, the Analyzer is going to ask to
calibrate the steer sensors, this is going to allow extend-
ing and retracting each steer cylinder individually dur-
ing this process. The JLG control system will ask to
calibrate the left front sensor, the left rear sensor, the
right front sensor and finally the right rear sensor in that
order. During this calibration mode each individual steer
cylinder will be extended and retracted to verify correct
pressures with the marked MS (Measure Steer) ports on
the steer / axle valve that pertains to that steer cylinder.
Refer to the Hydraulic Schematic in Section 7 - Schemat-
ics.
5-154 3121262
Figure 5-195. Steer Pressure Adjustments
3121262 5-155
4. Remove the front circular steer/axle access covers at the 5. Install a pressure gauge at the front axle/steer valve at
front of the chassis, and the rear square cover at the top MS2 port. This should be located on the left side of the
rear of the chassis to gain access to the axle/steer valves. valve closest to the left front wheel spindle. Position the
steer switch to activate the left front steer cylinder until
the rod is in the fully extended position and hold the
switch for a few seconds after the rod has been fully
extended. The MS2 port should read 2000 psi (138 Bar).
If the pressure is not 2000 psi (138 Bar) adjust relief valve
mounted next to the MS2 port, clockwise to increase or
counterclockwise to decrease pressure.
6. Remove the pressure gauge from MS2 port and install

on the MS1 port, which is on the right side of the front
axle/steer valve, closest to the right front wheel spindle.
Position the steer switch to activate the left front steer
cylinder until the rod is in the fully retracted position
and hold the switch for a few seconds after the rod has
stopped. The MS1 port should read 2600 psi (179 Bar). If
the pressure is not correct, adjust relief valve next to
MS1 port, clockwise to increase or counterclockwise to
decrease pressure.
5-156 3121262
7. This step involves aligning the left front wheel spindle 9. Remove the gauge from MS1 port and install on MS2
with the axle weldment. Position the left front wheel port, which is on the right side of the rear axle/steer
spindle “straight” using a square and rule or string for valve, closest to the right rear wheel spindle. Position
proper alignment (Refer to Section 6 - JLG Control Sys- the steer switch to activate the left rear steer cylinder
tem). Once the left front wheel spindle has been prop- until the rod is in the fully extended position and hold
erly measured, press “ENTER” on the Analyzer. This is the steer switch for a few seconds after the rod has been
calibrating data to the JLG Control System that the left fully extended. The MS2 port should read 2000 psi
front steer sensor is centered. (179 Bar). If the pressure is not correct, adjust the relief
valve mounted next to MS2 port clockwise to increase
8. Checking the left rear steer cylinder is identical to the
or counterclockwise to decrease pressure.
procedure for left front steer cylinder, except now we are
checking pressures at the rear axle/steer valve location.
Install pressure gauge at MS1 port. This should be
located on the left side of the valve closest to the left
rear wheel spindle. MS1 port should read 2600 psi
(179 Bar) when the left rear steer cylinder is activated
with the rod in the fully retracted position. If the pres-
sure is not 2600 psi (179 Bar) adjust relief valve mounted
next to MS1 port clockwise to increase or counterclock-
10. The next step is identical to the left front step men-
tioned above. Make sure the left rear wheel spindle is
straight and press “ENTER” to accept the new calibration
settings, now press “ESC” (escape) and scroll to the right
front steer calibration step.
11. Checking the right front steer cylinder is identical to the

procedure laid out for the left front steer cylinder, except
the pressures are now checked at MS3 port of the front
axle/steer valve. This should be at the right side of the
valve closest to the right front wheel spindle. Install the
gauge at MS3 port. Position the steer switch to activate
the right front steer cylinder until the rod is in the fully
retracted position and hold the steer switch for a few
seconds after the rod has been fully retracted. If the
pressure is not 2600 psi (179 Bar), adjust the relief valve
mounted next to the MS3 port clockwise to increase or
counterclockwise to decrease pressure.
3121262 5-157
12. Remove the gauge from MS3 port and install on MS4 16. The next step is identical to the left front step men-
port, which is on the left side of the front axle/steer tioned above, make sure the right rear wheel spindle is
valve, closest to the left front wheel spindle. Position the straight and press “ENTER” to accept the new calibration
steer switch to activate the right front steer cylinder settings, now escape out of the calibration menu and
until the rod is in the fully extended position and hold remove the Analyzer and pressure gauge.
the steer switch for a few seconds after the rod has
stopped extending. The MS4 port should read 2000 psi
(138 Bar). If the pressure is not correct, adjust relief valve Adjustments Made at the Platform Valve Bank
mounted next to the MS4 port clockwise to increase or
counterclockwise to decrease pressure. PLATFORM LEVEL UP
13. The next step is identical to the left front step men- 1. Install a high pressure gauge at the gauge port ML1.
tioned above. Make sure the right front wheel spindle is
straight and press “ENTER” to accept the new calibration 2. Activate level up to the end of stroke, it should read
settings. Scroll over to right rear steer calibration step. 2500 psi (172.3 Bar).
14. Checking the right rear steer cylinder is identical to the 3. All the relief valves are located on the same face. The
procedure laid out for the left rear steer cylinder. Install level up relief valve is the top. Turn clockwise to increase,
gauge at MS4 port of the rear axle/steer valve. This counterclockwise to decrease.
should be at the right side of the valve closest to the
right rear wheel spindle. Position the steer switch to acti-
PLATFORM LEVEL DOWN
vate the right rear steer cylinder until the rod is in the
fully extended position and hold the steer switch for a 1. Install a high pressure gauge at gauge port ML2.
few seconds after the rod has stopped extending. The
MS4 port should read 2000 psi (138 Bar). If the pressure 2. Activate level down to the end of stroke, it should read
is not correct, adjust relief valve next to the MS4 port 2000 psi (138 Bar).
clockwise to increase or counterclockwise to decrease
pressure. 3. The level down relief valve is the second from the top.
Turn clockwise to increase, counterclockwise to
15. Remove gauge from MS4 port and install on MS3 port,
decrease.
which is on the left side of the rear axle/steer valve, clos-
est to the left rear wheel spindle. Position the steer
switch to activate the right rear steer cylinder until the JIB PIN EXTEND
rod is in the fully retracted position and hold the steer
1. Install a high pressure gauge on gauge port MS1.
switch for a few seconds after the rod stops retracting. If
the pressure is not 2600 psi (179 Bar), adjust the relief
2. Using the analyzer and set pressures menu, Select jib
valve mounted next to the MS3 port clockwise to
lock pin extend. This relief valve is the bottom. Turn CW
increase or counterclockwise to decrease pressure.
to increase and CCW to decrease pressure.
5-158 3121262
Adjustments Made at the Jib Valve 6. Using the arrow keys scroll until MENU: SERVICE MODE is
JIB LEVEL UP reached. Press ENTER .

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.
2. Connect the analyzer to the ground control connector.

3. Position the main boom on the boom rest and the jib to
horizontal.
7. Enter code 58237 and Press ENTER . The screen

4. Using the analyzer, press the RIGHT or LEFT should read SERVICE MODE: JIB & SWING AND JIB LEVEL.
arrow key until ACCESS LEVEL 2 is reached. Press ENTER
.
5. Using the arrow keys, enter access code 33271 and press
ENTER .
3121262 5-159
11. If necessary to adjust pressure, CW increases. Jib level up

adjustment is adjacent to MLB.
SERVICE MODE:
JIB LEVEL
ESC ENTER
12. Make sure to reset Jib override to off after pressure is set,
and cycle machine power.
JIB LEVEL DOWN

MAE19060
1. Install high pressure gauge at MLA.
8. Press ENTER again. The screen will read JIB LEVEL
OVERRIDE: ON. Use the UP or DOWN arrow

keys to toggle the override from Off to On.
SERVICE MODE:
JIB LEVEL OVERRIDE:ON
ESC 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
MAE19060 ENTER .
9. Once turned on, operate the Jib Lift Up function. This

will activate the jib level up function.
10. When the function bottoms out, pressure should read

2600 psi.(180bar).
5-160 3121262
6. Using the arrow keys scroll until MENU: SERVICE MODE is
reached. Press ENTER .
SERVICE MODE:
JIB LEVEL
ESC ENTER
MAE19060
8. Press ENTER again. The screen will read JIB LEVEL
OVERRIDE: ON. Use the UP or DOWN arrow

7. Enter code 58237 and Press ENTER . The screen keys to toggle the override from Off to On.
should read SERVICE MODE: JIB & SWING AND JIB LEVEL.
SERVICE MODE:
JIB LEVEL OVERRIDE:ON
ESC ENTER
MAE19060
NOTE: Using this override may set the Jib Leveling System Fault,
depending upon how far out of level the jib is moved.
9. Once turned on, operate the Jib Lift Down function. This
will activate the Jib Level Down function.
3121262 5-161
10. When the cylinder is completely retracted, the pressure 13. Adjust the jib level using
should be 1500 psi. (104bar). CW increases and CCW the Jib Lift function
decreases setting. Jib level down adjustment is adjacent switch until the jib level
to MLA. control angle reads zero
(0).
14. After the control angle is set, use the UP or DOWN
arrow keys to toggle the override from On to Off.

15. Cycle power and operate the main boom to verify jib
level is working properly.
11. To adjust the jib back to level, go into override mode for
jib leveling. Turne the override mode to "On" and press
the ESCAPE key until out of the Service Modes

menu.
12. Go to the Diagnostics/Boom Sensors menu. Use the
Right arrow key until reaching the "Jib Level CNTL: Angle
0.0" screen.
5-162 3121262
JIB TELESCOPE OUT JIB TELESCOPE IN
1. Install a high pressure gauge at the MTB port. 1. Install a high pressure gauge at the MTA port.
2. Fully extend the jib telescope. 2. Fully retract the jib telescope.
3. Set the Jib Telescope pressure to 2850 psi (196.5 Bar). 3. Set the Jib Telescope In pressure to 2850 psi (196.5 Bar).
Turning the adjustment clockwise increases pressure,
Turning the adjustment clockwise increases pressure,
turning the adjustment counterclockwise decreases
turning the adjustment counterclockwise decreases pressure.
pressure.
3121262 5-163
JIB LIFT UP JIB LIFT DOWN

1. Install a high pressure gauge at the MJA port.
1. Install a high pressure gauge at the MJB port.
2. Fully extend the jib lift cylinder or cap port JB. 2. Fully retract the jib lift cylinder or cap port JB.
3. Set the Jib Lift Up pressure to 2800 psi (193 Bar). Turning 3. Set the Jib Lift Down pressure to 1200 psi (82.7 Bar).
the adjustment clockwise increases pressure, turning Turning the adjustment clockwise increases pressure,
the adjustment counterclockwise decreases pressure. turning the adjustment counterclockwise decreases
pressure.
5-164 3121262
5.7 DRIVE PUMPS (REXROTH) 2. Transmission does not propel the machine, diesel
engine running properly - Charge Pump/Relief Valve
Troubleshooting Procedure a. Is there any charge pressure at port G or indicated

by measuring pressure at Ma and Mb?
To aid in troubleshooting, refer also to the pressure measuring No - Proceed to step 2.d
port connections for test gauge installation information as Yes - Proceed to step 2.b
shown on the hydraulic circuit diagram. Procedure assumes b. Is the charge pressure at least 500 psi while running
proper gauges are installed. (Minimum gauges required: (2) 0- at high engine speed?
6000 psi, (1) 0-3000 psi & (1) 0-1000 psi [{2} 0-415 bar, {1} 0-210 No - Proceed to step 2.c
bar & {1} 0-70 bar]). This procedure was written to aid the trou- Yes - Proceed to step 3.a
bleshooter in following a logical approach to a hydraulic sys-
c. Can the charge pressure be raised by removing dirt/
tem fault.
debris from charge relief poppet or by adding or
1. Transmission does not propel the machine, diesel removing shims from the charge pressure relief
engine running properly valve mounted in the second pump of the triple?
No - Proceed to step 2.d
a. Is there oil in the reservoir? Yes - Adjust pressure to 500 psi +50 psi, -0 psi
No - Fill reservoir (34.4 bar +3.4 bar, -0 bar)
Yes - If yes, proceed to step 1.b
NOTE: The propulsion circuit uses a hot oil flushing valve to
b. Is the pump input shaft connected to the engine obtain brake release pressure. The hot oil flushing valve
flex plate or rear of forward pump? cartridge (#120) is mounted in the Traction Control Mani-
No - Connect pump input shaft fold. The flushing valve receives its oil from the "left side"
Yes - If yes, proceed to step 1.c wheel drive pump; the middle pump of the triple. With the
engine running and propelling the machine forward or
c. Are the hydraulic hoses and tubing connected in
reverse, the "hot oil flushing valve" and the brake release
accordance with the hydraulic circuit diagram?
pressure must be adjusted to 475 psi, +25 psi, -0 psi (32.7
No - Correct the hoses/tubing
bar, +1.7 bar, -0 bar), as set by adjusting pressure relief car-
Yes - If yes, proceed to step 1.d tridge (#130). The brake release pressure must be 25 psi less
d. Is the pump direction of rotation correct? (clockwise than the charge pump pressure. Measure pressure at port
as looking at the shaft) "MP" using a 0-1000 psi (0 - 70 bar) pressure gauge.
No - Fit pump having the correct direction of
d. Is the transmission pumps suction hose pinched
rotation
shut?
Yes - If yes, proceed to step 1.e
No - Proceed to step 2e
e. Are there O-rings missing from fittings (as example - Yes - Repair damaged hose
suction leak), pinched hoses, broken tubing, etc? e. Is the charge pump suction pressure/vacuum within
No - Proceed to step 1.f recommended limits? (0.8 bar absolute or 6.3 inches
Yes - Repair damage or fault of mercury)
f. Are the electrical connectors/wiring intact and No - Proceed to step 2.f
secure to the pump control solenoids? Yes - Proceed to step 2.g
No - Repair damage or fault f. Is the suction strainer inside the reservoir blocked,
Yes - If yes, proceed to step 1.g clogged, restricted?
No - Proceed to step 2.g
g. Does the engine "labor" when attempting drive, are Yes - Repair/replace with a clean suction strainer
the brakes released?
No - Proceed to step 1.h g. Is the reservoir air breather blocked or restricted?
Yes - Check brake release circuit, measure pressure No - Proceed to step 2.h
at port "MP" on Traction Control manifold Yes - Clean or replace air breather
h. Are all four wheel drive planetary reduction gear-

boxes engaged?
No - Engage wheel drive(s)
Yes - If yes, proceed to step 2.a
3121262 5-165
h. Remove charge pressure relief valve from the mid- f. Stroke pump in both directions, while measuring
dle pump and inspect. Is it damaged? pressure at Ma & Mb ports of the pump. Does any
No - Refit cartridge and proceed to step 2.i pressure greater than charge pressure alternate
Yes - Clean & inspect cartridge, poppet, springs, between ports Ma & Mb?
seals to determine cause of damage. Repair or fit a No - Verify that loading the pump will cause system
new cartridge and return to step 2.a pressure to increase above charge pressure. Proceed
to step 3.a
i. Remove and inspect charge pump assemblies. Are
Yes - Proceed to step 3.g
they damaged?
No - Proceed to step 2.j g. Is it possible to adjust high pressure relief valves
Yes - Repair and/or replace damaged components using 0-6000 psi (0 - 415 bar) gauges to monitor
and return to step 2.a pressure at Ma & Mb? (Refer to relief valve adjust-
ment)
j. Is the charge pump installed for the clockwise rota-
No - Replace high pressure relief valve and return to
tion?
step 3.c
No - Refit charge pump. Return to step 2.a
Yes - Adjust high pressure relief valves to 5000 psi
Yes - With proper charge pressure and transmission
+50 psi, -0 psi (344.7 bar +3.4 bar, -0 bar)
still does not operate, proceed to step 3.a
h. Actuate control in both directions. Does transmis-
3. Transmission does not propel the machine, diesel sion operate?
engine running properly - Pump Control: (Insure Gener- No - Check that minimum displacement stops on
ator Drive option is not turned "on") the wheel drive motors are adjusted properly, check
a. Are the electrical connectors & wiring connected that the motors stroke between maximum to mini-
properly to the pump control solenoids? mum.
No - Connect a ammeter in series with solenoid wir- Yes - Operate the transmission
ing. Is a current of 400 mA to 1060 mA being 4. Transmission Drive is Sluggish or Erratic
applied. (Current signal varies with joystick position)
Yes - Proceed to step 3.b a. Does the "EP" proportional pump control current
vary with joystick movement?
b. Are all four of the two-speed motors, mounted in No - Rectify the problem - broken wires, electrical
the wheel drive planetary reduction gearboxes, connector, open solenoid coil, etc.
shifted to maximum displacement (high torque - Yes - Proceed to step 4.b
low speed)?
No - Select maximum displacement b. Are all four (4) brakes fully released?
Yes - Proceed to step 3.c No - Check brake release pressure and insure each
wheel receives correct release pressure.
c. Actuate the pump control in both directions. Do the Yes - Proceed to step 4.c
pumps stroke? Do they go to full stroke?
c. Are the pumps stroking time orifices installed tight
No - Refer to the pump service manual and then
and clean?
proceed to step 3.d
No - Remove the Plugs in ports X1 and X2. Remove
Yes - Operate the transmission
orifices with a 3mm allen wrench. Check that orifices
d. Remove stroking orifices in X1 and X2. Install pres- are clean & re-install.
sure gauges in X 1 and X 2 (0-500 psi [0 - 35 bar]). Yes - Proceed to step 4.d
Stroke the pump in both directions. Do the pres- d. Is an motor displacement stroking time orifice
sures at X1 and X2 alternate between 30 & 250 psi (2 plugged or is the two-speed shift hose pinched?
& 17 bar)? Yes - Inspect and clean stroking orifice, check two-
No - Remove the EP control module & replace it with speed hose routing
a new unit. Repeat step 3.c
e. Is a flow divider/combiner cartridge stuck in the
Yes - Proceed to step 3.e.
Traction Control Manifold? Flow divider/combiner
e. Is the pressure at port "R", case pressure, less than 15 cartridge # 111 controls the right side wheels, # 112
psi (1 bar) gauge pressure? controls the left side wheels. Also check to insure
No - Correct problem restricting case drain oil flow bypass orifices #151 (right side) and # 152 (left side
(oil cooler blockage, pinched hoses, etc.) are not plugged.
Yes - Proceed to step 3.f
5-166 3121262
5. Transmission Drives in one direction only 7. Transmission Does Not Find or Hold Neutral
a. Are electrical connections to pump control propor- a. Does pump remain in neutral with electrical con-
tional solenoids correct, intact and without defects? nectors removed?
Yes - Proceed to step 5.b No - proceed to step 7.b
No - Rectify the problem Yes - Check electrical system for signal problem
b. Check hot oil flushing valve cartridge #120 located b. With electrical connectors removed and machines
in the Traction Control Manifold. wheels jacked off the ground and engine running,
Remove and inspect flushing valve cartridge for momentarily apply 12 volt DC signal (battery volt-
stuck spool or damaged cartridge O-ring seals & age) to a pump control solenoid. Does the pump
backup rings. return to neutral after the 12 volt signal is removed?
No - Apply 12 volts to opposite solenoid & recheck.
c. Inspect "Make-Up" check valve cartridges, #190.1- No - Replace pump control module, repeat step 7.a
190.4, installed in the Traction Control Manifold. Is a Yes - Possibly dirt was dislodged from control mod-
cartridge "stuck" open with debris or is an O-ring ule, re-check thoroughly to determine problem has
failed? definitely been resolved.
No - Proceed to step 5.d
Yes - Clean/repair or replace Make-Up check car- c. Check mechanical centering of the pumps
tridge. 8. Transmission Drives at a High Noise Level
d. Swap high pressure relief valves in the transmission. a. Are the wheel drive planetary reduction gearboxes
Does the transmission drive in the other direction? filled to the correct level and do they have the
No - Proceed to step 5.e proper lubricant?
Yes - Repair/clean/adjust or replace high pressure No - Fill gearbox with correct grade of oil to the pre-
relief valve on the non-driving side scribed level.
e. Replace "EP" control module. Does pump operate Yes - Proceed to step 8.b
properly? b. Is the engine flex plate and drive coupling correctly
No - Replace or repair pump installed and aligned with the transmission pump?
Yes - Operate the transmission No - Install flex plate and bell housing per manufac-
turer's instructions
6. Transmission Drives in Wrong Direction Yes - proceed to step 8.c
a. Check to see if electrical connectors or wiring have c. Is a rigid item or object contacting the resilient
been swapped on the pump. mounted engine/pump assembly?
b. Check to determine want end of the machine the No - Proceed to step 8.d
boom is swung over. Yes - Insure no item is contacting the unit, transmit-
ting air borne noise.
d. Is the suction pressure/vacuum at the charge
pumps inlets within recommended limits?
No - Return to step 1.h
Yes - Proceed to step 8.e
e. Is there air in the hydraulic fluid? This may be indi-
cated by foaming or milky colored oil.
No - Proceed to step 8.f
Yes - De-aerate the oil and inspect system for cause
of air induction. Check for loose or missing O-rings
on face seal connections.
3121262 5-167
f. Is a wheel drive hydraulic motor operating at exces- 11. Transmission Pump(s) Do Not Develop Maximum Horse-
sive speed? power (Flow & Pressure)
Yes - Check minimum displacement stop screw
adjustments on the motors. Should be 0.433" or a. Does the charge pump pressure meet specification?
11mm above the stop screw lock nut. Is one or more No - Return to step 2.a
motors "stuck" at minimum displacement, check for Yes - Proceed to step 11.b
plugged/blocked two-speed stroking orifice(s).
b. Does the pump case pressure exceed 15 psi gauge
9. Transmission Operates at a Higher than Normal Temper- pressure?
ature
No - Proceed to step 11.c
a. Is the reservoir temperature above 195oF (90.5° C)? Yes - Check case drain hoses, oil cooler, etc. for
No - 195oF (90.5° C) is the upper limit. If temperature pinched or restricted oil flow
is over 195oF (90.5° C), the oil cooler may need to be c. Are the pump(s) high pressure cross port relief
cleaned. valves adjusted to the required pressure (5000 psi)
Yes - Proceed to step 9.c so they do not bypass prematurely?
b. Are the hydraulic motor(s) stalling (wheels not turn- No - Inspect/clean/adjust and or replace valve car-
ing) intermittently? tridge
No - Proceed to step 9.c Yes - Replace the pump, after blocking the "A" & "B"
Yes - Hydraulic fluid is being heated through system ports, running the pump and measuring pressure
pressure relief valves. Shut down system and rectify developed at "A" & "B". This must be done to insure
the cause of motor stall. that flow & pressure loss in not elsewhere in the sys-
tem. (motors, swivel coupling, etc.)
c. Does oil temperature remain above 195oF (90.5° C),
after cleaning the oil cooler? d. Is the diesel engine capable of developing horse-
No - Operate transmission. Check oil cooler more power at design rpm?
often. Follow recommended troubleshooting procedures
Yes - Proceed to step 8.a to insure the engine is developing full power at
10. Transmission Operates at a Higher than Normal Temper- specified rpms.
ature
a. Check for differential temperature across the oil Charge Pressure Relief Valve Adjustment
cooler. Is there a temperature difference?
No - Check to determine if the bypass check valve
(10 psi [0.7 bar] crack pressure) is stuck open. Check
to determine if the oil cooler is restricted internally,
causing oil flow to pass across the bypass check
valve.
Yes - Proceed to step 8.b
NOTE: Oil cooler flow is received from the transmission pumps

cases, max. continuous pump case pressure is 15 psi gauge
pressure. Higher pressure will prematurely damage pump
shaft seals
b. Disconnect pump case drain from oil cooler & check CHARGE RELIEF
flow rate from charge pumps. Is the flow rate 3.8
GPM (14.4 LPM) with diesel idle speed of 1200 rpm?
With a low pressure (0 – 1000 psi [0 - 70 bar]) pressure gauge
No - Refer to charge pump removal & inspection
tee’d into the ”G” port or two (2) low pressure gauges installed
procedure
into ”Ma” and ”Mb”, run pump at engine idle speed. Do not
place the pump on stroke – low pressure gauges installed in
”Ma” & ”Mb” will be damaged! Prior to adjusting pressure,
insure charge pressure relief valve is clean of any dirt or debris.
The charge pressure relief valve does not wear appreciably
over time. If charge pressure was normal and then has
decayed, check for other causes of low charge pressure. If pres-
sure is low, remove relief valve and add shim(s). If pressure is
high, remove relief valve and take out shim(s).
5-168 3121262
NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are avail- Hydraulic Centering of Control Modules
able in 0.3, 0.5, and 1.0 mm thickness.
PREPARATION FOR ADJUSTMENT

When control modules are exchanged or replaced, it is gener-
ally necessary to center the new module. This is done by run-
ning the pump with gauges installed at ports X1, X2, MA, and
MB Release the jam nut and turn the adjustment screw on top
of the control module valve body.
Mechanical Centering of Pump
PREPARATION FOR ADJUSTMENT

The control piston has strong centering springs to ensure that
once the pump is adjusted for the neutral position it will
always return to neutral. If an adjustment is necessary follow
the steps listed below.
To ensure there is equal pressure on both sides of the control
module during the centering operation, it is necessary to con-
nect the X1 and X2 ports together by means of hose or tubing.
(No less than a 1/4 inch ID) The port sizes are:
Pump Size Allen Wrench Wrench
28 5 mm 17 mm
With pressure gages installed at MA, and MB, and with A and B
ports blocked (or motor stalled), and with the pump running, The adjustment screw is an eccentric, therefore, turning more
loosen the jam nut. Turn the mechanical centering adjusting
than 90’ in either direction will have no further centering
screw until 1000 psi is read on MA, or MB then turn screw
opposite direction until 1000 psi is read on other pressure effect, and could cause damage to the eccentric pin.
port. Turn the screw back, splitting the distance between the Pump Size Tool Required Wrench
previous two positions. This should be the neutral position.
28 Screwdriver 10 mm
Pressure on MA, and MB should be equal.
CENTERING THE EP CONTROL MODULE

With no electrical signal to solenoids A and B, (remove both
plug-in connectors), the EP control module is correctly
adjusted when any or all of the following conditions exist:
1. Approximately, when equal control pressures are

obtained at control pressure ports X1 and X2.
2. The hydraulic motor does not turn when the brake is

released.
3. Charge pressure is registered equally at ports MA and

MB, when the flow output of the pump is deadheaded
against a locked motor or a valve.
Tighten jam nut, stop the pump drive, remove the hose con- If difficulties are encountered in obtaining neutral position of
necting ports X1 and X2. the HD or EP control modules, check that the ends of the con-
3121262 5-169
trol spring are correctly located in the grooves near the end of Removal and inspection of charge pump
the feedback lever arms.
Before removing cap screws, mark the position of the charge
pump housing and separator plate in relation to the port
block.
High Pressure Relief Valve Adjustments

1. Remove relief valve cover from pump (ref. item 1).
Loosen screws with metric allen wrench.

Pump Size Allen Wrench
28 8 mm
2. Loosen jam screw (ref. item 2).

3. Holding spring loading nut (ref. item 4) rotate valve
spindle (ref. item 3). For high range relief valve, one turn
equals approximately 630 psi (44 bar). For low range
relief valve, one turn equals approximately 377 psi (26
bar).
4. After adjustment is completed torque jam screw (ref.
item 4) to 5 ft.lb. (7 Nm). Remove charge pump housing and inspect for wear or dam-
5.Install relief valve assembly into pump, reinstall cover age to gear set and 0-ring seals. Grease 0-rings prior to reas-
(ref. item 1) to proper torque.
Table 5-38. Torque Specs for Relief Valves into Port Block
Pump Size Wrench Size Torque

28 32 mm 66 ft.lb. (90 Nm)
5-170 3121262
sembly. Make sure 0-rings are completely seated in their Routine Maintenance
grooves.
The Variable Displacement Hydrostatic Transmission Pumps
are relatively maintenance free. Maintenance work is confined
to the system, by way of maintaining hydraulic fluid condition,
the "life blood" of the machine. Oil monitoring, changes and
filter renewal promote system cleanliness. This will prevent
premature breakdown and repairs. Under normal application
conditions, the following maintenance intervals are sug-
gested:
1. Renewal of Filter Elements
a. After commissioning or re-build.
b. At every 500 operating hours or when filter indica-
tor shows a dirty element.
c. With the suction strainer, the strainer should be
renewed as soon as charge pump inlet pressure is
less than -3.2 psi, 6.3"Hg or 0.8 bar absolute.
d. Only JLG recommended filter elements are to be
used. Paper elements cannot be cleaned; use throw-
Withdraw pinion shaft and inspect gear teeth and bearing sur- away cartridges.
faces for abnormal wear. 2. Hydraulic Fluid Change
When reassembling, make sure chamfer (on outer edge of
a. After 2000 operating hours (1st oil change)
driven gear and drive gear) is installed into housing per illus-
tration. b. Thereafter, every 2000 operating hours or annually,
irrespective of operating hours achieved.
c. Oil change should be performed with the system in
warm running condition. Before re-filling, the reser-
voir interior should be inspected and cleaned to
remove any sludge.
d. Rags or threaded material must not be used.
e. This machine has been designed & manufactured to
operate on an Exxon-Mobil Oil Co. hydraulic fluid,
Mobilfluid #424, Product #52233-4. Consult JLG
Industries prior to introducing any other type of
fluid to prevent interaction or possible contamina-
tion.
f. The recommended interval between oil changes is
based on various factors and should be carried out
Torque value for bolts when replacing charge pump. according to the degree of aging, contamination
Pump Size Torque and water content.
28 18 ft.lb. (24 Nm)
NOTE: If serious wear or damage has occurred to one component,

the complete charge pump assembly must be replaced
because they are matched components.
3121262 5-171
g. Under application conditions with a heavy occur- b. The air/oil cooler surfaces and engine radiator
rence of dust or severe temperature fluctuations, should be cleaned at the same time.
the intervals between fluid maintenance should be
shortened accordingly. c. If hose connections are disassembled, it is impera-
tive that the utmost care be taken that no foreign
bodies infiltrate the oil circuit. Catastrophic compo-
nent failure may occur.
PRACTICAL EXPERIENCE SHOWS THAT MOST FLUID MAIN-
TENANCE ERRORS OCCUR DURING AN OIL CHANGE DUE 5. Oil Level Inspection
TO:
a. Inspect oil level in the reservoir daily.
• USE OF AN UNSUITABLE HYDRAULIC FLUID b. If "topping off" is required, use only the same Mobil-
fluid #424, Product #52233-4.
• USE OF OIL CONTAMINATED DUE TO POOR STORAGE PRACTICES
• FAILURE TO CLEAN THE RESERVOIR c. Do Not Mix Fluids.
• INADEQUATE CLEANLINESS WHEN FILLING THE RESERVOIR (DIRTY 6. Hydraulic Fluid - The "Life Blood" of the Machine
DRUMS, CONTAINERS, WATER, ETC)
a. The type of hydraulic fluid supplied in the machine
3. Leakage Inspection from the factory was selected after extensive testing
and development. The fluid was selected to perform
a. After commissioning
under "most" applications and conditions. Should
b. The complete transmission drive system (pumps, this machine be in service for extended time peri-
motors, hosing, filters, valves, etc.) should be ods at the extremes (hot or cold), JLG should be con-
checked for leakage at regular intervals. sulted for assistance in selection of the most
c. Leaking joints & connections must only be tight- suitable fluid type and grade for your application.
ened when pressureless.
b. When operating at temperatures below 0oF, allow a
4. Cleanliness Inspection warm-up period, if at all possible, to a temperature
a. The oil tank breather should be regularly cleaned of of 40oF.
dirt and dust to prevent clogging. With each cylin-
c. When beginning motion of a "cold" machine, oper-
der movement, gallons of oil pumped, an equal
ate all functions at reduced speeds until the "cold"
amount of air exchange occurs across the reservoir
oil has circulated out of the drive loop.
breather. A dirty or clogged breather will affect all
machine functions!
5-172 3121262
Removal and Installation of Shaft Seal Press in shaft seal with bushing to the stop. Then replace snap
ring.
Remove the retaining ring with snap ring pliers.
Screw in sheet metal screw into the holes fitted with rubber.
Pull out shaft seal with pliers.
3121262 5-173
5.8 FUNCTION PUMP (REXROTH)
Figure 5-196. Function Pump - Sectional View
Spare Parts 2. Drive Shaft
1. Sealing kit, existing spare parts: shaft sealing ring, o-

rings, and a circlip.
3. Bearing set, miscellaneous parts.
5-174 3121262
4. Rotary Group complete: 9 pistons, cylinder subassem- Sealing the Drive Shaft
bly, valve plate, retaining plate, and retaining ball.
BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED

DURING THE REMOVAL OF THE SHAFT SEALING RING.
1. Remove the snap ring.
5. Swash Plate.
2. Change the shaft seal and check its sliding surface (drive
shaft) and housing. Grease the sealing ring.
6. Parts of the control valve: control piston, piston rod,

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

tape to prevent the shaft splines from damaging the
seal.
7. DFR pilot valve.
3121262 5-175
4. Assemble the sealing ring, fitting tool holds the correct 2. Mark the position of the port plate and remove the
position of the sealing ring in the pump housing. socket screw of the port plate.
5. Assemble the snap ring. 3. Remove the port plate together with the valve plate
(hold the valve plate so the plate can’t fall down).
6. Assemble the snap ring in the correct position.

4. Remove the o-ring.
Disassembly and Assembly of the Complete Unit

5. Disassemble the taper roller bearing (nearby port plate).
1. Disassemble the pilot valve.
5-176 3121262
6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position.
7. Unscrew the cap nut and remove it. 11. Disassemble the stopper max flow.
8. Loosen the fixing nut of the stopper max flow and disas- 12. Remove the threaded pin.
semble it.
13. Disassemble the plug.

9. Turn in the stopper max flow to get swivel angle zero.
3121262 5-177
14. Disassemble the control piston while moving the swash 18. Remove both bearing shells.
plate.
19. Remove the drive shaft.

15. The swash plate must be lifted a little bit to disassemble
the piston rod.
20. Disassemble the snap ring.
16. Remove the swash plate.
21. Disassemble the sealing ring.
17. Remove the spring.
5-178 3121262
22. The external front bearing ring is pulled out of the pump 25. The spring has additional pretension while you disas-
housing. semble the three pressure pins inside the cylinder.
23. Remove the o-ring. Lifting of the valve plate isn’t shown.
Assembly
1. Measurement of the taper roller bearing pretention.
24. A bearing puller is used to disassemble the external

bearing ring of the taper roller bearing inside the port
plate. Take care of the surface of the port plate.
2. Ensure there is a correct connection of the piston rod
and the swash plate.
3121262 5-179
3. Pumps clockwise driven must have a position of the Adjustments

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

the valve plate 4 degrees de-centered in the counter-
clockwise position.
MECHANICAL FLOW LIMITER

Differential volume if you are rotating the threaded pin - each
rotation is approximately 3.1 cm3.
5. Note the correct position of the drilling that connects Tightening Torques
high pressure to the control valve. Check control valve
drilling position at the pump housing and fit together. For break-off plugs, use Loctite #601.
For all other parts, use JLG Threadlocker PN 0100011.
Table 5-39. Tightening Torques
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8.8 2.3 5.0 8.5 21 41 72 115 176 240 350 600 1220
10.9 3.2 7.2 12 29 58 100 165 250 350 490 840 1670
12.9 4.1 8.5 14.5 35 70 121 195 300 410 590 990 2000
5-180 3121262
Figure 5-197. Function Pump, Pressure and Flow Control - Sheet 1
3121262 5-181
Pump Control Disassembly For Cleaning 3. Hydraulic fluid may drip from the pump. Wiping the sur-
face clean and installing some adhesive tape should pre-
NOTE: If the Function Pump does not perform correctly after vent oil from seeping from the pump control.
following the pre-start start-up procedures, it is possible that a 4. Work on a clean, lint free area.
contaminate particle has lodged in the pump control prevent-
ing proper operation. The pump control’s internal parts are NOTE: The pump control can be equipped with either O-rings or a
not provided as spare parts due to the close tolerances sealing plate. These components are NOT interchangeable.
required between the mating parts. However, the control can
5. Remove the three (3) ”0”-rings (Parker # 2-011, Viton 90
be disassembled, cleaned and placed back in service should
shore)
the only problem prove to be contamination. Disassembly,
inspection, cleaning and reassembly MUST BE done in a clean 6. Remove both the adjustment hex caps and bonded seal
well-illuminated area. rings. (17 mm wrench)
Pump Control removal: 7. Remove both the adjustment lock nuts and bonded seal
rings. (17 mm wrench)
1. Disconnect plug the hose attached to the pump control 8. Remove both the adjusting screws. (3-mm Allen
Port ”X”. wrench)
2. Remove the four (4) socket head cap screws that attach 9. Remove the spring cover hex cap for the ”outer” flow
the control to the pump. Insure that the three (3) ”0”- regulation adjustment this requires a 19-mm wrench.
rings are also removed with the control.
5-182 3121262
10. Remove the spring disc. 21. Inspect the housing for contamination or plugged ori-
fices. Clean orifices carefully with a dead soft steel wire
11. Remove the adjusting springs (two springs, one to insure they are open. Inspect all parts for burrs, scor-
”nested” inside the other) and spring follower. ing, debris, etc.
12. The flow regulation spool should slide from the control NOTE: On the mounting surface of the control housing, between
housing, (a magnet should aid in removal). If it does not, the oil ports is what appears to be a slotted head screw. IT
remove the hollow hex head plug at the rear of the flow IS NOT A SCREW. This is a bleed orifice, which must be ori-
regulation spool and carefully push the spool from the entated to allow proper control operation. The slot in the
housing - do not scratch/mar the spool’s bore. head should be oriented to fall in-line with the oil ports,
13. Remove the spring cover hex cap for the ”inner” pres- NOT PERPENDICULAR to the oil ports. If the slot is oriented
sure compensation adjustment – this requires a 30-mm perpendicular to the three ports, the pump pressure will
wrench. not return from load pressure to stand-by pressure at the
end of operating a function! The pump pressure will
14. Remove the spring disc. remain at the last highest pressure generated.)
15. Remove the adjusting springs (two springs, one
22. After all parts are clean and dry, lightly oil a control
”nested” inside the other).
spool and install in its bore. The spool must slide
16. Remove the spring follower. smoothly and easily within the housing. If it does not,
check for contamination. If contamination cannot be
17. The pressure compensation spool should slide from the found check for ”scoring” or ”burring” of the control
control housing, (a magnet should aid in removal). If it housing. If the spool does not slide smoothly & freely,
does not, remove the hollow hex head plug at the rear the control must be replaced with a new unit.
of the flow regulation spool and carefully push the spool
from the housing - do not scratch/mar the spool’s bore. 23. Lightly oil and check operation of the second spool. The
spools are installed correctly when there ”pointed” end
18. The spools are identical. faces the spring followers
19. Wash the housing and all parts in a clean JLG approved 24. Re-assemble in reverse order.
solvent such as non-chlorinated brake cleaner, Stoddard
solvent, etc. 25. Bench set the pressure adjustments as described in ”C.
4” of the Operating Instructions.
20. Blow off all the parts with clean, dry compressed air.
NOTE: The pump control can be equipped with either O-rings or a
sealing plate. These components are NOT interchangeable.
26. Re-install on the Function Pump, insure the ”0”-rings are

installed properly and tighten the four (4) M6 socket
head cap screws to 105 inch pounds.
3121262 5-183
5.9 DRIVE PUMPS (SAUER)
Electric displacement control Electric displacement control
Servo piston Servo piston
Swashplate feedback pin Swashplate feedback pin

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

g
Shaft seal
Rear shaft Front shaft
Swashplate bearing Shaft coupling Swashplate bearing
Swashplate Cylinder block Center shaft bearings Cylinder block Swashplate
Figure 5-200. Piston Pump Cross Sectional View
Port Locations and Gauge Installation
Table 5-40. 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]
5-184 3121262
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 5-201. Port locations - Sheet 1 of 2
3121262 5-185
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 5-202. Port locations - Sheet 2 of 2
5-186 3121262
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-
3121262 5-187
Table 5-41. Electrical troubleshooting
Item Description Action

Control operates pump in one direction only Control coil failure. Measure resistance at coil pins. Resistance
should be 14.2W (24V) or 3.66W (12V) at 20° C
[70° F]. Replace coil.
No pump function No power to controller. Restore power to controller.
Erratic pump function Electrical connection to pump is bad. Disconnect connection, check wires, recon-
nect wires.
Erratic or no machine function External controller malfunction or Verify external controller problem using spare
hydraulic system problem. controller. Replace controller. Check hydraulic
system fluid level/pressures/filters/etc. Fix
hydraulic system problems.
Table 5-42. 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 5-43. 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.
5-188 3121262
Table 5-44. 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 5-45. 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.
3121262 5-189
Table 5-46. 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.
5-190 3121262
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 5-203. Charge Pressure Adjustment
3121262 5-191
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 5-47. 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 5-204. Control Neutral Adjustment
5-192 3121262
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)
3121262 5-193
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 5-205. Servo and System Pressure Gauge Port Locations
5-194 3121262
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.
3121262 5-195
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 5-206. Control Module And Solenoid Removal/installation
5-196 3121262
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 5-207. Shaft Assembly
3121262 5-197
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.
5-198 3121262
Figure 5-208. Charge Pump
3121262 5-199
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 5-209. Charge Check / HPRV
5-200 3121262
Figure 5-210. 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.
3121262 5-201
Figure 5-211. 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.
5-202 3121262
Figure 5-212. Control Cutoff Valve
Table 5-48. 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 5-49. 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]
3121262 5-203
Figure 5-213. Fastener and Plug Locations
5-204 3121262
5.10 FUNCTION PUMP (SAUER) 6. Remove the bearing cup (B010), bearing cone (B020)
and housing O-ring (K060). Discard the O-ring.
Disassembly 7. Tilt the housing on its side to allow fluid to drain.
1. Remove the control from the endcap by removing the 4 8. Remove the cylinder block kit while holding onto the
control bolts (C300), using a 4 mm internal hex wrench. front shaft.
C200
s K041
C300
I4 mm
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.
3121262 5-205
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-
5-206 3121262
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 Slipperfoot 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-
3121262 5-207
BLOCK SPRING, AND WASHERS CONTROL

If cylinder kit was fully dissembled, visual inspection of the cyl- Carefully examine the plug(s) for signs of wear. Also check the
inder block, spring, and washers should indicate minimal wear. small tip of the plug(s) for heavy wear and replace if necessary.
Replace if cracks or other damage is present. 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
Washer
for scratches and / or burrs. Clean and coat all spools, bores,
and seals with a light coating of hydraulic oil.
Cylinder block spring C104
C103
C104A
Spring retainer
C103A
Retaining ring C112i

C132
CYLINDER BLOCK
Examine the running face of the cylinder block. The surface C105
should be smooth and free of nicks and burrs. Ensure that no
C106A
scratches or grooves exist; these may drastically reduce output C105A
flow. C106
B
C113
K041 C102
C115
C133 C114
A
C117
C135
C116
?at to 0.002 mm C117
[0.000079 in] C134
C118
C138A
J Frame 45-60 cc 65-75 cc
Minimum cylinder block height (A) 62.25 mm C138
[2.45 in]
Maximum block bore diameter (B) 19.8 mm 21.57 mm INPUT SHAFT
[0.785 in] [0.85 in] Check to see that the shaft (J010) and its splines are straight
and free of damage or heavy wear. Inspect the shaft surface
where it meets the shaft seal. Replace the shaft if a groove
exists at the sealing land surface that may let dirt into or
hydraulic fluid out of the unit. Clean the sealing area with a
nonabrasive material if necessary. Lubricate the shaft with a
light coat of hydraulic fluid.
J010
5-208 3121262
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
3121262 5-209
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.
5-210 3121262
3. Reinstall the swashplate/servo piston/bias spring 8. Install the pistons (K050) to the slipper retainer (K049).
assembly in its original orientation in the housing. Install the piston/retainer assembly into the cylinder
Rotate the servo piston perpendicular to the swash- block. Ensure the concave surface of the retainer seats
on the ball guide. If you’re reusing the pistons, install
plate, and at the same time compress the bias spring to
them to the original block bores. Lubricate the pistons,
fit into housing pocket. Lubricate all sides of the servo
slippers, retainer, and ball guide before assembly. Set
piston and its respective bore liberally with hydraulic oil. the cylinder kit aside on a clean surface until needed.
Also, lubricate the flat face of the swashplate to prevent
premature wear during start-up. NOTE: Be sure to install the slipper retainer so it mates correctly
with the ball guide (concave side of the slipper retainer
4. Insert the input shaft (J010) through the bearing into against the convex side of the ball guide).
the housing. You may need to push on the servo piston
9. Set the pump on its side. Secure the end of the shaft
to rotate the swashplate in order to put the shaft in
with one hand and keep it horizontal. Insert the cylinder
properly. kit onto the shaft. While holding the shaft still, slightly
rotate the cylinder block kit to help start the shaft
5. Coat all parts with hydraulic fluid prior to reassembly.
splines over the ball guide and align it with the block
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
TO 400 N [80 TO 90 LBF ]. USE A PRESS SUFFICIENT TO Fix the shaft
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.
Slightly rotate
6. Install the inner block spring washer (K042), block spring 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-
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
K049
valve plate. The timing pin should be installed to 3.61 ?
0.25.mm [0.14.?.0.01 in] above the valve plate surface.
K047
Apply a liberal amount of assembly grease to the back-
side of the valve plate surface to hold it in position.
K046
P010
K041
K042
K043
K044
K045
7. Turn the block over and install the hold-down pins

(K046), and ball guide (K047) to the cylinder block.
3121262 5-211
Install the valve plate over the timing pin, check valve cross pattern. Retorque the first screw to ensure proper
(B092), and bearing cup (B010). torque retention.
B090 J030
10 mm
127 to 155 N·m
[94 to 114 lbf·ft]
J050
B092
B010 J020
B091
B020
K060
NOTE: To insure proper pump operation, it is extremely important

to ensure that there is no contamination between the end-
cap and valve plate.
11. Install the bearing cone (B020) onto the shaft. Using
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
12. Lubricate the lip of the new shaft seal (K020) with clean
hydraulic fluid. Place a protective sleeve over the shaft
end to prevent damage to the seal during installation.
Keeping the seal perpendicular to the shaft, press the
new seal into the housing just far enough to clear the
retaining ring groove. Install seal with the cupped side
toward the shaft bearing. Do not damage the seal dur-
ing installation. Using the appropriate snap ring pli-
ers,install the seal retaining ring (K010). Remove the
installation sleeve.
K010
K020
13. Clean all control parts and cover with a light coating of
hydraulic fluid prior to reassembly.
5-212 3121262
14. Install the spherical end of the PC spool (C132) into the new O-rings. Torque the plugs at 10.8 to 13.5 Nm [8 to
PC bore (refer to illustration). Install the PC plug (C103) 10 lbft].
using a new O-ring (C103A). Torque at 10.8 to 13.5 Nm C103 C104
[8.to.10.lbft]. Place the two PC springs (C134, C135) onto
the PC spring guide (C133) and install into the PC bore. C103A C104A
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. C112
C132
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 C105
[8.0 to 10.0 lbf•f
t]
C103 C106A
C103A C105A
C106
C132
C113
C102
C115
7.5 to 10.8 N•m C133 C114

[5.5 to 8.0 lbf•f
t]
C117
C102 C135
C116
C134 C117
C133
C118
C136
C135
C138
C134
NOTE: PC and LS spools need to be adjusted to proper setting
C136
according to tag nomenclature.
C138 16. Using petroleum jelly to retain them, install 4 new seal
rings (C200) in the recesses on the control housing.
15. Hold the control in a horizontal position. Install the Install the control assembly onto the endcap using the 4
spherical end of the LS spool (C112) into the LS bore (see screws (C300). Torque at 5.4 to 7.5 Nm [4.0 to 5.5 lbft]
illustration). Using a new O-ring, install the LS plug using a criss cross pattern and retorque the first screw to
(C104), torque at 10.8 to 13.5 Nm [8 to 10 lbft]. Place the ensure proper torque retention.
2 LS springs (C114, C115) onto the LS spring guide
(C113) and install into the LS bore. Place a new O-ring
(C116) and back-up rings (C117) onto the LS adjustment
screw (C118). Install the LS plug assembly so that it sits C200
5.4 to 7.5 N• m
one turn below the surface of the control housing. [4 to 5.5 lbf•f
t]
Install and tighten set screw (C102) at 7.5 to 10.8 Nm 4 mm
[5.5.to 8.0 lbft]. Also, install the plugs (C105, C106) with C300
3121262 5-213
5.11 GEAR PUMP (SAUER) 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.
5-214 3121262
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.
3121262 5-215
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.
5-216 3121262
10. Remove the shaft seal. 2. Install shaft seal into front flange.
Check the shaft seal quality and remove if necessary. Prepare the flange and shaft seal by lightly lubricating
with grease.
To remove, pry the bottom of the shaft seal and force it
Seat the seal in the flange by hand. Then, using the shaft
out while rotating the flange to lift it out evenly. seal installation tool, press the seal until the tool stops
on the flange. This will insure the seal is inserted to the
Do not use the flange pilot to gain leverage, damage proper depth.
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.
3121262 5-217
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).
5-218 3121262
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.
3121262 5-219
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.
5-220 3121262
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.
3121262 5-221
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.
Threadloacker 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.).
5-222 3121262
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.
3121262 5-223
Trouble Shooting
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.
5-224 3121262
5.12 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.
3121262 5-225
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.
5-226 3121262
3121262 5-227
8 7 6 5 4
Main Lift Cylinder

Bore 9" 63.62 sq in
Swing Drive
Rod 4" 12.56 sq in
6.0 cu in motor Main Telescope Cylinder
H Annulus 51.05 sq in
Bore 5" 19.63 sq in
Stroke 62.125"
Rod 4" 12.56 sq in
Ratio 1.24:1
Annulus 7.07 sq in
Stroke 319.625"
Ratio 2.77:1
B A
F
V1 T
SWIVEL
PORT
#2
M1 1 MS 2 3 M4 4 5 M5 6 M7 7 8 M8
E
2750 3200
PSI 1800 PSI
2000
1500 PSI PSI
PSI
Emergency X X
Lower
D Main Control
B Valve
Swing Lift Telescope MP3
P3
MP 15 PSI
C
W
5 PSI
P1 LS P2 T3 GR T2
SWIVEL
PORT
2800
psi #1
B X
B APU
Variable pump
2.75 in3 (45CC) RETURN FILTER IN TANK
Load sense 300 PSI
Pressure Comp 3400 PSI B15 >= 200
43 PSI BYPASS
A
S L1 L
SHEET 1
8 7 6 5 4
Figure 5-214. Hydraulic Schematic - Sheet 1 of 10
5-228 3121262
5 4 3 2 1
Main Telescope Cylinder

H
Bore 5" 19.63 sq in
Rod 4" 12.56 sq in
Annulus 7.07 sq in
Stroke 319.625"
Ratio 2.77:1
F
V1 T V2
8 M8
E
3200
PSI
Main Control PAGE 1 D

Valve
MAIN BOOM FUNCTIONS
MP3
TO P1 PORT ON JIB CONTROL VALVE

P3
C
HIGH PRESSURE FILTER
B5 >= 1000
GR T2 BYPASS 100 PSI
TO T1 PORT ON JIB CONTROL VALVE
SWIVEL
PORT
#1
RETURN FILTER IN TANK

B15 >= 200
43 PSI BYPASS
SHEET 2 1001120628-G
5 4 3 2 1
MAF11270G
3121262 5-229
8 7 6 5 4
See Page 3 See Page 3

Port "P3" Port "P4"
Traction Control Traction Control
Valve Valve
SWIVEL SWIVEL
PORT V2 V2 PORT
G #1 #1
P T 2500 PSI MA1 P T 2500 PSI
a a
A3
V1 V1
F
P A A1 P A
REAR AXLE CYLINDER REAR AXLE CYLINDER
T B A2 LEFT SIDE RIGHT SIDE T B
2500 PSI 2500 PSI

A4
b b
2600 PSI MA2 2600 PSI

a a
S1
E
MS1 REAR STEER
P A P A
LEFT SIDE
T B T B
MS2
S2
b b
2000 PSI 2000 PSI
2600 PSI 2600 PSI

a a
S3
D
MS3
P A REAR STEER P A
RIGHT SIDE
T B T B
MS4
S4
b b
2000 PSI 2000 PSI
AXLE EXTENSION CYLINDERS STEERING CYLINDERS

B
Bore: 3.5" 9.62 in2 Bore: 4" 12.56 in2
Rod: 2.0" 3.14 in2 Rod: 1.75" 2.4 in2
Annulua: 6.48 in2 Annulua: 10.16 in2
Stroke: 27.125" Stroke: 9.25"
SHEET 3
8 7 6 5 4
5-230 3121262
5 4 3 2 1
See Page 3
Port "P4"
Traction Control
Valve
SWIVEL
V2 PORT V2 V2
#1 G
P T 2500 PSI MA1
a
A3
V1 V1 V1
F
P A A1
REAR AXLE CYLINDER FRONT AXLE CYLINDER FRONT AXLE CYLINDER
RIGHT SIDE T B A2 LEFT SIDE RIGHT SIDE
2500 PSI
A4
b
2600 PSI MA2

a
S1
E
MS1 FRONT STEER
P A
LEFT SIDE
T B
MS2
S2
b
2000 PSI
2600 PSI
a
S3
D
MS3
P A FRONT STEER
RIGHT SIDE
T B
MS4
S4
b
2000 PSI
PAGE 2
AXLE/STEER CONTROL
B
SHEET 4 1001120628-G
5 4 3 2 1
MAF11280G
3121262 5-231
8 7 6 5 4
FRONT DRIVE MIDDLE DRIVE CHARGE PUMP FILTER

PUMP PUMP B10 >= 1000
2.75 in3 2.75 in3 BYPASS 43 PSI
H
T P T P
PS B A G Fe PS B A G Fe
MB MB B
5000psi 5000psi
550
psi
MA MA A
R,T1,T2 R,T1,T2
A B S S
X1 X2 X1 X2
Suction
F Strainer
60 Mesh
Oil (238 Micron)
Cooler 3 PSI Bypass
PORT PORT PORT PORT PORT PORT PORT

#7 #6 #5 #2 #1 SWIVEL PORTS #4 #3
REAR AXLE
LEFT A2
D MP B2
MOTOR
A3
B
G1 G
500 PSI
B3
TRACTION
MANIFOLD
C
A5
B G1 G P2
P1
B1 STEER
BRAKE 2-SPEED
B B5
P4 P3 MBR BR TS A1
See Sheet #2
"P" Port
REAR DRIVE Steer Valve
BRAKES See Sheet #2
"P" Port
Steer Valve
SHEET 5
8 7 6 5 4
5-232 3121262
5 4 3 2 1
CHARGE PUMP FILTER

B10 >= 1000
BYPASS 43 PSI
H
Fe
Suction
Strainer F
60 Mesh
(238 Micron)
3 PSI Bypass
PORT PORT PORT

#4 #3 #7
E
FRONT AXLE
A2 LEFT
B2
MOTOR
A4 V V
B
G
G1
P P
L D
L1
A
B4
OSCILLATING
AXLE CIRCUIT
LOP
MLOP C
A6
FRONT DRIVE
B BRAKES
G
G1
L
PAGE 3
2-SPEED L1
B6 A DRIVE SYSTEM B
TS A1 REXROTH PUMPS
SHEET 6 1001120628-G
5 4 3 2 1
MAF11290G
3121262 5-233
8 7 6 5 4
M14 M14
H Front Rear
C2 C1
Drive C1 C2 Drive
Pump Pump
M3 MB MC E
F00B F00A F00B F00A
L3
L1
G
CW CW
M5 M4 L2 MA A B C D MD M5 M4
F
To port B, Main control
valve, page 1.
To port T2, main control

valve, Page 1
PORT PORT PORT PORT PORT PORT PORT

#7 #6 #5 #2 #1 SWIVEL PORTS #4 #3
REAR AXLE
LEFT A2
D MP B2
MOTOR
A3 A4
B
G1 G
500 PSI
D
B3 B4
LOP
TRACTION
MANIFOLD
C MLOP
A5 A6
B G1 G P2
P1
B1 STEER
BRAKE 2-SPEED
B
B5 B6
P4 P3 MBR BR TS A1
See Sheet #2
"P" Port
Steer Valve
See Sheet #2
"P" Port
REAR DRIVE FRONT DRIVE
Steer Valve
BRAKES BRAKES
A
SHEET 7
8 7 6 5 4
5-234 3121262
5 4 3 2 1
M14
Rear CHARGE PUMP FILTER H
C1
C2 Drive B5 >= 200
Pump BYPASS 50 PSI
Front Pump CHARGE PUMP

F00B F00A Fire coil C1; flow to port A, measure at port M4 1.025 in3
Fire coil C2; flow to port B; measure at port M5
L3 Rear Pump
Fire coil C1; flow to port C; measure at port M4
Fire coil C2; flow to port D; measure at port M5
30 Mesh
3 PSI Bypass G
CW
Oil Cooler Option

Port L3 of the pump
MD M5 M4 to the inlet of the
cooler. Cooler outlet
back to tank.
PORT PORT PORT

#4 #3 #7
FRONT AXLE
A2 LEFT
B2
MOTOR
A4 V V
B
G
G1
P P D
L
L1
A
B4
OSCILLATING
LOP AXLE CIRCUIT
MLOP
PAGE 4 C
A6
B
DRIVE SYSTEM
G
G1 SAUER/DANFOSS
L
PUMPS
BRAKE 2-SPEED L1
B
B6 A
TS A1
FRONT DRIVE
BRAKES
A
SHEET 8 1001120628-G
5 4 3 2 1
MAF11300G
3121262 5-235
8 7 6 5 4
C1 C2
H
JIB STOW ROTATOR
66 CU IN
10:1 PILOT RATIO
SPRING 3300 PSI
V1 T V2
JIB TELESCOPE CYLINDER

BORE 2.5" 4.91 sq in
G ROD 1.5" 1.78 sq in JIB LIFT CYLINDER
JIB LEVEL CYLINDER ANNULAR 3.14 sq in BORE 5" 19.63 sq in
BORE 5.5" 23.76 sq in STROKE 117.880" ROD 2.5" 4.91 sq in
ROD 2.5" 4.91 sq in RATIO 1.56:1 ANNULAR 14.73 sq in
ANNULAR 18.85 sq in STROKE 25.15"
STROKE 16.59" RATIO 1.33:1
RATIO 1.26:1
V2 V1
V2 V1
F
V1 V2
MTB
MLA MLB MTA MJA
LA LB TA TB SA SB JB MJB
JA
+0 +0
2600 - 50 2850
PSI - 50 +50
E PSI +50
1200 2800 -0
-0
+50 PSI PSI
1500 +50 2850 - 0
PSI -0 PSI
T3 0.3 2.0
GPM GPM
T2
T1
TO GR
C PORT ON
MAIN
CONTROL
VALVE
MP
TO PORT ON
HIGH PRESSURE
FILTER
B
P1
JIB CONTROL VALVE

P2
SHEET 9
8 7 6 5 4
5-236 3121262
5 4 3 2 1
C2
H
JIB STOW ROTATOR
66 CU IN
10:1 PILOT RATIO
SPRING 3300 PSI
T V2
PLATFORM ROTATOR
14.1 cu in
3:1 PILOT RATIO
SPRING 3000 PSI
G
JIB LIFT CYLINDER
BORE 5" 19.63 sq in
ROD 2.5" 4.91 sq in PLATFORM LEVEL CYLINDER C1 C2
ANNULAR 14.73 sq in BORE 3.5" 9.62 sq in
STROKE 25.15" ROD 1.5" 1.76 sq in
RATIO 1.33:1 JIB LOCK CYLINDER
ANNULAR 7.85 sq in BORE 2.5" 4.91 sq in
STROKE 14.79" ROD 1.75" 2.41 sq in
RATIO 1.23:1 ANNULAR 2.50 sq in
V1 STROKE 13.375"
RATIO 1.96:1
V2
V1 T V2
V2
V1
SB MJA
JA JB MJB
L1 L2 ML2
ML1 R1 R2 S2
S1
+50 +50 E
1200 2800 -0 + 0
-0 2000
PSI PSI - 50
PSI
2500 +50 2500 +50

PSI -0 PSI -0
2.0
GPM 0.2
GPM
T2
T1 C
MP 2.0
GPM
P PLATFORM CONTROL VALVE

B
JIB CONTROL VALVE PAGE 5

JIB BOOM FUNCTIONS
SHEET 10 1001120628-G
5 4 3 2 1
MAF11310G
3121262 5-237
NOTES:
5-238 3121262
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
3121262 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 3121262
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
3121262 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 3121262
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
3121262 6-5
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
6-6 3121262
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
3121262 6-7
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 personal-
ity settings first and then changing the model number of the machine configuration will cause the personality settings
to return to default values.
MODEL NUMBER: 0 No Model 1

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) 3(1500SJ)

4 6(1850SJ)
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)
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.
6-8 3121262
Default
Number
ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil
pressure is less than 8 PSI.
FUEL CUTOUT: 0 RESTART: Engine allowed to be restarted multiple times when very low fuel level is reached. 0
8*
1 ONE RESTART: Engine allowed to be restarted once for 2 minutes when very low fuel level is reached.
2 ENGINE STOP: Engine not able to restart when very low fuel level is reached.
* This menu item is only visible if non-dual fuel engines are selected.
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.
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out,
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.
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.
3121262 6-9
Default
Number
DRIVE: 0 2WD drive mode enabled. 1

12
1 4WD drive mode enabled.
SOFT TOUCH/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.
LOAD SYSTEM: 0 NO: No load sensor installed. 0

17*
1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
sec ON, 2 sec OFF).
4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform
alarm beeps (5 sec ON, 2 sec OFF).
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
LOAD TYPE: 0 NO CAN LSS: Non CAN based LSS installed. 1

18
1 CAN LSS: CAN based LSS installed.
6-10 3121262
Default
Number
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.
* Only visible under certain market selections.
* 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 133 teeth.
2 112 TEETH: Engine speed is calculated using 112 teeth.
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 UNTIS: 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.
3121262 6-11
Default
Number
FUEL TANK: 0 52 Gallon Fuel Tank 0

26
1 31 Gallon Fuel Tank
2 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
TEMP CUTOUT: 0 NO: No temperature cutout. 0

29*
1 YES: Temperature cutout enabled.
PLAT LVL OVR CUT: 0 NO: No platform cutout. 0

30
1 YES: Platform cutout enabled.
CRIBBING: 0 NO: Cribbing is not installed. 0

31*
1 YES: Cribbing is installed.
WATER IN FUEL SENSOR: 0 NO: Water in Fuel Sensor Option not installed. 0
32
1 YES: Water in Fuel Sensor Option installed.
6-12 3121262
Default
Number
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
3121262 6-13
Table 6-3. Machine Configuration Programming Settings

(Software Version P7.29)
ANSI Export
Australia
ANSI USA
Japan
CSA
1500SJ
CE
ANSI Export
Australia
ANSI USA
Japan
CSA
1500SJ
CE
Gen Set Cutout 0 0 0 0 0 0
Model Number 1 1 1 1 1 1 1 1 1 1 1 1
Envelope Height 0 0 0 0 0 0 Head & Taillights 0 0 0 0 0 0
Market 0 1 2 3 4 5 1 1 1 1 1 1
Engine 1 1 1 1 1 1 Load System 0 0 0 0 0 0
2 2 2 2 2 2 X 1 X 2 2 1
3 3 3 3 3 3 X 2 X 2 2 2
4 4 4 4 4 4 X 3 X 3 3 3
5 5 5 5 5 5 X 4 X X 4 4
6 6 6 6 6 6 Load Type 0 0 0 0 0 0
Glow Plug 0 0 0 0 0 0 1 1 1 1 1 1
1 1 1 1 1 1 Function Cutout X 0 0 1 0 0
2 2 2 2 2 2 X 1 1 X 1 1
Starter Lockout 0 0 0 0 0 0 X 2 2 X 2 2
1 1 1 1 1 1 3 3 3 X 3 3
Engine Shutdown 0 0 0 0 0 0 Ground Alarm 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Fuel 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
2 2 2 2 2 2 Flywheel Teeth 0 0 0 0 0 0
Chasis 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 Oscillating Axle 0 0 0 0 0 0
4 4 4 4 4 4 1 1 1 1 1 1
5 5 5 5 5 5 Display Units 0 0 0 0 0 0
Jib 0 0 0 0 0 0 1 1 1 1 1 1
1 1 1 1 1 1 Leveling Mode 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
4 Wheel Steer 0 0 0 0 0 0 ClearSky 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Drive Type 0 0 0 0 0 0 Fuel Tank 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Soft Touch/SkyGuard 0 0 0 0 0 0 2 2 2 2 2 2
1 1 1 1 1 1 Alert Beacon 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
3 3 3 3 3 3
Gen Set / Welder 0 0 0 0 0 0
1 1 1 1 1 1
2 2 2 2 2 2
6-14 3121262

ANSI Export
Australia
ANSI USA
Japan
CSA
1500SJ
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
1 1 1 X X 1
Water in Fuel Sensor X 0 X X X X
X 1 X X X X
Alarm/Horn X X X X X X
X X X X X X
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.
3121262 6-15
6.2 MACHINE PERSONALITY SETTINGS AND NOTE: Personality settings can be adjusted within the adjustment
range in order to achieve optimum machine performance.
FUNCTION SPEEDS
Table 6-4. Machine Personality Settings and Function Speeds
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 44-48 (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 93-104 (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
6-16 3121262
SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
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% 60 80-120 (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 85-110 (see orientation)
speed
CREEP DOWN XX% Displays/adjusts maximum main lift down 0 to 75% 45
speed
active
SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2

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% 40
MAX LEFT XXX% Displays/adjusts maximum swing left speed 0 to 100% 65 110-130 (see orientation)
CREEP LEFT XX% Displays/adjusts maximum swing left speed 0 to 65% 52
active
MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 40
MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 100% 60 110-130 (see orientation)
CREEP RIGHT XX% Displays/adjusts maximum swing right speed 0 to 65% 47
active
MAIN 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 30-45 (see orientation)
speed
MIN OUT XX% Displays/adjusts minimum main telescope out 0 to 65% 10
MAX OUT XXX% Displays/adjusts maximum main telescope out 0 to 100% 60 40-60 (see orientation)
speed
3121262 6-17
SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
PLATFORM LEVEL: ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5
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
PLATFORM ROTATE: ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1
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 24-30 (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 24-30 (180°)
speed
6-18 3121262
SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
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% 65

as Creep speed
MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 85 70-120
MIN DOWN XX% Displays/adjusts minimum jib down speed. 0 to 65% 60
Same as Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 85 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 20-35(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 15-25 (see orientation)
3121262 6-19
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 100% 60

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
GEN
SET/WELDER = 0
1001128803-F
6-20 3121262
6.3 MACHINE ORIENTATION WHEN SETTING Test Notes

FUNCTION SPEEDS 1. Personality settings can be adjusted anywhere within
the adjustment range in order to achieve optimum
LIFT UP, from platform control, lowest elevation up to maxi-
machine performance.
mum elevation, boom retracted, jib retracted.
2. Stop watch should start when the function is activated,
LIFT DOWN, from platform control, maximum elevation down not with the controller or switch.
to minimum elevation, boom retracted, jib retracted.
3. Unless noted, function speeds should be measured from
JIB LIFT UP, from platform control, lowest jib elevation up to platform.
maximum jib elevation, boom retracted, jib retracted.
4. Platform speed knob must be at full speed (fully clock-
JIB LIFT DOWN, from platform control, maximum jib elevation wise).
down to minimum jib elevation, boom retracted, jib retracted. 5. All test should be done with the oil temp above 100° F
(38° C).
SWING RIGHT(Max),360 Degrees, from platform control,
boom approximately 45° elevation, boom retracted, jib
retracted.
SWING LEFT (Max), 360 Degrees, from platform control,

boom approximately 45° elevation, boom retracted, jib
retracted.
TELESCOPE OUT, from platform control, boom @ 20 degrees,

500 lb. capacity selected.
TELESCOPE IN, from platform control, boom @20 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 set-

ting, platform speed knob at full creep
DRIVE REVERSE (Creep Max), high torque - low speed set-

ting, platform speed knob at full creep
DRIVE FORWARD (Elevated Max - Boom Beyond Trans-

port), high speed - low torque setting, platform speed knob
out of creep, Lift boom above transport, drive forward 50 ft.
DRIVE REVERSE (Elevated Max - Boom Beyond Transport),

high speed - low torque setting, platform speed knob out of
creep, Lift boom above transport, drive backward 50 ft.
3121262 6-21
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).
Interlocks: Any device that sends an electrical input. (For an
Two-wire: One wire (red) is driven high (5v) and the other low
example a limit switch, proximity switch, etc;)
(black) (0v) to send a signal; both wires ”float” (2.5v) when 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;
Steer: The GROUND MODULE stores crack points, sends
the high bus speed allow all modules to be constantly
desired drive direction, sends steering mode and sends axle
updated around 20 times per second. Typical traffic is 300 -
extend / retract commands. The PLATFORM MODULE reports
500 messages per second.
the steering switch position to the GROUND MODULE. The
CHASSIS MODULE modulates each steer left / right valve to
A complete CANbus circuit is approximately 60 ohms, which
maintain commanded wheel position.
can be verified at the ”T” fitting inside the ground station or
below the BLAM. Each individual circuit from the modules is Drive: The GROUND MODULE stores crack points, sends com-
approximately 120 ohms. mands for each drive pump to the BLAM. (Command is com-
puted from drive joystick input, interlocks, wheel angle, etc).
BLAM maintains proper current for the drive pumps by modu-
lating PWM outputs.
Lift, Tele, & Swing: The GROUND MODULE stores default val-
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.
6-22 3121262
Figure 6-2. Control System Block Diagram
3121262 6-23
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
degree of function interaction. For safety and proper machine Calibration Lift proportional valve/coil replacement
functionality, the calibration procedures must be repeated for Erratic controlled arc operation
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 Ground module replacement
motors, or pumps. Calibration Telescope proportional valve replacement
Erratic controlled arc operation
The chart below lists the calibrations required and potential Erratic controlled boom angle operation
reasons for re-calibration. All calibration procedures are menu
driven through the use of the standard analyzer. With the Jib Level Crack Point Jib Control Module replacement
exception of steering calibration, no external tools are Calibration Jib level proportional valve replacement
required to complete the calibration procedures.
Chassis Tilt Ground module removal or replacement
The user is prompted to exercise the machine in a specific Calibration Main terminal box removal or replacement
order to use the machines physical properties to consistently Tilt indication inaccuracy
establish sensor response and the interaction of valves, Boom Sensors Ground module removal or replacement
pumps, and motors. Steering calibration also uses the analyzer Calibration BLAM module removal or replacement
and is performed on one side of the machine at a time requir- Boom angle sensor removal or replacement
ing the use of a string or other means to determine when the Boom length sensor removal or replacement
tires are in line with each other. Calibrations are accessed by Moment pin removal or replacement
connecting the analyzer into the control system inside the Main Boom angle sensor calibration fault
main terminal box or on the bottom of the platform control Main Boom length sensor calibration fault
box. Moment pin fault
Failed BCS functional check
Table 6-5. Calibration Instructions Boom control system inaccuracies
Jib Sensor Calibration Ground module removal or replacement

Calibration Reasons for Re-calibration Replacement of any Jib sensor
Procedure Replacement of the Jib Control Module
Steering Calibration Ground module replacement Platform Load Control LSS module replacement
Chassis module replacement Calibration Load cell removal or replacement
Steer sensor removal or replacement Load control inaccuracy
Persistent wheel misalignment
Drive Calibration Ground module replacement

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

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

Calibration Ground module replacement
Platform level valve/coil replacement
Erratic platform leveling
Jib Level Crack Point Ground Module replacement

Calibration Jib Control Module replacement
Jib Level Sensor replacement
Jib Level valve/coil replacement
Erratic jib leveling
6-24 3121262
ANALYZER MENU
STRUCTURE
3121262
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 6-3. Analyzer Flow Chart - Sheet 1 of 5 (Software Version P7.29)
6-25
6-26
FROM
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
1 1 1 1 1 1 1 1 1
MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

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
3121262
FROM
MENU:
CALIBRATIONS
3121262
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 6-5. Analyzer Flow Chart - Sheet 3 of 5 (Software VersionP 7.29)
6-27
6-28
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
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 2 SKY WELDER 2

PRESS. REDUCTION
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 2 SKY GLAZIER 2
CHASSIS PRESSURE
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
3121262
FROM 2 2 2 2
DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS:
CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
PLATFORM LOAD
CAN1 STATISTICS 2 PLATFORM UP CAL: 2 DATALOG: 2 GROUND MODULE 2
3121262
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
6-29
Figure 6-8. Control Module Location
6-30 3121262
This page left blank intentionally
3121262 6-31
J8
J1
J7
J12
J2
J3 J4
1001119509-T
MAF07260T
Figure 6-9. Ground Control Module
6-32 3121262
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
FLYWHEEL SPEED PICKUP 15 DIGITAL OUTPUT
16 FREQUENCY INPUT COMM. ENABLE
(DIESEL ONLY) 16 UPPER TELESCOPE OUT DIGITAL OUTPUT
J1 17 GROUND GROUND INPUT J2 17 GROUND GROUND INPUT
18 SPARE GROUND GROUND INPUT 18 SPARE PIN GROUND INPUT
(Natural) 19 SPARE GROUND GROUND INPUT (Gray) 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
22 GENERATOR/WELDER (OPTION) DIGITAL OUTPUT 21 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
SWITCH 35 SWING RIGHT DIGITAL OUTPUT
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
3121262 6-33

1 SPARE VAVLE RETURN 1 GROUND INPUT Connector Pin Function Type
2 SPARE VAVLE RETURN 2 GROUND INPUT 1 PLATFORM EMS DIGITAL INPUT
3 GROUND GROUND INPUT 2 PLATFORM MODE DIGITAL INPUT
4 SPARE VAVLE RETURN 4 GROUND INPUT 3 GROUND MODE DIGITAL INPUT
5 SPARE VAVLE RETURN 5 GROUND INPUT 4 TOWER CYLINDER PRESSURE ANALOG INPUT
6 SPARE VAVLE RETURN 6 GROUND INPUT 5 REFERENCE VOLTAGE VOLTAGE OUTPUT
7 VBAT VBAT OUTPUT 6 CAN TERMINATION TERM I/O
J3 SPARE HS DIGITAL IN (FREQ. 7 SPARE ANALOG INPUT
8 DIGITAL INPUT 8 SPARE ANALOG INPUT 2 ANALOG INPUT
(Black) CAPABLE)
9 GROUND GROUND INPUT
9 ALTERNATOR EXCITATION INPUT DIGITAL INPUT
SPARE HS SWITCH INPUT (MODEL
10 DIGITAL INPUT 11 BOOM RETRACTED CLOSED DIGITAL INPUT
INPUT FOR 1100S) 12 BROKEN CABLE SWITCH DIGITAL IPUT
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
J7 19 SPARE PIN GROUND INPUT
1 AXLES SET LAMP DIGITAL OUTPUT
(Black) 20 SPARE ANALOG INPUT 1 ANALOG INPUT
2 500# CAPACITY LAMP DIGITAL OUTPUT
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
28 GROUND INPUT
MAIN TOWER TRANSPORT ANGLE OPTION)
11 DIGITAL INPUT 29 VBAT VBAT OUTPUT
OPEN
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
33 VBAT OUTPUT
16 AUXILIARY POWER DIGITAL INPUT 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
32 SPARE PIN GROUND INPUT
33 UPPER LIFT DOWN DIGITAL INPUT
34 SWING LEFT DIGITAL INPUT
35 SWING RIGHT DIGITAL INPUT
6-34 3121262
3121262 6-35
J5
J2
J8
J6
J7
J1
1600343-R
MAF07630R
Figure 6-10. Platform Control Module
6-36 3121262
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

LIFT / SWING JOYSTICK SUPPLY
CONNECTOR PIN ASSIGNMENT FUNCTION 1 SUPPLY VOLTAGE
DRIVE / STEER JOYSTICK SUPPLY VOLTAGE
1 SUPPLY VOLTAGE 2 LIFT CENTER TAP ANALOG INPUT
VOLTAGE
J5 3 LIFT SIGNAL ANALOG INPUT
2 DRIVE CENTER TAP ANALOG INPUT
4 SWING SIGNAL ANALOG INPUT
J6 3 DRIVE SIGNAL ANALOG INPUT (NATURAL)
5 SWING CENTER TAP ANALOG INPUT
4 STEER SIGNAL ANALOG INPUT
(BLACK) 6 NOT CONNECTED ANALOG INPUT
5 STEER LEFT ANALOG INPUT
7 LIFT / SWING JOYSTICK RETURN GRPOUND
6 STEER RIGHT ANALOG INPUT
8 SPARE PIN BLANK
7 DRIVE / STEER JOYSTICK RETURN GROUND
8 SPARE PIN BLANK

1 MODULE GROUND GROUND
J8
2 MODULE POWER BATTERY VOLTAGE
3121262 6-37

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
6-38 3121262
3121262 6-39
J1 J2
Gray Black
J4
Gray
Green Brown
J3 J5
1001112758-I
MAF07890I
Figure 6-11. Chasis Control Module
6-40 3121262

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
3121262 6-41
J1 J2
Gray Black
J4
Gray
Green Brown
J3 J5
1001112757-I
MAF07870I
Figure 6-12. BLAM Control Module (SN 030020900 through 0300248621)
6-42 3121262

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

3 CANBUS HIGH SERIAL I/O
(Gray) 5 CANBUS SHIELD POWER INPUT
6 BOOTSTRAP MODE DIGITAL INPUT

2 REF VOLTAGE FROM J3-1 ANALOG INPUT
5 MAIN CYL ANGLE #1(ABSOLUTE) ANALOG INPUT
8 BOOM LENGTH SENSOR ANALOG INPUT
3121262 6-43
J1 J2
Gray Black
J4
Gray
Green Brown
J3 J5
1001227960-C
MAF07920C
Figure 6-13. BLAM Control Module (SN 0300248622 to Present)
6-44 3121262

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
3121262 6-45
J1 J2
Gray Black
J4
Gray
Green Brown
J3 J5
1001119262-C
MAF07910C
Figure 6-14. Jib Control Module
6-46 3121262

1 Jib Lift Up Digital Output
1 Power Feed Thru to J2-1 Power I/O
2 Jib Lift Down Digital Output
3 Jib Swing Right Digital Output
3 Signal Feed Thru to J2-4 Digital Input
4 Jib Swing Left Digital Output
4 Master Ground Connect Power Input
5 Jib Telescope In Digital Output
5 Master Ignition Connect Power Input J5 6 Jib Telescope Out Digital Output
J1 6 CANbus High Serial I/O
(Brown) 7 Spare Output Digital Output
(Gray) 7 CANbus Low Serial I/O
8 Spare Output Digital Output
8 CANbus Shield Serial I/O
9 Ignition Power Output
9 CANbus Terminator Serial I/O
10 RS232 Receive Serial Input
10 CANbus Terminator Serial I/O
11 RS232 Transmit Serial Output
12 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

3 CANbus High Serial I/O
J4 4 CANbus Low Serial I/O
(Gray) 5 CANbus Shield Power Input
6 Bootstrap Mode Digital Input
3121262 6-47
PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 6-15. Analyzer Connecting Points
6-48 3121262
6.6 CONTROL SYSTEM BOOM SENSORS Sensor #2 - Main Boom Angle Sensors
NOTE: Note: The machine is defined as being in transport mode if:
Axles are retracted.

Main boom lift is below elevation angle.
Main boom telescope is fully retracted.
Jib boom telescope is fully retracted.
Jib boom locked inline with the main boom via the jib lock
pin.
Turntable swung so that the main boom is between the
rear wheels.
The Boom Control System (BCS) uses a number of sensors to

measure the position of the boom. The sensors used to deter-
mine main boom and jib boom position are shown in Figure 6-
16., Control System Boom Sensors.
Sensor #1 -Moment Pin
MOMENT
PIN
These sensors measure Main Boom angle in reference to grav-

ity. They are located in the rear of the Base Boom and mounted
such that they generate opposing signals with respect to
boom movement.
The Main Lift Cylinder is attached to the Turntable with a

Moment pin. This pin is fixed to the Turntable so as to allow
measurement of the force exerted by the cylinder regardless
of the cylinder orientation.
3121262 6-49
MAIN BOOM LIMIT SWITCH
MAIN BOOM STRING POT
MAIN BOOM
PROTRACTOR JIB TELESCOPE
MAIN BOOM SENSOR PROXIMITY SENSORS
ANGLE SENSORS
PLATFORM
WIRE ROPE PROXIMITY SENSOR LEVEL SENSORS
JIB ROTATE
SENSORS
JIB LEVEL PROTRACTOR SENSOR
JIB LOCK PIN PROXIMITY SENSORS
Figure 6-16. Control System Boom Sensors
6-50 3121262
Sensor #3 - Main Boom Length Sensor Sensor #4 - Main Boom Cylinder Angle Sensor
This sensor’s function is to measure Main Boom angle relative

to the Turntable. A rotary type sensor is mounted to the Turn-
table 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.
Sensor #5 - Main Boom Transport Length Switch
This sensor is used to measure total length of the Main Boom.

It is located in the rear of the Base Boom and consists of a wire
rope attached to a rotating drum.
This switch is used to indicate the Main Boom is in the

retracted position for transport. This sensor is a mechanical
limit switch.
3121262 6-51
Sensor #6 - Jib Level Angle Sensor Sensor #7 - Jib Lock Pin Switch with both normally
open and normally closed outputs
This sensor is used to indicate the Jib Lock Pin is fully engaged.
This is a proximity switch mounted to the Jib Pivot weldment.
Sensor #8 - Jib Stow Angle Sensor
This sensor is used to measure Jib Level angle relative to the This sensor is used to measure Jib swing angle. This is a rotary
Main Boom. A rotary type sensor is mounted between the sensor mounted to the underside of the Jib Pivot weldment. It
Main Boom Fly nose and the Jib Pivot weldment. It is a dual is a dual output sensor in a single mechanical body with elec-
output sensor in a single mechanical body with electrically trically opposing signals.
opposing signals.
Sensor #9 - Jib Lift Angle Sensor
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.
6-52 3121262
Sensor #10 - Dual Capacity / Jib Transport Length Sensor #11 - Platform Level Cylinder Angle Sensor
Switches This sensor is used to measure Platform angle relative to the
Jib. A linear position sensor is located inside the Platform Level
cylinder to measure cylinder stroke.
Sensor #12 - Platform Level Angle Gravity Sensors
These sensors are located on the Platform Support and are

used to measure platform angle with respect to gravity. They
are mounted such that they generate opposing signals.
Sensor #13 - Turntable Swing Angle
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.
This sensor is used to determine turntable swing angle. It is

used for turntable swing control when the boom is in trans-
port position (Axles Retracted). It is a dual output sensor in a
single mechanical body with electrically opposing signals.
3121262 6-53
6.7 JIB CONTROL MODULE 6.8 CAN GATEWAY

See Figure 6-14., Jib Control Module.
The Jib Control Module is mounted at the end of the main

boom to aid in control of Jib Lift, Jib Level, Jib Telescope, and The CAN gateway is located in the ground control box. To
Jib Swing functions and also to process the information trans- decrease overall bus loading, the CAN gateway module
mitted by the Jib Level angle sensor, the Jib Rotate angle sen- divides the CANbus so that the platform module, the jib con-
sor, and the Jib lock pin sensing proximity switch. trol module, the LSS (if equipped), and the in cylinder length
sensors are on gateway CAN bus 2 and the ground module,
the BLAM, the moment pin, and the chassis module are on
gateway CANbus 1. The CAN gateway is transparent to the
control system and passes all messages from one CANbus to
the other.
6-54 3121262
6.9 SYSTEM TEST 3. Before proceeding, ensure that the switches on the plat-
form console are in the following positions:
The Control System Incorporates a built-in system test to a. Drive speed switch is in the Middle position.
check the system components and functions. To use this func- (Turtle Icon)
tion, use the following procedures.
b. 4WS switch is in the Middle position. (2WS mode)
Test from the Platform c. Capacity select switch in the 1000 lb. (450 kg) mode.
d. Function speed potentiometer out of creep mode
1. Position the Platform/Ground select switch to the Plat- switch.
form position. e. Generator (if equipped) switched to the off position.
f. Head and Tail lights (if equipped) switched to the off
position.
2. Plug the analyzer into the connector at the base of the

platform control box.
3121262 6-55
4. Pull out the Emergency Stop switch and Start the 6. Use the arrow button to reach SYSTEM TEST. Hit Enter.
engine. The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
7. Follow the flow path in Figure 6-17., System Test Flow
Chart - Platform Tests and go through the component
tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
5. The analyzer screen should read:
6-56 3121262
3121262
Figure 6-17. System Test Flow Chart - Platform Tests
6-57
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 6-18., System Test Flow

Chart - Ground Station Tests and go through the compo-
nent tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
6-58 3121262
3121262
Figure 6-18. System Test Flow Chart - Ground Station Tests
6-59
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.
6-60 3121262

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.
3121262 6-61

Description
Analyzer Analyzer
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends.
If ENTER is pressed or clicked, each operator input is prompted for in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope switches are not
tested if TOWER TELE=NO. Jib switches are not tested if JIB = NO. Extendable axle switches are
not tested if EXT AXLES=NO. Four wheel steer switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX The named switch should be closed.
OPEN XXXXXXX The named switch should be opened.
XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction.
XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX The pump pot should be turned to maximum.
PUMP POT TO MIN The pump pot should be turned to minimum.
MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could be a short
between two inputs.
TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and
should now be rectified. Press ESC/CANCEL to return to the RUN SYSTEM TEST Analyzer menu.
6-62 3121262
Table 6-7. Machine Diagnostics Parameters
Diagnostics Submenu
Parameter (Displayed on Parameter Value
(Displayed on Analyzer Description
Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
1st Line)
DRIVE:
DRIVE FOR/REV XXX% Displays drive joystick direction & demand
STEER RIGHT/LEFT XXX% Displays steer switch direction & demand
4WS NORMAL/COOR/CRAB Displays status of four wheel steer input (Displayed if 4WS = 1)
BRAKES LOCKED/RELEASED Displays brake control system status
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
CRP MODE ACTIVE/NOT ACT Displays creep mode status
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE =
1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE =
1)
TWO SPEED OP/CL Displays status of two speed switch input if selected model has two speed.
2 speed mode ON/OFF Displays status of two speed valve if selected model has two speed
high engine OP/CL Displays status of high engine switch
LT F ANG XX.X Displays status of left front steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT F ANG XX.X Displays status of right front steer angle (Displayed if MODEL NUMBER = 7 or
8)
LT R ANG XX.X Displays status of left rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT R ANG XX.X Displays status of right rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
DOS LIM sw OP/CL Displays status of Drive Orientation System limit switch. (Displayed if MODEL
NUMBER = 7 or 8)
DOS O/R sw OP/CL Displays status of Drive Orientation Limit System override switch. (Displayed if
MODEL NUMBER = 7 or 8)
3121262 6-63
Diagnostics Submenu
1st Line)
BOOM:
U LIFT UP/DOWN XXX% Displays main lift joystick direction & demand
SWING RIGHT/LEFT XXX% Displays swing joystick direction & demand
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK
TYPE = 1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK
TYPE = 1)
LEVEL UP/DOWN XXX% Displays basket level switch direction & demand. NOTE: demand is controlled
by the pump pot
ROT. RIGHT/LEFT XXX% Displays basket rotate switch direction & demand. NOTE: demand is con-
trolled by the pump pot
U TELE IN/OUT XXX% Displays main telescope switch direction & demand. NOTE: demand is con-
T TELE IN/OUT XXX% Displays tower telescope switch direction & demand. NOTE: demand is con-
Not displayed if TOWER TELE=NO (machine digit = 0)
T LIFT UP/DOWN XXX% Displays tower lift switch direction & demand. NOTE: demand is controlled by
the pump pot
Not displayed if TOWER LIFT=NO (machine digit = 0)
JIB UP/DOWN XXX% Displays jib lift switch direction & demand. NOTE: demand is controlled by the
pump pot
Not displayed if JIB = NO (machine digit = 0)
JIB RIGHT/LEFT XXX% Displays jib swing switch direction & demand. NOTE: demand is controlled by
the pump pot
Displayed if JIB = SIDESWING (machine digit = 2)
JIB INLINE OP/CL Displays status of jib inline limit switch. Displayed on models equipped with
the Jib Stow System
JIB LIMIT OP/CL Displays status of jib right limit switch. Displayed on models equipped with
the Jib Stow System
JIB LIM OVRD OP/CL Displays status of jib limit override switch. Displayed on models equipped
with the Jib Stow System
PCV ON/OFF Displays status of Platform Control Valve. Displayed on models equipped with
Electronic Platform Leveling.
PUMP POT XXX% Displays pump pot demand. Not displayed if MODEL = 601 (machine digit =
4)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
6-64 3121262
Diagnostics Submenu
1st Line)
ENGINE:
START ACTIVE/NOT ACTIVE Displays status of the engine start circuit
AIR FILTER OP/CL Displays measured status of air filter by-pass switch. (Not displayed if MODEL
NUMBER = 7 or 8)
BATTERY XX.XV Displays measured battery voltage
COOLANT XXXC Displays measured coolant temperature
OIL PRS LOW / OK or XXPSI Displays measured oil pressure
FUEL SELECT GAS/LP Displays status of fuel select switch. (Displayed if MODEL NUMBER = 2)
AMB. TEMP XXXC Displays measured ambient air temperature
FUEL LEVEL ¼ / ½ / ¾ / FULL or LOW / OK Displays measured fuel level
XXXX rpm Engine RPM
3121262 6-65
Diagnostics Submenu
1st Line)
SYSTEM:
GM BATTERY XX.XV Ground module battery voltage
PM BATTERY XX.XV Platform module battery voltage
AMB. TEMP XXXC Ambient temperature
FSW1 OP/CL Displays footswitch status. NOTE: FSW1 is wired to the ground module.
FSW2 OP/CL Displays footswitch status. NOTE: FSW2 is wired to the platform module.
ABOVE ELEV. OP/CL/YESNO Displays above elevation cutout switch status or above angle status
LEN SW 1 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 7 or 8)
LEN SW 2 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 7 or 8)
RETRACTED YES/NO Displays status of boom length retracted (Displayed if MODEL NUMBER = 7 or
8)
TRANSPORT YES/NO Displays status of transport position
U LIFT CUTOUT OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 6)
T LIFT PROX OP/CL Displays status of tower lift proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
T TELE PROX OP/CL Displays status of tower telescope proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
BR CABLE CUT. OP/CL Displays status of broken cable switch (Displayed if BROKEN CABLE SWITCH =
1)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status. Not displayed if MODEL = 601
(machine digit = 4)
SUPER CREEP ON/OFF Displays super creep mode status (Displayed if MODEL NUMBER = 7 or 8)
TILT XX.X DEG Displays measured vehicle tilt. (Displayed if internal tilt sensor is configured)
LO TILTED - NO/YES Displays status of lo tilt input. (Displayed if external tilt sensor is configured)
6-66 3121262
Diagnostics Submenu
1st Line)
HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is configured)
AUX POWER OP/CL Displays the status of the auxiliary power switch input
HORN OP/CL Displays the status of the horn input
R FILTER OP/CL Displays the status of the return hydraulic filter by-pass switch. Displayed
ONLY if MODEL = 600 (Configuration digit = 3)
C FILTER OP/CL Displays measured status of charge pump filter bypass switch. Displayed ONLY
if MODEL = 600 (Configuration digit = 3)
JIB BLOCK OP/CL Displays jib block limit switch status. Not displayed if associated configuration
digit = 0
BASKET STOWD YES/NO Displays status of basket stowed mode. (Displayed if MODEL NUMBER = 7 or 8)
SOFT LIMIT OP/CL Displays status of soft touch limit switch. Not displayed if associated configu-
ration digit = 0
SOFT O/R OP/CL Displays status of soft touch override switch. Not displayed if associated con-
figuration digit = 0
GEN SET/WELDER OP/CL Displays generator/welder switch input status. Not displayed if associated
configuration digit = 0
LIGHTS OP/CL Displays head and tail light switch input status. Not displayed if associated
configuration digit = 0
BSK TILT1 XX.X Displays indicated platform tilt angle. Displayed on models equipped with
BSK TILT2 XX.X Displays indicated platform tilt angle. Displayed on models equipped with
AXLE RET SW OP/CL Displays status of axle extension user switches. (Displayed if MODEL NUMBER
= 7 or 8)
AXLE EXT SW OP/CL Displays status of axle retraction user switches. (Displayed if MODEL NUMBER
= 7 or 8)
AXLE LIM SW RET/EXT Displays status of axle extension limit switches. (Displayed if MODEL NUMBER
= 7 or 8)
DOS LIM SW OP/CL Displays status of Drive Orientation System Limit Switch. (Displayed if MODEL
NUMBER = 7 or 8)
DOS O/R SW OP/CL Displays status of Drive Orientation System Override switch. (Displayed if
MODEL NUMBER = 7 or 8)
CAPACITY SW 500/1000 Displays status of capacity selection switch. (Displayed if MODEL NUMBER = 7
or 8)
3121262 6-67
Diagnostics Submenu
1st Line)
OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLATING
AXLE = 1)
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
(Displayed if MODEL NUMBER = 7 or 8)
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration.
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration.
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration.
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration.
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
LOAD: Not displayed if LOAD=NO, LENGTH=NO, and ANGLE=NO (machine digits =

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

load cell will read 1000% Displayed if LOAD is not 0 and LOAD TYPE is 0.
OK/OVERLOADED Displayed if LOAD is not 0 and LOAD TYPE is 1.
6-68 3121262
Diagnostics Submenu
1st Line)
MOMENT: Displayed if MODEL NUMBER = 7 or 8
(LB-IN) ACTUAL XXXXXXXX Displays current moment value
(LB-IN) XXXXXXXX Displays current over moment setpoint.

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

UNDER
CAL PT XXXXXXXX Displays the under moment value recorded during boom sensor calibration.
UNDER
CAL PT XXXXXXXX Displays the yellow witness mark moment value recorded during boom sen-
WIT YEL sor calibration.
CAL PT XXXXXXXX Displays the green witness mark moment value recorded during boom sensor
WIT GRN calibration.
CYL PIN X.XXX Displays the current cylinder moment pin ratio of X and Y forces.
RATIO
PIN 0xXXXX Displays the current error flag status of the cylinder moment pin.
E FLAGS
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration.
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration.
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration.
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration.
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
3121262 6-69
Diagnostics Submenu
1st Line)
ENVELOPE: Displayed if MODEL NUMBER = 7 or 8
LENGTH XXXX.X Displays the current indicated boom length in inches.
ANGLE 1 XX.X Displays the current indicated boom angle 1 in degrees.
ANGLE 2 XX.X Displays the current indicated boom angle 2 in degrees.
A/D LNGTH XXXXX Displays the current indicated boom length in A/D counts.
A/D ANG1 XXXXX Displays the current indicated boom angle 1 in A/D counts or raw angle if cali-
brated.
A/D ANG2 XXXXX Displays the current indicated boom angle 2 in A/D counts or raw angel if cali-
brated.
CAN STATISTICS: CAN Statistics as detected by the Ground Module
RX/SEC XXX Displays the number of received messages per second
TX/SEC XXX Displays the number of transmitted messages per second
BUS OFF XX Displays the number of bus off occurrences
PASSIVE XX Displays the number of bus passive occurrences
6-70 3121262
Diagnostics Submenu
1st Line)
CALIBRATION DATA
BASKET UP XXX Displays the basket up calibration point
BASKET DOWN XXX Displays the basket down calibration point
L FWD DRIVE XXX Displays the left forward drive calibration point
R FWD DRIVE XXX Displays the right forward drive calibration point
L REV DRIVE XXX Displays the left reverse drive calibration point
R REV DRIVE XXX Displays the right reverse drive calibration point
F LT STEER XXX Displays the forward left steer calibration point
F RT STEER XXX Displays the forward right steer calibration point
R LT STEER XXX Displays the reverse left steer calibration point
R RT STEER XXX Displays the reverse right steer calibration point
U LIFT UP XXX Displays the main lift up calibration point
U LIFT DOWN XXX Displays the main lift down calibration point
U TELE IN XXX Displays the main telescope in calibration point
U TELE OUT XXX Displays the main telescope out calibration point
BM ANG 1 LO XXX Displays the boom angle 1 low calibration point
BM ANG 1 HI XXX Displays the boom angle 1 high calibration point
BM ANG 2 LO XXX Displays the boom angle 2 low calibration point
BM ANG 2 HI XXX Displays the boom angle 2 high calibration point
LEN RETRACT XXX Displays the length sensor retracted calibration point
LEN EXTEND XXXXX Displays the length sensor extended calibration point
LEN WIT XXXXX Displays the witness mark calibration point
LEN SWITCH XXXX Displays the length switch calibration point
3121262 6-71
Diagnostics Submenu
1st Line)
DATALOG:
ON XXXXhXXm Displays total controller on (EMS) time
ENGINE XXXXhXXm Display engine run time
DRIVE XXXXhXXm Displays total controller drive operation time
LIFT XXXXhXXm Displays total controller lift operation time
SWING XXXXhXXm Displays total controller swing operation time
TELE XXXXhXXm Displays total controller telescope operation time
MAX TEMP XXC Displays maximum measured ambient temp.
MIN TEMP XXC Displays minimum measured ambient temp.
MAX VOLTS XX.XV Displays maximum measured battery voltage
RENTAL XXXXhXXm Displays total controller operation time. NOTE: can be reset
ERASE RENTAL? Not available at OPERATOR ACCESS.

ENTER resets rental data log time to zero.
VERSIONS:
GM SW PX.X Displays ground module software version
GM HW REV XXXX Displays ground module hardware revision
GM SN XXXXXX Displays ground module serial number
PM SW PX.X Displays platform module software version
PM HW REV XXXX Displays platform module hardware revision
PM SN XXXXXX Displays platform module serial number
CM SW PX.X Displays chassis module software version
BM SW PX.X Displays BLAM module software version
C PIN SW Displayed if cylinder moment load pin transmits software version.
C PIN SN Displayed if cylinder moment load pin transmits serial number.
ANALYZER VX.XXXX Displays Analyzer software version
6-72 3121262
6.10 CALIBRATING STEER 1. Position the Platform/Ground select switch to the Plat-
form position.
When calibrating steering, each individual wheel must be cali-
brated in order to make the tire and wheel parallel with the
frame. Two methods to help ensure proper calibration are the
use of a carpenter’s square to square the spindle to the axle or
aligning the two wheels on one side using a stretched string.

3121262 6-73
3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Steer. The screen will read:
engine.
9. Hit Enter. The screen will read:
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.
6-74 3121262
10. Hit Enter. The screen will read: 13. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer.
15. Left Rear Steer Calibration will be followed by Right For-
ward Steer Calibration which will be followed by Right
Rear Steer Calibration.
16. After completing all the Steer Calibrations, hit ESC twice
to go back to CALIBRATIONS.
12. Activate the steer control until the tire and wheel are
straight in relationship with the chassis, then leave off
the control. The display will read FRT LEFT = and show
the numeric calibration value for that wheel.
3121262 6-75
6.11 CALIBRATING DRIVE 3. Pull out the Emergency Stop switch and Start the
engine.
1. Position the Platform/Ground select switch to the Plat-
form position.


Enter.
Enter.
6-76 3121262
8. Use the arrow keys to reach DRIVE. 10. Hit Enter again. The screen will read:
9. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read:
12. Activate the Drive Joystick forward full stroke until the
machine just begins to move, then leave off the joystick
immediately. The display will read CRK PT = and show
the numeric crack point value.
3121262 6-77
13. Hit Enter. The number displayed will be the value that 14. Hit Enter. The screen will read:
the crack point is set to. The screen will show:
15. Repeat steps 10 thru 12 for left reverse drive.

16. Left Reverse Drive Calibration will be followed by Right
Forward Drive Calibration which will be followed by
Right Reverse Calibration.
17. After completing all the Drive Calibrations, hit ESC twice
6-78 3121262
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).
3121262 6-79
Diagnostic Menu Press the LEFT and RIGHT Arrow keys to view the displays and
select the various sub-menus. To access a sub-menu, press the
The Diagnostic Menu is another troubleshooting tool for the ENTER key. Once in a sub-menu, press the LEFT and RIGHT
Load Sensing System. Sensor and status information is pre- Arrow keys to view the various displays (just like a Top Level
sented in real-time for the technician. Several sub-menus exist
to organize the data.
menu). To exit a sub-menu, press the ESC key .
Table 6-8, Diagnostic Menu Descriptions details the structure
To access the Diagnostic Menu, use the LEFT and RIGHT of the Diagnostic Menu, and describes the meaning of each
piece of information presented.
Arrow keys to select DIAGNOSTICS from the Top Level
Menu. Press the ENTER key to view the menu.
Table 6-8. Diagnostic Menu Descriptions
Diagnostics Menu Parameter (Displayed on Parameter Value

Description
(Displayed on Analyzer 1st Line) Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
PLATFORM LOAD STATE: OK / OVERLOAD LSS Status.
PLATFORM LOAD ACTUAL: XXX.X KG Calibrated weight of the platform.
??? if Platform Load is Unhealthy**.
PLATFORM LOAD (service*) GROSS: XXX.X KG Gross weight of the platform.
??? if both Cells are Unhealthy**.
PLATFORM LOAD (service*) OFFSET 1: XXX.X KG Stored offset weight of Cell 1.
??? if LSS is not calibrated.
PLATFORM LOAD (service*) OFFSET 2: XXX.X KG Stored offset weight of Cell 1.
PLATFORM LOAD (service*) ACCESSORY XXX.X KG Stored accessory weight.
PLATFORM LOAD (service*) UNRESTRICT XXX.X KG UGM will set Unrestricted Rated Load as defined by Machine Con-
figuration.
PLATFORM LOAD (service*) RESTRICT XXX.X KG UGM will set Restricted Rated Load as defined by Machine Config-
uration.
PLATFORM LOAD (service*) RAW 1: XXX.X KG Gross value from Cell 1.
??? if Unhealthy**.
PLATFORM LOAD (service*) RAW 2: XXX.X KG Gross value from Cell 2.
??? if Unhealthy**.
* Indicates only visible in service view mode
** Typically indicates a DTC is active
6-80 3121262
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).
3121262 6-81
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 6-9, 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 6-9. 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.
6-82 3121262
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:
3121262 6-83
12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-11. 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 6-10, SkyGlazier Capacity 500 lb (227 kg) 400 lb (181 kg) n/a
Reductions and Table 6-11, Pipe Rack Capacity Reduc- 550 lb (250 kg) 450 lb (204 kg) n/a
tions.
600 lb (272 kg) 500 lb (227 kg) n/a
The screen will read: 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 6-10, SkyGlazier Capacity
Reductions and Table 6-11, Pipe Rack Capacity Reduc-
tions.
Table 6-10. 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.
6-84 3121262
14. Press ENTER . If calibration is successful, the screen

will read:
3121262 6-85
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).
6-86 3121262
Troubleshooting
The following tables are furnished to provide possible resolu-
tions for common difficulties. Difficulties are classified as Gen-
eral, Calibration, Measurement Performance, and Host System
Functionality.
Table 6-12. LSS Troubleshooting Chart
Difficulty Possible Resolution

Empty Platform Weight (DIAGNOSTICS, PLAT- The LSS System is unable to properly measure the platform weight.
FORM LOAD) is not within ±15lbs (±7kg) of
zero. 1. The Load Cell is not properly plugged into the LSS Harness. It is possible poor electrical contact is made.
or
Platform Load readings (DIAGNOTICS, PLTLOAD) 2. Wiring leading to the Load Cell is damaged. Carefully inspect sensor wiring where it passes through cable clamps for signs of damage.
are unstable by more than ±2lbs (±1kg) (with- Inspect wiring where damage to the channel is apparent.
out the influence of vibration or wind).
or 3. The Load Cell was not assembled properly during installation. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAG-
There are large variations in Platform Load NOSTICS, CELL, LOAD displays and determine if the readings are reasonable. It is often helpful to apply slight downward pressure above the
(DIAGNOSTICS, PLTLOAD) based on the location sensor and observe that its output increases (increasing force measurement; decreasing means the sensor is mounted upside-down).
of the load. Tolerance to variations is 20lbs for
an evaluation using the technician’s weight, 4. The Load Cell is contaminated by debris or moisture. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS,
and +5% of Rated Load when using calibrated CELL, LOAD displays and determine if the readings are reasonable and stable (not changing by more than ±2lbs (±1kg) (without the influ-
weights. ence of vibration or wind). Lack of measurement stability is a key indication of contamination. Unplug the connector and inspect for dirt or
moisture. Look carefully into the female connector on the sensor’s cordset for evidence of contamination. Debris should be brushed away
with a soft bristle brush (do not introduce any cleaners as they will leave conductive residue). Moisture should be allowed to evaporate or
accelerated with a heat-gun (use low heat and be carefully to not melt connector materials). Moisture intrusion into the molded portion of
the connector (capillary action into the wire bundle) or the Shear Beam Load Cell itself will require replacement of the sensor.
5. The Load Cell has been mechanically damaged. If the Load Cell is physically deformed or has damage to the cover it should be replaced
immediately. It is also possible to have invisible mechanical damage resulting from an extreme overload (>6000lbs [>2722kg]).
The Visual and Audible Overload Warnings fail The Control System is failing to regard the overload signal from the LSS System, or the signal is shorted.
to sound when platform is loaded beyond Rated
Load, or when simulated by unplugging the 1. The Load Sensing System must be enabled within the Control System. Plug the JLG Analyzer into the Control System, enter the Access
Load Cell. Controls remain functional at Plat- Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu. The selection “2=CUTOUT PLT” should be displayed (plat-
form and Ground Control positions. form controls prevented during overload, ground controls remain operational). In country- or customer-specific circumstance, the selec-
tion “3=CUTOUT ALL” is used (platform and ground controls prevented during overload).
The Ground Audible Warning fails to sound, but The Ground Alarm is missing or improperly installed. Verify that the device is mounted. Verify wiring from the Main Terminal Box and
the Platform Audible Warning sounds properly. Ground Module.
Controls remain functional at the Ground Con- The JLG Control System is configured to prevent platform controls only in the event of overload. Alternately, the Host Control System can be
trol position during an overload, or when simu- configured to prevent ground and platform controls for country- or customer-specific circumstances.
lated by unplugging the Load Cell. The Controls Using the JLG Analyzer, enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter to
at the Platform Control position are prevented “2=CUTOUT PLT” to prevent platform controls in the event of overload. Set this parameter to “3=CUTOUT ALL” to prevent platform and
when using the engine, but not when using the ground controls in the event of overload.
Auxiliary Power Unit.
3121262 6-87
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 .
6-88 3121262
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.
3121262 6-89
6.14 ELECTRONIC PLATFORM LEVELING 4. A system fault will be logged.

5. All function speeds (lift, swing, telescope and drive) will
Platform Leveling Fault Warning be placed in creep mode (except when the platform is in
the transport position see below).
The electronic platform leveling system uses two tilt sensors
(mounted on either side of the platform rotator), a control When the unit is in the transport position and driving and the
valve (mounted to the platform support), a level cylinder, and current setpoint varies by ± 5.5º for more than 8 seconds the
the platform control module (mounted in the platform control events 1,2,3 & 4 above will occur. (note function speeds will
box) to automatically measure and control the incline of the operate normally). Cycling the EMS will clear the fault and
platform with respect to gravity. While in the automatic posi- allow the operator to operate the machine as a new level set-
tion of the boom control select platform leveling is active point is taken.
while operating drive, telescope, main lift, jib lift or swing and
is not active while operating any other function (e.g. rotate, jib, VALVE DRIVER ERRORS
or steer). While in the manual position of the boom control There are three possible level valve driver errors, short to bat-
select platform leveling is active while operating main lift and tery, short to ground, and open circuit.
jib lift only. The system controls the platform angle relative to
1. In the case of a short to ground or an open circuit, the
gravity using a set point established during power-up (cycling
platform valve cannot be turned on and the following
of the EMS) or at the conclusion of a manual platform level
will occur:
override by the operator using the platform level override
switch from either the platform or the ground control. In other a. All interactions with platform leveling shall cease
words the operator can chose a platform incline other than
b. The Electronic Leveling System Fault Lamp shall
level with gravity and the system will maintain that incline
flash (to indicate that the leveling function has been
automatically
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.
b. All interactions with platform leveling shall cease.
To reset the fault the emergency stop switch should be recy-
cled. c. The Electronic Leveling System Fault Lamp shall
lost).
d. The platform alarm will sound.
IF THE FAULT PERSISTS BRING THE PLATFORM TO THE GROUND POSITION,
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)
3. In the case of a short to battery on the platform dump
ERROR RESPONSE valve, the valve cannot be turned off. The controllability
If basket level varies from the current setpoint by ± 5.5º for of the platform leveling function will be impaired and
more than 1.5 seconds when the platform is not in the trans- the following will occur:
port position, the following events will occur:
a. All interactions with platform leveling shall cease.
1. The platform dump valve will be disabled (level, rotate
b. The Electronic Leveling System Fault Lamp shall
and jib functions disabled).
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.
6-90 3121262
e. All function speeds (lift, swing, telescope and drive) 6.15 CALIBRATING PLATFORM LEVEL
will be placed in creep mode (except when the plat-
form is in the transport position).
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
Lift, swing, drive and telescope will continue to operate
In each of the cases above it shall be necessary to re-cycle the Ground position.
EMS to clear the fault. Operable functions shall be in the creep
mode except while below elevation.
TILT SENSOR ERRORS
If the secondary tilt sensor is faulty, the control system will
continue to utilize information from the primary sensor.
If the primary sensor is faulty, the control system will switch to
the backup sensor for control.
In both cases above the following will occur:
1. The Electronic Leveling System Fault Lamp will flash (to
indicate that there is a leveling fault).
2. The platform alarm will sound.
3. A system fault will be logged.
4. All function speeds (lift, swing, telescope, jib and drive)
will be placed in creep mode (except when the platform 2. Plug the analyzer into the connector inside the Ground
is in the transport position). control box.
5. Automatic leveling remains active.
Lift, swing, drive and telescope will continue to operate.
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
mode except while below elevation.
When both sensors appear to be working but have measure-
ments that disagree by ±5.5º The following will occur:
1. All interactions with platform leveling shall cease.
2. The Electronic Leveling System Fault Lamp shall flash (to
indicate that the leveling function has been lost).
3. The platform alarm will sound.
4. A system fault will be logged.
5. All function speeds (lift, swing, telescope and drive) will
3. Pull out the Emergency Stop switch and start the
be placed in creep mode (except when the platform is in
engine.
the transport position)
At this point, the operator must use the level up and down
toggle switch to manually level during descent. It shall be nec-
essary to re-cycle the EMS to clear the fault.
3121262 6-91
4. The analyzer screen should read: STEP 2: BLEEDING THE PLATFORM VALVES
Ground position.

control box.

Enter.
7. Use the arrow button to reach PERSONALITIES adjust
the following personalities. Refer to the Personality
Ranges/Defaults table for proper setting values.
Basket Level Up Min

Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
8. Recycle EMS.
engine.
6-92 3121262
4. The analyzer screen should read: STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND
DOWN VALVE CRACKPOINTS
Ground position.

control box.

Enter.
7. Go to the PERSONALITIES menu.
8. Using the left arrow button, go to the GROUND MODE
menu.
9. Hit ENTER.
10. Using the UP/DOWN arrows, adjust the following per-
sonalities to 100%.
Basket Rotate
Basket Level
Jib U/D (if configured)
Start up the machine and exercise each above platform 3. Pull out the Emergency Stop switch and start the
function (from the ground) eight (8) to ten (10) times for engine.
5 seconds in each direction.
11. Return the personality settings back to the values as
shown in the Personality Ranges/Defaults table in Sec-
tion 6 - JLG Control System.
12. Recycle EMS.
3121262 6-93
4. The analyzer screen should read: 11. Using UP ARROW, increase the value until you see the
basket up movement.
12. Hit ENTER again. CAL. COMPLETE message should
appear
13. Engine should again return to idle.
14. Hit ESC should return to BASKET U CRKPT screen.
15. Hit RIGHT ARROW to get to the “BASKET D CRKPT”
screen. Hit ENTER.
16. CALIBRATE? prompt should appear. Hit ENTER again.
17. You will hear engine go to 1800 rpm.
Using UP ARROW, increase the value until you see the basket
down movement.
Hit ENTER again. CAL. COMPLETE message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.

Enter.
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the BASKET U CRKPT Screen. Hit ENTER.
6-94 3121262
6.16 CALIBRATING LIFT CRACK POINT 4. The analyzer screen should read:

Ground position.

control box.

Enter.
Enter.

engine.
3121262 6-95
8. Use the arrow keys to reach Upper Lift Crack Point 10. Hit Enter. The screen will read:
(UPPER LIFT CRKPT). The screen will read:
11. Hit Enter again. The screen will read:

9. Hit enter. The screen will read:
12. Activate the Lift Up function by fully stroking the joy-

stick until the boom starts to move, then leave off imme-
diately. The display will read CRK PT = and show the
numeric crack point value.
6-96 3121262
13. Hit enter. The number displayed will be the value that 6.17 CALIBRATING TELESCOPE CRACK POINT
1. Position the Platform/Ground select switch to the Plat-
form position.

15. Repeat steps 10 thru 12 for the Lift Down function.

16. After completing all the Tele Calibrations, hit ESC twice
3121262 6-97
3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Upper Telescope Crack Point
engine. (UPPER TELE CRKPT). The screen will read:

Enter.
Enter.
6-98 3121262
10. Hit Enter. The screen will read: NOTE: In the following step, a minimum value of 10 must be indi-
cated on the analyzer before the crack point can be set. The
JLG Control System will not accept a value less than 10 and
the analyzer will not advance to "CAL COMPLETE" if the
crack point is set at a lesser value.
12. While reading the crack point setting on the analyzer,

activate the Tele Out function until the boom starts to
move or until the crack point setting reaches a value of
10 if the boom begins to move at a value lesser than 10,
then leave off the control switch immediately. The dis-
play will read CRK PT = and show the numeric crack
point value.
13. Hit enter. The number displayed will be the value that
11. Hit enter again. The screen will read:
3121262 6-99
14. Hit Enter. The screen will read: 15. Hit Enter. The screen will read:
16. Repeat steps 10 thru 12 for the Tele In function.
17. After completing all the Tele Calibrations, hit ESC twice
6-100 3121262
6.18 CALIBRATING TILT SENSOR 3. Plug the analyzer into the connector inside the Ground
control box.
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE
FOLLOWING PROCEDURE IS PERFORMED.
DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE.
1. Use the following procedure to calibrate the tilt sensor.
Before the tilt sensor can be calibrated, the following

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

Enter.
Enter.
3121262 6-101
9. Use the arrow keys to reach the TILT SENSOR. The screen 11. When prompted, swing turntable 180° to opposite end
should read: of chassis.
12. Press ENTER. The screen should read:
10. Press ENTER.
13. Upon completing swing calibration, swing turntable

180° back to the stowed position.
14. Hit ESC twice to go back to CALIBRATIONS.
6-102 3121262
6.19 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.

control box. 5. Use the arrow button to reach OPERATOR ACCESS. Hit
Enter.
Enter.

engine.
3121262 6-103
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:
6-104 3121262
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.
3121262 6-105
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.
6-106 3121262
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:
3121262 6-107
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.
6-108 3121262
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.
3121262 6-109
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.
6-110 3121262
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.
3121262 6-111
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.
6-112 3121262
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.
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.
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.
3121262 6-113
6.20 CALIBRATING THE BOOM SENSORS 2. Position the Platform/Ground select switch to the
Ground position.
DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT IS NORMAL FOR

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

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

ing conditions must be met:
a. Steering, telescope crack points, and tilt previously
calibrated
b. Axles Extended
c. Wheels Straight control box.
d. Platform Unloaded
e. Jib Horizontal
f. Jib Swing Centered
g. Platform Level
h. Platform Centered
i. Turntable Centered
j. Boom Fully Retracted
k. Level Ground (within 1.5°)
Figure 6-19. Boom Sensor Calibration Position 1

engine.
6-114 3121262
5. The analyzer screen should read: 9. Use the arrow keys to reach BOOM SENSORS. The screen
should read:

Enter. 10. Hit Enter. The screen will read:
Enter.
3121262 6-115
11. After verifying all the conditions listed in step 1 are met, 13. After visually verifying that the jib is horizontal, hit Enter.
hit Enter. The screen will read: The screen will read:
12. After verifying all load (personnel or material) is 14. After visually verifying the platform is level, hit Enter. The
removed from the platform, hit Enter. The screen will screen will read:
read:
6-116 3121262
15. After visually verifying the platform is centered, hit 17. Use the up/down arrows to select YES if the accessory is
Enter. The screen will read: installed, NO if it is not installed and hit enter. The screen
will read:
16. After operating telescope in to verify the boom is fully

retracted, hit Enter. The screen will read: 18. Use the up/down arrows to select YES if the accessory is
installed, NO if it is not installed and hit enter. The screen
will read:
3121262 6-117
19. Use the up/down arrows to select YES if the accessory is 21. Use the up/down arrows to select YES if the accessory is
installed, NO if it is not installed and hit enter. The screen installed, NO if it is not installed and hit enter. The screen
will read: will read:
20. Use the up/down arrows to select YES if the accessory is 22. Use the up/down arrows to select yes if the accessory is
installed, NO if it is not installed and hit enter. The screen installed, no if it is not installed and hit Enter. The screen
will read: will read:
6-118 3121262
23. After making sure the machine is in Calibration Position The screen will read:
1, hit Enter. The screen will read:
24. Lift up to stop (full stroke of cylinder) for Calibration

Position 2. When the machine is in that position, hit
Enter.
3121262 6-119
25. Swing 180 degrees (centered over opposite end of chas- When Position 3 calibrating is complete the screen will
sis) for Calibration Position 3. read:
When the machine is in the proper position, hit Enter.

The screen will read:
6-120 3121262
26. Press Enter. The screen will read: When the machine is in the proper position, hit Enter.
Swing the machine back 180 degrees (centered over When Position 4 calibrating is complete, the screen will
original end of chassis) for Calibration Position 4. read:
3121262 6-121
27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter.
Telescope out to stop (boom must be fully extended) for

Calibration Position 5.
6-122 3121262
28. Retract to stop (boom must be fully retracted) for Cali- 29. Lift down to stop (boom must be on boom rest) for Cali-
bration Position 6. bration Position 7.

The screen will read as follows:

3121262 6-123
When Position 7 Calibrating is complete, the screen will 30. Lift until the function stops (controller will stop at 5
read: degrees above horizontal) for Calibration Position 8.

Press Enter. The screen will read:
6-124 3121262
Press Enter. The screen will read: When the boom is in the proper position, hit Enter. The
screen will read:
31. Telescope to the yellow witness mark (controller will be

close - operator must position the pointer to center line When Position 9 calibrating is complete, the screen will
on decal within 0.25" [6 mm]) for Calibration Position 9. read:
3121262 6-125
Press Enter. The screen will read: When the boom is in the proper position, the screen will
read:
32. Telescope in to green witness mark (controller will find

the position - operator must visually verify the position). Pressing enter will bring up:
6-126 3121262
33. Operate the Lift Up function switch. The control system 35. Operate the Jib Telescope Out function to the mechani-
will stop the boom at the desired angle. The display will cal stop. Press ENTER. The display will read:
read:
36. When the control system completes the calibration step

34. Operate the Telescope Out function switch. The control the display will read:
system will stop the boom at the desired length. The dis-
play will read:
3121262 6-127
37. Operate the Jib Telescope In function switch until the jib 39. When the calibration step is done, the display will read:
is telescoped in to the mechanical stop. Press ENTER.
The display will read:
40. Press ENTER. The display will read:
38. Operate the Boom Telescope In function switch. The

control system will stop the boom at the desired length.
The display will read:
6-128 3121262
41. Operate the Main Boom Telescope function until the 43. Press ENTER. The display will read:
main boom is telescoped in to the stop. The display will
read:
44. After completing all the Boom Sensors Calibrations, hit

ESC twice to go back to Calibrations.
42. Operate the Boom Lift Down function until the main
45. Cycle the emergency stop switch.
boom is lifted down to the rest. The display will read:
3121262 6-129
Boom Control System Check Procedure 5. Push and hold the gray Boom Control System Test But-
ton on the ground control panel. The lighting of the
Perform the following check with no load (personnel or mate-
green Boom Control System Calibrated indicator indi-
rial) in the platform from the ground control station.
cates the system is functioning properly. No indicator
1. With the boom fully retracted, raise the boom off the light or the lighting of the red Boom Control System
boom rest to horizontal. Warning indicator indicates the system must be repaired
by JLG authorized Service Personnel before the machine
2. Position the jib horizontal, jib straight, and platform can be used.
level.
3. Extend the boom until it stops.
4. Boom must stop on colored stripe matching the capac-

ity indicator. If the boom does not stop on the correct
stripe, the system must be repaired by JLG authorized
Service Personnel before the machine can be used.
6-130 3121262
FAULT
CODE
LIGHT
1706741A
1705744 A
1702566 B 1702565 B
1001125195 B
1702938 1705170 A
1001125194 A
PLATFORM
CONTROL
MODULE
GROUND
FAULT
CONTROL CODE
MODULE
LIGHT
Figure 6-29. Fault Code Light Location
3121262 6-131
Table 6-13. Diagnostic Trouble Code Chart
Flash
DTC Sequence Fault Message Fault Description Check
Code
001 0 1 EVERYTHING OK The normal help message in
Platform Mode.
002 0 2 GROUND MODE OK The normal help message in
Ground Mode.
0010 0 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELE-
VATED MAX" while the vehicle is
out of transport position.
000 0 0 <<< HELP COMMENT >>>
0011 0 11 FSW OPEN A drive / boom function was
selected with the Footswitch
open.
0012 0 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the
Creep Switch is open.
0013 0 13 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All functions at creep while the
Platform is elevated and the
Chassis is tilted.
0014 0 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 - Not reported during power-up.
degrees for more then 4 sec-
onds.
0015 0 15 LOAD SENSOR READING UNDER WEIGHT LSS has been calibrated and the Ensure platform is not resting on
UGM has determined that the the ground or is not leveled at an
load sensing system reading is extreme negative angle.
less than -50lbs for 2 seconds. If
the load sensing system deter- Re-calibrate the load sensing sys-
mines that the reading is greater tem if the above items are not a
than -50lbs for 5 seconds this factor.
fault will no longer be annunci-
ated.
No control system interlocks

present when DTC is active.
0016 0 16 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is an envelope violation. - Envelope control system
equipped vehicle only.
0017 0 17 OVER MOMENT - HYDRAULICS SUSPENDED There is an over moment viola- - Envelope control system
tion. equipped vehicle only.
0018 0 18 UNDER MOMENT - HYDRAULICS SUSPENDED There is an under moment viola- - Envelope control system
tion. equipped vehicle only.
0021 0 21 ADS 1213 REINITIALIZED
0030 0 30 RUNNING AT CREEP - PLATFORM STOWED
0031 0 31 FUEL LEVEL LOW - ENGINE SHUTDOWN
0035 0 35 APU ACTIVE
0037 0 37 JIB UNLOCKED OUT OF TRANSPORT - HYDRAULICS SUSPENDED
0038 0 38 SWING ENVELOPE ENCROACHED - HYDRAULICS
SUSPENDED
6-132 3121262
Flash
Code
210 2 1 <<< POWER-UP >>>
211 2 1 POWER CYCLE The normal help message is
issued at each power cycle.
212 2 1 KEYSWITCH FAULTY Both Platform and Ground
modes are selected simultane-
ously.
213 2 1 FSW FAULTY Both Footswitches are closed for
more then one second.
220 2 2 <<< PLATFORM CONTROLS >>>
227 2 2 STEER SWITCHES FAULTY Both Steer Left and Steer Right
inputs are closed simultane-
ously.
2211 2 2 FSW INTERLOCK TRIPPED The Footswitch was closed for - Can be reported during power-
more then seven seconds. up.
2212 2 2 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected - Can be reported during power-
with Footswitch open. up.
2213 2 2 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected
with Footswitch open.
2215 2 2 D/S JOY. OUT OF RANGE LOW The D/S Joystick reference volt- - Resistive joysticks, these faults
age is low. do not occur.
2216 2 2 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference volt- - Resistive joysticks.
age is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2217 2 2 D/S JOY. CENTER TAP BAD The D/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2218 2 2 L/S JOY. OUT OF RANGE LOW The L/S Joystick reference volt- - Resistive joysticks, these faults
age is low. do not occur.
2219 2 2 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference volt- - Resistive joysticks.
age is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2220 2 2 L/S JOY. CENTER TAP BAD The L/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2221 2 2 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A lift / swing function was
selected with Footswitch open.
2222 2 2 WAITING FOR FSW TO BE OPEN The Footswitch was closed dur- - Can be reported during power-
ing Platform selection. up.
2223 2 2 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE A boom function was selected
with Footswitch open.
2224 2 2 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed dur-
ing engine start.
3121262 6-133
Flash
Code
240 2 4 <<< OTHER CONTROLS >>>
250 2 5 <<< FUNCTION PREVENTED >>>
259 2 5 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been
changed.
2513 2 5 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the
vehicle generator is running
AND is configured to prevent
drive.
2514 2 5 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible
while the vehicle is being driven
AND is configured to not allow
simultaneous drive & boom
operation.
2515 2 5 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the
vehicle above elevation AND is
configured to prevent drive
while above elevation.
2516 2 5 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while
Boom functions are selected
AND is configured to not allow
simultaneous drive & boom
operation.
2517 2 5 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Driving is not possible while the
vehicle is tilted and above eleva-
tion AND is configured to pre-
vent drive while tilted and
above elevation.
2521 2 5 JIB SWING PREVENTED - IN 1000# MODE JIB Swing is not possible while
the vehicle is in 1000 LB Mode.
2522 2 5 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED CAN Dongle attached. Very lim-
ited restrictions for all hydrau-
lics systems.
2546 2 5 MACHINE SETUP FAULT - JIB SWING
2547 2 5 MACHINE SETUP FAULT - MODEL
2587 2 5 RUNNING AT CREEP - PLATFORM LEVELED UNDER The control system has deter-
mined that the platform is lev-
eled under and is being
considered to be in a loading/
unloading position. Boom,
Tower, and Level Override func-
tions will operate at creep
speed.
330 3 3 <<< GROUND OUTPUT DRIVER >>>
331 3 3 BRAKE - SHORT TO BATTERY There is a Short to Battery to the
Brake Valve.
332 3 3 BRAKE - OPEN CIRCUIT There is an Open Circuit to the
Brake Valve.
3311 3 3 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the - Ground Alarm equipped vehicles
Ground Alarm. only.
6-134 3121262
Flash
Code
3316 3 3 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Forward Drive Valve. cles only.
3317 3 3 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3318 3 3 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3320 3 3 RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Reverse Drive Valve. cles only.
3321 3 3 RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3322 3 3 RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3324 3 3 LEFT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Forward Drive Valve. cles only.
3325 3 3 LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3326 3 3 LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3328 3 3 LEFT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Reverse Drive Valve. cles only.
3329 3 3 LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3330 3 3 LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3336 3 3 ALTERNATOR/ECM POWER - SHORT TO GROUND There is a Short to Ground to the
Alternator/ECM.
3338 3 3 ALTERNATOR POWER - OPEN CIRCUIT There is an Open Circuit to the
Alternator.
3339 3 3 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the
Alternator
3340 3 3 AUX POWER - SHORT TO GROUND There is a Short to Ground to the
Auxiliary Power Pump Relay.
3341 3 3 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the
3342 3 3 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the
3343 3 3 COLD START ADVANCE SOLENOID - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Cold Start Advance Solenoid.
3344 3 3 COLD START ADVANCE SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
3345 3 3 COLD START ADVANCE SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
3349 3 3 ELECTRIC PUMP - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Pump Relay.
3350 3 3 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
Pump Relay.
3121262 6-135
Flash
Code
3351 3 3 ELECTRIC PUMP - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
Pump Relay.
3358 3 3 MAIN DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Dump Valve.
3359 3 3 MAIN DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Dump Valve.
3360 3 3 MAIN DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Dump Valve.
3361 3 3 BRAKE - SHORT TO GROUND There is a Short to Ground to the
Brake Valve.
3362 3 3 START SOLENOID - SHORT TO GROUND There is a Short to Ground to the - Diesel engines only.
Start Relay.
3363 3 3 START SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - Diesel engines only.
Start Relay.
3364 3 3 START SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - Diesel engines only.
Start Relay.
3368 3 3 TWO SPEED VALVE - SHORT TO GROUND There is a Short to Ground to the
Two Speed Valve.
3369 3 3 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the
Two Speed Valve.
3370 3 3 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the
Two Speed Valve.
3371 3 3 GROUND ALARM - SHORT TO GROUND There is a Short to Ground to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3372 3 3 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3373 3 3 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the - Generator / Welder equipped
Generator Relay. vehicles only.
3374 3 3 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the - Generator / Welder equipped
3375 3 3 GEN SET/WELDER - SHORT TO BATTERY There is a Short to Battery to the - Generator / Welder equipped
3376 3 3 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the - Head Light equipped vehicles
Head Light Relay. only.
6-136 3121262
Flash
Code
3377 3 3 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the - Head Light equipped vehicles
3378 3 3 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the - Head Light equipped vehicles
3379 3 3 HOUR METER - SHORT TO GROUND There is a Short to Ground to the
Hour Meter.
3380 3 3 HOUR METER - OPEN CIRCUIT There is an Open Circuit to the - Can be reported during power-
Hour Meter. up.
3381 3 3 HOUR METER - SHORT TO BATTERY There is a Short to Battery to the
Hour Meter.
3385 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Up Override equipped vehicles only.
Valve.
3386 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3387 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
3391 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Down Override equipped vehicles only.
Valve.
3392 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3393 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
3394 3 3 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Left Valve.
3395 3 3 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3396 3 3 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
3397 3 3 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Right Valve.
3398 3 3 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3399 3 3 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
33120 3 3 MAIN TELESCOPE IN VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope In Valve.
3121262 6-137
Flash
Code
33123 3 3 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope Out Valve.
33130 3 3 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the
Throttle Actuator.
33131 3 3 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the
Throttle Actuator.
33132 3 3 THROTTLE ACTUATOR - SHORT TO BATTERY There is a Short to Battery to the
Throttle Actuator.
33133 3 3 PLATFORM CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Control Valve. equipped vehicles only.
33134 3 3 PLATFORM CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
33135 3 3 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
33150 3 3 LIFT PILOT VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Pilot Valve. cles only.
33151 3 3 LIFT PILOT VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi-
33152 3 3 LIFT PILOT VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
33153 3 3 LIFT DOWN AUX VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Down Auxiliary Valve. cles only.
33154 3 3 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi-
33155 3 3 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
33173 3 3 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY There is a Short to Battery or an
OR OPEN CIRCUIT Open Circuit to the Axle Lockout
Valve.
33174 3 3 RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIR- There is a Short to Battery or an
CUIT Open Circuit to the Brake.
33182 3 3 LIFT VALVES - SHORT TO BATTERY
33186 3 3 MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT There is an Open Circuit to the
33188 3 3 MAIN TELESCOPE OUT VALVE - SHORT TO GROUND There is a Short to Ground to the
33189 3 3 MAIN TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the
33190 3 3 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the
33207 3 3 HORN - OPEN CIRCUIT There is an Open Circuit to the
Horn.
33208 3 3 HORN - SHORT TO BATTERY There is a Short to Battery to the
Horn.
33209 3 3 HORN - SHORT TO GROUND There is a Short to Ground to the
Horn.
6-138 3121262
Flash
Code
33279 3 3 GLOWPLUG - OPEN CIRCUIT There is an Open Circuit to the - Glowplugs equipped vehicles
Glow Plugs. only.
33280 3 3 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the - Glowplugs equipped vehicles
Glow Plugs. only.
33281 3 3 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the - Glowplugs equipped vehicles
Glow Plugs. only.
33285 3 3 ALTERNATOR EXCITATION LINE - SHORT TO BATTERY
33307 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Telescope Flow Control
Valve.
33308 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
Valve.
33309 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
Valve.
33311 3 3 MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Lift Flow Control Valve.
33312 3 3 MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
33313 3 3 MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
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
340 3 4 <<< PLATFORM OUTPUT DRIVER >>>
343 3 4 PLATFORM LEVEL UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Up Valve.
344 3 4 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Open Circuit to the Platform equipped vehicles only.
Level Up Valve.
347 3 4 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Down Valve.
348 3 4 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Level Down Valve.
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
3121262 6-139
Flash
Code
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
3512 3 5 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
3513 3 5 JIB TELESCOPE IN VALVE - SHORT TO GROUND
3514 3 5 JIB TELESCOPE IN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
3515 3 5 JIB TELESCOPE OUT VALVE - SHORT TO GROUND
3516 3 5 JIB TELESCOPE OUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
430 4 3 <<< ENGINE >>>
431 4 3 FUEL SENSOR SHORT TO BATTERY The Fuel Sensor reading is >
4.3V.
432 4 3 FUEL SENSOR SHORT TO GROUND The Fuel Sensor reading is <
0.2V.
433 4 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading - Deutz engine only.
is > 6.6V.
434 4 3 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading - Deutz engine only.
is < 0.1V for more then 5 sec- - Not reported during engine
onds. start.
435 4 3 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sen- - Deutz engine only.
sor reading is < 0.1V.
437 4 3 ENGINE TROUBLE CODE Displays engine SPN FMI code.
438 4 3 HIGH ENGINE TEMP (Ford engine only) The engine - Ford / Deutz engine only.
temperature is > 117 C.
(Deutz engine only) The engine
temperature is > 130 C.
439 4 3 AIR FILTER BYPASSED The Air Filter is clogged.
4310 4 3 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts
for more then 15 seconds after
engine start.
4311 4 3 LOW OIL PRESSURE (Ford engine only) The ECM has - Ford / Deutz engine only.
reported a low oil pressure fault.
(Deutz engine only) Oil pressure
is < 8 PSI for more then 10 sec-
onds after engine start.
6-140 3121262
Flash
Code
4313 4 3 THROTTLE ACTUATOR FAILURE The engine RPM is > XXX for
more then XX seconds.
4314 4 3 WRONG ENGINE SELECTED - ECM DETECTED A ECM was detected with a non-
ECM type engine selected.
4322 4 3 LOSS OF ENGINE SPEED SENSOR The engine RPM sensor indi- - Diesel engine only.
cates 0 RPM AND the Oil Pressure
Sensor indicates > 8 PSI for
three seconds.
4323 4 3 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indi- - Diesel engine only.
cates > 4000 RPM.
4375 4 3 WATER IN FUEL The engine has shut down Water in fuel filter for water or in
because an unacceptable fuel or water in fuel sensor.
amount of water has been
detected in the fuel or there is an
issue with the water in fuel sen-
sor.
If operating in platform mode,

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

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

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

platform is overloaded.
3121262 6-141
Flash
Code
444 4 4 LSS BATTERY VOLTAGE TOO LOW The load sensor has determined Check for issue with sensor supply
that its supply voltage is too low voltage.
(> 8V).

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

This fault, once annunciated is

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


660 6 6 <<< COMMUNICATION >>>
662 6 6 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN commu-
nication lost.
663 6 6 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE The control system has lost com- Check wiring to load sensor.
munication with the load sens-
ing system load pin.

666 6 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped engine only.
communication lost.
6610 6 6 CANBUS FAILURE - BLAM BLAM CAN communication lost. - BLAM equipped vehicles only.
6611 6 6 CANBUS FAILURE - CHASSIS MODULE Engine Control Module CAN - ECM equipped engine only.
communication lost.
6612 6 6 CANBUS FAILURE - CYLINDER LOAD PIN Cylinder Load Pin CAN commu- - Cylinder Load Pin equipped
nication lost. engine only.
6613 6 6 CANBUS FAILURE - EXCESSIVE CANBUS ERRORS There has been > 500 Bus Off
errors or >500 Bus Passive
Errors.
6622 6 6 CANBUS FAILURE - TCU MODULE Machine Setup/ Telemat-
ics=YES, No device heartbeat
for 30 sec
6-142 3121262
Flash
Code
6623 6 6 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telemat-
ics=YES, No device heartbeat
for 30 sec
6629 6 6 CANBUS FAILURE - TELEMATICS CANBUS LOADING X -Telematics only
TOO HIGH
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
680 6 8 <<< TELEMATICS >>>
681 6 8 REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP X -Telematics only
810 8 1 <<< TILT SENSOR >>>
813 8 1 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not
been calibrated.
815 8 1 CHASSIS TILT SENSOR DISAGREEMENT X
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 Ensure platform is not resting on
UGM has determined that the the ground or is not leveled at an
load sensing system reading is extreme negative angle.
underweight while a period of
time while operating drive or Re-calibrate the load sensing sys-
boom lift up at speeds greater tem if the above items are not a
than creep OR the UGM has factor.
determined that the load sens-
ing system reading is less than -
1.5 x Gross Platform Weight.

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

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

822 8 2 LSS CELL #2 ERROR822822
3121262 6-143
Flash
Code
8222 8 2 LSS STRAIN GAUGE 1 - STAGNANT The control system has deter- Possible sensor hardware issue.
mined that the strain gauge 1
reading in the load sensor is
stagnant (not changing).

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

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

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

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

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

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

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

machine will assume the plat-
form is overloaded.

6-144 3121262
Flash
Code
8225 8 2 LSS STRAIN GAUGE 2 - OUT OF RANGE LOW The shear beam is reporting an Possible sensor hardware issue.
out of range low issue with the

creep.

form is overloaded.

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

creep.

form is overloaded.

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

creep.

form is overloaded.

3121262 6-145
Flash
Code
8228 8 2 LSS STRAIN GAUGE 1 - INITIALIZATION ERROR The shear beam is reporting an Possible sensor hardware issue.
initialization issue with the
strain gauge 1 sensor.

creep.

form is overloaded.

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

creep.

form is overloaded.

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

creep.

form is overloaded.

823 8 2 LSS CELL #3 ERROR823823
6-146 3121262
Flash
Code
8231 8 2 LSS STRAIN GAUGE 2 - NOT CALIBRATED The shear beam is reporting a Possible sensor hardware issue.
calibration issue with the strain
gauge 2 sensor.

creep.

form is overloaded.

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

creep.

form is overloaded.

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

creep.

form is overloaded.

3121262 6-147
Flash
Code
8234 8 2 LSS STRAIN GAUGE 1 - NOT INSTALLED The shear beam is reporting a Possible sensor hardware issue.
not installed issue with the

creep.

form is overloaded.

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

creep.

form is overloaded.

8236 8 2 LSS NOT DETECTING CHANGE The control system has deter- Possible sensor hardware issue.
mined that the load sensor
reading has not deviated by
more than 1lb for 5s while oper-
ating drive or boom functions at
greater than creep speed.

8237 8 2 LSS STRAIN GAUGE 1 - A/D DEFECT The shear beam is reporting an Possible sensor hardware issue.
internal issue with the strain
gauge 1 sensor.

creep.

form is overloaded.

6-148 3121262
Flash
Code
8238 8 2 LSS STRAIN GAUGE 2 - A/D DEFECT The shear beam is reporting an Possible sensor hardware issue.
internal issue with the strain
gauge 2 sensor.

creep.

form is overloaded.

824 8 2 LSS CELL #4 ERROR824824
825 8 2 LSS HAS NOT BEEN CALIBRATED The load sensing system is con- Calibrate the load sensing system.
figured but has not been cali-
brated.

826 8 2 RUNNING AT CREEP - PLATFORM OVERLOADED All functions at creep, the Load
Sensing System indicates the
Platform is overloaded AND is
configured to warn only while
the Platform is overloaded.
827 8 2 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are
not possible while the Load
Sensing System indicates the
Platform is overloaded AND is
configured to prevent drive and
boom functions while the Plat-
form is overloaded.
828 8 2 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED Lift up and telescope out are not
possible while the Load Sensing
System indicates the Platform is
overloaded AND is configured to
prevent Lift up and telescope
out while the Platform is over-
loaded.
830 8 3 <<< PLATFORM LEVELING >>>
831 8 3 PLATFORM LEVELING OVERRIDE ON Platform Leveling forced on
with Access Level 0 selection.
832 8 3 PLATFORM LEVELING OVERRIDE OFF Platform Leveling forced off
with Access Level 0 selection.
833 8 3 PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED The Platform Level Up Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
834 8 3 PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED The Platform Level Down Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
3121262 6-149
Flash
Code
837 8 3 PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #1. equipped vehicles only.
838 8 3 PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Level Sensor #1.
8311 8 3 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #2. equipped vehicles only.
8312 8 3 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Level Sensor #2.
8313 8 3 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #1 rever- - Electronic leveling system
ence voltage is outside accept- equipped vehicles only.
able range (4.9 to 5.1 volts).
8314 8 3 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #2 rever- - Electronic leveling system
ence voltage is outside accept- equipped vehicles only.
able range (4.9 to 5.1 volts).
8315 8 3 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads the - Electronic leveling system
sensor values at power-up. The equipped vehicles only.
fault is triggered when there is a
± 5 degree difference from the
initial reading.
8316 8 3 PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST Platform Level Sensor #1 serial
communication lost.
8317 8 3 PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST Platform Level Sensor #2 serial
communication 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 - DISAGREEMENT
8333 8 3 JIB TRANSPORT SENSOR #2 - DISAGREEMENT
8334 8 3 JIB LIFT ANGLE SENSOR - NOT CALIBRATED
8335 8 3 JIB LEVEL UP CRACKPOINT - NOT CALIBRATED
8336 8 3 JIB LEVEL DOWN CRACKPOINT - NOT CALIBRATED
6-150 3121262
Flash
Code
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 - Envelope Control equipped vehi-
between the Boom Angle Sen- cles only.
sors.
842 8 4 BOOM LENGTH SWITCH FAILED The Boom Length Switches are - Envelope Control equipped vehi-
reporting the same state. cles only.
843 8 4 BOOM LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Boom Length cles only.
Switch and the Boom Length
Sensor.
844 8 4 BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE The Boom Length Sensor is not - Envelope Control equipped vehi-
changing during a boom tele- cles only.
scope command.
845 8 4 BOOM LENGTH SENSOR - OUT OF RANGE HIGH Boom Length Sensor out of - Envelope Control equipped vehi-
range high. cles only.
846 8 4 BOOM LENGTH SENSOR - OUT OF RANGE LOW Boom Length Sensor out of - Envelope Control equipped vehi-
range low. cles only.
847 8 4 BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH Boom Length out of range high. - Envelope Control equipped vehi-
cles only.
848 8 4 BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW Boom Length out of range low. - Envelope Control equipped vehi-
cles only.
849 8 4 BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 commu- - Envelope Control equipped vehi-
nications lost. cles only.
8410 8 4 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT Boom Angle Sensor #2 commu- - Envelope Control equipped vehi-
nications lost. cles only.
8411 8 4 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of - Envelope Control equipped vehi-
range. cles only.
8412 8 4 BOOM ANGLE SENSOR #2 - INVALID ANGLE Boom Angle Sensor #2 out of - Envelope Control equipped vehi-
range. cles only.
8413 8 4 WRONG TELESCOPE RESPONSE Boom telescope is moving in the - Envelope Control equipped vehi-
opposite direction of the com- cles only.
mand.
8414 8 4 WRONG LIFT RESPONSE Boom lift is moving in the oppo- - Envelope Control equipped vehi-
site direction of the command. cles only.
8479 8 4 MAIN CYLINDER ANGLE SENSOR #1 - OUT OF RANGE LOW
8480 8 4 MAIN CYLINDER ANGLE SENSOR #1 - OUT OF RANGE HIGH
8492 8 4 MAIN CYLINDER ANGLE SENSOR #2 - OUT OF RANGE LOW
8493 8 4 MAIN CYLINDER ANGLE SENSOR #2 - OUT OF RANGE HIGH
8494 8 4 MAIN CYLINDER ANGLE SENSORS - DISAGREEMENT
8495 8 4 TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE LOW
8496 8 4 TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE HIGH
8497 8 4 TURN TABLE SENSOR #2 - FREQUENCY OUT OF RANGE LOW
8498 8 4 TURN TABLE SENSOR #2 - FREQUENCY OUT OF RANGE HIGH
3121262 6-151
Flash
Code
8499 8 4 CHASSIS TURN TABLE SENSORS - DISAGREEMENT
84100 8 4 CHASSIS TURN TABLE SENSORS AND DRIVE ORIENTATION SWITCH - DIS-
AGREEMENT
84101 8 4 CHASSIS TURN TABLE SENSORS - NOT CALIBRATED
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
84107 8 4 JIB LIFT MOVEMENT WITHOUT COMMAND
84108 8 4 PLATFORM LEVEL MOVEMENT WITHOUT COMMAND
6-152 3121262
Flash
Code
84151 8 4 TOWER LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) Check Hardware, Wiring
that these faults can be set:
(a)
If the length sensor voltage
changes more than 0.0168 volts
within 40 milliseconds a counter
for the respective length sensor
shall be incremented to aid ser-
vice in diagnosing bad sensor
performance. The counter
below shall be incremented
anytime the description above is
met. It is cleared/reset by a
power cycle
TwrLenSnsr(1/
2)FaultCounter_PowerCycle >
30
(b)
The counter below shall be
incremented every time
TwrLenSnsr(1/
2)FaultCounter_PowerCycle
(described above) reached its
threshold. This value is stored in
EEPROM in order to track the his-
tory of the issue. (A successful
Boom Sensor Calibration will
reset this counter – this is
reflected in the boom sensor
calibration document)
TwrLenSnsr(1/
2)FaultCounter_EEPROM > 3
(c)
The fault counter below shall be
incremented every time the
trigger condition described in
section (a) is observed during
certain steps during Boom Sen-
sor Calibration (please see that
document section for further
details)
TwrLenSnsr(1/
2)FaultCounter_BmSnsrCal >
20
If (a) or (b) or (c) are met (fault

triggered) the machine will be
put into Electrical Retrieval
Fault, once triggered, is main-
tained within a given key-cycle
Machine will be trapped in
transport
3121262 6-153
Flash
Code
84152 8 4 TOWER LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) Check Hardware, Wiring
(a)
power cycle
TwrLenSnsr(1/
30
(b)
TwrLenSnsr(1/
TwrLenSnsr(1/
(c)
details)
TwrLenSnsr(1/
20

transport
6-154 3121262
Flash
Code
84153 8 4 BOOM LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) Check wiring and hardware
(a)
power cycle
BmLenSnsr(1/
30
(b)
BmLenSnsr(1/
BmLenSnsr(1/
(c)
details)
BmLenSnsr(1/
20

transport
3121262 6-155
Flash
Code
84154 8 4 BOOM LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) Check wiring and hardware
(a)
power cycle
BmLenSnsr(1/
30
(b)
BmLenSnsr(1/
BmLenSnsr(1/
(c)
details)
BmLenSnsr(1/
20

transport
6-156 3121262
Flash
Code
850 8 5 <<< MOMENT / LOAD PINS >>>
851 8 5 MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE The Moment Pin horizontal
force is out of range.
852 8 5 MOMENT PIN - VERTICAL FORCE OUT OF RANGE The Moment Pin vertical force is
out of range.
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.
860 8 6 <<< STEERING / AXLE >>>
861 8 6 RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH DIS- The Oscillating Axle Pressure - Electrically released Oscillated
AGREEMENT Switch indicates pressure while Axles equipped vehicles only.
not driving or does not indicate
pressure while driving and
restricted to transport.
862 8 6 AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Extend
Valve.
863 8 6 AXLE EXTEND VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Extend Valve.
864 8 6 AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Retract
Valve.
865 8 6 AXLE RETRACT VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Retract Valve.
866 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Right Valve.
867 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Right Valve.
868 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Left Valve.
3121262 6-157
Flash
Code
869 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Left Valve.
8610 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front
Steer Right Valve.
8611 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Right Valve.
8612 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front
Steer Left Valve.
8613 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Left Valve.
8614 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Right Valve.
8615 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Right Valve.
8616 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Left Valve.
8617 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Left Valve.
8618 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear
Steer Right Valve.
8619 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Right Valve.
8620 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear
Steer Left Valve.
8621 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Left Valve.
8622 8 6 FRONT RIGHT STEER SENSOR - DECOUPLED The Front Right Steer Sensor has
become decoupled.
8623 8 6 FRONT LEFT STEER SENSOR - DECOUPLED The Front Left Steer Sensor has
become decoupled.
8624 8 6 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has
become decoupled.
8625 8 6 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has
become decoupled.
8626 8 6 FRONT LEFT STEER SENSOR - NOT RESPONDING The Front Right Steer Sensor is
not responding to steer com-
mands.
8627 8 6 FRONT RIGHT STEER SENSOR - NOT RESPONDING The Front Left Steer Sensor is not
responding to steer commands.
8628 8 6 REAR LEFT STEER SENSOR - NOT RESPONDING The Rear Right Steer Sensor is
not responding to steer com-
mands.
6-158 3121262
Flash
Code
8629 8 6 REAR RIGHT STEER SENSOR - NOT RESPONDING The Rear Left Steer Sensor is not
responding to steer commands.
8630 8 6 FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Front Right
Steer Sensor.
8631 8 6 FRONT RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Right Steer Sensor.
8632 8 6 FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Front Left
Steer Sensor.
8633 8 6 FRONT LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Left Steer Sensor.
8634 8 6 REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Rear Right
Steer Sensor.
8635 8 6 REAR RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Right Steer Sensor.
8636 8 6 REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Rear Left
Steer Sensor.
8637 8 6 REAR LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Left Steer Sensor.
8651 8 6 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT Engine Start is prevented while
there is an Oscillating Axle fault
and vehicle is out of transport
position
876 87 6 WIRE ROPE SERVICE REQUIRED MACHINE SETUP → CABLE
SWITCH = YES;
Wire Rope Service = Enabled
990 9 9 <<< HARDWARE >>>
991 9 9 LSS WATCHDOG RESET
992 9 9 LSS EEPROM ERROR
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 MODULE SOFTWARE VERSION The Platform Module software
IMPROPER version is 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 REQUIRED The Platform Module software
requires an updated.
9915 9 9 CHASSIS TILT SENSOR NOT GAIN CALIBRATED The Chassis Tilt Sensor gain cali-
bration has been lost.
9916 9 9 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain cali-
bration has become corrupted.
3121262 6-159
Flash
Code
9917 9 9 HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST The Platform Module has
reported that its ADS1213 chip
has stopped asserting its inter-
rupt.
9918 9 9 HIGH RESOLUTION A2D FAILURE - REINIT LIMIT The Platform Module has
reported that its ADS1213 chip
had to be reset 3 or more times.
9919 9 9 GROUND SENSOR REF VOLTAGE OUT OF RANGE The Ground Module has - Not reported during power-up.
reported that its sensor refer-
ence voltage is outside accept-
able range.
9920 9 9 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE The Platform Module has - Not reported during power-up.
reported that its sensor refer-
ence voltage is outside accept-
able range.
9921 9 9 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY The Ground Module has
reported that its high side driver
cutout failed.
9922 9 9 PLATFORM MODULE FAILURE - HWFS CODE 1 The Platform Module has
reported that the V(Low) FET
has failed.
9923 9 9 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has
reported that the V(Low) FET
has failed.
9924 9 9 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED
9925 9 9 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION The Chassis Module software
IMPROPER version is not compatible with
the rest of the system.
9926 9 9 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER The BLAM software version is
not compatible with the rest of
the system.
9927 9 9 GROUND MODULE CONSTANT DATA UPDATE REQUIRED The Ground Module constant
data requires an updated.
9928 9 9 ENVELOPE CONTROL DISABLED Envelope Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
99285 9 9 LSS - FACTORY CALIBRATION ERROR The load sensor is reporting a Possible sensor hardware issue.
factor calibration issue (internal
error)


9929 9 9 MOMENT CONTROL DISABLED Moment Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
6-160 3121262
Flash
Code
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 - BLAM equipped vehicles only.
been calibrated.
9932 9 9 LIFT CRACKPOINTS NOT CALIBRATED The Lift Crackpoints have not
been calibrated.
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 calibrated.
9935 9 9 BLAM SENSOR SUPPLY OUT OF RANGE HIGH The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is high.
9936 9 9 BLAM SENSOR SUPPLY OUT OF RANGE LOW The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is low.
9937 9 9 LENGTH SENSOR REF VOLTAGE HIGH The Boom Length Sensors sup-
ply voltage is high.
9938 9 9 LENGTH SENSOR REF VOLTAGE LOW The Boom Length Sensors sup-
ply voltage is low.
9939 9 9 BLAM HIGH RES A/D FAILURE The BLAM high resolution ana- - BLAM equipped vehicles only.
log to digital converter has
failed.
9940 9 9 CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH The Chassis Sensors supply volt-
age is high.
9941 9 9 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW The Chassis Sensors supply volt-
age is low.
9944 9 9 CURRENT FEEDBACK GAINS OUT OF RANGE The factory set current feedback
gains are out of range.
9945 9 9 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT The factory set current feedback
checksum is not correct.
99155 9 9 JIB CONTROL MODULE - HIGH RESOLUTION A2D FAILURE
99156 9 9 JIB CONTROL MODULE - HIGH RESOLUTION A2D REFERENCE LOW
99157 9 9 JIB CONTROL MODULE - HIGH RESOLUTION A2D REFERENCE HIGH
99158 9 9 PLATFORM LEVEL ANGLE SENSOR - INTERNAL ERROR
99159 9 9 JIB LIFT ANGLE SENSOR - INTERNAL ERROR
99160 9 9 FUNCTIONS LOCKED OUT - JIB CONTROL MODULE SOFTWARE VERSION
IMPROPER
3121262 6-161
NOTES:
6-162 3121262
SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 GENERAL Polarity
This section contains basic electrical information and sche- Getting a negative Voltage or current reading when expecting
matics to be used for locating and correcting most of the oper- a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and
ating problems which may develop. If a problem should
that the leads are connected to the device under test correctly.
develop which is not presented in this section or which is not
Also check that the lead on the "COM" port goes to the Ground
corrected by listed corrective actions, technically qualified
or negative side of the signal and the lead on the other port
guidance should be obtained before proceeding with any
goes to the positive side of the signal.
maintenance.
Scale
NOTE: Some of the procedures/connectors shown in this section
may not be applicable to all models. M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
7.2 MULTIMETER BASICS
m = milli = (Displayed Number) / 1,000
A wide variety of multimeters or Volt Ohm Meters (VOM) can μ = micro = (Displayed Number) / 1,000,000
be used for troubleshooting your equipment. This section
shows diagrams of a common, digital VOM configured for sev- Example: 1.2 kW = 1200 W
eral different circuit measurements. Instructions for your VOM Example: 50 mA = 0.05 A
may vary. Please consult the meter operator’s manual for more
information. Voltage Measurement
Grounding
"Grounding the meter" means to take the black lead (which is
connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the Voltage source.
Backprobing
To "backprobe" means to take the measurement by accessing
a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining cir-
cuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around
the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gen-
tle pull to ensure the wires are still attached to the contact and Figure 7-1. Voltage Measurement (DC)
contacts are seated in the connector.
• If meter is not auto ranging, set it to the correct range
Min/Max (See multimeter’s operation manual)
• 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.
3121262 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-
tance)
• First test meter and leads by touching leads together.
• Circuit power must be turned OFF before testing resis-
Meter should produce an audible alarm, indicating
tance
continuity
• Disconnect component from circuit before testing
(See multimeter’s operation manual)
7-2 3121262
Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND

TO ELECTRICAL CONNECTIONS
NOTE: This section is not applicable for battery terminals.
JLG PN 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY 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
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.
3121262 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 3121262
DIN Connectors
This connector is typically used on hydraulic valves. Follow the
installation instructions.
Figure 7-6. Use of Seal Plugs

Exclusions
A limited number of connectors do not benefit from dielectric
grease, or may be permanently damaged by application.
AMP Mate-N-Lok Dielectric grease may not be required in properly sealed
enclosures.
This connector system is widely used inside enclosures for
general purpose interconnect. Follow the installation instruc-
tions.
3121262 7-5
BRAD HARRISON / PHOENIX CONTACT M12 ENGINE CONTROL UNIT CONNECTORS

The connector uses gold contact material to resist corrosion These connectors use back-seals for moisture integrity. How-
and an o-ring seal for moisture integrity. If dielectric grease is ever, the low-force contacts cannot displace dielectric grease
mistakenly applied to this connector system, the low-force and create electrical contact. It is possible to use solvents (i.e.
contacts cannot displace the grease to achieve electrical con- contact cleaner or mineral spirits) for the removal of improp-
tact. Once contaminated, there is no practical way to remove erly applied dielectric grease. The EMR4 engine control mod-
the dielectric grease (replacement of female contacts ule from Deutz employs this connector system (for example).
required). The JLG Load Sensing System and Rotary Angle
Sensors are examples of components with the M12 connector
system.
Figure 7-7. Brad-Harrison M12
Figure 7-8. Phoenix Contact M12
7-6 3121262
SEALED ENCLOSURES MOLEX CMC SERIES CONNECTORS

Application of dielectric grease is not required in properly The CMC connector family is a sealed, high-density connection
sealed enclosures. To meet criteria, the enclosure must be system using matte-seal technology for CP 0.635 and 1.50 mm
rated to at least IP66 (dust tight; protected from powerful jets terminals. To guarantee IP6K7 and IP6K9 sealing, a seal plug
of water). The enclosure must be fitted with a high quality, option is used. However, the low-force contacts cannot displace
continuous gasket and all wiring must pass through cable dielectric grease and create electrical contact. It is possible to use
solvents (i.e. contact cleaner or mineral spirits) for the removal of
entrances.
improperly applied dielectric grease. The flexbox control mod-
ules from JDES employ this connector
system (for example).
MIL-C-5015 SPEC CONNECTOR’S

Crown Connector Inc’s recommendation is to not use
dielectric grease for this series connector. For similar model
series connectors, the manufacturer should be contacted for
confirmation before applying dielectric grease. A typical appli-
cation for this connector is on David Clark Intercom connec-
tions in Aerial Work Platforms.
3121262 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 3121262
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.).
3121262 7-9
Figure 7-14. Connector Disassembly
Disassembly Service - Voltage Reading

5. 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.
6. Pry open the wedge lock to the open position.
It has been common practice in electrical troubleshooting to
7. 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 3121262
Figure 7-15. Connector Installation
3121262 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
5. 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.
6. 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 7. 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 3121262
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
8. Grasp contact about 25mm behind the contact crimp

11. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
9. Hold connector with rear grommet facing you.
12. Slide tool along into the insert cavity until it engages
10. 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
13. 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
3121262 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
10 3
CAN LO 2 - 9 4- IGNITION
CAN HI 2 - 8
5
7 6
TELEMATICS-READY PLUG
7-14 3121262
3121262
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 3121262
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
3121262 7-17
7-18
V39-JIB LIFT UP
TOP COIL
V4V42-JIB LIFT DOWN
BOTTOM COIL
JIB CONTROL VALVE

V41-JIB LEVEL UP
V42-JIB LEVEL DOWN TOP COIL
BOTTOM COIL
V44-JIB TELESCOPE
OUT TOP COIL
V34-JIB TELESCOPE IN
BOTTOM COIL
V34-JIB ENABLE
V87-JIB SWING LEFT

TOP COIL SN1367-JIB TRANSPORT-2 SN137-JIB TRANSPORT-1
PROXIMITY SENSOR PROXIMITY SENSOR
SN82-JIB LEVEL V87-JIB SWING RIGHT
ANGLE SENSOR BOTTOM COIL
SN115-JIB LIFT LENGTH SENSOR
SB114-LOCK PIN
PROXIMITY SENSOR
J1 J2
J4
J3 J5
JIB CONTROL MODULE
SN84-JIB SWING ANGLE SENSOR
MAF10380D
1001119385-D
Figure 7-25. Jib Electrical Components
3121262
3121262 7-19
13 14
AXLE LIMIT SWITCH 21 22
WIRING - TYP.
STEER ANGLE
SENSOR
BLACK
WHITE
AXLE
POWERTRACK AXLE LIMIT SWITCH
SWIVEL
V167 - FRONT AXLES EXTEND
V162 - LEFT FRONT STEER RIGHT
V163 - RIGHT FRONT STEER RIGHT

STEER
VALVE
TRACTION VALVE
FRONT OF MACHINE
V165 - RIGHT FRONT STEER LEFT

AXLE
POWERTRACK V164 - LEFT FRONT STEER LEFT
V166 - FRONT AXLES RETRACT
AXLE LIMIT SWITCH
1001119385-D
MAF10470D
Figure 7-26. Chassis Electrical Components - Sheet 1 of 2
7-20 3121262
13 14
21 22 AXLE LIMIT SWITCH
WIRING - TYP.
STEER ANGLE
SENSOR
AXLE LIMIT SWITCH AXLE

POWERTRACK
V161 - FRONT AXLES RETRACT
STEER VALVE CHASSIS

V153 - LEFT REAR STEER LEFT MODULE
J4 J5
REAR OF MACHINE
V159 - RIGHT REAR STEER LEFT J2
J1 J3
V124 - RIGHT REAR STEER RIGHT
V123 - LEFT REAR STEER RIGHT
AXLE
V160 - REAR AXLES EXTEND POWERTRACK
AXLE LIMIT SWITCH
STEER ANGLE
SENSOR
SHEET 2
1001119385-D
MAF10470D
Figure 7-27. Chassis Electrical Components - Sheet 2 of 2
3121262 7-21
8 7 6 5 4
GENERATOR CONTROL BOX
H
ALTERNATOR OIL TEMP
SWITCH ENGINE
OIL PRESS
SWITCH SPEED SENSOR
HYDRAULIC PUMPS
HEADLIGHT V278-DRIVE RIGHT SIDE V279-DRIVE LEFT SIDE
REVERSE (SAUER/REXROTH) FORWARD (SAUER)
V280-DRIVE LEFT SIDE

REVERSE (REXROTH)

DEUTZ EMR2
FORWARD (REXROTH)
MODULE
110V / 220V GENERATOR V277-DRIVE RIGHT SIDE REVERSE (SAUER)
FORWARD (SAUER/REXROTH
IN HEAD STYLE
GLOW PLUG
STARTER
INTAKE STYLE
F HEATER GLOW PLUG
TRANSPORT LIMIT SWITCH WIRE RELAY
REF. BOOM CABLES INST'L. START RELAY
BROKEN CABLE BOOM ANGLE

PROXIMITY SENSOR #1
SWITCH WIRE (RIGHT)
REF. BOOM TRANSPORT SWIVEL
SENSORS AND LIMIT
COVERS INST'L. SWITCH
LIFT CYLINDER (SEE WIRING)
LOAD SENSING
E PIVOT PIN
BOOM LENGTH
SENSOR
12/3 PLATF
DUMP HARNESS
BROKEN CABLE CONNECTION
JIB ENABLE VALVE NEAR JIB
PROXIMITY
BOOM ANGLE CONNECTOR; (SEE ENABLE VALVE
SWITCH SHEET 5) REF BOOM
SENSOR #2
(LEFT) CABLES INST'L;
SN08 - MAIN
BOOM CYLINDER
ANGLE SENSOR
TURNTABLE HARNESS
REF. M.T.B. ASS'Y.
D TURNTABLE
POWERTRACK
V249-TELESCOPE OUT
B.L.A.M.
V252-LIFT UP
MODULE
V255-SWING RIGHT
V246-DUMP
J2 J5
J4
MAIN CONTROL
VALVE
J1 J3
V250-LIFT
C PILOT
V251-LIFT
DOWN AUX.
V247-TELESCOPE
FLOW CONTROL
V248-TELESCOPE IN ALARM
V256-LIFT FLOW CONTROL
V253-LIFT DOWN
V254-SWING LEFT
GROUND
CONTROL
BOX
B
ATTACH MS214- TO THIS POINT

WITH THE BATTERY B- CABLE
STROBE FUEL LEVEL

SENSOR
A
HEAD AND TAIL AUX POWER AUX PUMP
LIGHT RELAY RELAY
HEADLIGHT
HORN
SHEET 1
8 7 6 5 4
Figure 7-28. Turntable Electrical Components - Sheet 1 of 2
7-22 3121262
5 4 3 2 1
NOTE: DO NOT ATTACH ANY WIRING HARNESSES

TRANSPORT LIMIT TO FUEL SUPPLY, RETURN OR VENT HOSES.
SWITCH WIRING.
APPLY IN ALL UNSEALED CONNECTORS PER MPS FI-001 AND FI-042.
APPLY TO FEMALE TERMINALS IN SEAED CONNECTORS AS SHOWN IN VIEW BELOW
WITH THE FOLLOWING EXCEPTIONS: H
13 14 ***DO NOT APPLY ON DEUTZ ENGINE EMR 2 MODULE CONNECTORS***
***DO NOT APPLY ON LSS WITH CIRCULAR CONNECTORS***
RED
21 22
BLACK
WHITE
DIELECTRIC GREASE,
APPROXIMATELY 1/2 FULL
(A THIN LAYER OF GREASE SECTION A-A
MAY REMAIN ON CONNECTOR
FACE AND ADJACENT AREAS)
G
THIS EXAMPLE OF A SEALED CONNECTOR SHOWN FOR
CLARITY. PROCESS APPLIES TO ALL SEALED CONNECTORS.
BLACK
RED
WHITE
TAIL LIGHT
GLOW PLUG F
RELAY
PLATFORM LEVEL
SENSOR #1
(RIGHT-PRIMARY)
PLATFORM
CONTROL BOX
V27-PLATFORM DUMP
SWIVEL
V28-PLATFORM LEVEL UP
V29-PLATFORM LEVEL DOWN
V31-PLATFORM ROTATE RIGHT
E
V30-PLATFORM ROTATE LEFT
V33-JIB LOCK PIN (OUT)

V32-JIB LOCK PIN (IN)
D
PLATFORM LEVEL
SENSOR #2
(LEFT-SECONDARY)
V249-TELESCOPE OUT
V252-LIFT UP
V255-SWING RIGHT
V246-DUMP
V27-PLATFORM DUMP
MAIN CONTROL
VALVE
V250-LIFT V28-PLATFORM LEVEL UP
PILOT BOTTOM COIL
C
TAIL LIGHT
V29-PLATFORM LEVEL DOWN
TOP COIL
V251-LIFT
DOWN AUX.
V-30 PLATFORM ROTATE LEFT
V247-TELESCOPE
FLOW CONTROL TOP COIL
V248-TELESCOPE IN ALARM
V256-LIFT FLOW CONTROL
V253-LIFT DOWN V31-PLATFORM ROTATE RIGHT
BOTTOM COIL V32-JIB LOCK PIN (IN)
V254-SWING LEFT TOP COIL
V-33-JIB LOCK PIN (OUT)
BOTTOM COIL
B
PLATFORM
VALVE REFERENCE
SCALE 1/2
ATTACH MS214- TO THIS POINT

WITH THE BATTERY B- CABLE
A
AUX POWER AUX PUMP
RELAY
SHEET 2 1001119385-D
5 4 3 2 1
MAF10490D
Figure 7-29. Turntable Electrical Components - Sheet 2 of 2
3121262 7-23
7-24
SW48-2A SW48-1A MS156
C001-J2 C001-J1
X155
GD47-J2 GD47-J1
GD47-J4
SW74 SW135 GD47-J3
SW73 SW72
SW76-2
SW76-1 X04 X05
S108
S145 S104
X141
AH142+
AH142-
C001-J8
SW66
SW118 X51
SW65
SW71 SW67
SW69 SW64 C001-J7
SW70 SW68
SW63
SW125-1 LB132-
SW125-2 SW129-2 LB132+
X54
SW129-1 LB128-
LB128+
Figure 7-30. Console Box Harness (Without Skyguard) - Sheet 1 of 2
3121262
WIRE LENGTH FROM TO WIRE LENGTH FROM TO

WIRE NO COLOR WIRE NO COLOR
GAUGE (in) REFERENCE PIN REFERENCE PIN GAUGE (in) REFERENCE PIN REFERENCE PIN
000-24-3 BLK 12 21 X51 18 CO01-J8 1 49-100 ORN/RED 18 39 GD47-J4 3 CO01-J2 11
000-46-1 BLK 18 21 X141 12 CO01-J7 29 49-1000 ORN/RED 18 39 GD47-J3 1 CO01-J2 19
000-49 BLK 12 21 X51 16 CO01-J8 1 49-101 ORN/RED 18 39 GD47-J3 5 CO01-J2 10
000-51-1 BLK 18 15 LB132- 1 LB128- 1 49-11 ORN/RED 18 39.25 SW118 2 CO01-J1 32
000-51-2 BLK 18 22 LB128- 1 GD47-J1 4 49-12 ORN/RED 18 17 X51 13 CO01-J1 33
000-51-3 BLK 18 45 GD47-J1 4 CO01-J2 25 49-120 ORN/RED 18 58.5 SW135 3 CO01-J1 22
000-52 BLK 18 45 GD47-J2 6 CO01-J2 18 49-13 ORN/RED 18 17 X51 15 CO01-J1 1
000-53 BLK 18 38 SW118 5 CO01-J1 13 49-15 ORN/RED 18 45 GD47-J2 1 CO01-J2 9
000-54 BLK 18 29 CO01-J7 20 AH142- 1 49-3 ORN/RED 18 39 GD47-J4 5 CO01-J2 6
13-1 BRN 18 53 SW71 3 CO01-J1 5 49-4 ORN/RED 18 29 CO01-J7 19 AH142+ 1
14-1 BRN 18 53 SW71 1 CO01-J1 6 49-40 ORN/RED 18 50 SW129-2 1 CO01-J1 29
2-1-2 YEL/RED 12 21 X51 12 CO01-J8 2 49-42 ORN/RED 18 41.5 LB128+ 1 CO01-J2 16
2-8-13 YEL/RED 12 21 X51 10 CO01-J8 2 49-63 ORN/RED 18 17 X141 2 CO01-J1 25
2-10-11 YEL/RED 18 15 SW125-1 1 SW71 2 49-67 ORN/RED 18 3 X155 4 X155 5
2-10-13 YEL/RED 18 17.5 SW135 2 SW72 2 49-68 ORN/RED 18 21 X141 3 CO01-J7 21
2-10-19 YEL/RED 18 13.5 SW129-1 1 SW69 2 49-69 ORN/RED 18 29.5 CO01-J7 18 X155 3
2-10-12 YEL/RED 18 16.5 SW71 2 SW135 2 49-70 ORN/RED 18 29.5 CO01-J7 8 X155 7
2-10-5 YEL/RED 18 16.25 SW66 2 SW118 3 49-80 ORN/RED 18 17 X141 16 CO01-J1 26
2-10-15 YEL/RED 18 11 SW73 2 SW74 2 49-81 ORN/RED 18 21 X141 17 CO01-J7 33
2-10-9 YEL/RED 18 12 SW68 2 SW69 2 49-89 ORN/RED 18 26 X54 4 CO01-J2 27
2-10-10 YEL/RED 18 16 SW129-1 1 SW70 2 49-90 ORN/RED 18 26 CO01-J2 29 X54 3
2-10-16 YEL/RED 18 58 SW74 2 CO01-J1 18 49-91 ORN/RED 18 26 X54 2 CO01-J2 28
2-10-4 YEL/RED 18 14 SW76-1 1 SW66 2 49-92 ORN/RED 18 26 X54 1 CO01-J2 26
2-10-6 YEL/RED 18 13.75 SW118 3 SW67 2 52-1 BLU/ORN 18 37 SW76-2 1 CO01-J1 31
2-10-2 YEL/RED 18 12.75 SW64 2 SW65 2 52-12 BLU/ORN 18 54 SW125-2 1 CO01-J1 30
2-10-18 YEL/RED 18 15 SW125-1 1 SW70 2 52-3 BLU/ORN 18 22 CO01-J2 33 X155 2
2-10-14 YEL/RED 18 14 SW72 2 SW73 2 52-4-1 BLU/ORN 18 39 GD47-J4 2 CO01-J2 15
2-10-3 YEL/RED 18 16 SW76-1 1 SW65 2 52-4-2 BLU/ORN 18 29.5 CO01-J7 9 X155 1
2-10-1 YEL/RED 18 13 SW63 2 SW64 2 53-1 BRN/ORN 18 55 SW72 1 CO01-J1 15
2-10-8 YEL/RED 18 17 SW67 2 SW68 2 54-1 RED/YEL 18 58 SW73 3 CO01-J1 21
2-11-2 YEL/RED 18 13.75 X141 1 S145 2 54-2 RED/YEL 18 39 GD47-J4 4 CO01-J2 12
2-11-3-1 YEL/RED 18 13.75 X141 15 S145 2 54-3 RED/YEL 18 39 GD47-J3 4 CO01-J2 13
2-11-3-2 YEL/RED 18 7.75 CO01-J2 32 S145 1 55-1 WHT 18 21 X141 10 CO01-J7 25
2-16-1 YEL/RED 18 22 CO01-J2 3 X155 8 55-16 YEL 18 58 SW64 3 CO01-J1 16
2-16-2 YEL/RED 18 3 X155 6 X155 8 55-17 YEL 18 58 SW64 1 CO01-J1 17
2-2-1 YEL/RED 18 55.5 X51 5 SW48-2A 2A 55-2 WHT 18 21 X141 11 CO01-J7 26
2-21-1 YEL/RED 18 45 GD47-J2 2 CO01-J2 7 55-30 RED/WHT 18 44.25 SW118 4 CO01-J1 34
2-3-3 YEL/RED 18 21 X51 4 CO01-J7 3 55-31 RED/WHT 18 44.25 SW118 6 CO01-J1 35
2-3-5 YEL/RED 18 55.5 SW48-1A 1A CO01-J7 2 55-46 ORN 18 60 SW63 3 CO01-J1 27
2-30-1 YEL/RED 18 21 X51 11 CO01-J7 1 55-50 ORN 18 58 SW74 1 CO01-J2 4
23-1 GRY 18 43.5 SW67 3 CO01-J1 7 55-51 ORN 18 39 GD47-J3 3 CO01-J2 30
23-3 GRY 18 21 X141 8 CO01-J7 5 59-1 WHT 18 45 SW69 3 CO01-J2 1
24-1 GRY 18 43.5 SW67 1 CO01-J1 8 59-60 WHT 18 41.5 LB132+ 1 CO01-J2 31
24-3 GRY 18 21 X141 9 CO01-J7 6 60-4 WHT 18 45 SW69 1 CO01-J2 2
25-1 PNK 18 41 SW65 3 CO01-J1 9 CANH YEL 18 24.5 X51 3 MS156 2
25-3-1 PNK 18 9.25 X51 9 S104 2 CANH YEL 18 23.5 MS156 1 CO01-J7 31
25-3-2 PNK 18 12.75 S104 1 CO01-J7 15 CANL GRN 18 24.5 X51 2 MS156 4
25-3-3 PNK 18 9.25 X141 7 S104 1 CANL GRN 18 23.5 MS156 3 CO01-J7 30
26-1 PNK 18 41 SW65 1 CO01-J1 10 CANS BLK 18 23.5 MS156 5 CO01-J7 32
26-3-1 PNK 18 9.25 X51 7 S108 2 CANS BLK 18 24.5 X51 1 MS156 6
26-3-2 PNK 18 12.75 S108 1 CO01-J7 16 X04-CANH BLUE N/A 24 X04 3 MS156 12
26-3-3 PNK 18 9.25 X141 6 S108 1 X04-CANL BLACK N/A 24 X04 4 MS156 10
27-1 BLU 18 51 SW70 3 CO01-J1 11 X04-CANS GRAY N/A 24 X04 5 MS156 8
28-1 BLU 18 51 SW70 1 CO01-J1 12 X04-GND WHITE N/A 20.5 X04 2 CO01-J7 14
29-1 BRN 18 48.5 SW68 3 CO01-J1 3 X04-PWR BROWN N/A 20.5 X04 1 CO01-J7 4
30-1 BRN 18 48.5 SW68 1 CO01-J1 4 X05-CANH BLUE N/A 24 MS156 11 X05 3
39-1 WHT/YEL 18 39 GD47-J3 2 CO01-J2 14 X05-CANL BLACK N/A 24 MS156 9 X05 4
43-1 YEL/WHT 18 39 SW66 3 CO01-J1 23 X05-CANS GRAY N/A 24 MS156 7 X05 5
44-1 YEL/WHT 18 39 SW66 1 CO01-J1 24 X05-GND WHITE N/A 20.5 CO01-J7 14 X05 2
47-1 BRN/WHT 18 45 GD47-J1 1 CO01-J2 22 X05-PWR BROWN N/A 20.5 CO01-J7 7 X05 1
47-10 BRN/WHT 18 39 GD47-J4 1 CO01-J2 20
47-12 BRN/WHT 18 39 GD47-J3 6 CO01-J2 8
47-13 BRN/WHT 18 45 GD47-J2 3 CO01-J2 21
47-2 BRN/WHT 18 45 GD47-J1 2 CO01-J2 24
47-3 BRN/WHT 18 45 GD47-J1 3 CO01-J2 23
47-4 BRN/WHT 18 45 GD47-J1 6 CO01-J2 35
48-1 WHT/YEL 18 55 SW72 3 CO01-J1 14
48-5 WHT/YEL 18 42.75 SW63 1 CO01-J1 28
48-6 WHT/YEL 18 39 GD47-J4 6 CO01-J2 17
Figure 7-31. Console Box Harness - Sheet 2 of 2
3121262 7-25
7-26
SW48-2A SW45-1A (PLATFORMMODULE) C001-J1
(EMS SW) (EMS SW) X155 C001-J2 (PLATFORMMODULE)
(SKYGUARD OPT MS156
CONN.) (CAN 1
GD47-J2 SPLICE)
GD47-J1
SW72 (PLATFORM DISPLAY)
(PLATFORM DISPLAY)
GD47-J4
SW73 (PLATFORM DISPLAY)
SW74
(START/AUX POWER) GD47-J3 X154
(PLATFORM DISPLAY)
PIN 13
PIN 6
PIN 3
(SKYGUARD OPT X1001
(CAPACITY SEL SW) SW135 CONN.) X05
SW76-2 (MATE WITH (PLT.LEVEL SENSOR)
(HORN)
(DRIVE X155) (CAN CONNECTOR)
ORIENTATION (SW)
SW76-1
(HORN)
X04
YEL/RED P8 -KL
YEL/RED P8 - KL
YEL/RED P1 - AB
(PLT.LEVEL SENSOR) X1002
S108
(SPLICE)
S145 S104
(SPLICE) (SPLICE) (CAN CONNECTOR)
AH142+ S366
(PIEZO ALARAM) (SPLICE)
X141
(TO BOOM CABLE)
AH142- C001-J8
(PIEZO ALARAM)
(PLATFORMMODULE)
SW118 SW66 X51

(PUMP POT) (AXLE EXTENDED/ (TO BOOM CABLE)
RETRACT SW)
SW71 SW69 SW65
(MAIN BOOM (JIB SWING SW) (PLT.LEVEL C001-J7
TELESCOPE SW) OVERRIDE SW) (PLATFORMMODULE)
SW68 R501
(JIB TELESCOPE SW)
SW64 (RESISTOR)
SW70 SW67
(JIB LIFT SW) (PLT.ROTATE SW) (STEER MODE)
SW125-2
LB132- (JIB LOCK PIN LIGHT)
(HEAD/TAIL LIGHT) SW129-2 SW63 X500
(SOFT TOUCH LB132+ (JIB LOCK PIN LIGHT) (PLATFORMSENSOR)
LB128- (SOFT TOUCH LIGHT) (HI DRIIVE)
SW125-1 OVERRIDE) X54
LB128+ (SOFT TOUCH LIGHT) (ANALYZER)
(HEAD/TAIL LIGHT) SW129-1
(SOFT TOUCH
OVERRIDE)
RL503
(PLT.SENSOR RELAY 1)
RL502
(PLT.SENSOR RELAY 1)
1001186905-D
MAF10680D
Figure 7-32. Console Box Harness-With Skugurad (SN 0300220152 through 0300234293)
3121262
23-1 GRY 18 SW67 3 CO01-J1 7

23-3 GRY 18 X141 8 CO01-J7 5
WIRE WIRE FROM TO
COLOR 24-1 GRY 18 SW67 1 CO01-J1 8
NO GAUGE REFERENCE PIN REFERENCE PIN
24-3 GRY 18 X141 9 CO01-J7 6
000-24-3 BLK 12 X51 18 CO01-J8 1
25-1 PNK 18 SW65 3 CO01-J1 9
000-46-1 BLK 18 X141 12 CO01-J7 29
25-3-1 PNK 18 X51 9 S104 2
000-49 BLK 12 X51 16 CO01-J8 1
25-3-2 PNK 18 S104 1 CO01-J7 15
000-51-1 BLK 18 LB132- 1 LB128- 1
25-3-3 PNK 18 X141 7 S104 1
000-51-2 BLK 18 LB128- 1 GD47-J1 4
26-1 PNK 18 SW65 1 CO01-J1 10
000-51-3 BLK 18 GD47-J1 4 CO01-J2 25
26-3-1 PNK 18 X51 7 S108 2
000-52 BLK 18 GD47-J2 6 CO01-J2 18
26-3-2 PNK 18 S108 1 CO01-J7 16
000-53 BLK 18 SW118 5 CO01-J1 13
26-3-3 PNK 18 X141 6 S108 1
000-54 BLK 18 CO01-J7 20 S366 1
27-1 BLU 18 SW70 3 CO01-J1 11
000-54-1 BLK 18 S366 2 AH142- 1
28-1 BLU 18 SW70 1 CO01-J1 12
13-1 BRN 18 SW71 3 CO01-J1 5
29-1 BRN 18 SW68 3 CO01-J1 3
14-1 BRN 18 SW71 1 CO01-J1 6
30-1 BRN 18 SW68 1 CO01-J1 4
2-1-2 YEL/RED 12 X51 12 CO01-J8 2
39-1 WHT/YEL 18 GD47-J3 2 CO01-J2 14
2-8-13 YEL/RED 12 X51 10 CO01-J8 2
43-1 YEL/WHT 18 SW66 3 CO01-J1 23
2-10-11 YEL/RED 18 SW125-1 1 SW71 2
44-1 YEL/WHT 18 SW66 1 CO01-J1 24
2-10-13 YEL/RED 18 SW135 2 SW72 2
BRN/
2-10-19 YEL/RED 18 SW129-1 1 SW69 2 47-1 18 GD47-J1 1 CO01-J2 22
WHT
2-10-12 YEL/RED 18 SW71 2 SW135 2 BRN/
47-10 18 GD47-J4 1 CO01-J2 20
2-10-5 YEL/RED 18 SW66 2 SW118 3 WHT
2-10-15 YEL/RED 18 SW73 2 SW74 2 BRN/
47-12 18 GD47-J3 6 CO01-J2 8
2-10-9 YEL/RED 18 SW68 2 SW69 2 WHT
2-10-10 YEL/RED 18 SW129-1 1 SW70 2 BRN/
47-13 18 GD47-J2 3 CO01-J2 21
WHT
2-10-16 YEL/RED 18 SW74 2 CO01-J1 18
BRN/
2-10-4 YEL/RED 18 SW76-1 1 SW66 2 47-2 18 GD47-J1 2 CO01-J2 24
WHT
2-10-6 YEL/RED 18 SW118 3 SW67 2 BRN/
2-10-2 YEL/RED 18 SW64 2 SW65 2 47-3 18 GD47-J1 3 CO01-J2 23
WHT
2-10-18 YEL/RED 18 SW125-1 1 SW70 2 BRN/
47-4 18 GD47-J1 6 CO01-J2 35
2-10-14 YEL/RED 18 SW72 2 SW73 2 WHT
2-10-3 YEL/RED 18 SW76-1 1 SW65 2 48-1 WHT/YEL 18 SW72 3 CO01-J1 14
2-10-1 YEL/RED 18 SW63 2 SW64 2 48-5 WHT/YEL 18 SW63 1 CO01-J1 28
2-10-8 YEL/RED 18 SW67 2 SW68 2 48-6 WHT/YEL 18 GD47-J4 6 CO01-J2 17
2-11-2 YEL/RED 18 X141 1 S145 2
2-11-3-1 YEL/RED 18 X141 15 S145 2
2-11-3-2 YEL/RED 18 CO01-J2 32 S145 1
2-16-1 YEL/RED 18 CO01-J2 3 X155 8
2-16-2 YEL/RED 18 X155 6 X155 8
2-2-1 YEL/RED 18 X51 5 SW48-2A 2A
2-21-1 YEL/RED 18 GD47-J2 2 CO01-J2 7
2-3-3 YEL/RED 18 X51 4 CO01-J7 3
2-3-5 YEL/RED 18 SW48-1A 1A CO01-J7 2
2-30-1 YEL/RED 18 X51 11 CO01-J7 1
3121262 7-27
59-1 WHT 18 SW69 3 CO01-J2 1

WIRE FROM TO 59-60 WHT 18 LB132+ 1 CO01-J2 31
WIRENO COLOR
GAUGE REFERENCE PIN REFERENCE PIN 60-4 WHT 18 SW69 1 CO01-J2 2
49-100 ORN/RED 18 GD47-J4 3 CO01-J2 11 CANH YEL 18 X51 3 X1002 A
CO01- CANH YEL 18 MS156 1 CO01-J7 31
49-1000 ORN/RED 18 GD47-J3 1 19
J2 CANL GRN 18 X51 2 X1002 B
49-101 ORN/RED 18 GD47-J3 5 CO01-J2 10 CANL GRN 18 MS156 3 CO01-J7 30
49-11 ORN/RED 18 SW118 2 CO01-J1 32 CANS BLK 18 MS156 5 CO01-J7 32
49-12 ORN/RED 18 X51 13 CO01-J1 33 CANS BLK 18 X51 1 X1002 C
49-120 ORN/RED 18 SW135 3 CO01-J1 22 CANH YEL 18 X1001 A MS156 2
49-13 ORN/RED 18 X51 15 CO01-J1 1 CANL GRN 18 X1001 B MS156 4
49-15 ORN/RED 18 GD47-J2 1 CO01-J2 9 CANS BLK 18 X1001 C MS156 6
49-3 ORN/RED 18 GD47-J4 5 CO01-J2 6 X04-CANH BLUE N/A X04 3 MS156 12
49-4 ORN/RED 18 CO01-J7 19 AH142+ 1 X04-CANL BLACK N/A X04 4 MS156 10
49-40 ORN/RED 18 SW129-2 1 CO01-J1 29 X04-CANS GRAY N/A X04 5 MS156 8
49-42 ORN/RED 18 LB128+ 1 CO01-J2 16 X04-GND WHITE N/A X04 2 CO01-J7 14
49-63 ORN/RED 18 X141 2 CO01-J1 25 X04-PWR BROWN N/A X04 1 CO01-J7 4
49-67 ORN/RED 18 X155 4 X155 5 X05-CANH BLUE N/A MS156 11 X05 3
49-68 ORN/RED 18 X141 3 CO01-J7 21 X05-CANL BLACK N/A MS156 9 X05 4
49-69 ORN/RED 18 CO01-J7 18 X155 3 X05-CANS GRAY N/A MS156 7 X05 5
49-70 ORN/RED 18 CO01-J7 8 X155 7 X05-GND WHITE N/A CO01-J7 14 X05 2
49-80 ORN/RED 18 X141 16 CO01-J1 26 X05-PWR BROWN N/A CO01-J7 7 X05 1
49-81 ORN/RED 18 X141 17 CO01-J7 33 P1 YEL/RED 18 RL503 87 X154 3
49-89 ORN/RED 18 X54 4 CO01-J2 27 P2 YEL/RED 18 R501 2 X155 13
49-90 ORN/RED 18 CO01-J2 29 X54 3 P3 YEL/RED 18 RL502 87 CO01-J1 2
49-91 ORN/RED 18 X54 2 CO01-J2 28 P4 ORN/RED 18 RL502 86 X500 4
49-92 ORN/RED 18 X54 1 CO01-J2 26 P4-1 ORN/RED 18 RL502 86 RL503 86
52-1 BLU/ORN 18 SW76-2 1 CO01-J1 31 P5 ORN/RED 18 RL502 85 X500 3
52-12 BLU/ORN 18 SW125-2 1 CO01-J1 30 P5-1 ORN/RED 18 RL502 85 RL503 85
52-3 BLU/ORN 18 CO01-J2 33 X155 2 P6 BLACK 18 X500 2 S366 2
52-4-1 BLU/ORN 18 GD47-J4 2 CO01-J2 15 P8 YEL/RED 18 X154 6 X154 13
52-4-2 BLU/ORN 18 CO01-J7 9 X155 1 P9 YEL/RED 18 RL503 30 X155 13
53-1 BRN/ORN 18 SW72 1 CO01-J1 15 P9-1 YEL/RED 18 RL503 30 RL502 30
54-1 RED/YEL 18 SW73 3 CO01-J1 21 P10 YEL/RED 18 X500 1 R501 1
54-2 RED/YEL 18 GD47-J4 4 CO01-J2 12
54-3 RED/YEL 18 GD47-J3 4 CO01-J2 13
55-1 WHT 18 X141 10 CO01-J7 25
55-16 YEL 18 SW64 3 CO01-J1 16
55-17 YEL 18 SW64 1 CO01-J1 17
55-2 WHT 18 X141 11 CO01-J7 26
55-30 RED/WHT 18 SW118 4 CO01-J1 34
55-31 RED/WHT 18 SW118 6 CO01-J1 35
55-46 ORN 18 SW63 3 CO01-J1 27
55-50 ORN 18 SW74 1 CO01-J2 4
55-51 ORN 18 GD47-J3 3 CO01-J2 30
7-28 3121262
3121262 7-29
7-30
SW48-2A SW48-1A X154
(EMS SW) (EMS SW) (SKYGUARD OPT CONN.)
(MATE WITH X155) MS509
(CAN2 SPLICE) C001-J1
(PLATFORM MODULE)
C001-J2
(PLATFORM MODULE) MS156
GD47-J2 (CAN2 SPLICE)
(PLATFORM DISPLAY)
GD47-J1
(PLATFORM
SW72 GD47-J4 DISPLAY) X1001
(START/AUX POWER) (CAN CONNECTOR)
(PLATFORM DISPLAY)
SW73 X155 X5A
(CAPACITY SEL SW) (SKYGUARD (INTERFACE)
GD47-J3 OPT CONN.) X1005
SW74 ( P L AT F O R M D I S - (LSS)
(DRIVE
ORIENTATION SW) SW135
(BOOM CTL SEL SW) SW76-2 X05
(HORN) (PLT.LEVEL SENSOR)
IP301 X04
SW76-1 (MUST INCLUDE (PLT.LEVEL SENSOR)
S370
(HORN) 5A FUSE) (SPLICE) S368
(SPLICE)
X1002
S367
(SPLICE) S108
S145 (SPLICE)
(SPLICE) (CAN CONNECTOR)
AH142+ S104
(PIEZO A:ARAM) (SPLICE) X141
(TO BOTTOM CABLE)
AH142-
(PIEZO A:ARAM)
C001-J8
(PLATFORM MODULE)
SW66
(AXLE EXTEND/
RETRACT SW)
X51
SW118 (TO BOTTOM CABLE)
(PUMP OUT)
SW65
SW71 SW69 (PLT.LEVEL
(MAIN BOOM TELESCOPE SW) (JIB SWING OVERRIDE SW) C001-J7
(PLATFORM MODULE)
SW68
(JIB TELESCOPE SW64
SW) SW67 (STEER MODE)
SW125-2 SW70 (PLT.ROTATE SW) X54
(HEAD/TAIL LIGHT) (JIB LIFT SW) (ANALYZER)
SW63
(HI DRIVE)
SW129-2
(SOFT TOUCH LB132-
SW125-1 (JIB LOCK PIN LIGHT)
(HEAD/TAIL LIGHT) OVERRIDE)
LB132+
SW129-1 (JIB LOCK PIN LIGHT)
(SOFT TOUCH OVERRIDE)
LB128+
(SOFT TOUCH LIGHT) LB128-
(SOFT TOUCH LIGHT)
MAF10690E
100220867-E
Figure 7-33. Console Box Harness - With Skyguard (SN 0300234294 to Present)
3121262
47-10 BRN/WHT 18 GD47-J4 1 CO01-J2 20

FROM TO 47-12 BRN/WHT 18 GD47-J3 6 CO01-J2 8
WIRE
REFER- 47-13 BRN/WHT 18 GD47-J2 3 CO01-J2 21
WIRENO COLOR GAUGE REFERENCE PIN PIN
ENCE 47-2 BRN/WHT 18 GD47-J1 2 CO01-J2 24
000-24-3 BLK 12 X51 18 CO01-J8 1 47-3 BRN/WHT 18 GD47-J1 3 CO01-J2 23
000-46-1 BLK 18 X141 12 CO01-J7 29 47-4 BRN/WHT 18 GD47-J1 6 CO01-J2 35
000-49 BLK 12 X51 16 CO01-J8 1 48-1 WHT/YEL 18 SW72 3 CO01-J1 14
000-51-1 BLK 18 LB132- 1 LB128- 1 48-5 WHT/YEL 18 SW63 1 CO01-J1 28
000-51-2 BLK 18 LB128- 1 GD47-J1 4 48-6 WHT/YEL 18 GD47-J4 6 CO01-J2 17
000-51-3 BLK 18 GD47-J1 4 CO01-J2 25
000-52 BLK 18 GD47-J2 6 CO01-J2 18
000-53 BLK 18 SW118 5 CO01-J1 13
FROM TO
000-54 BLK 18 CO01-J7 20 AH142- 1 WIRE
WIRENO COLOR REFER-
13-1 BRN 18 SW71 3 CO01-J1 5 GAUGE REFERENCE PIN PIN
14-1 BRN 18 SW71 1 CO01-J1 6 ENCE
2-1-2 YEL/RED 12 X51 12 CO01-J8 2 49-100 ORN/RED 18 GD47-J4 3 CO01-J2 11
2-8-13 YEL/RED 12 X51 10 CO01-J8 2 49-1000 ORN/RED 18 GD47-J3 1 CO01-J2 19
2-10-11 YEL/RED 18 SW125-1 1 SW71 2 49-101 ORN/RED 18 GD47-J3 5 CO01-J2 10
2-10-13 YEL/RED 18 SW135 2 SW72 2 49-11 ORN/RED 18 SW118 2 CO01-J1 32
2-10-19 YEL/RED 18 SW129-1 1 SW69 2 49-12-1 ORN/RED 18 X51 13 CO01-J1 33
2-10-12 YEL/RED 18 SW71 2 SW135 2 49-120 ORN/RED 18 SW135 3 CO01-J1 22
2-10-5 YEL/RED 18 SW66 2 SW118 3 49-13-1 ORN/RED 18 X51 15 CO01-J1 1
2-10-15 YEL/RED 18 SW73 2 SW74 2 49-15 ORN/RED 18 GD47-J2 1 CO01-J2 9
2-10-9 YEL/RED 18 SW68 2 SW69 2 49-3 ORN/RED 18 GD47-J4 5 CO01-J2 6
2-10-10 YEL/RED 18 SW129-1 1 SW70 2 49-4 ORN/RED 18 CO01-J7 19 AH142+ 1
2-10-16 YEL/RED 18 SW74 2 CO01-J1 18 49-40 ORN/RED 18 SW129-2 1 CO01-J1 29
2-10-4 YEL/RED 18 SW76-1 1 SW66 2 49-42 ORN/RED 18 LB128+ 1 CO01-J2 16
2-10-6 YEL/RED 18 SW118 3 SW67 2 49-63 ORN/RED 18 X141 2 CO01-J1 25
2-10-2 YEL/RED 18 SW64 2 SW65 2 49-67 ORN/RED 18 X155 4 X155 5
2-10-18 YEL/RED 18 SW125-1 1 SW70 2 49-68 ORN/RED 18 X141 3 CO01-J7 21
2-10-14 YEL/RED 18 SW72 2 SW73 2 49-69 ORN/RED 18 CO01-J7 18 X5A 4
2-10-3 YEL/RED 18 SW76-1 1 SW65 2 49-70 ORN/RED 18 CO01-J7 8 X155 7
2-11-2 YEL/RED 18 X141 1 S145 2 49-89 ORN/RED 18 X54 4 CO01-J2 27
2-11-3 YEL/RED 18 X141 15 S145 2 49-90 ORN/RED 18 CO01-J2 29 X54 3
2-11-1 YEL/RED 18 CO01-J2 32 S145 1 49-91 ORN/RED 18 X54 2 CO01-J2 28
2-16-1 YEL/RED 18 X155 6 X155 8 49-92 ORN/RED 18 X54 1 CO01-J2 26
2-2 YEL/RED 18 X51 5 SW48-2A 2A 52-1 BLU/ORN 18 SW76-2 1 CO01-J1 31
2-21 YEL/RED 18 GD47-J2 2 CO01-J2 7 52-12 BLU/ORN 18 SW125-2 1 CO01-J1 30
2-3-3 YEL/RED 18 X51 4 CO01-J7 3 52-3 BLU/ORN 18 CO01-J2 33 X155 2
2-3-5 YEL/RED 18 SW48-1A 1A CO01-J7 2 52-4-1 BLU/ORN 18 GD47-J4 2 CO01-J2 15
2-30-1 YEL/RED 18 X51 11 CO01-J7 1 52-4-2 BLU/ORN 18 CO01-J7 9 X155 1
23-1 GRY 18 SW67 3 CO01-J1 7 53-1 BRN/ORN 18 SW72 1 CO01-J1 15
23-3 GRY 18 X141 8 CO01-J7 5 54-1 RED/YEL 18 SW73 3 CO01-J1 21
24-1 GRY 18 SW67 1 CO01-J1 8 54-2 RED/YEL 18 GD47-J4 4 CO01-J2 12
24-3 GRY 18 X141 9 CO01-J7 6 54-3 RED/YEL 18 GD47-J3 4 CO01-J2 13
25-1 PNK 18 SW65 3 CO01-J1 9 55-1 WHT 18 X141 10 CO01-J7 25
25-3-1 PNK 18 X51 9 S104 2 55-16 YEL 18 SW64 3 CO01-J1 16
25-3-2 PNK 18 S104 1 CO01-J7 15 55-17 YEL 18 SW64 1 CO01-J1 17
25-3-3 PNK 18 X141 7 S104 1 55-2 WHT 18 X141 11 CO01-J7 26
26-1 PNK 18 SW65 1 CO01-J1 10 55-30 RED/ 18 SW118 4 CO01-J1 34
26-3-1 PNK 18 X51 7 S108 2 WHT
26-3-2 PNK 18 S108 1 CO01-J7 16 55-31 RED/ 18 SW118 6 CO01-J1 35
26-3-3 PNK 18 X141 6 S108 1 WHT
27-1 BLU 18 SW70 3 CO01-J1 11 55-46 ORN 18 SW63 3 CO01-J1 27
28-1 BLU 18 SW70 1 CO01-J1 12 55-50 ORN 18 SW74 1 CO01-J2 4
29-1 BRN 18 SW68 3 CO01-J1 3 55-51 ORN 18 GD47-J3 3 CO01-J2 30
30-1 BRN 18 SW68 1 CO01-J1 4 59-1 WHT 18 SW69 3 CO01-J2 2
39-1 WHT/YEL 18 GD47-J3 2 CO01-J2 14 59-60 WHT 18 LB132+ 1 CO01-J2 31
43-1 YEL/WHT 18 SW66 3 CO01-J1 23 60-4 WHT 18 SW69 1 CO01-J2 1
44-1 YEL/WHT 18 SW66 1 CO01-J1 24 CANH YEL 18 X51 3 X1002 A
47-1 BRN/WHT 18 GD47-J1 1 CO01-J2 22 CANH YEL 18 MS156 1 CO01-J7 31
CANL GRN 18 X51 2 X1002 B
3121262 7-31
CANL GRN 18 MS156 3 CO01-J7 30

CANS BLK 18 MS156 5 CO01-J7 32
CANS BLK 18 X51 1 X1002 C
CANH YEL 18 X1001 A MS156 2
CANL GRN 18 X1001 B MS156 4
CANS BLK 18 X1001 C MS156 6
X04-CANH BLUE N/A X04 3 MS156 12
X04-CANL BLACK N/A X04 4 MS156 10
X04-CANS GRAY N/A X04 5 MS156 8
X04-GND WHITE N/A X04 2 CO01-J7 14
X04-PWR BROWN N/A X04 1 CO01-J7 4
X05-CANH BLUE N/A MS509 11 X05 3
X05-CANL BLACK N/A MS509 9 X05 4
X05-CANS GRAY N/A MS509 7 X05 5
X05-GND WHITE N/A S368 2 X05 2
X05-PWR BROWN N/A S367 2 X05 1
P3 YEL/RED 18 X5A 5 CO01-J1 2
P6 BLACK 18 X5A 2 AH142- 1
X1005- WHITE N/A X1005 2 S367 2
PWR
X1005- BLUE N/A X1005 3 S368 2
GND
X1005- BLACK N/A X1005 4 MS509 2
CANH
X1005- GRAY N/A X1005 5 MS509 4
CANL
80-2 BLACK 18 MS509 8 MS156 7
80-3 YELLOW 18 MS509 12 MS156 11
80-4 GREEN 18 MS509 10 MS156 9
PWR-J7 BROWN 18 C001-J7 7 S367 1
GND-J7 WHT 18 C001-J7 34 S368 1
2-16 YEL/RED 18 CO01-J2 3 X155 8
2-16-1 YEL/RED 18 X155 3 S370 1
FUSELEAD BLK 18 X5A 1 S370 2
2-16-1 ORN/RED 18 X154 3 X154 6
7-32 3121262
3121262 7-33
7-34 3121262
Figure 7-34. Platform Valve Harness - Sheet 2 of 2
3121262 7-35
Figure 7-35. Jib Valve Harness - Sheet 1 of 3
7-36 3121262
3121262 7-37
X57
7-38
CO49-J4
X58
SN114
LOCK PN
V44 PROXY SENSOR
JIB TELE OUT
V39
V43 CO49-J5
JIB LIFT UP SN84
JIB TELE IN
JIB SWING
V88
JIB SWING RIGHT ANGLE SENSOR
V40
JIB LIFT DOWN V41
JIB LEVEL UP CO49-J2
DETAIL B
SN82
JIB LEVEL
ANGLE SENSOR
CO49-J3
SN115
V42
JIB LEVEL DOWN MS109
V87 MS349
JIB SWING LEFT CO49-J1 MS112
DETAIL C
DETAIL A
SN136
JIB TRANSPORT
X PROXY SENSOR 2
SEE DETAIL B
SN137
X JIB TRANSPORT SEE DETAIL C
PROXY SENSOR 1
SEE DETAIL A
3121262
WIRE WIRE LENGTH FROM TO

COLOR
NO GAUGE (in) REFERENCE PIN REFERENCE PIN
000-39-2_1 BLACK 18 24.2 SN136 3 MS112 12
000-39-3_1 BLACK 12 15.6 X57 16 MS112 10
000-39-4_1 BLACK 12 12.5 MS112 1 X58 16
000-39-5_1 BLACK 14 21.8 MS112 11 CO49-J1 4
000-40_1 BLACK 18 36.8 SN137 3 CO49-J4 8
000-41_1 BLACK 18 96.2 SN114 3 CO49-J4 2
000-43-1_1 BLACK 18 25.6 CO49-J2 3 MS349 1
000-43-2_1 BLACK 18 86.6 V41 2 MS349 11
000-43-3_1 BLACK 18 86.9 V42 2 MS349 2
000-44-1_1 BLACK 18 22.7 CO49-J5 12 MS350 1
000-44-2_1 BLACK 18 69.2 V39 2 MS350 1
000-44-3_1 BLACK 18 69.3 V40 2 MS350 1
000-44-4_1 BLACK 18 67.8 V43 2 MS350 1
000-44-5_1 BLACK 18 68.3 V44 2 MS350 1
000-44-6_1 BLACK 18 84.9 V88 2 MS350 1
000-44-7_1 BLACK 18 85.4 V87 2 MS350 1
000-45-2_1 BLACK 12 16.0 X57 18 MS112 3
000-45-3_1 BLACK 12 12.7 MS112 2 X58 18
2-15-1_1 YELLOW/RED 14 21.6 MS112 8 CO49-J1 5
2-15-2_1 YELLOW/RED 12 12.6 MS112 4 X58 12
2-16-2_1 YELLOW/RED 18 24.4 SN136 1 MS112 9
2-16-3_1 YELLOW/RED 18 36.6 SN137 1 CO49-J4 7
2-16_1 YELLOW/RED 18 96.8 SN114 1 CO49-J4 1
2-2-2_1 YELLOW/RED 18 7.7 X57 5 X58 5
2-21-1_1 YELLOW/RED 18 6.8 X58 6 X57 6
2-3-1_1 YELLOW/RED 18 6.1 X58 4 X57 4
2-30-1_1 YELLOW/RED 18 7.7 X58 11 X57 11
2-8-10_2 YELLOW/RED 12 16.1 X57 10 MS112 6
2-8-11_2 YELLOW/RED 12 15.8 X57 12 MS112 7
2-8-12_1 YELLOW/RED 12 12.6 MS112 5 X58 10
25-3-4_1 PINK 18 7.2 X58 7 X57 7
26-3-4_1 PINK 18 6.3 X58 9 X57 9
27-3-1_1 BLUE 18 22.8 MS349 4 CO49-J5 1
27-3-2_1 BLUE 18 25.1 CO49-J2 2 MS349 3
27-3-3_1 BLUE 18 68.5 V39 1 MS349 9
27-3-4_1 BLUE 18 28.5 X57 13 CO49-J1 2
28-3-1_1 BLUE 18 21.5 MS349 6 CO49-J5 2
28-3-2_1 BLUE 18 25.1 CO49-J2 1 MS349 5
28-3-3_1 BLUE 18 69.5 V40 1 MS349 7
28-3-4_1 BLUE 18 28.1 X57 15 CO49-J1 1
29-3_1 BROWN 18 69.2 CO49-J5 5 V43 1
30-3_1 BROWN 18 71.5 CO49-J5 6 V44 1
49-12-2_1 ORANGE/RED 18 26.4 X58 13 SN136 4
49-13-2_1 ORANGE/RED 18 26.0 X58 15 SN136 2
49-14_1 ORANGE/RED 18 37.2 CO49-J2 7 SN137 2
49-1_1 ORANGE/RED 18 97.3 SN114 2 CO49-J2 5
49-21_1 ORANGE/RED 18 38.0 CO49-J2 6 SN137 4
49-2_1 ORANGE/RED 18 97.0 CO49-J2 4 SN114 4
55-3_2 BLUE 18 92.8 CO49-J2 11 V41 1
55-4_1 BLUE 18 91.7 CO49-J2 12 V42 1
59-3_1 WHITE 18 87.9 CO49-J5 4 V87 1
60-3_1 WHITE 18 87.1 CO49-J5 3 V88 1
CAN1-HIGH_4 YELLOW 18 23.3 CO49-J4 3 MS109 12
CAN1-HIGH_5 YELLOW 18 13.3 MS109 1 X58 3
CAN1-HIGH_6 YELLOW 18 28.1 X57 3 CO49-J1 6
CAN1-LOW_4 GREEN 18 23.6 CO49-J4 4 MS109 10
CAN1-LOW_5 GREEN 18 14.3 MS109 3 X58 2
CAN1-LOW_6 GREEN 18 29.6 X57 2 CO49-J1 7
CAN1-SHIELD_3 BLACK 18 14.2 MS109 5 X58 1
CAN1-SHIELD_4 BLACK 18 22.9 CO49-J4 5 MS109 8
CAN1-SHIELD_5 BLACK 18 30.4 X57 1 CO49-J1 8
CBL-10_1 RED 18 88.0 CO49-J3 4 SN82 B
CBL-10_2 WHITE 18 89.2 CO49-J3 5 SN82 D
CBL-10_3 BLACK 18 87.9 CO49-J3 6 SN82 A
CBL-10_4 ORANGE 18 87.6 CO49-J3 1 SN82 F
CBL-10_5 BLUE 18 90.2 CO49-J3 2 SN82 C
CBL-10_6 GREEN 18 89.5 CO49-J3 3 SN82 E
CBL-11_1 RED 18 105.8 CO49-J3 10 SN84 B
CBL-11_2 WHITE 18 107.8 CO49-J3 11 SN84 D
CBL-11_3 BLACK 18 107.0 CO49-J3 12 SN84 A
CBL-11_4 ORANGE 18 105.9 CO49-J3 7 SN84 F
CBL-11_5 BLUE 18 107.8 CO49-J3 8 SN84 C
CBL-11_6 GREEN 18 107.6 CO49-J3 9 SN84 E
SN115-CANH_1 BLUE 20 11.7 MS109 2 SN115 3
SN115-CANL_1 BLACK 20 11.1 MS109 4 SN115 4
SN115-CANS_1 GRAY 20 10.7 MS109 6 SN115 5
SN115-GND_1 WHITE 20 24.9 CO49-J1 12 SN115 2
SN115-PWR_1 BROWN 20 21.9 CO49-J1 11 SN115 1
3121262 7-39
7-40
C011-J3 C011-J1
X35
MS97-1
X19
X56
X291
X289
X36
C011-J2
C011-J5
1001119394 B
Figure 7-38. Boom Length and Angle Harness - Sheet 1 of 2
3121262
WIRE WIRE LENGTH FROM TO

COLOR
NO GAUGE (in) REFERENCE PIN REFERENCE PIN
000-05-2 BLK 14 11 X289 2 CO11-J1 4
000-10 BLK 18 16 CO11-J5 12 X56 6
000-27-1 BLK 18 9.5 CO11-J3 9 S94 2
000-27-2 BLK 18 9.5 X19 2 S94 1
000-27-3 BLK 18 9.5 S94 1 X19 4
000-28 BLK 18 5 CO11-J1 12 CO11-J1 2
000-29 BLK 18 19 CO11-J3 6 X291 3
000-30 BLK 18 19 CO11-J3 12 X291 6
000-55-1 BLK 18 12 CO11-J2 3 S83 1
000-55-2 BLK 18 12 X35 3 S83 2
000-55-3 BLK 18 12 X35 4 S83 2
000-56-1 BLK 18 12 CO11-J2 2 S85 1
000-56-2 BLK 18 12 X36 3 S85 2
000-56-3 BLK 18 12 X36 4 S85 2
2-1-4 YEL/RED 14 11 X289 1 CO11-J1 5
2-80 YEL/RED 18 19 CO11-J3 7 X19 1
2-81 YEL/RED 18 19 X35 1 CO11-J5 9
2-82 YEL/RED 18 24 X36 1 CO11-J2 1
2-9 YEL/RED 18 5 CO11-J1 11 CO11-J1 1
49-110 ORN/RED 18 19 CO11-J3 8 X19 3
49-111 ORN/RED 18 24 X35 2 CO11-J2 8
49-112 ORN/RED 18 24 X36 2 CO11-J2 9
49-18 ORN/RED 18 5 CO11-J3 1 CO11-J3 2
49-19 ORN/RED 18 19 CO11-J3 11 X291 2
49-9 ORN/RED 18 19 CO11-J3 5 X291 5
50-6 RED/WHT 18 19 CO11-J3 4 X291 1
50-7 RED/WHT 18 19 CO11-J3 10 X291 4
60-1-1 ORN 18 16 X289 4 CO11-J5 3
7-2-1 ORN 18 11 CO11-J2 12 X56 3
7-3-1 ORN 18 11 CO11-J2 11 X56 4
8-2-1 ORN 18 11 CO11-J5 2 X56 1
8-3-1 ORN 18 11 CO11-J5 1 X56 2
TP CBL-15 SHIELD 18 11 CO11-J1 8 MS97-1 C
TP CBL-15 BLK 18 11 CO11-J1 7 MS97-1 B
TP CBL-15 RED 18 11 CO11-J1 6 MS97-1 A
Figure 7-39. Boom Length and Angle Harness - Sheet 2 of 2
3121262 7-41
7-42 3121262
1001119652-J
MAF10480J
Figure 7-40. Main Terminal Box Harness - Sheet 1 of 4
3121262 7-43
7-44
X361 X46
CO239-J8
MS134 CO239-J7
LB232 LB231 CO239-J12
MS95
X272
LB233
LB230 SW223 X146
SW225 MS287
LB234 SW221
LB229 X245
SW228-2 RL80 S363

MS96 S218 S364
S365 IP212 IP102

IP213
S362 IP140
SW228-1
LB235
CO239-J2 CO75-J1
LB236 SW222
SW226 SW219 CO75-J2
LB237 SW220 SW139-3
LB238 SW139-1 SW139-B
SW227
CO239-J4
SW206-1A CO239-J1
PIN1 PIN2
SW206-1B SW206-2A
GD275
SW206-2B
DIODE INSTALL DETAIL

IP212 & IP213
MAF10500J
1001119652-J
Figure 7-41. Main Terminal Box Harness - Sheet 2 of 4
3121262
WIRE NO WIRE COLOR WIRE GAUGE FROM TO WIRE NO WIRE COLOR WIRE GAUGE FROM TO
000-03A BLK 14 363 (1) 361 (2) 2-31 YEL/ RED 18 CO239- J7 (30) CO239- J7 (23)
000-03B BLK 18 MS96 (11) 363 (1) 2-3 YEL/ RED 18 S218 (2) IP212 (2)
000-03 BLK 18 RL80 (2) 363 (2) 2-40-01 YEL/ RED 18 CO239- J4 (25) SW219 (2)
000-08 BLK 18 MS96 (6) CO75- J1 (11) 2-40-02 YEL/ RED 18 SW219 (2) SW220 (2)
000-24-1 BLK 16 CO239- J2 (29) 146 (10) 2-40-03 YEL/ RED 18 SW220 (2) SW221 (2)
000-25 BLK 16 CO239- J2 (18) 146 (8) 2-40-04 YEL/ RED 18 SW223 (2) SW222 (2)
000-26 BLK 18 CO239- J2 (19) 146 (3) 2-40-05 YEL/ RED 18 SW228-1 (1) SW223 (2)
000-2 BLK 12 MS96 (1) CO239- J8 (1) 2-40-06 YEL/ RED 18 SW225 (2) SW222 (2)
000-31-01 BLK 18 CO239- J4 (31) LB238 (2) 2-40-07 YEL/ RED 18 GD275 (1) SW227 (2)
000-31-02 BLK 18 LB237 (2) LB238 (2) 2-40-08 YEL/ RED 18 SW225 (2) SW226 (2)
000-31-03 BLK 18 LB236 (2) LB237 (2) 2-40-09 YEL/ RED 18 SW226 (2) SW227 (2)
000-31-04 BLK 18 LB235 (2) LB236 (2) 2-40-10 YEL/ RED 18 SW221 (2) SW228-1 (1)
000-31-05 BLK 18 LB234 (2) LB235 (2) 2-5 YEL/ RED 18 CO239- J1 (28) 245 (1)
000-31-08 BLK 18 LB231 (2) LB232 (2) 2-6 YEL/ RED 18 CO239- J7 (34) IP102 (2)
000-31-09 BLK 18 LB230 (2) LB231 (1) 2-8-10 YEL/ RED 12 MS95 (2) 46 (10)
000-31-10 BLK 18 LB229 (2) LB230 (2) 2-8-11 YEL/ RED 12 MS95 (3) 46 (12)
000-31-11 BLK 18 GD275 (2) LB229 (2) 2-8-1A YEL/ RED 18 364 (1) 361 (3)
000-37 BLK 18 CO239- J1 (31) 245 (4) 2-8-1B YEL/ RED 12 364 (1) MS95 (12)
000-39-1 BLK 12 MS96 (2) 46 (16) 2-8-1 YEL/ RED 12 RL80 (4) 364 (2)
000-45-1 BLK 12 MS96 (3) 46 (18) 2-8-2 YEL/ RED 12 CO239- J8 (2) MS95 (1)
000-9 BLK 18 272 (A) MS96 (12) 2-8-5 YEL/ RED 18 MS95 (9) CO239- J4 (24)
1-1-2 RED 10 SW206- 1B (1B) SW206-1A (1A) 2-8-7 YEL/ RED 18 MS95 (10) CO75- J1 (12)
1-3A RED 18 365 (1) 361 (1) 2-8 YEL/ RED 18 SW139-3 (1) IP213 (2)
1-3B RED 18 272 (B) 365 (1) 3-2 TAN 18 SW220 (1) CO239- J4 (23)
1-3 RED 18 SW206- 1A (1A) IP140 (2) 3-3 TAN 18 SW220 (3) CO239- J4 (33)
2-1-1 YEL/ RED 12 SW206- 2A (2A) RL80 (1) 13-2 BRN 18 SW221 (1) CO239- J4 (7)
2-1-2 YEL/ RED 18 SW206- 2B (2B) SW139- B (1) 14-2 BRN 18 SW221 (1) CO239- J4 (30)
2-2-1 YEL/ RED 18 CO239- J7 (2) S218 (1) 21-2 WHT 18 SW219 (1) CO239- J4 (34)
2-20 YEL/ RED 18 46 (6) CO239- J7 (15) 22-2 WHT 18 SW219 (3) CO239- J4 (35)
2-2A YEL/ RED 18 362 (1) 361 (4) 23-2 GRY 18 SW225 (1) CO239- J4 (18)
2-2B YEL/ RED 18 362 (1) 46 (5) 24-2 GRY 18 SW225 (3) CO239- J4 (6)
2-2 YEL/ RED 18 362 (2) SW139- 1 (1) 25-2 PNK 18 SW226 (1) CO239- J4 (17)
2-3-2 YEL/ RED 18 CO239- J7 (1) S218 (1) 25-3 PNK 18 CO239- J2 (5) 46 (9)
2-3-4 YEL/ RED 18 46 (4) S218 (2) 26-2 PNK 18 SW226 (3) CO239- J4 (5)
2-30-1 YEL/ RED 18 SW139-3 (1) CO239- J7 (3) 26-3 PNK 18 CO239- J2 (7) 46 (7)
2-30 YEL/ RED 18 46 (11) CO239- J7 (14) 27-2 BLU 18 SW222 (3) CO239- J4 (19)
27-3-4 PNK 18 CO239- J1 (3) 46 (13)
28-2 PNK 18 SW222 (1) CO239- J4 (8)
28-3-4 PNK 18 CO239- J2 (31) 46 (15)
29-2 BRN 18 SW223 (1) CO239- J4 (11)
30-2 BRN 18 SW223 (3) CO239- J4 (22)
39-1 WHT/ YEL 18 LB230 (1) CO239- J4 (1)
47-5 BRN/ WHT 18 LB233 (1) CO239- J4 (29)
47-6 BRN/ WHT 18 LB232 (1) CO239- J4 (28)
47-8 BRN/ WHT 18 LB234 (1) CO239- J4 (26)
48-1 WHT/ YEL 18 LB227 (1) CO239- J4 (4)
48-6 WHT/ YEL 18 LB231 (1) CO239- J4 (15)
49-100 ORN/ RED 18 LB237 (1) CO239- J4 (14)
49-101 ORN/ RED 18 LB236 (1) CO239- J4 (3)
3121262 7-45
WIRE NO WIRE COLOR WIRE GAUGE FROM TO

49-102 ORN/ RED 18 SW228-2 (1) CO239- J7 (21)
49-103 ORN/ RED 18 LB235 (1) CO239- J4 (13)
49-16 ORN/ RED 18 CO239- J12 (6) CO239- J12 (7)
49-17 ORN/ RED 18 CO239- J7 (6) CO239- J7 (17)
49-5 ORN/ RED 18 CO239- J1 (29) 245 (2)
49-64 ORN/ RED 18 CO239- J7 (11) 146 (2)
49-65 ORN/ RED 18 CO239- J7 (35) 146 (6)
49-6 ORN/ RED 18 CO239- J1 (30) 245 (3)
49-88 ORN/ RED 18 CO239- J7 (12) 146 (4)
50-2-1 RED/ WHT 18 CO239- J2 (3) 146 (9)
50-3 RED/ WHT 16 CO239- J2 (1) 146 (7)
53-2 BRN/ ORN 18 SW227 (3) CO239- J4 (16)
54-4 RED/ YEL 18 LB229 (1) CO239- J4 (2)
54-5 RED/ YEL 18 LBS238 (1) CO239- J4 (27)
CANI- H_GTWY YEL 18 CO75- J1 (10) MS287 (12)
CANI- H_MDI YEL 18 MS287 (1) GD275 (4)
CANI- HIGH YEL 18 MS287 (2) CO239- J7 (13)
CANI- L_GTWY GRN 18 CO75- J1 (9) MS287 (3)
CANI- L_MDI GRN 18 MS287 (4) GD275 (3)
CANI- LOW GRN 18 MS287 (10) CO239- J7 (24)
CANI- SHIELD BLK 18 MS287 (5) CO239- J7 (18)
CANI (A)- HIGH YEL 18 46 (3) CO75- J2 (10)
CANI (A)- LOW GRN 18 46 (2) CO75- J2 (9)
CAN2-HIGH YEL 18 CO239- J12 (3) MS134 (12)
CAN2-HIGH YEL 18 MS134 (1) 272 (C)
CAN2-LOW GRN 18 MS134 (3) 272 (D)
CAN2-LOW GRN 18 CO239- J12 (4) MS134 (10)
CAN2- SHIELD BLK 18 CO75- J2 (3) 46 (1)
CAN2- SHIELD BLK 18 MS134 (5) 272 (E)
CAN2- SHIELD BLK 18 CO239- J12 (5) MS134 (8)
SEE DETAIL - IP213 (1) RL80 (5)
SEE DETAIL - IP212 (1) RL80 (5)
SEE NOTE NA 365 (2) IP140 (1)
SEE NOTE NA 272 (H) IP102 (1)
7-46 3121262
Figure 7-42. Turntable Harness - Sheet 1 of 3
1001119653-H
MAF10540H
3121262 7-47
7-48
V246
AH260 MAIN DUMP
V253 V254
MN LFT DN SWG-LFT V255
SWG-RT
V256 V250
LFT FLOW LIFT PILOT
V252
X26 MN LFT UP
V249
TELE OUT V247
TELE FLOW
V248
X274 TELE IN
V251
X266 LFT DN AUX
RL267-30 S263
RL267-85 S262
CONNECTION ORIENTATION
DETAIL
RL267-86 V247
V250
MS214- V256
MS97-2
X288 MS97-3 AH259 V249
CO239-J1 V252
MS134 V255
RL52 V246
MS287 X147 V248
V251
AH259-G V253
V254
MS96
S86
X93
MS95
CO239-J3
CO239-J2 SN258
LB264
MAF10550H
1001119653-H
Figure 7-43. Turntable Harness - Sheet 2 of 3
3121262
WIRE NO WIRE COLOR WIRE GAUGE FROM TO WIRE NO WIRE COLOR WIRE GAUGE FROM TO
000-01 BLACK 12 MS96 (1) MS214- (1) 14-3 BROWN 18 V249 (1) CO239- J2 (16)
000-04 BLACK 12 MS96 (1) X26 (5) 21-3 WHITE 18 V254 (1) CO239- J2 (34)
000-05-1 BLACK 12 MS96 (1) X288 (2) 22-3 WHITE 18 V255 (1) CO239- J2 (35)
000-06 BLACK 18 MS96 (1) LB264 (2) 47-12 BROWN/ WHITE 18 SN258 (1) CO239- J2 (25)
000-07 BLACK 18 RL267- 85 (1) MS214- (1) 47-8-1 BROWN/ WHITE 18 SN86 (1) CO239- J1 (32)
000-22 BLACK 18 CO239- J1 (9) X266 (6) 47-8-2 BROWN/ WHITE 18 X274 (5) S86 (2)
000-3 BLACK 18 MS214- (1) RL52 (2) 47-9 BROWN/ WHITE 18 CO239- J3 (9) S86 (1)
000-33 BLACK 18 SN258 (2) CO239- J2 (6) 48-3 WHITE/ YELLOW 18 CO239- J1 (11) X274 (2)
000-34 BLACK 18 AH259- G (1) CO239- J2 (17) 48-7 WHITE/ YELLOW 16 X266 (8) X93 (1)
000-35-1 BLACK 18 CO239- J2 (30) S263 (2) 48-8 WHITE/ YELLOW 18 CO239- J1 (7) X266 (7)
000-35-2 BLACK 16 AH260 (2) S263 (1) 48-9 WHITE/ YELLOW 18 CO239- J1 (12) X266 (4)
000-35-3 BLACK 18 V246 (2) S263 (1) 50-1 RED/ WHITE 18 V246 (1) CO239- J2 (13)
000-35-4 BLACK 18 V255 (2) S263 (1) 52-10 BLUE/ ORANGE 18 AH260 (1) CO239- J2 (27)
000-35-5 BLACK 18 V255 (2) V254 (2) 52-12 BLUE/ ORANGE 18 CO239- J2 (26) X147 (1)
000-35-6 BLACK 18 V252 (2) S263 (1) 52-2 BLUE/ ORANGE 18 AH259 (1) CO239- J2 (2)
000-35-7 BLACK 18 V252 (2) V253 (2) 52-5 BLUE/ ORANGE 18 CO239- J1 (22) X266 (3)
000-35-8 BLACK 18 V253 (2) V256 (2) 52-3 BROWN/ ORANGE 18 RL267- 86 (1) CO239- J1 (13)
000-36-1 BLACK 18 CO239- J2 (14) S262 (2) 55-10 BROWN 18 V247 (1) CO239- J2 (9)
000-36-2 BLACK 18 V249 (2) S262 (1) 55-20 TAN 18 V256 (1) CO239- J2 (19)
000-36-3 BLACK 18 V248 (2) V249 (2) 55-21 TAN 18 V250 (1) CO239- J2 (10)
000-36-4 BLACK 18 V247 (2) S262 (1) 55-22 TAN 18 V251 (1) CO239- J2 (12)
000-36-5 BLACK 18 V251 (2) V247 (2) 55-45 ORANGE 18 CO239- J1 (23) X26 (7)
000-36-6 BLACK 18 V250 (2) V251 (2) 55-47 ORANGE 18 CO239- J1 (20) X26 (6)
000-38 BLACK 16 MS96 (1) X93 (2) 60-1-2 ORANGE 18 X288 (4) X26 (8)
000-42 BLACK 16 CO239- J1 (8) X266 (2) SEE NOTE 1-1 SW206- 1B (1B) IP284 (2)
1-1 RED 10 S240 (2) IP284 (1) TP CBL- 13 RED 18 MS97- 2 (A) MS287 (11)
1- FSLINK - 14 S240 (1) RL267- 30 (1) TP CBL- 13 BLACK 18 MS97- 2 (C) MS287 (7)
2-1-88 YEL/ RED 16 CO239- J1 (10) X266 (1) TP CBL- 13 RED 18 MS97- 2 (B) MS287 (9)
2-12 YEL/ RED 12 RL52 (1) S301 (1) TP CBL- 14 BLACK 18 X26 (3) MS97- 3 (C)
2-13 YEL/ RED 14 RL52 (4) X26 (4) TP CBL- 14 BLACK 18 MS97- 3 (A) X26 (1)
2-8-3 YEL/ RED 12 MS95 (1) X288 (1) TP CBL- 14 YEL/ RED 18 MS97- 3 (B) X26 (2)
2-8-4 YEL/ RED 18 RL52 (5) MS95 (1) TP CBL 12 YEL/ RED 18 MS134 (2) X274 (3)
2-8-6 YEL/ RED 16 MS95 (1) X274 (1) TP CBL 12 YEL/ RED 18 MS134 (6) X274 (6)
2-8-8 YEL/ RED 16 MS95 (1) X266 (5) TP CBL 12 YEL/ RED 18 MS134 (4) X274 (4)
2-8-9 YEL/ RED 18 MS95 (1) LB264 (1)
2- FSLINK - 14 RL267- 30 (1) S301 (2)
3-3 TAN 18 V252 (1) CO239- J2 (11)
4-3 TAN 18 V253 (1) CO239- J2 (22)
13-3 BROWN 18 V248 (1) CO239- J2 (4)
3121262 7-49
V277 V278
X62
S103
V279
V280
WIRE LENGTH FROM TO

WIRE NO COLOR
GAUGE (IN.) REFERENCE PIN REFERENCE PIN
000-22-1 BLACK 18 190 X62 6 S103 1
000-22-2 BLACK 18 20 V279 2 S103 2
000-22-3 BLACK 18 20 V280 2 S103 2
000-22-4 BLACK 18 20 V278 2 S103 2
000-22-5 BLACK 18 20 V277 2 S103 2
7-2-2 ORANGE 18 210 V278 1 X62 3
7-3-2 ORANGE 18 210 V277 1 X62 4
8-2-2 ORANGE 18 210 V280 1 X62 1
8-3-2 ORANGE 18 210 V279 1 X62 2
1001120276 A
Figure 7-44. Pump Harness
7-50 3121262
Figure 7-45. Chassis Harness - Sheet 1 of 2
1001119395-C
MAF10560C
3121262 7-51
ORIENT ALL CONNECTORS AS SHOWN WITH THIS
7-52
DETAIL, FLAT BLADE TOWARDS WIRE ENTRANCE.
UNLESS OTHERWISE NOTED.
V124 V159
V163 V165
V164
V123 V153
V162
V161 V160
V166 V167
DETAIL B
DETAIL A
S171
S119
S122 C021-J5
SN179 S199
S120
S121 C021-J3
X110 SN183 X113
SN181
C021-J1
X107 SN185
X111
C021-J4
DETAIL C
C021-J2
S192
S190
S191
S187
S188 S173
S189 S172
S170
X22
S175
SEE DETAIL C
V195 S169
S174 V194
SN193
S168 V196
SEE DETAIL B
SN178
SEE DETAIL A
1001119395-C
MAF10570C
Figure 7-46. Chassis Harness - Sheet 2 of 2
3121262
39-2-43-1 YEL/ WHT S172 (1) (4) CO21- J2 (11)

WIRE NO WIRE COLOR WIRE GAUGE FROM TO 40-2 YEL/ WHT V166 (1) S173 (2)
000-14 BLACK 18 V194 (2) CO21- J4 (2) 40-2-44-1 YEL/ WHT S173 (1) CO21- J2 (12)
000-15 BLACK 14 X22 (5) CO21- J1 (4) 43-1 YEL/ WHT V160 (1) S172 (2)
000-16 BLACK 18 V196 (2) CO21- J1 (12) 44-1 YEL/ WHT V161 (1) S173 (2)
000-17 BLACK 18 V195 (2) CO21- J4 (8) 10-1 YELLOW V162 (1) CO21- J5 (2)
000-19 BLACK 18 S121 (1) CO21- J3 (9) 10-2 YELLOW V163 (1) CO21- J5 (2)
000-20 BLACK 18 S120 (1) CO21- J3 (6) 11-1 YELLOW V153 (1) CO21- J5 (2)
000-12-01 BLACK 18 S170 (2) CO21- J5 (12) 11-2 YELLOW V159 (1) CO21- J5 (2)
000-12-02 BLACK 18 S168 (2) S170 (1) 12-1 YELLOW V123 (1) CO21- J5 (2)
000-12-03 BLACK 18 V164 (2) S168 (1) 12-2 YELLOW V124 (1) CO21- J5 (2)
000-12-04 BLACK 18 S170 (1) S169 (2) 9-1 YELLOW V164 (1) CO21- J5 (2)
000-12-05 BLACK 18 V165 (2) S168 (1) 9-2 YELLOW V165 (1) CO21- J5 (2)
000-12-06 BLACK 18 V163 (2) S168 (1)
000-12-07 BLACK 18 V162 (2) S168 (1)
000-12-08 BLACK 18 V153 (2) S169 (1)
000-12-09 BLACK 18 V159 (2) S169 (1)
000-12-10 BLACK 18 V123 (2) S169 (1)
000-12-11 BLACK 18 V124 (2) S169 (1)
000-13-01 BLACK 18 CO21- J2 (3) S175 (2)
000-13-02 BLACK 18 S175 (1) V160 (2)
000-13-03 BLACK 18 S175 (2) S174 (2)
000-13-04 BLACK 18 V166 (2) S174 (1)
000-13-05 BLACK 18 V167 (2) S174 (1)
000-13-06 BLACK 18 S175 (1) V161 (2)
000-17-01 BLACK 18 S119 (1) CO21- J3 (3)
000-17-02 BLACK 18 S119 (2) SN193 (B)
000-18-01 BLACK 18 S122 (1) CO21- J3 (12)
000-18-02 BLACK 18 SN193 (1) S122 (2)
CABLE-01_BLACK BLACK X22 (2) CO21- J1 (7)
CABLE-02_BLACK BLACK SN179 (22) S188 (1)
CABLE-07_BLACK BLK X107 (3) S119 (2)
55-45 ORANGE 18 X22 (7) V195 (1)
55-47 ORANGE 18 X22 (6) V194 (1)
60-2 ORANGE 18 X22 (8) V196 (1)
49-7 ORN/ RED 18 SN193 (C) CO21- J2 (8)
49-8 ORN/ RED 18 CO21- J2 (9) SN193 (D)
49-10 ORN/ RED 18 CO21- J1 (9) CO21- J1 (10)
49-104 ORN/ RED 18 CO21- J2 (4) S189 (2)
49-105 ORN/ RED 18 CO21- J2 (5) S192 (2)
49-106 ORN/ RED 18 X22 (12) CO21- J2 (6)
49-107 ORN/ RED 18 SN178 (3) CO21- J2 (7)
CABLE-01_RED RED X22 (1) CO21- J1 (6)
CABLE-07_RED RED X107 (1) S171 (2)
CABLE-10_RED RED X113 (1) S199 (2)
50-4-1 RED/ WHT 18 S171 (1) CO21- J3 (1)
50-4-2 RED/ WHT 18 SN193 (A) S171 (2)
50-5-1 RED/ WHT 18 S199 (1) CO21- J3 (10)
50-5-2 RED/ WHT 18 S199 (2) SN193 (F)
CABLE-01_SHIELD SHIELD X22 (3) CO21- J1 (8)
CABLE-07_SHIELD SHIELD X107 (4) S119 (2)
CABLE-02_WHITE WHITE SN179 (21) S187 (1)
CABLE-07_WHITE WHITE X107 (2) CO21- J3 (2)
2-4 YEL/ RED 18 CO21- J1 (11) X22 (11)
2-1-1 YEL/ RED 18 X22 (4) CO21- J1 (5)
2-1-2 YEL/ RED 18 CO21- J4 (1) S190 (2)
2-1-3 YEL/ RED 18 CO21- J4 (7) S187 (2)
2-1-4 YEL/ RED 18 SN178 (1) CO21- J5 (9)
39-2 YEL/ WHT V167 (1) S172 (2)
3121262 7-53
MS97-1
X289
X56
C011-J1
C011-J2
Figure 7-47. BLAM Harness

C011-J5
C011-J3
X36
X291
X19
X35
1001119394-B
MAF10810B
7-54 3121262
FROM TO
WIRENO WIREGAUGE
COLOR REFERENCE PIN REFERENCE PIN
000-05-2 BLK 14 X289 2 CO11-J1 4
000-10 BLK 18 CO11-J5 12 X56 6
000-27-1 BLK 18 CO11-J3 9 S94 2
000-27-2 BLK 18 X19 2 S94 1
000-27-3 BLK 18 S94 1 X19 4
000-28 BLK 18 CO11-J1 12 CO11-J1 2
000-29 BLK 18 CO11-J3 6 X291 3
000-30 BLK 18 CO11-J3 12 X291 6
000-55-1 BLK 18 CO11-J2 3 S83 1
000-55-2 BLK 18 X35 3 S83 2
000-55-3 BLK 18 X35 4 S83 2
000-56-1 BLK 18 CO11-J2 2 S85 1
000-56-2 BLK 18 X36 3 S85 2
000-56-3 BLK 18 X36 4 S85 2
2-1-4 YEL/RED 14 X289 1 CO11-J1 5
2-80 YEL/RED 18 CO11-J3 7 X19 1
2-81 YEL/RED 18 X35 1 CO11-J5 9
2-82 YEL/RED 18 X36 1 CO11-J2 1
2-9 YEL/RED 18 CO11-J1 11 CO11-J1 1
49-110 ORN/RED 18 CO11-J3 8 X19 3
49-111 ORN/RED 18 X35 2 CO11-J2 8
49-112 ORN/RED 18 X36 2 CO11-J2 9
49-18 ORN/RED 18 CO11-J3 1 CO11-J3 2
49-19 ORN/RED 18 CO11-J3 11 X291 2
49-9 ORN/RED 18 CO11-J3 5 X291 5
50-6 RED/WHT 18 CO11-J3 4 X291 1
50-7 RED/WHT 18 CO11-J3 10 X291 4
60-1-1 ORN 18 X289 4 CO11-J5 3
7-2-1 ORN 18 CO11-J2 12 X56 3
7-3-1 ORN 18 CO11-J2 11 X56 4
8-2-1 ORN 18 CO11-J5 2 X56 1
8-3-1 ORN 18 CO11-J5 1 X56 2
TPCBL-15 SHIELD 18 CO11-J1 8 MS97-1 C
TPCBL-15 BLK 18 CO11-J1 7 MS97-1 B
TPCBL-15 RED 18 CO11-J1 6 MS97-1 A
3121262 7-55
7-56 3121262
X5
X2
X1
X7
S1
S2
S3
X4
X9
X3
1001142736-F
MAF10830F
Figure 7-48. Beacon Light Harness- Sheet 1 of 2
3121262 7-57
X3
X7
S1
X5
Figure 7-49. Beacon Harness- Sheet 2 of 2

S2
X1
X2
S3
X4
X9
1001142736-F
MAF10820F
7-58 3121262
X1
X5
CONN WIRE
WIRELABEL GAUGE JACKET TO CONN WIREC
POS COLOR WIRELABEL GAUGE JACKET TO
POS OLOR
1 WHT IGNITION 18AWG GXL S3(1)
J1939CA
2 BLK GROUND 18AWG GXL S1(2) 1 YEL CANHIGH 18AWG X2(9)
BLE
3 J1939CA
2 YEL CANHIGH 18AWG X4(C)
4 BLE
5 J1939CA
3 GRN CANLOW 18AWG X2(10)
6 BLE
7 RED BEACONPWR 18AWG GXL X3(1) J1939CA
4 GRN CANLOW 18AWG X4(D)
BLE
8
J1939CA
9 5 SHLD CANSHIELD 18AWG X2(11)
BLE
10 J1939CA
11 6 SHLD CANSHIELD 18AWG X4(E)
BLE
12 J1939CA
7 SHLD CANSHIELD 18AWG X7(C)
BLE
J1939CA
8 SHLD CANSHIELD 18AWG X9(E)
BLE
X2
J1939CA
CONN WIREC 9 GRN CANLOW 18AWG X7(B)
WIRELABEL GAUGE JACKET TO BLE
POS OLOR
J1939CA
1 10 GRN CANLOW 18AWG X9(D)
BLE
2 J1939CA
3 11 YEL CANHIGH 18AWG X7(A)
BLE
4 J1939CA
12 YEL CANHIGH 18AWG X9(C)
5 BLE
6
7
8 X3
J1939CA CONN WIREC
9 YEL CANHIGH 18AWG X5(1) WIRELABEL GAUGE JACKET TO
BLE POS OLOR
J1939CA 1 RED BEACONPWR 18AWG GXL X1(7)
10 GRN CANLOW 18AWG X5(3)
BLE 2 BLK GROUND 18AWG GXL S1(1)
J1939CA
11 SHLD CANSHIELD 18AWG X5(5)
BLE
12
X7
CONN WIREC
WIRELABEL GAUGE JACKET TO
POS OLOR
J1939CA
A YEL CANHIGH 18AWG X5(11)
BLE
J1939CA
B GRN CANLOW 18AWG X5(9)
BLE
J1939CA
C SHLD CANSHIELD 18AWG X5(7)
BLE
3121262 7-59
S3 X4
CONN WIREC CONN WIREC
WIRELABEL GAUGE JACKET TO WIRELABEL GAUGE JACKET TO
POS OLOR POS OLOR
1 WHT IGNITION 18AWG GXL X1(1) A BLK GROUND 18AWG GXL S2(2)
2 WHT IGNITION 18AWG GXL X9(H) B RED BATTERY 18AWG GXL X9(B)
2 WHT IGNITION 18AWG GXL X4(H) J1939CA
C YEL CANHIGH 18AWG X5(2)
BLE
J1939CA
D GRN CANLOW 18AWG X5(4)
BLE
S2
J1939CA
CONN WIREC E SHLD CANSHIELD 18AWG X5(6)
WIRELABEL GAUGE JACKET TO BLE
POS OLOR
F
1 BLK GROUND 18AWG GXL S1(2)
G
2 BLK GROUND 18AWG GXL X9(A)
H WHT IGNITION 18AWG GXL S3(2)
2 BLK GROUND 18AWG GXL X4(A)
J
S1
CONN WIREC
POS OLOR
1 BLK GROUND 18AWG GXL X3(2)
2 BLK GROUND 18AWG GXL X1(2)
2 BLK GROUND 18AWG GXL S2(1)
X9
CONN WIREC
POS OLOR
A BLK GROUND 18AWG GXL S2(2)
B RED BATTERY 18AWG GXL X4(B)
J1939CA
C YEL CANHIGH 18AWG X5(12)
BLE
J1939CA
D GRN CANLOW 18AWG X5(10)
BLE
J1939CA
E SHLD CANSHIELD 18AWG X5(8)
BLE
F
G
H WHT IGNITION 18AWG GXL S3(2)
J
7-60 3121262
3121262 7-61
7-62
SN18
SOCKET 1 RED RED PIN 1

SOCKET 2 BLUE BLUE PIN 2
TILT SENSOR CABLE #1 TILT SENSOR CABLE #1
SOCKET 3 BLACK BLACK PIN 3
SN 17
SOCKET 15 ORANGE ORANGE PIN 1

X138
SOCKET 16 YELLOW YELLOW PIN 2
TILT SENSOR CABLE #2 TILT SENSOR CABLE #2
SOCKET 17 BLACK BLACK PIN 3
V32 V30
V28
SOCKET 6
SOCKET 7
SOCKET 8
SOCKET 9
SOCKET 10
SOCKET 11
SOCKET 12
S78
V31 V29
V33
1001119390-D
MAF10840D
Figure 7-50. Platform Harness
3121262
FROM TO
WIRENO COLOR WIREGAUGE
REFERENCE PIN REFERENCE PIN
000-46-2 BLACK 18 X138 12 S78 1
000-46-3 BLACK 18 V28 2 S78 1
000-46-4 BLACK 18 V29 2 S78 1
000-46-5 BLACK 18 V30 2 S78 1
000-46-6 BLACK 18 V31 2 S78 2
000-46-7 BLACK 18 V32 2 S78 2
000-46-8 BLACK 18 V33 2 S78 2
23-3 GRAY 18 X138 8 V30 1
24-3 GRAY 18 X138 9 V31 1
25-3-5 PINK 18 X138 7 V28 1
26-3-5 PINK 18 X138 6 V29 1
55-5 WHITE 18 X138 10 V32 1
55-6 WHITE 18 X138 11 V33 1
SNCBL-1 BLACK 18 X138 3 SN18 3
SNCBL-1 BLUE 18 X138 2 SN18 2
SNCBL-1 RED 18 X138 1 SN18 1
SNCBL-2 ORANGE 18 SN17 1 X138 15
SNCBL-2 BLACK 18 SN17 3 X138 17
SNCBL-2 YELLOW 18 X138 16 SN17 2
3121262 7-63
7-64 3121262
3121262
T920
X902 RL930
X941
X901
RL930-1
RL930-2
RL931-86
X1011 RL931-87
MS932 RL931-87
-2
X950 X960
-1
RL931-87
RL931-85
ECM-J2
X965 EIC
X955 X999, X1000, X1001, X1002,
X1003, X1004, X1005, X1006,
ECM-J1 X1007, X1008, X1009, X1010
EC18
EC241-L
RL974
SN939
MAF10850G
1001138346-G
Figure 7-51. Engine Harness - Sheet 1 of 6
7-65

X965
X955
S953
S954
S968
ECM-J2
S969
S945
ECM-J1
S944
1001138346-G
MAF10860G
7-66 3121262
42
ECM-J1 43
CONN WIRE 44 BLK 148-44 0.75mm² FLRYW X1002(3)

WIRELABEL GAUGE JACKET TO 45
POS COLOR
1 RED 148-1 2.5mm² FLRYW S944(2) 46
2 BLK 148-2 2.5mm² FLRYW S945(2) 47
3 RED 148-3 2.5mm² FLRYW S944(2) 48
4 BLK 148-4 2.5mm² FLRYW S945(2) 49
5 RED 148-5 2.5mm² FLRYW S944(2) 50
6 BLK 148-6 2.5mm² FLRYW S945(2) 51
7 52
8 J1939CA
53 GRN CAN2LO 18AWG S968(1)
9 BLE
10 J1939CA
54 YEL CAN1HI 18AWG S953(1)
BLE
11
55
12
56 BLK 148-56 0.75mm² FLRYW X1002(4)
13 BLK 148-13 0.75mm² FLRYW X1008(7)
57 BLK 148-57 0.75mm² FLRYW X1002(5)
14
58
15 BLK 148-15-68 0.75mm² FLRYW ECM-J1(68)
59
16
60
17
61 BLK 148-61 0.75mm² FLRYW X1002(6)
18
62
19
63
20
64 BLK 148-64 0.75mm² FLRYW X1002(7)
21
65
22
66
23
67
24
68 BLK 148-15-68 0.75mm² FLRYW ECM-J1(15)
25
69
26 BLK 148-26 0.75mm² FLRYW X1008(8)
70
27
71
28
72 BLK 148-72 0.75mm² FLRYW X1002(8)
29 BLK 148-29 0.75mm² FLRYW X1002(1)
73
30
74
31
J1939CA
32 75 YEL CAN2HI 18AWG S969(1)
BLE
33 J1939CA
34 76 GRN CAN1LO 18AWG S954(1)
BLE
35 77
36 78
37 79
38 BLK 148-38 0.75mm² FLRYW X1002(2) 80
39 81
40 82 BLK 148-82 0.75mm² FLRYW X1002(9)
41 83
3121262 7-67
84 29 BLK 248-29 0.75mm² FLRYW X1001(6)

85 BLK 148-85 0.75mm² FLRYW X1002(10) 30
86 31
87 BLK 148-87 0.75mm² FLRYW X1002(11) 32 BLK 248-32 1.5mm² FLRYW X999(5)
89 34
90 35 BLK 248-35 0.75mm² FLRYW X1001(7)
91 36
92 37 BLK 248-37 0.75mm² FLRYW X1000(1)
93 38 SHLD 248-38 0.75mm² SHLD X1000(6)
94 39 BLK 248-39 0.75mm² FLRYW X1000(4)
J1939CA 40 BLK 248-40 0.75mm² FLRYW X1001(8)
NC SHLD CAN1SHLD 18AWG X1008(6)
BLE 41
42
43 BLK 248-43 0.75mm² FLRYW X1001(9)
ECM-J2
44 BLK 248-44 0.75mm² FLRYW X1001(10)
CONN WIREC
WIRELABEL GAUGE JACKET TO 45
POS OLOR
1 46 BLK 248-46 1.5mm² FLRYW X999(7)
2 BLK 248-2 1.5mm² FLRYW X999(6) 47
4 BLK 248-4 1.5mm² FLRYW X999(10) 49
5 BLK 248-5 1.5mm² FLRYW X999(9) 50
6 51
8 53 SHLD 248-53 0.75mm² SHLD X1000(3)
9 54 BLK 248-54 0.75mm² FLRYW X1000(5)
10 55
11 56
12 57
13 58
14 59
15 60
16 BLK 248-16 1.5mm² FLRYW X999(2)

17
S954
18 BLK 248-18 1.5mm² FLRYW X999(4)
CONN WIREC
19 BLK 248-19 1.5mm² FLRYW X999(11) WIRELABEL GAUGE JACKET TO
POS OLOR
20 BLK 248-20 1.5mm² FLRYW X999(12) J1939CA
1 GRN CAN1LO 18AWG ECM-J1(76)
21 BLE
22 J1939CA
2 GRN CAN1LO 18AWG X1008(5)
23 BLK 248-23 0.75mm² FLRYW X1000(8) BLE
24 BLK 248-24 0.75mm² FLRYW X1001(1) J1939CA
2 GRN CAN1LO 18AWG X955(B)
BLE
25 BLK 248-25 0.75mm² FLRYW X1001(2)
26 BLK 248-26 0.75mm² FLRYW X1001(3)
27 BLK 248-27 0.75mm² FLRYW X1001(4)
28 BLK 248-28 0.75mm² FLRYW X1001(5)
7-68 3121262
S969
X955
CONN WIRE
CONN WIRE WIRELABEL GAUGE JACKET TO
WIRELABEL GAUGE JACKET TO POS COLOR
POS COLOR
J1939CA
J1939CA 1 YEL CAN2HI 18AWG ECM-J1(75)
A YEL CAN1HI 18AWG S953(2) BLE
BLE
J1939CA
J1939CA 2 YEL CAN2HI 18AWG X1008(1)
B GRN CAN1LO 18AWG S954(2) BLE
BLE
J1939CA
C 2 YEL CAN2HI 18AWG X965(A)
BLE
X965 S945
CONN WIRE CONN WIRE
POS COLOR POS COLOR
J1939CA 1 BLK 000-148-246 8AWG GXL X1011(1)
A YEL CAN2HI 18AWG S969(2)
BLE 2 BLK 148-2 2.5mm² FLRYW ECM-J1(2)
J1939CA 2 BLK 148-4 2.5mm² FLRYW ECM-J1(4)
B GRN CAN2LO 18AWG S968(2)
BLE
2 BLK 148-6 2.5mm² FLRYW ECM-J1(6)
C
S953
S968 CONN WIRE
CONN WIRE WIRELABEL GAUGE JACKET TO
WIRELABEL GAUGE JACKET TO POS COLOR
POS COLOR J1939CA
J1939CA 1 YEL CAN1HI 18AWG ECM-J1(54)
1 GRN CAN2LO 18AWG ECM-J1(53) BLE
BLE J1939CA
J1939CA 2 YEL CAN1HI 18AWG X1008(4)
2 GRN CAN2LO 18AWG X1008(2) BLE
BLE J1939CA
J1939CA 2 YEL CAN1HI 18AWG X955(A)
2 GRN CAN2LO 18AWG X965(B) BLE
BLE
S944
CONN WIRE
POS COLOR
1 RED 1-148-135 8AWG GXL X1007(1)
2 RED 148-1 2.5mm² FLRYW ECM-J1(1)
3121262 7-69

X965
X955
S953
S954
S968
ECM-J2
S969
S945
ECM-J1
S944
1001138346-G
MAF10860G
7-70 3121262
X1003
X1008
CONN WIREC
CONN WIREC WIRELABEL GAUGE JACKET TO
WIRELABEL GAUGE JACKET TO POS OLOR
POS OLOR
1 BLK 248-33 1.5mm² FLRYW EIC(62)
J1939CA
1 YEL CAN2HI 18AWG S969(2) 2 BLK 248-16 1.5mm² FLRYW EIC(35)
BLE
J1939CA 3 BLK 248-48 1.5mm² FLRYW EIC(42)
BLE 4 BLK 248-18 1.5mm² FLRYW EIC(37)
3 5 BLK 248-32 1.5mm² FLRYW EIC(38)
BLE 7 BLK 248-46 1.5mm² FLRYW EIC(40)
BLE
9 BLK 248-5 1.5mm² FLRYW EIC(20)
J1939CA
6 SHLD CAN1SHLD 18AWG ECM-J1(NC) 10 BLK 248-4 1.5mm² FLRYW EIC(19)
BLE
7 BLK 148-13 0.75mm² FLRYW ECM-J1(13) 11 BLK 248-19 1.5mm² FLRYW EIC(47)
X1007 X1001

POS OLOR POS OLOR
1 RED 1-148-135 8AWG GXL S944(1) 1 BLK 248-24 0.75mm² FLRYW ECM-J2(24)
2 BLK 248-25 0.75mm² FLRYW ECM-J2(25)
3 BLK 248-26 0.75mm² FLRYW ECM-J2(26)
X1002 4 BLK 248-27 0.75mm² FLRYW ECM-J2(27)
CONN WIREC 5 BLK 248-28 0.75mm² FLRYW ECM-J2(28)
POS OLOR 6 BLK 248-29 0.75mm² FLRYW ECM-J2(29)
1 BLK 148-29 0.75mm² FLRYW ECM-J1(29) 7 BLK 248-35 0.75mm² FLRYW ECM-J2(35)
5 BLK 148-57 0.75mm² FLRYW ECM-J1(57) 11
6 BLK 148-61 0.75mm² FLRYW ECM-J1(61) 12
7 BLK 148-64 0.75mm² FLRYW ECM-J1(64)
8 BLK 148-72 0.75mm² FLRYW ECM-J1(72)
9 BLK 148-82 0.75mm² FLRYW ECM-J1(82) X1009
10 BLK 148-85 0.75mm² FLRYW ECM-J1(85) CONN WIREC
11 BLK 148-87 0.75mm² FLRYW ECM-J1(87) POS OLOR
12 BLK 148-88 0.75mm² FLRYW ECM-J1(88) 1 RED 1-148-135 8AWG GXL RL930-2(1)
3121262 7-71
X1005
X1006
CONN WIREC
POS OLOR
1 BLK 248-24 0.75mm² FLRYW EIC(22)
1 BLK 148-29 0.75mm² FLRYW SN939(1)
2 BLK 248-25 0.75mm² FLRYW EIC(31)
2 BLK 148-38 0.75mm² FLRYW EIC(52)
3 BLK 248-26 0.75mm² FLRYW EIC(25)
3 BLK 148-44 0.75mm² FLRYW EIC(50)
4 BLK 248-27 0.75mm² FLRYW EIC(29)
4 BLK 148-56 0.75mm² FLRYW EIC(34)
5 BLK 248-28 0.75mm² FLRYW EIC(24)
5 BLK 148-57 0.75mm² FLRYW X941(2)
6 BLK 248-29 0.75mm² FLRYW EIC(27)
6 BLK 148-61 0.75mm² FLRYW EIC(17)
7 BLK 248-35 0.75mm² FLRYW RL931-85(1)
7 BLK 148-64 0.75mm² FLRYW X941(1)
8 BLK 248-40 0.75mm² FLRYW EIC(28)
8 BLK 148-72 0.75mm² FLRYW EIC(49)
9 BLK 248-43 0.75mm² FLRYW EIC(23)
9 BLK 148-82 0.75mm² FLRYW EIC(51)
10 BLK 248-44 0.75mm² FLRYW EIC(26)
10 BLK 148-85 0.75mm² FLRYW EIC(46)
11
11 BLK 148-87 0.75mm² FLRYW SN939(2)
12
12 BLK 148-88 0.75mm² FLRYW S946(2)
X999
CONN WIREC
POS OLOR
1 BLK 248-33 1.5mm² FLRYW ECM-J2(33)
2 BLK 248-16 1.5mm² FLRYW ECM-J2(16)
3 BLK 248-48 1.5mm² FLRYW ECM-J2(48)
4 BLK 248-18 1.5mm² FLRYW ECM-J2(18)
5 BLK 248-32 1.5mm² FLRYW ECM-J2(32)
7 BLK 248-46 1.5mm² FLRYW ECM-J2(46)
11 BLK 248-19 1.5mm² FLRYW ECM-J2(19)
12 BLK 248-20 1.5mm² FLRYW ECM-J2(20)
7-72 3121262
3121262 7-73
7-74
X1011
X1002 X1006
X1007
X1009
X1008
X1010
X1000
X1004
X1001
X1005
X999 X1003
1001138346-G
MAF10870G
3121262
X1005
X1009
CONN WIREC
POS OLOR
1 BLK 248-24 0.75mm² FLRYW EIC(22)
1 RED 1-148-135 8AWG GXL RL930-2(1)
2 BLK 248-25 0.75mm² FLRYW EIC(31)
3 BLK 248-26 0.75mm² FLRYW EIC(25)
X1006 4 BLK 248-27 0.75mm² FLRYW EIC(29)

5 BLK 248-28 0.75mm² FLRYW EIC(24)
CONN WIREC
WIRELABEL GAUGE JACKET TO 6 BLK 248-29 0.75mm² FLRYW EIC(27)
POS OLOR
1 BLK 148-29 0.75mm² FLRYW SN939(1) 7 BLK 248-35 0.75mm² FLRYW RL931-85(1)
2 BLK 148-38 0.75mm² FLRYW EIC(52) 8 BLK 248-40 0.75mm² FLRYW EIC(28)
5 BLK 148-57 0.75mm² FLRYW X941(2) 11
6 BLK 148-61 0.75mm² FLRYW EIC(17) 12
7 BLK 148-64 0.75mm² FLRYW X941(1)
8 BLK 148-72 0.75mm² FLRYW EIC(49)
9 BLK 148-82 0.75mm² FLRYW EIC(51) X1011
10 BLK 148-85 0.75mm² FLRYW EIC(46) CONN WIREC
WIRELABEL
POS OLOR GAUGE JACKET TO
11 BLK 148-87 0.75mm² FLRYW SN939(2)
1 BLK 000-148-246 8AWG GXL S945(1)
12 BLK 148-88 0.75mm² FLRYW S946(2)
X999
CONN WIREC
POS OLOR
1 BLK 248-33 1.5mm² FLRYW ECM-J2(33)
2 BLK 248-16 1.5mm² FLRYW ECM-J2(16)
3 BLK 248-48 1.5mm² FLRYW ECM-J2(48)
4 BLK 248-18 1.5mm² FLRYW ECM-J2(18)
5 BLK 248-32 1.5mm² FLRYW ECM-J2(32)
7 BLK 248-46 1.5mm² FLRYW ECM-J2(46)
11 BLK 248-19 1.5mm² FLRYW ECM-J2(19)
12 BLK 248-20 1.5mm² FLRYW ECM-J2(20)
3121262 7-75
X1000 X1004
WIRELABEL WIRELABEL
POS OLOR GAUGE JACKET TO POS OLOR GAUGE JACKET TO
3 SHLD 248-53 0.75mm² SHLD ECM-J2(53) 3 SHLD 248-53 0.75mm² SHLD EIC(9)
6 SHLD 248-38 0.75mm² SHLD ECM-J2(38) 6 SHLD 248-38 0.75mm² SHLD EIC(1)
8 BLK 248-23 0.75mm² FLRYW ECM-J2(23) 8 BLK 248-23 0.75mm² FLRYW MS932(E)
9 9
10 10
11 11
12 12
X1010
CONN WIREC
WIRELABEL
J1939CA
BLE
J1939CA
BLE
3
J1939CA
BLE
J1939CA
BLE
J1939CA
6 SHLD CAN1SHLD 18AWG X901(6)
BLE
7 BLK 148-13 0.75mm² FLRYW SN939(3)
8 BLK 148-26 0.75mm² FLRYW RL930(2)
7-76 3121262
3121262 7-77
X902
X941
X901

X960
X950
MS932
S963
S964
S946
1001138346-G
MAF10880G
7-78 3121262
X901 X950
CONN WIREC WIRE
WIRELABEL CONN
POS OLOR GAUGE JACKET TO WIRELABEL
POS GAUGE JACKET TO
1 COLOR
2 WHT 48-3 18AWG GXL RL974(1) A YEL 2-48-2 18AWG GXL S946(1)
J1939CA B BLK 000-48-2 18AWG GXL T920(1)
BLE C
J1939CA D
BLE E
5 RED 47-8 16AWG GXL EC241-L(1) J1939CA
F GRN CAN1LO 18AWG S952(2)
J1939CA BLE
6 SHLD CAN1SHLD 18AWG X1010(6)
BLE J1939CA
G GRN CAN2LO 18AWG S963(2)
BLE
J1939CA
H YEL CAN2HI 18AWG S964(2)
X902 BLE
CONN WIRE J
WIRELABEL
POS COLOR GAUGE JACKET TO K
1 YEL 2-1-99 18AWG GXL MS932(G) L
2 J1939CA
M YEL CAN1HI 18AWG S951(2)
3 BLE
4
5
6 S964
7 CONN WIREC
WIRELABEL
8
J1939CA
1 YEL CAN2HI 18AWG X1010(1)
BLE
J1939CA
X941 2 YEL CAN2HI 18AWG X950(H)
BLE
CONN WIRE J1939CA
WIRELABEL 2 YEL CAN2HI 18AWG X960(A)
POS COLOR GAUGE JACKET TO BLE
1 BLK 148-64 0.75mm² FLRYW X1006(7)
2 BLK 148-57 0.75mm² FLRYW X1006(5)
3 WHT 48-96 14AWG GXL RL930-1(1)
4 BLK 000-48-1 14AWG GXL T920(1)
3121262 7-79
S946 MS932
CONN WIRE CONN WIRE
WIRELABEL WIRELABEL
POS COLOR GAUGE JACKET TO POS COLOR GAUGE JACKET TO
1 YEL 2-48-1 16AWG GXL MS932(H) A
1 YEL 2-48-2 18AWG GXL X950(A) B
2 YEL 2-48-3 18AWG GXL RL931-86(1) C
2 YEL 2-48-4 18AWG GXL RL930(1) D
2 BLK 148-88 0.75mm² FLRYW X1006(12) E BLK 248-23 0.75mm² FLRYW X1004(8)
F ORG 248-23-1 18AWG GXL RL931-87(1)
G YEL 2-1-99 18AWG GXL X902(1)
X960 H YEL 2-48-1 16AWG GXL S946(1)
CONN WIRE
WIRELABEL
POS COLOR GAUGE JACKET TO
J1939CA
A YEL CAN2HI 18AWG S964(2)
BLE
J1939CA
B GRN CAN2LO 18AWG S963(2)
BLE
C
S963
CONN WIRE
WIRELABEL
J1939CA
1 GRN CAN2LO 18AWG X1010(2)
BLE
J1939CA
2 GRN CAN2LO 18AWG X950(G)
BLE
J1939CA
2 GRN CAN2LO 18AWG X960(B)
BLE
7-80 3121262
3121262 7-81
T920
RL930

RL930-1
RL930-2
RL931-86
RL931-87
RL931-87-2
RL931-87-1
RL931-85
S952 S951
1001138346-G
MAF10890G
7-82 3121262
RL931-85 RL930
CONN WIRE CONN WIRE
WIRELABEL WIRELABEL
POS COLOR GAUGE JACKET TO POS COLOR GAUGE JACKET TO
1 BLK 248-35 0.75mm² FLRYW X1005(7) 1 YEL 2-48-4 18AWG GXL S946(2)
2 BLK 148-26 0.75mm² FLRYW X1010(8)
RL931-86
CONN WIREC RL930-1
WIRELABEL
POS OLOR GAUGE JACKET TO CONN WIRE
WIRELABEL
1 YEL 2-48-3 18AWG GXL S946(2) POS COLOR GAUGE JACKET TO
1 WHT 48-96 14AWG GXL X941(3)
RL931-87-1
CONN WIREC RL930-2
WIRELABEL
POS OLOR GAUGE JACKET TO CONN WIREC
WIRELABEL
1 RED 48-14 8AWG GXL EC18(2) POS OLOR GAUGE JACKET TO
1 RED 1-148-135 8AWG GXL X1009(1)
RL931-87
CONN WIREC T920
WIRELABEL
POS OLOR GAUGE JACKET TO CONN WIREC
WIRELABEL
1 RED 48-13 8AWG GXL EC18(1) POS OLOR GAUGE JACKET TO
1 BLK 000-48-1 14AWG GXL X941(4)
1 BLK 000-48-2 18AWG GXL X950(B)
RL931-87-2 1 BLK 000-48-4 18AWG GXL RL974(2)
CONN WIREC 1
WIRELABEL
1 ORG 248-23-1 18AWG GXL MS932(F)
S951
CONN WIRE
WIRELABEL
S952 POS COLOR GAUGE JACKET TO
CONN WIRE J1939CA
WIRELABEL 1 YEL CAN1HI 18AWG X1010(4)
POS COLOR GAUGE JACKET TO BLE
J1939CA J1939CA
1 GRN CAN1LO 18AWG X1010(5) 2 YEL CAN1HI 18AWG X901(3)
BLE BLE
J1939CA J1939CA
2 GRN CAN1LO 18AWG X901(4) 2 YEL CAN1HI 18AWG X950(M)
BLE BLE
J1939CA
2 GRN CAN1LO 18AWG X950(F)
BLE
3121262 7-83
EC241-L
RL974
EIC
EC18

SN939
1001138346-G
MAF10900G
7-84 3121262
42 BLK 248-48 1.5mm² FLRYW X1003(3)

EIC 43
CONN WIREC 44
POS OLOR 45
1 SHLD 248-38 0.75mm² SHLD X1004(6) 46 BLK 148-85 0.75mm² FLRYW X1006(10)
2 47 BLK 248-19 1.5mm² FLRYW X1003(11)
3 48 BLK 248-20 1.5mm² FLRYW X1003(12)
4 49 BLK 148-72 0.75mm² FLRYW X1006(8)
5 50 BLK 148-44 0.75mm² FLRYW X1006(3)
6 51 BLK 148-82 0.75mm² FLRYW X1006(9)
7 52 BLK 148-38 0.75mm² FLRYW X1006(2)
8 53
9 SHLD 248-53 0.75mm² SHLD X1004(3) 54
10 55
11 56
12 57
13 BLK 248-52 0.75mm² FLRYW X1004(2) 58
14 BLK 248-37 0.75mm² FLRYW X1004(1) 59
15 BLK 248-39 0.75mm² FLRYW X1004(4) 60
16 61 BLK 248-2 1.5mm² FLRYW X1003(6)
18
19 BLK 248-4 1.5mm² FLRYW X1003(10)
20 BLK 248-5 1.5mm² FLRYW X1003(9)
21 BLK 248-54 0.75mm² FLRYW X1004(5)
22 BLK 248-24 0.75mm² FLRYW X1005(1)
23 BLK 248-43 0.75mm² FLRYW X1005(9)
24 BLK 248-28 0.75mm² FLRYW X1005(5)
25 BLK 248-26 0.75mm² FLRYW X1005(3)
26 BLK 248-44 0.75mm² FLRYW X1005(10)
27 BLK 248-29 0.75mm² FLRYW X1005(6)
28 BLK 248-40 0.75mm² FLRYW X1005(8)
29 BLK 248-27 0.75mm² FLRYW X1005(4)
30
31 BLK 248-25 0.75mm² FLRYW X1005(2)
32 BLK 248-7 0.75mm² FLRYW X1004(7)
33
34 BLK 148-56 0.75mm² FLRYW X1006(4)
35 BLK 248-16 1.5mm² FLRYW X1003(2)
36
37 BLK 248-18 1.5mm² FLRYW X1003(4)
38 BLK 248-32 1.5mm² FLRYW X1003(5)
39
40 BLK 248-46 1.5mm² FLRYW X1003(7)
41 BLK 248-3 1.5mm² FLRYW X1003(8)
3121262 7-85
EC18
CONN WIRE
WIRELABEL
1 RED 48-13 8AWG GXL RL931-87(1)
2 RED 48-14 8AWG GXL RL931-87(1)
SN939
CONN WIRE
WIRELABEL
1 BLK 148-29 0.75mm² FLRYW X1006(1)
2 BLK 148-87 0.75mm² FLRYW X1006(11)
3 BLK 148-13 0.75mm² FLRYW X1010(7)
4
EC241-L
CONN WIRE
WIRELABEL
1 RED 47-8 16AWG GXL X901(5)
RL974
CONN WIRE
WIRELABEL
1 WHT 48-3 18AWG GXL X901(2)
1
2 BLK 000-48-4 18AWG GXL T920(1)
7-86 3121262
3121262 7-87
8 7 6 5 4
T/T SWING MAIN LIFT MAIN TELESCOPE JIB TELESCOPE JIB LIFT PLATFORM ROTATE
KEY SWITCH DIAGNOSITC DISPLAY
EMERGENCY MOUNTED IN GROUND BOX TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH
HOURMETER MOMENT CONTROL TEST
EMS IGNITION RELAY
PUSH BUTTON
87a
SEE ZONE-[6,C]
87
30
85
86
SW206-1A
SW206-2A
SW206-1B
SW206-2B
SW228-1
SW228-2
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
SW219
SW220
SW221
SW223
SW222
SW225
SW139-B1
1A
2A
1B
2B
SW139-B
SW139-1
SW139-3
SW139-2
SW139-4
RL80
1
4
1
3
2
5
H
ORN/RED 49-102
YEL/RED 2-40-02
YEL/RED 2-40-03
YEL/RED 2-40-10
YEL/RED 2-40-04
YEL/RED 2-40-06
YEL/RED 2-40-05
BLU 28-2
YEL/RED 2-40-02
YEL/RED 2-40-03
YEL/RED 2-40-10
YEL/RED 2-40-04
YEL/RED 2-40-06
YEL/RED 2-40-08
YEL/RED 2-40-05
BLU 27-2
GRY 23-2
GRY 24-2
RED 1-1-2 (10)
BRN 29-2
YEL/RED 2-1-2
YEL/RED 2-1-2
YEL/RED 2-1-1 (12)
YEL/RED 2-1-1 (12)
BRN 14-2
BRN 13-2
TAN 3-3
YEL/RED 2-2
TAN 3-2
WHT 22-2
YEL/RED 2-8
YEL/RED 2-40-01
WHT 21-2
3
4
5
6
1
2
BRN 30-2
GD275
IP213
IP212
30A
YEL/RED 2-30-1
YEL/RED 2-40-07
BLK 000-31-11
IP284
YEL/RED 2-8
BLK 000-03
YEL/RED 2-3
YEL CAN1-H_MDI
GRN CAN1-L_MDI
YEL/RED 2-8-1 (12)
RED 1-1 (10)
TURNTABLE HARNESS
YEL/RED 2-2
SEE ZONE-[7,A]
S362
RED 1-3
YEL/RED 2-3
SEE ZONE-[7,A]
G
CAN-1 SPLICE (GROUND) CAN-2 SPLICE
BRN 30-2
WHT/YEL 48-1
BRN/ORN 53-2
ORN/RED 49-103
ORN/RED 49-101
ORN/RED 49-100
YEL/RED 2-40-01
WHT/YEL 39-1
BRN/WHT 47-6
WHT/YEL 48-6
RED/YEL 54-4
BRN/WHT 47-5
BRN/WHT 47-8
MNTD BESIDE GROUND MODULE MNTD BESIDE GROUND MODULE
BLU 28-2
BLU 27-2
GRY 23-2
BLK 000-31-01
GRY 24-2
PNK 25-2
RED/YEL 54-5
PNK 26-2
BRN 29-2
BRN 14-2
BRN 13-2
WHT 22-2
WHT 21-2
TAN 3-3
TAN 3-2
11
12
10
11
12
10
1
2
3
4
9
5
6
7
8
1
2
3
4
9
5
6
7
8
MS287
MS134
12
34
25
35
23
33
7
30
11
22
8
19
20
9
18
6
17
5
4
16
2
1
15
28
29
26
13
3
14
27
31
32
5A
YEL CAN1-H_MDI
GRN CAN1-L_MDI
IP140
F
RED
BLK
SHIELD
YEL CAN2-HIGH
GRN CAN2-LOW
BLK CAN2-SHIELD
SWGLT
IGN
SWGRT
LIFTUP
LIFTDN
TELEIN
TELEOT
JIBIN
JIBOUT
JIBDN
JIBUP
ROTR
ROTL
LVLUP
LVLDN
STRT
AUX
500#
AXLE
GLOW
TEMP
OILP
ALT
BCSCAL
BCS
OVRLD
1000#
GND
SHIELD TP-CBL12
BLK CAN1-SHIELD
GRN CAN1-LOW
YEL CAN1-HIGH
RED TP-CBL12
BLK TP-CBL12
J4 (BLUE)
GRN CAN1-L_GTWY
YEL CAN1-H_GTWY
X361
TELEMATICS
RED 1-3A S365
1
BLACK S363
2
YEL/RED 2-8-1A
3
YEL/RED 2-2A S364
4 SEE ZONE-[7,C]
SEE ZONE-[7,C]
SEE ZONE-[7,C]
SHIELD
BLK CAN2-SHIELD
RED
BLK
GRN CAN2-LOW
TURNTABLE HARNESS
TURNTABLE HARNESS
TURNTABLE HARNESS
YEL CAN2-HIGH
RED 1-3B
B
J
5A YEL/RED 2-6
H
ADVANCED G IP102
DIAGNOSTIC F
YEL CAN2-HIGH
C CO239-J12
CONNECTOR GRN CAN2-LOW
D
BLK CAN2-SHIELD
1 J12 (BLACK)
E 2
BLK 000-9
A 5 CAN2S
X272 4 CAN2L
3 CAN2H
ORN/RED 49-16
6 CAN2T
7 CAN2T
8
12 120
D 11 CO239-J7
BLK 000-25 (16) SEE ZONE-[1,D] BLK CAN1-SHIELD
8 18 CAN1S
RED/WHT 50-3 (16) SEE ZONE-[1,D] GRN CAN1-LOW
7 24 CAN1L
BLK 000-24-1 (16) SEE ZONE-[1,D] YEL CAN1-HIGH
10 13 CAN1H
RED/WHT 50-2-1 (16) SEE ZONE-[1,D] YEL/RED 2-30-1
9 3 GNDMODE
ORN/RED 49-88 ORN/RED 49-88
4 12 BRKNCBL
YEL/RED 2-61 YEL/RED 2-61
5 32 IGN
BLK 000-26 BLK 000-26
3 19 GND
1 29 IGN 120
2 11 BMRTCL
6 35 BMRTOP
X146 6 CANT
ORN/RED 49-17
17 CANT
BLK 000-9
12 5
BLK 000-03 YEL/RED 2-6
11 34 IGN
10 16
MOUNTED IN GROUND BOX
BLK 000-01 (12)

9
BLK 000-06
TURNTABLE HARNESS
TURNTABLE HARNESS YEL/RED 2-31
4 J7 (BLACK)
8 23 GNDE
GROUND BUSS
BLK 000-38 SEE ZONE [2,B]

7 30 IGN
BLK 000-08
6 7
BLK 000-05-1 (12) ORN/RED 49-102
C 5
BLK 000-04 (12)
TURNTABLE HARNESS
TURNTABLE HARNESS
SEE ZONE-[5,H] 21 PTST
4 10
BLK 000-45-1 (12)
3 20
BLK 000-39-1 (12)
2 25
BLK 000-2 (12)
1 8
MS96 28
26
YEL/RED 2-8-1 B (12)
12 9
11 31
YEL/RED 2-8-7
10 33
YEL/RED 2-8-5 SEE ZONE [3,F]

9 27
YEL/RED 2-8-8 SEE ZONE [2,B]
8 22
IGNITION BUSS
YEL/RED 2-8-6 SEE ZONE [2,C] YEL/RED 2-3-2

7 1 PLTS
YEL/RED 2-8-9 TURNTABLE HARNESS YEL/RED 2-2-1
6 2 PLTE
YEL/RED 2-8-3 (12) TURNTABLE HARNESS
5 14 GNDMODE
YEL/RED 2-8-4 (18) TURNTABLE HARNESS
4 15 FTSWCL
YEL/RED 2-8-11 (12)
3
YEL/RED 2-8-10 (12)
2
CO239-J8
YEL/RED 2-8-2 (12)

1
2
3
4
1
MS95
YEL/RED 2-8-2 (12)
B 1
2
BLK 000-2 (12)
YEL/RED 2-30
3
YEL/RED 2-20
S218
4
5
6
CAN-2 LOW 7
CAN-1 REPEATER MODULE TO PLATFORM
CAN-2 HIGH 8
MOUNTED WITH GROUND MODULE
GRN CAN1-L_GTWY
CAN-1 LOW 9
YEL CAN1-H_GTWY
CAN-1 HIGH 10
BLK 000-08
GROUND 11
YEL/RED 2-8-7
IGNITION 12
CO75-J1
YEL/RED 2-3-4
YEL/RED 2-3
1
BLK 000-45-1 (12)
BLK 000-39-1 (12)
YEL/RED 2-8-11 (12)
YEL/RED 2-8-10 (12)
2
BLK CAN2-SHIELD
CAN-2 - SHIELD 3
4
5
YEL/RED 2-3
6
BLU 27-3-4
SEE ZONE-[8,G]
BLU 28-3-4
YEL/RED 2-2B
PNK 25-3
PNK 26-3
7 SEE ZONE-[8,G]
8
A CAN-3 LOW 9
GRN CAN1(A)-LOW
YEL CAN1(A)-HIGH
CAN-3 HIGH 10
11
12
X46
CO75-J2
3
2
5
1
10
12
16
18
8
14
17
19
4
11
6
13
9
7
15
***120 RESISTOR ACROSS J2-9 & J2-10

BOOM CABLE CONNECTOR
SEE SHEET 3, ZONE C-8
SHEET 1
8 7 6 5 4
Figure 7-58. Ground Control Box Wiring Diagram - Sheet 1 of 2
7-88 3121262
5 4 3 2 1
JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER
TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH
MOMENT CONTROL TEST
PUSH BUTTON
SEE ZONE-[6,C]
SW228-1
SW228-2
1
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
SW223
SW222
SW225
SW226
SW227
(CE ONLY)
500# CAP AXLE SET GLOW PLUG HIGH COOLANT LOW OIL NO ALTERNATOR MOMENT CNTL BOOM CONTROL PLATFORM 1000# CAP
H
LIGHT LIGHT LIGHT TEMP LIGHT PRES LIGHT OUTPUT LIGHT TEST LIGHT SYSTEM LIGHT OVERLOAD LIGHT
ORN/RED 49-102
YEL/RED 2-40-10
YEL/RED 2-40-04
YEL/RED 2-40-06
YEL/RED 2-40-08
YEL/RED 2-40-09
YEL/RED 2-40-05
BLU 28-2
YEL/RED 2-40-04
YEL/RED 2-40-06
YEL/RED 2-40-08
YEL/RED 2-40-09
YEL/RED 2-40-05
YEL/RED 2-40-07
BLU 27-2
GRY 23-2
GRY 24-2
PNK 25-2
PNK 26-2
WHT/YEL 48-1
BRN/ORN 53-2
BRN 29-2
BRN 30-2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
LB229
LB230
LB231
LB232
LB233
LB234
LB235
LB236
LB237
LB238
BLK 000-31-10
BLK 000-31-09
BLK 000-31-08
BLK 000-31-07
BLK 000-31-06
BLK 000-31-05
BLK 000-31-04
BLK 000-31-03
BLK 000-31-02
BLK 000-31-10
BLK 000-31-09
BLK 000-31-08
BLK 000-31-07
BLK 000-31-06
BLK 000-31-05
BLK 000-31-04
BLK 000-31-03
BLK 000-31-02
RED/YEL 54-4
WHT/YEL 39-1
BLK 000-31-11
WHT/YEL 48-6
BRN/WHT 47-6
BRN/WHT 47-5
BRN/WHT 47-8
ORN/RED 49-103
ORN/RED 49-101
ORN/RED 49-100
RED/YEL 54-5
BLK 000-31-01
G
BRN 30-2
ORN/RED 49-103
WHT/YEL 48-1
BRN/ORN 53-2
ORN/RED 49-101
ORN/RED 49-100
YEL/RED 2-40-01
WHT/YEL 39-1
BRN/WHT 47-6
WHT/YEL 48-6
RED/YEL 54-4
BRN/WHT 47-5
YEL/RED 2-8-5
BRN/WHT 47-8
BLU 28-2
[2,B]
BLK 000-31-01
BLU 27-2
GRY 23-2
GRY 24-2
RED/YEL 54-5
PNK 25-2
PNK 26-2
BRN/WHT 47-9
BRN 29-2
BRN 14-2
BRN 13-2
WHT 22-2
WHT 21-2
YEL/RED 2-8-5
TAN 3-3
TAN 3-2
6
7
8
CO239-J4
12
34
25
35
23
33
7
30
11
22
8
19
20
9
18
6
17
5
4
16
2
1
15
28
29
26
13
3
14
27
31
32
21
10
24
14
13
12
11
10
9
8
7
6
5
4
3
2
1
F
SWGLT
IGN
SWGRT
LIFTUP
LIFTDN
TELEIN
TELEOT
JIBIN
JIBOUT
JIBDN
JIBUP
ROTR
ROTL
LVLUP
LVLDN
STRT
AUX
500#
AXLE
GLOW
TEMP
OILP
ALT
BCSCAL
BCS
OVRLD
1000#
GND
IGN
ALTE
J3 (BLACK)
WHT 22-3
SWGRT 35 VALVE HARNESS
WHT 21-3
J4 (BLUE) SWGLT 34 VALVE HARNESS
33
32
BLK 000-35-1
GND 30 VALVE HARNESS
28
BLU/ORN 52-10
GNDALRM 27 VALVE HARNESS
BLU/ORN 52-12
HEAD/TAIL 26 VALVE HARNESS
BRN/WHT 47-12
FUEL
BLK CAN2-SHIELD
25 VALVE HARNESS
24
23
TAN 4-3
LIFTDN 22 VALVE HARNESS
21
20
TAN 55-20
LIFTFLOW 19 VALVE HARNESS
GND 17
BLK 000-34
BRN 14-3
VALVE HARNESS E
MNTELEOUT 16 VALVE HARNESS
J2 (GRAY) 15
BLK 000-36-1
GND 14 VALVE HARNESS
RED/WHT 50-1
MAINDMP 13 VALVE HARNESS
TAN 55-22
LIFTDNAUX 12 VALVE HARNESS
TAN 3-3
LIFTUP 11 VALVE HARNESS
TAN 55-21
LIFTPILOT 10 VALVE HARNESS
BRN 55-10
TELEFLOW 9 VALVE HARNESS
8
BLK 000-33
GND 6 VALVE HARNESS
BRN 13-3
CO239-J12 MNTELEIN 4 VALVE HARNESS
BLU/ORN 52-2
1 J12 (BLACK) HORN 2
BLK 000-25
VALVE HARNESS
2 GND 18 SEE ZONE-[7,D]
RED/WHT 50-3
5 CAN2S JIB DMP 1 SEE ZONE-[7,D]
BLK 000-24-1
4 CAN2L GND 29 SEE ZONE-[7,D]
RED/WHT 50-2-1
3 CAN2H PLTDMP 3 SEE ZONE-[7,D]
BLU 28-3-4
6 CAN2T JIBDNO/R 31
PNK 26-3
7 CAN2T PLVLDNO/R 7
PNK 25-3
8 PLVLUPO/R 5
120 CO239-J2
CO239-J7 X245
D
YEL/RED 2-5
18 CAN1S ANALP 28 1
24 CAN1L ANALR 29
ORN/RED 49-5
2 ANALYZER
ORN/RED 49-6
13 CAN1H ANALT 30 3
BLK 000-37
3 GNDMODE ANALG 31 4
12 BRKNCBL 35
32 IGN 34
19 GND 33
29 IGN 120 27
11 BMRTCL 26
35 BMRTOP 25
6 CANT 24
BRN/WHT 47-9
17 CANT 21 X274
BRN/WHT 47-8-1 BRN/WHT 47-8-2
5 ALTE 32 5
WHT/YEL 48-3 S86
34 IGN START 11
RED TP-CBL12
2 ENGINE
16 19 [3,E] 3
BLK TP-CBL12 CONNECTOR #1
4 J7 (BLACK) J1 (WHITE) 18 [3,E]
SHIELD TP-CBL12 S276
4
23 GNDE 17 [4,E] 6
YEL/RED 2-8-6
30 IGN 16 [2,B] 1
7 15
21 PTST 14 C
10 1
ORN 55-45
20 BRK 23 T/T HARNESS
ORN 55-47
25 2SPD 20 T/T HARNESS
BRN/ORN 53-3
8 AUXP 13 T/T HARNESS
28 4
26 6
9 5
31 2
YEL/RED 2-1-88
33 10 X266
BLK 000-42 (16)
27 GND 8 2
WHT/YEL 48-8
22 SP 7 7
BLU/ORN 52-5 ENGINE
1 PLTS GEN 22 3
WHT/YEL 48-9
2 PLTE GLOW 12 4
CONNECTOR #2
BLK 000-22
14 GNDMODE GND 9 6
BLU 27-3-4
15 FTSWCL JIBUPO/R 3 1
YEL/RED 2-8-8
CO239-J1 [2,B] 5
WHT/YEL 48-7 (16)
8
CO239-J8
1
2
3
4
YEL/RED 2-8-2 (12)
(CAT ENGINE ONLY) B

BLK 000-2 (12)
X93 ELECTRIC FUEL

WHT/YEL 48-7 (16)
1
[2,C]
BLK 000-38
2 PUMP CONNECTOR
LOCATED NEAR
FUEL TANK
SHEET 2 1001120332-E
5 4 3 2 1
MAF10580E
Figure 7-59. Ground Control Box Wiring Diagram - Sheet 2 of 2
3121262 7-89
7-90 3121262
1500SJ ELECTRICAL SCHEMATIC

SHEET 2: PLATFORM BOX
BOX ASSEMBLY
CONSOLE BOX HARNESS
SHEET 3: PLATFORM AND JIB COMPONENTS

WIRE HARNESS INST'L
PLATFORM VALVE HARNESS
JIB VALVE HARNESS
BOOM CABLES
PLATFORM DUMP HARNESS JIB ENABLE HARNESS
BOOM CONTROL CABLE
LIMIT SWITCH HARNESS
10/3 AC CABLE (MAIN BOOM) (DOM)/ (CE) (IF EQUIPPED) (CONNECTORIZED FOR JIB)
GENERATOR POWER CABLE (MAIN BOOM)
JIB CONTROL CABLE
10/3 AC CABLE (JIB) (DOM)/ (CE) (IF EQUIPPED)
GENERATOR POWER CABLE (JIB)
SHEET 4: TURNTABLE & BOOM

WIRE HARNESS INST'L
BLAM HARNESS (SIMILAR TO EXISTING)
MAIN BOOM CYLINDER ANGLE HARNESS
SHEET 5: GROUND CONTROL BOX

MTB (REXROTH) INST'L
MTB (SAUER) INST'L, MTB (TIER 4 FINAL) INST'L
MAIN TERMINAL BOX ASSEMBLY
MTB HARNESS
TURNTABLE HARNESS
PUMP HARNESS
SHEET 6: CHASSIS
WIRE HARNESS INST'L
CHASSIS HARNESS (SIMILAR TO EXISTING)
SHEET 7: ENGINE - DEUTZ EMR2
SHEET 8: ACCESSORIES
SHEET 9: ENGINE - TIER 4 FINAL - DEUTZ EMR4
SHEET 10: CRIBBING HARNESS /ALERT BEACON OPTIONGEN 2 PLAT INTERFACE
SHEET 1 1001119266-V
3121262 7-91
7-92
F
B
C
A
G
H
D
R
R
BCS
FAILURE
SHEET 10 [B,5]
TO X5B
PLTF LEVEL
2
4
1
3
5
6
GD47-J1
BRN/WHT 47-1 FUEL 1/4
X5A
1
8
8
G
G
2
INTERFACE
GEN 2 PLAT
BLK P6
3
BLK 000-51-3 FUEL GND
AXLE SET
YEL/RED P1
YEL/RED P3
4
YEL/RED P2
GENERATOR
BLK 000-51-2 SPARE14
YEL/RED 2-16-3
[5,G] 5
BRN/WHT 47-4 FUEL FULL
6
DRIVE
OVERLOAD
ORIENTATION
[F,4]
[A,6]
GD47-J2
ORN/RED 49-15 CREEP
1
1
2
3
4
YEL/RED 2-21 ENABLE
2
BRN/WHT 47-13 LOW FUEL
G
3
N/C
4
X54-ANALYZER
N/C
5
500# MODE
1000# MODE
BOTTOM OF CONSOLE BOX

BLK 000-52 GROUND
6
R
R
TILT
LED BOARD
CABLE
BROKEN
GD47-J3
PLATFORM DISPLAY
ORN/RED 49-1000 BCS

1
WHT/YEL 39-1 AXLE SET
2
ORN 55-51 DRIVE ORIENTATION
3
RED/YEL 54-3 1000# MODE
Y
Y
4
ORN/RED 49-101 BROKEN CABLE
5
FAULT
BRN/WHT 47-12 SYSTEM FAULT
ENGINE
SYSTEM
PREHEAT
7
7
G
G
GD47-J4
CREEP
BRN/WHT 47-10 PLATF LEVEL FAILURE

ENABLE
1
BLU/ORN 52-4-1 GENERATOR
S369
2
ORN/RED 49-100 OVERLOAD
ORN/RED 49-92
ORN/RED 49-91
ORN/RED 49-90
ORN/RED 49-89
3
RED/YEL 54-2 500# MODE
4
G
ORN/RED 49-3 TILT

Y
5
WHT/YEL 48-6 ENGINE PREHEAT
DRIVE & STEER 6
SPARE14
ELECTRONIC JOYSTICK
LOW FUEL
PIEZO
DRIVE LIFT & SWING
ALARM
Y
STEER ELECTRONIC JOYSTICK

G
G
G
5K
SWING LIFT
FUEL GAUGE
5K 5K
1
1
WHT/YEL 48-5
1
AH142-
AH142+
YEL/RED 2-10-1
2
YEL/RED 2-16
BLK P6
YEL/RED 2-11-1
BLU/ORN 52-3
ORN 55-46
3
WHT/YEL 39-1
BRN/WHT 47-4
BLU/ORN 52-4-1
ORN/RED 49-101
WHT 60-4
ORN 55-51
WHT/YEL 48-6
BRN/WHT 47-1
YEL/RED 2-21
ORN/RED 49-1000
BRN/WHT 47-10
ORN/RED 49-100
WHT 59-60
ORN 55-50
RED/YEL 54-2
BRN/WHT 47-12
ORN/RED 49-3
ORN/RED 49-42
BRN/WHT 47-2
BRN/WHT 47-3
BLK 000-51-3
BLK 000-52
BRN/WHT 47-13
RED/YEL 54-3
WHT 59-1
ORN/RED 49-15
4
HIGH DRIVE
5
TOGGLE SWITCH
6
SW63
CO01-J2
3
9
7
6
2
1
4
5
12
14
8
17
16
13
10
29
19
30
33
23
18
15
34
28
21
22
24
35
11
31
32
25
20
26
27
BLK
RED
BRN
GRN
YEL 55-17
BLU
WHT
1
BLK 000-54
BLK
BLU
RED
YEL/RED 2-10-1
BRN
ORN/RED 49-4
BLU/YEL
2
ORN/YEL
YEL 55-16
3
WHT/YEL
WHT/RED
WHT/GRN
CO01-J5 YEL/RED 2-10-2
1/4
1/2
3/4
IGN
IGN
IGN
4
ENV
TILT
GEN
DOS
DOS
GND
GND
500#
FULL
ALVL
JIBLT
AXLE
JIBRT
GRN
1000#
LFUEL
CREEP
ENBLE
GLOW
OR
STEER MODE
JIBLCK
2 5
ANALT
CTAP
ANALP
ANALR
SYSDIS
OVRLD
[G,3]
[G,3]
[A,8]
ANALG
SFTTCH
BKNCBL
TOGGLE SWITCH
BRN
6
6
3 LFT 6
SHEET 8
SHEET 8
RED
SEE SHEET 3
1 VREF SW64
ZONE C-8, C-6

BLU
6
BLK PNK 26-1
8 1
BLU/YEL YEL/RED 2-10-2
7 2
15 POS MATE-N-LOCK
GND
ORN/YEL PNK 25-1
4 3
J5 (WHITE)
SWG
WHT YEL/RED 2-10-3
J2 (GRAY)
5 4
CONNECTOR IN CONSOLE BOX

CTAP
YEL/RED P2
YEL/RED P9
5
TOGGLE SWITCH
6
PLATF LEVEL OVERRIDE
CO01-J6 SW65
15 15 8
BLU YEL/RED 2-10-3
14 14 2 CTAP SW76-1
BLK YEL/RED 2-10-4
13 13 7 GND 1
BRN
12 12 3 DRV SW76-2
HORN
RED BLU/ORN 52-1

11 11 4 1
WHT/GRN
PUSH BUTTON
10 10 5 STRLT
YEL/RED 2-16-2 WHT/RED
6 6 1
J6 (BLACK)
VREF
WHT/YEL
5 5 6 STRRT
ORN/RED 49-67 YEL/WHT 44-1
4 4 1
9 9 2
YEL/RED 2-16-1 ORN/RED 49-4 WHT/YEL 48-5 YEL/WHT 43-1
8 8 19 ALRM ENGSPD 28 3
BLU/ORN 52-3 BLK 000-54 ORN 55-46 YEL/RED 2-10-5
2 2 20 GND 2SPD 27 4
ORN/RED 49-70 S366 ORN/RED 49-70 YEL 55-17
7 7 8 FTSWOP CRDSTR 17 5
TOGGLE SWITCH
BLU/ORN 52-4-2 BLU/ORN 52-4-2 YEL 55-16

1 1 9 GEN CRBSTR 16 6
AXLE EXTEND/RETRACT
ORN/RED 49-69 ORN/RED 49-69 PNK 26-1 SW66

3 3 18 SFTTCH PLVLDN 10 SW118
X155 BLK P6 PNK 25-1
X154 17 PLVLUP 9 1
ORN/RED 49-81 BLU/ORN 52-1 ORN/RED 49-11
33 GND HORN 31 2
BLK 000-46-1 YEL/WHT 44-1 YEL/RED 2-10-5
29 GND AXLRET 24 3
WHT 55-2 YEL/WHT 43-1 RED/WHT 55-30
26 JBLKOUT AXLEXT 23 4
WHT 55-1 ORN/RED 49-11 RED/WHT 55-31
GENERIC
25 JBLKIN CREEP 32 5
PUMP POT
5
5
GRY 24-3 RED/WHT 55-30 BLK 000-53
Figure 7-60. Electrical Schematic - Sheet 2 of 18

SHEET 8 [G,2]
6 PROTRT POTREF 34 6
GRY 23-3 RED/WHT 55-31 YEL/RED 2-10-6
5 PROTLT PUMPPOT 35
ORN/RED 49-68 BLK 000-53
21 GND POTGND 13
PNK 26-3-2 GRY 24-1
16 PLVLDN PROTLT 8
PNK 25-3-2 GRY 23-1
15 PLVLUP PROTRT 7
YEL/RED 2-30-1 BRN 30-1
1 GNDMODE JIBTELEOUT 4
YEL/RED 2-3-3 BRN 29-1
3 PLTFEMS JIBTELEIN 3
YEL/RED 2-3-5 ORN/RED 49-40
2 PLTFEMS SFTTCH 29
BROWN PWR-J7 BLU 28-1
7 IGN JIBDN 12
BLU 27-1
22
J1 (WHITE)
J7 (BLACK)
GND JIBUP 11
BROWN X04-PWR BLU/ORN 52-12
GOLD PIN
4 IGN HEAD/TAIL 30
WHITE GND-J7 BRN 14-1
34 GND MNTELEOUT 6
BLK CANS BRN 13-1 LB132+
32 CAN1S MNTELEIN 5
GRN CANL ORN/RED 49-120 WHT 59-60
30 CAN1L ENVLP 22 1
120
YEL CANH BRN/ORN 53-1
31 CAN1H AUX 15
LIGHT
WHT/YEL 48-1
10 START 14 1
JIB LOCK PIN
RED/YEL 54-1
11 500/1000 21 LB132-
YEL/RED 2-10-16
12 IGN 18
13 2 YEL/RED P3 SHEET 8 [H,3]
WHITE X04-GND OR GRY 24-1
14 20 1
[A,8] YEL/RED 2-10-6
23 19 2
ORN/RED 49-80 GRY 23-1
24 PLVL2 26 3
ORN/RED 49-63 YEL/RED 2-10-8
27 25 4
SILVER PIN
PLVL1
ORN/RED 49-12-1
28 PROX2NO 33 5
TOGGLE SWITCH
ORN/RED 49-13-1
PLATFORM ROTATE
35 PROX2NC 1 6
CO01-J1 SW67
BLK 000-51-1
1
2
BRN 30-1
1
YEL/RED 2-10-8
CAN2-SPLICE (PLATFORM) CAN1-SPLICE (PLATFORM) 2
BRN 29-1
3 x 4 Buss Bar 3 x 4 Buss Bar 3
CO01-J8
4
4
YEL/RED 2-10-9
4
5
JIB TELESCOPE
TOGGLE SWITCH
6
SW68
1
2
11
12
3
4
9
10
5
6
7
8
1
2
11
12
3
4
9
10
5
6
7
8
LB128
BLK 000-51-2
[1,F] 1
BLK 000-49 (12)
MS156
MS509
BLK 000-24-3 (12)

YEL/RED 2-1-2 (12)
YEL/RED 2-8-13 (12)
LIGHT
ORN/RED 49-42
1
SOFT TOUCH
LB128
WHT 60-4
1
YEL/RED 2-10-9
2
BLK CANS
BLK CANS
YEL CANH
GRN CANL
YEL CANH
GRN CANL
BLACK 80-2
GREEN 80-4
WHT 59-1
BLACK 80-2
GREEN 80-4
YELLOW 80-3
3
YELLOW 80-3
YEL/RED 2-10-19
BLUE X05-CANH
GRAY X05-CANS
4
GRAY X04-CANS
BLUE X04-CANH
BLACK X05-CANL
BLACK X04-CANL
GRAY X1005-CANL
JIB SWING
BLACK X1005-CANH
Platform Box
TOGGLE SWITCH
6
SW69
SHEET 2
3121262
10 10 5 STRLT
YEL/RED 2-16-2 WHT/RED
6 6 1 VREF
WHT/YEL
5 5 6 STRRT
ORN/RED 49-67 YEL/WHT 44-1
4 4 1
3121262
9 9 2
YEL/RED 2-16-1 ORN/RED 49-4 WHT/YEL 48-5 YEL/WHT 43-1
8 8 19 ALRM ENGSPD 28 3
BLU/ORN 52-3 BLK 000-54 ORN 55-46 YEL/RED 2-10-5
2 2 20 GND 2SPD 27 4
ORN/RED 49-70 S366 ORN/RED 49-70 YEL 55-17
SHEET 2
7 7 8 FTSWOP CRDSTR 17 5
TOGGLE SWITCH
BLU/ORN 52-4-2 BLU/ORN 52-4-2 YEL 55-16
1 1 9 GEN CRBSTR 16 6
AXLE EXTEND/RETRACT
ORN/RED 49-69 ORN/RED 49-69 PNK 26-1 SW66
3 3 18 SFTTCH PLVLDN 10 SW118
X155 BLK P6 PNK 25-1
X154 17 PLVLUP 9 1
ORN/RED 49-81 BLU/ORN 52-1 ORN/RED 49-11
33 GND HORN 31 2
BLK 000-46-1 YEL/WHT 44-1 YEL/RED 2-10-5
29 GND AXLRET 24 3
WHT 55-2 YEL/WHT 43-1 RED/WHT 55-30
26 JBLKOUT AXLEXT 23 4
WHT 55-1 ORN/RED 49-11 RED/WHT 55-31
GENERIC
25 JBLKIN CREEP 32 5
PUMP POT
5
5
GRY 24-3 RED/WHT 55-30 BLK 000-53
SHEET 8 [G,2]
6 PROTRT POTREF 34 6
GRY 23-3 RED/WHT 55-31 YEL/RED 2-10-6
5 PROTLT PUMPPOT 35
ORN/RED 49-68 BLK 000-53
21 GND POTGND 13
PNK 26-3-2 GRY 24-1
16 PLVLDN PROTLT 8
PNK 25-3-2 GRY 23-1
15 PLVLUP PROTRT 7
YEL/RED 2-30-1 BRN 30-1
1 GNDMODE JIBTELEOUT 4
YEL/RED 2-3-3 BRN 29-1
3 PLTFEMS JIBTELEIN 3
YEL/RED 2-3-5 ORN/RED 49-40
2 PLTFEMS SFTTCH 29
BROWN PWR-J7 BLU 28-1
7 IGN JIBDN 12
BLU 27-1
22
J1 (WHITE)
J7 (BLACK)
GND JIBUP 11
BROWN X04-PWR BLU/ORN 52-12
GOLD PIN
4 IGN HEAD/TAIL 30
WHITE GND-J7 BRN 14-1
34 GND MNTELEOUT 6
BLK CANS BRN 13-1 LB132+
32 CAN1S MNTELEIN 5
GRN CANL ORN/RED 49-120 WHT 59-60
30 CAN1L ENVLP 22 1
120
YEL CANH BRN/ORN 53-1
31 CAN1H AUX 15
LIGHT
WHT/YEL 48-1
10 START 14 1
JIB LOCK PIN
RED/YEL 54-1
11 500/1000 21 LB132-
YEL/RED 2-10-16
12 IGN 18
13 2 YEL/RED P3 SHEET 8 [H,3]
WHITE X04-GND OR GRY 24-1
14 20 1
[A,8] YEL/RED 2-10-6
23 19 2
ORN/RED 49-80 GRY 23-1
24 PLVL2 26 3
ORN/RED 49-63 YEL/RED 2-10-8
27 25 4
SILVER PIN
PLVL1
ORN/RED 49-12-1
28 PROX2NO 33 5
TOGGLE SWITCH
ORN/RED 49-13-1
PLATFORM ROTATE
35 PROX2NC 1 6
CO01-J1 SW67
BLK 000-51-1
1
2
BRN 30-1
1
YEL/RED 2-10-8
CAN2-SPLICE (PLATFORM) CAN1-SPLICE (PLATFORM) 2
BRN 29-1
3 x 4 Buss Bar 3 x 4 Buss Bar 3
CO01-J8
4
4
YEL/RED 2-10-9
4
5
JIB TELESCOPE
TOGGLE SWITCH
6
SW68
1
2
11
12
3
4
9
10
5
6
7
8
1
2
11
12
3
4
9
10
5
6
7
8
LB128
BLK 000-51-2
[1,F] 1
BLK 000-49 (12)

MS156
MS509
BLK 000-24-3 (12)

YEL/RED 2-1-2 (12)
YEL/RED 2-8-13 (12)
LIGHT
ORN/RED 49-42
1
SOFT TOUCH
LB128
WHT 60-4
1
YEL/RED 2-10-9
2
BLK CANS
BLK CANS
YEL CANH
GRN CANL
YEL CANH
GRN CANL
BLACK 80-2
GREEN 80-4
WHT 59-1
BLACK 80-2
GREEN 80-4
YELLOW 80-3
3
YELLOW 80-3
YEL/RED 2-10-19
BLUE X05-CANH
GRAY X05-CANS
4
GRAY X04-CANS
BLUE X04-CANH
BLACK X05-CANL
BLACK X04-CANL
GRAY X1005-CANL
JIB SWING
BLACK X1005-CANH
5
Platform Box
TOGGLE SWITCH
6
SW69
YEL/RED 2-10-19 SW129-1

YEL/RED 2-10-10
1
SW129-2
ORN/RED 49-40
1
OVERRIDE
SOFT TOUCH
BLU 28-1
1
YEL/RED 2-10-10
2
BLU 27-1
3
YEL/RED 2-10-18
4
JIB LIFT
5
TOGGLE SWITCH
6
SW70
YEL/RED 2-10-18
3
3
SW125-1
YEL/RED 2-10-11
1
SW125-2
LIGHT
BLU/ORN 52-12
1
HEAD/TAIL
BRN 14-1
1
S368 YEL/RED 2-10-11
2
BRN 13-1
3
S367 YEL/RED 2-10-12
4
5
TOGGLE SWITCH
6
MAIN BOOM TELESCOPE
SW71
YEL/RED 2-11-1
YEL/RED 2-10-12
X1001
2
ORN/RED 49-120
3
YEL/RED 2-10-13
B
C
A
4
5
TOGGLE SWITCH
6
BOOM CONTROL SELECT
SW135
PNK 25-3-2
PNK 26-3-2 S104
X1002
Sheet_3 (Platf_and_Jib)-[8,C]
Sheet_3 (Platf_and_Jib)-[6,C]
S145
S108
2
2
GRAY X1005-CANL
WHITE X1005-PWR
BLACK X1005-CANH
BLUE X1005-GND
BRN/ORN 53-1
1
YEL/RED 2-10-13
2

WHT/YEL 48-1
3
YEL/RED 2-10-14
4
ORN/RED 49-81
BLK 000-46-1
WHT 55-2
ORN/RED 49-68
WHT 55-1
GRY 24-3
GRY 23-3
1
2
3
4
5
5
BLUE X05-CANH
BLACK X04-CANL
X1005
BLACK X05-CANL
GRAY X05-CANS
TOGGLE SWITCH
BLUE X04-CANH
WHITE X05-GND
WHITE X04-GND
GRAY X04-CANS
BROWN X05-PWR
START/AUX POWER
6
BROWN X04-PWR
GRN CANL
BLK 000-24-3 (12)

YEL/RED 2-8-13 (12)
BLK 000-49 (12)

YEL/RED 2-1-2 (12)
BLK CANS
GRN (FOOT SWITCH)

YEL CANH
YEL/RED 2-2
YEL/RED 2-3-3
SW72
YEL/RED 2-30-1
LSS
YEL/RED 2-3-5
YEL/RED 2-11-2
YEL/RED 2-11-3
PNK 26-3-1
PNK 25-3-1
ORN/RED 49-13-1
ORN/RED 49-12-1
YEL/RED 2-2
1
YEL/RED 2-10-14
2
RED/YEL 54-1
3
X51
X05
X04
YEL/RED 2-10-15
4
7
9
4
8
6
3
2
1
5
1
2
3
4
5
1
2
3
4
5
ORN/RED 49-80
ORN/RED 49-63
15
13
19
17
14
11
18
16
12
10
5
DISPLAY
PNK 25-3-3
PNK 26-3-3
GRAPHIC
SW48-2B
SW48-1B
SW48-2A
SW48-1A
1
2
3
4
5
1
2
3
4
5
SENSOR
2B
1B
TOGGLE SWITCH
2A
1A
CAPACITY SELECT
15
13
19
17
7
9
14
11
4
8
6
18
16
12
10
3
2
1
5
PLATF LEVEL
X286
X117
SW73
X60
X141
1
9
8
3
4
7
6
5
2
15
20
17
12
11
10
13
21
18
14
19
16
ORN 55-50
1
SEE
SEE
YEL/RED 2-10-15
15
1
20
17
12
11
10
9
8
3
13
21
18
4
14
7
6
5
19
2
16
2
SEE
SHEET 3
SHEET 3
EMS YEL/RED 2-10-16

ZONE E-8
3
ZONE E-8
X138
SHEET 3
SWITCH
ZONE D-8
4
5
TOGGLE SWITCH
6
DRIVE ORIENTATION
SW74
SEE
SHEET 3
ZONE G-8
1
1
1001119266-V
F
B
C
A
G
H
MAF09700V
7-93
8 7 6 5 4
SENSOR #2 (LH) SENSOR #1 (RH) JIB LIFT

PLATF LEVEL PLATF LEVEL PLATF ROT PLATF ROT JIB LOCK JIB LOCK PLATFORM
PLATFORM LEVEL SENSOR PLATFORM LEVEL SENSOR LENGTH SENSOR
UP DOWN LEFT RIGHT PIN - IN PIN - OUT DUMP JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN
PROXIMITY SENSOR PROXIMITY SENSOR PROXIMITY SENSOR
CANH
CANS
CANL
GND
PWR
H
1
2
1
2
1
2
1
2
1
2
1
2
1
2
V28
V29
V30
V31
V32
V33
V27
5
4
3
2
1
SN115
1
2
3
1
2
3
3
4
2
1
3
4
2
1
1
2
4
3
SN136
SN137
SN114
SN17
SN18
BLK 000-46-3
PNK 25-3-5
BLK 000-46-4
PNK 26-3-5
GRY 23-3
GRY 24-3
BLK 000-46-7
WHT 55-5
BLK 000-46-8
WHT 55-6
RED (12)
BLK (12)
BLK SN115-CANL
BLU SN115-CANH
WHT SN115-GND
BRN SN115-PWR
GRY SN115-CANS
ORN
YEL
BLK
BLK 000-41
ORN/RED 49-1
ORN/RED 49-2
YEL/RED 2-16
RED
BLU
BLK
ORN
ORN/RED 49-21
ORN/RED 49-14
YEL/RED 2-16-3
BLK 000-40
15 15
YEL
16 16
BLK
17 17
RED
BLK 000-46-5
BLK 000-46-6
1 1
BLU
2 2
ORN/RED 49-12-2
BLK 000-39-2
ORN/RED 49-13-2
YEL/RED 2-16-2
BLK
3 3
5 5
19 19
PNK 25-3-5
7 7
PNK 26-3-5
6 6
GRY 23-3
SEE SHEET 2 8 8
GRY 24-3
9 9
ZONE C-1 10 10
WHT 55-5
WHT 55-6
11 11
G BLK 000-46-4 BLK 000-46-7
BLK 000-46-3 S78 BLK 000-46-8
BLK 000-46-2 BLK 000-46-2
12 12
21 21
4 4
13 13
14 14
18 18 LSS MODULE
20 20 MOUNTED UNDER
X141 X138 CONSOLE BOX
J1 (GRAY) J2 (BLACK)
CO148-J1
CO148-J2
10
11
12
10
11
12
1
2
3
4
5
6
7
8
9
4
9
5
1
2
3
6
7
8
BROWN LSS-PWR
WHITE LSS-GND
BLUE LSS-CANH BLK CAN1-SHIELD
8
BLACK LSS-CANL
7
MOUNTED IN JCM BOX
GRAY LSS-CANS GRY SN115-CANS

6
CAN-1 SPLICE (JIB)
BLK CAN1-SHIELD
5
3 x 4 Buss Bar
GRN CAN1-LOW
10
1 9
GRAPHIC DISPLAY BLK SN115-CANL
2 4
MOUNTED ON PLATFORM GRN CAN1-LOW
3 3
YEL CAN1-HIGH
4 12
X149
SEE SHEET 2 5 11
1
2
3
4
5
BLU SN115-CANH
6 2
ZONE E-1 BRN LCD-PWR
7 1
YEL CAN1-HIGH
GRAY LCD-CANS MS109
5 5 8
BLACK LCD-CANL
4 M12 TEE OPT 4
BLUE LCD-CANH
9
3 3 10
2 W/LSS ADDED 2
WHITE LCD-GND
11
BROWN LCD-PWR BRN LCD-PWR
1 1 12
E X05 X286 S292 CO217-J1
YEL/RED 2-16-2
9
YEL/RED 2-15-1 (14)
8
MOUNTED IN JCM BOX
YEL/RED 2-8-11 (12)

IGNITION/GROUND
7
BROWN YEL/RED 2-8-10 (12)
LENGTH SENSOR
2 x 6 Buss Bar
1 1 1 PWR 6
PLATF LEVEL
WHITE YEL/RED 2-8-12 (12)

SEE SHEET 2 2 2
BLUE
2 GND 5
YEL/RED 2-15-2 (12)
3 3 3 CANH 4
ZONE E-1 4 4
BLACK
4 CANL 12
BLK 000-39-2
GRAY BLK 000-39-5 (14)
5 5 5 CANS 11
X04 X117 SN116 BLK 000-39-3 (12)
10
BLK 000-45-2 (12)
3
BLK 000-45-3 (12)
2
BLK 000-39-4 (12)
1
MS112
BLK (12)
2
RED (12)
1
X300
X59
BLK 12 AWG BLK 000-39-4 (12)
16 16 16 16
BLK/WHT 12 AWG BLK 000-45-3 (12)
D 18
12
18
12
RED 12 AWG
18
12
18
12
YEL/RED 2-15-2 (12)
ORN 12 AWG YEL/RED 2-8-12 (12)
10 10 10 10
RED 18 AWG YEL CAN1-HIGH
3 3 3 3
BLK 18 AWG GRN CAN1-LOW
2 2 2 2
SHIELD 18 AWG BLK CAN1-SHIELD
BOOM CABLE 1 1
ORN/BLK 18 AWG
1 1
ORN/RED 49-12-2
13 13 13 13
YEL/BLK 18 AWG ORN/RED 49-13-2
CONNECTOR 15 15
ORN 18 AWG
15 15
YEL/RED 2-3-1
4 4 4 4
BLU 18 AWG YEL/RED 2-2-2
SEE SHEET 2 5 5
YEL 18 AWG
5 5
YEL/RED 2-21-1
6 6 6 6
BRN 18 AWG PNK 25-3-4
ZONE D-2 7 7 7 7
8 8 8 8
RED/BLK 18 AWG PNK 26-3-4
9 9 9 9
BLU/BLK 18 AWG YEL/RED 2-30-1
11 11 11 11
14 14 14 14
17 17 17 17
19 19 19 19
X51 X60 X58
GRN
Sheet_2 (Platform-Box)-[2,D]
GRN
Sheet_2 (Platform-Box)-[2,D]
C 15 15
15 15 14 14
14 14 13 13
YEL/RED P8 12 12
13 13
12 12 11 11
11 11 15 POSITION 10 10
9 9
15 POSITION 10 10 WHT
9 9 MATE-N-LOCK 8 8
BLK
WHT 7 7
MATE-N-LOCK 8 8 BLK
7 7
BLK SEE SHEET 2 6 6
WHT
YEL/RED P8 5 5
SEE SHEET 2 6 6
ZONE A-4 4 4
BLK
5 5 WHT
ZONE A-5 4 4 3 3
BRN/ORN 52-3
WHT 2 2
3 3 BRN/ORN 52-4
BRN/ORN 52-3 1 1
2 2
BRN/ORN 52-4 X155 X154
1 1
X155 X154
SHEET 8
[G,3]
SHEET 8
[G,3]
WHT
GRN
WHT
BLK
BLK
WHT
BLK
WHT
GRN
BLK
B
SW150
SW144
SN151
SN152
SW150
SW144
1
2
3
4
5
6
1
2
1
2
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
LIMIT SWITCH LIMIT SWITCH

FOOT SWITCH
TOGGLE SWITCH LH SOFT TOUCH RH SOFT TOUCH
FOOT SWITCH MNTD ON PLTF FLOOR
TOGGLE SWITCH GENERATOR (OPT)
MNTD ON PLTF FLOOR
GENERATOR (OPT)
OPTION 2: SKYGUARD ONLY

OPTION 1: SKYGUARD ONLY AND SOFT TOUCH
SHEET 3
8 7 6 5 4
7-94 3121262
5 4 3 2 1
MOUNTED IN JCM BOX

JIB LIFT JIB LEVEL JIB LEVEL JIB LIFT JIB LIFT JIB TELE JIB TELE JIB SWING JIB SWING JIB
LENGTH SENSOR 3 x 4 Buss Bar
JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN UP DOWN UP DOWN IN OUT RIGHT LEFT ENABLE
PROXIMITY SENSOR PROXIMITY SENSOR PROXIMITY SENSOR
11
12
10
CANH
CANS
CANL
1
2
3
4
9
5
6
7
8
GND
MS349
PWR
H
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
V41
V42
V39
V40
V43
V44
V88
V87
V34
BLU 28-3-1
BLU 27-3-1
BLK 000-43-1
BLU 27-3-3
BLK 000-43-3
BLU 28-3-3
BLU 28-3-2
BLK 000-43-2
BLU 27-3-2
5
4
3
2
1
SN115
BLK 000-43-3
BLU 55-3
BLU 55-4
BRN 29-3
RED (12)
BLK 000-43-2
BLK 000-44-4
BLK 000-44-5
BRN 30-3
BLK (12)
BLK 000-44-6
WHT 60-3
BLK 000-44-7
WHT 59-3
BLU 27-3-3
BLK 000-44-2
BLU 28-3-3
BLK 000-44-3
3
4
2
1
3
4
2
1
1
2
4
3
SN136
SN137
SN114
BLK SN115-CANL
BLU SN115-CANH
WHT SN115-GND
BRN SN115-PWR
GRY SN115-CANS
BLK 000-41
ORN/RED 49-1
ORN/RED 49-2
YEL/RED 2-16
ORN/RED 49-21
ORN/RED 49-14
YEL/RED 2-16-3
BLK 000-40
CO49-J2
ORN/RED 49-12-2
BLK 000-39-2
ORN/RED 49-13-2
YEL/RED 2-16-2
BLU 27-3-2 BLU 27-3-1

2 JIBUPO/R JIBUP 1
BLU 28-3-2 BLU 28-3-1
1 JIBDNO/R JIBDN 2
BLU 55-4 BRN 29-3
12 JLVLDN JIBTELEIN 5
J2 (BLACK)
BLK 000-43-1 BRN 30-3
3 GND JIBTELEOUT 6
BLU 55-3 WHT 60-3
11 JLVLUP JIBSWGRT 3
ORN/RED 49-2 WHT 59-3
4 LOCKNO JIBSWGLT 4
ORN/RED 49-1
5 LOCKNC 7
ORN/RED 49-14
7 PROX1NC 8
J5 (RUST)
ORN/RED 49-21
6 PROX1NO 9
8 10 G
9 11
BLK 000-44-1
10 GND 12
CO49-J5
8
BLK 000-44-7
MOUNTED IN JCM BOX

CO49-J4 7
BLK 000-41 BLK 000-44-6
2 GND 6
1 x 8 Buss Bar
YEL/RED 2-16 BLK 000-44-5
1 IGN JIB 5
J4 (GRAY)
BLK 000-44-4
6 4
YEL/RED 2-16-3 BLK 000-44-3
BLK 000-40
7
8
IGN
GND
CONTROL BLK 000-44-2
3
2
BLK CAN1-SHIELD BLK 000-44-1
GRN CAN1-LOW
5
4
CAN1S
CAN1L
MODULE 1
MS350
YEL CAN1-HIGH
3 CAN1H
SN84
JIB SWING ANGLE SENSOR

RED
DUAL OUTPUT ROTARY

B
WHT
CO49-J1 D
RED BLK
10 5VREF 10 A
WHT ORN
9 ROT2 11 F
BRN SN115-PWR
3 J1 (GRAY) GND 12
BLK
ORN
BLU
GRN
C
11 IGN 5VREF
J3 (GREEN)
7 E
WHT SN115-GND
12 GND ROT1 8
BLU F
YEL/RED 2-15-1 (14) GRN
5 IGN GND 9
BLK 000-39-5 (14) RED
4 GND 5VREF 4
BLU 28-3-4 WHT
1 JUMP TO J2-1 LVL2 5
BLU 27-3-4 BLK SN82
2 JUMP TO J2-2 GND 6
JIB LEVEL ANGLE SENSOR

YEL CAN1-HIGH ORN RED
DUAL OUTPUT ROTARY

6 CAN1H 5VREF 1 B
GRN CAN1-LOW BLU WHT
7 CAN1L LVL1 2 D
BLK CAN1-SHIELD GRN BLK
8 CAN1S GND 3 A
CO49-J3 ORN
F
BLU
C
GRN
E
CONNECTION LOCATED NEAR BLK (12)

Sheet_4 (T/T & Boom)-[4,H]
JIB ENABLE VALVE RED (12)
Sheet_4 (T/T & Boom)-[4,H]
BLK (12) BLU (12) BLU (12)
2 2 Sheet_4 (T/T & Boom)-[4,H]
RED (12) ORN (12) ORN (12)
1 1 Sheet_4 (T/T & Boom)-[4,H]
X300 X299
X57 X61 X46
BLK CAN1-SHIELD SHIELD 18 AWG
1 1 1 1
GRN CAN1-LOW BLK 18 AWG
YEL CAN1-HIGH
2
3
2
3
RED 18 AWG
2
3
2
3
D
BLU 27-3-4 ORN/BLK 18 AWG
13 13 13 13
BLU 28-3-4 YEL/BLK 18 AWG
YEL/RED 2-8-11 (12)
15 15
RED 12 AWG
15 15 MAIN TERMINAL
12 12 12 12
BLK 000-39-3 (12) BLK 12 AWG
BLK 000-45-2 (12)
16 16
BLK/WHT 12 AWG
16 16 BOX CONNECTION
18 18 18 18
YEL/RED 2-8-10 (12) ORN 12 AWG
YEL/RED 2-3-1 YEL/RED 2-3-1
10 10
ORN 18 AWG
10 10 SEE SHEET 5
4 4 4 4
YEL/RED 2-2-2 YEL/RED 2-2-2 BLU 18 AWG
5 5
YEL 18 AWG
5 5 ZONE A-6
6 6 6 6
PNK 25-3-4 PNK 25-3-4 BRN 18 AWG
7 7 7 7
8 8 8 8
PNK 26-3-4 PNK 26-3-4 RED/BLK 18 AWG
9 9 9 9
YEL/RED 2-30-1 YEL/RED 2-30-1 BLU/BLK 18 AWG
11 11 11 11
14 14 14 14
17 17 17 17
19 19 19 19
X55
GRN
WHT
BLK
BLK
WHT
BLK
WHT
BRN/ORN 52-3
BRN/ORN 52-4
SHEET 8
[G,3]
WHT
GRN
WHT
BLK
BLK
WHT
BLK
B
SW150
SW144
SN151
SN152
1
2
3
4
5
6
1
2
1
2
1
2
3
4
5
6
LIMIT SWITCH LIMIT SWITCH

FOOT SWITCH
TOGGLE SWITCH LH SOFT TOUCH RH SOFT TOUCH
MNTD ON PLTF FLOOR
GENERATOR (OPT)
OPTION 2: SKYGUARD ONLY

AND SOFT TOUCH
SHEET 3 1001119266-V
5 4 3 2 1
MAF09710V
3121262 7-95
7-96
F
B
C
A
G
H
D
Boom Length Sensor
X20
6 6 X56 X62
ORN 8-2-1
5 5 1 1
BRN/BLK - BLK 000-27-3 ORN 8-3-1
SN09 4 4 S94 2 2
8
8
BLK BLK BLK 000-27-2 BLK 000-10
COMMON B 2 2 6 6
BLU BLU ORN/RED 49-110 ORN 7-2-1
OUTPUT C 3 3 3 3
PUMP
RED RED YEL/RED 2-80 ORN 7-3-1
POWER A 1 1 4 4
String Pot
ZONE B-8
SEE SHEET 7
X19 5 5
CONNECTOR
Boom Length Sensor

BRN/BLK
GRN BLK 000-30
E 6 6
BLU ORN/RED 49-9
C 5 5
ORN RED/WHT 50-7
F 4 4
BLK BLK 000-29
A 3 3
WHT ORN/RED 49-19
D 2 2
ANGLE SENSOR
RED RED/WHT 50-6
B 1 1
ORN 60-1-1
MAIN BOOM CYLINDER

X290 X291
SN08
ORN 8-2-1
ORN 8-3-1
BLK 000-10
YEL/RED 2-81
YEL/RED 2-80
ORN/RED 49-110
BLK 000-27-1
ORN/RED 49-18
4
6
5
7
8
9
2
1
3
3
4
5
6
7
8
2
1
9
CO11-J3
CO11-J5
11
10
12
10
11
12
IGN
GND
GND
GND
GND
REFV
AXLE
5VREF
5VREF
5VREF
5VREF
BMLEN
MNCYL2
MNCYL1
LTDRVRV
LTDRVFD
J3 (GREEN)
J5 (RUST)
J2 (BLACK)
(BLAM)
7
7
J1 (GRAY) J4 (GRAY)
IGN
GND
CAN1S
CAN1L
CAN1H
JUMP TO J2-1
JUMP TO J2-2
GND
IGN
CAN1S
CAN1L
CAN1H
GND
IGN
GND
MNANG2
IGN
GND
MNANG1
RTDRVFD
RTDRVRV
5
4
8
7
6
9
10
3
1
2
12
11
5
4
3
2
1
6
8
7
4
5
6
7
2
9
1
3
8
10
11
12
CO11-J1
CO11-J4
CO11-J2
BOOM LENGTH & ANGLE MODULE

BLK
RED
BLK
BLK
RED
GRN
WHT
SHIELD
ORN 7-3-1
ORN 7-2-1
YEL/RED 2-8-3 (12)
BLK 000-28
BLK 000-28
YEL/RED 2-9
YEL/RED 2-9
Sheet_5 (Ground Box)-[7,C]
BLK 000-05-1 (12)
BLK 000-56-1
BLK 000-55-1
YEL/RED 2-82
BLK 000-04 (12)
BLK 000-05-2 (14)

ORN/RED 49-112
ORN/RED 49-111
YEL/RED 2-1-4 (14)

SN10
E
B
A
NEAR BLAM
CONNECTIONS
PWR
GND
CANL
CANH
YEL/RED 2-8-3 (12)
1 1
BLK 000-04 (12) BLK 000-05-1 (12)
5 2 2
9 3 3
ORN 60-1-2 ORN 60-1-1 YEL/RED 2-81 RED
8 4 4 1 1 1
X288 X289 LIFT CYLINDER ORN/RED 49-111 BLU
10 2 2 2
LOAD PIN BLK 000-55-2 BLK
12 3 3 3
#1 Right Side
YEL/RED 2-13 (14) S83 BLK 000-55-3 BLK SN06

4 4 4
Boom Angle Sensor
11 MS97-3 X35 X37
6
6
RED RED
1 A
BLK BLK
2 B
SHIELD SHIELD SHIELD
CONNECT TO
3 C C
ORN 55-47 BLK
6 MS97-2 B
SWIVEL CONNECTOR
ORN 55-45 RED RED YEL/RED 2-82 ORN
7 A A 1 1 1
X26 BLK MS97-1 ORN/RED 49-112 YEL
B 2 2 2
SHIELD BLK 000-56-2 BLK
C 3 3 3
#2 Left Side
S85 BLK 000-56-3 BLK SN07

4 4
Boom Angle Sensor
X36 X38

5
5
YEL/RED 2-8-9
Sheet_5 (Ground Box)-[7,C] 1
LIGHT
BLK 000-06
Sheet_5 (Ground Box)-[7,C] 2
STROBE
LB264
AH260 V246
BLK 000-35-2 BLK 000-35-3
2 2
MAIN
DUMP
BLU/ORN 52-10 RED/WHT 50-1

1 1
ALARM
MOTION
BLU (12)
Sheet_3 (Platf_and_Jib)-[1,D]
ORN (12)
AH259-G Sheet_3 (Platf_and_Jib)-[1,D]
BLK 000-34 BLK 000-35-4
1 V255
BLK 000-35-5
AH259 2
HORN
RIGHT
BLU/ORN 52-2 WHT 22-3 BLK (12)

SWING
1 1 Sheet_3 (Platf_and_Jib)-[1,D]
RED (12)
4
4
Turntable & Boom

Empty: 270 SN258 V254 SN241
Full: 30 BLK 000-33 BLK 000-35-5 BRN
2 2 1
LEFT
BRN/WHT 47-12 WHT 21-3 BLK

SWING
1 1 4
BLU
FUEL SENSOR
3
BROKEN CABLE
PROXIMITY SENSOR
BLK 000-35-6
V252
BLK 000-35-7
2
UP
TAN 3-3
1
MAIN LIFT
BLK 000-35-2
BLK 000-35-3
BLK 000-35-4
SHEET 4
3121262
5 4 3 2 1
BROKEN CABLE BOOM LENGTH

PROXIMITY SENSOR LIMIT SWITCH
H
13
21
22
14
SN242
1
4
3
SN241
RED
BLK
WHT
WHT
BRN
BLK
BLU
X244 X146
WHT
1 1
BLU (12)
ORN (12)
BLK (12)
RED (12)
BLK
2 2
RED
6 6
BLU
3 3
BLK
BRN
4 4 SEE SHEET 5
5 5
RED (12)
BLK (12)
7 7 ZONE D-8
8 8
ORN (12)
9 9
BLU (12)
10 10
11 11
STROBE 12 12
MAIN SWING SWING MAIN LIFT MAIN LIFT LIFT MAIN TELE MAIN TELE TELESCOPE LIFT DOWN LIFT
LIGHT DUMP RIGHT LEFT UP DOWN FLOW CONTROL OUT IN FLOW CONTROL AUXILARY PILOT
G
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
V246
V255
V254
V252
V253
V256
V249
V248
V247
V251
V250
1
2
LB264
BLK 000-35-3
RED/WHT 50-1
BLK 000-35-4
BLK 000-35-5
WHT 22-3
BLK 000-35-5
WHT 21-3
BLK 000-35-6
BLK 000-35-7
TAN 3-3
BLK 000-35-7
BLK 000-35-8
TAN 4-3
BLK 000-35-8
TAN 55-20
BLK 000-36-2
BLK 000-36-3
BRN 14-3
BLK 000-36-3
BRN 13-3
BLK 000-36-4
BLK 000-36-5
BRN 55-10
BLK 000-36-6
TAN 55-22
TAN 55-21
CO239-J2
TAN 55-21
10
TAN 55-22
12
BRN 55-10
9
BRN 13-3
YEL/RED 2-8-9
4
BLK 000-06
BRN 14-3
16
TAN 55-20
19
TAN 4-3
22
TAN 3-3
11
WHT 21-3
34
WHT 22-3
35
RED/WHT 50-1
13
F
BLK 000-36-2 BLK 000-36-1
14
BLK 000-35-4 S262
J2 CONNECTOR
BLK 000-35-3 BLK 000-35-1 BLK 000-35-1

30
BLK 000-35-2 S263
BLU/ORN 52-10
ON GROUND BOARD
27
BLK 000-34
BLU/ORN 52-2
17 (GRAY)
2
BLK 000-33
BRN/WHT 47-12
6 SEE SHEET 5
25
15 ZONE E-3
18
20
21
23
24
BLU/ORN 52-12 BLU/ORN 52-12
1 26
X147 28
BRN/WHT 47-12
BLU/ORN 52-10
HEAD & TAILLIGHT

BLU/ORN 52-2
32
BLK 000-35-2
BLK 000-34
BLK 000-33
SIGNAL 33
8
1
165AH/1150CCA
29
12V BATTERY
31
E
CHASSIS POWER 7
AH259-G
AH260
AH259
SN258
RELAY 5
3
2
1
2
1
BT200+
1
1
BT200-
87a
87
30
85
86
Empty: 270
Full: 30
BLK (1/0)
BLK (1/0)
RED (1/0)
RED (1/0)
MOTION HORN
4
1
3
2
5
RL52
ALARM
FUEL SENSOR
RED (1/0)
YEL/RED 2-13 (14)
YEL/RED 2-12 (12)
BLK 000-3
YEL/RED 2-8-4
Sheet_7 (Deutz Engine)-[8,F]

BLK (1/0)
Sheet_7 (Deutz Engine)-[8,F]
BRN/ORN 53-3
RED 1-1 (10)
Sheet_5 (Ground Box)-[8,G]
S240
RL267-87
D
RED (1/0) 87
1
1-FSLNK (14)
RL267-30
RED (1/0) 30
AUX PUMP
1
RELAY
YEL/RED 2-12 (12) 2-FSLNK (14)
RL267-86
S301 BRN/ORN 53-3 86
1
RL267-85
BLK 000-07 85
1
MS214+
RED (1/0)
AUX PUMP
1
MOTOR
BLK 000-07
BLK (1/0)
MS214- M
1
BLK 000-3
BLK 000-01 (12)
BLK 000-01 (12)

Sheet_5 (Ground Box)-[7,B]
C
YEL/RED 2-8-4
Sheet_5 (Ground Box)-[7,B]
SHIELD
Sheet_5 (Ground Box)-[5,F]
BLK
RED
ORN 55-47
ORN 55-45
Turntable & Boom

A
SHEET 4 1001119266-V
5 4 3 2 1
MAF09720V
3121262 7-97
8 7 6 5 4
T/T SWING MAIN LIFT MAIN TELESCOPE JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER
KEY SWITCH DIAGNOSITC DISPLAY
EMERGENCY MOUNTED IN GROUND BOX TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH
HOURMETER MOMENT CONTROL TEST
EMS IGNITION RELAY
PUSH BUTTON

87a
87
30
85
86
SW206-1A
SW206-2A
SW206-1B
SW206-2B
SW228-1
SW228-2
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
SW219
SW220
SW221
SW223
SW222
SW225
SW226
SW227
SW139-B1
1A
2A
1B
2B
SW139-B
SW139-1
SW139-3
SW139-2
SW139-4
RL80
1
4
1
3
2
5
H
WHT 21-2
YEL/RED 2-40-01
WHT 22-2
YEL/RED 2-40-02
TAN 3-2
YEL/RED 2-40-02
TAN 3-3
YEL/RED 2-40-03
BRN 13-2
YEL/RED 2-40-03
BRN 14-2
YEL/RED 2-40-10
YEL/RED 2-40-10
YEL/RED 2-40-05
ORN/RED 49-102
BRN 29-2
YEL/RED 2-40-05
BRN 30-2
YEL/RED 2-40-04
BLU 28-2
YEL/RED 2-40-04
BLU 27-2
YEL/RED 2-40-06
GRY 23-2
YEL/RED 2-40-06
GRY 24-2
YEL/RED 2-40-08
PNK 25-2
YEL/RED 2-40-08
PNK 26-2
YEL/RED 2-40-09
WHT/YEL 48-1
YEL/RED 2-40-09
BRN/ORN 53-2
YEL/RED 2-40-07
RED 1-1-2 (10)
YEL/RED 2-1-1 (12)

YEL/RED 2-1-2
YEL/RED 2-2
YEL/RED 2-1-2
YEL/RED 2-30-1
YEL/RED 2-8
YEL/RED 2-8-1
YEL/RED 2-1-1 (12)
3
4
5
6
1
2
GD275
IP213
IP212
GRN CAN1-L_MDI
YEL CAN1-H_MDI
YEL/RED 2-40-07
BLK 000-31-11
30A
IP284
BLK 000-03
YEL/RED 2-8
YEL/RED 2-3
RED 1-1 (10)
Sheet_4 (T/T & Boom)-[8,D]
S362
YEL/RED 2-2B
Sheet_5 (Ground Box)-[8,A]
YEL/RED 2-3
Sheet_5 (Ground Box)-[8,A]
G
RED 1-3
CAN-1 SPLICE (GROUND) CAN-2 SPLICE

MNTD BESIDE GROUND MODULE MNTD BESIDE GROUND MODULE
ORN/RED 49-103
ORN/RED 49-101
ORN/RED 49-100
YEL/RED 2-40-01
BRN/WHT 47-6
BRN/WHT 47-5
BRN/WHT 47-8
BRN/ORN 53-2
BLK 000-31-01
YEL/RED 2-8-5
WHT/YEL 48-1
WHT/YEL 39-1
WHT/YEL 48-6
RED/YEL 54-4
RED/YEL 54-5
WHT 21-2
WHT 22-2
BRN 13-2
BRN 14-2
BRN 29-2
BRN 30-2
PNK 25-2
PNK 26-2
GRY 23-2
GRY 24-2
BLU 28-2
BLU 27-2
TAN 3-2
TAN 3-3
11
12
10
11
12
10
1
2
3
4
9
5
6
7
8
1
2
3
4
9
5
6
7
8
MS287
MS134
CO239-J4
YEL CAN1-H_MDI
YEL CAN1-HIGH
RED
YEL CAN1-H_GTWY
GRN CAN1-L_GTWY
GRN CAN1-L_MDI
BLK
GRN CAN1-LOW
BLK CAN1-SHIELD
SHIELD
YEL CAN2-HIGH
RED TP-CBL12
YEL CAN2-HIGH
GRN CAN2-LOW
BLK TP-CBL12
GRN CAN2-LOW
BLK CAN2-SHIELD
SHIELD TP-CBL12
BLK CAN2-SHIELD
12
34
25
35
23
33
7
30
11
22
8
19
20
9
18
6
17
5
4
16
2
1
15
28
29
26
13
3
14
27
31
32
21
10
24
14
13
12
11
10
9
8
7
6
5
4
5A
IP140
SWGLT
IGN
SWGRT
LIFTUP
LIFTDN
TELEIN
TELEOT
JIBIN
JIBOUT
JIBDN
JIBUP
ROTR
ROTL
LVLUP
LVLDN
STRT
AUX
500#
AXLE
GLOW
TEMP
OILP
ALT
BCSCAL
BCS
OVRLD
1000#
GND
IGN
ALTE
F
S365
S363
J4 (BLUE)
S364
RED 1-3A
1
BLK 000-03A
2
YEL/RED 2-8-1A
TELEMATICS 3
4
YEL/RED 2-2A Sheet_5 (Ground Box)-[7,C]
X361
Sheet_4 (T/T & Boom)-[8,B]
WHT 71-1 MSSO SW

E
RED 1-3B
B
J
5A YEL/RED 2-6
H
ADVANCED G IP102
DIAGNOSTIC F
YEL CAN2-HIGH
C CO239-J12
CONNECTOR GRN CAN2-LOW
D
BLK CAN2-SHIELD
1 J12 (BLACK)
E 2
BLK 000-9
A 5 CAN2S
X272 4 CAN2L
3 CAN2H
ORN/RED 49-16
6 CAN2T
7 CAN2T
WHT 71-1 MSSO SW
8
12 12 120
11 11 CO239-J7
BLK 000-25 (16) BLK CAN1-SHIELD
8 8 Sheet_5 (Ground Box)-[8,D] 18 CAN1S
RED/WHT 50-3 (16) GRN CAN1-LOW
7 7 Sheet_5 (Ground Box)-[8,D] 24 CAN1L
BLK 000-24-1 (16) YEL CAN1-HIGH
10 10 Sheet_5 (Ground Box)-[8,D] 13 CAN1H
RED/WHT 50-2-1 (16) YEL/RED 2-30-1
D SEE SHEET 3 9 9
ORN/RED 49-88
Sheet_5 (Ground Box)-[8,D] 3
ORN/RED 49-88
GNDMODE
4 4 12 BRKNCBL
ZONE H-8 5 5
YEL/RED 2-61
32
YEL/RED 2-61
IGN
BLK 000-26 BLK 000-26
3 3 19 GND
1 1 29 IGN 120
2 2 11 BMRTCL
6 6 35 BMRTOP
X244 X146 6 CANT
ORN/RED 49-17
17 CANT
BLK 000-9
12 5
BLK 000-03B YEL/RED 2-6
11 34 IGN
10 16
BLK 000-01 (12)
9
BLK 000-06
Sheet_4 (T/T & Boom)-[8,C]
YEL/RED 2-31
4 J7 (BLACK)
8 Sheet_4 (T/T & Boom)-[5,F] 23 GNDE
GROUND BUSS
BLK 000-38
7 [7,B] 30 IGN
BLK 000-08
6 7
BLK 000-05-1 (12) ORN/RED 49-102
5 Sheet_4 (T/T & Boom)-[3,A] Sheet_5 (Ground Box)-[4,H] 21 PTST
BLK 000-04 (12)
4 Sheet_4 (T/T & Boom)-[3,A] 10
BLK 000-45-1 (12)
3 20
BLK 000-39-1 (12)
2 25
BLK 000-2 (12)
1 8
BLK 117
MS96 GND
C
12
YEL/RED 2-8-1B (12)
CRIBBING
OPTION { Sheet_10 - [2,G]
Sheet_10 - [2,G]
RED 118
28
26
9
11 31
YEL/RED 2-8-7
10 33 VBAT
YEL/RED 2-8-5
9 [6,F] 27
YEL/RED 2-8-8
8 [7,B] 22
IGNITION BUSS

7 [7,C] 1 PLTS
6 Sheet_4 (T/T & Boom)-[5,F] 2 PLTE
YEL/RED 2-8-3 (12)
5 Sheet_4 (T/T & Boom)-[3,A] 14 GNDMODE
YEL/RED 2-8-4 (18)
4 Sheet_4 (T/T & Boom)-[8,C] 15 FTSWCL
YEL/RED 2-8-11 (12)
3
YEL/RED 2-8-10 (12)
2
YEL/RED 2-8-2 (12)
1
2
3
4
CO239-J8
1
MS95
1
2
BLK 000-2 (12)
YEL/RED 2-8-2 (12)
YEL/RED 2-30
YEL/RED 2-20
3
S218
4
5
6
CAN-2 LOW 7
B
CAN-1 REPEATER MODULE TO PLATFORM
CAN-2 HIGH 8
MOUNTED WITH GROUND MODULE
GRN CAN1-L_GTWY
CAN-1 LOW 9
YEL CAN1-H_GTWY
CAN-1 HIGH 10
BLK 000-08
GROUND 11
YEL/RED 2-8-7
IGNITION 12
CO75-J1
YEL/RED 2-3-4
YEL/RED 2-3
1
2
BLK CAN2-SHIELD
CAN-2 - SHIELD 3
4
5
YEL/RED 2-3
6 Sheet_5 (Ground Box)-[8,G]
YEL/RED 2-8-10 (12)
YEL/RED 2-8-11 (12)
YEL/RED 2-2B
BLK 000-39-1 (12)
BLK 000-45-1 (12)
7 Sheet_5 (Ground Box)-[8,G]

8
BLU 27-3-4
BLU 28-3-4
GRN CAN1(A)-LOW
PNK 25-3
PNK 26-3
CAN-3 LOW 9
YEL CAN1(A)-HIGH
CAN-3 HIGH 10
11
12
X46
CO75-J2 BOOM CABLE CONNECTOR

3
2
5
1
10
12
16
18
8
14
17
19
4
11
6
13
9
7
15

10
12
16
18
14
17
19
11
13
15
***120 RESISTOR ACROSS J2-9 & J2-10

3
2
5
1
9
7
X61
SHEET 5
8 7 6 5 4
7-98 3121262
5 4 3 2 1
JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER
TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH (CE ONLY)
MOMENT CONTROL TEST 500# CAP AXLE SET GLOW PLUG HIGH COOLANT LOW OIL NO ALTERNATOR MOMENT CNTL BOOM CONTROL PLATFORM 1000# CAP GENERIC
PUSH BUTTON LIGHT LIGHT LIGHT TEMP LIGHT PRES LIGHT OUTPUT LIGHT TEST LIGHT SYSTEM LIGHT OVERLOAD LIGHT GENERIC

SW228-1
SW228-2
SW358-1
SW358-2
1
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
SW223
SW222
SW225
SW226
SW227
LB229
LB230
LB231
LB232
LB233
LB234
LB235
LB236
LB237
LB238
H
YEL/RED 2-40-10
YEL/RED 2-40-05
ORN/RED 49-102
BRN 29-2
YEL/RED 2-40-05
BRN 30-2
YEL/RED 2-40-04
BLU 28-2
YEL/RED 2-40-04
BLU 27-2
YEL/RED 2-40-06
GRY 23-2
YEL/RED 2-40-06
GRY 24-2
YEL/RED 2-40-08
PNK 25-2
YEL/RED 2-40-08
PNK 26-2
YEL/RED 2-40-09
WHT/YEL 48-1
YEL/RED 2-40-09
BRN/ORN 53-2
YEL/RED 2-40-07
RED/YEL 54-4
BLK 000-31-11
BLK 000-31-10
WHT/YEL 39-1
BLK 000-31-10
BLK 000-31-09
WHT/YEL 48-6
BLK 000-31-09
BLK 000-31-08
BRN/WHT 47-6
BLK 000-31-08
BLK 000-31-07
BRN/WHT 47-5
BLK 000-31-07
BLK 000-31-06
BRN/WHT 47-8
BLK 000-31-06
BLK 000-31-05
ORN/RED 49-103
BLK 000-31-05
BLK 000-31-04
ORN/RED 49-101
BLK 000-31-04
BLK 000-31-03
ORN/RED 49-100
BLK 000-31-03
BLK 000-31-02
RED/YEL 54-5
BLK 000-31-02
BLK 000-31-01
BLK 72-2 MSSO GND

BLK 72-1 MSSO CONFIG
WHT 71-1 MSSO SW

G
YEL/RED 2-8-5
[2,B]
Sheet_5 (Ground Box)-[1,E]

BRN/WHT 47-9
BLK 72-1 MSSO CONFIG
ORN/RED 49-103
ORN/RED 49-101
ORN/RED 49-100
YEL/RED 2-40-01
BRN/WHT 47-6
BRN/WHT 47-5
BRN/WHT 47-8
BRN/ORN 53-2
BLK 000-31-01
YEL/RED 2-8-5
WHT/YEL 48-1
WHT/YEL 39-1
WHT/YEL 48-6
RED/YEL 54-4
RED/YEL 54-5
WHT 21-2
WHT 22-2
BRN 13-2
BRN 14-2
BRN 29-2
BRN 30-2
PNK 25-2
PNK 26-2
GRY 23-2
GRY 24-2
BLU 28-2
BLU 27-2
TAN 3-2
TAN 3-3
CO239-J4
CO239-J3
12
34
25
35
23
33
7
30
11
22
8
19
20
9
18
6
17
5
4
16
2
1
15
28
29
26
13
3
14
27
31
32
21
10
24
14
13
12
11
10
9
8
7
6
5
4
3
2
1
SWGLT
IGN
SWGRT
LIFTUP
LIFTDN
TELEIN
TELEOT
JIBIN
JIBOUT
JIBDN
JIBUP
ROTR
ROTL
LVLUP
LVLDN
STRT
AUX
500#
AXLE
GLOW
TEMP
OILP
ALT
BCSCAL
BCS
OVRLD
1000#
GND
IGN
ALTE
J3 (BLACK) F
SWGRT 35
J4 (BLUE) SWGLT 34
33
32
GND 30
28
GNDALRM 27
HEAD/TAIL 26
FUEL 25
24
23
LIFTDN 22
21 SEE SHEET 3 FOR
20
LIFTFLOW 19 OTHER CONNECTIONS
GND 17
MNTELEOUT 16
J2 (GRAY) 15
GND 14
E
MAINDMP 13
LIFTDNAUX 12
LIFTUP 11
LIFTPILOT 10
TELEFLOW 9
8
GND 6
CO239-J12 MNTELEIN 4
1 J12 (BLACK) HORN 2
BLK 000-25
2 GND 18 Sheet_5 (Ground Box)-[2,D]
RED/WHT 50-3
5 CAN2S JIB DMP 1 Sheet_5 (Ground Box)-[2,D]
BLK 000-24-1
4 CAN2L GND 29 Sheet_5 (Ground Box)-[2,D]
RED/WHT 50-2-1
3 CAN2H PLTDMP 3 Sheet_5 (Ground Box)-[2,D]
BLU 28-3-4
6 CAN2T JIBDNO/R 31
PNK 26-3
7 CAN2T PLVLDNO/R 7
PNK 25-3
8 PLVLUPO/R 5
120 CO239-J2
CO239-J7 X245
YEL/RED 2-5
18 CAN1S ANALP 28 1
24 CAN1L ANALR 29
ORN/RED 49-5
2 ANALYZER
ORN/RED 49-6
13 CAN1H ANALT 30 3
BLK 000-37
3 GNDMODE ANALG 31 4 D
12 BRKNCBL 35
32 IGN 34
BLK 72-2 MSSO GND
19 GND 33
29 IGN 120 27
11 BMRTCL 26
35 BMRTOP 25
6 CANT 24
BRN/WHT 47-9
17 CANT 21 X274 X271
BRN/WHT 47-8-1 BRN/WHT 47-8-2
5 ALTE 32
WHT/YEL 48-3 S86
5 5 ENGINE
34 IGN START 11 2 2
16 19 [3,E]
RED TP-CBL12
3 3
CONNECTOR #1
BLK TP-CBL12
4 J7 (BLACK) J1 (WHITE) 18 [3,E]
SHIELD TP-CBL12 S276
4 4
SEE SHEET 7
23 GNDE 17 [4,E] 6 6
YEL/RED 2-8-6
30 IGN 16 [2,B] 1 1 ZONE E-1
7 15
21 PTST 14
10 1
ORN 55-45
20 BRK 23 Sheet_4 (T/T & Boom)-[8,B]
ORN 55-47
25 2SPD 20 Sheet_4 (T/T & Boom)-[8,B]
BRN/ORN 53-3
8 AUXP 13 Sheet_4 (T/T & Boom)-[8,D]
28 GND 4
26 6 C
9 5
31 2
YEL/RED 2-1-88
33 VBAT 10 X266 X201
BLK 000-42 (16)
27 GND 8 2 2
WHT/YEL 48-8
22 SP 7 7 7
1 PLTS GEN 22
BLU/ORN 52-5
3 3
ENGINE
WHT/YEL 48-9
2 PLTE GLOW 12
BLK 000-22
4 4 CONNECTOR #2
14 GNDMODE GND 9 6 6
BLU 27-3-4
15 FTSWCL JIBUPO/R 3 1 1
CO239-J1 [2,B]
YEL/RED 2-8-8
5 5
SEE SHEET 7
WHT/YEL 48-7 (16)
8 8 ZONE F-1
1
2
3
4
CO239-J8
X93 (CAT ENGINE ONLY)

BLK 000-2 (12)
YEL/RED 2-8-2 (12)
WHT/YEL 48-7 (16)

1
[2,C]
BLK 000-38
2
ELECTRIC FUEL
PUMP CONNECTOR
LOCATED NEAR
FUEL TANK
B
Ground Box
BOOM CABLE CONNECTOR
A
SHEET 5 1001119266-V
5 4 3 2 1
MAF09730V
3121262 7-99
F
B
C
A
G
H
7-100
SN193
RED/WHT 50-4-2
B
ORN/RED 49-8
D
BLK 000-17-2
A
RED/WHT 50-5-2
F
ORN/RED 49-7
TURNTABLE
C
ANGLE SENSOR
BLK 000-18-2
E
8
8
LEFT FRONT RIGHT FRONT

STEER SENSOR STEER SENSOR
3
2
1
3
2
1
SN92
SN81
BLK
BLK
BLU
BLU
RED
RED
7
7
BLK 000-17-2
RED/WHT 50-4-2
X100 X107 S171
RED RED RED/WHT 50-4-1
1 1
BLU WHT
2 2
BLK BLK BLK 000-17-1
3 3
BRN/BLK BRN/BLK S119
4 4
X101 X110 CO21-J3

SWIVEL
RED RED BLK 000-16

1 1 1 12
COUPLING
VREF GND X22

BLU WHT WHT ORN/RED 49-10
2 2 2 FTRTSTR CANT 10 9 9 9 9
BLK BLK BLK 000-20 BLK 000-17-1 ORN/RED 49-10
3 3 3 GND CANT 9 10 10 10 10
BRN/BLK BRN/BLK S120 RED RED RED GRN
4 4 4 VREF CAN1H 6 1 1 1 1
WHT BLK BLK YEL
5 FTLTSTR CAN1L 7 2 2 2 2
120
BLK 000-20 SHIELD SHIELD BLK
6 GND CAN1S 8 3 3 3 3
BLK 000-19 YEL/RED 2-1 YEL/RED 2-1 RED (14)
9 GND IGN 5 4 4 4 4
WHT BLK 000-15 (14) BLK 000-15 (14) BLK (14)
8 RERTSTR 4 5 5 5 5
J3 (GREEN)
GND
BRN/BLK BRN/BLK RED YEL/RED 2-4
4 4 7 VREF 3 11 11 11 11
BLK BLK BLK 000-19 BLK 000-18-1 ORN/RED 49-106
3 3 12 GND 2 12 12 12 12
BLU WHT S121 WHT ORN 55-47-2 YEL
2 2 11 RELTSTR 1 6 6 6 6
RED RED YEL/RED 2-4 ORN 55-45 ORG
J1 (GRAY)
1 1 10 VREF IGN 11 7 7 7 7
ORN 60-2 VIO
SEE SHEET 4 ZONE B-6
X105 X111 CO21-J1 8 8 8 8

BLK 000-18-2 X26
BRN/BLK BRN/BLK
4 4
BLK BLK BLK 000-18-1
3 3
BLU WHT S122 BLK 000-17
2 2 GND 8
RED RED RED/WHT 50-5-1 BLK 000-14
1 1 GND 2
X106 X113 RED/WHT 50-5-2 S199 ORN 60-2
6 1
BLK 000-16
5 2
BLK
VALVE
4 V196
BLK
6
6
J4 (GRAY)
3
YEL/RED 2-1-3
OSC. AXLE LOCK-OUT
IGN 7
YEL/RED 2-1-2
IGN 1
BLK
BLU
RED
ORN 55-45
BLK
BLU
RED
CO21-J4 1
BLK 000-17
2
CHASSIS MODULE
VALVE
BRAKE
V195
CO21-J5
YEL 9-1
SN99
SN98
4 LTFTSTRRT 10
3
2
1
3
2
1
YEL 9-2 ORN/RED 49-8
2 RTFTSTRLT TTANG2 9
YEL 10-2 ORN/RED 49-7 ORN 55-47-2
1 RTFTSTRRT TTANG1 8 1
YEL 10-1 ORN/RED 49-106 BLK 000-14
3 LTFTSTRRT DOS 6 2
VALVE
YEL 11-1 V194

8 LTRESTRLT 2
TWO SPEED
YEL 11-2
6 RTRESTRLT 1
YEL 12-2 ORN/RED 49-104
5 RTRESTRRT FAXLS 4
YEL 12-1 ORN/RED 49-105
J5 (RUST)
7 5
J2 (BLACK)
LTRESTRRT RAXLS
BLK 000-12-01 YEL/WHT 40-2-44-1
12 GND AXLRT 12
BLK 000-13-1
RIGHT REAR LEFT REAR 10 GND 3
YEL/WHT 39-2-43-1
SN176
STEER SENSOR STEER SENSOR 11 AXLET 11

2
1
STEER LEFT STEER LEFT YEL/RED 2-1-4 ORN/RED 49-107

9 IGN AXLPR 7
RIGHT FRONT LEFT FRONT CO21-J2
FRONT AXLES
RETRACT
BLK 000-12-01
PROXIMITY SENSOR
2
1
2
1
DRIVE ORIENTATION
V165
V164
S170
1
2
V166
YEL 9-2
YEL 9-1

5
5
BLK 000-12-05
BLK 000-12-03
BLK 000-13-4
YEL/WHT 40-2
BLK 000-12-04
BLK 000-12-02
BLK 000-12-02
S168
ORN/RED 49-105
YEL/RED 2-1-2
ORN/RED 49-104
YEL/RED 2-1-3
BLK 000-13-5
YEL/WHT 39-2
BLK 000-12-06
YEL 10-2
BLK 000-12-07
YEL 10-1
S192
S190
S189
S187
V167
2
1
V163
V162
2
1
2
1
S191
S188
FRONT AXLES
BLK
BLK
BLK
BLK
WHT
WHT
WHT
WHT
EXTEND RIGHT FRONT LEFT FRONT
BLK 000-13-4
BLK 000-13-5
STEER RIGHT STEER RIGHT
S174
STEER LEFT STEER LEFT
REAR AXLES RIGHT REAR LEFT REAR
4
4
RETRACT
WHT
2
1
2
1
1
2
BLK
V159
V153
BLK 000-13-3
V161
LEFT FRONT AXLE
YEL/RED 2-1-4
ORN/RED 49-107
EXTEND LIMIT SWITCH
YEL 11-2
YEL 11-1
BLK 000-12-09
BLK 000-12-08
BLK 000-13-6
YEL/WHT 44-1
SN178
1
3
SHEET 6
3121262
5 4 3 2 1
H
LEFT FRONT AXLE RIGHT FRONT AXLE LEFT REAR AXLE RIGHT REAR AXLE
EXTEND LIMIT SWITCH EXTEND LIMIT SWITCH RETRACT LIMIT SWITCH RETRACT LIMIT SWITCH
WHT
BLK
WHT
BLK
WHT
BLK
WHT
BLK
G
YEL/RED 2-1-3 WHT

S187 BLK
S188 WHT
ORN/RED 49-104 BLK
S189
YEL/RED 2-1-2 WHT
S190 BLK
S191 WHT
ORN/RED 49-105 BLK
S192
PRESSURE SWITCH
F
AXLE LOCK OUT
ORN/RED 49-107
3
YEL/RED 2-1-4
1
SN178
BLK 000-12-04
BLK 000-12-01 BLK 000-12-02
YEL/WHT 39-2-43-1
S170
BLK 000-12-02
BLK 000-12-04
YEL/WHT 40-2-44-1
D
S168
S169
S172
STEER RIGHT
STEER RIGHT
LEFT FRONT
LEFT FRONT
YEL 9-1 YEL 10-1 YEL 11-1 YEL 12-1

STEER LEFT
STEER LEFT
LEFT REAR
LEFT REAR
1 1 1 1
BLK 000-12-03 BLK 000-12-07 BLK 000-12-08 BLK 000-12-10
YEL/WHT 39-2
YEL/WHT 43-1
2 2 2 2
V164 V162 V153 V123
S173
RIGHT FRONT
RIGHT FRONT
STEER RIGHT
STEER RIGHT
RIGHT REAR
RIGHT REAR
YEL 9-2 YEL 10-2 YEL 11-2 YEL 12-2

STEER LEFT
STEER LEFT
1 1 1 1
BLK 000-12-05 BLK 000-12-06 BLK 000-12-09 BLK 000-12-11
2 2 2 2
V165 V163 V159 V124
YEL/WHT 40-2
YEL/WHT 44-1
C
FRONT AXLES
FRONT AXLES
REAR AXLES
REAR AXLES
BLK 000-13-4 YEL/WHT 39-2 BLK 000-13-6 YEL/WHT 43-1

RETRACT
RETRACT
2 1 2 1
EXTEND
EXTEND
YEL/WHT 40-2 BLK 000-13-5 YEL/WHT 44-1

1 2 1 2
V166 V167 V161 V160
BLK 000-13-5 BLK 000-13-2

BLK 000-13-4 BLK 000-13-3 BLK 000-13-3 BLK 000-13-1
S174 BLK 000-13-6 S175
Chassis B
SHEET 6 1001119266-V
5 4 3 2 1
MAF09740V
3121262 7-101
5 4 3 2 1
H H
GLOW PLUGS
IN HEAD
WHT/YEL 48-13 (8)
1
EC91
GLOWPLUG START
RELAY RELAY
ENGINE TRAY ENGINE

PIVOT PIN BLOCK
1
1
X268
X269
X270
85
86
30
87
85
86
30
87
RL197-86
RL198-85
RL197-85
RL198-86
RL198-30
RL198-87
RL197-30
RL197-87
1
1
G G
BLK (1/0)
BLK (14)
BLK (1/0)
BLK (1/0)
BLK (14)
BLK (14)
WHT/YEL 48-9
RED (1/0)
RED (1/0)
WHT/YEL 48-13 (8)
BLK (14)
WHT/YEL 48-3
RED (1/0)
RED (1/0)
WHT/YEL 48-12 (12)

1
EC204-B-
STARTER
WHT/YEL 48-12 (12)
12V
1
BLK (1/0) EC204
RED (1/0) RED (1/0)
RED (8)
1 M
EC204-B+
X266 X201
WHT/YEL 48-9
ENGINE 4 4
5 5
CONNECTOR #2 1 1
F 3 3 F
SEE SHEET 5 6 6
BLK 000-21
2 2
ZONE C-1 7 7
8 8
S261 EC203-B+
#12_FUSE-LINK (12)
1 B+
ALTERNATOR
14V, 95A
EC203-D+
BRN/WHT 47-8
1 D+
EC203-W
1 W
E E
CO133-J1
BLK 000-21
1 25
4 24
5 23
6 22
7 21
8 20
ENGINE 6 6
WHT/YEL 48-3
9 19
2 2 15 18
CONNECTOR #1 5 5
BRN/WHT 47-8
16 17
BLK BLK
4 4 13 16
SEE SHEET 5 3 3
RED RED
12
DEUTZ 15
YEL/RED 2-1-99 YEL/RED 2-1-99 BLK 2-1-99
ZONE D-1 1 1
S265
14
EMR2
14
X274 X271 18 13
19 12
DEUTZ A
20
MODULE 11
BLK 000-1 BLK 000-1
B 2 10
DIAGNOSTIC K
11 9
PORT L 10 8
D X273 21 7 D
22 6
23 5
24 4
25 3
3 2
17 1
CO133-J2
RIGHT SIDE RIGHT SIDE

DRIVE FORWARD DRIVE REVERSE
C Deutz Engine - EMR2 C

1
2
1
2
V277
V278
ORN 7-3-2
BLK 000-22-5
ORN 7-2-2
BLK 000-22-4
5 5
ORN 7-3-2
4 4
ORN 7-2-2
PUMP 3 3
BLK 000-22-5
CONNECTOR 6 6
BLK 000-22-1 BLK 000-22-4
S103 BLK 000-22-3
SEE SHEET 4 BLK 000-22-2
ORN 8-2-2
CONNECT TO X56 1 1
ORN 8-3-2
2 2
X56 X62
BLK 000-22-2
BLK 000-22-3
B B
ORN 8-3-2
ORN 8-2-2
V279
V280
1
2
1
2
DRIVE FORWARD DRIVE REVERSE

LEFT SIDE LEFT SIDE
A A
SHEET 7 1001119266-V
5 4 3 2 1
MAF09750V
7-102 3121262
3121262 7-103
8 7 6 5 4
H
LEFT FRONT RIGHT FRONT
LIGHT LIGHT
HEAD & TAIL LIGHT
RELAY
(OPTION)
1
87a
7500W GENERATOR
86
85
30
87
5
CONTROL BOX
2
3
1
4
C
B
WHITE
WHITE
BLACK
BLACK
BLACK
WHITE
YEL/RED 2-8-8
BLU/ORN 52-5
BLK 000-22
WHITE
RED 1-1 (12)
WHITE
CONNECT TO X147 BLU/ORN 52-12

1
IN TURNTABLE
X201
CONNECT TO B- BLACK 4
G 1
ENGINE 5
YEL/RED 2-8-8 5A
ON ENGINE TRAY 1 IP328
CONNECTOR #2 3
BLU/ORN 52-5
BLK 000-22
CONNECT TO B+ #14 FUSIBLE LINK 6
1
REFERENCE ONLY 2
ON AUX POWER RELAY 7 WIRES INSERTED ON ASSY LINE
8
BLACK
CONNECTED TO B- 1
BLACK (12) BLACK
7500W GENERATOR
ON AUX POWER RELAY
BLACK
BLACK
BLACK
WHITE
WHITE
WHITE
1
F
LEFT REAR RIGHT REAR 110V GENERATOR
LIGHT LIGHT RELAY
PARKER SENSOR
87a
(OPTION)
86
85
30
87
HEAD & TAIL LIGHTS &
1500W POWERMITE X1
CHASSIS ILLUMINATION 5
2
3
1
4
CONNECTOR 1
YEL/RED EMS GND 2-1-5
BLK GND
1
2
3
4
2
BLK CAN L
3
RED CAN H
4
BLACK
RED 1-3 (12)

BLU/ORN 52-6 NC
BLACK
BLU/ORN 52-6
WHITE
GREEN
E 2
YEL/RED 12AWG YEL/RED 12AWG
2
X2
BLK 12AWG BLK 12AWG YEL/RED EMS GND 2-1-4
BLU/ORN 52-5
1
BLK 16AWG BLK 16AWG
1 CONNECT TO J8 2
BLK GND
J8 J8_1 1
SHT 2 ZONE C-4
P-J8
MOLEX
X201 042816-0212
4
#14GA FUSIBLE LINK CONNECT TO B+ SIDE OF
ENGINE 5 1
3A
1
START OR AUX POWER RELAY
CONNECTOR #2 3
IP312
3A
6
REFERENCE ONLY 2
BLACK
1
CONNECT TO B-
ON ENGINE TRAY
IP313
7
8
BLK 16AWG
BLK 16AWG
2500W GENERATOR
D
LIGHTS
1 1
2 2
3 3
4 4
LIGHTS_1
INSIDE CONSOLE BOX

2 2
BLK 12AWG BLK 12AWG
1 1
YEL/RED 16AWG
J8 BLK 16AWG BLK 16AWG J8_1

BLK 16AWG
3A
IP324
3A
C
IP325
PLATFORM FLOOD LIGHTS
BLK 16AWG
BLK 16AWG
1
ON/OFF SWITCH
YEL/RED 16AWG
2
YEL/RED 16AWG
3
4
5
6
SWITCH
LIGHTS
S402
1 1
2 2
3 3
4 4
LIGHTS_1
BLK 16AWG
YEL/RED 16AWG
FLOOD_1 INSIDE CONSOLE BOX
1 1
BLK 16AWG
2 2
BLK OR BRN
BLK OR BRN
LED FLOODLIGHT
TRAPEZOID BEAM PATTERN
B MOUNTED ON RAIL CORNER MOUNTED ON RAIL CORNER
RED
RED
S401
FLOOD_2
YEL/RED 16AWG BLK OR BRN RED
1 1
BLK 16AWG RED BLK OR BRN
2 2
LED FLOODLIGHT LED WORKLIGHT

SPOT BEAM PATTERN
TRAPEZOID BEAM PATTERN SPOT BEAM PATTERN
LED WORKLIGHT
PLATFORM FLOOD LIGHTS PLATFORM WORK LIGHTS

(OPTION) (OPTION)
SHEET 8
8 7 6 5 4
7-104 3121262
5 4 3 2 1
H
PLATFORM SENSOR
(OPTION)
7500W GENERATOR
RL502-87
CONTROL BOX SHEET 2 YEL/RED P3 YEL/RED P3
1
87
[F,4]
A
C
B
RL502-30
YEL/RED P9-1 30
1
RL502-87A
87a
1
RL502-85
YEL/RED 2-8-8
BLU/ORN 52-5
BLK 000-22
ORN/RED P5 85
1
ORN/RED P5-1
RL502-86
ORN/RED P4 86
1
PLATFORM SENSOR ORN/RED P4-1
ORN/RED P4
4
3 ORN/RED P5
YEL/RED 2-8-8
IP328
5A
2
BLK P6 SHEET 2
[B,5]
G
YEL/RED P10 YEL/RED P2 SHEET 2
BLU/ORN 52-5 1
R501 [A,3]
BLK 000-22
WIRES INSERTED ON ASSY LINE RL503-87

SHEET 3 YEL/RED P1 YEL/RED P1 87
[B,7] 1
YEL/RED P9 YEL/RED P9
[B,5] RL503-30
YEL/RED P9-1 30
1
RL503-87A
7500W GENERATOR SHEET 2
1
87a
[B,6]
RL503-85
ORN/RED P5-1 85
1
RL503-86
ORN/RED P4-1 86
1
LOW TEMPERATURE CUTOUT OPTION P-J8A

X3 F
YEL/RED EMS GND 2-1-3 CONNECT TO P8 2
BLK GND
(MATING CONNECTOR OF J8)
1
MOLEX SHT 2 ZONE C-4

042818-0212
(OPTION)
PARKER SENSOR
1500W POWERMITE X1 YEL/RED EMS GND 2-1-3
CONNECTOR 1
YEL/RED EMS GND 2-1-5 YEL/RED EMS GND 2-1-4
BLK GND S531
1
2
3
4
2
3
BLK CAN L
RED CAN H BLK GND
BLK GND
BLK GND
X4
4 B
CONNECT TO X1002
NC S532 A
BLACK C SHT 2 ZONE D-2
BLK CAN L
BLU/ORN 52-6
BLK CAN L BLK CAN L DEUTSCH

WHITE
RED CAN H
GREEN
RED CAN H
S533 JLG PN 4460536
RED CAN H
S534
SHIELD CANSHD X5
SHIELD CANSHD SHIELD CANSHD B
CONNECT TO X1001
X2 A
SHT 2 ZONE D-2
E
S535 C
YEL/RED EMS GND 2-1-4
CONNECT TO J8 2
BLK GND
SHT 2 ZONE C-4 1 DEUTSCH
P-J8 JLG PN 4460539
MOLEX LTC OPTION BOOM HARNESS
042816-0212
#14GA FUSIBLE LINK CONNECT TO B+ SIDE OF
1
START OR AUX POWER RELAY
BLACK
1
CONNECT TO B-
ON ENGINE TRAY

2 2
BLK 12AWG BLK 12AWG
1 1
J8 BLK 16AWG BLK 16AWG J8_1
4000W GENERATOR GENERATOR
CONTROL
BOX
B A C
3A
IP324
3A
C
BLACK
IP325
BLU/ORN 52-5
BLK 16AWG
BLK 16AWG
SEE SHEET5, ZONE B3

BLU/ORN 52-5
SEE SHEET5, ZONE B3
SEE SHEET6, ZONE B6
SEE SHEET6, ZONE B6

LIGHTS
1 1
2 2
3 3
4 4
LIGHTS_1
INSIDE CONSOLE BOX

BLK OR BRN
BLK OR BRN
MOUNTED ON RAIL CORNER B

RED
RED
RED
BLK OR BRN Accessories
LED WORKLIGHT
SPOT BEAM PATTERN
PLATFORM WORK LIGHTS

(OPTION)
SHEET 8 1001119266-V
5 4 3 2 1
MAF09760V
3121262 7-105
8 7 6 5 4
ECM-J2 X999 X1003 EIC BUSSMANN DIODE PACK

BLK 248-33 INJECTOR 1 BLK 248-33 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT)
33 1 1 62 (BLUE)
BLK 248-16 INJECTOR 1 BLK 248-16 INJECTOR 1 1.5mm² YELLOW CONNECTOR GLOWPLUG SOLENOID
16 2 2 35
BLK 248-48 INJECTOR 4 BLK 248-48 INJECTOR 4 1.5mm² GENERIC 150 AMP
48 3 3 42
BLK 248-18 INJECTOR 4 BLK 248-18 INJECTOR 4 1.5mm² RELAY, POWER MODULE
18 4 4 37
H 32
BLK 248-32 INJECTOR 3
BLK 248-2 INJECTOR 3
5 5
BLK 248-32 INJECTOR 3 1.5mm²
BLK 248-2 INJECTOR 3 1.5mm²
38
5A 10A
2 6 6 61
BLK 248-46 INJECTOR 2 BLK 248-46 INJECTOR 2 1.5mm²
46 7 7 40
BLK 248-3 INJECTOR 2 BLK 248-3 INJECTOR 2 1.5mm²
3 8 8 41
87
30
86
BLK 248-5 MPROP ACTUATOR
6 9 9 2
BLK 248-4 MPROP ACTUATOR BLK 248-5 MPROP ACTUATOR 1.5mm²
5 10 10 20
MS932
RL930-B+
RL931-87
RL931-87
RL931-30
RL931-86
BLK 248-19 EXH GAS RECIRC BLK 248-4 MPROP ACTUATOR 1.5mm²
RL931-87
RL930-1
RL930-2
D
H
G
A
C
B
1
2
1
E
F
4 11 11 19
RL930
BLK 248-20 EXH GAS RECIRC BLK 248-37 ENGINE SPEED CAMSHAFT 0.75mm²
37 12 12 14
BUSBAR
BLK 248-52 ENGINE SPEED CAMSHAFT 0.75mm²
BLK 248-23 GLOW SENSE 0.75mm²
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

52 13
YEL 2-1-99 IGNITION 18AWG

ORG 248-23-1 GLOW SENSE 18AWG
SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm²
53 9
150A
BLK 248-39 ENGINE SPEED CRANKSHAFT 0.75mm²
39 15

BLK 248-54 ENGINE SPEED CRANKSHAFT 0.75mm²
54 21
RED 1-148-135 ECM PWR 8AWG

X1000 X1004
WHT 48-96 FUEL PUMP 14AWG


BLK 248-37 ENG CAM SHLD 248-38 ENGINE SPEED CRANKSHAFT 0.75mm²
38 1 1 1
RED 48-14 GLOW 8AWG
RED 48-13 GLOW 8AWG

BLK 148-7 RAIL PRESSURE FUEL BLK 248-52 ENG CAM BLK 248-7 RAIL PRESSURE FUEL 0.75mm²
7 2 2 32
BUSBAR
SHLD 248-53 ENG CAM
8 3 3 57
BLK 248-39 ENG CRANK
9 4 4 3
BLK 248-54 ENG CRANK
10 5 5 4
SHLD 248-38 ENG CRANK
11 6 6 5
12 7 7 6
13 8 8 7
14 9 9 8
A [J2] 15 10 10 10
17 11 11 11
G ECM CONNECTOR 19 12 12
BLK 248-19 EHXAUST GAS RECIRCULATION 1.5mm²
47
EIC (ENGINE INTERFACE CONNECTION)

20 48
21 12
22 59
BLK 248-23 GLOW SENSE
S946
23 X1001 X1005 16
BLK 248-24 BOOST PRESSURE / TEMP 0.75mm² BLK 248-24 BOOST PRESSURE / TEMP 0.75mm²
24 1 1 22
BLK 248-25 RAIL PRESSURE FUEL 0.75mm² BLK 248-25 RAIL PRESSURE FUEL 0.75mm²
25 2 2 31
BLK 248-26 RAIL PRESSURE FUEL 0.75mm² BLK 248-26 RAIL PRESSURE FUEL 0.75mm²
26 3 3 25
BLK 248-27 BOOST PRESSURE / TEMP 0.75mm² BLK 248-27 BOOST PRESSURE / TEMP 0.75mm²
27 4 4 29
BLK 248-28 COOLING TEMPERATURE 0.75mm² BLK 248-28 COOLING TEMPERATURE 0.75mm²
28 5 5 24
BLK 248-29 OIL PRESSURE 0.75mm² BLK 248-29 OIL PRESSURE 0.75mm²
29 6 6 27
30 7 7 33
31 8 8 60
BLK 148-61 FUEL LOW PRESSURE 0.75mm²
34 9 9 17
BLK 248-35 GLOW RELAY CONTROL GND
35 10 10 18
36 11 11 58
1 12 12 30
BLK 248-40 AIR INLET TEMP BLK 248-40 AIR INLET TEMP 0.75mm²
40 28
BLK 148-56 AIR INLET TEMP 0.75mm²
41 34
42 36
BLK 248-43 OIL PRESSURE BLK 248-43 OIL PRESSURE 0.75mm²
43 23
BLK 248-44 OIL PRESSURE BLK 248-44 OIL PRESSURE 0.75mm²
44 26
45 39
F 47 43
49 44
50 45
51 46
BLK 148-72 THROTTLE FLAP 3 0.75mm²
55 49
56 50
BLK 148-38 THROTTLE FLAP 4 0.75mm²
57 52
58 51
59 53
60 54
55
56
ECM-J1
1.5MM (7,29,51,73) 7
8
9
10
11
12
BLK 148-13 COOLANT LEVEL SIG
13
S951
14
E 15
BLK 148-15-68 CLUTCH SWITCH
16
17
S952
18
19
20
21
22
23
24
25
BLK 148-26 FUEL PUMP RELAY CONTROL GND
26
27
28
1.5MM (7,29,51,73) BLK 148-29 COOLANT LEVEL PWR
29
30
31
32
33
34
35
36
37 X1002 X1006
D 38
BLK 148-38 THROTTLE FLAP 4
1 1
39 2 2
40 3 3
41 4 4
42 5 5
43 6 6
BLK 148-44 EXH GAS RECIRC
44 7 7
45 8 8
46 9 9
47 10 10
48 11 11
49 12 12
50
1.5MM (7,29,51,73) 51
52
GRN CAN 2 LO DIAG CAN LOW S968
53
YEL CAN 1 HI CUSTOMER CAN HIGH
54
55 S953
BLK 148-56 AIR INLET TEMP
56
BLK 148-57 WATER IN FUEL SW RTN
57
K [J1] 58 X965
YEL CAN 2 HI 120 OHM
59 A A
ECM CONNECTOR 60
GRN CAN 2 LO
B B
C 61
BLK 148-61 FUEL LOW PRESSURE
C C
62 X966
63
BLK 148-64 WATER IN FUEL SW
64
65
66
67 X955
BLK 148-15-68 CLUTCH SWITCH YEL CAN 1 HI 120 OHM
68 A A
GRN CAN 1 LO
69 B B
70 C C
71 X956
BLK 148-72 THROTTLE FLAP 3
72
1.5MM (7,29,51,73) 73
74 S969
YEL CAN 2 HI DIAG CAN HIGH
75
GRN CAN 1 LO CUSTOMER CAN LOW
76
77 S954
X1008 X1010
YEL CAN 2 HI
78 1 1
GRN CAN 2 LO
79 2 2
80 3 3
YEL CAN 1 HI
81 4 4
BLK 148-82 EXH GAS RECIRC GRN CAN 1 LO
82 5 5
SHLD CAN 1 SHLD
83 6 6
B 84 7 7
BLK 148-85 EXH GAS RECIRC
85 8 8
86
BLK 148-87 COOLANT LEVEL GND
87
BLK 148-88 IGNITION
88
89
90
91
92
93
94
RED 148-5 ECM PWR 2.5mm²
5 S944 X1007
RED 148-3 ECM PWR 2.5mm²
3 1 1
RED 148-1 ECM PWR 2.5mm² X1009
1
2.5MM (1-6) BLK 148-2 ECM GND 2.5mm²
2 S945
BLK 148-4 ECM GND 2.5mm²
4
BLK 148-6 ECM GND 2.5mm²
6
SHLD CAN 1 SHLD
NC
SHEET 9
8 7 6 5 4
7-106 3121262
5 4 3 2 1
BUSSMANN DIODE PACK

FUEL PUMP 20A (SW), ECM 30A (CONT)
Deutz Engine
(BLUE)
YELLOW CONNECTOR GLOWPLUG SOLENOID GLOWPLUGS
GENERIC 150 AMP
RELAY, POWER MODULE
H
5A 10A
GENERIC
Tier 4 Final
87
30
86
85
GENERIC
ALTERNATOR
B+
MS932
RL930-B+
RL931-85
RL931-87
RL931-87
RL931-30
RL931-86
RL931-87
W
RL930-1
RL930-2
D
H
G
A
C
B
1
2
1
2
E
F
L
RL930
EC18
BUSBAR
EC241-B+
EC241-W
EC241-L
1
1
BLK 248-23 GLOW SENSE 0.75mm²
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²

BATTERY
150A
RED 1-148-135 ECM PWR 8AWG
RED 47-8 ALT EXCITE 16AWG


RED 48-14 GLOW 8AWG
RED 48-13 GLOW 8AWG
RED 48-13 GLOW 8AWG

RED 48-14 GLOW 8AWG
POSITIVE
BUSBAR
RED - - 4AWG
BUSBAR
RED - - 2/0AWG
X923
RED - - 2/0AWG
1
150A
G
BUSBAR
EC971-B+
1 M
S946
EC971
GENERIC
GENERIC
1
EC971-B-
1
RL974
WHT 48-3 START 18AWG
1 DEUTZ PROVIDED
BLK 000-48-4 ENG GND
2
START RELAY
X901
1 VSW
WHT 48-3 START 18AWG START
2
YEL CAN 1 HI CUSTOMER CAN HIGH CAN + (HI)
3
GRN CAN 1 LO CUSTOMER CAN LO
4 CAN - (LOW) ENGINE CONNECTOR #1
RED 47-8 ALT EXCITE 16AWG
5 ALT EXCITE TO SHEET 5, D1
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD CAN SHIELD
6
F
X902
YEL 2-1-99 IGNITION 18AWG EMR4 IGNITION
1
2 GROUND
3 GENERATOR ENABLE
4 GLOW
5 GENERATOR POWER ENGINE CONNECTOR #2

6 GENERATOR GROUND TO SHEET 5, C1
7 PLUGGED
8 PLUGGED
S951
E
S952
X950
YEL 2-48-2 IGNITION
A
B
C
D
E
GRN CAN 1 LO CUSTOMER CAN LO
F
GRN CAN 2 LO DIAG CAN LOW
S963 S964 YEL CAN 2 HI DIAG CAN HIGH
G DEUTZ DIAGNOSTIC
H
J
K
L
YEL CAN 1 HI CUSTOMER CAN HIGH
M D
X960
YEL CAN 2 HI DIAG CAN HIGH 120 OHM
A A
GRN CAN 2 LO DIAG CAN LOW
B B
C C
X961
SN939 PWR
BLK 148-29 COOLANT LEVEL PWR 0.75mm²
NORMALLY CLOSED
1
COOLANT LEVEL
BLK 148-13 COOLANT LEVEL SIG 0.75mm²

3 SIG
BLK 148-87 COOLANT LEVEL GND 0.75mm²
2
4
GND
C
X941 X942
WIF SWITCH
BLK 148-64 WATER IN FUEL SW 0.75mm² BLK 148-64 WATER IN FUEL SW 16AWG
1 1 1
BLK 148-57 WATER IN FUEL SW RTN 0.75mm² BLK 148-57 WATER IN FUEL SW RTN 16AWG
2 2
2
SN959
WATER IN FUEL
3 3
BLK 000-48-1 ENG GND 14AWG BLK 000-48-1 ENG GND 14AWG
4 4
FUEL PUMP
1
M
EC958
2 FUEL PUMP
X958A EC958+
WHT 48-96 FUEL PUMP
FUEL PUMP
1 1
2
EC958- M
1
X1008 X1010
BLK 000-48-2 ENG GND T920 2 x 5mm 14 AWG RING
YEL CAN 2 HI
1 1
BLK 000-48-1 ENG GND 14AWG
1 GND
GRN CAN 2 LO
2 2
3 3 3/8" 10-12 AWG RING
YEL CAN 1 HI
4 4 X1011
GRN CAN 1 LO BLK 000-148-246 ECM GND 8AWG
5 5 1
SHLD CAN 1 SHLD
6 6
7 7 3/8" 8 AWG RING B
8 8
SHEET 9 1001119266-V
5 4 3 2 1
MAF09770V
3121262 7-107
F
B
C
A
G
H
7-108
BEACON MODULE
12
WHT - CAN SHIELD
11
BLK - CAN LOW
10
RED - CAN HIGH
9
8
8
8
7
6
5
4
3
2
1
X2
X5
RED - CAN HIGH
1
BLK - CAN LOW
3
WHT P1 87 WHT - CAN SHIELD
5
2
1
WHT P9-1 30 RED - CAN HIGH
2
X3
87a BLK - CAN LOW
4
WHT P5-1 85 WHT - CAN SHIELD
6
RED - CAN HIGH
RELAY #1
WHT P4-1 86 11
PLTFM SNSR
BLK - CAN LOW
RL503 9
WHT - CAN SHIELD
7
RED - CAN HIGH
12
7
7
BLK - CAN LOW

ALERT BEACON OPTION
10
WHT - CAN SHIELD
BLK - GROUND
8 RED - BEACON PWR
IP144
18 OHM
TO ENG DIAG CONN (ORIGINAL)
RL502 J
WHT P4-2 WHT - IGNITION
WHT P5-2 86 H
85 G
NOTE:
87a F
WHT P9-2 WHT - CAN SHIELD
30 E
RELAY #2
WHT P3 BLK - CAN LOW
D
PLTFM SNSR
87 RED - CAN HIGH
C
RED - BATTERY
S1
B
BLK - GROUND
A
X9
CAN TERMINATOR
WHT - CAN SHIELD
C
S191
S192
BLK - CAN LOW
B
RED - CAN HIGH
HARNESS,GEN 2 PLAT INTERFACE

A
6
6
BLK - GROUND
X7
TO ENG DIAG CONN (NEW)

X500
6 PIN CONNECTOR AND RELAYS LOCATED

WHT P5 J
4 4 WHT - IGNITION S3
WHT P4 H
3 3
WHT P6 G
2 2 F
WHT P10 WHT - CAN SHIELD
1 1 E
PLTFM SNSR
ON THE LEFT SIDE OF THE CONTROL PLATFORM BOX.

BLK - CAN LOW
D
RED - CAN HIGH
C
RED - BATTERY
B
WHT - IGNITION
BLK - GROUND
RED - BEACON PWR
IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE, SEE SHEET 8.

BLK - GROUND S2
A
X4
X1
1
2
3
4
5
6
7
8
9
10
11
12
WHT P3
WHT P2
WHT P1
WHT P6
X5B
5
4
1
3
2
6

INTERFACE
GEN 2 PLAT
5
5
TO X5A
BEACON MODULE
SHEET 2 [A,8]
4
4
SHEET 10
3121262
5 4 3 2 1
CRIBBING HARNESS OPTION
TO CRIBBING MODULE - J2 TO CRIBBING MODULE- J1 H
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
X878
X383
CRIBBING ENABLE LAMP
YEL CANH_5
GRN CANL_7
RED 103
BLK 102
RED/ORN 116
BLK/ORN 114
1
2
LB373
BLK 113
BLK/ORN 114
G
CRIBBING ENABLE SW
SW374
RED 115
BLK 102 S369 BLK 117
J7 28 CONNECT TO
RED 103 BLK BLK RED 118 J7 33 GROUND CONTROLLER (SHEET 5)
S370 S371
IP914
MS377-3 INLINE FUSE 5A
GRN CANL_7
1
YEL CANH_5
2
YEL CANH_6 YEL CANH_6 CONNECT TO
2 J7 13
GRN CAN1-LOW
MS377-2 1
GRN CANL_8 GRN CANL_8 J7 24 GROUND CONTROLLER (SHEET 5)
1
YEL CAN1-HIGH
2 MS377-1 F
EXTRACT WIRES FROM
GROUND CONTROLLER J7-13 & J7-24
AND CONNECT AS SHOWN
(SEE SHEET 5)
(EXISTING HARNESS)
SHEET 10 1001119266-V
5 4 3 2 1
MAF09780V
3121262 7-109
NOTES:
7-110 3121262
3121262
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417
Visit our website for JLG Worldwide Locations

www.jlg.com

N 1500SJ JLG Service Manual English

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N 1500SJ JLG Service Manual English

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Service and Maintenance Manual

May 24, 2019 - Rev N

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 - September 12, 2011

SECTION NO. TITLE PAGE NO.

SECTION NO. TITLE PAGE NO.

SECTION NO. TITLE PAGE NO.

SECTION NO. TITLE PAGE NO.

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SECTION NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

FIGURE NO. TITLE PAGE NO.

TABLE NO. TITLE PAGE NO.

TABLE NO. TITLE PAGE NO.

Capacity - ANSI Turning Radius (Axles Retracted)

Capacity - CE & Australia Turning Radius (Axles Extended)

Wheelbase 12ft. 6in. (3.81 m)

Tailswing 5ft. 5-7/8 in. (1.6 m)

Ground Clearance (Axle) 12 in. (30.4 cm)

Ground Clearance (Chassis) 25.5 in. (64.7 cm)

1.3 CAPACITIES 1.5 ENGINE DATA

Table 1-9. Mobilfluid 424 Specs

1.7 MAJOR COMPONENT WEIGHTS

Type Synthetic Biodegradable

at 100° C 7.8 cSt Swing Drive 290 132

Type Synthetic Biodegradable Platform 36 x 96 245 111

ISO Viscosity Grade 46 Platform 36 x 72 195 89

Specific Gravity 32.1 Boom Telescope Cylinder 1432 650

Figure 1-1. Maintenance and Lubrication Diagram

1.8 OPERATOR MAINTENANCE 2. Swing Gearbox

Table 1-16. Lubrication Specifications.

b. Swing Gearbox (SN 0300254532 to Present)

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-

1. Swing Bearing - Remote Lube

3. Swing Brake 4. A. Wheel Drive Hub - Bonfiglioli

Lube Point(s) - Level/Fill Plug

B: Wheel Drive Hub - Reggiana Riduttori

Lube Point(s) - Level/Fill Plug

5. Hydraulic Return Filter 7. Hydraulic Oil

FULL LEVEL (HOT OIL)

Lube Point(s) - Fill Cap

Lube Point(s) - Replaceable Element

9. A. Oil Change w/Filter - Deutz 2011

Lube Point(s) - Replaceable Element

B. Fuel Filter - Deutz TCD2.9 12. Fuel Pre-Filter TCD2.9

Lube Point(s) - Replaceable Element

Lube Point(s) - Replaceable Element 13. Radiator Coolant TCD2.9

Lube Point(s) - Fill Cap

Lube Point(s) - Replaceable Element