JLG PDF

Service and Maintenance Manual
Model
1850SJ
P/N - 3121619
January 27, 2016

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

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

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

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

VENTS.
3121619 – JLG Lift – A-1

INTRODUCTION
REVISON LOG
Original Issue - June 18, 2014

Revised - September 25, 2014
Revised - May 15, 2015
Revised - November 5, 2015
Revised - January 27, 2016
A-2 – JLG Lift – 3121619

TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
C Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - SPECIFICATIONS
1.1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.5 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.8 Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do the Following When Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3121619 – JLG Lift – i

TABLE OF CONTENTS

SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Axle Extension System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Steering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Drive/Steering Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6 Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.7 Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8 Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.9 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Disengage Drive Motors & Brakes for Towing, etc. (Free Wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Engage Drive Motors & Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.10 Gear Hub Oil Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Change Gear Hub Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.11 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Shaft Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.12 Setting Swing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.13 Swing Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.14 Chassis Tilt Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.15 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.16 Deutz Turbocharger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Operating Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3.17 Diesel Exhaust Fluid (DEF) Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Cleaning and Flushing the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3.18 Deutz Engine with Diesel Exhaust Fluid (DEF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.19 Selective Catalytic Reduction (SCR) - Machines Using Diesel Exhaust Fluid (DEF) . . . . . . . . . . . . . . . . . . . . . . 3-56
Standstill Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Maintenance Standstill Cleaning Initiation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Cancelling Maintenance Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Unsuccessful Cleaning Event. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
ii – JLG Lift – 3121619

TABLE OF CONTENTS

SECTION 4 - BOOM & PLATFORM
4.1 Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Broken Cable Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drive/Steer - Boom Function Interlock System (CE/AUS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Jib Stow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Envelope Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Moment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Control System (BCS) Functional Check (Push to Test) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Controlled Arc System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Controlled Boom Angle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Slow Down System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Dual Capacity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Swing Speed Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Platform Load Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom Control Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom Recovery Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2 Boom Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3 Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4 Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.5 Boom Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.6 Boom Lubrication Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.7 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.8 Hose Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.9 Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
4.10 JIB Shimming Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Jib Straight Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Stowed Jib Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4.11 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Eight Year Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.12 Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Boom Preparation for Section Repositioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Confirm Proper Boom Deployment Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Boom Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4.13 Broken Boom Cable Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Adjusting the Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4.14 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
One Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Two Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
3121619 – JLG Lift – iii

TABLE OF CONTENTS

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS
5.1 Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tapered Thread Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straight Thread Types, Tube and Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straight Thread Types, Port Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Flange Connection Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Assembly And Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.. . . . . . . . 5-6
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections. . . . . . . . . . . . 5-7
Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Assembly Instructions for 45° SAE Flare Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . . . . . . . . . . . . . . . . . . . 5-15
Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends . . . . . . . . . . . . . . . . . . . . . 5-34
Assembly instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Assembly Instructions for Flange Connections: (FL61 and FL62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
FFWR and TFFT Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.3 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Axle Extend Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Jib Level (Slave) Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Platform Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Boom Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Jib Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
Jib Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
5.4 Cylinder Length Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
5.5 Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5.6 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
1. Setup of the Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
2. Adjustments Made at the Main Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
3. Adjustments Made at the Frame Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-120
4. Adjustments Made at the Platform Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
5. Adjustments Made at Jib Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
6. Adjustments Made in Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
iv – JLG Lift – 3121619

TABLE OF CONTENTS

5.7 Drive Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
Charge Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-132
Mechanical Centering of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133
Hydraulic Centering of Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133
High Pressure Relief Valve Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
Removal and inspection of charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135
Removal and Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
5.8 Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
Load Sensing (LS) control with Pressure Compensator (PC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
............................................................................................... 5-144
Disassemble Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-147
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-149
5.9 Drive & Function Pump Start Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-153
Start-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-153
SECTION 6 - JLG CONTROL SYSTEM
6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
To Connect the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Ground Control Console Display Gauge - Machines using Diesel Exhaust Fluid (DEF) . . . . . . . . . . . . 6-6
6.2 Machine Personality Settings and Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.3 MACHINE ORIENTATION WHEN SETTING Function SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.4 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.6 Control System Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Sensor #1 - Load Pin (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Sensor #2 - Main Boom Angle Sensors (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Sensor #3 - Main Boom Length Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Sensor #4 - Main Boom Cylinder Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Sensor #5 - Main Boom Transport Length Switch (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Sensor #6 - Jib Level Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Sensor #7 - Jib Lock Pin Proximity Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Sensor #8 - Jib Stow Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Sensor #9 - Jib Lift Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Sensor #10 - Dual Capacity / Jib Transport Length Switches (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Sensor #11 - Platform Level Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Sensor #12 - Platform Level Angle Gravity Sensors (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #13 - Turntable Swing Angle (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #14 - Steer Angle Sensor (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #15 - Axle extend/retract Sensor (4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #16 - Brake-Two Speed Pressure Sensor (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #17 - Chassis Tilt Sensor (Externally mounted) (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #18 - Tilt Sensor (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #19 - Warm up Switch (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #20 - Main Valve Pressure Transducer (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Sensor #21 - Main Lift Cylinder Pressure Transducer (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
3121619 – JLG Lift – v

TABLE OF CONTENTS

6.7 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
6.8 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Axle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Boom Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
6.9 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Platform Leveling Fault Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Fault Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.6 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Connector Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Component Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
vi – JLG Lift – 3121619

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
2-1. Engine Operating Temperature Specifications - Deutz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-2. Hydraulic Oil Operating Temperature Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1. Crab Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Coordinated Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. 2 Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-4. Axle Hose Routing - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-5. Axle Hose Routing - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-6. Steering/Axle Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-7. Drive System Hydraulic Circuit - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-8. Drive System Hydraulic Circuit - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-9. Turntable Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-10. Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-11. Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-12. Disengaging Drive Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-13. Gear Hub Oil Fill and Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-14. Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-15. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-16. Removing Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-17. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-19. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-20. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-21. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-22. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-23. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-24. Shaft & Front Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-25. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-26. Cylinder Kit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-27. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-28. Swash Plate and Journal Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3-29. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-30. Cylinder Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-31. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-32. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-33. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-34. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-35. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-37. Swing Bearing Removal - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3121619 – JLG Lift – vii

LIST OF FIGURES

3-41. Diesel Exhaust Fluid (DEF) Tank - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3-42. Diesel Exhaust Fluid (DEF) Tank - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3-43. Diesel Exhaust Fluid (DEF) System - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-49. Engine Electrical Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-50. Mixing Petroleum With Summer Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
4-1. Boom Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-2. Boom Assembly - Sheet 1 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-11. Locations for Threadlocker Application - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-16. Boom Assembly Torque Values - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-20. Hose Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4-21. Section 3 Boom Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4-24. Jib Hydraulics - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4-31. Jib Assembly - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4-35. Jib Stow Shimming Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4-36. Fully Retracted Boom Section Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-37. Initial Exposed Thread Length for Wire Rope Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4-38. Boom Wire Rope Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4-39. Broken Cable Proximity Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
viii – JLG Lift – 3121619

LIST OF FIGURES

4-40. Powertrack Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4-44. Powertrack Shimming Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4-45. Powertrack Locations for Threadlocker Application and Torque - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4-49. Powertrack Hose Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4-53. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5-13. FFWR Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5-14. Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5-15. Turntable Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-16. Hydraulic Hose Installation - Sheet 1 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5-24. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-25. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-26. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-27. Axle Extend Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-28. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5-29. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5-30. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5-31. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5-32. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-33. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-34. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
3121619 – JLG Lift – ix

LIST OF FIGURES

5-38. Jib Level (Slave) Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-39. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-40. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-41. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-43. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-44. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-45. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-46. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-48. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-49. Cylinder Length Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-50. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-51. Platform Level Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
5-52. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5-56. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
5-57. Cylinder Head Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
5-61. Rod and Cylinder Head Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
5-62. Cylinder Head Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
5-66. Boom Lift Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5-71. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5-72. Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5-77. Cylinder Length Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5-79. Jib Lift Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5-84. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5-85. Cylinder Head Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5-90. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
x – JLG Lift – 3121619

LIST OF FIGURES

5-91. Jib Lock Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
5-92. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5-93. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5-95. Steer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5-96. Piston and Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5-97. Cylinder Head and Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5-98. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5-99. Cylinder Head and Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5-101. Jib Telescope Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5-102. Piston and Spacer Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5-104. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5-105. Piston and Spacer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5-107. Cylinder Head Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
5-108. Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
5-110. Port Block And Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
5-112. Boom Telescope Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
5-113. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5-114. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5-116. Cylinder Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
5-117. Cylinder Head and Spacer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
5-118. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
5-119. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
5-120. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5-121. Rod Assembly And Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5-122. Cylinder Length Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
5-123. Oil Sampling Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5-124. Main Valve Identification - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5-125. .................................................................................................... 5-110
5-126. Main Valve Identification - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5-127. Main Valve Torque Values - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5-128. Main Valve Torque Values - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
5-129. Function Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5-130. Control Assembly Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5-131. PC Control Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
5-132. LS Control Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
5-133. Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-144
5-134. Coupling and Control Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
5-135. Endcap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
5-136. Cylinder Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
5-137. Swash Plate and Servo Piston Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
5-138. Housing Bearing and Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
5-139. Control Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
3121619 – JLG Lift – xi

LIST OF FIGURES

5-140. Cylinder Block Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-147
5-141. Piston and Slipper Wear Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-147
5-142. Cylinder Block Wear Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-148
5-143. Valve Plate Wear Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-148
5-144. Endplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-149
5-145. Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-149
5-146. Swash Plate Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-150
5-147. Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-150
5-148. Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-150
5-149. Valve Plate and Endcap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
5-150. Shaft Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-151
5-151. Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-152
5-152. Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-152
5-153. Hydraulic Schematic - Sheet 1 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-156
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3. Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-4. Engine Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-5. Ground Control Console Display Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-6. Control System CAN Circuit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-7. Control System CAN Circuit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6-8. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-9. Analyzer Flow Chart - Personalities (Software Version 7.X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-10. Analyzer Flow Chart - Machine Setup (Software Version 7.X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6-11. Analyzer Flow Chart - Calibrations (Software Version 7.X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-12. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-15. Ground Control Module - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-18. Chassis Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6-19. BLAM Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6-20. Jib Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6-21. Analyzer Connecting Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6-22. Main Boom Angle Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6-23. Main Boom Cylinder Angle (Protractor) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6-24. Main Boom Transport Length Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-25. Jib Lock Pin Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6-26. Jib Level Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6-27. Jib Stow Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6-28. Jib Transport Length Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-29. Platform Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
6-30. System Test Flow Chart - Platform Tests - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6-31. System Test Flow Chart - Platform Tests - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
6-32. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
xii – JLG Lift – 3121619

LIST OF FIGURES

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 Female Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6. Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-7. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-8. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-12. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-13. Connector Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-14. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-15. DT/DTP Contact Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-16. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-17. HD/HDP Locking Contacts Into Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-18. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-19. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-20. Platform Box Wiring Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-21. Platform Box Wiring Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-22. Platform Box Wiring Harness - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7-23. Platform Valve Wiring Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-24. Platform Valve Wiring Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7-25. Jib Valve Wiring Harness - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-26. Jib Valve Wiring Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7-27. Jib Valve Wiring Harness - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-28. BLAM Module Wiring Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-29. BLAM Module Wiring Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7-30. Load Sensing Pin Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7-31. Base Boom Sensor Cable - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7-32. Base Boom Sensor Cable - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7-33. Base Boom Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7-34. Base Boom Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7-35. Beacon/Strobe Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-36. Fuel Pump & Water-In-Fuel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7-37. Turntable Wiring Harness - Sheet 1 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7-41. Turntable Wiring Harness - Sheet5 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7-46. Ground Console Wiring Harness - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7-47. Ground Concole Wiring Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7-48. Ground Concole Wiring Harness - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
7-49. Chassis Harness - Sheet 1 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
3121619 – JLG Lift – xiii

LIST OF FIGURES

7-55. Hydraulic Valve Bank Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
7-58. Drive Pump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
7-59. T4i Engine Harness - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7-60. T4i Engine Harness - Sheet 2of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
7-63. CAN Engine Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
7-64. CAN Engine Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
7-65. Generator Enable Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
7-66. Generator Enable Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
7-67. T4F Engine Harness - Sheet 1 of 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
7-76. T4F Engine Harness - Sheet 10 of 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
7-81. Urea Tank/Supply Module Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
7-82. Urea Tank/Supply Module Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
7-83. Electrical Installation - Sheet 1 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
7-92. Electrical Installation - Sheet 10 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
7-93. Battery Jump-Start Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7-94. Battery Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
7-95. Battery Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
xiv – JLG Lift – 3121619

LIST OF FIGURES

7-96. Electrical Schematic - Sheet 1 of 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
7-105. Electrical Schematic - Sheet 10 of 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
3121619 – JLG Lift – xv

LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5 Engine Data - Deutz TD 3.6L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-9 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-10 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-11 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-12 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-13 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2 Excessive Noise and/or Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-3 System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-4 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-5 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-6 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-7 Cylinder Block Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-8 Maintenance Standstill Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3-9 Cleaning When Crystallization is Detected During SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3-10 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
5-1 NPTF Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-2 BSPT Pipe Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-3 37° Flare (JIC)Thread - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-4 37° Flare (JIC)Thread - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5 45° Flare (SAE) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6 45° Flare (SAE) - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7 O-ring Face Seal (ORFS) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-8 O-ring Face Seal (ORFS) - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-9 DIN 24°Cone (MBTL & MBTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-10 Bulkhead Fittings (BH) - INCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-11 Bulkhead Fittings (BH) - METRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-12 O-ring Boss (ORB) - Table 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-18 Metric Flat Face Port (MFF) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-21 Metric Flat Face Port (MFF) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-22 Metric Flat Face Port (MFF) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-24 Metric Pipe Parallel O-Ring Boss (MPP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
xvi – JLG Lift – 3121619

LIST OF TABLES

5-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-31 Flange Code (FL61 & FL62) -Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-32 Flange Code (FL61 & FL62) - Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-33 Torque Specs for Relief Valves into Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
6-1 Analyzer Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-2 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-3 Machine Configuration Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-4 Machine Personality Settings and Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6-6 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-7 Diagnostic Fault Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6-8 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
7-1 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
3121619 – JLG Lift – xvii

LIST OF TABLES
This page left blank intentionally.
xviii – JLG Lift – 3121619

SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS Table 1-2. Dimensional Data
Horizontal Reach over end

Table 1-1. Operating Specifications
Unrestricted Capacity 70 ft. 6 in. (21.59 m)
Capacity - ANSI Restricted Capacity 59 ft. 6 in. (18.13 m)
Unrestricted 500 lbs (227 kg) Horizontal Reach over side
Restricted 1000 lbs (454 kg) Unrestricted Capacity 71 ft. 9 in. (21.86 m)
Capacity - CE & Australia Restricted Capacity 60 ft. 8 in. (18.49 m)
Unrestricted 500 lbs (230 kg) Overall Width
Restricted 1000 lbs (450 kg) Axles Retracted 8 ft. 2 in. (2.48 m)
Maximum Travel Grade, stowed 40% Axles Deployed 16 ft. 6.5 in. (5.04 m)
Position (Gradeability) Wheelbase
Maximum Travel Grade, stowed 5° Axles Retracted 17 ft. 1.5 in. (5.22 m)
Position (Side Slope) 4° - CE/Aus Axles Deployed 15 ft. 0.5 in. (4.59 m)
Drive Speed 2.8 mph (4.5 kph) Tailswing 7 ft. 7.5 in. (2.32 m)
Drive Speed at Elevation 0.3 mph (0.48 kph) Ground Clearance (Axle) 9.75 in. (0.25 m)
Gross Machine Weight - Approximate 59,900 lb. (27170 kg.) Ground Clearance (Chassis) 1 ft. 4.25 in. (0.41 m)
Ground Bearing Pressure - Maximum 119.6 psi (8.41 kg/cm2) 1.3 CAPACITIES
Maximum Wind Speed 28 mph (12.5 m/s) Table 1-3. Capacities
Maximum Manual Force 90 lbs (400N) Hydraulic Oil Tank 75.1 Gal. (284.2 L)
Maximum System Voltage 12 volts Fuel Tank 52.8 Gal. (200 L)
Maximum Main Relief Hyd. Pressure 5000 psi (345 Bar) Drive Hub 2.6 quarts (2.5 liters)
Swing Gearbox 3 qt. (2.8 L)

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

tion
Unrestricted Capacity 80 ft. (24.38 m)
Restricted Capacity 68 ft. 11 in. (21.01 m)
3121619 – JLG Lift – 1-1

1.5 ENGINE DATA 1.7 HYDRAULIC OIL

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

S.A.E. Viscosity
Number of Cylinders 4 Operating
Grade
Temperature Range
Bore 3.9 in. (98 mm)
Stroke 4.7 in. (120 mm) +0° to + 180° F 10W
(-18° to +83° C)
Total Displacement 221 cu.in. (3.6 L)
+0° to + 210° F 10W-20, 10W30
Firing Order 1-3-4-2 (-18° to +99° C)
Output 99.8 hp (74.4 kW) +50° to + 210° F 20W-20
Low Idle Engine RPM 1000 ±50 (+10° to +99° C
High Engine RPM 2300±50
NOTE: Hydraulic oils require anti-wear qualities at least API Ser-
vice Classification GL-3, and sufficient chemical stability
1.6 MAJOR COMPONENT WEIGHTS for mobile hydraulic system service.
NOTE: Aside from JLG recommendations, it is not advisable to

mix oils of different brands or types, as they may not con-
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT tain the same required additives or be of comparable vis-
WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT- cosities. If use of hydraulic oil other than Mobil 424 is
FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. desired, contact JLG Industries for proper recommenda-
tions.
Table 1-6. Critical Stability Weights
OIL SAMPLING
Components LBS. KG.
This machine is equipped with an oil sampling valve to
Tire & Wheel 1025 465 allow for verification of hydraulic oil condition. Refer to
Section 5 - Hydraulics for Oil Sampling procedures.
Drive Hub & Motor 337 153
Table 1-8. Mobilfluid 424 Specs
Swing Drive 223 101.2
SAE Grade 10W30
Engine Assembly 822 373
Gravity, API 29.0
Complete Boom (including jib & platform) 23,600 10705
Density, Lb/Gal. 60°F 7.35
Main Boom Assembly 21,600 9798 Pour Point, Max -46°F (-43°C)
Jib Assembly 1493 677 Flash Point, Min. 442°F (228°C)
Viscosity
Brookfield, cP at -18°C 2700
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152
1-2 – JLG Lift – 3121619

Table 1-9. Mobil DTE 13M Specs Table 1-12. Exxon Univis HVI 26 Specs
ISO Viscosity Grade #32 Specific Gravity 32.1
Specific Gravity 0.877 Pour Point -76°F (-60°C)
Pour Point, Max -40°F (-40°C) Flash Point 217°F (103°C)
Flash Point, Min. 330°F (166°C) Viscosity
Viscosity at 40° C 25.8 cSt
at 40° C 33cSt at 100° C 9.3 cSt
at 100° C 6.6 cSt Viscosity Index 376
at 100° F 169 SUS NOTE: Mobil/Exxon recommends that this oil be checked on
a yearly basis for viscosity.
at 210° F 48 SUS
cp at -20° F 6,200
Viscosity Index 140
Table 1-10. UCon Hydrolube HP-5046
Type Synthetic Biodegradable

Specific Gravity 1.082
Pour Point, Max -58°F (-50°C)
pH 9.1
Viscosity
at 0° C (32° F) 340 cSt (1600SUS)
at 40° C (104° F) 46 cSt (215SUS)
at 65° C (150° F) 22 cSt (106SUS)
Viscosity Index 170
Table 1-11. Mobil EAL H 46 Specs
Type Synthetic Biodegradable

ISO Viscosity Grade 46
Specific Gravity .910
Pour Point -44°F (-42°C)
Flash Point 500°F (260°C)
Operating Temp. 0 to 180°F (-17 to 162°C)
Weight 7.64 lb. per gal.
(0.9 kg per liter)
Viscosity
at 40° C 45 cSt
at 100° C 8.0 cSt
Viscosity Index 153
3121619 – JLG Lift – 1-3

Figure 1-1. Maintenance and Lubrication Diagram
1-4 – JLG Lift – 3121619

1.8 MAINTENANCE AND LUBRICATION 2. Swing Gearbox
NOTE: The following numbers correspond to those in Figure 1-1.,

Maintenance and Lubrication Diagram.
Table 1-13. Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424
EO Engine (crankcase) API CJ-4
Lube Point(s) - Fill Plug

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

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

4. Hydraulic Return Filter 6. Hydraulic Charge Filter
Lube Point(s) - Replaceable Element

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

or 300 hours thereafter.
Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter.
Comments - Remove wing nut and cover to replace.
Under certain conditions, it may be necessary to replace
on a more frequent basis.
1-6 – JLG Lift – 3121619

8. Hydraulic Oil 10. Oil Change w/Filter - DeutzS
Lube Point(s) - Fill Cap

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

Interval - Change after first 50 hours and every 6 months Lube Point(s) - Replaceable Element
or 300 hours thereafter. Interval - Every year or 500 hours of operation
3121619 – JLG Lift – 1-7

12. Fuel Pre-Filter 14. Boom
Lube Point(s) - Apply to wear pad contact paths

Lube - Super Lube®
Interval - Every year or 600 hours of operation. Refer to
the Service Manual for detailed procedures
15. Radiator
Lube Point(s) - Fill Cap

Lube - Anti-Freeze Coolant (Refer to Engine Manual for
compatible coolants)
Capacity - 13.2 qt. (12.5 L)
16. Diesel Exhaust Fluid (DEF) (If Equipped)

Interval - Every year or 500 hours of operation
13. Air Filter
Lube Point - Fill Cap

Lube - DEF
Capacity - 5.7 gal. (21.5 L)
17. DEF Supply Module Filter (If Equipped)

Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator
Comments - Check dust valve for dirt daily
Interval - 500 hours or 2 years, whichever comes first
1-8 – JLG Lift – 3121619

Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
3121619 – JLG Lift – 1-9

To rqu e
Torqu e
Torq ue
Tor que
Torq ue
1-10 – JLG Lift – 3121619

Torq ue
Tor que
Torqu e
Cl amp L oa d
Torq ue
To rqu e
To rque
3121619 – JLG Lift – 1-11

To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
Figure 1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
1-12 – JLG Lift – 3121619

To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue
Figure 1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
3121619 – JLG Lift – 1-13

NOTES:
1-14 – JLG Lift – 3121619

SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND inspections. Reference the appropriate areas of this manual for
servicing and maintenance procedures.
MAINTENANCE
General Annual Machine Inspection
This section provides the necessary information needed by The Annual Machine Inspection must be performed on an
those personnel that are responsible to place the machine in annual basis, no later than thirteen (13) months from the date
operation readiness and maintain its safe operating condition. of the prior Annual Machine Inspection. JLG Industries recom-
For maximum service life and safe operation, ensure that all mends this task be performed by a Factory-Trained Service
the necessary inspections and maintenance have been com- Technician. JLG Industries, Inc. recognizes a Factory-Trained
pleted before placing the machine into service. 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-
It is important to establish and conform to a comprehensive nance Manual and appropriate JLG inspection form for perfor-
inspection and preventive maintenance program. The follow- mance of this inspection.
ing table outlines the periodic machine inspections and main-
tenance recommended by JLG Industries, Inc. Consult your Reference the JLG Annual Machine Inspection Form and the
national, regional, or local regulations for further requirements Inspection and Preventive Maintenance Schedule for items
for aerial work platforms. The frequency of inspections and requiring inspection during the performance of this inspec-
maintenance must be increased as environment, severity and tion. Reference the appropriate areas of this manual for servic-
frequency of usage requires. ing and maintenance procedures.
Pre-Start Inspection For the purpose of receiving safety-related bulletins, it is

important that JLG Industries, Inc. has updated ownership
It is the User’s or Operator’s primary responsibility to perform a
information for each machine. When performing each Annual
Pre-Start Inspection of the machine prior to use daily or at
each change of operator. Reference the Operator’s and Safety Machine Inspection, notify JLG Industries, Inc. of the current
Manual for completion procedures for the Pre-Start Inspec- machine ownership.
tion. The Operator and Safety Manual must be read in its
entirety and understood prior to performing the Pre-Start Preventive Maintenance
Inspection.
In conjunction with the specified inspections, maintenance
Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
The Pre-Delivery Inspection and Frequent Inspection shall be
performed by a qualified JLG equipment mechanic. JLG Indus- mechanic as a person who, by possession of a recognized
tries, Inc. recognizes a qualified JLG equipment mechanic as a degree, certificate, extensive knowledge, training, or experi-
person who, by possession of a recognized degree, certificate, ence, has successfully demonstrated the ability and profi-
extensive knowledge, training, or experience, has successfully ciency to service, repair, and maintain the subject JLG product
demonstrated the ability and proficiency to service, repair, and model.
maintain the subject JLG product model.
Reference the Preventive Maintenance Schedule and the
The Pre-Delivery Inspection and Frequent Inspection proce-
appropriate areas of this manual for servicing and mainte-
dures are performed in the same manner, but at different
times. The Pre-Delivery Inspection shall be performed prior to nance procedures. The frequency of service and maintenance
each sale, lease, or rental delivery. The Frequent Inspection must be increased as environment, severity and frequency of
shall be accomplished for each machine in service for 3 usage requires.
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.
Reference the JLG Pre-Delivery and Frequent Inspection Form

and the Inspection and Preventive Maintenance Schedule for
items requiring inspection during the performance of these
3121619 – JLG Lift – 2-1

SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operation and Safety Manual
At each Operator change.
Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
rental delivery. and applicable JLG inspection form.
Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
purchased used.
Annual Machine Inspec- Annually, no later than 13 months from the date of Owner, Dealer, or User Factory-Trained Service Service and Maintenance Manual
tion the prior inspection. Technician and applicable JLG inspection form.
(Recommended)
Preventive At intervals as specified in the Service and Mainte- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance nance Manual.
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are disconnected,
clear adjacent areas as well as the openings and fittings
themselves. As soon as a line or component is discon-
General nected, cap or cover all openings to prevent entry of for-
The following information is provided to assist you in the use eign matter.
and application of servicing and maintenance procedures
contained in this book. 3. Clean and inspect all parts during servicing or mainte-
nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
Safety and Workmanship sure all parts are clean before they are installed. New
parts should remain in their containers until they are
Your safety, and that of others, is the first consideration when
ready to be used.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without
the aid of a mechanical device. Do not allow heavy objects to Components Removal and Installation
rest in an unstable position. When raising a portion of the
equipment, ensure that adequate support is provided. 1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
Cleanliness cables, etc.) should be parallel to each other and as near
perpendicular as possible to top of part being lifted.
1. The most important single item in preserving the long
service life of a machine is to keep dirt and foreign mate- 2. Should it be necessary to remove a component on an
rials out of the vital components. Precautions have been angle, keep in mind that the capacity of an eyebolt or
taken to safeguard against this. Shields, covers, seals, similar bracket lessens, as the angle between the sup-
and filters are provided to keep air, fuel, and oil supplies porting structure and the component becomes less
clean; however, these items must be maintained on a than 90 degrees.
scheduled basis in order to function properly.
3. If a part resists removal, check to see whether all nuts,
bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.
2-2 – JLG Lift – 3121619

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

SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL. Hydraulic System
1. Always use new replacement hardware when installing 1. The primary enemy of a hydraulic system is contamina-
locking fasteners. Use bolts of proper length. A bolt tion. Contaminants enter the system by various means,
which is too long will bottom before the head is tight e.g., using inadequate hydraulic oil, allowing moisture,
against its related part. If a bolt is too short, there will grease, filings, sealing components, sand, etc., to enter
not be enough thread area to engage and hold the part when performing maintenance, or by permitting the
properly. When replacing bolts, use only those having pump to cavitate due to insufficient system warm-up or
the same specifications of the original, or one which is leaks in the pump supply (suction) lines.
equivalent.
3121619 – JLG Lift – 2-3

SECTION 2 - GENERAL
2. The design and manufacturing tolerances of the compo- Changing Hydraulic Oil
nent working parts are very close, therefore, even the
smallest amount of dirt or foreign matter entering a sys- 1. Filter elements must be changed after the first 50 hours
tem can cause wear or damage to the components and of operation and every 300 hours (unless specified oth-
generally results in faulty operation. Every precaution erwise) thereafter. If it is necessary to change the oil, use
must be taken to keep hydraulic oil clean, including only those oils meeting or exceeding the specifications
reserve oil in storage. Hydraulic system filters should be appearing in this manual. If unable to obtain the same
checked, cleaned, and/or replaced as necessary, at the type of oil supplied with the machine, consult local sup-
specified intervals required in the Lubrication Chart in plier for assistance in selecting the proper equivalent.
Section 1. Always examine filters for evidence of metal Avoid mixing petroleum and synthetic base oils.
particles.
2. Use every precaution to keep the hydraulic oil clean. If
3. Cloudy oils indicate a high moisture content which per- the oil must be poured from the original container into
mits organic growth, resulting in oxidation or corrosion. another, be sure to clean all possible contaminants from
the service container. Always clean the mesh element of
If this condition occurs, the system must be drained,
the filter and replace the cartridge any time the system
flushed, and refilled with clean oil.
oil is changed.
4. It is not advisable to mix oils of different brands or types, 3. While the unit is shut down, a good preventive mainte-
as they may not contain the same required additives or nance measure is to make a thorough inspection of all
be of comparable viscosities. Good grade mineral oils, hydraulic components, lines, fittings, etc., as well as a
with viscosities suited to the ambient temperatures in functional check of each system, before placing the
which the machine is operating, are recommended for machine back in service.
use.
Lubrication Specifications
NOTE: Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing components. 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
Hydraulic Oil single purpose grease requirements. Should any question
arise, regarding the use of greases in maintenance stock, con-
1. Refer to Section 1 for recommendations for viscosity
sult your local supplier for evaluation. Refer to Section 1 for an
ranges. explanation of the lubricant key designations appearing in the
Lubrication Chart.
2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured using
the following methods.
Platform Drift
Measure the drift of the platform to the ground. Lower booms
(if equipped) slightly elevated, main boom fully extended with
the rated load in the platform and power off. Maximum allow-
able drift is 2 inches (5 cm) in 10 minutes. If the machine does
not pass this test, proceed with the following.
2-4 – JLG Lift – 3121619

SECTION 2 - GENERAL
Cylinder Drift 4. Re-assembly of pinned joints using filament wound

bearings.
Table 2-2. Cylinder Drift a. Housing should be blown out to remove all dirt and
debris...bearings and bearing housings must be free
Max. Acceptable Drift
Cylinder Bore Diameter of all contamination.
in 10 Minutes
b. Bearing / pins should be cleaned with a solvent to
inches mm inches mm remove all grease and oil...filament wound bearing
3 76.2 0.026 0.66 are a dry joint and should not be lubricated unless
3.5 89 0.019 0.48 otherwise instructed (i.e. sheave pins).
4 101.6 0.015 0.38 c. Pins should be inspected to ensure it is free of burrs,
nicks, and scratches which would damage the bear-
5 127 0.009 0.22 ing during installation and operation.
6 152.4 0.006 0.15
7 177.8 0.005 0.13 2.6 WELDING ON JLG EQUIPMENT
8 203.2 0.0038 0.10 NOTE: This instruction applies to repairs, or modifications to the
9 228.6 0.0030 0.08 machine and to welding performed from the machine on
an external structure, or component,
Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temperature Do the Following When Welding on JLG Equipment
and temperature stabilized.
• Disconnect the battery.
The cylinder must have the normal load, which is the normal • Disconnect the moment pin connection (where fitted)
platform load applied.
• Ground only to structure being welded.
If the cylinder passes this test, it is acceptable.
Do NOT Do the Following When Welding on JLG
NOTE: This information is based on 6 drops per minute cylinder Equipment
leakage.
• Ground on frame and weld on any other area than the
2.5 PINS AND COMPOSITE BEARING REPAIR chassis.
GUIDELINES • Ground on turntable and weld on any other area than the
turntable.
Filament wound bearings. • Ground on the platform/support and weld on any other
1. Pinned joints should be disassembled and inspected if area than the platform/support.
the following occurs: • Ground on a specific boom section and weld on any other
area than that specific boom section.
a. Excessive sloppiness in joints.
b. Noise originating from the joint during operation. • Allow pins, wear pads, wire ropes, bearings, gearing, seals,
valves, electrical wiring, or hoses to be between the
2. Filament wound bearings should be replaced if any of grounding position and the welded area.
the following is observed:
a. Frayed or separated fibers on the liner surface.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
b. Cracked or damaged liner backing.
PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
c. Bearings that have moved or spun in their housing. RING, BOOM WIRE ROPES ETC.)
d. Debris embedded in liner surface.
3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to
inspection):
a. Detectable wear in the bearing area.
b. Flaking, pealing, scoring, or scratches on the pin sur-
face.
c. Rusting of the pin in the bearing area.
3121619 – JLG Lift – 2-5

SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Weekly Monthly Pre-Delivery2 Annual4 Every 2

Preventive Preventive or Frequent3 (Yearly) Years
Maintenance Maintenance 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 5 1 1,5
Floor 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly
Swing Bearing 1,2,14 1,2,3,13,14
Oil Coupling 9
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly
Tires 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 15 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Extendable Axle Systems 5,8 5,8
Steer Components
Spindle Thrust Bearing/Washers 1,2
Drive Hubs 11 11
2-6 – JLG Lift – 3121619

SECTION 2 - GENERAL
INTERVAL

Functions/Controls
Platform Controls 5 6 6
Ground Controls 5 6 6
Function Control Locks, Guards, or Detents 1,5 5 5
Footswitch 5 5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems 5 5
Drive Brakes 5
Swing Brakes 5
Auxiliary Power 5 5
Power System
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 9,11 11 11
Air/Fuel Filter 1,7 7 7
Exhaust System 1,9 9 9
Batteries 1,9 19
Battery Fluid 11 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 2 1,5 1,5
Hydraulic/Electric System
Hydraulic Pumps 1,9 1,2,9
Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2
Hydraulic Hoses, Lines, and Fittings 1,9 12 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1,9 2 1,5 1,5 24
Hydraulic Filter 1,9 7 7
Hydraulic Fluid 7,11 7,11
Electrical Connections 1 20 20
Instruments, Gauges, Switches, Lights, Horn 1 5,23
General
Operation and Safety Manuals in Storage Box 21 21
ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only) 21
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
3121619 – JLG Lift – 2-7

SECTION 2 - GENERAL
INTERVAL

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
2-8 – JLG Lift – 3121619

SECTION 2 - GENERAL
1001159163 A
Figure 2-1. Engine Operating Temperature Specifications - Deutz
3121619 – JLG Lift – 2-9

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 ppmBe per OECD 203
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval
4150740 B
Figure 2-2. Hydraulic Oil Operating Temperature Specifications
2-10 – JLG Lift – 3121619

SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES AND WHEELS The proper procedure for attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO
Tire Damage NOT use a lubricant on threads or nuts.
For pneumatic tires, JLG Industries, Inc. recommends that
2. Tighten nuts in the following sequence:
when any cut, rip, or tear is discovered that exposes sidewall or
tread area cords in the tire, measures must be taken to remove
the JLG product from service immediately. Arrangements
must be made for replacement of the tire or tire assembly.
For polyurethane foam filled tires, JLG Industries, Inc. recom-

mends that when any of the following are discovered, mea-
sures must be taken to remove the JLG product from service 16 10
14
immediately and arrangements must be made for replace- 5 8
ment of the tire or tire assembly. 12 19
18 4
• a smooth, even cut through the cord plies which exceeds 3
inches (7.5 cm) in total length 3 17
20 11
• any tears or rips (ragged edges) in the cord plies which
7 6
exceeds 1 inch (2.5 cm) in any direction 13 9 2 15
• any punctures which exceed 1 inch in diameter
• any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria, the

tire must be inspected on a daily basis to insure the damage
hasn’t propagated beyond the allowable criteria.
Wheel and Tire Replacement 3. The tightening of the nuts should be done in stages. Fol-
lowing the recommended sequence, tighten nuts per
The rims installed on each product model have been designed wheel torque chart.
for stability requirements which consist of track width, tire
pressure, and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc., without Table 3-1. Wheel Torque Chart
written factory recommendations, may result in an unsafe
TORQUE SEQUENCE
condition regarding stability.
1st Stage 2nd Stage 3rd Stage
Wheel Installation 35 ft. lbs. 80 ft. lbs. 140 ft. lbs.
It is extremely important to apply and maintain proper wheel (45 Nm) (100 Nm) (185 Nm)
mounting torque.
4. Wheel nuts should be torqued before first road use and
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.
Tighten the lug nuts to the proper torque to prevent wheels
from coming loose. Use a torque wrench to tighten the fasten-
ers. If you do not have a torque wrench, tighten the fasteners
with a lug wrench, then immediately have a service garage or
dealer tighten the lug nuts to the proper torque. Over-tighten-
ing will result in breaking the studs or permanently deforming
the mounting stud holes in the wheels.
3121619 – JLG Lift – 3-1

3.2 AXLE EXTENSION SYSTEM 3.3 DRIVE ORIENTATION SYSTEM

NOTE: The boom must be oriented between the rear wheels to The Drive Orientation System (DOS) is intended to indicate to
extend or retract the axles. the operator conditions that could make the direction of
movement of the chassis different than the direction of move-
The Axle Extension System allows each of the four axles to be ment of the drive/steer control handle. The system indicates to
extended and retracted together while maintaining full steer- the operator the need to match the black and white direc-
ing control as the machine is driven. The system allows the tional arrows on the platform control panel to the arrows on
axles to extend or retract only while the boom is in the trans- the chassis for the intended direction of travel. The system
port position (see Transport Position Sensing System in Sec- uses a proximity switch mounted on the hydraulic swivel, an
tion 4) and in order to minimize wheel scrubbing during axle indicator light and an override switch on the platform display
movement, a minimum drive speed must be attained before panel. The proximity switch trips when the turntable is swung
axle extension/retraction will be permitted. The system uses +/- 35 degrees off center of the normal driving position. This
four linear sensors (one at each axle) to sense when the axles occurs roughly when the boom is swung past a rear tire. When
are fully extended. If any of the linear sensors detect an out of the turntable is in the normal drive position with the boom
range value for axle set, the control system considers the axles between the rear tires, no indications or interlocks are made.
retracted. To extend/retract the axles, the user engages the When the machine is actively driving when the turntable is
axle extend/retract switch on the platform console and the swung past the switch point, the system is ignored until drive/
drive control at the same time. The axle set indicator will be off steer is released. When drive is initiated with the boom swung
when the axles are not fully extended and the axle extend/ past the switch point, the DOS indicator will flash and the
retract switch is not engaged. It will flash while the axles are drive/steer functions will be disabled. The operator must
extending or retracting and will be on constantly when the engage the DOS override switch to enable Drive/steer (high
axles are fully extended. With the axles not fully extended, the drive will remain disabled). When the DOS is enabled, the DOS
boom is restricted to operation within the transport position indicator will flash during the 3 second interval until the drive
(see Transport Position Sensing System in Section 4). If a signal function is selected. If the timer expires, the DOS override
from any axle linear sensor is lost when the boom is beyond switch must be re-engaged to enable drive/steer.
the transport position, the axle set indicator will flash and
drive/steer functions will be disabled until the boom is
brought back into the transport position. The steering angle
will be automatically limited to +/- 20 degrees anytime the
axles are not fully extended. If the wheel angle is more than +/
- 20 degrees when the axle retract command is engaged, the
control system will automatically reduce the wheel angle to 20
degrees during axle retraction.
3-2 – JLG Lift – 3121619

3.4 STEERING CONTROL SYSTEM

There are three different modes of steering selectable by the
position of the steer select switch on the platform control
panel: crab, coordinated, and conventional two wheel steer-
ing. These are shown below.
Figure 3-3. 2 Wheel Steer
Each wheel has its own steer cylinder, wheel angle sensor, axle
extend linear sensor, and proportional valve, allowing the con-
trol system to position each wheel to the ideal angle for all
steering modes and all steering commands. This is done
Figure 3-1. Crab Steer whether the axle is retracted, extended, or somewhere in
between. Changes in steering modes while drive is engaged
causes the wheels to automatically adjust to the appropriate
angle for the selected steering mode based on the position of
the inside front wheel. If the steer select switch is changed
without the footswitch depressed or the EMS is off, the wheels
will not move until the footswitch is depressed and a steering
or drive command has been initiated. The steering angles are
limited to +/- 20 degrees anytime the axles are not fully
extended. See the Axle Extension System for interaction with
the axle extension system. If a wheel cannot achieve its com-
manded 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
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
Figure 3-2. Coordinated Steer resynchronized by fully steering against the mechanical stops.
Axle extend sensor failures will result in an approximated

steering control logic that will allow the operator to move the
machine until it can be repaired. The axle at the failed sensor
3121619 – JLG Lift – 3-3

will be driven based on the information available from the 3.6 TRACTION CONTROL SYSTEM
other sensors. This axle will not track perfectly and will
become farther out of position over time. When the wheel The traction control system uses the steering sensors from the
steering control system to optimize the performance of the
becomes prohibitively out of position, the wheels can be
drive system. This is especially important due to the disparity
resynchronized by fully steering against the mechanical stops.
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
3.5 DRIVE/STEERING SPEED CONTROL path and therefore the required wheel speed of each wheel as
the steering angles change and steering modes change. The
The Drive/Steering Speed Control system uses the steering control system can then command the ideal flow from each of
sensors from the steering control system to increase operator the two drive pumps, one for the right side of the machine and
control and comfort by reducing the effect of turning the one for he left side. Two flow dividers, one for the right side,
chassis on the resulting lateral platform speed. The system front to back and one for the left side, front to back absorb the
proportionally varies the drive speed based on the predicted variation in wheel speed, front to back.
turning radius of the chassis for both coordinated and conven-
tional two wheel steer modes. The tighter the turn the slower
the allowable drive speed. As crab steer does not steer on a
radius, full drive speed is maintained regardless of steer angle.
3-4 – JLG Lift – 3121619

3121619 – JLG Lift – 3-5

Figure 3-4. Axle Hose Routing - Sheet 1 of 2
3-6 – JLG Lift – 3121619

Figure 3-5. Axle Hose Routing - Sheet 2 of 2
3121619 – JLG Lift – 3-7

Figure 3-6. Steering/Axle Hydraulic Circuit
3-8 – JLG Lift – 3121619

FRONT
3121619
TO TO TO TO TO
SWIVEL PORT 7 SWIVEL PORT 6 SWIVEL PORT 5 SWIVEL PORT 4 SWIVEL PORT 3
B X A
X
A
B
X
X HU B/D RIV E MOTOR
LEFT FR ONT
H UB /D R IV E MOTOR
X B1
BR
A1
X
TOP VIE W OF
TR AC TION VALVE
RIGHT
A6
B5
B6 A5
TS
D A4
A3 B2 X R IGHT VIEW OF
LEFT LE FT V IE W OF TR AC TION VALV E
B4
– JLG Lift –
TRA CTION VA LVE B3
FR ON T VIE W OF
TR AC TION VALV E
A2
X
BOTTOM V IE W OF
TR AC TION VALVE
X B
X
A R IGH T RE AR
X H U B/DR IVE M OTOR
B
LEFT R EAR
H UB/D R IV E MOTOR REAR
Figure 3-7. Drive System Hydraulic Circuit - Sheet 1 of 2
3-9
3-10
FRO NT
TO
SWIVEL PORT 7
BR X1
LEFT FRONT RIGHT FRONT
HUB/DRIVE MOTOR HUB/DRIVE MOTOR
L1 X L1
X
X
X1
BR
CASE DRAIN MANIFOLD

BR
X X
TOP VIEW OF
TRACTION VALVE
X X
X X
L EFT RIGHT
TS
– JLG Lift –
X
X
TRACTION VALVE
X1
BR
X L1 L1
X
BR
X1
LEFT REAR RIGHT REAR
HUB/DRIVE MOTOR HUB/DRIVE MOTOR
REA R
Figure 3-8. Drive System Hydraulic Circuit - Sheet 2 of 2
3121619
Figure 3-9. Turntable Hydraulic System
3121619 – JLG Lift – 3-11

3.7 DRIVE ASSEMBLY
5 7
4
6
3
1. Drive Hub 3. Drive motor 5. Bolt 7. Bolt

2. O-Ring 4. Washer 6. Washer
Figure 3-10. Drive Assembly
3-12 – JLG Lift – 3121619

3.8 DRIVE HUB
1
22
2 20 23
3 38
4 21 24
5 39
6
25
39
7 41
8 40
26 42
9
10 27 43
28
44
11
29 45
12
46
30
47
13
48
49
14
31
50
15
51
32
16 49
48
33
52
17
33
53
34
54
18
35
55
36
19 56
37
1001149921
1. Ring 9. Pin 17. Pinion 25. Flange 33. Seal 41. Plastic Plug 49. O-Ring
2. Screw 10. O-Ring 18. Hub Housing 26. O-Ring 34. Coupling 42. Input Shaft 50. Brake Piston
3. Cover 11. Pinion 19. Screw 27. Ring Nut 35. Spring 43. Iron Disc 51. Brake Spring
4. Gasket 12. Retaining Ring 20. Screw 28. Set Screw 36. Retaining Ring 44. Brake Disc 52. Spacer
5. Plug 13. Gear Reduction Assy 21. Plug 29. Bearing 37. Bearing 45. Spacer 53. Retaining Ring
6. Cover 14. Pinion 22. Retaining Ring 30. Hub Support 38. Axle 46. Seal 54. O-Ring
7. O-Ring 15. Ring 23. Bearing 31. O-Ring 39. Plug 47. O-Ring 55. Motor Support
8. Shim 16. Gear Reduction Assy 24. Planet Wheel 32. Bearing 40. Plug 48. Seal 56. Screw
Figure 3-11. Drive Hub
3121619 – JLG Lift – 3-13

Disassembly 4. Remove, Ring (1), Cover (6), O-Ring (7), Spacer (8) and
O-Ring (10). Do not damage O-Rings. Check and remove
1. Remove plugs (5) and pour lubricant in a container. Gasket (4) if damaged.
Reinstall plugs.
2. Remove six screws (56), motor flange(55), and O-Ring
(54). Do not damage O-Ring.
55 10
54 6
56 1
7 8
18
5. Remove Pinion (11), Gear Reduction Assembly (13), and

Gear Reduction Assembly (16).
3. Remove two screws (2), cover (3), and pin (4).
16
13
11
3
2
3-14 – JLG Lift – 3121619

6. Remove two Screws (19), Planetary Ring (18) and O-Ring 8. Remove three snap rings (22) and planetary gears (24)
(26). Do not damage O-Ring. from spindles on Flange (25).
25
26
24
18
22
19
7. Remove Coupling (34) and Spring (35). 9. Remove two Set Screws (28) from Ring Nut (27). Remove
Ring Nut from Flange (25).
25
35
28
34 27
3121619 – JLG Lift – 3-15

10. Remove Hub Support (30), Bearing (29), O-Ring (31), 12. Remove Snap Ring (53), Spacer (52), Seal (48), O-Ring
Bearing (32), and two Seals (33) from Axle (38). (49), and Brake Piston (50) from Axle (38). Remove five
Brake Springs (51) from Brake Piston (50). Use com-
pressed air to remove Brake Piston from Axle.
38
33
32
31 51
30
49
48
29
52
53
50 38
11. Remove six screws (20), Plug (21), and Flange (25) from
Axle (38)., 13. Remove O-Ring (49), Seal (48), O-Ring (47), Seal (48),
Spacer (45), nine Brake Discs (43) and eight Iron Discs
(44) from Axle (38).
25
44
45
47
38 48
49 38
21
20 43
46
3-16 – JLG Lift – 3121619

14. Remove Split Ring (36), Input Shaft (42), and Bearing (37) 3. Install Seal (46), O-Ring (47), Seal (48), and O-Ring (49) in
from Axle (38). Axle (38). Starting with Brake Disk (43) alternate with
Iron Disk (44) until a total of eight Brake Disks and nine
Iron Discs are installed on Input Shaft (42 - not shown) in
Axle.
38
42
37 44
36
45
47
48
49 38
43
46
Assembly
NOTE: Thoroughly clean and coat all parts with grease before
assembling. 4. Install Brake Piston (50) in Axle (38). Install five Brake
Springs (51) Piston holes. Install O-Ring (49) and Seal
1. Check parts are free of damage, burrs, or other defects. (48) in Axle. Install Spacer (52) against Piston and secure
with Split Ring (53).
2. Install Bearing (37) in Axle (38). Install Input Shaft (42) in
Axle and Bearing. Secure with Split Ring (36).
38
42
51
49
48
52
53
37
36
50 38
3121619 – JLG Lift – 3-17

5. Install Flange (25) on Axle (38), with Plug (21) and six NOTE: Install Ring Nut with convex part facing bearing.
screws (20).
7. Install Ring Nut (27) on Flange (25). Prevent Flange from
turning and torque Ring Nut to 295 ft-lb (400 Nm).
Tighten and back off two times to completely seat bear-
ings. Tighten to final torque of 221 ft-lb (300 Nm). Check
roll torque with seal is within 7 - 11 ft-lb (10 - 15 Nm).
25 Apply Loctite 243 or equivalent to two Setscrews (28).
Install and torque Setscrews to 7.4 ft-lb (10 Nm) .
38
21
20
NOTE: Flat surface of bearings face toward inside of Hub Support.
6. Install two seals (33) on Axle (38). Install O-Ring (31) in

25
Hub Support (30). Install Bearing (32) and Bearing (29) in
Hub Support. Install assembled Hub Support on Axle as
shown below. 28
27
38
8. Install three planetary gears (24) on Flange spindles (25).
Secure with Snap Rings (22). Lubricate planetary gear
33 bearings.
32
31 25
30
29
24
22
3-18 – JLG Lift – 3121619

9. Install Spring (35) and Coupling (34). 11. Install Gear Reduction Assembly (16), Gear Reduction
Assembly (13), and Pinion (11) in Planetary Housing.
Lubricate all bearings.
16
13
11
35
34
10. Install O-Ring (26). Install Planetary Ring (18) with two 12. Install O-Ring (7) and O-Ring (10) in Cover (6). Liberally
Screws (19). Torque Screws to 36.8 ft-lb (50 Nm). coat Spacer (8) with grease and center on hole at center
of Cover. Install Cover on Planetary Ring Assembly (18)
and secure with Ring (1). Replace Gasket (4) as needed.
26
18
10
6
1
7 8
18
19 4
3121619 – JLG Lift – 3-19

13. Install O-Ring (54) and Motor Flange (55). Apply Loctite 15. Install Pin (4) and Cover (3). Secure with two Screws (2).
243 or equivalent to six Screws (56). Install and torque Torque to 7 ft-lb (10 Nm).
Screws to 177 ft-lb (240 Nm).
55
54
56
3
2
14. Check completed Drive Hub assembly rotates freely.
FAILURE TO PROPERLY FILL DRIVE HUB WITH OIL BEFORE OPERATION WILL
RESULT IN EQUIPMENT FAILURE AND COULD CAUSE DEATH, SERIOUS INJURY,
OR DAMAGE TO PROPERTY AND EQUIPMENT.
16. Follow oil change procedures and refill Drive Hub before
operating equipment.
3-20 – JLG Lift – 3121619

3.9 FREE WHEELING OPTION 3.10 GEAR HUB OIL SERVICE

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

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

HUB
DISENGAGEMENT
COVER (REVERSED)
DRIVE
HUB 2
Drive Hub Disengaged
Figure 3-13. Gear Hub Oil Fill and Drain
Figure 3-12. Disengaging Drive Hubs
3121619 – JLG Lift – 3-21

5
4
6
3
1
9
3 10
11
2 7 12
13
8
14
15
20 16
17
18
19
21
22
23
24
26
30
25
27
29 31
32 28
33
34
35
36
34
3160339
1. Bolt 7. Needle Bearing 13. Cylinder Block 19. O-Ring 25. Gasket 31. Shaft
2. Motor End cap 8. Valve Plate 14. Slipper Pin 20. Servo Piston 26. Plug 32. Bearing
3. Locating Pin 9. Snap Ring 15. Guide 21. Spring 27. O-Ring 33. Snap Ring
4. O-Ring 10. Spring Retainer 16. Slipper Retainer 22. Pin 28. Plug 34. Snap Ring
5. Plug 11. Spring 17. Cylinder Piston 23. Swashplate 29. O-Ring 35. Seal
6. Dowel Pin 12. Washer 18. Piston Ring 24. Bearing Kit 30. Housing 36. Seal Support Washer
Figure 3-14. Drive Motor
3-22 – JLG Lift – 3121619

3.11 DRIVE MOTOR Shaft Seal Replacement

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

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

INSPECTION 2. Using a 1/4 in hex wrench remove plug (3).

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

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

2. Plug 7. Spring 12. Shift Spool
3. Plug 8. Spring 13. Orifice Poppet
4. O-ring 9. Spring
5. O-ring 10. Washer
Figure 3-17. Loop Flushing Spool
3-24 – JLG Lift – 3121619

Troubleshooting
Table 3-2. Excessive Noise and/or Vibration
Item Description Action

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

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

Check signal line to servo control Obstructed or restricted flow through servo control signal lines could Ensure signal lines are not obstructed or restricted and signal pressure is
port. result in slow shift or no shift motor conditions. adequate to shift motor.
Check correct supply and drain ori- Supply and drain orifices determine motor shift. The smaller the orifice, Ensure proper control orifices are installed in motor and not obstructed.
fices are properly installed and not the longer the time it takes to shift the motor. Obstruction also increases Clean or replace as necessary.
obstructed. shift times.
3121619 – JLG Lift – 3-25

Disassembly
NOTE: Removal of endcap voids warranty.
17
19
During assembly, coat all moving parts with a film of clean
hydraulic oil. This ensures parts will be lubricated during
start-up.
Replace all O-Rings and gaskets. 15
It is recommended that all O-rings be replaced. Lightly 14

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

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

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

port plugs (21, if equipped with axial ports). Discard O-
rings.
3-26 – JLG Lift – 3121619

22 25
30 27
29
29
23 26
28
24
25. Valve Plate 28. O-ring

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

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

34 33 32
31
32. Snap Ring

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

Lift Here
36 39
35
37
38 40
43
42
41
35. Inner Snap Ring 37. Bearing

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

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

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

27. Turn block over. Using a press, apply pressure on block

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

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

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

FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS
SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING.
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED.
3-30 – JLG Lift – 3121619

CYLINDER BLOCK
Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface.
Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing
will not reduce block height below minimum specification. Table 3-7, Cylinder Block Measurements.
Table 3-7. Cylinder Block Measurements
Measurement L25 L30 L35 K38 K45

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

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

Replace journal bearings if scratched, warped, or excessively
worn. Polymer wear layer must be smooth and intact.
3121619 – JLG Lift – 3-31

SHAFT BEARINGS Assembly

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

6. Install journal bearings (13) in housing seats. Use assem-

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

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

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

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

retainer assembly in cylinder block. Ensure concave sur-
face of retainer seats on ball guide. If reusing pistons,
install them in original block bores. Lubricate pistons,
slippers, retainer, and ball guide before assembly. Set
cylinder kit aside on a clean surface until needed.
3121619 – JLG Lift – 3-33

8. Press front shaft bearing (15) on shaft (16). Press bearing 11. Lubricate and install servo spring (20) and minimum
on shaft with lettering facing out. Lubricate bearing roll- angle stop (21) in housing bore.
ers. Install snap-ring (17) on shaft.
21
20
15
16
17
18
15. Front Shaft Bearing 17. Snap Ring

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

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

Install cylinder kit (19) on shaft. Install with slippers fac-
ing swashplate. Rock the shaft to align block splines and
slide cylinder kit into place. Orient motor with shaft
pointing downward and verify cylinder kit, swashplate,
20. Servo Spring
journal bearings, and servo piston are properly installed.
21. Minimum Angle Stop
19 Figure 3-31. Servo Spring and Minimum Angle Stop
19. Cylinder Kit
Figure 3-30. Cylinder Kit Installation
3-34 – JLG Lift – 3121619

12. Press rear shaft bearing (22) in endcap. Install bearing 15. Install endcap (25) on housing with endcap screws (26).
with letters facing out. Press until bearing surface is 0.08 Ensure endcap will properly seat to housing without
±0.01 in (2 ±0.25 mm) above endcap surface. interference. Improper assembly of internal compo-
nents may prevent endcap from seating properly.
Ensure O-rings seat properly when installing endcap.
22 0.12 in
0.08 in 23 (3 mm)
26
8 mm
35-45 ft-lbs
23 (47-61 Nm)
22
24
25
23
22. Rear Shaft Bearing

23. Timing Pin
24. Valve Plate
Figure 3-32. Valve Plate and Rear Bearing 25. End Cap
13. Install timing pin (23) into its bore in the endcap. Install 26. Screw
pin with groove facing toward or away from shaft. Press
Figure 3-33. End Cap
pin until end protrudes 0.12 ±0.01 in (3 ±0.25 mm)
above endcap surface. 16. Using an 8 mm internal hex wrench, tighten endcap
screws. Tighten screws in opposite corners slowly and
14. Install valve plate (24) on endcap. Install valve plate with
evenly to compress the servo spring and properly seat
yellow surface toward cylinder block. Align slot in valve
the endcap. Torque endcap screws 35-45 ft-lb (47-61
plate with timing pin. Apply a liberal coat of assembly
Nm).
grease to endcap side of valve plate to keep it in place
during installation. 17. Before installing shaft seal, ensure shaft turns smoothly
with less than 120 in-lb (13.5 Nm) of force. If shaft does
not turn smoothly within specified maximum force, dis-
assemble and check unit.
3121619 – JLG Lift – 3-35

18. Cover shaft splines with an installation sleeve. Install a 20. Install orifice poppet (30).
new shaft seal (27) with cup side facing motor. Press seal
in housing until it bottoms out. Press evenly to avoid
binding and damaging seal. Install seal support washer 37
(28) and snap ring (29). 36
39 33 41
34 11/16 in
30
27 ft-lb
40 (37 Nm)
5/8 in
27 28 29 20 ft-lb
(27 Nm)
32 31
35
38
42
11/16 in
27 ft-lb
(37 Nm)
27. Shaft Seal

28. Seal Support Washer 30. Orifice Poppet 34. Spring 37. O-ring 40. Plug
29. Snap Ring 31. Shift Spool 35. Spring 38. O-ring 41. Plug
32. Spring 36. Spring 39. O-ring 42. Plug
Figure 3-34. Shaft Seal 33. Spring
19. Install remaining plugs and fittings to housing. Refer to Figure 3-36. Loop Flushing Spool
drawing below for wrench sizes and installation torques.
21. Install shift spool (31).
5/16 in 22. Install spring retaining washers on springs (32 and 33).
63 ft-lb (85 Nm)
1/4 in 23. Carefully install centering springs (34, 35, and 36).
33 ft-lb (45 Nm) 24. Install new O-rings (37, 38, and 39).
25. Using a 5/8 in wrench torque plug (40) to 20 ft-lb (27
Nm).
26. Using a 11/16 in wrench, torque plugs (41 and 42) to 27
ft-lb (37 Nm).
9/16 in
125 ft-lb
(170 Nm)
3 mm
1.5 - 2.5 ft-lb
(2 - 3 Nm)
1/4 in
33 ft-lb (45 Nm)
5/16 in
63 ft-lb (85 Nm)
Figure 3-35. Plugs and Fittings Installation
3-36 – JLG Lift – 3121619

Initial Start-up 2. Place shim between pinion and bearing on bearing high
spot.
Follow this procedure when starting-up a new motor or when
installing a motor that has been removed.
INSPECT MOTOR FOR DAMAGE BEFORE INSTALLATION. MAKE CERTAIN ALL

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

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

Set backlash 0.10 to 0.15" (0.254 to 0.381 mm) using the fol-
lowing procedure.
1. Place machine on firm, level ground. NOTE: Make sure turntable is properly supported during the fol-
lowing step. The turntable can swing a few degrees when
turntable lock is removed if turntable is not balanced.
4. Remove turntable lock pin.
3121619 – JLG Lift – 3-37

5. Apply JLG Thread locking compound P/N 0100019 to 10. Discard shim.
the bolts. Pre-torque the five bolts to 45 ft-lb (6 kgm).
11. Rotate bearing high spot 15° to the second drive hub.
Repeat procedure.
6. Tighten setscrew until pinion is completely snug against
shim and bearing. Back off setscrew.
7. Torque setscrew to 50 ft-lb (7 kgm).
8. Apply JLG Thread locking compound P/N 0100019.

Tighten jam nut.
9. Torque bolts to 340 ft-lb (47 kgm).
3-38 – JLG Lift – 3121619

3121619
Upperstructure - 39,000 lbs (17,690 kg)
31 .7 " (8 0 cm)
CEN TER
OF
GRAVITY
– JLG Lift –
Figure 3-37. Swing Bearing Removal - Sheet 1 of 4
3-39
3-40 – JLG Lift – 3121619

B oom Assembly - 21,650 lbs ( 9,82 0 kg)
3121619
– JLG Lift –
CENTER
OF
GRAVITY
Main Boo m Pivot
3-41
3-42
83.3" (212 cm) Turntable - 15,350 lbs (6,963 kg)
Note: Attach Lifting Device to

Turntable Cutouts Closest to
This Side of Turntable
– JLG Lift –
3121619
3.13 SWING CONTROL SYSTEM main boom length is less than 1477.7 inches in the 500 lb
mode or 1442.8 inches in the 1000 lb mode.
The swing control system uses the turntable swing angle sen-
sor in addition to the Drive Orientation System (DOS) proxim- The 8.0º angle is used exclusively for the purpose of automati-
ity switch to prevent turntable swing while the axles are cally shifting the drive motors to the maximum displacement
retracted. Swing will be allowed to +/- 35 degrees (before the position (slow speed).
DOS proximity switch trips) to facilitate positioning the turnta- The control system responds to indicated angle readings 0.3
ble for transport of the machine. Attempts to swing past this degree smaller than the required angles to account for calibra-
position will be disallowed by the control system and the tion and sensor variation.
operator will be prompted via the LCD display in the platform
to swing in the opposite direction to return the boom behind
the rear wheels. Once the axles are extended the boom has 3.15 AUXILIARY POWER SYSTEM
360 degree continuous turntable swing. If the turntable is
swung past +/- 35° when the boom is lowered into the trans- The auxiliary power system is intended as a secondary means
port position, the operator will have to swing the turntable of moving the boom in the event of primary power loss. This
back within the rear wheels before attempting to retract the system uses an electric motor/pump unit powered by two12V
axles. batteries capable of operating all functions except drive, con-
trolled arc, controlled boom angle, and envelope tracking.
During main lift up or down functions, no other functions are
3.14 CHASSIS TILT INDICATOR SYSTEM permitted and during main lift up functions, automatic plat-
The Chassis Tilt Indicator System measures turntable angle form leveling is not active but jib leveling is active. To reduce
with respect to level ground. The tilt sensor (mounted to a battery demand and extend system run time, the auxiliary
bracket on the side of the turntable near the boom pivot pin) power functionality differs from the primary power functional-
has three settings; 3.0 side tilt, 5.0 omni directional tilt, and an ity. The auxiliary power main lift down function supplies pilot
8.0 omni directional tilt. pressure to the main lift cylinder. This allows gravity to lower
the boom. The system redirects discharge oil from the main lift
cylinder to retract the main telescope cylinder. At high main
boom angles the envelope may be encroached during lift
down requiring the operator to use main telescope in.
When the main boom is retracted to transport length, the
main telescope in valve is dropped out and lift down is oper-
ated alone allowing platform to reach the ground. This not
only greatly reduces power required for these functions but
also lowers the boom within the envelope regardless of start-
ing position. Jib lift down function may then be operated
allowing platform to reach ground level. Envelope control and
moment control remain active during auxiliary power func-
tion.
The 5.0 omni directional angle setting is used for the purpose
of warning the operator by means of the chassis tilt light in the
platform display panel. Additionally when used in conjunction
with the Beyond Transport - Drive Speed Cutback System, the
tilt sensor will cause an alarm to sound and automatically put
all functions in the creep speed mode and drive will be cut
out. With the exception of the drive being cut out, this is a
warning system only indicating to the operator that the
machine has reached the out of level limit. The machine will
continue to function. The operator is responsible to prevent
the machine from attaining an unstable position.
The 3.0° side tilt setting is used in conjunction with the main
boom length and when exceeded, imposes the same func-
tionality as the 5.0° omni directional setting plus prevents
boom telescope out. The side tilt setting is ignored when the
3121619 – JLG Lift – 3-43

3.16 DEUTZ TURBOCHARGER OPERATION LOW AIR TEMPERATURES & INACTIVE OPERATION
If the engine has been inactive for some time or the air tem-
Good engine operating procedures are essential to prolong perature is very low, crank the engine first and then run at idle.
turbocharger life. This allows the oil to circulate throughout the full system
before high loads and speeds are applied to engine and turbo-
Particular attention to oil system and air system will eliminate
charger.
the two main causes of turbocharger failure. To prevent this
Operators/Owners must ensure that :-
SHUT DOWN
1. Air and oil filters are checked regularly to the manufac- Before shutting the engine down, let the turbocharger cool
turer's specifications. down. When an engine runs at maximum power/high torque,
the turbocharger is operating at very high temperatures and
2. Engine maintenance intervals are adhered to. speeds. Hot shut down can cause reduced service life which is
3. Engine and equipment are operated in such a way that avoidable by a minute or two of idling. Most mobile equip-
is not harmful to the life of the turbocharger. ment applications include an adequate cooling period during
parking or mooring procedures.
Operating Practices Allow the engine to idle for 1-5 minutes to allow the high tem-
peratures and speed to reduce and thus prolong the life of the
Operators and owners can get maximum service life from their
turbocharger.
turbochargers if a few good practices are followed:
ENGINE IDLE
START UP Avoid running the engine for long periods in idle mode
When starting the engine use minimum throttle and run in (greater than 20-30 minutes). Under idling conditions low
idle mode for approximately one minute. Full working oil pres- pressures are generated in the turbocharger which can cause
sure builds up within seconds but it is useful to allow the tur- oil mist to leak past seals into the two end housings. Although
bocharger moving parts to warm up under good lubricating no real harm is done to the turbocharger, as load is applied
conditions. Revving the engine within the first few seconds of temperatures increase and the oil will start to burn off and
start up causes the turbocharger to rotate at high speeds with cause blue smoke emission problems.
marginal lubrication which can lead to early failure of the tur-
bocharger. In the picture above you can see discoloration on the shaft
caused only by heat. If the engine is allowed to Idle for a
AFTER SERVICING period of time, lube oil will continue to flow cooling the tur-
After servicing the engine or turbocharger, ensure the turbo- bine shaft.
charger is pre-lubed by adding clean engine oil into the turbo- You can also see spots on the turbo where grooves have been
charger oil inlet until full. After pre-lubing, crank the engine "worn" in to the turbine shaft at the point where the radial
without firing (engine/fuel pump stop out) to allow oil to cir- bearing sits. Dirty oil/contaminates in the oil can become
culate through the full system under pressure. On starting the trapped in between the radial bearing and the surface of the
engine, run at idle for a few minutes to ensure the oil and bear- shaft becoming abrasive and ultimately grinding away the
ing systems are operating satisfactorily. material.
3-44 – JLG Lift – 3121619

3.17 DIESEL EXHAUST FLUID (DEF) TANK Cleaning and Flushing the Tank
Refer to Figure 3-41. and Figure 3-42. If contaminated fluid or foreign material is found in the tank,
the tank must be cleaned. Use the following procedure for
Diesel exhaust fluid (DEF) is a urea solution consisting of 32.5%
cleaning.
urea and 67.5% deionized water. DEF is used in selective cata-
lytic reduction (SCR) to lower nitrogen oxide (NOx) concentra- 1. Remove the DEF tank drain plug, and drain any fluid into
tion in exhaust emissions. a suitable container. Dispose of fluid properly.
DEF is temperature sensitive in storage. If stored between 75°F 2. Clean the header with a mixture of warm water and a
(24°C) and 12°F (-10°C), it can be stored for 2 years. In the light petroleum based soap.
machine’s DEF tank, the storage life is 4 months. After 4
months, the DEF must be drained from the tank, properly dis- 3. Clean DEF tank with a high pressure washer, or flush
posed of, and the tank cleaned and flushed. If the machine has tank with hot water for five minutes and drain water.
been idle in an extreme cold environment (-40° to 32°F [-40° to 4. If DEF fluid lines are contaminated, tag and remove the
0°C]), the interval is reduced to 2 months. lines from the DEF pump module and flush with a mix-
ture of warm water and a light petroleum based soap.
NOTE: DEF freezes at 12°F (-11°C).
5. Refill DEF tank with water until it overflows. Completely
flush tank with water.
6. Empty DEF tank, and dispose of contaminated water
properly.
7. Rinse the tank and all soap residue with deionized or
distilled water and allow to air dry.
3121619 – JLG Lift – 3-45

Figure 3-41. Diesel Exhaust Fluid (DEF) Tank - Sheet 1 of 2
3-46 – JLG Lift – 3121619

1. Coolant Tube 13. Header

2. Level Tube 14. Metallic Flange
3. DEF Filter 15. Cover
4. Tie-Wrap 16. Screw
5. Rubber Bushing 17. Spring Tube
6. Float Assembly 18. Urea Quality Sensor
7. Suction Tube 19. DEF Electric Assembly
8. Suction Strengthening Plate 20. Breather
9. Return Tube 21. Cap
10. Return Strengthening Plate 22. Drain Plug
11. Connector 23. Tank
12. Rubber Header
Figure 3-42. Diesel Exhaust Fluid (DEF) Tank - Sheet 2 of 2
3121619 – JLG Lift – 3-47

3-48
– JLG Lift –
Figure 3-43. Diesel Exhaust Fluid (DEF) System - Sheet 1 of 7
3121619
3121619
– JLG Lift –
3-49
3-50
– JLG Lift –
3121619
3121619
– JLG Lift –
3-51
3-52
– JLG Lift –
3121619
3121619
– JLG Lift –
3-53
Figure 3-49. Engine Electrical Circuit
3-54 – JLG Lift – 3121619

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

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

RANTY COVERAGE.
Diesel Fuel
Engines equipped with an SCR system (Selective Catalytic Figure 3-50. Mixing Petroleum With Summer Diesel Fuel
Reduction) may only be operated with sulphur-free diesel
fuels (EN 590, ASTM D975 Grade 2-D S15, ASTM D975 Grade 1- The mixing should take place in the engine tank. First pour in
D S15 or heating oil in EN 590 quality). Otherwise compliance the necessary amount of petroleum or kerosene, and then add
with the emission requirements and durability is not guaran- the diesel fuel.
teed.
In a warranty case the customer must prove by a certificate

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

Fuels with a sulphur content > 0.5% (m/m) (5,000 mg/kg)
demand a shorter lubricating oil change interval. Fuels with a
high sulphur content may not be used in engines with exhaust
gas after-treatment. Fuels with a sulphur content > 1.0% (m/
m) are not permissible due to high corrosion and considerable
shortening of the engine life. Low-ash / low SAPS engine lubri-
cating oils (sulphate ash max. 1.0% (m/m)) may only be used in
engines without exhaust after-treatment systems if the sul-
phur content in the fuel does not exceed 50 mg/kg. However,
low-ash lubricating oils may be used in engines without
exhaust gas after-treatment systems up to sulphur contents of
500 mg/kg if the base number (TBN) is at least 9 mg KOH/g.
3121619 – JLG Lift – 3-55

3.19 SELECTIVE CATALYTIC REDUCTION (SCR) - 2. Move the machine to an area free of flammables and
personnel that could be exposed to hot exhaust. Launch
MACHINES USING DIESEL EXHAUST FLUID (DEF) the cleaning process by pressing the SCR button on the
Selective Catalytic Reduction (SCR) is an emissions control Ground Console for 3 seconds. The Indicator Gauge will
used in diesel engines. display the following screen.
This system injects a liquid-reductant agent through a special

catalyst into the exhaust stream of a diesel engine. The reduc-
tant source is usually automotive-grade urea known as Diesel
Exhaust Fluid (DEF). DEF sets off a chemical reaction that con-
verts nitrogen oxides into nitrogen, water, and tiny amounts of
carbon dioxide (CO2), which is then expelled through the
engine exhaust pipe.
For peak operation, the SCR system must be cleaned using
one of two methods, Standstill Cleaning and Maintenance
Standstill Cleaning. Standstill Cleaning is any cleaning
requested by the engine outside of the regular maintenance
window (for example, if the system detects crystallization in
the DEF solution). Maintenance Standstill Cleaning is cleaning
requested by the engine on the maintenance interval. 3. The Main Cleaning process will begin and last for
SCR technology is designed to permit nitrogen oxide (NOx) approximately 30 to 60 minutes. The following screen
reduction reactions to take place in an oxidizing atmosphere. will show that the process has begun and includes a sta-
It is called "selective" because it reduces levels of NOx using tus bar that indicates the progress of the cleaning pro-
ammonia as a reductant within a catalyst system. The chemi- cess.
cal reaction is known as "reduction" where the DEF is the
reducing agent that reacts with NOx to convert the pollutants
into nitrogen, water and tiny amounts of CO2. The DEF can be
rapidly broken down to produce the oxidizing ammonia in the
exhaust stream. SCR technology alone can achieve NOx reduc-
tions up to 90 percent.
NOTE: The system will reset the maintenance interval back to 0

hours after Standstill or Maintenance Standstill cleaning
events are performed.
Standstill Cleaning
The following conditions must be met to perform Standstill
Cleaning.
• Machine must be stationary
• Engine must be idling
• Coolant temperature must be above 104° F (40° C)
• Diesel Exhaust Fluid (DEF) tank must not be frozen
• Machine in Ground Station mode
1. The Selective Catalytic Reduction Indica-
tor will flash when standstill cleaning is
required.
3-56 – JLG Lift – 3121619

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

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

Maintenance Standstill Cleaning will be stopped immediately
if:
• The Platform/Ground Select switch is switched from
Ground to Platform mode
• Function switch is enabled to perform a boom function
• The Engine is powered down
If Maintenance Standstill Cleaning is interrupted, it must be re-
initiated.
If Maintenance Standstill Cleaning is interrupted, it must be re-
initiated and the Indicator Gauge will display the "Regen
Failed" screen as shown.
3121619 – JLG Lift – 3-57

Table 3-8. Maintenance Standstill Cleaning
Machine Hours
Standstill Cleaning System Distress SCR Cleaning
Since Last Derate Comments
Levels Light Light
Cleaning
0-500 Between 500 and 1000 hours, clean-
Normal
0 -- -- None ing cycle can be initiated with JLG
Operation 500-1000 analyzer.
Standstill
1 1000-1100 -- None
Required
0.5 Hz Engine coolant temperature muxt
be >40° C and DEF should be thawed
Machine placed in before cleaning can be initiated.
Warning
2 1100-1125 Creep and DTC
Level
active
Continuous 0.5 Hz
Idle Lock. Boom Contact Deutz Dealer.
Shut Off Functions Locked
3 >1125
Level Out and Trapped in
Blinking 3 Hz Transport.
Table 3-9. Cleaning When Crystallization is Detected During SCR
Machine Hours
Cleaning
Crystallization after System Distress SCR Cleaning
Initiation Derate
Levels Crystallization Light Light
Methods
No Crystallization
Normal Operation -- -- -- None
Detected
Crystallization Detected SCR Switch

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

Crystallization Detected Contact Deutz Functions Locked
>600
Shut Off Level Dealer. Out and Trapped in
Blinking 3 Hz Transport.
3-58 – JLG Lift – 3121619

Table 3-10. Engine Fault Codes
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
38 731 523925 3 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A88, K57 cannot be 1- Lamps K57: Warn Ash Charge, Diagnostic, pins A88, K57.
activated. Warn Coolant Temp/Level, Warn Oil,
Internal ECU power stage switched off. Warn Boost Air, Warn Air Filter, Warn Water in
Fuel, SCR, Regeneration, Engine
Running.
2- Relay Preheat A88
3- Exhaust Flap A88
40 733 523927 3 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A04, A05 cannot be 1- Urea Pump A04 pins A04, A05.
activated. 2- SCR Heater A05
Internal ECU power stage switched off.
42 167 523924 4 Overload at Pins O_V_RH2x: A01, K74, K91. Suspected components: Threshold for error detection is an internal ECU
Components on A01, K74, K91 cannot be 1- Pin K91: threshold.
activated. Clutch switch, Brake switch, Engine brake Check wiring harness and connected loads on
Internal ECU power stage switched off. demand, Regeneration activation, Parking pins A01, K74, K91 and/or reflash ECU.
brake, Gearbox N, Fan control 1 If error is still present, exchange ECU.
2- Pin K74:
Boost air cooler bypass or electrical fuel pump
relay, Fan control 2/fuel valve for flame
star
43 731 523925 4 Short circuit to ground actuator relais 3 Suspected components: Threshold for error detection is an internal ECU
Overload at Pins O_V_RH3x: A88, K57 1- Pin A88: threshold.
Preheat relay, Exhaust flap Check wiring harness and connected loads on
2- Pin K 57: pinsA88, K57.
- control lamps: If error is still present, exchange ECU.
- OBD, preheat lamp, warning temp., warning
oil, maintenance lamp, regeneration
indicator, alternator management, engine run-
ning, diagnostic
44 732 523926 4 Short circuit to ground aktuator relais 4. Suspected components:Fan, Wiring harness Threshold for error detection is an internal ECU
Overload at Pins O_V_PCV: A90 threshold.
Check wiring harness and connected loads on
pin A90.
If error is still present, exchange ECU.
45 318 168 3 Battery voltage: the voltage measured by Battery voltage above warning threshold Check wiring harness and connected alternator.
ECU is out of the target range, system reac- (~38,9Volt), Short cut to battery possible.
tion is initiated
46 318 168 4 Battery voltage: the voltage measured by Battery voltage below warning threshold, Check wiring harness and connected alternator.
ECU is out of the target range, system reac- Short cut to ground
tion is initiated
47 318 168 2 Battery voltage: the voltage measured by If Batteryvoltage (Ubatt_U) > 17V or 31V for Check wiring harness and connected alternator.
ECU is out of the target range, system reac- mor than =0.5sec a warning is generated
tion is initiated Battery voltage above warning threshold
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Deutz Blink
Code Code
73 7-2-2 523912 4 @ engines < 4l: The sensed raw voltage value is below the mini- The sensed raw voltage value
Throttle valve error, Open Load or Short cut mum threshold. DPM_uRawBrnDVDsP is above the minimum
to Battery, blocked valve or wrong control threshold
signal for valve. DPM_SRCBrnDVDsP.uMin_C
@ engines with Burner T4i: @ CRT < 4l: check throttle valve
Pressure Sensor error after valve (DV2), @ engines with Burner T4i: check back-pressure
lower limit reached valve
84 271 639 14 CAN bus 0: the ECU is not allowed to send CAN BusOff error; CAN 0 (Customer CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold.
detected. BusOff bit for CAN A node is set.
Check wiring of CAN bus and if necessary repair
it, check connection cable and if
necessary repair or replace it, check resistance in
CAN lines (120 Ohm)
85 271 1231 14 CAN bus 1: the ECU is not allowed to send CAN BusOff error; CAN 1 (Diagnostic CAN) Threshold for error detection is an internal ECU
detected BusOff bit for CAN B node is set.
Warning, no diagnostic with SERDIA2010 Check wiring of CAN bus and if necessary repair
possible it, check connection cable and if
CAN lines (120 Ohm)
86 271 1235 14 CAN bus 2: the ECU is not allowed to send CAN BusOff error; CAN 2 (Engine CAN) Threshold for error detection is an internal ECU
detected. BusOff bit for CAN C node is set.
Warning, depends on engine, EAT. Check wiring of CAN bus and if necessary repair
it, check connection cable and if
CAN lines (120 Ohm)
88 223 102 2 Charge air pressure messured by sensor is Charged air cooler pressure below threshold. Check waste gate system if necessary replace
above the shut off threshold. TC,
check CAC if all channels are clean,check charge
air piping if nececery.
89 223 102 2 Charge air pressure messured by sensor is Charge air pressure above shut off threshold Check waste gate system if necessary replace
above the warning threshold TC, check CAC if all channels are clean,
check charge air piping if necessery.
93 225 110 1 Coolant temperature sensor: the voltage of Suspected components:wiring harness, cool- Check wiring harness and connected Coolant
the sensor measured by ECU is out of the tar- ant temperature sensor. Temp Sens.
get range.
96 225 110 3 Coolant temperature sensor: the voltage of Short cut to battery or open load. Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- connection cable and if necessary
get range repair or replace it.
97 225 110 4 Coolant temperature sensor: the voltage of Voltage Surveillance has found shortcut to Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- Ground at Coolant Temperatur Sensor. connection cable and if necessary
get range repair or replace it
Measure Voltage at Coolant Temperature Sen-
sor and renew harness if needed.
98 232 110 0 Coolant temperature: the coolant tempera- Cooling temperature too high. Coolant temper- Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target ature above warning threshold level, check cooling system in general,
range; the ECU activates a system reaction check thermostat function, check water pump
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Deutz Blink
Code Code
99 232 110 0 Coolant temperature: the coolant tempera- Coolant temperature above shut off threshold. Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target level, check cooling system in general,
range. check thermostat function, check water pump
The ECU activates a system reaction
101 235 111 1 Coolant level: the coolant level calculated by Coolant level too low, leakage in cooling sys- Check coolant level, inspect cooling system for
ECU is underneath the allowed minimum. tem, sensor defective, wiring damaged. leakage and if necessary repair it,
check sensor and wiring
121 341 1109 2 Request of engine shut off: the operator Engine Shut Off demand has been ignored by Depending on error requested a shut off.
ignores the engine shut off request within an the user
allowed period.
122 591 523698 11 Shut off request from supervisory monitor- Engine Shut Off due to supervisory function Threshold for error detection is an internal ECU
ing function threshold.
Check error memory for additional errorcode to
find root cause.
Depending on additional error follow the docu-
mented "Take action for repair".
129 596 3224 2 DLC Error of CAN-Receive-Frame AT1IG1Vol Not Used Threshold for error detection is an internal ECU
NOX Sensor (SCR-system upstream cat; DPF- threshold.
system downstream cat); length of frame Check Nox-Sensor and the wiring from CAN-
incorrect BUS.
130 597 3224 9 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX sensor and sensor connection check
AT1IG1Vol; NOX sensor (SCR-system
upstream cat; DPF-system downstream cat)
133 766 523938 9 Timeout Error (BAM to packet) for CAN- Failure of the CAN Bus message NOX sensor and sensor connection check
Receive-Frame AT1IGCVol1 information;
factors & Sensorcalibration for NOX Sensor
(SCR-system upstream cat; DPF-system
downstream cat)
134 766 523939 9 Broadcast Announce Message of the calibra- Defective Nox sensor, faulty parameterization NOX sensor and sensor connection check
tion message
of the upstream catalytic NOx sensor has
failed.
Timeout Error (BAM to BAM) for CAN-
Receive-Frame AT1IGCVol1 information.
(SCR-system upstream cat, DPF-system
downstream cat).
135 766 523940 9 Timeout Error (PCK2PCK) for CAN-Receive- Failure of the CAN Bus message NOX sensor and sensor connection check
Frame AT1IGCVol1 information; factors &
Sensorcalibration for NOX Sensor (SCR-sys-
tem upstream cat; DPF-system
downstream cat)
138 114 3234 2 DLC Error of CAN-Receive-Frame AT1O1Vol Failure of the CAN Bus message NOX downstream sensor and sensor connection
NOX Sensor (SCR-system downstream cat; check
DPF-system downstream cat); length of
frame incorrect
139 117 3234 9 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX downstream sensor and sensor connection
AT1OG1Vol; NOX sensor (SCR-system down- check
stream cat; DPF-system downstream cat)
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Deutz Blink
Code Code
140 767 523941 9 Timeout Error (BAM to packet) for CAN- Timeout Error (Missing CAN Bus message) NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information; check
(SCR-system downstream cat; DPF-system
downstream cat)
141 767 523942 9 Timeout Error (BAM to BAM) for CAN- Defective Nox sensor, faulty parameterization. NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information, check.
Calibration message 1 of the after catalyst
NOx sensor has failed.
Factors & Sensorcalibration for NOX Sensor
(SCR-system downstream cat, DPF-system
downstream cat)
142 767 523943 9 Timeout Error (PCK2PCK) for CAN-Receive- The fault is detected when a timeout error in NOX downstream sensor and sensor connection
Frame AT1OGCVol2 information; factors & packet 2 of NOxSenVol2Rx frame occurs. check
Sensorcalibration for NOX Sensor (SCR-sys-
tem downstream cat; DPF-system
downstream cat)
168 763 523935 12 Timeout Error of CAN-Transmit-Frame Fault is detected if a TimeOut of the EEC3VOL1 Check wiring harness and customer nodes
EEC3VOL1; Engine send messages frame has occured.
169 764 523936 12 Timeout Error of CAN-Transmit-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
EEC3VOL2; Engine send messages
171 3-3-3 523212 9 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer devices
ComEngPrt; Engine Protection
179 527 523240 9 Timeout CAN-message FunModCtl; Func- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
tion Mode Control short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
291 119 523776 9 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Threshold for error detection is an internal ECU
- active threshold.
Check CAN Bus cabling (Bus sheduling, polarity,
short circuit, power interrupt), test
range.
292 119 523777 9 Message TSC1-TE has been missing (passive) Passive timeout Error (Missing CAN Bus mes- Check CAN Bus cabling (Bus scheduling, polar-
sage) ity, short circuit, power interrupt), test
range, check actuator
305 118 898 9 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
- active short circuit, power interrupt), test
range.
360 737 523982 0 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not high. to too high battery voltage. repair or replace if necessary.
361 737 523982 1 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not low. to too low battery voltage. repair or replace if necessary.
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Deutz Blink
Code Code
376 281 630 12 Internal hardware monitoring: the ECU finds Section could not be erased Threshold for error detection is an internal ECU
an error during the access to its EEPROM threshold.
memory or works with an alternative value There is no healing possible for the error. In the
every new initialization phase, the
debounce level is set to zero.
If not programmed, EEPROM is defect --> ECU is
defect, reprogramm ECU and if
necessary replace it.
377 281 630 12 Internal hardware monitoring: the ECU finds Minimum 3 blocks could not be readed, There is no healing possible for the error. In the
an error during the access to its EEPROM EEPROM has Checksum Error every new initialization phase, the
memory or works with an alternative value debounce level is set to zero.
If not programmed, EEPROM is defect -->ECU is
necessary replace it
378 281 630 12 Internal hardware monitoring: the ECU finds Block could not be written for minimum 3 times Threshold for error detection is an internal ECU
an error during the access to it's EEPROM threshold.
memory or works with an alternative value If not programmed, EEPROM is defect --> ECU is
necessary replace it.
381 693 411 4 Range check cannot be done or interrupted. EGR or wiring defect Check wiring harness and connected EGR.
387 555 523612 12 Internal hardware monitoring: the CPU of Injector shut off demand for the ICO coordinator Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- System responses: threshold.
nally; no item will be created in error mem- not Caution ! Sequence error, check error memory
ory for other errors.
389 214 190 0 Engine speed: the engine speed calculated Overspeed monitoring during 1 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over Limit.
390 214 190 11 Engine speed: the engine speed calculated Overspeed monitoring during 2 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over limit.
391 214 190 14 Engine speed: the engine speed calculated Overspeed monitoring during ORC (Override check powertrain settings regarding overspeed
by ECU is above the target range; the ECU conditions) if engine speed was over
activates a system reaction 2900rpm
417 312 171 3 Sensor error SCR-System environment tem- open loop to sensor Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check high and if necessary replace it, check connection
cable and if necessary repair or replace it.
418 312 171 4 Sensor error SCR-System environment tem- short circuit to Ground Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check low and if necessary replace it, check connection
cable and if necessary repair or replace it
419 212 190 8 Camshaft speed sensor: the ECU receives no When disturbed camshaft signal detected. Threshold for error detection is an internal ECU
signal and uses the signal from crankshaft Error in sensor or wiring. threshold, occurs by disturbed
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
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Deutz Blink
Code Code
420 212 190 12 Camshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
Threshold: adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
421 213 190 2 ECU measures a deviation between cam- Offset error between crankshaft and camshaft. Threshold for error detection is an internal ECU
shaft and crankshaft angle to target. threshold, occurs by offset between
crankshaft and camshaft.
Check increment wheel position, clean and
Check Camshaft and Crankshaft senor or wiring.
422 212 190 8 Sensor crankshaft speed; disturbed signal Error in sensor or wiring. Threshold for error detection is an internal ECU
Crankshaft sensor defect. threshold, occurs by disturbed
crankshaft signal.
Check increment wheel position, clean and
Check Crankshaft Sensor or wiring.
423 212 190 12 Crankshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the Crankshaft signal.
engine speed. Check increment wheel position, clean and
adjust if necessary, check Crankshaft
sensor postition or wiring.
464 228 97 3 Fuel filter water level sensor: the voltage of Sensor not connected or sensor defect. Check of wiring and water in fuel sensor.
sensor measured by ECU is out of the target Check cabling, if charge Water in Fuel sensor is
range not working, check sensor and if
necessary replace it,
check connection cable and if necessary repair
or replace it.
465 228 97 4 Fuel filter water level sensor: the voltage of cable break or short circuit, sensor defective, Check sensor and if necessary replace it, check
sensor measured by ECU is out of the target connection cable damaged. connection cable
range. Short cut to ground. and if necessary repair or replace it.
472 216 94 3 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range Short cut to battery or open loop connection cable and if necessary repair or
replace it
473 216 94 4 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range short cut to ground connection cable and if necessary repair or
replace it
474 216 94 1 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Check low fuel pressure system (fuel feed pump,
culated by ECU is underneath the target relay , fuse, wiring, sensor) and if
range; the ECU activates a system reaction necessary repair or replace it.
543 263 676 11 Cold start aid relay error. Relay defect or wire harness problem Threshold for error detection is an internal ECU
threshold.
check wire harness, replace relay
544 263 676 11 Cold start aid relay open load Relay or wire harness Threshold for error detection is an internal
threshold.
check wire harness, replace relay
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Deutz Blink
Code Code
545 263 729 5 The cold start aid relay is according to wiring Relay defect or wire harness problem Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, check wires
547 263 729 12 The cold start aid relay is overheated, which High temperature around the cold start relay. Check the functionality of relay and replace it if
causes this error needed.
Check the temperature around the cold start
relay during worst case operation.
549 263 729 3 wiring to the intake air heater device is Intake Air Heater Device: overload, short-circuit Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, Check wiring to the intake air
heater device.
551 263 729 4 wiring to the air intake heater is faulty Relay (for cold start aid) cable break or short to Threshold for error detection is an internal ECU
ground: threshold.
Electrical error, check wiring to the air intake
heater.
559 1-5-8 523895 13 Missing or wrong injector adjustment value Missing or wrong injector adjustment value for Threshold for error detection is an internal ECU
programming (IMA) injector 1 (in firing cyl. 1. threshold.
order). Check correct injector adjustment value (IMA).
Use SERDIA UseCase to check it.
programming (IMA) injector 2 (in firing cyl. 2 threshold.
order). check dataset and flash correct injector adjuste-
ment value (IMA). Use SERDIA
UseCase to check it.
561 1-5-8 523897 13 Missing or wrong injector adjustment value Missing or wrong parametrisation of injector Threshold for error detection is an internal ECU
programming (IMA) injector 3 (in firing adjustment cyl. 3. threshold.
565 151 523350 4 Injector cylinder bank 1: the current drop Short circuit injection bank 1 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
566 152 523352 4 Injector cylinder bank 2: the current drop Short circuit injection bank 2 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
repair/replace it.
567 153 523354 12 Internal hardware monitoring: the ECU Defective powerstage in ECU Threshold for error detection is an internal ECU
detects an error of its injector high current threshold.
output. Chip of CY33x defect power stage If error is not removable, change ECU.
components
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Deutz Blink
Code Code
568 154 651 5 Injector cyl. 1: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 1 threshold.
repair/replace it.
repair/replace it.
repair/replace it.
repair/replace it.
repair/replace it.
repair/replace it.
580 154 651 3 Injector cyl. 1: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 1 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
damaged test for diagnosis.
test for diagnosis.
test for diagnosis.
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Deutz Blink
Code Code
test for diagnosis.
592 135 523615 5 Detecting an open load fault in the metering wiring harness defective, cable break Threshold for error detection is an internal ECU
unit threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
593 135 523615 12 powerstage of metering unit is overheated over temperature Threshold for error detection is an internal ECU
threshold.
Check functionality of metering unit and
replace it if needed.
Check temperature of metering unit and
improve the installation in case of overheating.
594 135 523615 3 Fuel metering unit: the current drain mea- short circuit to battery high side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
595 135 523615 4 Fuel metering unit: the current drain mea- short circuit to ground high side Threshold for error detection is an internal ECU
596 135 523615 3 Fuel metering unit: the current drain mea- short circuit to battery low side Threshold for error detection is an internal ECU
597 135 523615 4 Fuel metering unit: the current drain mea- short circuit to ground low side Threshold for error detection is an internal ECU
612 555 523612 12 Internal hardware monitoring: the CPU of Plausibility check failed (MoCADC_uNTP_mp is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- higher than MoCADC_uNTPMax_C). threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory.
613 555 523612 12 Internal hardware monitoring: the CPU of Analysis of test voltage (Value is out of the tar- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- get -> ECU internal error) threshold.
nally; no item will be created in error mem- Check wiring, check connected sensors actua-
ory tors.
614 555 523612 12 Internal hardware monitoring: the CPU of Analysis of the ratiometric correction (Value is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- out of the target -> ECU internal error) threshold.
nally; Check wiring, check connected sensors actua-
no item will be created in error memory tors.
615 555 523612 12 Internal hardware monitoring: the CPU of Error report due to an error in the plausbility of Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Function Coordination(FC) and threshold.
nally; Monitoring Modul(MM)(ECU internal error) If error is still present, exchange ECU.
no item will be created in error memory
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Deutz Blink
Code Code
616 555 523612 12 Internal hardware monitoring: the CPU of Error report due to an interrupted SPI communi- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- cation (ECU internal error) threshold.
ory
617 555 523612 12 Internal hardware monitoring: the CPU of multiple error in complete ROM-test during Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- postdrive detected (ECU internal error) threshold.
ory
618 555 523612 12 Internal hardware monitoring: the CPU of Too less bytes received by monitoring memory Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- from CPU as response (ECU internal threshold.
nally; no item will be created in error mem- error). Loss of synchronization sending bytes to If error is still present, exchange ECU.
ory the monitoring memory from CPU
619 555 523612 12 Internal hardware monitoring: the CPU of Suspected components: Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Injector threshold.
nally; no item will be created in error mem- ECU If error is still present, exchange ECU.
ory wiring harness/connector
620 555 523612 12 Internal hardware monitoring: the CPU of Error trying to set MM Response time (ECU Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- internal error) threshold.
ory
621 555 523612 12 Internal hardware monitoring: the CPU of Error detected in the internal ECU communica- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- tion, Too many SPI errors during threshold.
nally; no item will be created in error mem- MoCSOP execution If error is still present, exchange ECU.
ory
623 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- under voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in undervoltage monitoring
624 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- monitoring module (ECU internal error). threshold.
ory
625 555 523612 12 Internal hardware monitoring: the CPU of Time out error trying to set or cancelling the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- alarm task (ECU internal error). Failure threshold.
nally; no item will be created in error mem- setting the alarm task period If error is still present, exchange ECU.
ory
627 555 523612 12 Internal hardware monitoring: the CPU of Error in time monitoring of the shut-off path Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- test (ECU internal error). Diagnostic fault threshold.
nally; no item will be created in error mem- check to report the timeout in the shut If error is still present, exchange ECU.
ory off path test
628 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- over voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in overvoltage monitoring
629 555 523612 12 The two voltage values (ADC_VAL1, Defect pedal or wiring Threshold for error detection is an internal ECU
ADC_VAL2), detected by threshold.
the accelerator pedal, are not plausible to Check Pedal, repair or exchange the Pedal.
each other. Check wiring.
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Deutz Blink
Code Code
630 555 523612 12 Impermissible offset between the engine Calculated engine speed in level 1/2 implausi- Threshold for error detection is an internal ECU
speed of level 2 and level 1 ble (-> ECU internal error). threshold.
631 555 523612 12 Diagnostic fault check to report the plausi- Implausible injection energizing time for either Threshold for error detection is an internal ECU
bility error between level 1 energizing time PiIx or MI1 or PoIx. threshold.
and level 2 information If error is still present, exchange ECU.
632 555 523612 12 Error in the plausibility of the start of ener- Implausible start of energising of either PiIx or Threshold for error detection is an internal ECU
gising angles MI1 or PoIx. threshold.
633 555 523612 12 Error in the plausibility of the energising The energising times of the zero fuel quantity Threshold for error detection is an internal ECU
times of the zero fuel quantity calibration calibration ZFC is out of the target. (-> threshold.
ECU internal error) If error is still present, exchange ECU.
634 555 523612 12 Error in the plausibility of PoI2 efficiency. Error in the plausibility of PoI2 efficiency. Threshold for error detection is an internal ECU
threshold.
635 555 523612 12 Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an internal ECU
threshold.
636 555 523612 12 Error in the plausibility of PoI3 efficiency. Error in the plausibility of PoI3 efficiency. Threshold for error detection is an internal ECU
threshold.
637 555 523612 12 Engine speed: the engine speed calculated Error in the plausibility of current energising Threshold for error detection is an internal ECU
by ECU is above the target range; the ECU time with maximum permitted energising threshold.
activates a system reaction time. Diagnostic fault check to report the error If error is still present, exchange ECU.
due to Over
Run
638 555 523612 12 Error in the plausibility of the wave correc- Error in the plausibility of the wave correction Threshold for error detection is an internal ECU
tion parts parts threshold.
639 555 523612 12 Plausibility error of the Rail pressure sensor In case the gradient of rail pressure is larger than Threshold for error detection is an internal ECU
the max threshold or lesser than the threshold.
min threshold. Check metering unit or cable.
Rail metering unit defect. Check Rail pressure. Check the Rail System of
Leakge in the Rail System. leakage.
640 555 523612 12 Error in the torque comparison between per- Error in the torque comparison between the Threshold for error detection is an internal ECU
missible engine torque and current actual permissible inner engine torque and the threshold.
torque current plausible actual torque. If error is still present, exchange ECU.
641 555 523612 12 Diagnosis of curr path limitation forced by The torque comparison is not plausible with the Threshold for error detection is an internal ECU
ECU monitoring level 2 torque monitoring. threshold.
642 555 523612 12 Diagnosis of lead path limitation forced by The setpoint path of the air system is limited by Threshold for error detection is an internal ECU
ECU monitoring level 2 the limitation torque of the functional threshold.
control unit monitoring. If error is still present, exchange ECU.
643 555 523612 12 Diagnosis of set path limitation forced by If the quantity setpoint is exceeds the limit of Threshold for error detection is an internal ECU
ECU monitoring level 2. the torque function. threshold.
644 555 523612 3 supply voltage too high not used Threshold for error detection is an internal ECU
threshold.
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Deutz Blink
Code Code
646 555 523612 4 supply voltage too low not used Threshold for error detection is an internal ECU
threshold.
714 555 523612 12 Error report "WDA wire is active" due to a Error detection by monitoring module Threshold for error detection is an internal ECU
defect query/response communication threshold.
Software reset.
715 555 523612 12 Error report "ABE wire is active" due to The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
undervoltage detection electrical system voltage (defective threshold.
autobattery) Software reset.
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage
recognition.
716 555 523612 12 Error report "ABE wire is active" due to over- If the ABE/WDA powerstage shut-off is active Threshold for error detection is an internal ECU
voltage detection due to an overvoltage detection. threshold.
software reset.
717 555 523612 12 Error report "ABE/WDA active" due to an The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
unknown reason electrical system voltage (defective threshold.
autobattery) Software reset.
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage
recognition.
732 224 100 3 Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiring
measured by ECU is out of the target range Check cabling. If sensor not working, check sen-
sor and if necessary replace it,
or replace it.
733 224 100 4 Oil pressure sensor: the voltage of sensor Short circuit to ground The sensed raw voltage value Oil_uRawPSwmp
measured by ECU is out of the target range is above Oil_SRCPSwmp.uMin_C
Check cabling, if sensor not working, check sen-
sor and if necessary replace it, check
connection cable and if necessary repair or
replace it
No detail informationen!
736 231 100 1 Oil pressure is below the target range (warn- Oilpressure too low (pressure below warning Threshold for error detection is an internal ECU
ing threshold) threshold) threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value
737 231 100 1 Oil pressure is below the target range (shut Oilpressure too low (pressure below shut off Threshold for error detection is an internal ECU
off threshold) threshold). threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value.
747 145 1237 2 Override switch switch: the ECU receives a Switch is blocked, taster locked, connection If the Block Button is pressed shorter than the
permanent signal. cable damaged Maximum Plausible pressing Time.
plausbility error "override switch > 250ms Check cabling, if sensor is not working, check
pressed". switch and if necessary replace it, check
replace it.
3-70 – JLG Lift – 3121619

Deutz Blink
Code Code
752 136 107 0 Air filter differential pressure: the pressure Pressure loss above target range with system Check airfilter and if necessary clean or renew it,
difference of the intake air between the filter reaction, air filter clogged or defective, check cabling, check sensor and if
inlet and outlet calculated by ECU is above sensor not working, connection cable damaged necessary replace it, check connection cable
the target range and the ECU activates a Pressure value above warning threshold and if necessary repair or replace it
system reaction
772 223 102 2 Deviation between sensed intake manifold deviation between ambient pressure sensor 1) Exchange boost pressure sensor
pressure is not plausible compared to envi- and charge air pressure sensor at not 2) Exchange ECU
ronment pressure. Which sensor is not okay running engine to high
can not be said.
774 223 102 1 charge air pressure below lower limit measured charge air pressure below the thresh- Check complete air system of engine for mas-
old. sive leakage, especially from compressor
to intake air manifold.
Check air filter.
Exchange charge air presure sensor.
776 223 102 3 Charge air pressure sensor: the measured The Sensor Voltage is above the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and if necessary replace it, check connection
cable and if necessary repair or replace it.
777 223 102 4 Charge air pressure sensor: the measured The Sensor Voltage is below the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and
if necessary replace it, check connection cable
and if necessary repair or replace it
791 693 411 0 delta pressure across venturi in EGR line sensed value of venturi difference pressure > Threshold for error detection is an internal ECU
above physical high limit high limit threshold.
EGR-Valve blocked open
EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect
792 693 411 1 delta pressure across venturi in EGR line sensed value of venturi difference pressure < Threshold for error detection is an internal ECU
below physical low limit low limit threshold.
Check correct mounting of difference pressure
sensor at venturi tube
Exchange difference pressure sensor broken
3121619 – JLG Lift – 3-71

Deutz Blink
Code Code
793 693 411 11 DFC is stored in EEPROM and status kept until deviation between desired O2 concentration in Threshold for error detection is an internal ECU
check is allowed intake air manifold threshold.
to be carried out again and the real O2-concentration within intake air EGR-Valve mechanically blocked open or closed
DFC can be reset by service routine 216 manifold > limit EGR-pipe blocked with metall plate instead
sealing downstream EGR-Valve
EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
795 693 411 3 The sensed raw voltage EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the maxi- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
796 693 411 4 The sensed raw voltage value EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the mini- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
825 253 523009 9 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the number of allowed activations. old of the pressure limiting valve. fault with Serdia.
826 146 523470 2 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
827 146 523470 2 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
828 146 523470 12 Rail pressure relief valve: is open. Shut Off after PRV Open Threshold for error detection is an internal ECU
Shutoff conditions. threshold.
Check PRV opening counter and if necessary
replace PRV,
check rail-pressure sensor for plausibility and if
check FCU and if necessary replace it.
829 146 523470 12 Rail pressure relief valve is open. Warning PRV open Threshold for error detection is an internal ECU
Warning conditions. threshold.
replace PRV,
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Deutz Blink
Code Code
830 146 523470 14 Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal ECU
threshold.
Only after ECU reset.
replace it,
831 146 523470 11 Rail pressure relief valve can not be opened Railpressure out of tolerance range (PRV can not Threshold for error detection is an internal ECU
due to the railpressure. be opened by a pressure peak in this threshold.
operating point) Check railpressure, check rail pressure sensor for
plausibility, check FCU.
832 146 523470 11 Rail pressure is out of the expected average Averaged rail pressure is outside the expected Threshold for error detection is an internal ECU
range. tolerance range. threshold.
The PRV can not be opened at this operating Check PRV and replace if necessary.
point with a pressure shock.
833 2-5-3 523009 10 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the allowed opening time. old of the pressure limiting valve. fault with Serdia.
839 1-4-3 523450 4 Diagnostic fault check for min error of COM The sensed raw value is less than the threshold. Check cabling, check sensor and if necessary
message. replace it,
or replace it.
856 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Pressure governor deviation exceeds the limit- Threshold for error detection is an internal ECU
lated by ECU is below the target range which ing value based on the engine speed. threshold.
is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
857 134 523613 0 Rail pressure: the fuel pressure in rail calcu- maximum positive deviation of rail pressure Threshold for error detection is an internal ECU
lated by ECU is below the target range which exceeded concerning set flow of fuel. threshold.
is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
858 134 523613 0 Rail pressure: the fuel pressure in rail calcu- leakage is detected based on fuel quantity bal- Threshold for error detection is an internal ECU
lated by ECU is above the target range which ance. threshold.
is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
859 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Maximum negative rail pressure deviation with Threshold for error detection is an internal ECU
lated by ECU is above the target range which metering unit on lower limit is exceeded. threshold.
is dependant on the engine speed. (A) Check backflow pressure
tor) if necessary
3121619 – JLG Lift – 3-73

Deutz Blink
Code Code
861 134 523613 1 Rail pressure: the fuel pressure in rail calcu- Rail pressure falls below the limiting value Threshold for error detection is an internal ECU
lated by ECU is below the target range based on the engine speed. threshold.
which is dependant on the engine speed. (A) Check backflow pressure
tor) if necessary
862 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Rail pressure exceeds the limiting value. (A) Check backflow pressure
lated by ECU is above the target range. (B) Check pressure relief valve and metering
unit.
(C) Change components if necessary
864 134 523613 2 Rail pressure metering unit, Setpoint of Pressure pump delivery quantity in overrun Threshold for detection is an internal ECU
metering unit in overrun mode not plausi- exceeds the threshold based on the threshold.
ble. pressure. (A) Check backflow pressure
(B) Check pressure relief valve and metering
unit.
876 146 523470 7 Rail pressure is out of the expected average Rail pressure is out of the expected average (A) Check railpressure relief valve and replace if
range. range. necessary.
PRV can not be opened. (B) Check high pressure pumps, pressure relief
valve and metering unit.
877 147 157 3 Rail pressure sensor: the voltage of sensor Short cut to battery. Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. Damaged rail pressure sensor. necessary replace it,
or replace it.
878 147 157 4 Rail pressure sensor: the voltage of sensor Check cabling, check rail pressure sensor and if Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. necessary replace it, necessary replace it,
check connection cable and if necessary repair check connection cable and if necessary repair
or replace it. or replace it.
925 148 523720 8 Supply module heater: Duration of switch on uty cycle for temperature readout from supply When the received supply module heater tem-
is too long. module heater to the control unit is out perature duty cycle SCR_rSMT is out of
of range; Supply modul defect, fault in the wir- the failurerange (SCR_rSMFailMax_C <
ing. SCR_rSMHtrT < SCR_rSMFailMin_C)
Supply module check and replace if necessary.
Check the wiring.
926 148 523720 8 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply When the received supply module heater duty
over error threshold. module heater to the control unit is not cycle SCR_rSMHtrT is in the valid range
valid. (SCR_r-
Supply modul defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
927 689 523721 11 Supply module heater: temperature mea- Duty cycle for temperature readout from supply Threshold for detection is an internal ECU
surement not available. module heater to the control unit is not threshold.
available. No erasing in the current driving cycle.
Check the wiring.
928 928 691 8 Supply module heater: PWM time periode PWM signal for temperature readout from sup- The Time period of the received PWM signal
out of valid range. ply module to the control unit is out of SCR_tiSMPerPwm is within the specified
range. range of150ms to 250ms
Check the wiring.
3-74 – JLG Lift – 3121619

Deutz Blink
Code Code
929 691 523722 8 Supply module heater: Faulty PWM signal PWM Signal for temperature readout from sup- Threshold for error detection is an internal ECU
from supply module. ply module to the control unit is not valid. threshold.
Supply modul defect, fault in the wiring. When valid Sync followed by temperature
information signal is received AND valid sync
and temperaturesignal for both information is
received one after the other.
Check the wiring.
930 689 523721 8 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply Supply module check and replace if necessary.
over error threshold. module to the control unit is out of Check the wiring.
range.
Supply modul defect, fault in the wiring.
931 689 523721 8 Supply module heater: Dutycycle timing out Duty cycle for temperature readout from supply When the received supply module duty cycle
of valid range. module to the control unit is not valid. SCR_rSMT is in the valid range
Supply modul defect, fault in the wiring. (SCR_rSMTVld-Min_C <= SCR_rSMT <=
SCR_rSMTVldMax_C), OR in the failure
range (SCR_rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C)
Check wiring.
932 1-2-6 29 3 Diagnostic fault check of short circuit to sup- The signal exceeds the applicatable threshold; If the signal is below the applicatable threshold
ply voltage signal range violation APP_uRawSRCHiHTLIS_C, the signal
(signal range check high) of acceleration range violation is reset
pedal signal. after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal is below the threshold
APP_uHTLISCCPHi[1], a signal range violation
is reset
after debouncing.
935 2-2-6 91 3 Analog accelerator pedal sensor 1 or double Sensor defect. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- Short cut to battery or open loop. and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it.
compared with the position of the second If the signal is below the applicatable threshold
pedal APP_uRaw1SRCHigh_C, the signal
range violation is reset after
the healing debouncing.
937 1-2-6 29 4 Diagnostic fault check of short circuit to The signal is below the applicatable threshold; If the signal exceeds the applicatable threshold
ground (signal range check low) of accelera- signal range violation APP_uRawSRCLoHTLIS_C, the signal
tion pedal signal range violation is reset
after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal exceeds the threshold
APP_uHTLISCCPLo[1], a signal range violation
is reset
after debouncing.
3121619 – JLG Lift – 3-75

Deutz Blink
Code Code
940 2-2-6 91 4 Analog accelerator pedal sensor 1 or double Short circuit to ground. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it
compared with the position of the second If the signal exceeds the applicatable threshold
pedal APP_uRaw1SRCLow_C, the signal
range violation is reset after the
healing
946 282 1079 13 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of the Pin A19: DEF press / Exh.PressBeforeTurb (P3) / working voltage and if necessary correct
power supply voltage of sensor output 1. Air Pump Press it,
/BrnFuelPressAfterDV2 Pin K19: Fan Speed Sen- check connection cable and if necessary repair
sor or replace it,
Pin A21: LDF6T / OilPress / LowFuelPress Pin if error is not removable, change ECU.
A17: Rail Pressure Sensor
Suspected components EDC17cv54
Pin A21: CAM speed Pin K44: Delta Press Venturi
/ Poti EGR or Inlet Throttle
Pin A24: LDF6T / OilPress / LowFuelPressPin
K43: Reserve 5V Sensor Supply
Pin A09: second footpedal
Pin A21: Cam speed Pin K44: DEF press / Air Fil-
terDiffPress
Pin A24: LDF6T / OilPress / LowFuelPress Pin
K43: second footpedal
Pin A09: Delta Press Venturi
detects a deviation of the target range of the Pin K16: second footpedal working voltage and if necessary correct
power supply voltage of sensor output 2. Pin A20: Exh.PressAfterTurb/DPFDiffPress/ it, check connection cable and if necessary
BrnDV1Press/HCIPressDV1DV2 repair or replace it, if error is not removable,
Suspected components EDC17cv54 change ECU.
Pin K45: DPF Diff Press / Exh. Press After Turb /
Fan Speed Sensor
Pin A46: first footpedal
Pin A22: Fan Speed Sensor
Pin K45: Position EGR or Intake throttle flap
Pin K46: First footpedal
detects a deviation of the target range of the Pin A18: DeltaPressVenturi / Position intake working voltage and if necessary correct
power supply voltage of sensor output 3. throttle flap it,
Pin K20: First footpedal check connection cable and if necessary repair
Pin K21: Air FilterDiffPress or replace it,
Suspected components EDC17cv54 and cv56 if error is not removable, change ECU.
Pin A07: Rail pressure
956 512 677 3 Start relay (high side power stage): the cur- Short cut HighSide-output to battery. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the tar- threshold.
get range. Check cabling and start relay and if necessary
replace it,
or replace it.
3-76 – JLG Lift – 3121619

Deutz Blink
Code Code
957 512 677 4 Start relay (high side power stage): Shortcut HighSide-output to ground. Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold.
the target range. Check cabling and start relay and if necessary
replace it,
or replace it.
958 512 677 5 Start relay (low side power stage): the cur- Open circuit/disconnection LowSide-Output. Threshold for error detection is an internal ECU
get range Check cabling and start relay and if necessary
replace it,
or replace it.
959 512 677 12 Start relay (low side power stage): the cur- Temperature over limit. Threshold for error detection is an internal ECU
replace it,
or replace it.
960 512 677 3 Start relay (low side power stage): the cur- Shortcut LowSide-Output to battery. Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- threshold.
replace it,
or replace it.
961 512 677 4 Start relay (low side power stage): the cur- Shortcut LowSide-Output to ground. Threshold for error detection is an internal ECU
replace it,
check connection cable of terminal 50 and if
necessary repair or replace it.
973 555 523612 14 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- threshold.
nally;
no item will be created in error memory.
974 555 523612 14 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
nally;
no item will be created in error memory.
975 555 523612 14 Internal hardware monitoring: the CPU of Visibility of SoftwareResets in DSM Threshold for error detection is an internal ECU
nally; If possible the software update has to be done.
no item will be created in error memory Replace the ECU.
976 2-2-6 91 11 Diagnostic fault check of synchronism of sin- Measured voltage of accelerator pedal 1 is out of Threshold for error detection is an internal ECU
gle potentiometer and Low idle switch(LIS). plausible range. threshold.
Check cabling, check accelerator pedal and
pedal sensor and if necessary replace it,
or replace it.
When the PWM period APP_tiPWMPer is in
between APP_tiSRCLoPWMPer_C and
APP_tiSRCHiPWMPer_C .
3121619 – JLG Lift – 3-77

Deutz Blink
Code Code
978 1-2-6 29 2 Diagnostic fault check of synchronism of Plausibility error between sensor and idle Threshold for error detection is an internal ECU
hand throttle and Low idle switch(LIS). switch threshold.
The accelerator pedal must have detected full
load and idle plausibility at least once.
980 515 523550 12 Terminal 50 was operated for more than 2 Startinformation to Starter (T50-switch) Threshold for error detection is an internal ECU
minutes. This may happen due to short to erratic/defect. threshold.
battery or wrong usage of Terminal 50. Check cabling, if sensor not working, check start
Starter control is disabled until this error is switch and if necessary replace it,
healed. check connection cable and if necessary repair
or replace it.
992 128 105 1 Charged Air cooler down stream tempera- Sensed temperature within intake air manifold actual temperature below -40°C?
ture. < threshold. exchange sensor
Temperature below lower physical thresh-
old.
994 128 105 3 Charge air temperature sensor: the voltage Short circuit to battery. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage > limit age) > Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
995 128 105 4 Charge air temperature sensor: the voltage Short circuit to ground or open load. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage < limit. age) is below Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it
996 233 105 0 Charge air temperature downstream calcu- Charge air temperature (downstream) over Check CAC system and clean it. Check fan func-
lated by ECU is above the target range. warning threshold. tionality.
The ECU activates a system reaction. Check cooling perfomance with temperature
measurement.
997 233 105 0 Charge air temperature downstream calcu- Charge air temperature (downstream) over the Check CAC system and clean it. Check fan func-
lated by ECU is under the shut down thresh- low threshold. tionality. Check cooling perfomance
old. with temperature measurement.
The ECU activates a system reaction.
1007 682 412 3 EGR downstream temperature sensor: the Short circuit to battery. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage > limit Exchange TEGR-sensor.
the target range.
1008 682 412 4 EGR downstream temperature sensor: the Short circuit to ground or open load. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage < limit Exchange TEGR-sensor.
the target range.
1011 771 523960 0 Physical range check high for EGR cooler Sensed temperature downstream EGR-cooler EGR-Valve blocked open
downstream temperature. > limit. EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
3-78 – JLG Lift – 3121619

Deutz Blink
Code Code
1012 771 523960 1 Physical range check low for EGR cooler sensor voltage > lower limit EGR-Valve blocked open
downstream temperature. EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
1014 594 5763 6 Actuator error EGR-Valve. Short cut to batterie. Check wiring and repair or replace if necessary,
Signal range check high. check actuator with SERDIA test for
EGR and if necessary replace it.
1015 594 520521 5 Actuator error EGR-Valve. Short cut to ground. Check wiring and repair or replace if necessary,
Signal range check low. check actuator with SERDIA test for
EGR and if necessary replace it.
1016 594 5763 7 Actuator position for EGR valve is not plausi- Position error of throttle flap (deviation > 7%). Threshold for error detection is an internal ECU
ble, internal error, angular misalignement of threshold.
the flap. Threshold for error detection, deviation from
setpoint > 7%.
Troubleshooting with SERDIA 2010 Use Case
"EGR Diagnostic".
1022 5-9-4 5763 6 Actuator error EGR-Valve; signal range check Short circuit to battery or open circuit. Check cabling, actuator defect, check actuator
high, measured current by ECU is over target and if necessary replace it, check
replace it.
1023 5-9-4 5763 5 Actuator error EGR-Valve; signal range check Short circuit to ground. Check wiring, check cabels and repair or replace
low, measured current is below target if necessary, check actuator with
SERDIA 2010 test for EGR and if necessary
replace it.
1024 594 5763 3 Actuator of the external EGR valve: the ECU Short cut to battery or open loop. Check cabling, actuator defect, check actuator
detects a short circuit to battery or open and if necessary replace it, check
load. connection cable and if necessary repair or
replace it.
1025 594 5763 4 Actuator of the external EGR valve: the ECU Short cut to ground Check cabling, actuator defect, check actuator
detects a short circuit to ground. and if necessary replace it, check
replace it.
3121619 – JLG Lift – 3-79

Deutz Blink
Code Code
1036 683 4768 2 Static plausibility check: Static plausibility check: Check ambient temperature => value plausi-
The exhaust temperature value from the The exhaust temperature value from the sensor ble?
sensor before DOC, the exhaust temperature before DOC, the exhaust temperature upstream DOC sensor mounted within exhaust
value from the sensor after DOC, the temper- value from the sensor after DOC, the tempera- line?
ature value from the sensor before ture value from the sensor before T upstream DOC sensor physically mounted in
SCR-Cat, the environment temperature and SCR-Cat, the environment temperature and the correct position upstream DOC? (not
the coolant engine temperature their ratios coolant engine temperature their ratios upstream SCR or downstream DOC?)
to each other exceed their related thresh- to each other exceed their related thresholds. Check T upstream DOC sensor
olds. (difference between temperature after DOC and Check other T-sensors within EAT-system
Dynamic plausibility check with environ- temperature before DOC > Threshold 1 (Exh_tOxiCatDs & UCatUsT_tFlt_mp show
ment temperature sensor value: difference between temperature befor DOC and plausible values? No errors on them?
The exhaust temperature value from the before SCR > Threshold 2
sensor before DOC is lower than an applica- difference between temperature after DOC and
ble environment temperature threshold before SCR < Threshold 3
difference between temperature after DOC and
ambinet temperature < Threshold 4
differnece between temperatur ambient tem-
perature and engine temperature <
Threshold 5)
Dynamic plausibility check with environment
temperature sensor value:
The exhaust temperature value from the sensor
before DOC is lower than an applicable
environment temperature threshold (< envi-
ronmental temperature + Threshold 6)
1039 683 4765 0 The exhaust temperature value from the sensed temperature upstream DOC > shut-off Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle,
is above an applicable upper shutoff thresh- Check Turbocharger and Piping each for leakage
old and correct function
TOxiCatUs_tShOffThresHiAds_C = Thresh- Check injectors: is an injector got stuck?
old 1 in Normal and Exchange temperature sensor upstream DOC
Heatmodes
(TOxiCatUs_tShOffThresHiRgn_C = Thresh-
old 2
in stand-still)
1040 683 4765 0 The exhaust temperature value from the Sensed temperature upstream DOC > warning Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle, Turbocharger and Piping each
is above an applicable upper warning for leakage and correct function
threshold Check injectors: is an injector got stuck?
TOxiCatUs_tWarnThresHi_C = Threshold Exchange temperature sensor upstream DOC
1044 683 4768 3 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is above upstream DOC
ECU is out of the target range Exh_SRCTOxiCatUs.uMax_C Exchange temperature sensor upstream DOC
Shortcut to battery
1045 683 4768 4 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is upstream DOC
ECU is out of the target range below Exh_SRCTOxiCatUs.uMin_C Exchange temperature sensor upstream DOC
Shortcut to ground
3-80 – JLG Lift – 3121619

Deutz Blink
Code Code
1069 668 4360 0 The filtered urea cat upstream temperature Sensed temperature upstream SCR > physical Check temperature difference across DOC
is greater than an applicable maximum tem- high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at higher
perature threshold engine load => high difference > 100 K?
If yes, the engine emitts too many Hydrocar-
bons => check injectors: is an injector got
stuck?
=> Check EGR Valve
If difference normal the exhaust out of the engie
itself is too hot:
=> Check air path of engine: EGR-Valve,
Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
If that error was set while stand-still operation
the error source could be exothermal
soot burn off in DPF (which should not happen)
=> Dismount DPF and check it visually
exchange temperature sensor upstream SCR
1070 668 4360 1 The filtered temperature before urea cat is Sensed temperature upstream SCR catalyst < Cold start and ambient temperature < Thresh-
less than an applicable minimum tempera- than physical low limit old? Missdetection?
ture threshold Check wiring harness to UCatUsT-sensor
Exchange UCatUsT-sensor
1072 668 4361 3 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst > maximum limit Check wiring
of the target range Short circuit to battery Replace UCatUsT-sensor
1073 668 4361 4 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst < minimum limit Check wiring
of the target range Short circuit to ground Replace UCatUsT-sensor
1075 677 3361 6 Urea dosing valve: the current measured Fault in the wiriing Check wiring
value by ECU at the end of the injection is too Defect urea dosing injection valve Check the urea dosing injection valve
high
1077 677 3361 3 Urea dosing valve (low side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range See substitute function
Check the wiring
1078 677 3361 3 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the target range Check the wiring
1079 677 3361 4 Urea dosing valve (low side power stage): Fault in the wiring Check the wiring
the current drain measured by ECU is above
the target range
1080 677 3361 4 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the target range Check the wiring
1090 674 4345 5 Urea backflow line heater: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Broken wiring, broken heating element in back- Check heating element
flow line
3121619 – JLG Lift – 3-81

Deutz Blink
Code Code
1092 674 4345 3 Urea backflow line heater: the current drain Shortcut to battery Threshold for error detection is an internal ECU
Short cut to battery or broken wiring, broken Check heating element
heating element in backflow line
1093 674 4345 4 Urea backflow line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
Short cut to ground or broken wiring, broken Check heating element
heating element in backflow line
1094 673 4343 5 Urea pressure line heater: the current drain Open load Threshold for error detection is an internal ECU
Broken wiring, broken heating element in pres- Check heating element
sure line
1096 673 4343 3 Urea pressure line heater: the current drain shortcut to battery Threshold for error detection is an internal ECU
broken heating element in pressure line Check heating element
1097 673 4343 4 Urea pressure line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
Short cut to ground or broken wiring, broken Check heating element
heating element in pressure line
1098 676 523718 5 Urea heater relay: the current drain mea- Open load Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase it threshold
is a result error: KWP 1089 Test SCR main relay
Broken wiring Check cabling, if necessary replace relay.
broken relay
1100 676 523718 3 Urea heater relay: the current drain mea- Shortcut to battery Threshold for error detection is an internal ECU
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
1101 676 523718 4 Urea heater relay: the current drain mea- Shortcut to ground Threshold for error detection is an internal ECU
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
1102 675 4341 5 Urea heater supply line: the current drain electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
Check wire harness
Check supply line
Check wire harness
Check supply line
3-82 – JLG Lift – 3121619

Deutz Blink
Code Code
1106 672 523719 5 Urea supply module heater: the current Open load Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase is threshold
range a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply mod-
Heating element in supply module defect ule
1108 672 5232719 3 Urea supply module heater: the current Short circuit to battery Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error:KWP 1089 Check wiring
1109 672 523719 4 Urea supply module heater: the current Shortcut to ground Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error: KWP 1089 Check wiring
1110 671 4366 5 Urea tank heating valve: the current drain Open load Threshold for error detection is an internal ECU
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
1112 671 4366 3 Urea tank heating valve: the current drain Shortcut to battery Threshold for error detection is an internal ECU
1113 671 4366 4 Urea tank heating valve: the current drain Shortcut to ground Threshold for error detection is an internal ECU
1117 666 523632 11 Urea supply module pump: the current drain When the pump motor does not switch to pump Threshold for error is an internal ECU threshold
measured by ECU is above the target range actuation mode after temperature
measurement has
been carried out.
1118 666 4375 5 Urea supply module pump: the ECU can not Open load Threshold for error detection is an internal ECU
measure any reaction during pump control Broken wiring threshold
Pump in urea supply module defect The hardware detects the presence of load on
the PWM output power stage for the
urea pump module actuator.
Check wiring
Check pump in the urea supply module
1120 666 4375 3 Urea supply module pump: the current drain Shortcut to battery Threshold for error detection is an internal ECU
a result error: KWP 1089 The hardware detects absence of any short cir-
Broken wiring cuit to battery on the PWM output power
Pump in urea supply module defect stage for the urea pump module actuator
Check wiring
3121619 – JLG Lift – 3-83

Deutz Blink
Code Code
1121 666 4375 4 Urea supply module pump: the current drain Shortcut to ground Threshold for error detection is an internal ECU
a result error: KWP 1089 The hardware detects a short circuit to ground
Broken wiring error on the PWM output power stage
Pump in urea supply module defect for the UreaPump Module Motor Actuator. The
error is updated by setting bit 1 of
measuring point UPmp-
Mot_stPrevTstRslt_mp
Check wiring
1122 665 4334 0 The absolute pressure value of the urea Suspected Components: Check the urea pump
pump is greater than an applicable maximal Urea pump defect Check the supply module pressur sensor
filtered pressure threshold Supply module pressure sensor defect Clean the urea pump (filter)
Pump contains dirty parts
1123 665 4334 1 Urea supply module pressure sensor: The Check the urea pump Check the urea pump
absolute pressure value of the urea pump is Check the supply module pressur sensor Check the supply module pressur sensor
less than an applicable minimal filtered Clean the urea pump (filter) Clean the urea pump (filter)
pressure threshold
1127 665 523632 3 Urea supply module pressure sensor: the Shortcut to battery Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
1128 665 523632 4 Urea supply module pressure sensor: the Shortcut to ground Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
The sensed raw voltage value
SCR_uRawUPmpP is above
SCR_SRCUPmpP.uMin_C
1129 667 4376 5 Urea supply module reversal valve: the cur- Open load Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- Fault in the wiring threshold
get range Reversal valve in the urea supply module defect Check wiring
Check urea supply modul
1131 667 4376 3 Urea supply module reversal valve: the cur- Shortcut to battery Threshold for error detection is an internal ECU
1132 667 4376 4 Urea supply module reversal valve: the cur- Shortcut to ground Threshold for error detection is an internal ECU
3-84 – JLG Lift – 3121619

Deutz Blink
Code Code
1135 669 3031 0 The urea tank temperature sensor detects a Sensed urea tank temperature > physical range Case "CANBUS sensor":
value above the maximum allowed thresh- high limit Check urea tank temperature: really hot?
old Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Tank heater permantly on?
Check wiring of DEF-quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really hot?
Check urea tank temperature SCR_tSensUTnkT
Compare urea tank temperature to EnvT_t or to
SCR_tSMT (the urea temperature
inside the supply module) identical?
Tank heater permantly on?
Check wiring of analog DEF T & Level sensor
1136 669 3031 1 The urea tank temperature sensor detects a sensed urea tank temperature < physical range Case "CANBUS sensor":
value lower than the minimum allowed low limit Check ambient temperature EnvT_t => About
threshold. -40 °C? If yes Error could be plausible
Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Check wiring of DEF-quality sensor
Check quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really that cold?
Check ambient temperature EnvT_t =>
About -40 °C? If yes Error could be plausible
Check urea tank temperature SCR_tSensUTnkT
Check wiring of analog DEF T & Level sensor
Check analog DEF T & Level sensor
1137 6-6-9 4365 2 Signal error in case of Urea tank temperature CAN message is not send properly. Check sensor connector
trnasmitted via CAN-signal Com_tUTnkT. Check CANbus
1138 6-6-9 4365 3 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The Sensed raw voltage value SCR_uRawUTnkT
is below SCR_SRCUTnkT.uMax_C.
Check wiring.
1139 6-6-9 4365 4 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The sensed raw voltage value SCR_uRawUTnkT
is above SCR_SRCUTnkT.uMin_C.
Check wiring.
1157 228 97 12 Fuel filter water level sensor: the maximum Water level in fuel pre-filter reservoir over limit Measure Voltage at Water in Fuel Sensor and
level is exceeded (bad fuel quality) renew harness if needed.
1170 555 523612 12 Internal hardware monitoring: the CPU of Error during positive test (ECU internal error). Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Diagnostic fault check to report that the threshold.
nally; no item will be created in error mem- positive test failed Reflash ECU. If error is still activ replace ECU.
ory
3121619 – JLG Lift – 3-85

Deutz Blink
Code Code
1180 318 168 0 Battery voltage: the voltage measured by Battery voltage over limit Check alternator, regulator of alternator and if
ECU is out of the target range necessary replace it, check wiring and
voltage of alternator
1181 318 168 1 Battery voltage: the voltage measured by Battery voltage below limit Check alternator, cabling, contact resistance,
ECU is out of the target range safety fuses, too high load in energy
system, check battery and if necessary replace it
1183 226 172 1 sensed air temperature within air intake sensed air temperature within air intake path of Cold start and ambient temperature < thresh-
path of engine below physical low limit engine below physical low limit old
Check wiring harness to AFST-sensor
Exchange AFST-sensor
1222 2-1-2 190 14 Camshaft- and Crankshaft speed sensor sig- Sensors for engine speed are defect. Threshold for error detection is an internal ECU
nal not available on CAN or defect. threshold.
Check wiring, check cabels and repair or replace
if necessary.
1223 594 5763 6 Actuator EGR-Valve: Open load on ECU out- Open circuit on component wiring Threshold for error detection is an internal ECU
put is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
1224 594 5763 6 Actuator EGR-valve: too high curent is going Overload on component wiring Threshold for error detection is an internal ECU
into the actuator. Output is switched off threshold.
1226 594 5763 3 Actuator EGR-valve: short cut to battery is Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
detected threshold.
1227 594 5763 3 Actuator EGR-valve: short cut to battery on Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
ECU pin is detected threshold.
1228 594 5763 4 Actuator EGR-valve: short cut to ground on Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
1229 594 5763 4 Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal ECU
1230 5-9-4 5763 6 Actuator error EGR-valve; Overload by short- Short Circuit over Load Threshold for error detection is an internal ECU
circuit threshold.
Check wiring, component
1231 5-9-4 5763 11 Power stage overtemperature due to high Temperature dependent Over Current Threshold for error detection is an internal ECU
current. threshold.
Check wiring, component
1232 5-9-4 5763 4 Actuator error EGR-Valve (2.9;3.6) or Throt- Monitoring for CY146 Under Voltage. Threshold for error detection is an internal ECU
tle-Valve (4.1;6.1;7.8); Voltage below threshold.
threshold Check wiring, component
3.6) Drosselklappe (4.1;6.1;7.8); Voltage
below threshold;
3-86 – JLG Lift – 3121619

Deutz Blink
Code Code
1239 788 523984 3 Actuator relay 5: the voltage measured by Short-Circuit to battery to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
1241 176 523986 4 Actuator relay 4: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
1242 791 523987 4 Actuator relay 5: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
1337 565 2797 4 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 0 threshold.
Note: affected injector has to be evaluated
according to firing order
1338 566 2798 4 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 1 threshold.
Note: affected injector has to be evaluated
1339 565 2797 4 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 0 Note: affected injector has to be evaluated
1340 566 2798 4 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 1 Note: affected injector has to be evaluated
1381 839 164 2 Rail pressure safety function is not executed Rail pressure is still above threshold. Threshold for error detection is an internal ECU
correctly threshold.
Reset the fault and at reappearance check ECU
and injection system
1398 681 1136 0 ECU internal temperature; temperature Short-Circuit in ECU, ECU heated by hot air Close warm air circuits, replace ECU
measured by ECU is out of the target range
1425 226 172 0 sensed intake air temperature at air filter > sensed intake air temperature at air filter > Check outside conditions:
physical high limit physical high limit Temperature > Threshold within the intake air
system of the engine?
E.G: engine sucks in air from hot asphalt out of
paver bucket
Sensor positioned within black air filter housing
above engine lid at hot environmental
conditions and idling or similar?
=> if yes check with application team to adapt
limits
if not check sensor and wiring harness
exchange sensor
1434 8-3-6 524050 11 CAN; not used not used not used
1435 8-3-7 524051 11 CAN; not used not used not used
3121619 – JLG Lift – 3-87

Deutz Blink
Code Code
1455 711 3711 12 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC
DPF temperature < Threshold 1 temperature, is below or above Exh_tSensOxiCatUs within Stand-still: > 450
Temperature Phy_tPfWgh, the weighted the target temperature towards the end of the °C? If
DPF temperature > Threshold 2 stand-still main phase. not:
towards the end of the stand-still main => Check air path of engine: EGR-Valve,
phase. Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
Check temperature difference across DOC by
Exh_tSensOxiCatDs -
Exh_tSensOxiCatUs within Stand-still: <
100°C? If not:
Check exhaust pipe downstream turbo charger
for oil?
check injectors: is an injector got stuck?
Too many hydrocarbons in exhaust? White
smoke (at hot EAT system, not at cold
start)?
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check exhaust gas temperature sensors within
EAT-system: T upstream DOCC, T
downstream DOC & T upstream SCR catalyst
all three of them can influence Phy_tPfWgh
1505 8-4-3 524057 2 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Threshold for error detection is an internal ECU
culated by ECU is underneath the target threshold.
range; the ECU activates a system reaction Check low fuel pressure system (fuel feed pump,
relay , fuse, wiring, sensor) and if
1533 246 524074 9 Open load sensor internally at NOx-sensor Open load sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
dismounting. => If water inside, replace sen-
sor.
Check mounting position of sensor and judge it
regarding condense water formation /
agglomeration.
Check wiring harness
Exchange sensor
1534 247 524075 11 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
sor.
agglomeration? Rearrange if critical and possi-
ble
Exchange sensor
3-88 – JLG Lift – 3121619

Deutz Blink
Code Code
1535 248 524076 9 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
sor.
agglomeration.
Exchange sensor
1536 249 524077 11 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
sor.
agglomeration.
Exchange sensor
1537 255 524078 9 Lambda value of NOx-Sensor downstream sensed lambda value of Nox-sensor down- Check whether NOx-sensor downstream SCR
SCR is out of range. stream SCR catalyst is > physical high limit catalyst is physically mounted within the
When the filtered Lambda concentration ComRxSCR_rCanLamDs_mp > threshold exhaust line
value at the sensor Check Lambda values of NOx-sensor down-
(ComRxSCR_rFltLamDs_mp) is greater than stream SCR catalystat at idle conditions,
the physical range check max. lambda ComRxSCR_rCanLamDs_mp > threshold?
threshold Compare to ComRxSCR_rCanLamUs_mp. Val-
ues must be almost identical
Check CANBus of NOx-sensor downstream SCR
catalyst
Check NOx-sensor downstream SCR catalyst
wiring
itself
Replace NOx-sensor downstream SCR catalyst
3121619 – JLG Lift – 3-89

Deutz Blink
Code Code
1538 256 524079 9 sensed lambda value of NOx-sensor down- sensed lambda value of NOx-sensor down- Compare to ComRxSCR_rCanLamUs_mp.
stream SCR catalyst is < physical low limit stream SCR catalyst is < physical low limit ComRxSCR_rCanLamDs_mp must be
ComRxSCR_rCanLamDs_mp < threshold ComRxSCR_rCanLamDs_mp < threshold almost identical!
If almost identical,
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check injection system of engine. Injector
stuck?
if sensed lambda upstream SCR higher
(ComRxSCR_rCanLamUs_mp) : Diesel in
Urea-tank?
Check CANBus of NOx-sensor downstream SCR
catalyst
wiring
itself
1539 257 524080 9 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check whether NOx-sensor upstream SCR cata-
upstream SCR catalyst is > physical high SCR catalyst is > physical high limit lyst is physically mounted within the
limit ComRxSCR_rCanLamUs_mp > Threshold exhaust line
ComRxSCR_rCanLamUs_mp > Threshold Check Lambda values of NOx-sensor upstream
SCR catalystat at idle conditions,
ComRxSCR_rCanLamUs_mp < Threshold?
Compare to ComRxSCR_rCanLamDs_mp. Must
be almost identical
Check CANBus of NOx-sensor upstream SCR cat-
alyst
Check NOx-sensor upstream SCR catalyst wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
1540 258 524081 9 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check air path of engine: EGR-Valve, Intake-
upstream SCR catalyst is < physical low limit SCR catalyst is < physical low limit Throttle, Turbocharger and Piping each
ComRxSCR_rCanLamUs_mp < Threshold ComRxSCR_rCanLamUs_mp < Threshold for leakage and correct function
Check injection system of engine. Injector
stuck?
Check CANBus of NOx-sensor upstream SCR cat-
alyst
1542 261 524083 9 sensed NOx-value of NOx-sensor down- sensed Nox-value of Nox-sensor downstream Check CANBus of NOx-sensor downstream SCR
stream SCR catalyst < Threshold SCR catalyst < physical low limit catalyst
wiring
itself
3-90 – JLG Lift – 3121619

Deutz Blink
Code Code
1544 912 524085 9 sensed Nox-value of Nox-sensor upstream sensed Nox-value of Nox-sensor upstream SCR Check CANBus of NOx-sensor upstream SCR cat-
SCR catalyst < Threshold catalyst < physical low limit alyst
1555 869 524063 5 Urea backflow line heater: broken wiring Open Load on wiring to component Check wiring, component
detected
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
1556 869 524063 5 Urea main relay: broken wiring detected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
1557 869 524063 5 Urea pressure line heater: broken wiring Open load on wiring to component Check wiring, component
detected
Threshold 1 <
2
1558 869 524063 3 SCR heater mainrelay; short circuit to battery Short-Circuit to battery on wiring to component Check wiring, component
Threshold 1 <
2
1559 869 524063 4 Connection between heating valve (Y31) on Faulty wiring, faulty heater relay (K27-K31), Disconnect plug from heating valve (Y31) and
the control unit Pin A:92 and defective heating valve (Y31), reset fault.
Load side SCR heater main relay (K31) is a broken element in heating. If fault is still present you have to look in the wir-
short cut to ground. ing of Y31 to the control unit Pin A:92.
Threshold 1 < If error is no longer present, you have to check
SCRHtr_rUHtrMeasRatio_mp < Threshold the wiring of Y31 via relay K31
2 and possibly the heating cables and relay (K27-
K30).
1560 869 524063 5 SCR relay for suction line not connected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
1561 869 524063 5 Open load on wiring to component Open load on wiring to component Check wiring, component
Threshold 1 <
2
1562 869 524063 5 SCR heater tank; open load Open load on wiring to component Check wiring, component
3121619 – JLG Lift – 3-91

Deutz Blink
Code Code
1565 892 524065 0 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check for crystallisation in exhaust line
from the urea cat upstream cal high range limit f(exhaust volume upstream SCR and dwnstream of urea injector
sensor is greater than an applicable maxi- flow) Check correct connection from exhaust line to
mum pressure threshold UCatUsP_pRelFlt_mp > UCatUsP_pMax_mp pressure sensor upstream SCR catalyst:
syphons?, water in tube?, water in sensor?
Check that exhaust pipe outlet is free (down-
stream SCR catalyst)
Check wiring of pressure sensor upstream SCR
catalyst
Check pressure sensor upstream SCR catalyst:
sensor has no connection to vehicle body? =>
Ensure that sensor is free
Does sensor oscillate heavely at engine low idle
/ high idle? => try to supress the
oscillating
Exchange pressure sensor upstream SCR cata-
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
1566 892 524065 1 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check correct connection from exhaust line to
from the urea cat upstream sensor is less cal high range limit f(exhaust volume pressure sensor upstream SCR catalyst:
than an applicable minimum pressure flow) leakage?
threshold UCatUsP_pRelFlt_mp < UCatUsP_pMin_mp Check electric connector: 4h pin open / new
connector type used? pressure exchange
from inside electrical connector with the envi-
ronemt possible
Check exhaust line: any leakages upstream of
SCR catalyst?
catalyst
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
1569 892 524065 3 voltage of pressure sensor upstream SCR > voltage of pressure sensor upstream SCR > volt- Check wiring of pressure sensor upstream SCR
voltage high limit age high limit catalyst
Check pressure sensor upstream SCR catalyst
lyst
3-92 – JLG Lift – 3121619

Deutz Blink
Code Code
1570 892 524065 4 voltage of pressure sensor upstream SCR < voltage of pressure sensor upstream SCR < volt- Check wiring of pressure sensor upstream SCR
voltage low limit age low limit catalyst. Check pressure sensor
upstream SCR catalyst. Exchange pressure sen-
sor upstream SCR catalyst
1581 894 524067 0 Filtered urea supply module heater temper- sensed temperature of supply module heater > Compare SCR_tSMT with SCR_tSMHtrT. Both
ature value is above an applicable maximum physical high range limit show the same value?
heater temperature threshold of the supply Check urea tank temperature
module (SCR_tAdapUTnkT). Very hot (> 70°C), urea
The temperature is read out via the PWM sig- tank heater
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module heater temperature sensor
defect
Supply module heater defect
Supply module defect
1582 894 524067 1 Filtered urea supply module heater temper- sensed temperature of supply module heater < Check ambient temperature EnvT_t < Thresh-
ature value is below an applicable minimum threshold old?
heater temperature threshold of the supply Compare SCR_tSMT with SCR_tSMHtrT
module Check wiring with regard to supply modul
The temperature is read out via the PWM sig- heater
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module heater temperature sensor
tion was switched on. When that state is defect
left the sensed temperature value is frozen. Supply module defect
1585 894 524067 0 Filtered urea supply module temperature sensed temperature of urea within supply mod- Compare SCR_tSMT with SCR_tSMHtrT. Both
value (SCR_tSMT) is above an applicable ule > physical high range limit show the same value?
maximum temperature threshold of the Check urea tank temperature
supply module (SCR_tAdapUTnkT). Very hot (> 70°C), ure tank
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module temperature sensor defect
Supply module heater defect
Supply module defect
3121619 – JLG Lift – 3-93

Deutz Blink
Code Code
1586 894 524067 1 Filtered urea supply module temperature sensed temperature of urea within supply mod- Check ambient temperature EnvT_t < thresh-
(SCR_tSMT) value is below an applicable ule < physical low range limit old?
minimum temperature threshold of the sup- Compare SCR_tSMT with SCR_tSMHtrT
ply module Check wiring with regard to supply modul
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module temperature sensor defect
tion was switched on. When that state is Supply module defect
left the sensed temperature value is frozen.
1593 129 1761 0 The urea tank level sensor detects a value Suspected components: Check level sensor and float gauge
higher than the maximum allowed thresh- Urea Quality Sensor defect
old mechanical defect at the float gauge
1594 129 1761 1 The DEF tank level sensor detects a value Suspected components: Check level sensor and float gauge
lower than the minimum allowed threshold Urea Quality Sensor defect
mechanical defect at the float gauge
1598 892 524065 2 Comparison of urea cat upstream exhaust absolut value of difference between sensed Check electric connector: 4h pin open / new
gas- and environment pressure, the differ- pressure upstream SCR catalyst and connector type used?
ence should not exceed a certain limit environmental pressure > limit pressure exchange from inside electrical con-
abs(UCatUsP_pDiffEnvCat_mp) > Thresh- abs(UCatUsP_pDiffEnvCat_mp) > Threshold nector with the environemt possible?
old water in sensor?
sensor frozen?
catalyst
lyst
Check intake manifold pressure sensor
(Air_pCACDs)
Check ambient pressure sensor (EnvP_p)
3-94 – JLG Lift – 3121619

Deutz Blink
Code Code
1639 966 524147 13 No proper urea pressure level could be build This error shows up, if no proper urea pressure Make sure that frozen lines, pump or tank can be
up within the SCR system state "Fill Lines" level could be build up within the SCR excluded!
=> SCRCo_stStatus_mp = 1 within some system state "Fill Lines" => Check whether there is urea in the urea tank
miuntes SCRCo_stStatus_mp = 1 within some minutes Check urea lines:
Once the urea pump pressure has exceeded the All lines connected? The right lines connected to
threshold the error is declared as the correct places?
okay. Suction line blocked?
Suspected components: No leakage? Not also urea to the outside but also
Suction line blocked air into the lines, especially in the
PWM Powerstage has a defect and a default suction line!
value which leads not to a rising pressure Perform service routine "pressure test":
Pump Pressure sensor defect Does the urea pump work? => check wiring
pump filter contains dirty parts harness & PWM signal for pump
reverting valve continously open Does the urea pressure rise?
DFC already healed?
If all unsuccessful so far:
Check urea pressure sensor: At ignition on and
SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
Check reverting valve => see
DFC_SCRCoRevVlvBlk
Check pump filter: dirt inside?
Suspected components:
Urea pump broken
Reverting valve continously open
Urea suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
Pump Pressure sensor broken
1646 869 524063 12 SCR supply module temperature is not Suspected components: Check
reaching a threshold before a calibratable Enviroment temperature sensor defect Environment temperature sensor
time is exceeded. SCR supply module temperature sensor defect SCR supply module temperature sensor
Corresponding to the environmental Tem- SCR supply module electrical heater defect SCR supply module electrical heater
perature a specific defrosting time is given.
After starting the defrosting a clock counter
is starting. Does the counter reach the given
defrosting time limit, an error will be
detected. Is the temperature reached in time
the clock counter will be reset
Example: by using the calibrated tempera-
ture/time curve --> environmental temper-
ature 0°C --> defrosting time limit 6000s --
> if the clock counter reaches 6000s the error
will
be detected
3121619 – JLG Lift – 3-95

Deutz Blink
Code Code
1655 138 1761 14 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <5% below applicable threshold 5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
SCRUTnk_rVol_mp must change.
Exchange DEF level sensor, if no change of value
or it's implausible.
1656 138 1761 14 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <2.5% below 2.5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
Exchange DEF level sensor, if no change of value
or it's implausible.
1666 924 524100 9 Timeout error of CAN-Transmit-Frame Com- Open load on CANBUS wiring. Check wiring, component.
DPFHisDat.
1672 9-4-2 524118 9 Timeout error of CAN-Receive-Frame If the frame CM1 message is not transmitted Check CAN Bus cabling (Bus sheduling, polarity,
ComRxCM1 successfully short circuit, power interrupt), test
range.
1676 928 524104 9 Timeout error of CAN-Receive-Frame Com- Time out of Check CANBUS EAT Control Receive Threshold for error detection is an internal ECU
RxDPFCtl. CM1 Module Customer Recieve Message, PGN65348. threshold.
Message. The message is not received. Check CANBUS EAT Control Receive Message,
PGN65348.
CM1 Module Customer Recieve Message.
1683 9-4-5 524121 9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
RxTrbChActr short circuit, power interrupt), test
range.
1687 9-4-9 524125 9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
TxTrbChActr short circuit, power interrupt), test
range.
1705 972 524156 9 Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
ComRxEBC2 from wheel speed sensor. Defect on wheel speed sensor. short circuit, power interrupt), test
range.
Replace the wheel speed sensor.
1752 415 2791 7 EGR actuator is mechanically blocked. EGR actuator faulty or blocked. Threshold for error detection is an internal ECU
threshold.
Check the EGR actuator and EGR valve to
mechanical blockage / clean.
Check for free movement of the valve. If it'S
blocked, then exchange the EGR valve.
1753 415 2791 2 corrupted CAN communication with actua- CAN bus error or faulty EGR actuator. Threshold for error detection is an internal ECU
tor. threshold.
Check other CAN bus components. If no mes-
sage is sent, fix the wiring.
If o.k. exchange EGR actuaror.
3-96 – JLG Lift – 3121619

Deutz Blink
Code Code
1754 415 2791 13 EGR actuator can not learn stop positions. Error detection during the learning process. Threshold for error detection is an internal ECU
Possibly only second failure if other EGRTV threshold.
failures occure. Start Serdia Usecase to reset EGR actuator.
Check EGR valve and mounting situation. If o.k.
change EGR actuator.
1755 415 2791 12 Internal electrical fault of EGR actuator. Internal damage of EGR actuator due to high Threshold for error detection is an internal ECU
temperature or electrical wiring issue. threshold.
Exchange EGR actuator.
1756 415 2791 13 EGR actuator can not learn stop positions Interruption of learning process due to mechan- Threshold for error detection is an internal ECU
because procedure was interrupted. ical damage. threshold.
Start Serdia Usecase to reset EGR actuator.
1757 415 2791 6 Overcurrent to EGR actuator. High voltage from battery. Check battery voltage. Check if EGR is blocked or
EGR actuator is blocked or moving very hard. not running smoothly.
If everything is o.k. change EGR actuator.
1758 415 2791 3 Overvoltage at EGR actuator. High voltage from the battery Check battery voltage.
1759 415 2791 4 Undervoltage at EGR actuator. Low voltage from the battery. Check battery voltage.
1760 415 2791 13 Stop positions of EGR valve not o.k. Mechanical damage of EGR actuator. Threshold for error detection is an internal ECU
EGR valve is blocked or moving very hard. threshold.
Start Serdia Usecase to reset EGR actuator.
1761 415 2791 7 EGR actuator spring broken. mechanical damage of spring due to overstress. Threshold for error detection is an internal ECU
threshold.
Exchange EGR actuator.
1762 415 2791 16 Internal actuator temperature above thresh- overheating of EGR actuator Let EGR actuator cool down, check heat accu-
old. mulation during worst case operation.
1763 415 2791 0 Internal actuator temperature is above Overheating of EGR actuator during operation. Let EGR actuator cool down and check heat
threshold. accumulation during worst case operation.
1827 192 524141 7 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
1857 555 523612 12 Fault in the monitoring during the engine wiring is not according DEUTZ requirements Threshold for error detection is an internal ECU
start. Start requested in level 1, but not engine start conditions are not observed threshold.
released in level 2 which leads to no fuel low battery voltage during start check other active errors and fix them.
injection. malfunction of starter check all needed engine start conditions, e.g.
neutral switch.
check the engine speed during starting of the
engine. If it's too low, then check the
battery voltage and then check the starter for
malfunction.
3121619 – JLG Lift – 3-97

Deutz Blink
Code Code
1858 192 524141 7 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
1863 995 524177 7 The error shows up, if no proper urea presure This error shows up, if no proper urea presure Make sure that DEF lines, pump and tank are not
could be build up within the SCR system could be build up within the SCR system frozen.
state "Fill Lines" => SCRCo_stStatus_mp = state "Fill Lines" => SCRCo_stStatus_mp = 1. Check for DEF level in the tank.
1. 3 cases can lead to the error: Check DEF lines:
Case A: increasing pressure is detected within Are all DEF lines connected?
15s the check has passed => no error Is the suction line blocked?
Case B: The pressure threshold was not reached Is ther any leakage? Not only urea to the outside
within the 60s but case A was not but also air into the lines, especially in
positiv. the suction line!
Case C: The minimum pressure of 3000 hPa was Perform SERDIA usecase "pressure test":
not reached within the 60s. Does the DEF pump work? => check wiring har-
ness & PWM signal for pump.
Does the urea pressure increase?
All errors are already healed?
If still unsuccessful so far:
Check urea pressure sensor: At ignition on and
Check DEF pump filter: Is any dirt inside?
Suction line
PWM Powerstage has a defect and a default
value which leads not to a rising pressure
DEF pump pressure sensor defect
DEF pump filter contains dirty parts
3-98 – JLG Lift – 3121619

Deutz Blink
Code Code
1864 996 524178 7 The urea pump is not able to control the urea The urea pump controller is not able to control Make sure that DEF lines, pump and tank are not
pressure between 9bar and 11 bar. the urea pressure between 9bar and 11 frozen.
bar due to malfunction in the SCR system. Check for DEF level in the tank
Suspected components: Check DEF lines:
- DEF pump broken All lines connected? The right lines connected to
- Reverting valve continously open the correct places?
- Urea suction line, backflow line broken or con- Suction line blocked?
nection swapped Is there any leakage? Not also urea to the out-
- PWM Powerstage has a defect side but also air into the lines, especially
- Pump Pressure sensor broken in the suction line!
Perform SERDIA usecase "pressure test":
Does the DEF pump work properly? => check
wiring harness & PWM signal for pump
Does the DEF pressure rise?
Is the error healed?
If still unsuccessful so far:
- Check DEF pressure sensor: At ignition on and
- Check reverting valve
- Check DEF pump filter: dirt inside?
DEF pump broken
Reverting valve continously open
DEF suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
DEF pump pressure sensor broken
1865 668 4360 2 Error at static plausibility check: Error at static plausibility check: Check whether temperature sensor upstream of
absolut temperature difference of sensed absolut temperature difference of sensed tem- SCR catalyst is physically mounted
temperature upstream SCR catalyst and perature upstream SCR catalyst and within exhaust pipe
ambient temperature > as static plausibility ambient temperature > as static plausibility If cold start condition can be made sure (engine
limit limit was off for at least 8 h) compare
at engine cold start (engine was off for at at engine cold start (engine was off for at least 8 values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
least 8 h), temperature upstream of SCR cat- h), temperature upstream of SCR Exh_tOxiCatDs and
alyst is expected to be identical to ambient catalyst is expected to be identical to ambient SCR_tSensUCatUsT at ignition on, without
temperature => see enable conditions for temperature => see enable conditions for starting the engine. All identical?
details. details. Compare values of Exh_TOxiCatUs,
Error at dynamic plausibility check: Error at dynamic plausibility check: Exh_tOxiCatDs and SCR_tSensUCatUsT after 15
temperature difference of sensed tempera- temperature difference of sensed temperature min in constant operation point: show all simi-
ture upstream SCR catalyst and ambient upstream SCR catalyst and ambient lar values (30 K tolerance width). Are
temperature < as dynamic plausibility limit temperature < as dynamic plausibility limit ambient temperature and (EnvT_t), cooling
dynamic check is blocked if static plausibility dynamic check is blocked if static plausibility water temperature (EngDa_tEng) plausible?
check is already faulty check is already faulty Sensor coated with urea crystalls? Dismount
=> Temperature upstream SCR catalyst => Temperature upstream SCR catalyst must urea injector and inspect temperature
must be by 40°C higher than ambient tem- be by 40°C higher than ambient sensor upstream SCR catalyst visually
perature if engine runs and a certain delay temperature if engine runs and a certain delay Check wiring of sensor
time has expired. time has expired. Replace sensor
3121619 – JLG Lift – 3-99

Deutz Blink
Code Code
1866 665 4334 2 absolute difference of sensed urea pump absolute difference of sensed urea pump pres- Check environment pressure sensor (EnvP_p)
pressure (SCR_pAbsSensUPmpP) and ambi- sure (SCR_pAbsSensUPmpP) and => plausible value?
ent pressure (EnvP_p) > limit ambient pressure (EnvP_p) > limit Engine shut-off and immediately re-started?
abs(UPmpP_pDiffPmpEnv_mp) > abs(UPmpP_pDiffPmpEnv_mp) > => Shut-off again. Wait until afterun of
UPmpP_pDiffPmpEnv_C (250 hPa) UPmpP_pDiffPmpEnv_C ECU has finished, re-Start engine
Back-flow line free? Does the urea pump pres-
sure show values < 1000 hPa in SCR
state emptying (64)?
Check revision valve => Does the urea pump
pressure show values < 1000 hPa in SCR
state emptying (64)? => exchange supply
module
Supply module pressure sensor defect =>
exchange supply module
1867 894 524067 2 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module heater temperature and supply module heater temperature and and CEngTds_t and
ambient temperature ambient temperature SCR_tAdapUTnkT => All identical? If not:
UPmpT_tDiffPmpHtrAmb_mp > threshold UPmpT_tDiffPmpHtrAmb_mp > threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Problem at Supply module unit (broken?) =>
1868 894 524067 2 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module temperature and ambient supply module temperature and ambient and CEngTds_t and
temperature > threshold temperature UPmpT_tDiffPmpAmb_mp > SCR_tAdapUTnkT => All identical? If not:
threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Problem at Supply module unit (broken?) =>
1874 971 524152 2 CAN message is not received fora definite CAN message is not received for a definite time Check eletrical connection oif urea quality sen-
time => error is set. As soon as the message => error is set. As soon as the sor
is received the error heals. message is received the error heals. Check engine CAN bus
Check urea quality sensor itself
Exchange urea quality sensor
1875 997 524153 2 CAN message is not reseived for a definite CAN message is not reseived for a definite time Check eletrical connection of suction unit sen-
time => error is set. As soon as the message => error is set. As soon as the sor (combined sensor with tank level and
is received the error heals. message is received the error heals. tank temperature)
Check engine CAN bus
Check level sensor itself
Exchange suction unit
3-100 – JLG Lift – 3121619

Deutz Blink
Code Code
1880 138 1761 14 The DEF tank level is below the threshold. actual DEF tank level SCRUTnk_rVol_mp [%] is Check DEF level => if empty, refill
below the threshold Check DEF level sensor.
If there is urea in the tank loose the sensor and
move it. The floater must be free and
move if you lift the sensor body.
Compare SCRUTnk_rVol_mp to:
1 = SCR_rawUTnkLvl
2 = SCR_rAdapUtnkLvl
3 = SCRUTnk_rActTnkVol
*SCRUTnk_facVolPer_mp
In case of malfunction, exchange DEF level sen-
sor.
1881 683 4768 2 At engine cold start conditions the sensed Difference temperature of exhaust gas temper- Check whether all exhaust gas temperature
exhaust gas temperature downstream DOC ature downstream DOC and fixed sensors within the EAT system are
(Exh_tSensTOxiCatDs) ambient temperature at ignition on exceeds a mounted properly: Within the exhaust line and
has exceeded the sum of ambient tempera- certain limit earlier than the difference at correct positions.
ture (EnvT_t) + offset (40°C) earlier than the temperature of exhaust gas temperature Check the position of the sensor upstream SCR
sensed exhaust gas upstream DOC and fixed ambient temperature which might be physically mounted in
temperature upstream of DOC at ignition on. the wrong position.
(Exh_tSensTOxiCatUs). If cold start condition can be made sure (engine
The check is only performed once each igni- was off for at least 8 h) compare
tion cycle and only if the start is judged a cold values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
start. Exh_tOxiCatDs and
Error status is frozen for that ignition cycle. SCR_tSensUCatUsT at ignition on, without
No healing possible. starting the engine. All identical? Then the
sensors itself are okay.
Check exhaust piping for leakage.
Check wiring of sensors
Replace sensors
Check DOC => physicallly intact?
1891 272 524190 14 Not enough urea in tank or low urea quality Low DEF tank level Check DEF level in tank. If there is no DEF, refill
or hardware tampering failure is detected or Low DEF quality up to volume above the warning
hardware failure is detected Hardware Tampering is active threshold.
Hardware Failure is active Check the DEF quality in the tank. If wrong fluid
is filled, refill with proper DEF.
Check other errors based on hardware malfunc-
tions.
1892 273 524191 14 A low DEF tank level or a low DEF quality is Low DEF tank level Threshold for error detection is an internal ECU
detected or hardware tampering(system Low DEF quality threshold.
components are pinched off) or hardware Hardware Tampering is active Check the DEF level in tank. If there is no DEF,
failures as shortcut to battery, shortcut to Hardware Failure is active refill up above the warning level.
ground Check DEF quality filled in the tank.
etc. are detected. Check other errors based on hardware tamper-
ing or failure.
3121619 – JLG Lift – 3-101

Deutz Blink
Code Code
1893 275 524193 8 The total time in standstill-regeneration Stand-still mode is very often aborted by the Read out stand-still statistics => see service
mode exceeds the long-limit threshold operator. manual:
within last 500h total engine run time. Stand-still mode does not reach required tem- Stand-still operation finished or often inter-
The error is activated if the engine runs to perature level and regeneration level is rupted by driver / engine shut-off? => Run
many times in Standstill regeneartion. therefore reached after a short time again stand-still and instruct operator
Stand-still operation required often by soot
load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPf allow it:
Perform Stand-still and check reached temper-
ature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min
stand-still main phase 590°C are reached?
Temerature traces are steady and even?
Temperature downstream DOC higher than
upstream DOC but difference does not
exceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C downstream
DOC are not reached) => exchange DOC
Very big difference (>100 K after 25 min stand-
still main phase, 590 °C downstream
DOC exceeded) => check injection system of
engine & engine air path
3-102 – JLG Lift – 3121619

Deutz Blink
Code Code
1894 276 524194 8 The total time in standstill-regeneration Stand-still mode is aborted / interrupted too Read out stand-still statistics => see service
mode exceeds the long-limit threshold: 2,5h often by the operator manual:
stand-still operation within 50h total motor Stand-still is required too often due to miscalcu- Stand-still operation finished or often inter-
run time. lation in the soot model rupted by driver / engine shut-off? => Run
The error is activated if the engine runs to Stand-still mode does not reache temperature stand-still and instruct operator
much time in short Standstill regeneartion. level and regeneration level is therefore Stand-still operation required often by soot
reached after a short time again. load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPF allows it:
Perform Stand-still and check reached temper-
ature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min
stand-still main phase 590°C are reached?
Temerature traces are steady and even?
Temperature downstream DOC higher than
upstream DOC but difference does not
exceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C downstream
DOC are not reached) => exchange DOC
Very big difference (>100 K after 25 min stand-
still main phase, 590 °C downstream
DOC exceeded) => check injection system of
engine & engine air path
1895 277 3519 12 The integrated temperature sensor of the Temperature sensor inside the UQS defect. Check the temperature sensor signal for plausi-
Urea Quality Sensor measures higher tem- CAN Communication corrupted. bility. In case of improper signal,
perature than threshold Overheating of the DEF tank due to malfunction exchange the suction unit in the tank.
of the heating valve. Check CAN bus communication for proper sig-
Flow direction is of coolant is wrong due to nal. In case of improper signal, exchange
mixed up the hoses routed to the heating the suction unit in the tank.
valve. Check the function of heating valve and routing
Overheating of the DEF tank due to heat transfer of the hoses. The coolant flow through
from neighbor parts. the heating valve must be observed according
to the shown arrow.
In case all actions above are OK, check the real
temperature in the DEF tank during
worst case condition and improve the installa-
tion of the DEF tank.
1896 278 3520 3 The integrated diagnostic of the Urea Quality wiring harness of UQS corrupted Threshold for error detection is an internal ECU
Sensor recognized a short circuit to battery CAN Communication corrupted threshold.
Check the wiring harness from the ECU to the
suction unit of the DEF tank
Check the CAN bus communication. If the signal
is corrupt, then exchange the suction
unit.
3121619 – JLG Lift – 3-103

Deutz Blink
Code Code
1897 278 3520 4 The integrated diagnostic of the Urea Quality wiring harness to the suction unit in the DEF Threshold for error detection is an internal ECU
Sensor recognized a short circuit to ground. tank is corrupted threshold.
CAN Communication corrupted Check the wiring to the suction unit in the DEF
tank.
Check the CAN bus communication. In case the
communication is corrupt, exchange
the suction unit in the DEF tank.
1898 277 3519 3 The integrated diagnostic of the tempera- Wrong diagnostic of the short circuits logic Check the wiring to the suction unit in the DEF
ture sensor of the Urea Quality Sensor recog- inside the temperature sensor of the UQS tank.
nized a short circuit to battery. CAN Communication corrupted Check the CAN bus communication of the suc-
The UQS Sensor is an combined sensor of tion unit. In case the communication is
tank temperature, filling grade and DEF corrupt, exchange the suction unit.
quality and it is also an CAN sensor --> no
PIN
1899 277 3519 4 The integrated diagnostic of the tempera- DEF quality sensor in the suction unit of the DEF Check the wiring to the suction unit of the DEF
ture sensor of the Urea Quality Sensor recog- tank is defect tank.
nized a short circuit to ground CAN Communication corrupted Check the CAN bus communication from the
suction unit. In case the signal is corrupt,
exchange the suction unit in the DEF tank.
3-104 – JLG Lift – 3121619

Deutz Blink
Code Code
1900 279 524195 14 The standstill request of detected crystalli- Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line and
zation is ignored for more than reached a level which indicates inspect visually the injector and the
5h(>300min) crystallisation inside of exhaust line. exhaust line for urea crystallisation upstream of
This will be activated if there is a standstill The error detection depends on the sensed pres- SCR catalyst:
request activated by Crystalisation Monitor- sure upstream of the SCR catalyst and If crystallisation can be clearly seen, then stand-
ing. the calculated exhaust volume flow through still must be processed.
the mixer pipe. Has the engine been operated in low load for
In case of error is set, but no crystallisation can longer time? If yes, then it could be the
be found in the mixing pipe, a possible reaoson for crystallisation.
reason can be the defect sensors: Does the NOx-Sensors work properly? Compare
- exhaust pressure & temperature upstream of ComRxSCR_rNOxUs to
the SCR catalyst, ComRxSCR_rNOxDs, when
- the ambient pressure ComRxSCR_stNOxRdyUs = 1 &
- the exhaust mass flow => Check air path sys- ComRxSCR_stNOxRdyDs = 1 (Warm engine
tem at the engine. and EAT-system,
SCRT_tCatAvrgExhGs_mp > 250°C,
SCR_stStatus = "Dosing" = 8): sensed NOx
upstream of SCR catalyst must be higher than
downstream of SCR catalyst.
Go to idle and wait until SCR system enters sta-
tus "stand-by" (no dosing),
SCRT_tCatAvrgExhGs_mp < 225°C:
ComRxSCR_rNOxUs = ComRxSCR_rNOxDs
Clean urea injector: rinse it thourougly under
water
Check EGR-Path: difference pressure sensor at
venturi tube, EGR cooler, EGR-Valve,
Reed-Valve, Intake throttle regarding function
and leakage. Does the EGR-cooler leak
water in the exhaust?
Check air path for leakage
Check turbocharger
No crystallisation can be seen in the mixing
pipe:
Check exhaust pressure sensor upstream of SCR
catalyst (SCR_pSensUCatUsP):
tube, water in sensor?
Check environmental pressure sensor
(EnvP_p): plausible?
Check exhaust temperature sensor upstream of
SCR-catalyst (SCR_tSensUCatUsT):
plausible compared to Exh_tOxiCatUs &
Exh_tOxiCatDs e.g. when engine has idled for
20 minutes?
=> Run stand-still to remove crystallisation
and to reset the DFC
3121619 – JLG Lift – 3-105

Deutz Blink
Code Code
1904 2-7-8 3520 2 Measured DEF Quality from UQS is too low. Suspected components: Check that there is liquid urea of known quality
Quality value received from UQS is < 22 % for Urea quality sensor defect in the tank first
a certain time and a certain number or for Wrong installation (measuring air) Check urea tank level. Add urea until level is at
measuring conditions not observed for a cer- Urea level sensor defect least 10 cm above sensor.
tain time. Non urea filled in tank Ensure that urea is not frozen / sufficient urea is
CANBUS problems liquid
Evaluation conditions for new quality check not Check Sensor: Are urea tank temperature and
fulfilled after one previous mal detection level displayed? Changes the level if you
refill urea?
Check electrical connection
Check CANBus
New quality detection is carried out if urea re-
fill is detected or if an quality evaluation
was triggered and was not finished success-
fully: To provoke a quality measurement: refill
urea, at least 10 % of tank volume
Wait until quality evaluation was carried out,
can take up to 30 minutes => check value.
It should be about 33 %
Exchange quality sensor
1907 278 3520 13 Urea quality at UQS out of range the speci- Suspected components Check DEF quality and/or DEF quality sensor
fied thresholds; invalid quality of the urea DEF quality sensor
qualiy DEF
1908 277 3519 13 Temperature at UQS out of range the speci- Suspected Components Check temperature system and/or DEF quality
fied thresholds; invalid quality of the tem- Tank heater sensor
perature DEF sensor
1911 127 3532 3 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or sensor.
greater than the maximum physical range UQS defect
threshold
Comment: tank temperature is measured by
the UQS sensor
1912 127 3532 4 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or Sensor.
lower than the minimum physical range UQS defect
threshold.
1914 669 4365 3 Internal error of DEF qualitysensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF qualitysensor
Wiring harness
1915 6-6-9 4365 4 Internal error of DEF qualitysensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF qualitysensor
Wiring harness
1917 2-8-6 3936 14 Standstill escalation by time. In case the Stand-still request ignored by the operator. Perform Stand-still. If soot load level of DPF has
standstill request will not be released within Display / stand-still request lamp broken. increased too high already call service
50 h by the driver this fault code will be set. to perform stand-still.
In case the DPF soot load level remove DPF =>
Exchange DPF.
3-106 – JLG Lift – 3121619

SECTION 4. BOOM & PLATFORM
4.1 BOOM SYSTEMS Beyond Transport - Drive Speed Cutback System

When boom is positioned beyond the Transport Position, the
drive motors are automatically restricted to their maximum
Broken Cable Indicator System displacement position (slow speed).
The boom on this model is a 5 section proportionally driven
telescopic boom. Section #2 is driven directly by the telescope Drive/Steer - Boom Function Interlock System (CE/
cylinder. Section #3, #4, and #5 (fly boom) are each driven by
separate wire rope systems. Each rope system contains redun- AUS ONLY)
dant ropes that are capable of allowing the operator to The Drive/Steer - Boom Function Interlock System uses the
unknowingly continue use of the machine with a single rope Transport Position Sensing System (item 14) to sense when the
failure. These kinds of failures with the extend ropes are self boom and jib are out of the transport position. All controls are
revealing to the operator so proper action can be taken. Fail- simultaneously functional when the booms are within the
ures within section #4 and section #5 extend ropes are self transport position as on the standard machine. When the
revealing as they are exposed on the exterior of the boom boom/jib are beyond the transport position, the control func-
where a broken rope would be obvious. Failures within section tions are interlocked to prevent simultaneous operation of any
#3 ropes require the addition of the Broken Cable Indicator boom function with drive/steer. The first function set to be
System in order to be self-revealing to the operator. This sys- operated in this mode, becomes the master function set. In
tem uses proximity sensors to detect excessive movement of other words, while operating drive/steer functions the boom
the sensed ropes as would be expected with a rope failure. A functions are inoperable. Likewise, while operating boom
broken rope detection results in illuminating the Cable Break functions drive/steer functions are inoperable.
indicator on the platform control panel. No restrictions are
made to the functionality of the control system. It is the Jib Stow System
responsibility of the operator to take the appropriate action.
The machine's stowed length can be reduced to facilitate
transportation on standard trailers by swinging the jib to the
Transport Position Sensing System right using the hydraulic power of the jib stow rotator. The
The transport position sensing system uses the main boom control system will prevent swinging the jib unless the axles
angle sensors, the main boom length sensor mounted in the are retracted, the boom and jib are in the transport position. If
pivot end of the main section #1boom in addition to the boom the transport criteria are met and the operator commands jib
length switch mounted on the platform end of the main base swing right via the jib swing function switch. The control sys-
boom and transport proximity switches mounted to the jib fly tem will retract the jib lock pin and begin to swing the jib into
boom to sense when the main boom and jib boom are in the the stowed position. When the jib is stowed, automatic plat-
position associated with high speed travel. Above transport form leveling is disabled, the boom is restricted to the trans-
angle is recognized when the main boom (using the cylinder port position, and axle extension is disabled. This system is
angle sensors) is more than 5º with respect to the turntable functional only in the 500# mode of the Dual Capacity System.
and resets to within transport position when both main boom Jib telescope function will resume when the jib is nearly fully
angle sensors read less than 3º with respect to the turntable. stowed alongside the main boom. Conversely, the jib must be
Transport length is recognized when the main boom length retracted into the transport position before the jib is allowed
switch and main boom length sensor read less than 17" exten- to swing left into the locked position. Once the jib reaches the
sion for the main boom. Transport position is also determined inline position, and the operator is maintaining the jib swing
when the jib boom length switches indicate the jib is fully left function switch the control system will attempt to lock the
retracted. During failures of either the main boom length jib lock pin. If successful, the jib lock pin lamp will illuminate
transport switch or the main boom length sensor the main continuously after the operator releases jib swing function
boom transport length will be determined by the remaining switch.
sensor or switch. In addition, for a failure of either jib transport
length switch, jib length will be determined by the remaining
switch.
This system is used to control the following systems:
• Beyond Transport - Drive Speed Cutback System
• Drive/Steer - Boom Function Interlock System - CE Only
• Jib Stow System
• Axle Extension System
3121619 – JLG Lift – 4-1

Envelope Control System tions due to moment system violations related to forward
reach are disallowing jib functions, lift down, telescope out,
The Envelope Control System is the primary means of control-
swing, drive, and steer. The restricted functions due to
ling the stability of the machine by restricting the working
moment system violations related to backward reach are disal-
envelope of the main boom. The envelope shape, is such that,
lowing jib functions, lift up, telescope in, swing, drive and
positions of stability and structural integrity can be controlled
steer. Recognized failures within this system will result in con-
including the restriction of forward and rearward reach of the
trol by the Envelope Control System, reduced function speeds,
platform. This system uses the two main boom angle sensors,
and BCS warning light illumination. The boom will be
the main boom length sensor, and the main boom transport
restricted from leaving the transport position (see item 14)
length switch to continuously measure the position of the
until the failure is resolved.
main boom and control its position within the predetermined
envelope. The two main boom angle sensors measure the
angle of the main boom relative to gravity and are continu- Boom Control System (BCS) Functional Check
ously monitored for mutual agreement. The main boom (Push to Test) System
length sensor measures the length of the main boom and is
monitored for response to main telescope command and for The machine is equipped with a system for the operator to
agreement with the fixed position length switch (Main boom daily verify the proper functioning of the Boom Control Sys-
length transport switch). Violations of the main boom position tem (Envelope Control System and the Moment Control Sys-
to allowable envelope positions will result in reduced function tem). The operator is instructed to position the boom in the
speeds, BCS warning light illumination, and restriction of func- position described by the instruction decal and to then verify
tions. The platform alarm will sound and the BCS light will the control system cut out the main telescope movement at
flash with attempts to operate restricted functions. The the correct length. When the operator pushes the button
restricted functions due to envelope violations related to for- mounted on the ground control panel, the control system
ward reach are disallowing main lift down, main telescope out, compares the current moment reading in the moment system
swing, drive and steer. The restricted functions due to enve- to the moment expected for this position. If the current
lope violations related to backward reach are disallowing main moment is within allowable tolerance for the test position, the
lift up, main telescope in, swing, drive, and steer. Recognized green BCS indicator will illuminate indicating the system is
failures within this system will result in control by the Moment working properly. If the current moment is not within the
Control System, reduced function speeds, and BCS warning allowable tolerance for the test position, the red BCS indicator
light illumination. The unit will be restricted from leaving the will illuminate indicating the machine requires service by JLG
transport position until the failure is resolved. authorized service personnel before the system is used. Failure
of this test will not restrict the functionality of the machine
and will not cause a system fault. It is the operators responsi-
Moment Control System bility to take proper action. The machine can be in either
The Moment Control System is the secondary means of con- capacity mode of the dual capacity system for this system
trolling the stability of the machine. This system uses a load check.
cell pin to attach the lift cylinder of the main boom to the turn-
table. This pin is instrumented with gauges allowing the forces
in the pin to be monitored. These forces are used to compare
Controlled Arc System
the actual boom moment (force at a distance) to a predeter- The Controlled Arc System uses the envelope control sensors
mined allowable boom moment. In controlling the boom to enhance the control of the main boom within the working
moment, the position and load of the boom is controlled. The envelope. The purpose of the controlled arc system is to mini-
moment control system will detect moments larger than mize the interaction of lift functions with envelope edges and
expected as well as those smaller than expected. This effec- to increase user efficiency. This minimizes the effect of a long
tively controls the forward and rearward positions of the boom working in a comparatively narrow envelope. Because
boom. The moment control system varies the maximum the boom is permitted to extend to longer lengths at high
allowable moment based on ground slope. On level ground angles than at it is low angles, lift commands would normally
and with rated load in the platform, the allowable moments cause the boom to violate the permitted envelope while lifting
establish a working envelope slightly larger than the Envelope down or conversely require the operator to frequently com-
Control System's envelope to minimize interaction of the sys- mand telescope out while lifting to high heights. The con-
tems. With increasing ground slopes and rated load in the trolled arc system optimizes the envelope shape by
platform, the allowable moments may establish a working automatically introducing telescope in or out during “lift only”
envelope smaller than the Envelope Control System's enve- commands. Telescope flow is regulated during lift commands
lope and may result in moment violations at the extreme plat- to maintain a constant percentage of available boom length
form positions. Violations of the moment control systems (0% is always fully retracted, 100% is variable as the permitted
allowable moment will result in reduced function speeds, BCS length changes when the boom is raised). The target percent-
warning light illumination, and restriction of functions. The age will be maintained throughout the lift command whether
platform alarm will sound and the BCS light will flash with it is maintaining 0%, 100%, or any percentage in between. The
attempts to operate restricted functions. The restricted func- target percentage is established at the start of lift command or
4-2 – JLG Lift – 3121619

end of manual telescope commands when using multiple Slow Down System
functions with lift. The telescope command can be used inde-
When the main boom approaches the edges of the working
pendently or in combination with other functions. Manual
envelope, all functions (except jib and platform functions, tele-
introduction of telescope will override the controlled arc sys-
scope in or out on the rearward edge and telescope in on the
tem and result in conventional control. Controlled arc will be
forward edge) are automatically slowed down by the control
disabled with any sensor failure, any moment violation, any
system to reduce the machine dynamics and improve opera-
envelope violation, or with auxiliary power functions. The con-
tor control. The slow down starts within 4 feet of all edges and
trolled arc functionality can be turned off using the manual
is at the fully reduced speeds 2 feet from all edges. The control
position of the boom control select switch. When selected, this
system indicates to the operator this automatic introduction
system is active at all boom angles and lengths.
of slow down by flashing the creep light on the platform dis-
play panel. This feature applies to both platform and ground
Controlled Boom Angle System controls, however, no indication is made on the ground con-
The Controlled Boom Angle System uses the envelope control trol panel. This is not adjustable using the analyzer.
sensors to enhance the control of the boom by minimizing the
interaction of swing and drive functions with the envelope Dual Capacity System
edges. This interaction is due to two factors. First, the envelope
The Dual Capacity System on this machine is a multiple enve-
is controlled relative to gravity regardless of ground slope and
lope control system as opposed to an indication system. The
second, the turntable/boom mounting is effected by swing
control system changes the working envelope and moment
and drive functions when the ground slope varies. This can
limits to match the capacity select mode to either the 500#
cause the boom position to vary within the envelope or even
mode or the 1000# mode. It then displays the capacity mode
violate the envelope edges when swinging or driving without
on the platform and ground display panel and controls the
intentionally moving the boom. The controlled boom angle
positions of the boom within the allowable envelope for that
system minimizes this effect by automatically introducing lift
mode. This mode is selectable by the operator with the dual
up or down during swing and drive commands to maintain a
capacity select switch on the platform control panel. The 500#
constant boom angle relative to gravity for all boom angles
mode has the largest envelope. The 1000# mode has a smaller
greater than 8 degrees. Controlled boom angle is disabled
envelope and requires the jib to be retracted fully. To select
with any envelope or moment violations or failures. The con-
the 1000# mode the boom must already be in the smaller
trolled boom angle functionality can be turned off using the
1000# envelope. When the operator selects the 1000# mode
manual position of the boom control select switch.
and this condition is met, the capacity light changes from 500#
to 1000# and the envelope and permitted moment values are
Envelope Tracking changed accordingly. When the operator selects the 1000#
The Envelope Tracking System uses the envelope control sen- mode and this condition is not met, both capacity lights will
sors to enhance the control of the boom within the working flash, the platform alarm will sound, and all functions will be
envelope. Due to the shape of the working envelope, the max- disabled until the capacity select switch is put back into the
imum boom angle varies with telescope length. To maintain 500# position.
unrestricted operation of the boom, the lift down function is
automatically introduced while telescoping in only when the Swing Speed Proportioning
boom is on the rearward edge of the envelope. This only
Swing Speed Proportioning uses the boom length and angle
occurs when telescoping in along the rearward edge and is
sensors to improve the comfort, speed and control of the turn-
not used elsewhere within the envelope or when telescoping
table swing function. Turntable swing speed is increased as
out. Envelope tracking is disabled with any envelope or
the distance of the platform to the center of rotation is
moment violations or failures. The envelope tracking function-
decreased. This results in approximately constant platform
ality can be turned off using the manual position of the boom
speeds regardless of boom position. Swing speed proportion-
control select switch.
ing is disabled with any envelope sensors failure. Disabling of
swing speed proportioning will default to the slowest swing
speed setting.
3121619 – JLG Lift – 4-3

Platform Load Sensing System Boom Control Select

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

Boom Recovery Mode

Boom Recovery Mode allows the boom to be lifted down and Press ENTER , the screen should read:
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.
Boom Recovery override is accessible in Access Level 1. Using
the Left and Right arrow keys until the screen

shown below is reached.
To enable the override mode 58237 must be entered as the

code. When the code is entered, the screen will show:
3121619 – JLG Lift – 4-5

4.2 BOOM REMOVAL AND INSTALLATION

Use the Left or Right arrow key until you see:
Removal
1. If necessary, remove the platform.
2. If necessary, remove the jib.
3. Tag and disconnect hoses T2 T3, 7, 8, and Pressure Filter
lines from the main valve. Cap or plug all openings.
Press Enter . Once Enter is pressed using the Up
or Down arrow key will turn the boom recovery

on or off. Once turned on, main boom lift down will be
enabled and main telescope in will be enabled to recover the
boom. After the boom is brought down it will be trapped into
transport. Reset or turning it off is achieved by escaping out of
the service mode, by cycling power to the machine, or re-
entering the service mode and manually turning it off.
4-6 – JLG Lift – 3121619

Figure 4-1. Boom Hydraulic System
3121619 – JLG Lift – 4-7

4. Tag and disconnect all electrical lines from the limit 9. Carefully lift the boom from the machine, taking care to
switches and generator that go to from the turntable to feed the hydraulic and electrical lines up alongside the
the powertrack. boom as it is raised.
Installation
1. Lift the boom almost into position.
2. Feed the hydraulic hoses and electrical lines down
alongside the hood.
3. Loosely connect the powertrack end. Remember to
5. Elevate the boom enough to remove the upper lift cylin- tighten the bolts the rest of the way when installation is
der pin. Use an overhead crane or similar lifting device complete.
to support the weight of the boom.
6. Using an adequate lifting device, support the weight of
the lift cylinder and remove the lift cylinder pin. Lower
the lift cylinder down until it rests on the boom rest.
4. Lower the boom into position and install the boom

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

port the rear of the boom.
8. Remove the boom pivot pin.
4-8 – JLG Lift – 3121619

5. Raise the front of the boom enough to allow connection 4.3 BOOM ASSEMBLY
of the lift cylinder.
Assembly
NOTE: Throughout this procedure, boom sections are identified
numerically, 1-5. Boom Section 1 is at the base, Boom Sec-
tion 5 is the fly.
NOTE: During Assembly, Super Lube® lubricant (JLG p/n 3020042)

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

is to be moderately applied to all outer surfaces of interior
wear pads after they are assembled to the insertion end of
boom sections. Care should be taken to avoid application
6. Attach a lifting strap to the lift cylinder. Raise the lift cyl- on exposed painted surfaces of the fully extended boom.
inder into place and install the lift cylinder pin.
AVOID APPLICATION
ON EXPOSED
PAINTED SURFACES
WEAR PAD
SURFACES
NOTE: Boom section 5 weighs approximately 1682 lbs. (763 kg).
7. Connect the hydraulic lines as tagged during removal. 1. Place boom section 5 on a proper supporting device.
8. Connect the electrical lines as tagged during removal.
9. If removed, install the jib.
10. If removed install the platform.
3121619 – JLG Lift – 4-9

2. Install the side rear wear pads and shims. Coat the 5. Install the section 5 extend ropes into the mounting
retaining bolts with JLG threadlocking compound P/N holes in the bottom of section 5. Place tape over the
0100011 and secure the wear pads with the bolts and holes to keep the cables in place during assembly as
washers. Torque the bolts to 40.5 ft.lbs. (55 Nm). shown.
3. Install the top and bottom rear wear pads and shims.
Coat the retaining bolts with JLG threadlocking com-
pound P/N 0100011 and secure the wear pads with the
bolts and washers. Torque the bolts to 40.5 ft.lbs. (55
Nm).
4. Install the section 5 retract ropes to into the holes in the

side of section 5. Place tape over the holes to keep the
cables in place during assembly as shown.
4-10 – JLG Lift – 3121619

Figure 4-2. Boom Assembly - Sheet 1 of 9
3121619 – JLG Lift – 4-11

4-12 – JLG Lift – 3121619

3121619 – JLG Lift – 4-13

4-14 – JLG Lift – 3121619

3121619 – JLG Lift – 4-15

4-16 – JLG Lift – 3121619

3121619 – JLG Lift – 4-17

4-18 – JLG Lift – 3121619

3121619 – JLG Lift – 4-19

4-20
– JLG Lift –
Figure 4-11. Locations for Threadlocker Application - Sheet 1 of 5
3121619
3121619
– JLG Lift –
4-21
4-22
– JLG Lift –
3121619
3121619
– JLG Lift –
4-23
4-24
– JLG Lift –
3121619
3121619
– JLG Lift –
Figure 4-16. Boom Assembly Torque Values - Sheet 1 of 4
4-25
4-26
– JLG Lift –
3121619
3121619
– JLG Lift –
4-27
4-28
– JLG Lift –
3121619
6. Place boom section 4 on a proper supporting device. 10. Install the wire rope retainer blocks to the front of sec-
tion 4 boom using the washers, bolts, and nuts.
7. Apply Super Lube® lubricant (JLG p/n 3020042) to all 4

sides of the boom approximately 3 to 4 feet on both
ends. Apply Super Lube® to section 5 on the end that
will go into section 4 only. Apply super lube to all outer 11. Install the bottom front wear pads and shims to section
surfaces of interior wear pads after they are installed. 4. Coat the retaining bolts with JLG threadlocking com-
8. Avoid getting super lube on painted surfaces. Slide sec- pound P/N 0100011 and secure the wear pads with the
tion 5 into section 4 using adequate lifting equipment. bolts and washers. Torque the bolts to 43 ft.lbs. (58 Nm).
12. Install the front side wear pads and shims to section 4.
bolts and washers. Torque the bolts to 28 ft.lbs. (38 Nm).
13. Install the front bottom wear pad and shims to section 4.
14. Install the front top wear pads and shims to section 4.
15. Install the rear top wear pads and shims to section 4.
NOTE: Apply a thin coat of moly paste (JLG P/N 3020039) on the pound P/N 0100011 and secure the wear pads with the
inside diameter of the sheave bearing before installation of bolts and washers. Torque the bolts to 28 ft.lbs. (38 Nm).
sheaves.
16. Install the section 4 retract wire ropes to the rear of sec-
NOTE: Ensure the wire ropes remain untwisted through boom section 4.
tion 4.
NOTE: The retract wire ropes must be installed before side wear
9. Install the sheaves to the front of section 4. Apply JLG pads are installed.
threadlocking compound P/N 0100011to the bolts and
use the bolts, pins, keepers, and washers to secure the 17. Install the rear side wear pads and shims to the outside
sheaves. Route the wire rope around the sheaves. of section 4. Coat the retaining bolts with JLG thread-
locking compound P/N 0100011 and secure the wear
pads with the bolts and washers. Torque the bolts to
40.5 ft.lbs. (55 Nm).
18. Install the rear side wear pads to the inside of section 4.
3121619 – JLG Lift – 4-29

19. Install the rear bottom wear pads to the outside of sec- 22. Install the section 4 extend ropes to section 4.
tion 4. Coat the retaining bolts with JLG threadlocking
compound P/N 0100011 and secure the wear pads with
the bolts and washers. Torque the bolts to 28 ft.lbs. (38
Nm).
20. Coat the inside diameter of the sheave bushings with
moly paste and install the wire rope sheaves to the rear
of section 4 boom using the bushings.
23. Place boom section 3 on a proper supporting device.
21. Coat the sheave retaining bolts with JLG Threadlocker P/

N 0100019 and the sheave plate/retainer block retaining
bolts with JLG Threadlocker P/N 0100011. Install the
sheave plate and rope retainer blocks to the rear of sec-
tion 4 using the retaining bolts. Torque the sheave
retaining bolts to 178 ft.lbs. (241 Nm). Torque the sheave
plate/retainer block bolts to 40.5 ft.lbs. (55 Nm)
ends. Apply Super Lube® only to the insertion end of
section 4. Apply Super Lube® to all outer surfaces of inte-
rior wear pads after they are installed. Avoid getting
Super Lube® on painted surfaces. Slide the section 4/
section 5 assembly into section 3 using proper lifting
procedures. The section 5 end of the section 4/5 assem-
bly must be raised after section 4 is inserted in section 3
to allow the four extend rope anchors to clear the top of
the four extend sheave mounts at the section 5 end of
section 3.
4-30 – JLG Lift – 3121619

25. Install the fixed sheave shields, and deflector sheaves 27. Coat the bolts with JLG Threadlocker P/N 0100011 and
using the retaining bolts and washers. Coat the bolts install the section 5 extend ropes to section 3 using nuts,
with JLG Threadlocker P/N 0100011 before installation. keeper plates, bolts, and washers.
Torque the bolts to 28 ft.lbs. (38 Nm).
28. Coat the bolts with JLG Threadlocker P/N 0100011 and
install the front bottom wear pads to section 3 using
washers, bolts, and shims. Torque the bolts to 43 ft.lbs.
26. Coat the bolts with JLG Threadlocker P/N 0100011 and (58 Nm)
install the section 5 retract ropes to section 3 using the
nuts, keeper plates, bolts, and washers.
3121619 – JLG Lift – 4-31

29. Apply a thin coat of moly paste on I.D. of sheave bear- washers, bolts, and shims. Torque the bolts to 28 ft.lbs.
ings. Coat the bolts with JLG Threadlocker P/N 0100011 (38 Nm))
and install the sheaves to the front of section 3 using the
pin, keeper, bolt, and washer.
30. Coat the bolts with JLG Threadlocker P/N 0100011.
Install the rope retaining blocks to the front of section 3
using washers, bolts, and nuts.

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

Install the front upper wear pads to section 3 using
4-32 – JLG Lift – 3121619

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

will go into section 2 only. Apply super lube to all outer
surfaces of interior wear pads after they are installed.
Slide sections 3,4, and 5 as an assembly into section 2
using proper lifting procedures.
Install the wear pads to section 2 using the bolts and
washers. Torque the bolts to 43 ft.lbs. (58 Nm).
3121619 – JLG Lift – 4-33

51. Apply moly paste to the I.D. of the sheave bearings. 57. Coat the bolts with JLG Threadlocker P/N 0100011.
Install the sheaves to section 2 boom. Install the front bottom wear pads to section 1 using
52. Coat the two sheave center bolts with JLG Threadlocker
(55 Nm).
P/N 0100019 and the sheave plate retaining bolts with
JLG Threadlocker P/N 0100011. Install the sheave plates 58. Coat the bolts with JLG Threadlocker P/N 0100011.
and rope retainer blocks to section 2 using the retaining Install the front side wear pads to section 1 using wash-
bolts. Torque the sheave center bolts to 178 ft.lbs. (241 ers, bolts, and shims. Torque the bolts to 43 ft.lbs. (58
Nm). Torque the sheave plate retaining bolts to 41 ft.lbs. Nm).
(55 Nm)
53. Coat the bolts with JLG Threadlocker P/N 0100011. Install the front top wear pads to section 1 using wash-
Install the bottom rear wear pad to section 2 using ers, bolts, and shims. Torque the bolts to 28 ft.lbs. (38
washers, and bolts. Torque the bolts to 28 ft.lbs. (38 Nm).
Nm)
NOTE: Boom section 1 weighs approximately 6045 lbs. (2742 kg). Install the cover to the section 1.
NOTE: Center the cover over the hole in section 1.

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

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

section 2 bottom plate.

Install the section 3 retract ropes to section 1 using
deflectors, bolts, nuts, washers, and keepers.
4-34 – JLG Lift – 3121619

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

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

inder barrel trunnion blocks to boom section 2 and
remove the trunnion blocks.
3121619 – JLG Lift – 4-35

6. Remove the bolts securing the extend rope support and 4.5 BOOM SHIMMING PROCEDURE
disconnect the support from boom section 3.
NOTE: Throughout this procedure, boom sections are identified
numerically, 1-5. Boom Section 1 is at the base, Boom Sec-
tion 5 is the fly.
1. Measure and record any sweep dimension and direction

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

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

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

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

and slide Section 5 boom to that side. Insert the other
side pads using shims measure how many will be
required to fill the remaining space. Once this is estab-
lished, install the total amount of shims as evenly as pos-
sible between the two sides unless corrections are
needed to compensate for out of square booms or for
additional corrections for any sweep recorded in step 1.
Care should be taken to keep the bottom pads evenly
loaded while shimming the side pads. If the sweep is to
the left the external side pads on the left should have
more shims than the right side pads and vice-versa.
NOTE: Do not use a wedge to install more shims than will fit with
the use of a pry bar. This may result in a boom being
shimmed too tight. The use of pry bars should only be used
to finish installing a shim that can be installed by hand
more than ½ of its length.
8. Install the top wear pads and shims into the end of Sec-
tion 4 leaving a gap of 0” to 1/16” between the top of
the Section 5 and the pad inside Section 4.
4-36 – JLG Lift – 3121619

9. Repeat steps 1-7 above to install the Section 5/4 assem- 4.7 BOOM CLEANLINESS GUIDELINES
bly into boom Section 3.
The following are guidelines for internal boom cleanliness for
10. Repeat steps 1-7 above to assemble the Section 5/4/3
machines that are used in excessively dirty environments.
assembly into Section 2.
11. Repeat steps 1-7 above to assemble the Section 5/4/3/2 1. JLG recommends the use of the JLG Hostile Environment
assembly into Section 1. Package if available to keep the internal portions of a
boom cleaner and to help prevent dirt and debris from
12. Complete the boom and machine assembly. The boom entering the boom. This package reduces the amount of
should be functionally tested and evaluated for boom contamination which can enter the boom but does not
sweep. If necessary, the boom may be re-shimmed by eliminate the need for more frequent inspections and
moving shims from one side to the other to further cor- maintenance when used in these types of environ-
rect any remaining boom sweep. There may be some ments.
instances where no shims are used under a given side
pad to pass the criteria for boom sweep at final inspec- 2. JLG recommends that you follow all guidelines for ser-
tion of machine. vicing your equipment in accordance with the instruc-
tions outlined in the JLG Service & Maintenance Manual
4.6 BOOM LUBRICATION APPLICATION for your machine. Periodic maintenance and inspection
is vital to the proper operation of the machine. The fre-
This procedure applies to booms after assembly or during
quency of service and maintenance must be increased
annual application using Super Lube® lubricant (JLG p/n
as environment, severity and frequency of usage
3020042).
requires.
NOTE: This procedure should also be performed when the tele-
scope in or telescope out functions are not operating 3. Debris and foreign matter inside of the boom can cause
smoothly. premature failure of components and should be
removed. Methods to remove debris should always be
NOTE: This procedure should also be performed when the desired done using all applicable safety precautions outlined in
telescope out length can not be achieved. NEVER increase the JLG Service & Maintenance Manuals.
telescope out pressure to achieve desired telescope length.
4. The first attempt to remove debris from inside the boom
must be to utilize pressurized air to blow the debris
1. Position the boom on the boom rest using the 500lb
toward the nearest exiting point from the boom. Make
capacity setting.
sure that all debris is removed before operating the
2. Telescope main boom section as far as it will extend at machine.
this position, approximately 3 ft. (0.9 m).
5. If pressurized air cannot dislodge the debris, then water
3. From the front of the machine (boom pivot end), moder- with mild solvents applied via a pressure washer can be
ately apply lubricant to the interior surfaces of boom used. Again the method is to wash the debris toward the
sections 1, 2, 3, and 4. To prevent misdiagnosis of nearest exiting point from the boom. Make sure that all
hydraulic leaks, take care to prevent excessive applica- debris is removed, that no “puddling” of water has
tion of lubrication. occurred, and that the boom internal components are
4. At the rear of the machine, apply lubricant to the side, dry prior to operating the machine. Make sure you com-
top and bottom surfaces of boom sections 5, 4, 3, and 2 ply with all federal and local laws for disposing of the
specifically to wear pad contact paths. To prevent misdi- wash water and debris.
agnosis of hydraulic leaks, take care to prevent excessive
6. If neither pressurized air nor washing of the boom dis-
application of lubrication.
lodges and removes the debris, then disassemble the
5. After application of the lubricant is complete, cycle the boom in accordance to the instructions outlined in the
boom through its full range of travel 2 times. JLG Service & Maintenance Manual to remove the
debris.
3121619 – JLG Lift – 4-37

4.8 HOSE ADJUSTMENT PROCEDURE 5. With clamp D set, pull the hoses and cables until they
are resting against the flat bars on the outside radius of
1. Load the hoses and cables into the powertracks and the power track. Force additional hydraulic hose slack
push tubes according to Figure 4-52., Powertrack Hose into the power track by pushing the hoses from the
Installation - Sheet 4 of 4. Location E. Tighten the clamp at location E.
6. While maintaining the hose and cable configuration
2. Adjust the hose and cable lengths at the fly nose clamp shown in Figure 4-52., Powertrack Hose Installation -
(Location A) per their respective drawings and install Sheet 4 of 4, insert a tool to ensure the minimum bend
clamp. Tighten the clamp at the end of the top push radius of 4 inches is not being violated as the hoses are
tube (Location B). Each clamp is considered tight when routed into the trays at location E. Once adjusted,
the contained hoses and cables cannot be moved. tighten the clamp at Location F and remove the tool.
Check additional lengths of the hoses and cables
3. With clamp B set, pull the hoses and cables until they are against the pull lengths listed on their respective draw-
resting against the flat bars on the outside radius of the ings.
power track. Force additional hydraulic hose slack into
the power track by pushing the hoses from the Location 7. Attach all hydraulic hoses and pressurize the hoses by
C. Tighten the clamp at location C. dead heading a function. Check hose clearance in both
power tracks. There should be clearance between the
4. While maintaining the hose and cable configuration hoses and the inside rollers or flat bars. Release the func-
listed in Figure 4-52., Powertrack Hose Installation - tion.
Sheet 4 of 4, insert a tool to ensure the minimum bend
8. If the hoses were in contact, loosen the clamps and pull
radius of 4 inches is not being violated as the hoses are
additional length from the lower clamp (additional
routed into the push tube at location C. Once adjusted,
length at location B should be pulled through clamp C,
tighten the clamp at Location D and remove the tool.
additional length at location D should be pulled
through clamp E). Steps 3 thru 7 should be followed
when adjusting the hoses.
9. Repeat steps 7 and 8 until there is no contact between
the hoses and the inside radius of the power track.
4-38 – JLG Lift – 3121619

Figure 4-20. Hose Adjustment
3121619 – JLG Lift – 4-39

Figure 4-21. Section 3 Boom Cables
4-40 – JLG Lift – 3121619

3121619 – JLG Lift – 4-41

4-42 – JLG Lift – 3121619

Figure 4-24. Jib Hydraulics - Sheet 1 of 7
3121619 – JLG Lift – 4-43

4-44
JIB TELESCOPE CYLIND ER
V2 V1
PLATF ORM LEVEL
CYLINDER
V2 V1
V2 V1
JIB LIF T CYLINDER
V1
V2
T
FRONT VIEW OF
TB
PLATF ORM CONT ROL
JB VALVE
P
TA JA
T2 L1 L2
JIB STOW ROTATOR T2
T3 R2
P2 R1
T1 S1 S2
– JLG Lift –
SA LA
SB LB
V1
T
F RONT VIEW V2
JIB CONTROL VALVE
V2 V1
PLAT FORM ROTAT OR
JIB LEVEL CYLINDER

JIB LOC K CYLINDER
1001157243-C
3121619
3121619
JIB TELE CYLIND ER
PORT BLOCK
JIB LOCK C YL INDER

PL ATFOR M VALVE
– JLG Lift –
JIB CONTR OL VALVE
PLATFORM LEVEL CYLINDER
1001157243- C
4-45
4-46
JIB LOCK CYLINDER
PLATFORM VALVE
– JLG Lift –
JIB CONTROL VALVE
3121619
3121619
PLATFORM VALVE
– JLG Lift –
1001157243-C
4-47
4-48
0.75 " AIR LINE
.25" POWER CABLE
0.815" GEN CABLE

– JLG Lift –
.2 5" POWER CABL E
0.7" CONTROL CABLE

0.75" AIR LINE
0 .81 5" GEN C ABLE
1001157243-C
3121619
3121619
187 303
272 269
– JLG Lift –
A A
389 382 362 324 379 423 382 313 401 271 459
319
195
300 MAINTAIN H OSE LOOP

AT THIS DIMENSION
1600 PULLED LENGTH OF H OSES
STRETCH H OSE OUT AN D MEASURE IN A STRAIGHT LINE NOTE: AL L DIMEN SIONS IN MM.
1001157243-C
4-49
4.9 JIB 8. Remove the bolt and keeper pin securing the jib level
pivot pin and remove the pin. Place blocking under the
cylinder rod or a soft material under the cylinder rod to
Removal protect the rod from being scratched.
1. Lower the platform to the ground or onto blocking to

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

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

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

place so it does not fall. NOTE: The jib and platform assembly weighs approximately 2100
lbs. (953 kg.).
7. Disconnect the jib protractor sensor linkage from the
boom.
4-50 – JLG Lift – 3121619

9. Attach an adequate supporting device to the jib to sup- threads and secure the pin in place with the keeper pin
port its weight. Remove the bolt and keeper pin secur- and bolt. Torque the bolt to 165 ft.lbs. (224 Nm).
ing the jib pivot pin and remove the pin.
5. Place the mounting bracket on the jib valve and bolt the
jib valve to the fly boom section.
10. Remove the jib and platform assembly from the boom.
6. Install the wiring harnesses and hydraulic hoses on the
Installation jib valve as tagged during removal.
7. Install the jib valve protection plate.

1. Attach an adequate lifting device to the jib and position
it in front of the boom. 8. Perform a boom calibration as described in Section 6
2. Place something under the front of the jib that will allow under Calibrating the Boom Sensors.
it to slide or move along the ground easily. Attach a lift-
ing device to the rear of the jib, allowing the front to 4.10 JIB SHIMMING PROCEDURES
pivot on the ground.
3. Lift the jib into position on the boom fly section and Jib Straight Shimming Procedure
install the jib pivot pin. Secure the pin in place with the
keeper pin and bolt. 1. Install the Jib Lock Cylinder and fully extend the rod
through the bearing housings in the jib rotator and jib
pivot.
2. Alight the jib pivot straight with the jib assembly.
3. Insert the shim between the wear pad and the pivot pad
mount.
4. Add enough shims as required to fill the gap between

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

straight with the jib assembly as shown below.
4. Attach a lifting device to the front of the jib and align
WITH JIB ASSEMBLY AS SHOWN
the jib level cylinder attachment fittings. Install the pivot
pin. Apply JLG Threadlocker P/N 0100019 to the bolt
3121619 – JLG Lift – 4-51

RUBBER PAD
HOSE CLAMP
* BOLT
KEEPER
* BOLT PIN
KEEPER
PIN TORQUE 60 FT.LBS. (82 Nm)
TORQUE 120 FT.LBS. (163 Nm)

* BOLT
KEEPER
PIN

PLATFORM ROTATOR
BAR CLAMP
COVER
SCREW
*
RUBBER PAD
Adhesive PN# 0100081

BOLT
KEEPER
PIN
* JLG Threadlocker PN# 0100011
JLG Threadlocker PN# 0100019
TORQUE 25 FT.LBS. (34 Nm) **
Figure 4-31. Jib Assembly - Sheet 1 of 4
4-52 – JLG Lift – 3121619

* BOLT
BOLT
**
JIB LIFT CYLINDER JIB PIVOT
* BOLT
KEEPER
PIN
JIB ROTATE ACTUATOR

SHIMS
BOLT *
TORQUE 340 FT.LBS.
(460 Nm)

JLG Threadlocker PN# 0100019
**
3121619 – JLG Lift – 4-53

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
CAP AS SHOWN
ALIGN HOLES IN LOCK CYL
WITH PROTRUSIONS
IN CAP AS SHOWN
A
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 *
1001158944-E
4-54 – JLG Lift – 3121619

SCREW
NUT
*
WASHERS
CABLE GUIDE
PAD
GUIDE BLOCK
BRACKET
JIB ROTATE
ACTUATOR
ORIENT PORT ON LOCK

CYL AS SHOWN
PIVOT PAD MOUNT
BEARING JIB ROTATOR

BOTTOM PLATE
JIB PIVOT
BEARING
BEARING WEAR PADS
SHIMS
* BOLT
TORQUE BOLTS TO 20 FT-LBS
Loctite RC 609 Threadlocker
3121619 – JLG Lift – 4-55

Stowed Jib Shimming Procedure 2. Insert a shim between the wear pad and pivot pad
mount.
1. Rotate the jib to the appropriate position as shown
below.
3. Add shims as required to fill the gap between the wear

pad and the edge of the side plate of the jib rotator.
4. Shim until the distance between the jib and the side of
the base boom reaches the dimension shown in Figure
4-35., Jib Stow Shimming Measurements.
Figure 4-35. Jib Stow Shimming Measurements
4-56 – JLG Lift – 3121619

4.11 WIRE ROPE Three Month Inspection

1. Remove boom covers and visually (with flashlight)
Inspection inspect the ropes for rust, broken wires, frays, abuse, or
any signs of abnormalities.
NOTE: The pictures in this paragraph are just samples to show the 2. Check rope tension by deflecting the ropes by
replacement criteria of the rope. hand...properly tensioned ropes should have little or no
movement.
1. Inspect ropes for broken wires, particularly valley wire
NOTE: Delayed movement of the fly boom indicates loose wire
breaks and breaks at end terminations. ropes.
Eight Year Inspection

1. Mandatory wire rope and sheave replacement.
Additional inspection required if:

Flexing a wire rope can often expose broken wires hid-
den in valleys between strands. a. Machine is exposed to hostile environment or con-
ditions.
b. Erratic boom operation or unusual noise exists.
2. Inspect ropes for corrosion. c. Machine is idle for an extended period.
d. Boom is overloaded or sustained a shock load.
3. Inspect ropes for kinks or abuse.
e. Boom exposed to electrical arc...wires may be fused
internally.
Replacement Criteria
1. Sheaves and wire rope must be replaced as sets.
A kink is caused by pulling down a loop 2. Rusted or corroded wire ropes.
in a slack line during improper handling,
installation, or operation. 3. Kinked, “bird caged”, or crushed ropes.
4. Ropes at end of adjustment range.
4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.) 5. Sheaves failing wearout gage inspection.
6. Ropes with 6 total broken wires in one rope lay, 3 in one
5. Inspect sheaves for condition of flanges. (See Dimension
strand in one rope lay, 1 valley break, or 1 break at any
Of Sheaves for proper dimension.) end termination.
6. Inspect sheaves with a groove wearout gauge for exces-
sive wear.
Observe the groove so that it may be clearly seen

whether the contour of the gauge matches the
contour of the bottom of the groove.
7. Ropes passing inspection should be lubricated with wire

rope lubricant before reassembly.
3121619 – JLG Lift – 4-57

4.12 WIRE ROPE TENSIONING ADJUSTMENT 2. Take preliminary measurements of the position of each
boom section with the boom in the fully retracted posi-
If new wire ropes are installed, there is a general starting point tion and compare them to Figure 4-36., Fully Retracted
for the initial exposed thread length for each wire rope Boom Section Positions.
adjuster stud. Refer to Figure 4-36., Fully Retracted Boom Sec- 3. If the measurements fall within tolerance shown on Fig-
tion Positions for these dimensions. The proper position of the ure 4-36., proceed to the Wire Rope Tensioning Proce-
boom sections (See Figure 4-36.) must be achieved with wire dure.
rope equalized on both sides of the sheaves and ropes prop-
erly seated in sheave grooves prior to tensioning. This will NOTE: Proper boom position does not confirm that rope tension is
allow for proper tensioning of the wire ropes. correct, at this point.
There are two major steps to this procedure: 4. If the measurements do not fall within the tolerances in
Figure 4-36., adjust the position using the re-position
• Positioning the boom sections so proper tensioning can be
procedures in this sub-section
achieved
• Tensioning the wire rope BOOM SECTION #2 REPOSITIONING:
NOTE: Boom Section #2 is positioned by the telescope cylinder. No
Boom Preparation for Section Repositioning adjustments to this section are necessary. The wire ropes
within this assembly only control the movement of the
NOTE: Because each rope actuated section controls the move- remaining smaller sections.
ment of the next smaller section, any repositioning of the
larger will affect the position of the next smaller. Correctly
position Section #3 before setting the position of Section
#4, followed by section #5.
Use the Boom Telescope function to position the boom sec-

tions. Using the wire rope adjustment nuts to position the
boom sections will cause damage to the wire rope adjust-
ers.
1. Before making any adjustments, confirm the boom

assembly is in the fully retracted position (See Figure 4-
36., Fully Retracted Boom Section Positions).
Figure 4-36. Fully Retracted Boom Section Positions
4-58 – JLG Lift – 3121619

3121619
– JLG Lift –
Figure 4-37. Initial Exposed Thread Length for Wire Rope Adjustment
4-59
BOOM SECTION #3 REPOSITIONING: needs to move to be within tolerance (for example,

if the section must move 0.5 inches to fall within the
1. If Boom Section #3 falls within the dimension and toler-
dimension shown, tighten the nut so it moves 0.5
ance shown in Figure 4-36. with the boom fully
retracted, proceed to Boom Section #4 Repositioning inches further from the exposed end of the adjust-
procedure in this section. ment stud).
2. If Boom Section #3 does not fall within the dimension f. Fully retract the boom.
and tolerance shown in Figure 4-36. with the boom fully
g. To remove slack resulting from the adjustment in
retracted, perform the following procedure:
step e., tighten the Section #4 Extend adjustment.
3. If the Section needs to be RETRACTED (measured
dimension is greater than dimension shown in Figure 4- h. To remove slack resulting from the adjustment in
36.): step d., tighten the Section #4 Retract Adjustment
Nuts shown below until they contact the rope
a. Remove any covers necessary to access the wire mount plate.
rope adjustment nuts.
b. Remove lock plates and nylon collar locknuts from

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

sion is less than dimension shown in Figure 4-36.):
a. Remove any covers necessary to access the wire


c. Extend the boom assembly such that the platform

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

d. Extend the boom assembly such that the platform moving them a distance equal to twice what the
moves 4 to 5 feet (1.2m-1.5m) from the fully section needs to move to be within tolerance. (E.g. If
retracted position. the section must move ½” to fall within the dimen-
e. Tighten the Section #3 Retract Adjustment Nuts, sion shown, loosen the nut such that it moves 1”
moving them a distance equal to what the section closer to the exposed end of the adjustment stud.)
4-60 – JLG Lift – 3121619

6. Verify that the exposed boom section dimensions meet

the dimension and tolerance of Figure 4-36..
a. If Section #3 still does not fall within the dimension

and tolerance of Figure 4-36., repeat the steps out-
lined in 3. Boom Section #3 Repositioning.
b. If Section #3 does fall within the dimension and tol-
erance of Figure 4-36., proceed to 4. Boom Section
#4 Repositioning.
BOOM SECTION #4 REPOSITIONING:

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

e. Retract the boom assembly such that the platform 3. If the Section needs to be RETRACTED (measured
moves 2 to 3 feet (0.6m-0.9m) from the previous dimension is greater than dimension shown in Figure 4-
extended position in Step c. 36.):
f. Tighten the Section #3 Extend Adjustment Nuts a. Remove any covers necessary to access the wire
shown below, moving them a distance equal to rope adjustment nuts.
what the section needs to move to be within toler-
ance. (For example, if the section must move 0.5 b. Remove lock plates and nylon collar locknuts from
inches to fall within the dimension shown, tighten wire rope adjustment studs.
the nut such that it moves 0.5 inches further from c. Loosen the Section #4 Extend Adjustment Nuts,
the exposed end of the adjustment stud.) moving them a distance equal to twice what the
section needs to move to be within tolerance. (E.g. If
the section must move ½” to fall within the dimen-
sion shown, loosen the nut such that it moves 1”
closer to the exposed end of the adjustment stud.)
d. Extend the boom assembly such that the platform
retracted position.
e. Tighten the Section #4 Retract Adjustment Nuts
shown below, moving them a distance equal to
what the section needs to move to be within toler-
ance. (E.g. If the section must move ½” to fall within
the dimension shown, tighten the nut such that it
moves ½” farther from the exposed end of the
adjustment stud.)

Step d., tighten the Section #4 Extend Adjustment
Nuts until they contact the rope mount plate.
h. Extend the boom assembly so the platform moves 4
i. Repeat Step h. three times to equalize rope position.
j. Go to Step 5.
f. Fully retract the boom.
5. Fully retract the boom sections.
3121619 – JLG Lift – 4-61

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

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

the dimension and tolerance of Figure 4-36.

lined in 4. Boom Section #4 Repositioning.
e. Retract the boom assembly such that the platform b. If Section #4 does fall within the dimension and tol-
moves 2 to 3 feet (0.6m-0.9m) from the previous erance of Figure 4-36., proceed to 5. Boom Section
extended position in step c. #5 Repositioning.
4-62 – JLG Lift – 3121619

BOOM SECTION #5 REPOSITIONING:

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

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

dimension is greater than dimension shown in Figure 4-
36.):
step c, tighten the Section #5 Retract Adjustment
Nuts shown below until they contact the rope
mount plate.

c. Loosen the Section #5 Extend Adjustment Nuts,

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

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


d. Extend the boom assembly such that the platform wire rope adjustment studs.
moves 4 to 5 feet (1.2m-1.5m) from the fully c. Extend the boom assembly so the platform moves 4
retracted position. to 5 feet (1.2m-1.5m) from the fully retracted posi-
tion.
e. Tighten the Section #5 Retract Adjustment Nuts
d. Loosen the Section #5 Retract Adjustment Nuts,
what the section needs to move to be within toler- twice what the section needs to move to be within
ance. (E.g. If the section must move ½” to fall within tolerance. (E.g. If the section must move ½” to fall
the dimension shown, tighten the nut such that it within the dimension shown, loosen the nut such
moves ½” farther from the exposed end of the that it moves 1” closer to the exposed end of the
adjustment stud.) adjustment stud.)
3121619 – JLG Lift – 4-63

has been consumed. Do not continue with the remainder

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

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

moves 2 to 3 feet (0.6m-0.9m) from the previous
extended position in Boom Section #3 Positioning,
Step 4c.
f. To remove slack resulting from the adjustment in
Step 3d, tighten the Section #4 Extend Adjustment 2. Remove lock plates and nylon collar nuts from wire rope
Nuts shown below until they contact the rope adjustment studs.
mount plate. 3. Position the boom so that it is horizontal within +/- 5º,
and not supported by the boom rest.
4. Extend the boom assembly such that the platform
moves 4 to 5 feet (1.2m-1.5m) from the fully retracted
position. The purpose of this step is to position the
boom sections such that the ropes to be tensioned are
not under load. If the extending boom reaches end of
stroke and then automatically retracts a small amount,
the ropes may still be under load. In such case, the fol-
lowing additional steps are necessary:
a. Note where the boom reached end of stroke.
g. Go to Step 5. b. Retract 3 to 4 feet (1m-1.3m).
c. Extend the boom, stopping just before end of stroke
5. Fully retract the boom sections. is reached.
the dimension and tolerance of Figure 4-36..

lined in Boom Section #5 Repositioning.
b. If Section #5 does fall within the dimension and tol-
erance of Figure 4-36., proceed to Wire Rope Ten-
sioning Procedure.
Wire Rope Tensioning Procedure

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

proper deployment function of the boom assembly and by
the dimensions and tolerances shown in Figure 4-36..
If the boom sections have been properly positioned but

there is not enough adjustment travel remaining on a wire 5. Using tool, JLG p/n 1001162217, torque Section #3
rope to achieve proper torque, the service life of the rope Retract Adjustment Nuts to 38 ft-lb (51.5 Nm), alternat-
4-64 – JLG Lift – 3121619

ing between the two ropes until both maintain the 10. Using tool, JLG p/n 1001162216, torque Section #4
required torque. Extend Adjustment Nuts to 17 ft-lb (23 Newton meters),
alternating between the two ropes until both maintain
the required torque.
6. Using tool, JLG p/n 1001162217, torque Section #4

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

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

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

retract the boom or bottom out any section.

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

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

b. Extend the boom 4 to 5 feet (1.2m-1.5m) from the
fully retracted position or to the stroke limit identi-
fied in 6.4.
c. Repeat 12a and 12b for a minimum of three cycles,
stopping with the boom extended 4 to 5 feet (1.2m-
1.5m) from the fully retracted position or to the
stroke limit identified in Step 4.
13. Verify wire rope torque values for retract ropes.
3121619 – JLG Lift – 4-65

14. Retract the boom 2-3 feet (.6m – 1.0m) Do NOT fully Re-Assembly
retract the boom or bottom out any section.
1. Install nylon collar locknuts on Section #4 extend wire
15. Verify wire rope torque values for extend ropes. rope fittings.
16. If the torque values are NOT correct, repeat the Wire a. Do not re-use the nylon collar lock nuts. Replace
Rope Tensioning Procedure. with new nylon collar lock nuts.
b. Torque locknuts to 10 ft-lb (13.5 Nm).
17. If the torque values are correct, proceed to Confirm
Proper Boom Deployment Function. 2. Reinstall lock plates to remaining adjuster nuts.
3. Install all covers.
Confirm Proper Boom Deployment Function
Exercise the boom telescope function. When wire ropes are Boom Calibration
properly torqued, all traveling sections will move simultane- Any adjustment of wire rope tension should be immediately
ously when extending and retracting. followed by Boom Calibration.
Figure 4-38. Boom Wire Rope Torques
4-66 – JLG Lift – 3121619

4.13 BROKEN BOOM CABLE PROXIMITY SWITCH 3. Tighten the jam nut.
This system uses a proximity switch to detect excessive move-

ment of the cable block. If movement is detected the Cable
Break indicator will illuminate in the platform control panel.
No restrictions are made to the functionality of the control sys-
tem. It is the responsibility of the operator to take immediate
action.
To avoid damaging the proximity switch, install and adjust

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

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

applied and the sensor is within the proper range.
Figure 4-39. Broken Cable Proximity Switch Location
3121619 – JLG Lift – 4-67

4-68
– JLG Lift –
1. Powertrack 4. Rubber Pad 6. Clamp Plate
2. Powertrack 5. Powertrack 7. Rubber Pad
3. Clamp Plate
Figure 4-40. Powertrack Installation - Sheet 1 of 4
3121619
3121619
– JLG Lift –
1. Clamp Plate 3. Clamp Plate 5. Clamp Plate
2. Rubber Pad 4. Rubber Pad 6. Rubber Pad
4-69
4-70
– JLG Lift –
1. Clamp Bar 5. Track Support Cover 9. Power Track Support 13. Support Bracket
2. Rubber Pad 6. Spacer Tube 10. Track Support Cover 14. Hose Cover
3. Spacer Tube 7. Power Track Support 11. Support Bracket 15. Track Support Cover
4. Power Track Support 8. Track Support Cover 12. Support Bracket 16. Support Bracket
3121619
3121619
– JLG Lift –
1. Support Bracket 4. Upper Push Tube Assembly 7. Adjusting Shims 10. Mounting Plate
2. Push Tube Pad 5. Adjusting Shims 8. Lower Push Tube Assembly 11. Adjusting Shims
3. Push Tube Pad 6. Mounting Plate 9. Adjusting Shims 12. Support Bracket
4-71
Figure 4-44. Powertrack Shimming Instructions
4-72 – JLG Lift – 3121619

3121619
– JLG Lift –
Figure 4-45. Powertrack Locations for Threadlocker Application and Torque - Sheet 1 of 4
4-73
4-74
– JLG Lift –
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3121619
– JLG Lift –
4-75
4-76
– JLG Lift –
3121619
3121619
– JLG Lift –
Figure 4-49. Powertrack Hose Installation - Sheet 1 of 4
4-77
4-78
– JLG Lift –
3121619
3121619
– JLG Lift –
4-79
4-80
– JLG Lift –
3121619
4.14 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.
3121619 – JLG Lift – 4-81

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.
4-82 – JLG Lift – 3121619

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.
3121619 – JLG Lift – 4-83

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
4-84 – JLG Lift – 3121619

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.
3121619 – JLG Lift – 4-85

C,D
A Torque to 40 ft.lbs. (55 Nm)

B Loctite #242
C Torque to 480 ft. lbs. (650 Nm)
D Check torque every 150 hours of operation
E Torque to 85 ft. lbs. (116 Nm)
Figure 4-53. Platform Support Torque Values
4-86 – JLG Lift – 3121619

SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS
5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in the
SYSTEM fitting, making sure the entire o-ring is completely satu-
rated.
When assembling connectors in the hydraulic that use o-ring
fittings, it is necessary to lubricate all fittings with hydraulic oil
prior to assembly. To lubricate the fittings, use one of the fol-
lowing procedures.
NOTE: All O-ring fittings must be pre-lubricated with hydraulic oil

prior to assembly.
Cup and Brush

The following is needed to correctly oil the o-ring in this man-
ner:
• A small container for hydraulic oil 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring is
• Small paint brush coated with hydraulic oil.
1. Hold the fitting in one hand while using the brush with
the other hand to dip into the container. Remove excess
hydraulic oil from the brush so an even film of oil is
applied on the o-ring.
3121619 – JLG Lift – 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 – JLG Lift – 3121619

5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512
TORQUE SPECIFICATION
Tapered Thread Types
NPTF = national tapered fuel (Dry Seal) per SAE J476/J512
Figure 5-4. SAE Thread
ORFS = o-ring face seal per SAE J1453
Figure 5-1. NPTF Thread

BSPT = British standard pipe tapered per ISO7-1
Figure 5-5. ORFS Thread

MBTL = metric flareless bite type fitting, pressure rating L
(medium) per ISO 8434, DIN 2353
MBTS = metric flareless bite type fitting, pressure rating S
(high) per ISO 8434, DIN 2353
Figure 5-2. BSPT Thread Figure 5-6. MTBL-MBTS Thread
Straight Thread Types, Tube and Hose Connections BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
JIC = 37° flare per SAE J514
Figure 5-3. JIC Thread

Figure 5-7. Bulkhead Thread
3121619 – JLG Lift – 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 – JLG Lift – 3121619

Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the
correct torque values.
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the con- a. Verify the material designation in the table head-
nector being installed. Refer to the Figures and Tables in this ings.
section. b. If specifications are given only for steel fittings and
components, the values for alternate materials shall
GENERAL TUBE TYPE FITTING ASSEMBLY be as follows: Aluminum and Brass- reduce steel val-
INSTRUCTIONS ues by 35%; Stainless Steel- Use the upper limit for
steel.
1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling 5. To achieve the specified torque, the torque wrench is to
or assembly. Nicks and scratches in sealing surfaces can be held perpendicular to the axis of rotation.
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting attach-
ment to ensure that the tube has not been damaged.
3. The assembly process is one of the leading causes for
contamination in air and hydraulic systems. Contamina-
tion can prevent proper tightening of fittings and adapt-
ers from occurring.
a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as nec-
essary before re-installing.
c. Sealing compounds should be applied where speci- Figure 5-11. Torque Wrench Angle
fied; however, care should be taken not to introduce
sealant into the system. 6. Refer to the appropriate section in this manual for more
d. Avoid applying sealant to the area of the threads specific instructions and procedures for each type of fit-
where the sealant will be forced into the system. ting connection
This is generally the first two threads of a fitting.
e. Sealant should only be applied to the male threads.
f. Straight thread fittings do not require sealants. O-
rings or washers are provided for sealing.
g. When replacing or installing an O-ring, care is to be
taken while transferring the O-ring over the threads
as it may become nicked or torn. When replacing an
O-ring on a fitting, the use of a thread protector is
recommended.
h. When installing fittings with O-rings, lubrication
shall be used to prevent scuffing or tearing of the O-
ring. See O-ring Installation (Replacement) in this
section.
3121619 – JLG Lift – 5-5

Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE
ALIGNMENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST
Thread Tapered (NPTF) Connections. TURN FOR ALIGNMENT.
1. Inspect components to ensure male and female port
5. Rotate male fitting the number of turns per Table 5-1,
threads are free of rust, splits, dirt, foreign matter, or
NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT
burrs.
procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to
NOTE: TFFT values provided in Table 5-1, NPTF 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-
4. Mark fittings, male and female. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR. mating components.
Table 5-1. NPTF Pipe Thread
TYPE/FITTING IDENTIFICATION
Turns From Finger
Thread Size ØA*
Material Dash Size Tight (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
STEEL, ALUMINUM, OR BRASS MATING C
4 1/4 - 18 0.54 13.61 2 to 3

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

16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
* ØA thread dimension for reference only.
** See FFWR and TFFT Methods subsection for TFFT procedure requirements.
5-6 – JLG Lift – 3121619

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

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

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

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

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

12 3/4 - 14 1.04 26.44 2 to 3
16 1 - 11 1.31 33.25 1.5 to 2.5
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
* ØA thread dimension for reference only.
** See Appendix B for TFFT procedure requirements.
3121619 – JLG Lift – 5-7

Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table Table 5-3, 37°
Flare (JIC)Thread - Steel or Table 5-4, 37° Flare
1. Inspect the flare for obvious visual squareness and con- (JIC)Thread - Aluminum/Brass while using the Double
centricity issues with the tube OD. Ensure surface is Wrench Method per Double Wrench Method. Refer to
smooth, free of rust, weld and brazing splatter, splits, FFWR and TFFT Methods for procedure requirements if
dirt, foreign matter, or burrs. If necessary replace fitting using the FFWR method.
or adapter.
NOTE: Torque values provided in Table Table 5-3, 37° Flare
(JIC)Thread - Steel and Table 5-4, 37° Flare (JIC)Thread -
Aluminum/Brass are segregated based on the material
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT configuration of the connection.
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO
LEAKAGE. ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
COMPONENTS’ indicate either the following material configu-
2. Align tube to fitting and start threads by hand. rations:
• STEEL fittings with ALUMINUM or BRASS mating compo-
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
nents
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
mating components.
5-8 – JLG Lift – 3121619

Table 5-3. 37° Flare (JIC)Thread - Steel
Type/Fitting Identification Torque

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

Dash Size Size Resistance
(F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --
3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4

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

8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
* ØA and ØB thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121619 – JLG Lift – 5-9

Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass
TYPE/FITTING IDENTIFICATION Torque

Flats from
Thread Wrench
MATERIAL

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

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

6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1
** See FFWR and TFFT Methodsfor FFWR procedure requirements.
5-10 – JLG Lift – 3121619

Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using
1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section. Refer to
centricity issues with the tube OD. Ensure surface is FFWR and TFFT Methods for procedure requirements if using
smooth, free of rust, weld and brazing splatter, splits, the TFFT method.
dirt, foreign matter, or burrs. If necessary replace fitting
or adapter. NOTE: Torque values provided in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass are segre-
gated based on the material configuration of the connec-
tion.
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
LEAKAGE. COMPONENTS’ indicate either the following material configu-
rations:
2. Align tube to fitting.
3. Tighten fitting by hand until hand tight. nents
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. mating components.
3121619 – JLG Lift – 5-11

Table 5-5. 45° Flare (SAE) - Steel

Thread
MATERIAL

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

8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125
Table 5-6. 45° Flare (SAE) - Aluminum/Brass

Thread
MATERIAL

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

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

10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83
** See FFWR and TFFT Methods for TFFT procedure requirements.
5-12 – JLG Lift – 3121619

Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal
(ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu-
Fittings minum/Brass while using the Double Wrench Method.
Refer to FFWR and TFFT Methods for procedure require-
1. Ensure proper O-ring is installed. If O-ring is missing ments if using the FFWR method.
install per O-ring Installation (Replacement).
NOTE: Torque values provided in Table 5-7, O-ring Face Seal
2. Ensure surface is smooth, free of rust, weld and brazing (ORFS) - Steel and Table 5-8, O-ring Face Seal (ORFS) - Alu-
splatter, splits, dirt, foreign matter, or burrs. If necessary minum/Brass are segregated based on the material config-
uration of the connection.
replace fitting or adapter.
COMPONENTS’ indicate either the following material configu-
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO rations:
THE THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD • STEEL fittings with ALUMINUM or BRASS mating compo-
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
4. Place the tube assembly against the fitting body so that • ALUMINUM or BRASS fittings with ALUMINUM or
the flat face comes in contact with the O-ring. Hand BRASS mating components
thread the nut onto the fitting body.
Table 5-7. O-ring Face Seal (ORFS) - Steel
Flats from Wrench

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

Tube
Dash Size Hose
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Nuts
Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
STEEL MATING COMPONENTS;
STEEL FITTINGS WITH
10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4

12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
3121619 – JLG Lift – 5-13

Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass
Flats from Wrench

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

Dash Size Tube
Hose
Size Nuts
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS FITTINGS OR
8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4

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

12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
** See FFWR and TFFT Methods for FFWR procedure requirements.
5-14 – JLG Lift – 3121619

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.
3121619 – JLG Lift – 5-15

Table 5-9. DIN 24°Cone (MBTL & MBTS)
DIN 24° CONE FLARELESS BITE FITTING

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

MATERIAL
ØA* ØB* C* ØD* Wrench

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

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

FFWR is the recommended
10 M16 x 1.5 14.50 16.00 7.00 10.20 method of fitting assembly. 1.5 to 1.75
12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
Torque values are application
15 M22 x 1.5 20.50 22.00 7.00 15.20 specific due to variability in the 1.5 to 1.75
18 M26 x 1.5 24.50 26.00 7.50 18.20 fitting supplier, coating, 1.5 to 1.75
lubrication, and other physical
22 M30 x 2 27.90 30.00 7.50 22.20 characteristics of the connection. 1.5 to 1.75
STEEL FITTINGS WITH STEEL MATING COMPONENTS
28 M36 x 2 33.90 36.00 7.50 28.20 1.5 to 1.75

Refer to the specific procedure
35 M45 x 2 42.90 45.00 10.50 35.30 in the 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
Tube Thread M Torque Flats from

ØA* ØB* C* ØD* Wrench
TYPE
O.D. Size [Ft-Lb] [N-m]

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

FFWR is the recommended
10 M18 x 1.5 16.50 18.00 7.50 10.20 method of fitting assembly. 1.5 to 1.75
12 M20 x 1.5 18.50 20.00 7.50 12.20 1.5 to 1.75
Torque values are application
14 M22 x 1.5 20.50 22.00 8.00 14.20 specific due to variability in the 1.5 to 1.75
16 M24 x 1.5 22.50 24.00 8.50 16.20 fitting supplier, coating, 1.5 to 1.75
lubrication, and other physical
20 M30 x 2 27.90 30.00 10.50 20.20 characteristics of the connection. 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 1.5 to 1.75
Refer to the specific procedure
30 M42 x 2 39.90 42.00 13.50 30.20 in the 1.5 to 1.75
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
* ØA, ØB, C, & ØD thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
5-16 – JLG Lift – 3121619

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.
3121619 – JLG Lift – 5-17

Table 5-10. Bulkhead Fittings (BH) - INCH
FASTENING JAM NUT

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

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

STEEL FITTINGS
(UNF) Min Nom Max Min Nom Max

3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
37° FLARE (JIC) BULKHEAD FITTING
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
10 7/8-14 85 90 94 115 122 127
12 1 1/16-12 135 142 149 183 193 202
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
5-18 – JLG Lift – 3121619

Table 5-11. Bulkhead Fittings (BH) - METRIC
FASTENING JAM NUT

for Bulkhead Connectors
Connecting Torque
Thread M Size
MATERIAL TYPE Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
DIN 24° CONE FLARELESS BITE
10 M16 x 1.5 22 23 24 30 31 33
(MBTL) BULKHEAD FITTING
12 M18 x 1.5 35 37 39 47 50 53
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
STEEL FITTINGS
Connecting Torque
Thread M Size
Tube O.D.
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING
[Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
14 M22 x 1.5 44 47 50 60 64 68
16 M24 x 1.5 70 75 80 95 102 108
20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
3121619 – JLG Lift – 5-19

Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru
Table 5-17 while using the Double Wrench Method.
Fittings
a. The table headings identify the straight thread O-
1. Inspect components to ensure that male and female ring port and the type on the other side of the fit-
port threads are free of rust, splits, dirt, foreign matter, or ting. The torque will be applied to the straight
burrs. thread O-ring port.
2. Ensure proper O-ring is installed. If O-ring is missing b. Torque values provided in Table 5-12 thru Table 5-17
install per O-ring Installation (Replacement). are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO • STEEL fittings with ALUMINUM or BRASS mating compo-
THE THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD nents
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
4. For Non-Adjustable and Plugs, thread the fitting by mating components.
hand until contact.
7. Inspect to ensure the O-ring is not pinched and the
5. For Adjustable fittings, refer to Adjustable Stud End washer is seated flat on the counter bore of the port.
Assembly for proper assembly.
5-20 – JLG Lift – 3121619

Table 5-12. O-ring Boss (ORB) - Table 1 of 6
HEX TYPE PLUGS & STUD ENDS

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

6 9/16-18 0.56 14.28 29 31 32 40 42 43
8 3/4-16 0.75 19.10 52 55 57 70 75 77
10 7/8-14 0.87 22.22 85 90 94 115 122 127
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
HEX TYPE PLUGS & STUD ENDS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
4 7/16-20 0.44 11.11 14 15 16 19 20 22

5 1/2-20 0.50 12.70 15 16 17 20 22 23
6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
3121619 – JLG Lift – 5-21

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
5-22 – JLG Lift – 3121619

ADJUSTABLE STUD END

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

6 9/16-18 0.56 14.28 29 31 32 40 42 43
8 3/4-16 0.75 19.10 52 55 57 70 75 77
10 7/8-14 0.87 22.22 85 90 94 115 122 127
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
ADJUSTABLE STUD END
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (39) (41) (43) 4 5 5
3 3/8-24 0.37 9.52 (65) (69) (72) 7 8 8
4 7/16-20 0.44 11.11 10 11 11 14 15 15

5 1/2-20 0.50 12.70 14 15 15 19 20 20
6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
3121619 – JLG Lift – 5-23

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
5-24 – JLG Lift – 3121619

TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

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

6 9/16-18 0.56 14.28 34 36 38 46 49 52
8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5
4 7/16-20 0.44 11.11 6 7 7 8 9 9

5 1/2-20 0.50 12.70 9 10 10 12 14 14
6 9/16-18 0.56 14.28 22 24 25 30 33 34
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
3121619 – JLG Lift – 5-25

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
5-26 – JLG Lift – 3121619

Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18,
Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5-
Metric (MFF) Fittings 23 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the Metric port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the Metric port.
b. Torque values provided in Table 5-18, Table 5-19,
2. If O-ring is not pre-installed, install proper size, taking Table 5-20, Table 5-21, Table 5-22, and Table 5-23
care not to damage it. See O-ring Installation (Replace- are segregated based on the material configuration
ment) for instructions. of the connection. ‘ALUMINUM/BRASS FITTINGS OR
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
by hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
3121619 – JLG Lift – 5-27

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
5-28 – JLG Lift – 3121619



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
3121619 – JLG Lift – 5-29

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
5-30 – JLG Lift – 3121619

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
3121619 – JLG Lift – 5-31

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
5-32 – JLG Lift – 3121619

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 -- -- -- -- -- --
3121619 – JLG Lift – 5-33

Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24
while using the Double Wrench Method.
Port Assembly Stud Ends
a. The table headings identify the Metric port and the
1. Inspect components to ensure that male and female type on the other side of the fitting. The torque will
threads and surfaces are free of rust, splits, dirt, foreign be applied to the Metric port.
matter, or burrs. b. Torque values provided in Table 5-24 are segregated
2. If O-ring is not preinstalled, install proper size, taking based on the material configuration of the connec-
care not to damage it. See O-ring Installation (Replace- tion. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/
ment) for instructions. BRASS MATING COMPONENTS’ indicate either the
following material configurations:
nents
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO
THE THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD • ALUMINUM or BRASS fittings with STEEL mating compo-
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
3. Pre-lubricate the O-ring with Hydraulic Oil. mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting 7. Inspect to ensure the O-ring is not pinched and the
by hand until contact. washer is seated flat on the counter bore of the port.

5-34 – JLG Lift – 3121619

Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
STUD ENDS STUD ENDS

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

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

M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
3121619 – JLG Lift – 5-35

Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
STUD ENDS STUD ENDS

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

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

M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
5-36 – JLG Lift – 3121619

Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25,
Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5-
(BSPP) Fittings 30 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the BSPP port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the BSPP port.
b. Torque values provided in Table 5-25, Table 5-26,
2. If O-ring is not preinstalled, install proper size, taking Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are
care not to damage it. See O-ring Installation (Replace- segregated based on the material configuration of
ment) for instructions. the connection. ‘ALUMINUM/BRASS FITTINGS OR
CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
by hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.
3121619 – JLG Lift – 5-37

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
5-38 – JLG Lift – 3121619

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
3121619 – JLG Lift – 5-39

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
5-40 – JLG Lift – 3121619

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
3121619 – JLG Lift – 5-41

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
5-42 – JLG Lift – 3121619

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS

TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end
Connecting
Thread G
Size
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133 Fitting type not typically specified on
JLG applications. Refer to the specific
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133
procedure in this Service Manual.
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
Connecting
Thread G
Size
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87 Fitting type not typically specified on
JLG applications. Refer to the specific
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87
procedure in this Service Manual.
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
3121619 – JLG Lift – 5-43

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.
5-44 – JLG Lift – 3121619

Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners
STEEL 4-BOLT FLANGE SAE J518

(INCH FASTENERS)
Bolt Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with
Inch
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws
Flange
TYPE Size
SAE Dash [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
CODE 61 SPLIT FLANGE (FL61)
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101

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

16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
* A dimension for reference only.
3121619 – JLG Lift – 5-45

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.
5-46 – JLG Lift – 3121619

Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper
hose installation. A twisted lay-line usually indicates the hose
To prevent undesired hose or connector rotation, two is twisted. See Figure 5-12. for double wrench method require-
wrenches must be used; one torque wrench and one backup ments.
wrench. If two wrenches are not used, inadvertent component
rotation may occur which absorbs torque and causes
improper joint load and leads to leaks. For hose connections,
Figure 5-12. Double Wrench Method
3121619 – JLG Lift – 5-47

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.
5-48 – JLG Lift – 3121619

Figure 5-14. Adjustable Stud End Assembly
O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On

straight threads, ensure O-ring is seated all the way past
Care must be taken when installing O-rings over threads dur- the threads prior to installation.
ing replacement or installation. O-rings could become nicked 5. Inspect O-ring for any visible nicks or tears. Replace if
or torn. A damaged O-ring could lead to leakage problems. found.
1. Inspect O-ring for tears or nicks. If any are found replace

O-ring.
2. Ensure proper O-ring to be installed. Many O-rings look

the same but are of different material, different hard-
ness, or are slightly different diameters or widths.
3. Use a thread protector when replacing O-rings on fit-

tings.
3121619 – JLG Lift – 5-49

Figure 5-15. Turntable Hydraulic System
5-50 – JLG Lift – 3121619

Figure 5-16. Hydraulic Hose Installation - Sheet 1 of 8
3121619 – JLG Lift – 5-51

5-52 – JLG Lift – 3121619

3121619 – JLG Lift – 5-53

5-54 – JLG Lift – 3121619

3121619 – JLG Lift – 5-55

5-56 – JLG Lift – 3121619

3121619 – JLG Lift – 5-57

5-58 – JLG Lift – 3121619

5.3 HYDRAULIC CYLINDERS 5. Mark cylinder head and barrel with center punch marks
for later realignment. Remove the capscrews (4).
Axle Extend Cylinder
Refer to Figure 5-27.
DISASSEMBLY
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

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

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

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

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

vise or holding fixture as close to the piston as possible.
3121619 – JLG Lift – 5-59

1. Bushing 6. Wiper Seal 10. O-Ring 14. O-Ring 18. Tapered Bushing
2. Barrel 7. Seal 11. Wear Ring 15. Piston 19. Bolt
3. Counterbalance Valve 8. Cylinder Head 12. Spacer 16. Lock Ring 20. Bushing
4. Capscrew 9. Backup Ring 13. Backup Ring 17. Seal 21. Rod
5. Washer Ring
Figure 5-27. Axle Extend Cylinder Assembly
5-60 – JLG Lift – 3121619

9. Loosen and remove bolts from tapered bushing and pis- CLEANING AND INSPECTION
ton.
1. Clean parts thoroughly with approved cleaning solvent.
10. Insert bolts in threaded holes in outer piece of tapered
2. Inspect cylinder rod for scoring, tapering, ovality, or
bushing. Progressively tighten bolts until bushing is
other damage. If necessary, dress rod with Scotch Brite
loose. Remove tapered bushing from piston.
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.
Tapered 5. Inspect threaded portion of barrel for damage. Dress
Rod
Bushing threads as necessary.
6. Inspect piston surface for damage, scoring, or distortion.
Piston Dress piston surface or replace piston as necessary.
7. Inspect threaded portion of piston for damage. Dress
threads as necessary.
Bolt
8. Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.
Figure 5-28. Tapered Bushing Removal
9. Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
11. By hand, screw the piston counterclockwise and remove necessary.
it from cylinder rod. 10. Inspect threaded portion of head for damage. Dress
11. Inspect seal and O-ring grooves in head for burrs and
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, sharp edges. Dress applicable surfaces as necessary.
SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
BEFORE REMOVING FOR PROPER INSTALLATION. 12. Inspect cylinder head outside diameter for scoring,
damage, ovality, and tapering. Replace as necessary.
12. Remove and discard backup ring, o-ring, and backup 13. Inspect rod and barrel bearings for signs of correct
ring from inside grooves of piston. Remove and discard excessive wear or damage. Replace as necessary.
two lock rings and seals from outer grooves of piston.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
13. Remove piston spacer from rod. etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
14. Remove rod from holding fixture. Remove cylinder head
steel bushing is worn or damaged, rod/barrel must
and washer ring.
be replaced.
15. Remove and discard two wear rings, wiper seal, and rod c. Lubricate inside of the steel bushing with WD40
seal from inside of cylinder head. Remove and discard O- prior to bearing installation.
ring and backup ring from outer groves of cylinder head.
NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
3121619 – JLG Lift – 5-61

d. Press bushing in barrel or rod bushing with correct 3. Install rod seal, wiper ring, and wear rings in cylinder
size arbor. head as shown.
Composite Barrel or
Bushing Rod Bushing
Composite
Bushing
Arbor
Figure 5-29. Bushing Installation
14. Inspect spacer for burrs and sharp edges. If necessary,

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

Apply a light film of hydraulic oil to all components before
grooves of piston.
assembly.
1. Install backup ring and o-ring in outside diameter

grooves of cylinder head.
Figure 5-31. Piston Seal Kit Installation
8. Using suitable protection, clamp cylinder rod in a vise or

similar holding fixture as close to piston as possible.
5-62 – JLG Lift – 3121619

9. Thread piston on cylinder rod hand tight. Ensure O-ring 13. Retorque the capscrews evenly and progressively in
and back-up rings are not damaged or dislodged. rotation to 9 ft.lbs. (12 Nm).
NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
10. Assemble the tapered bushing loosely into the piston
AND PISTON.
and insert capscrews through the drilled holes in the
bushing and into the tapped holes in the piston.
14. Clamp barrel securely and support rod. Insert piston end
into barrel cylinder. Do not damage or dislodge piston
O-ring and seal ring.
15. Continue pushing rod in barrel until cylinder head can
be inserted into barrel cylinder.
NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011)

to capscrews.
16. Secure cylinder head and washer ring with eight cap-
screws.
17. Install two counterbalance valves with new O-rings in
valve block. Torque to 30-35 ft-lb (40-47 Nm).
Figure 5-32. Tapered Bushing Installation
11. Tighten the capscrews evenly and progressively in rota-

tion to 9 ft.lbs. (12 Nm).
12. 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.
b. Tap each space once; this means the tapered bush-
ing is tapped 3 times as there are 3 spaces between
the capscrews.
Figure 5-34. Rod Assembly Installation
Figure 5-33. Seating the Tapered Bearing
3121619 – JLG Lift – 5-63

Jib Level (Slave) Cylinder 5. Mark cylinder head and barrel with center punch marks
(3) for later realignment. Remove eight cylinder head
Refer to Figure 5-38. capscrews
DISASSEMBLY



SURE.
support cylinder rod.
3. Remove cartridge-type counterbalance valve and fittings PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
from cylinder port block. Discard O-rings. SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND
PISTON.
6. Clamp barrel securely. Unscrew cylinder head and pull
rod assembly from barrel.
7. Protect cylinder rod from damage and clamp in a vise or
ROD SUPPORT
holding fixture as close to piston as possible.
PROTECTED ROD CLAMP
ROD SUPPORT
BARREL CLAMP
SUPPORT TABLE
SUPPORT TABLE
Figure 5-35. Cylinder Barrel Support
Figure 5-37. Cylinder Rod Support
5-64 – JLG Lift – 3121619

2
1
3*
3*
17**
16 13 14
15 13
8 6
18 12
5
19
18
4
11
10
21
*Torque to 50-55 ft-lb (67-75 Nm) 20
**Torque to 30 ft-lb (41 Nm)
20 1001155834
1. Bushing 5. Washer Ring 9. Wear Ring 13. Back-Up Ring 17. Bolt
2. Barrel 6. Wiper Seal 10. Backup Ring 14. O-Ring 18. Lock Ring
3. Counterbalance Valve 7. Rod Seal 11. O-Ring 15. Piston 19. Seal
4. Capscrew 8. Cylinder Head 12. Spacer 16. Tapered Bushing 20. Bushing
21. Rod
Figure 5-38. Jib Level (Slave) Cylinder Assembly
3121619 – JLG Lift – 5-65

8. Using suitable protection, clamp cylinder rod in a vise or 13. Remove and discard two lock rings (18) and seals (19)
similar holding fixture as close to piston as possible. from outside grooves of piston.
9. Loosen and remove bolts from tapered bushing and pis-
ton. 15
bushing. Progressively tighten bolts until bushing is
18
loose. Remove tapered bushing from piston.
14
11. Screw piston counter-clockwise by hand and remove
from cylinder rod.
13
19
Tapered 18
Rod
Bushing
Figure 5-40. Piston Disassembly
Piston
14. Remove piston spacer (12) from rod (7).
Bolt (8) and washer ring (5)
16. Remove and discard three wear rings (9), wiper seal (6),
Figure 5-39. Tapered Bushing Removal and rod seal (7) from inside of cylinder head (8). Remove
and discard O-ring (11) and backup ring (10) from outer
groves of cylinder head.
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, 9
8 6
BEFORE REMOVING FOR PROPER INSTALLATION.
12. Remove and discard backup ring (13), O-ring (14), and
backup ring (13) from inside grooves of piston (15).
11
10
7
Figure 5-41. Cylinder Head Disassembly
5-66 – JLG Lift – 3121619

CLEANING AND INSPECTION d. Press bushing in barrel or rod bushing with correct
size arbor.
2. Inspect cylinder rod for scoring, tapering, ovality, or Composite Barrel or
other damage. If necessary, dress rod with Scotch Brite Bushing Rod Bushing
or equivalent. Replace rod if necessary. Composite
Bushing
or other damage. Check inside diameter for tapering or Arbor
5. Inspect threaded portion of barrel for damage. Dress
6. Inspect piston surface for damage, scoring, or distortion. dress inside diameter surface with Scotch Brite or equiv-
Dress piston surface or replace piston as necessary. alent.
7. Inspect threaded portion of piston for damage. Dress 15. Inspect port block fittings and holding valves. Replace
threads as necessary. as necessary.
8. Inspect seal and O-ring grooves in piston for burrs and 16. Inspect oil ports for blockage or presence of dirt or other
sharp edges. Dress surfaces as necessary. foreign material. Repair as necessary.
necessary.
10. Inspect threaded portion of head for damage. Dress
sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring,
13. Inspect rod and barrel bearings for signs of correct
excessive wear or damage. Replace as necessary.
etc. to facilitate bearing installation.
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.

3121619 – JLG Lift – 5-67

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

ter grooves of cylinder head (8).
2. Install rod seal (7), wiper seal (6), and three wear rings (9) 14
in cylinder head as shown. 13
17
21 13
4
14

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

and back-up rings are not damaged or dislodged.
NOTE: Piston and mating end of rod must be free of oil when
18 installing tapered bushing.
20
9. Thread piston on rod until it aligns with spacer end and
Figure 5-43. Cylinder Head Assembly install tapered bushing.
3. Slide washer ring (5) on rod (21). Install cylinder head

assembly (8) on rod. Do not damage or dislodge wiper
and rod seals. Push cylinder head to rod end.
4. Install spacer (12) on rod (21).
5-68 – JLG Lift – 3121619

NOTE: Apply JLG Threadlocker (P/N 0100011) to tapered bushing

bolts.
10. Assemble the tapered bushing loosely into the piston SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
and insert capscrews through the drilled holes in the AND PISTON.
bushing and into the tapped holes in the piston.
O-ring and seal ring.
15. Continue pushing rod (21) in barrel (2) until cylinder
head (8) can be inserted into barrel cylinder.
NOTE: Apply locking primer and medium strength (Blue) Locking

Compound (JLG P/N 0100011 or equivalent to capscrews.
16. Secure cylinder head (8) and washer ring (5) with eight
capscrews (4).
17. Install two counterbalance valves (3) with new O-rings in

3*

tion to 30 ft-lb (41 Nm). 3* 8
5
bushing with a hammer (16 to 24 oz.) and brass shaft 2 4
21
capscrews.
the capscrews. Figure 5-47. Rod Assembly Installation
13. Re-torque capscrews evenly and progressively in rota-

tion to 30 ft-lb (41 Nm).
3121619 – JLG Lift – 5-69

Platform Level Cylinder Remove cylinder length sensor assembly (6) from barrel
(3).
DISASSEMBLY
CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A 5 8

3
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 7
6
1. Connect a suitable auxiliary hydraulic power source to 9
10
cylinder port fitting.
support cylinder rod, if applicable.
11
3. Place cylinder barrel in a suitable holding fixture. 12
Figure 5-49. Cylinder Length Sensor Removal


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

4. Remove cartridge-type counterbalance valve and fit-

tings from cylinder port block. Discard O-rings.
5. If neccessary, remove eight capscrews (8) and retainer
cap (7). Remove O-Ring plug (12) and setscrew (11). . .
Mark For Reassembly
Figure 5-50. Cylinder Head Removal
5-70 – JLG Lift – 3121619

4 6
5 8
3
10
4
11**
12
1
2*
13***
14
15
16
17
16
15
18
19
18
21
20
22
23
24****
25
26
29 27
*Torque to 30-35 ft-lb (41-47 Nm)

**Torque to 4 in-lb (.4 Nm)
28 ***Torque to 9 ft-lb (12 Nm)
****Torque to 200 ft-lb (271 Nm)
1001139999
29
1. Screw 6. Length Sensor 11. Setscrew 16. Seal 21. Backup Ring 26. Seal
2. Counterbalance Valve 7. Retainer Cap 12. Plug 17. Piston 22. O-Ring 27. Rod Wiper
3. Barrel 8. Capscrew 13. Capscrew 18. Backup Ring 23. O-Ring 28. Rod
4. Bushing 9. Retaining Ring 14. Tapered Bushing 19. O-Ring 24. Head 29. Bushing
5. Spacer Sleeve 10. Sensor Magnet 15. Lock Ring 20. Spacer 25. Wear Ring
Figure 5-51. Platform Level Cylinder Assembly
3121619 – JLG Lift – 5-71

OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON. SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
9. Clamp barrel securely. Pull rod assembly and cylinder
head from barrel. 14. Remove and discard two lock rings (15), seals (16),
backup ring (18), O-ring (19), and backup ring (18) from
10. Protect cylinder rod from damage and clamp in a vise or piston (17).
holding fixture as close to piston as possible. 15. Remove piston spacer (20) from rod.
ROD SUPPORT 15
16
SUPPORT TABLE 15
17
18
19
18
20
ton.
(24).
12. Insert bolts in threaded holes in outer piece of tapered 17. Remove and discard backup ring (21), O-ring (22), O-ring
bushing. Progressively tighten bolts until bushing is (23), rod wiper (27), seal (26), and two wear rings (25),
loose. Remove tapered bushing from piston. from cylinder head (24).
21
22
23
Tapered
Rod
Bushing
Piston
24
Bolt
25
Figure 5-53. Tapered Bushing Removal 26
27
13. Screw piston counter-clockwise by hand and remove Figure 5-55. Cylinder Head Disassembly
from cylinder rod.
5-72 – JLG Lift – 3121619

CLEANING AND INSPECTION d. Press bushing into barrel or rod bushing with cor-
rect size arbor.
Composite Barrel or
2. Inspect cylinder rod for scoring, tapering, ovality, or Bushing Rod Bushing
other damage. If necessary, dress rod with Scotch Brite Composite
or equivalent. Replace rod if necessary. Bushing

Arbor
or other damage. Check inside diameter for tapering or Figure 5-56. Composite Bushing Installation
15. Inspect port block fittings and holding valve. Replace as
5. Inspect threaded portion of barrel for damage. Dress necessary.
6. Inspect piston surface for damage, scoring, or distortion. foreign material. Repair as necessary.
Dress piston surface or replace piston as necessary.
ASSEMBLY
NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
assembly.
necessary. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION.
threads as necessary. 1. Install O-ring (23), O-ring (22), and backup ring (21) in
outside diameter grooves of cylinder head (24).
sharp edges. Dress applicable surfaces as necessary. 2. Install two wear rings (25) seal (26), and rod wiper (27), in
cylinder head as shown.
21
13. Inspect cylinder length sensor components for damage. 22
Replace as needed.
23
14. Inspect rod and barrel bearings for signs of excessive
wear or damage. Replace as necessary.

etc. to facilitate bearing installation.
24
be replaced.
25
c. Lubricate inside of steel bushing with WD40 before 26
installing bushings. 27
NOTE: Lubrication is not required with nickel plated pins and Figure 5-57. Cylinder Head Seal Kit Installation
3121619 – JLG Lift – 5-73

3. Install cylinder head assembly on rod. Do not damage or through the drilled holes in the bushing and into the
dislodge wiper and rod seals. Push head along rod to tapped holes in the piston.
rod end.
4. Install piston spacer (20) on rod.
5. Install backup ring (18), O-ring (19) and backup ring (18)
in inner diameter grooves of piston (17). Install two seals
(16) and lock rings (15) in outer grooves of piston.
15
16
15

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

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

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

valve block. Torque to 30-35 ft-lb (41-47 Nm)
5-74 – JLG Lift – 3121619

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

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

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

dislodge piston loading O-ring and seal ring. . .
17. Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder..
1
Figure 5-62. Cylinder Head Tightening
24 19. Secure cylinder head (24) with setscrew (1).

3
28
28
Figure 5-61. Rod and Cylinder Head Installation
3121619 – JLG Lift – 5-75

Boom Lift Cylinder 5. Mark cylinder head and barrel with center punch marks
for later realignment. Remove cylinder head cap screws.
DISASSEMBLY



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

5-76 – JLG Lift – 3121619

3*
4*
5
22** 21
17 16 15
14
13 10
9
18 8
19
20
19 7
18
6
12
11
24
23
1001158853
23
1. Bearing 6. Capscrew 11. Wiper Seal 16. Backup Ring 21. Bushing
2. Counterbalance Valve 7. Washer Ring 12. Rod Seal 17. Piston 22. Bolt
3. Counterbalance Valve 8. Wear Ring 13. Head 18. Lock Ring 23. Bushing
4. Counterbalance Valve 9. Backup Ring 14. Backup Ring 19. Seal 24. Rod
5. Barrel 10. O-Ring 15. O-Ring 20. Wear Ring
Figure 5-66. Boom Lift Cylinder Assembly
3121619 – JLG Lift – 5-77

8. Remove three bolts attaching tapered bushing to pis- 12. Remove rod from holding fixture. Remove cylinder head
ton. (13) and washer ring (7) from rod.
9. Insert bolts in threaded holes in outer piece of Tapered 13. Remove and discard wiper seal (11), rod seal (12), wear
Bushing. Alternately tighten bolts until bushing is loose ring (8), back-up ring (9), and O-ring (10).
on piston. Remove tapered bushing from piston.
10. Remove piston from cylinder rod. 9
13 10
Tapered
Rod
Bushing
Piston
Bolt

11
12

REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION CLEANING AND INSPECTION
11. Remove and discard backup ring (14), O-ring (15), and
backup ring (16) from inside of piston (17). Remove and
discard two lock rings (18), seals (19), and wear ring (20)
or equivalent. Replace rod if necessary.
from outside of piston.
17 16 4. Inspect inner surface of cylinder barrel tube for scoring
15
18 5. Inspect threaded portion of barrel for damage. Dress

14 threads as necessary.
19
20 threads as necessary.
19 8. Inspect seal and O-ring grooves in piston for burrs and
18
necessary.
5-78 – JLG Lift – 3121619

11. Inspect seal and O-ring grooves in head for burrs and ASSEMBLY
12. Inspect cylinder head outside diameter for scoring, JLG Parts Manual.
13. Inspect rod and barrel bearings for signs of correct assembly.
excessive wear or damage. Replace as necessary.

etc. to facilitate bearing installation. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
b. Inspect steel bushing for wear or other damage. If CYLINDER OPERATION.
be replaced. 1. Install O-ring (10), backup ring (9), wear ring (8), rod seal
(12), and wiper seal (11) in cylinder head (13).
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
10 9
13
bearings. Install pin in composite bushing dry. 8
d. Press bushing into barrel or rod bushing with cor-

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

11
12
14. Inspect port block fittings and holding valves. Replace
as necessary. Figure 5-71. Cylinder Head Assembly
foreign material. Repair as necessary. 2. Slide washer ring (7) and cylinder head Assembly (13) on
rod (26).
3121619 – JLG Lift – 5-79

3. Install backup ring (16), O-ring (15), and backup ring (14) 7. Tighten the capscrews evenly and progressively in rota-
to inside groves of piston (17). tion to 60 ft-lb (81 Nm).
4. Install wear ring (20), two seals ring (19), and lock rings 8. After the screws have been torqued, tap the tapered
(18) to outside grooves of piston (17). bushing with a hammer (16 to 24 oz.) and brass shaft
17 16
15 capscrews.
18
the capscrews.
14
19
20
19
18
Figure 5-72. Piston Assembly
5. Install piston assembly (17) and tapered bushing (23) on Figure 5-74. Seating the Tapered Bearing
rod (26).
9. Re-torque the capscrews evenly and progressively in
NOTE: When installing the tapered bushing, piston and mating rotation to 60 ft-lb (81 Nm).
6. Apply JLG Threadlocker (P/N 0100011) to tapered bush-

ing capscrews. Assemble the tapered bushing loosely
into the piston and insert capscrews through the drilled
holes in the bushing and into the tapped holes in the
piston.
5-80 – JLG Lift – 3121619

10. Remove cylinder rod from holding fixture. 15. Apply primer and medium-strength locking compound
JLG P/N 0100011or equivalent to eight capscrews (6).
11. Position cylinder barrel in a suitable holding fixture. Secure cylinder head assembly (13) and washer ring (7)
to barrel (5)with capscrews.

AND PISTON.
12. Clamp barrel (5) securely and support rod (24). Insert
piston (17) end in barrel. Do not damage or dislodge pis-
5 13
ton O-rings or seal rings.
7
13. Continue pushing rod in barrel until cylinder head (13) 17
6
can be inserted in barrel.
24
14. Install cylinder head until tight and marks made during
disassembly are aligned.
3121619 – JLG Lift – 5-81

Jib Lift Cylinder 5. If necessary, remove eight capscrews (11) and retainer
cap (10). Remove O-Ring plug (5) and setscrew (4).
Refer to Figure 5-79. Remove cylinder length sensor assembly (9) from barrel
(1).
DISASSEMBLY
5
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A 4
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 6 11
1
10
1. Connect a suitable auxiliary hydraulic power source to 9
cylinder port block fitting. 8
7

SURE.

Shut down and disconnect power source. Adequately Figure 5-77. Cylinder Length Sensor Removal
support cylinder rod, if applicable.
6. Tap around outside of cylinder head retainer with a suit-
3. Place cylinder barrel in a suitable holding fixture. able hammer to break thread-locking compound.
7. Mark cylinder head and barrel with center punch marks
for later realignment. Remove eight cylinder head cap
screws.


4. Remove cartridge-type counterbalance valve and fit-

tings from cylinder port block. Discard O-rings.
5-82 – JLG Lift – 3121619

5
4**
3
6
11
10
9
2* 8
7
1
3
2*
12***
13
14
15
16
15
14
17
18
17
21
19
22
20
23
24
25
26
27
28
28
*Torque to 50-55 ft-lb (67-75 Nm)

29 **Torque to 4 in-lb (.4 Nm)
***Torque to 9 ft-lb (12 Nm)
30
1001140104
1. Barrel 7. Sensor Magnet 13. Tapered Bushing 19. O-Ring 25. Seal
2. Counterbalance Valve 8. Internal Retaining Ring 14. Lock Ring 20. Spacer 26. Rod Wiper
3. Bushing 9. Cylinder Length Sensor 15. Seal 21. O-Ring 27. Washer Ring
4. Setscrew 10. Retainer Cap 16. Piston 22. Backup Ring 28. Capscrew
5. O-Ring Plug 11. Capscrew 17. Backup Ring 23. Cylinder Head 29. Rod
6. Spacer 12. Bolt 18. O-Ring 24. Wear Ring 30. Bushing
Figure 5-79. Jib Lift Cylinder Assembly
3121619 – JLG Lift – 5-83

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
PISTON. BEFORE REMOVING FOR PROPER INSTALLATION.
8. Clamp barrel securely. Pull rod assembly and cylinder 13. Remove and discard two lock rings (14), seals (15),
head from barrel. backup ring (17), O-ring (18), and backup ring (17) from
piston (16).
holding fixture as close to piston as possible. 14. Remove piston spacer (20) from rod (29). Remove and
discard O-ring (19) from inside of spacer.
ROD SUPPORT
14
SUPPORT TABLE 15
14
16
17
18
17
19
20
ton. Figure 5-82. Piston Disassembly

bushing. Progressively tighten bolts until bushing is 15. Remove rod from holding fixture. Remove cylinder head
loose. Remove tapered bushing from piston. (21) and washer ring (24).
12. Screw piston counter-clockwise by hand and remove 16. Remove and discard O-ring (21), backup ring (22), rod
from cylinder rod. wiper (26), seal (25), and two wear rings (24), from cylin-
der head (23).
Tapered 24
Rod
Bushing
21
25
26 22
Piston
23
Bolt
Figure 5-81. Tapered Bushing Removal Figure 5-83. Cylinder Head Disassembly
5-84 – JLG Lift – 3121619

CLEANING AND INSPECTION d. Press bushing into barrel or rod bushing with cor-
rect size arbor.
Composite Barrel or
2. Inspect cylinder rod for scoring, tapering, ovality, or Bushing Rod Bushing
other damage. If necessary, dress rod with Scotch Brite Composite
or equivalent. Replace rod if necessary. Bushing

Arbor
or other damage. Check inside diameter for tapering or Figure 5-84. Composite Bushing Installation
5. Inspect threaded portion of barrel for damage. Dress 15. Inspect port block fittings and holding valve. Replace as
threads as necessary. necessary.
6. Inspect piston surface for damage, scoring, or distortion. 16. Inspect oil ports for blockage or presence of dirt or other
Dress piston surface or replace piston as necessary. foreign material. Repair as necessary.
7. Inspect threaded portion of piston for damage. Dress ASSEMBLY

8. Inspect seal and O-ring grooves in piston for burrs and JLG Parts Manual.
9. Inspect cylinder head inside diameter for scoring or assembly.
necessary.
10. Inspect threaded portion of head for damage. Dress IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
threads as necessary. CYLINDER OPERATION.
1. Install backup ring (22) and O-ring (21) in outside diame-
ter grooves of cylinder head (23).
2. Install two wear rings (24) seal (25), and rod wiper (26), in
cylinder head as shown.
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.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt 24

etc. to facilitate bearing installation. 21
25
b. Inspect steel bushing for wear or other damage. If 26 22
be replaced. 23
c. Lubricate inside of steel bushing with WD40 before

installing bushings.
NOTE: Lubrication is not required with nickel plated pins and Figure 5-85. Cylinder Head Seal Kit Installation
3121619 – JLG Lift – 5-85

3. Install washer ring (27) on rod (29). Install cylinder head piston and insert capscrews through the drilled holes in
assembly on rod. Do not damage or dislodge wiper and the bushing and into the tapped holes in the piston.
rod seals. Push head along rod to rod end.
4. Install O-ring (19) in spacer (20). Slide piston spacer on
rod.
5. Install backup ring (17), O-ring (18) and backup ring (17)
in inner diameter grooves of piston (16). Install two seals
(15) and lock rings (14) in outer grooves of piston.
14
15
14

tion to 9 ft.lbs. (12 Nm).
16 11. After the screws have been torqued, tap the tapered
17 bushing with a hammer (16 to 24 oz.) and brass shaft
18
17 (approximately 3/4" in diameter) as follows;
19
20
Figure 5-86. Piston Seal Kit Installation capscrews.
6. Using suitable protection, clamp cylinder rod in a vise or ing is tapped 3 times as there are 3 spaces between
similar holding fixture as close to piston as possible. the capscrews.
7. Thread piston on cylinder rod hand tight. Ensure O-ring
and back-up rings are not damaged or dislodged.

NOTE: When installing the tapered bushing, piston and mating


ing bolts. Assemble the tapered bushing loosely into the

rotation to 9 ft.lbs. (12 Nm).
5-86 – JLG Lift – 3121619

15. Secure cylinder head (26) and washer ring (27) with
eight capscrews (28).
AND PISTON. 1
loading O-ring and seal ring.
gland can be inserted into barrel cylinder.
NOTE: Apply JLG Threadlocker (P/N 0100011) or equivalent to

capscrews. 29
27
28
29

valve block. Torque to 50-55 ft-lb (67-75 Nm)
17. If removed, install the cylinder length sensor. See Sec-

tion 5.4, Cylinder Length Sensor.
3121619 – JLG Lift – 5-87

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

Shut down and disconnect power source.

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

realignment. Unscrew cylinder head with pin-face span-
ner wrench.
. .
Mark For Reassembly
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL

SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND
PISTON.
5-88 – JLG Lift – 3121619

5
6
10
11 1001119313
1. Rod 4. Barrel 7. O-Ring 10. Seal

2. Seal 5. O-Ring 8. Head 11. Rod Wiper
3. Wear Ring 6. Backup Ring 9. Wear Ring
Figure 5-91. Jib Lock Cylinder Assembly
3121619 – JLG Lift – 5-89

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

necessary.



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

foreign material. Repair as necessary.
ASSEMBLY
JLG Parts Manual.

assembly. Figure 5-92. Cylinder Head Installation
1. Position cylinder barrel in a suitable holding fixture.
2. Use seal tool to install new rod seal into applicable cylin-
der head gland groove.

CYLINDER OPERATION.
3. Install O-ring (7), back-up ring (6), and O-ring (5) in appli-
cable outside diameter groove of cylinder head (8).
5-90 – JLG Lift – 3121619

Steer Cylinder 7. Protect cylinder rod from damage and clamp in a vise or
ROD SUPPORT
DISASSEMBLY
SUPPORT TABLE
CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A



SURE.
Shut down and disconnect power source. Figure 5-94. Cylinder Rod Support
3. Place cylinder barrel in a suitable holding fixture.
4. Remove self-tapping screw (9) from cylinder head (5)
and barrel (2). REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,
5. Unscrew cylinder head with pin-face spanner wrench. SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION
8. Remove setscrew (13) from piston (12). remove piston

from rod (21).
9. Remove and discard O-ring (11), seal (15), and wear ring
(14) from piston. Remove rod from clamp or vise.

PISTON.

head from barrel.
3121619 – JLG Lift – 5-91

1001155986
1. Bushing 4. Seal 7. Backup Ring 10. Wear Ring 13. Setscrew 16. Bushing
2. Barrel 5. Head 8. O-Ring 11. O-Ring 14. Wear Ring 17. Rod
3. Wiper Seal 6. O-Ring 9. Screw 12. Piston 15. Seal
Figure 5-95. Steer Cylinder Assembly
5-92 – JLG Lift – 3121619

10. Remove cylinder head assembly (5) from rod (17). 12. Inspect cylinder head outside diameter for scoring,
Remove and discard two wear rings (10), seal (4), wiper damage, ovality, and tapering. Replace as necessary.
seal (3), O-ring (8), backup ring (7), and O-ring (6) from
cylinder head.
ASSEMBLY
JLG Parts Manual.

assembly.

CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
TATION.
1. Install seal (4) and wiper seal (3) to inside grooves of cyl-
inder head (5).
Figure 5-96. Piston and Cylinder Head Disassembly 2. Install two wear rings (10) in cylinder head.
3. Install O-Ring (6), backup ring (7), and O-ring (8) to out-
side grooves of cylinder head.
CLEANING AND INSPECTION
4. Slide cylinder head assembly on rod.
5. Install O-ring (11) to inside groove of piston (12).
other damage. If necessary, dress rod with Scotch Brite 6. Install wear ring (14) and seal (15) in outside grooves of
or equivalent. Replace rod if necessary. piston.
8. Apply medium-high strength (red) thread-locking com-
4. Inspect inner surface of cylinder barrel tube for scoring pound JLG P/N 0100071 or equivalent to rod threads.
ovality. Replace if necessary. 9. Thread piston assembly on rod. Do not dislodge or dam-
age O-ring. Torque piston to 30 ft-lb (40 Nm).




necessary.

3121619 – JLG Lift – 5-93

10. Install setscrew (13) in piston. Torque to 90 in-lb (10 Nm). 15. Adjust cylinder head until screw hole aligns with barrel.
Install screw (9).
5
Figure 5-97. Cylinder Head and Piston Assembly
Figure 5-98. Cylinder Head Installation

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

rod. Insert piston end into barrel cylinder. Do not dam-
age or dislodge piston O-rings or seal rings.
12. Apply ant-seize compound to cylinder head threads.
13. Continue pushing rod into barrel until cylinder head can
be inserted into barrel cylinder.
14. Screw in cylinder head (5) to barrel (2). Torque to 100 ft-
lb (135 Nm).
5-94 – JLG Lift – 3121619

Jib Telescope Cylinder

Refer to Figure 5-101. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
PISTON.
DISASSEMBLY
8. Clamp barrel securely. Pull rod assembly out until piston
bottoms to cylinder head.
9. Remove capscrew and pull rod assembly and cylinder
CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
head from barrel.
1. Connect a suitable auxiliary hydraulic power source to holding fixture as close to piston as possible.
ROD SUPPORT
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. SUPPORT TABLE

SURE.

Shut down and disconnect power source.
3. Place cylinder barrel in a suitable holding fixture. Clean

outside of cylinder to prevent contamination.
4. Remove two bolts (3), four washers (4), two nuts (9) and
wear pad (5) from bracket (7). Repeat for remaining wear
pad.
5. Remove eight socket head screws (6) and two pad sup- Figure 5-100. Cylinder Rod Support
ports (7) from cylinder head (12). Reinstall one socket
head screw finger-tight. 11. Remove piston assembly (19) from rod (22) with spanner
wrench.
6. Remove three cartridge valves from valve block.
12. Remove spacer assembly (16) from rod (22).
7. Tap around outside of cylinder head retainer with a suit-
13. Remove cylinder head assembly (12) from rod (22).
able hammer to break thread-locking compound.
2 12
9
8
7
22
4
3
7
6
Figure 5-99. Cylinder Head and Wear Pads
3121619 – JLG Lift – 5-95

2**
2** 3
20***
19
18
21 16
22
21 13
11
17
10
9
8
15
14 6
12 5
4
8
7*
23
*Torque to 20 ft-lb (27 Nm)

**Torque to 25-30 ft-lb (33-40 Nm)
***Torque to 100 ft-lb (135 Nm)
1001158991
1. Shuttle Valve 5. Washer 9. Washer 13. Cylinder Head 17. Spacer 21. Wear Ring
2. Counterbalance Valve 6. Wear Pad 10. Nut 14. Backup Ring 18. O-Ring 22. Seal
3. Barrel 7. Capscrew 11. Wiper 15. O- Ring 19. O-Ring 23. Rod
4. Bolt 8. Support Pad 12. Seal 16. Wear Ring 20. Piston
Figure 5-101. Jib Telescope Cylinder Assembly
5-96 – JLG Lift – 3121619

CLEANING AND INSPECTION
BEFORE REMOVING FOR PROPER INSTALLATION. CLEAN PARTS THOROUGHLY WITH WATER AND A RUST PREVENTATIVE ONLY.
DO NOT USE ANY FORM OF DETERGENT OR SOAP.
14. Remove and discard O-ring (19), two wear rings (21),
and seal (22) from piston (20). 1. Inspect cylinder rod for scoring, tapering, ovality, or
15. Remove and discard O-ring (18) from spacer (17). or equivalent. Replace rod if necessary.

20
19
18

21
22
21
17
Figure 5-102. Piston and Spacer Disassembly other damage, and for ovality and tapering. Replace as
necessary.
16. Remove rod from holding fixture and remove cylinder
head.
17. Remove and discard wiper (11), seal (12), wear ring (16),
O-ring (15), and backup ring (14) from cylinder head 9. Inspect seal and O-ring grooves in head for burrs and
(13). sharp edges. Dress applicable surfaces as necessary.

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

15 as necessary.

14 12
3121619 – JLG Lift – 5-97

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

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

2. Install seal (12) and wiper (11) in cylinder head. 21
3. Install backup ring (14) and O-ring (15) in outside diame- 22
ter grooves of cylinder head. 21
16 17
13 Figure 5-105. Piston and Spacer Assembly

11

15
9. Apply medium-strength locking compound JLG P/N
0100011or equivalent to rod threads.
10. Install piston on cylinder rod. Do not damage or dis-
lodge O-ring. Torque to 100 ft-lb (135 Nm).
14 12 11. Remove cylinder rod from holding fixture.
12. Position cylinder barrel in a suitable holding fixture.
Figure 5-104. Cylinder Head Assembly

4. Install cylinder head assembly on rod. Do not damage or
dislodge wiper and rod seals. Push head along rod to
AND PISTON.
rod end.
O-rings and seals.
gland can be inserted into barrel cylinder.
5-98 – JLG Lift – 3121619

NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011) 17. Install shuttle valve (1) with new O-ring in valve block.
or equivalent to capscrew threads. Torque to 20 ft-lb (27 Nm).
15. Install two pad supports (7) to cylinder head (12) and
barrel (2) with eight capscrews (6). Torque capscrews to
20 ft-lb (27 Nm) following sequence shown in Figure 5-
107.
2
2 12
9
8
7
22
4
3
2
7
6
Figure 5-108. Valve Installation
5 1
3 7
8
4
2 6
Figure 5-107. Cylinder Head Torque Sequence
16. Install each wear pad (5) with two bolts (3), four washers
(4) and two bolts (9).
3121619 – JLG Lift – 5-99

Boom Telescope Cylinder 7. Tap around outside of Cylinder Head with a suitable
hammer to break thread-locking compound. Unscrew
Refer to Figure 5-112. Cylinder Head (23).
DISASSEMBLY

27
26
23
25
24
DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE. 28
Shut down and disconnect power source. Adequately Figure 5-110. Port Block And Rod Removal
support cylinder rod.
3. Place cylinder barrel in a suitable holding fixture.

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

BARREL CLAMP head from barrel.
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
4. Remove check valves (3), counterbalance valves (4), and

fittings from valve block (2). Discard O-rings. Remove
four capscrews (1) and valve block from rod (7). Discard
O-rings (5, 6).
5. Mark cylinder head (23) and barrel (28) with center
punch marks for later realignment. Remove two cap-
screws (27) and bracket (26).
6. Remove six remaining capscrews (25) and washers (24).
5-100 – JLG Lift – 3121619

27
26
25
24
23
22
21
20
19
18
17 12
16
15 14
10
28
1001178592
1. Capscrew 6. O-Ring 11. Wear Ring 16. Spacer 21. Wiper Seal 26. Bracket
2. Valve Block 7. Rod 12. Seal 17. Wear Ring 22. Retaining Ring 27. Capscrew
3. Check Cartridge 8. Bolt 13. Backup Ring 18. O-Ring 23. Cylinder Head 28. Barrel
4. Counterbalance Valve 9. Tapered Bushing 14. Washer Ring 19. Back-Up Ring 24. Washer
5. O-Ring 10. Piston 15. Capscrew 20. Rod Seal 25. Capscrew
Figure 5-112. Boom Telescope Cylinder Assembly
3121619 – JLG Lift – 5-101

10. Remove three bolts attaching tapered bushing to pis- 14. Remove capscrew (15) and spacer (16) from rod (7).
ton.
15. Remove rod from holding fixture.
NOTE: Record orientation of rings for reassembly.
bushing. Alternately tighten bolts until bushing is loose
on piston. Remove tapered bushing from piston.
16. Remove cylinder head (23) from rod (7). Remove and
12. Remove piston from cylinder rod. discard O-Ring (18), backup ring (19), retaining ring (22),
wiper seal (21), rod seal (20), and two wear rings (17).
22
19
Tapered
Rod
Bushing 18
21
Piston
20
Bolt
23

17
13. Remove and discard two backup rings (13), washer ring
(14), two wear rings (11), and seal (12) from piston (10).
13
14
11
11
5-102 – JLG Lift – 3121619

CLEANING AND INSPECTION ASSEMBLY
1. Clean parts thoroughly with approved cleaning solvent. NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
other damage. If necessary, dress rod with Scotch Brite Apply a light film of hydraulic oil to all components before
or equivalent. Replace rod if necessary. assembly.

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

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

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

damage, ovality, and tapering. Replace as necessary. 23
12. Inspect spacer for burrs and sharp edges. Dress inside 17
diameter surface with Scotch Brite or equivalent.
13. Inspect port block fittings and cartridge valves. Replace Figure 5-116. Cylinder Head Seal Kit Installation
as necessary.
4. Install cylinder head assembly (23) on rod (7). Do not
damage or dislodge wiper and rod seals. Push cylinder
head along rod to rod end.
3121619 – JLG Lift – 5-103

5. Install Spacer (16) on Rod (7) with screw hole facing NOTE: Piston and mating end of rod must be free of oil when
toward piston end. Align hole in spacer and rod. Apply installing tapered bushing.
locking primer and medium strength (Blue) locking
compound JLG P/N 0100011 or equivalent to socket 10. Thread piston on rod until it aligns with spacer end and
head capscrew (10). Install capscrew.
ing bolts. Assemble the tapered bushing loosely into the
piston and insert capscrews through the drilled holes in
the bushing and into the tapped holes in the piston.
23
16
15
Figure 5-117. Cylinder Head and Spacer Installation
6. Install backup ring (13), washer ring (14), and backup

ring (13) in piston (11).
7. Install seal (12), and two wear rings (11) on piston.
tion to 30 ft-lb (41 Nm).
13
bushing with a hammer (16 to 24 oz.) and brass shaft
14 capscrews.
11
11

9. Carefully thread piston on cylinder rod hand tight,

Ensure O-ring and back-up rings are not damaged or
dislodged.
5-104 – JLG Lift – 3121619

b. Tap each space once; this means the tapered bush- 19. Install cylinder head (23) in barrel (28) and align marks
ing is tapped 3 times as there are 3 spaces between made during disassembly.
the capscrews.
NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011
to capscrews.
20. Install bracket (26) with two capscrews (27).

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

27
26
rotation to 30 ft-lb (41 Nm). 23
15. Remove cylinder rod from holding fixture.
25
16. Position cylinder barrel in a suitable holding fixture. 24
28
AND PISTON. Figure 5-121. Rod Assembly And Valve Installation
17. Clamp barrel clamped securely and support rod. Insert

piston end into barrel. Do not damage or dislodge pis-
ton O-ring and seal ring.
18. Push rod in barrel until cylinder head can be inserted.
3121619 – JLG Lift – 5-105

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 5-122. 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.
5-106 – JLG Lift – 3121619

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.
3121619 – JLG Lift – 5-107

Installation 3. Apply lubricant JLG P/N 3020039 to the setscrew and

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

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

pin.
6. Install the keeper pin and retaining bolt.
7. Check the cylinder for proper operation.
5-108 – JLG Lift – 3121619

5.5 OIL SAMPLING 4. Unscrew the knurled end which is attached to the chain.
See Figure 5-123., Oil Sampling Valve Location.
This machine is equipped with an oil sampling valve to

allow for verification of hydraulic oil condition.
Procedure
1. Function the machine for approximately 15 minutes
operating all functions.
2. Switch the select switch to the ground controls and start
the engine.
3. Locate the oil sampling valve on the front of the main
control valve.
5. Place a drip pan under the spout and push in for approx-
imately 10 seconds. This should flush out the valve.
6. Open and place the sample bottle under the spout.
7. Push in on the end of the valve and fill up the bottle.
8. Cap the bottle immediately.
9. Thread the knurled cap back onto the valve.
10. The sample is complete.
Figure 5-123. Oil Sampling Valve Location
3121619 – JLG Lift – 5-109

Figure 5-124. Main Valve Identification - Sheet 1 of 2
5-110 – JLG Lift – 3121619

Figure 5-126. Main Valve Identification - Sheet 2 of 2
3121619 – JLG Lift – 5-111

Item Ft.Lbs. Nm
1 60-70 81-95
2 25-30 34-40.5
3 40-49 54-66
4 2.2-3 3-4
5 30-35 40.5-47
6 122-133 165-180
7 3.7-5.2 5-7
8 28.8-37.6 39-51
9 46 62
10 30-37 40.5-50
11 13 17.5
Figure 5-127. Main Valve Torque Values - Sheet 1 of 2
5-112 – JLG Lift – 3121619

Figure 5-128. Main Valve Torque Values - Sheet 2 of 2
3121619 – JLG Lift – 5-113

5.6 PRESSURE SETTING PROCEDURE 4. To make an adjustment to this pressure, go back to the
engine compartment to the function pump which is the
Cold temperatures have a significant impact on pressure read- rear pump. The high pressure relief adjustment is the
ings. JLG Industries Inc. recommends operating the machine adjustment closest to the pump case.
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. Setup of the Function Pump

PRESSURE COMPENSATOR (PC) SETTING
1. Install a high pressure gauge 5000 psi (345 bar) at the
“MP” port of the main valve block.
5. Loosen the locking set screw at the side of the adjust-

ment. Adjust the PC to obtain 4000 psi (275 bar), clock-
wise increases pressure.
6. After adjusting the pressure, tighten the locking set

screw, and reconnect the Lift Down coil.
STAND BY PRESSURE OR LOAD (LS) SENSE PRESSURE
1. Install a low pressure gauge at port “MP” of the main

valve block. The gauge must be capable of reading 300
psi (21 bar).
2. Remove the Deutsch connector from the lift down coil.
2. Start the engine, the gauge should read 300psi (21 bar).
3. To make an adjustment to this pressure, go to the

3. Activate lift down. The gauge should read 4000 psi. (275 engine compartment, locate the function pump.
bar).
5-114 – JLG Lift – 3121619

4. The stand by adjustment is the outside adjustment. 2. Remove deutsch connector from lift down coil.
Using the same procedure as in the (PC) setting above
adjust (LS) to 300psi (21bar).
3. Turn adjustment screws on the pressure reducing valve

2. Adjustments Made at the Main Valve Bank located at 3 o’clock adjacent to port P4, and the relief
valve, located at 5 o’clock adjacent to port P4, fully clock-
wise. Energize Lift Down, the gauge should read approx-
REDUCED PRESSURE SECTION
imately 4000 psi (275bar), turn adjusting screw on relief
1. Install pressure gauge at port MP4. valve CCW to obtain gauge reading of 3550 psi. (241bar)
With lift down still energized, turn adjusting screw on
pressure reducing valve CCW to obtain a gauge reading
of 3200 psi. (221 bar).
3121619 – JLG Lift – 5-115

2. Plug and cap the hose on port 5. Activate lift up. The
gauge should read 3700 psi. (255 bar).
4. Reconnect lift down coil.

5. Retighten locknuts. 3. The adjustment cartridge is located to the right of port
5. Turn clockwise to increase pressure, counter clockwise
LIFT UP to decrease.
1. Install a high pressure gauge at the “M5” port of the
main valve block.
5-116 – JLG Lift – 3121619

LIFT DOWN SWING

1. Install a high pressure gauge at the “M4” port of the 1. Install a high pressure gauge at port “MS2”.
main valve block.
2. Install the Turntable lock pin.

2. Activate lift down to the end of stroke. The gauge
should read 2850 psi. (196 bar). The adjustment car- 3. Activate swing right, the gauge should read 2000 psi.
tridge is located to the left of the “M4” gauge port. Turn The adjustment cartridge is located at beside the “MS2”
clockwise to increase, counterclockwise to decrease. gauge port. Turn clockwise to increase, counterclock-
wise to decrease.
3121619 – JLG Lift – 5-117

4. Install gauge at MS3, Activate swing left, the gauge TELESCOPE OUT
should read 2000 psi. (138 bar), The adjustment is
NOTE: NEVER increase telescope out pressure to achieve desired
located at 9 o’clock beside port 3, Turn clockwise to telescope length.
increase pressure, counter clockwise to decrease pres-
sure. 1. Install a high pressure gauge at the “M8” port of the
main valve bank.
2. Plug the telescope out hose either at the valve bank

(port #8) or at the inlet of the telescope cylinder (V1).
Activate telescope out. The gauge should read 3000 psi
(207 Bar). The adjustment cartridge is located at 2
o’clock adjacent to M8 gauge port. Turn clockwise to
increase, counter clockwise to decrease.
5-118 – JLG Lift – 3121619

2. Plug the telescope in hose either at the valve bank (port

#7) or at the inlet of the telescope cylinder (V2).
TELESCOPE IN
1. Install a high pressure gauge at the “M7” port of the 3. Activate telescope in. The gauge should read 3300 psi.
main valve block. (227 bar). The adjustment cartridge is located at 3
o’clock adjacent to “M7” gauge port. Turn clockwise to
increase, counterclockwise to decrease.
3121619 – JLG Lift – 5-119

3. Adjustments Made at the Frame Valve Bank 3. Turn clockwise to increase, counterclockwise to
decrease.
AXLE EXTEND AND RETRACT, FRONT AND REAR
1. To extend the axles drive the machine back and forth
until extended. A machine that cannot be driven must
be jacked up.
2. On both the front and rear frame valve banks install a
high pressure gauge on ports “MA1” for retract and
“MA2” for extend. The gauge should read 2500 psi. for
both directions.
5-120 – JLG Lift – 3121619

STEERING, FRONT AND REAR 4. Adjustments Made at the Platform Valve Bank
1. The axles must be extended to set the steer pressures.
PLATFORM LEVEL UP
2. Install a high pressure gauge at “MS2” and “MS4” gauge
ports for steer right (extend), adjust to 2000 psi, and 1. Install a high pressure gauge at gauge port “ML1”.
“MS1 and “MS3” for steer left (retract), adjust to 2600 psi,
on both the front and rear valves. Each relief valve is
located next to its own gauge port. Turn clockwise to
2. Activate level up to the end of stroke, the gauge should

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

1. Install a high pressure gauge at gauge port “ML2”.
3121619 – JLG Lift – 5-121

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

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

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

arrow key until ACCESS LEVEL 2 is reached. Press ENTER
.
5. Using the arrow keys, enter access code 33271 and press
2. Using the analyzer and “set pressures” menu, select jib
lock pin extend. This is the bottom relief valve on the
platform valve. Turn CW to increase and CCW to ENTER .
decrease pressure.
5-122 – JLG Lift – 3121619

6. Using the arrow keys scroll until MENU: SERVICE MODE is

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

.
OVERRIDE: OFF. Use the UP or DOWN arrow

keys to toggle the override from Off to On.
10. Once turned on, operate the Jib Lift Up function. This
will activate the jib level up function.
3121619 – JLG Lift – 5-123

11. When the function bottoms out, pressure should read 6. Using the arrow keys scroll until MENU: SERVICE MODE is
2600 psi.(180bar).
12. If necessary to adjust pressure, CW increases and CCW reached. Press ENTER .
decreases setting. Jib level up adjustment is adjacent to
MLB.
JIB LEVEL DOWN

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

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

arrow key until ACCESS LEVEL 2 is reached. Press ENTER
.
5. Using the arrow keys, enter access code 33271 and press
ENTER .
5-124 – JLG Lift – 3121619

10. Once turned on, operate the Jib Lift Down function. This
will activate the Jib Level Down function.
8. Enter code 58237 and Press ENTER . The screen
should read SERVICE MODE: JIB & SWING AND JIB LEVEL. 11. When the cylinder is completely retracted, the pressure
should be 1500 psi. (104bar). CW increases and CCW
decreases setting. Jib level down adjustment is adjacent
to MLA.
12. 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.
13. Go to the Diagnostics/Boom Sensors menu. Use the
Right arrow key until reaching the "Jib Level CNTL: Angle
9. Press ENTER again. The screen will read JIB LEVEL 0.0" screen.
OVERRIDE: OFF. Use the UP or DOWN arrow

keys to toggle the override from Off to On.
NOTE: Using this override may set the Jib Leveling System Fault,
depending upon how far out of level the jib is moved.
3121619 – JLG Lift – 5-125

14. Adjust the jib level using the JIB TELESCOPE IN

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

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

3. Set pressure at 2850 psi. (197bar). CW increases and
CCW decreases setting. Adjustment is the one closest to
MTB.
5-126 – JLG Lift – 3121619

JIB LIFT UP JIB LIFT DOWN

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

and Counterclockwise decreases setting. Adjustment is 3. CW increases and CCW decreases setting. Adjustment is
on the boom side of MJB. on the boom side of MJA.
3121619 – JLG Lift – 5-127

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

pump.
LOOP FLUSHING RELIEF

1. Install pressure gauge at port MP on traction valve.
2. With the drive hubs disconnected, start the engine.
2. With hubs still disconnected energize Drive, adjust loop
flushing valve to obtain gauge reading of 350psi (24bar).
Clockwise increases pressure, counter clockwise
decreases.
5-128 – JLG Lift – 3121619

5.7 DRIVE PUMPS 2. Transmission does not propel the machine, diesel
engine running properly - Charge Pump/Relief Valve
Troubleshooting Procedure a. Is there any charge pressure at port G or indicated
by measuring pressure at Ma and Mb?
To aid in troubleshooting, refer also to the pressure measuring No - Proceed to step 2.d
port connections for test gauge installation information as Yes - Proceed to step 2.b
shown on the hydraulic circuit diagram. Procedure assumes
b. Is the charge pressure at least 500 psi while running
proper gauges are installed. (Minimum gauges required: (2) 0-
at high engine speed?
6000 psi, (1) 0-3000 psi & (1) 0-1000 psi [{2} 0-415 bar, {1} 0-210
No - Proceed to step 2.c
bar & {1} 0-70 bar]). This procedure was written to aid the trou-
Yes - Proceed to step 3.a
bleshooter in following a logical approach to a hydraulic sys-
tem fault. c. Can the charge pressure be raised by removing dirt/
debris from charge relief poppet or by adding or
1. Transmission does not propel the machine, diesel
removing shims from the charge pressure relief
engine running properly
valve mounted in the second pump of the triple?
a. Is there oil in the reservoir? No - Proceed to step 2.d
No - Fill reservoir Yes - Adjust pressure to 500 psi +50 psi, -0 psi (34.4
Yes - If yes, proceed to step 1.b bar +3.4 bar, -0 bar)
b. Is the pump input shaft connected to the engine NOTE: The propulsion circuit uses a hot oil flushing valve to
flex plate or rear of forward pump? obtain brake release pressure. The hot oil flushing valve
No - Connect pump input shaft cartridge (#120) is mounted in the Traction Control Mani-
Yes - If yes, proceed to step 1.c fold. The flushing valve receives its oil from the "left side"
c. Are the hydraulic hoses and tubing connected in wheel drive pump; the middle pump of the triple. With the
accordance with the hydraulic circuit diagram? engine running and propelling the machine forward or
reverse, the "hot oil flushing valve" and the brake release
No - Correct the hoses/tubing pressure must be adjusted to 475 psi, +25 psi, -0 psi (32.7
Yes - If yes, proceed to step 1.d bar, +1.7 bar, -0 bar), as set by adjusting pressure relief car-
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 rota- d. Is the transmission pumps suction hose pinched
tion shut?
Yes - If yes, proceed to step 1.e No - Proceed to step 2e
e. Are there O-rings missing from fittings (as example - Yes - Repair damaged hose
suction leak), pinched hoses, broken tubing, etc? e. Is the charge pump suction pressure/vacuum within
recommended limits? (0.8 bar absolute or 6.3 inches
No - Proceed to step 1.f of mercury)
Yes - Repair damage or fault No - Proceed to step 2.f
f. Are the electrical connectors/wiring intact and Yes - Proceed to step 2.g
secure to the pump control solenoids? f. Is the suction strainer inside the reservoir blocked,
No - Repair damage or fault clogged, restricted?
Yes - If yes, proceed to step 1.g 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? g. Is the reservoir air breather blocked or restricted?
No - Proceed to step 1.h No - Proceed to step 2.h
Yes - Check brake release circuit, measure pressure Yes - Clean or replace air breather
at port "MP" on Traction Control manifold
h. Are all four wheel drive planetary reduction gear-
boxes engaged?
No - Engage wheel drive(s)
Yes - If yes, proceed to step 2.a
3121619 – JLG Lift – 5-129

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: (Ensure 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 ensure 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 ensure
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
5-130 – JLG Lift – 3121619

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 - Ensure 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.
3121619 – JLG Lift – 5-131

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 ensure
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 diesel engine capable of developing horsepower
No - Operate transmission. Check oil cooler more at design rpm?
often. Follow recommended troubleshooting procedures
Yes - Proceed to step 8.a to ensure engine is developing full power at speci-
10. Transmission Operates at a Higher than Normal Temper- fied 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,
ensure charge pressure relief valve is clean of any dirt or
debris. The charge pressure relief valve does not wear appre-
ciably 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).
5-132 – JLG Lift – 3121619

NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are avail- Hydraulic Centering of Control Modules
able in 0.3, 0.5, and 1.0 mm thickness.
PREPARATION FOR ADJUSTMENT

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

The control piston has strong centering springs to ensure that
once the pump is adjusted for the neutral position it will
always return to neutral. If an adjustment is necessary follow
the steps listed below.
To ensure there is equal pressure on both sides of the control
module during the centering operation, it is necessary to con-
nect the X1 and X2 ports together by means of hose or tubing.
(No less than a 1/4 inch ID) The port sizes are:
Pump Size Allen Wrench Wrench
28 5 mm 17 mm
With pressure gages installed at MA, and MB, and with A and B
ports blocked (or motor stalled), and with the pump running, The adjustment screw is an eccentric, therefore, turning more
loosen the jam nut. Turn the mechanical centering adjusting
than 90’ in either direction will have no further centering
screw until 1000 psi is read on MA, or MB then turn screw
effect, and could cause damage to the eccentric pin.
opposite direction until 1000 psi is read on other pressure
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-
3121619 – JLG Lift – 5-133

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 5-33. Torque Specs for Relief Valves into Port Block
Pump Size Wrench Size Torque

28 32 mm 66 ft.lb. (90 Nm)
5-134 – JLG Lift – 3121619

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.
3121619 – JLG Lift – 5-135

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 MAINTENANCE ERRORS
OCCUR DURING AN OIL CHANGE DUE TO: 5. Oil Level Inspection
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-
• USE OF OIL CONTAMINATED DUE TO POOR STORAGE PRACTICES
fluid #424, Product #52233-4.
• FAILURE TO CLEAN THE RESERVOIR
c. Do Not Mix Fluids.
• INADEQUATE CLEANLINESS WHEN FILLING THE RESERVOIR (DIRTY
DRUMS, CONTAINERS, WATER, ETC) 6. Hydraulic Fluid - The "Life Blood" of the Machine
3. Leakage Inspection a. The type of hydraulic fluid supplied in the machine

from the factory was selected after extensive testing
a. After commissioning
and development. The fluid was selected to perform
b. The complete transmission drive system (pumps, under "most" applications and conditions. Should
motors, hosing, filters, valves, etc.) should be this machine be in service for extended time peri-
checked for leakage at regular intervals. ods at the extremes (hot or cold), JLG should be con-
c. Leaking joints & connections must only be tight- sulted for assistance in selection of the most
ened when pressureless. suitable fluid type and grade for your application.
4. Cleanliness Inspection b. When operating at temperatures below 0oF, allow a

a. The oil tank breather should be regularly cleaned of warm-up period, if at all possible, to a temperature
dirt and dust to prevent clogging. With each cylin- of 40oF.
der movement, gallons of oil pumped, an equal
c. When beginning motion of a "cold" machine, oper-
amount of air exchange occurs across the reservoir
ate all functions at reduced speeds until the "cold"
breather. A dirty or clogged breather will affect all
oil has circulated out of the drive loop.
machine functions!
5-136 – JLG Lift – 3121619

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.
3121619 – JLG Lift – 5-137

5.8 FUNCTION PUMP
Figure 5-129. Function Pump Components
Pump Operation Load Sensing (LS) control with Pressure

The variable pump converts input torque to hydraulic power.
Compensator (PC)
Rotational force is transmitted through the input shaft to the
cylinder block. The input shaft is supported by tapered roller
bearings at the front and rear of the pump and is splined into
the cylinder block.
The cylinder block contains nine pistons. Each piston has a

brass slipper connected at one end by a ball joint. Slippers are
held to the swashplate by the spring retainer and block spring.
The block spring holds the cylinder block to the valve plate.
Reciprocating movement of pistons occurs as slippers slide
against the inclined swashplate during rotation.
The bias spring pushes against the servo piston which pulls Figure 5-130. Control Assembly Components
the swashplate causing the pump to stroke. Internal pressure
on the servo piston acts against the bias spring to reduce The LS control consists of two spool valves that connect the
swashplate angle causing the pump to de-stroke. Swashplate servo piston either to pump case or system pressure.
angle determines pump outlet flow. The pump control sets The PC spool controls the pressure-compensating function of
swashplate angle by metering system pressure to the servo the control. The LS spool controls the load-sensing function.
piston. The PC spool has priority over the LS spool.
5-138 – JLG Lift – 3121619

Control Adjustment 2. Start prime mover and allow fluid to reach normal oper-
ating temperature. Operate a hydraulic function to its
full extension, loading the pump at maximum pressure
and zero flow.
ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN HAVE
SUFFICIENT FORCE TO PENETRATE SKIN CAUSING SERI- 3. Loosen PC set screw and turn PC adjusting plug until
OUS INJURY AND/OR INFECTION. RELIEVE PRESSURE IN 4100 psi (283 bar) is indicated on pressure gauge at port
SYSTEM BEFORE REMOVING HOSES, FITTINGS, GAUGES, M1. Clockwise rotation increases pressure, counterclock-
OR COMPONENTS. wise rotation decreases; approximate gain 610 psi (42
bar) per turn.
NOTE: If pressure does not increase, an external system relief valve

UNINTENDED MOVEMENT OF MACHINE OR MECHANISM may require adjustment. External system relief valve must
MAY CAUSE INJURY TO TECHNICIAN OR BYSTANDERS. be set above PC setting for proper operation.
SECURE MACHINE OR DISABLE/DISCONNECT MECHANISM
WHILE SERVICING. 4. Hold PC adjusting plug in position. Torque PC set screw
to 5.5 - 8 lb ft-lb (7.5 -10.8 Nm). Stop prime mover,
remove pressure gauges, and return system to normal
CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID THE MAN- operating configuration.
UFACTURER’S WARRANTY. TAKE PRECAUTIONS TO ENSURE SYSTEM CLEANLI- NOTE: If pressure does not increase, an external system relief valve
NESS WHEN REMOVING AND REINSTALLING SYSTEM LINES. may require adjustment. External system relief valve must
be set above PC setting for proper operation.
PC CONTROL SETTING
1. Install pressure gauge in port M1 to measure system
pressure. Install pressure gauge in case drain port L1 or
L2 to measure case pressure.
Figure 5-131. PC Control Setting
3121619 – JLG Lift – 5-139

LS CONTROL SETTING 8. Holding LS adjusting plug in position. Torque LS set

screw to 5.5 - 8 ft-lb (7.5 - 10.8 Nm).
5. Install pressure gauge in port M1 to measure system
pressure. Install pressure gauge in drain port L1 or L2 to 9. Operate a hydraulic function to its full extension loading
measure case pressure. Tee-in a gauge to the LS/remote the pump at maximum pressure and zero flow.
PC signal line (port X). NOTE: Set load sensing pressure with .8 mm choke OFF.
6. Start prime mover and allow fluid to reach normal oper-
ating temperature. Slowly operate a hydraulic function 10. Loosen PC set screw and turn PC adjusting plug until
that will demand approximately half flow from pump, 300 psi (21 bar) is indicated on pressure gauge at port
but keep system pressure below PC set point. M1. Clockwise rotation increases pressure, counterclock-
wise rotation decreases it; approximate gain = 610 psi
7. Loosen LS set screw. While watching pressure gauges, (42 bar) per turn.
turn LS adjusting plug until desired pressure differential
11. Holding PC adjusting plug in position. Torque PC set
between port M1 and port X is achieved. Clockwise rota-
screw to 5.5 - 8 ft-lb (7.5 - 10.8 Nm).
tion increases setting, counterclockwise rotation will
decrease it; approximate gain = 250 psi (17 bar) per turn. 12. Stop prime mover, remove pressure gauges, and return
system to normal operating configuration.
Figure 5-132. LS Control Setting
5-140 – JLG Lift – 3121619

Troubleshooting
EXCESSIVE NOISE OR VIBRATION
Check fluid in reservoir. Insufficient hydraulic fluid causes cavitation. Fill reservoir to proper level.
Check for air in system. Air in system causes noisy, erratic control. Purge air and tighten fittings. Check inlet for leaks.
Check pump inlet pressure/vacuum. Improper inlet conditions cause erratic behavior and low Correct pump inlet pressure /vacuum conditions.
output flow.
Inspect shaft couplings. A loose or incorrect shaft coupling causes excessive noise Repair or replace coupling. Ensure correct coupling is
and/or vibration. used.
Check shaft alignment. Misaligned shafts create excessive noise and/or vibra- Correct shaft misalignment.
tion.
Hydraulic fluid viscosity above acceptable limits. Hydraulic fluid viscosity above acceptable limits or low Allow system to warm up before operating, or use fluid
fluid temperature will not allow pump to fill or control to with appropriate viscosity grade for expected operating
operate properly. temperatures.
SLOW ACTUATOR RESPONSE

Check external system relief valve Low external relief valve setting slows down system. Adjust external relief valve setting following manufac-
setting. turer’s recommendations. External relief setting must be
above PC setting to operate properly.
Check PC and LS control setting. Low PC setting prevents the pump from achieving full Adjust PC and LS setting.
stroke. Low LS setting limits output flow.
Check LS control signal pressures. Incorrect LS signal will not allow pump to operate cor- Inspect system to ensure that proper LS signal transmit to
rectly. pump.
Internal system leaks. Worn internal parts don’t allow pump to operate prop- Refer to Authorized Service Center for required repair.
erly.
Hydraulic fluid viscosity above Hydraulic fluid viscosity above acceptable limits or low Allow system to warm up before operation or sue fluid
acceptable limits. fluid temperature will not allow the pump to fill or con- with the appropriate viscosity grade for expected operat-
trol to operate properly. ing temperatures.
Check external system valving. Malfunctioning valving may not allow system to respond Repair or replace system valving as required.
properly.
Check pump case pressure. High case pressure causes the system to be sluggish. Correct case drain line restrictions.
Check pump inlet pressure/vacuum. High inlet vacuum causes low output flow. Correct inlet pressure conditions.
3121619 – JLG Lift – 5-141

SYSTEM OPERATING HOT

Check fluid level in reservoir. Insufficient volume of hydraulic fluid will not meet sys- Fill reservoir to proper level. Verify proper size of reser-
tem cooling demands. voir.
Inspect heat exchanger. Check air flow and input air tem- Insufficient air flow, high input air temperature, or Clean, repair, or replace heat exchanger as required. Ver-
perature for heat exchanger. undersized heat exchanges will not meet system cooling ify proper size of heat exchanger.
demands.
Check external system relief valve setting. Fluid passing through relief valve adds heat to system. Adjust external system relief valve setting following
manufacturer’s recommendations. External relief
valve setting must be above PC setting for proper opera-
tion.
Check pump inlet pressure/vacuum. High inlet vacuum adds heat to system. Correct inlet pressure/vacuum
conditions.
LOW PUMP OUTPUT

Check fluid level in reservoir. Insufficient hydraulic fluid will limit output flow and Fill the reservoir to proper level.
cause internal damage to pump.
Hydraulic fluid viscosity above Fluid viscosity above acceptable limits or low fluid tem- Allow system to warm up before operating, or use fluid
acceptable limits. perature will not allow the pump to fill or control to oper- with the appropriate viscosity grade for expected operat-
ate properly. ing temperatures.
Check external system relief valve Eternal relief valve set below PC setting causes low out- Adjust external relief valve following manufacturer’s
setting put flow. recommendation. External relief valve setting must be
Check PC and LS control setting. Low PC setting prevents the pump from achieving full Adjust PC and LS setting.
stroke.
Check pump inlet pressure/vacuum. High inlet vacuum causes low output flow. Correct inlet pressure conditions.
Check input speed. Low input speeds decrease flow. Adjust input speed.
Check pump rotation. Incorrect rotational configuration causes low flow. Use pump with appropriate rotational configuration.
UNSTABLE PRESSURE OR FLOW

Check for air in system. Air in system causes erratic operation. Activate PC allowing system to bleed air. Check inlet line
for leaks and eliminate source of air ingression.
Check control spools. Sticking control spools cause erratic operation. Inspect spools for free movement. Clean or replace.
Check LS setting. Low LS setting may cause instability. Adjust LS setting to proper level.
Check LS signal line. Blocked LS signal line interferes with proper LS opera- Remove blockage.
tion.
Check external relief valve and PC setting. Insufficient pressure differential between PC setting and Adjust external relief valve or PC control settings to
external relief valve. appropriate level. Relief valve setting must be
Check external relief valve. Chattering external relief valve may cause unstable feed- Adjust or replace relief valve.
back to pump control.
5-142 – JLG Lift – 3121619

SYSTEM PRESSURE NOT REACHING PC SETTING

Check PC control setting. System pressure will not rise above PC setting. Adjust PC to appropriate setting.
Check external relief valve. External relief valve setting below PC setting presents Adjust external relief valve according to manufacturer’s
pressure compensation. recommendations. External relief valve must be set
Inspect PC control spring. Damaged or missing spring will cause erratic operation. Replace spring as required.
Inspect PC spool for wear. Wear of PC spool causes internal leakage in control. Replace spool as required.
Inspect PC spool for proper orientation. Improper orientation results in poor operation. Correct orientation of spool.
Check PC control for contamination. Contamination may interfere with movement of PC Clean PC control components. Take appropriate action to
spool. eliminate contamination.
HIGH INLET VACUUM
HIGH INLET VACUUM CAUSES CAVITATION WHICH CAN DAMAGE INTERNAL

PUMP COMPONENTS.

Check fluid temperature. Low temperature increases viscosity. High fluid viscosity Allow system to warm up before operating.
causes high inlet vacuum.
Inspect inlet screen. Blocked or restricted inlet screen. Clean screen/remove blockage.
Check inlet piping. Too many fittings, bends, or long piping causes high inlet Eliminate fittings to make path more direct.
vacuum.
Hydraulic fluid viscosity above acceptable limits. High fluid viscosity causes high inlet vacuum. Select fluid with appropriate viscosity for expected oper-
ating temperature.
3121619 – JLG Lift – 5-143

12
13
11
14
10
9
8
7 12
6
3
50 2
49 1
48 47 5
46 4
45
43*** 16
55 21
44* 22 17
54 40** 18
53 23
52 39 24 19
51 39 41
39 20
40** 42 40**
37
36 38 27
35 39
40**
34 25
33**** 28 26
29 *Torque to 5.5 - 8 ft-lb (7.5 - 10.8 Nm)
30 **Torque to 8 - 10 ft-lb (10.8 - 13.5 Nm)
31 ***Torque to 4 - 5.5 ft-lb (5.4 - 7.5 Nm)
****Torque to 94 - 114 ft-lb (127 - 155 Nm)
32
1001169892
1. Piston Ring 12. Plug 23. Spring Retainer 34. End Cap 45. Spring Guide
2. Servo Piston 13. O-Ring 24. Retaining Ring 35. Orifice Backup Plug 46. Inner Spring
3. Bias Spring 14. Lip Seal 25. End Cap Seal 36. Orifice 47. Outer Spring
4. Swashplate 15. Retaining Ring 26. Valve Plate 37. O-Ring 48. Backup Ring
5. Shaft 16. Piston Assembly 27. Slotted Pin 38. PC Spool 49. O-Ring
6. Retaining Ring 17. Slipper Retainer 28. Bearing Cone 39. O-Ring 50. LS Adjustment Screw
7. Swashplate Bearing 18. Slipper Retainer Guide 29. Bearing Cup 40. Plug 51. Spring Guide
8. Shaft 19. Hold-Down Pin 30. Poppet 41. LS Spool 52. Inner Spring
9. Bearing Cup 20. Cylinder Block 31. Spring 42. Control Housing 53. Outer Spring
10. Bearing Cone 21. Washer 32. Coupling 43. Capscrew 54. O-Ring
11. Housing 22. Block Spring 33. Capscrew 44. Setscrew 55. PC Adjustment Screw
Figure 5-133. Piston Pump Assembly
5-144 – JLG Lift – 3121619

Disassemble Pump 7. Set housing on side to allow fluid to drain.

8. Prevent shaft (8) from moving. Remove cylinder block
1. Remove coupling (11) from endcap (34).
assembly (20) from housing (11).
2. Remove four capscrews (43) and control assembly (42)
9. Set cylinder block on a clean dry surface.
from endcap (34).
3. Remove and discard four 0-rings (37).
11
43
20 8
42
37
34
Figure 5-136. Cylinder Block Removal

32
10. Position pump with shaft pointing down.
11. Pull shaft (8) from housing (11).
12. Compress bias spring (3). Rotate servo piston assembly
Figure 5-134. Coupling and Control Removal (2) towards swashplate (4).
13. Lift swash plate/servo piston assembly up at an angle
4. Remove four capscrews (33) and endcap (34). Keep valve
and remove it from housing.
plate (26) from falling off.
14. Remove snap ring (6), clevis pin (5), servo piston (2), and
5. Place endcap and valve plate in a clean area to protect
bias spring (3) from swash plate (4). Discard snap ring.
from contamination.
15. Remove three O-rings (1) from servo piston (2). Discard
6. Remove bearing cup (29) bearing cone (28) and 0-ring
O-rings.
(25). Discard 0-ring.
11 11
6
27
3
34
2
1
33
25
5
28 26
29 4
Figure 5-135. Endcap Removal Figure 5-137. Swash Plate and Servo Piston Removal
3121619 – JLG Lift – 5-145

16. Remove tapered roller bearing cup (10) and cone (9). DISASSEMBLE PC/ LS CONTROL
17. Examine cradle bearings (7) to determine if they need 1. Remove four plugs (40) and 0-rings (39). Discard 0-rings.
replacement.
2. Remove two set screws (43).
NOTE: Spools must be reinstalled in original bores in same direc-

REMOVING PINS WILL DAMAGE CRADLE BEARINGS. MAKE SURE YOU HAVE tion as removed. Note orientation of each spool for reinser-
REPLACEMENT BEARINGS BEFORE REMOVING PINS. NOTE LOCATION AND tion.
ORIENTATION OF BEARINGS FOR RE-INSTALLATION.
3. Remove PC spool (41). Remove LS spool (38).
18. If cradle bearings need replacing, remove two pins (7A) 4. Remove adjusting screw (54) and 0-ring (53). Discard O-
from cradle bearings (7). Remove cradle bearings. ring. Remove outer spring (52), inner spring (51), and
19. Place housing (11) with flange facing up. spring guide (50).
20. Remove snap ring (15). Carefully pry out shaft seal (14). If 5. Remove adjusting screw (49), 0-ring (48) and 2 backup
you are unable to pull shaft seal out, try to push seal out rings (47). Discard 0-ring and backup rings.
through inside of housing. 6. Remove outer spring (46), inner spring (45), and spring
guide (44).
14
11 50
49
48
47
46
7 45
7A 55
54 44
40
10 53
52 39
9 51 39 41
39
40
42
36 40
38
Figure 5-138. Housing Bearing and Seal Removal 35 39
Figure 5-139. Control Disassembly
5-146 – JLG Lift – 3121619

DISASSEMBLE CYLINDER BLOCK Inspection

1. Pull to remove slipper retainer (17) with pistons (16) Wash all parts (including end-cap and housing) thoroughly
from cylinder (20). with clean solvent and allow to air dry. Blow out housing and
NOTE: Units with high hourly usage may develop wear patterns. end cap oil passages with compressed air. Conduct inspection
Number pistons and bores for reassembly if reused. in a clean area and keep all parts free from contamination.
Clean and dry parts again after any rework or resurfacing.
2. Remove ball guide (18).
PISTONS AND SLIPPERS
3. Remove three pins (19).
1. Inspect pistons for damage and discoloration. Discol-
NOTE: Most repairs do not require block spring removal. Perform ored pistons may indicate excessive heat; do not reuse.
this procedure only if you suspect problems with the block
2. Inspect running surface of slippers. Replace piston
spring.
assemblies with scored or excessively rounded slipper
edges. Measure slipper foot thickness. Replace exces-
sively worn slippers. Check slipper axial end-play.
Replace piston assemblies with excessive end-play.
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK
SPRING REQUIRES ABOUT 80 - 90 LBF (350 - 400 N). USE A
PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REA-
SONABLE EFFORT. ENSURE SPRING IS SECURE BEFORE Maximum End Play
ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. 0.002 in (0.05 mm)
RELEASE PRESSURE SLOWLY AFTER RETAINING RING IS
REMOVED. Minimum Slipper Slipper
4. Turn block over. Using a press, apply pressure on block Foot Thickness
0.127 in (3.23 mm)
spring washer (23) to compress block spring (22).
Remove retaining ring (24). Carefully release pressure
and remove outer block spring washer (23), block spring
(22), and inner block spring washer (21) from cylinder
block.
Figure 5-141. Piston and Slipper Wear Measurement
BALL GUIDE, SLIPPER RETAINER, AND HOLD DOWN

PINS
16
1. Ball guide should be free of nicks and scratches, and not
21 17
excessively scored. Examine for discoloration that may
22 18
23 19 indicate excessive heat or lack of lubrication.
24
2. Slipper retainer should be flat. Slippers should fit in
20
retainer with minimal side play. Place hold-down pins
on a flat surface and roll them to make sure they are
straight. Replace any damaged parts.
Figure 5-140. Cylinder Block Disassembly BLOCK SPRING, AND WASHERS

Cylinder block, spring, and washers should show minimum
wear. Replace if cracks or other damage is present.
3121619 – JLG Lift – 5-147

CYLINDER BLOCK JOURNAL BEARINGS

Examine cylinder block running face. Surface should be Inspect journal bearings for damage or excessive wear.
smooth and free of nicks and burrs. Ensure no scratches or Replace journal bearings if scratched, warped, or excessively
grooves exist; these may drastically reduce output flow. worn. Polymer wear layer must be smooth and intact.
VALVE PLATE
Maximum bore diameter
0.785 in (19.8 mm) 1. Inspect valve plate for scratches and grooves. Check for
evidence of any cavitation along the running face. If pit-
ting from cavitation exists, replace valve plate.
2. Check for excess wear on brass running face. If any dis-
Minimum Cylinder coloration or burn marks are observed, replace valve
Block Height plate.
2.45 in (62.25 mm)
3. Run a fingernail or pencil tip across diameter of sealing
land surface. Deep or outstanding grooves may
decrease pump flow. Lap or replace if grooves or nicks
Flat to 0.000079 in are present. Inspect mating surfaces of end cap and
(0.002 mm) valve plate for contamination; even a few thousandths
of an inch may affect pump operation.
Figure 5-142. Cylinder Block Wear Measurements
4. Measure thickness of valve plate. Ensure valve plate par-
allelism is equal to or less than 0.001 in (0.025 mm).
CONTROL
Appearance should be flat and smooth running face and
1. Examine PC and LS plugs for signs of wear. Check small bottom surface.
tip of plugs for heavy wear and replace if necessary.
5. Valve plate should be flat to 0.0002 in (0.005 mm) con-
2. Inspect spool springs to make sure they are intact. vex. A magnetic particle inspection is recommended to
Check inside and outside surfaces of springs for wear detect cracks. Valve plate must be replaced if any cracks
and replace if necessary. exist.
3. Check spool's outside diameter for scratches and burrs.
0.153 in (3.88 mm ) Min
Clean and coat all spools, bores, and seals with a light
coating of hydraulic oil.
0.001 in
INPUT SHAFT (0.025 mm)
1. Check shaft and splines are straight and free of damage
or heavy wear. Inspect shaft surface where it meets shaft
seal. Replace shaft if a groove exists at sealing land sur- 0.0002 in
face that may let dirt into or hydraulic fluid out of unit. (0.005 mm)
Convex Max
2. Clean sealing area with a nonabrasive material if neces-
sary. Lubricate shaft with a light coat of hydraulic fluid.
SWASH PLATE
1. Inspect each surface of swash plate for wear. All swash
plate surfaces should be smooth. Inspect swash plate's
slipper running surface for damage and brass transfer. Figure 5-143. Valve Plate Wear Measurements
Excessive brass transfer from slippers may indicate they
should be replaced.
2. Check swash plate bearing journal for scratches. Replace
swash plate if necessary
5-148 – JLG Lift – 3121619

ENDCAP Assembly
1. Inspect endcap (34). Remove poppet (30) and spring
(31). BEARINGS, SWASH PLATE, AND SHAFT
2. Check and record orientation of timing pin (27). Split in NOTE: If journal bearings are reused, reinstall in original orienta-
timing pin should be face in or out of slot in valve plate. tion and position.
3. Inspect poppet for wear on sealing face and replace if 1. Coat journal bearings (7) with hydraulic fluid and install
necessary. Make sure spring is undamaged. Replace any in pump housing (11). Punch in retaining pins (7A) a
components if excess wear is present. minimum of 0.002 in (0.5 mm) below bearing surface.
2. Reinstall shaft bearing cup (10) and cone (9).
34
27 11
30
7
31
7A
10
9
Figure 5-144. Endplate Inspection
Figure 5-145. Bearing Installation

SERVO PISTON
Check servo piston assembly for wear or damage. Check corre-
3. Install three O-rings (1) on servo piston (2). Insert servo
sponding endcap bore for galling or excessive wear. Replace
piston through spring (3) and align hole with swash
piston if damaged.
plate (4) mounting holes. Secure with clevis pin (5) and
split ring (6).
HOUSING
Inspect housing is clean and free of foreign material. Inspect 4. Coat curved surface of swash plate (4) with hydraulic
swash plate bearing surfaces, and endcap mating surfaces. fluid.
SHAFT BEARINGS 5. Reinstall swash plate assembly in original orientation in

Tapered roller bearing consists of a cup and cone. Make sure housing.
cup and cone are free of excessive wear or contamination. 6. Lubricate all sides of the servo piston and its bore liber-
Rotate bearings to check for smoothness. If a contaminated ally with hydraulic oil. Rotate servo piston perpendicular
bearing is suspected, clean with a solvent and lubricate with to swash plate, and at the same time compress bias
hydraulic fluid. Replace bearing if problem is not remedied by spring to fit into housing pocket.
cleaning. Inspect for uneven wear. If abnormal wear is found,
replace bearing. 7. Lubricate flat face of swash plate to prevent premature
wear during start-up.
3121619 – JLG Lift – 5-149

8. Insert input shaft (8) through bearing into housing (11). 6. Install slipper retainer (17) with concave side against
You may need to push on servo piston to rotate swash convex side of ball guide (18).
plate.
11
6
16
21 17
3
22 18
2 23 19
1 24
20
5
4
8
Figure 5-147. Cylinder Assembly
Figure 5-146. Swash Plate Installation
CYLINDER ASSEMBLY INSTALLATION
CYLINDER ASSEMBLY 1. Set pump on its side. Hold end of shaft (8) with one
hand and keep it horizontal. Install cylinder assembly
1. Coat all parts with hydraulic fluid before reassembly.
(20) on shaft.
2. Hold shaft still and slightly rotate cylinder block to help
start shaft splines over ball guide and align it with block
RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING
splines. When cylinder block kit slides completely over
REQUIRES ABOUT 80 TO 90 LBF (350 T O 400 N). USE A
shaft splines, reposition unit with flange facing down.
PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REA-
SONABLE EFFORT. ENSURE SPRING IS SECURE BEFORE
ATTEMPTING TO INS TALL SPIRAL RETAINING RING.
RELEASE PRESSURE SLOWLY AFTER RETAINING RING IS 11
INSTALLED.
2. Install inner block spring washer (21), block spring (22),
and outer washer (23) in cylinder block. Using a press,
20 8
compress block spring and install retaining ring (24) in
cylinder block groove.
3. Turn block over. Install three hold-down pins (19) and
ball guide (18) to cylinder block.
4. Install pistons (16) to slipper retainer (17). Install piston/
retainer assembly in cylinder block (20). Ensure concave
surface of retainer seats on ball guide. If reusing pistons,
install them to original block bores.
5. Lubricate pistons, slippers, retainer, and ball guide Figure 5-148. Cylinder Installation
before assembly. Set cylinder kit aside on a clean surface
until needed.
5-150 – JLG Lift – 3121619

VALVE PLATE AND ENDCAP clear retaining ring groove. Install retaining ring (15).
Remove installation sleeve.
1. Clean valve plate (26) and endcap (34). Install timing pin
(27) in endcap. Verify it is properly oriented with split
facing in or out of slot in valve plate (26) 0.14 ± 0.01
(3.61 ± 0.25 mm) above valve plate surface. 14 15
2. Apply a liberal amount of assembly grease to back side
of valve plate surface to hold it in position. Install valve
plate over timing pin, check valve, and bearing cup.
NOTE: To ensure proper pump operation, it is extremely impor-

tant there is no contamination between endcap and valve
plate.
3. Install bearing cone (28) on shaft. Using assembly grease

to hold seal (25), install endcap to housing. Ensure seals
remain properly seated and are not pinched during
assembly. Install and torque four capscrews (33) 94 - 114 Figure 5-150. Shaft Seal Installation
ft-lb (127 - 155 Nm), using an alternating pattern. Re-
torque the first screw to ensure proper torque retention. NOTE: Clean all control parts and apply a light coating of hydrau-
lic fluid before reassembly.
11
PC CONTROL ASSEMBLY
1. Clean all control parts and apply a light coating of
hydraulic fluid before reassembly.
27 2. Install spherical end of PC spool (38) in PC bore. Install
34 new O-ring (39) on PC plug (40.) Install and torque plug
8 - 10 ft-lb (10.8 - 13.5 Nm). Place inner PC spring (52)
33 and outer PC spring (53) on PC spring guide (51). Install
25 in PC bore. Place new 0-ring (54) on PC plug (55). Install
28 26
so it sits one turn below surface of control housing.
29
Install set screw (44). Torque to 5.5 - 8.0 ft-lb (7.5 to 10.8
Nm).
Figure 5-149. Valve Plate and Endcap Installation
SHAFT SEAL
1. Lubricate lip of new shaft seal (14) with clean hydraulic
fluid. Place protective sleeve over shaft end to prevent
damage to seal during installation. Install seal with
cupped side toward shaft bearing. Keep seal perpendic-
ular to shaft and press seal in housing just far enough to
3121619 – JLG Lift – 5-151

LS CONTROL ASSEMBLY CONTROL ASSEMBLY INSTALLATION

1. Hold control in a horizontal position. Install spherical 1. Using petroleum jelly to retain them, install four new
end of LS spool (41) in LS bore. Install new 0-ring (48) on seal rings (37) in control assembly (42) recesses.
LS Plug (50). Install LS plug and torque to 8 - 10 ft-lb
2. Install control assembly (42) on endcap (34) with four
(10.8 - 13.5 Nm). Place inner LS spring (46) and outer LS
capscrews (43). Torque to 4.0-5.5 ft-lb (5.4 to 7.5 Nm) in
spring (47) on LS spring guide (45). install in LS bore.
an alternating pattern. Re-torque the first screw for
Place a new 0-ring (C116) and back-up rings (C117) onto
proper torque retention.
the LS adjustment screw (C118).
3. Install coupling (32) on shaft (8).
2. Install LS plug assembly so it sits one turn below surface
of control housing. Install and torque set screw to (C1
02) 5.5 - 8.0 ft-lb (7.5 - 10.8 Nm). Install plugs (C105, C1
06) with new 0-rings. Torque plugs to 8 - 10 ft-lb (10.8 to 43
13.5 Nm).
3. Adjust PC and LS spools to proper setting according to
tag nomenclature.
42
50
49 37
48
47
46 34
45
55
54 44
40 32
53
52 39
51 39 41
39
40
42 Figure 5-152. Control Installation
36 40
38
35 39
Figure 5-151. Control Assembly
5-152 – JLG Lift – 3121619

5.9 DRIVE & FUNCTION PUMP START UP Brake release pressure is controlled by a pressure relief valve
cartridge # 130 and a solenoid operated brake release direc-
PROCEDURES tional control cartridge, #170, also located in the Traction Con-
trol Manifold.
Start-Up Procedure START-UP OF NEW OR OVERHAULED INSTALLATIONS:
The Boom Lift uses a Triple Combination Pump coupled to the 1. Ensure all electrical checks have been performed and
Deutz diesel engine. The pumps are connected in-line to each machine is set up correctly using JLG Analyzer.
other as follows: 2. Ensure machine has all four wheels jacked & blocked off
the ground per JLG procedures.
1. Front hydrostatic transmission pump, or drive pump, is
coupled directly to the diesel engine and provides oil 3. Ensure triple pump assembly is installed and connected
flow to operate the machine's right side wheels. correctly per hydraulic circuit diagram.
4. Disconnect electrical connector from diesel throttle
2. Middle hydrostatic transmission pump, or drive pump, is
actuator to prevent engine start.
coupled to back of the front pump and provides oil flow
to operate machine's left side wheels. 5. Crank the engine until charge pressure reaches 50 psi or
more.
3. Third or rear pump is the function pump. It is coupled to
the back of the middle pump and provides oil flow to 6. Re-connect throttle actuator electrical connector and
operate boom, axle, steer and platform functions. start engine. Allow engine to run at idle speed only for at
least 5 minutes. This will allow hydrostatic system to fill.
Transmission pumps share some common connections. Each 7. Listen for any abnormal noises.
pump charge oil suction ports are connected by steel tubing.
Charge pumps discharge oil flows are connected and flow to a 8. Check for oil leaks.
common charge pump in-line oil filter. Cleaned and filtered oil 9. Check charge pressure (500 psi +50psi, - 0 psi [34.4 bar
flows back to the transmission pumps "G" ports. Pump case +3.4 bar, - 0 bar]). Pressure can be measured a pump
drain ports are connected (T1 & T2). ports Ma & Mb or by "teeing" into charge oil filter inlet.
Charge pressure is checked with the joystick in neutral.
Oil flow from middle pumps T1 port flows to the oil cooler.
A 0-1000 psi (0-70 bar) pressure gauge must be used. (If
Charge pump oil pressure is regulated by a single boost oil
pressure gauges were installed in Ma & Mb to check
pressure relief valve installed in the middle pump. The front
charge pressure, disconnect the gauges installed in Ma
pump has an orifice cartridge (0.047" diameter) installed in
& Mb, as they will be damaged if loop pressure rises
place of a charge oil pressure relief cartridge. This ensures only
above 1000 psi [34.4 bar].)
one valve controls charge pressure and provides an amount of
charge oil flow to the front pump's case for flushing & removal 10. Operate drive system in "turtle mode" forward and
of hot oil. reverse.
Each pump has a separate electrical proportional directional 11. De-aerate system by bleeding fluid from Ma & Mb ports.
control valve to control oil flow and direction. Signals or com-
mand values to each pump are similar except when steering.
During steering and moving, the pump supplying oil to
"inside turning radius" has a command less than pump supply-
ing oil flow to "outside turning radius" pump.
"Posi-Traction" control, front to rear on each side of machine is
accomplished by a flow divider/combiner cartridge installed
in the Traction Control Manifold. There is a flow divider/com-
biner for each side. Each flow divider/combiner also has a
"bleed orifice" to limit amount of flow splitting or combining.
The middle transmission pump also supplies oil to a hot oil
flushing valve cartridge, #120, in the Traction Control Mani-
fold. This cartridge provides brake release oil pressure.
BRAKE RELEASE OIL PRESSURE MUST BE SET 25 PSI (1.7 BAR) BELOW BOOST
OIL PRESSURE RELIEF VALVE. IF BRAKE RELEASE PRESSURE IS SET TOO LOW,
BRAKE DRAG AND PUMP CONTROL WILL BE AFFECTED. IF SET TOO HIGH,
DAMAGE TO WHEEL DRIVE PARKING BRAKES COULD RESULT. CONNECT
APPROPRIATE PRESSURE GAUGES TO THE UNIT BEFORE STARTING.
3121619 – JLG Lift – 5-153

12. Switch drive mode speed control from "turtle" to "rab- 17. Check oil level & temperature.
bit". Gradually increase drive speed forward & reverse, 18. Remove and inspect charge pressure oil filter. Replace
still with no load - wheels off ground. with new element.
13. With joystick in neutral, check for creep in neutral. If evi- 19. Operate transmission under no load conditions for
dent, most likely dirt is present in the proportional about 15 minutes to stabilize temperature and remove
pump control, an incorrect electrical signal is present on any residual air from the fluid.
the pump's electrical control(s), or the control was not
centered properly when overhauled. See service manual 20. Lower machine to ground. Operate transmissions under
for centering instructions. full and normal conditions.
21. Erratic operation may indicate there is still air trapped in
14. Check controls are connected so transmissions operate
system. By working pump controls forward and reverse,
in correct direction related to control input.
remaining air can be eliminated. System is free of air
15. Continue to monitor all pressure gauges & correct any when all functions can be operated smoothly and when
irregularities. oil in reservoir is no longer aerated. (Usually less than
one hour of operation)
NOTE: Step 17 disables machine's ability to release brakes.
NOTE: If transmissions do not perform correctly after following
16. Remove brake coil (keep electrical connection intact) pre-start & start-up procedures, refer to relevant sections of
from brake release solenoid cartridge located on Trac- trouble-shooting procedures.
tion Manifold. Stroke transmission pumps slightly (less
than 20%) and check setting of 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.
5-154 – JLG Lift – 3121619

3121619 – JLG Lift – 5-155

8 7 6 5
TELE CYL LIFT CYL
TELESCOPE
BORE: 5.5 IN
ROD: 4.5 IN
STROKE 333.15 BORE: 8.0 IN
ROD: 7.0 IN
STROKE 84.9
LIFT
D
EXH RET EXT
V2 V1 MD
T2 7 M7 8 M8 4 M4 5 M5 5A
3300 psi 3000 psi

(227.5BAR) (206.8BAR)
A B
2850 psi
P T (196.5BAR)
TELE LIFT
DIRECTIONAL DIRECTIONAL A B
RETURN P T 3700 psi

PLATFORM (258.5BAR)
C T3
115 psi 15 psi
(7.9BAR) (1.03BAR)
AUX
LIFT
AUX PILOT
TELE
FLOW
CONTROL LIFT 15 psi
FLOW
MAIN
CONTROL
DUMP
REDUCING
3200 PSI
(220.7 BAR)
15 psi
15 psi (1.03BAR)
(1.03BAR)
B
MP P1 P2 LS T1
SWIVEL
PORT #1
RETURN FILTER IN
B10>=1000
TANK
43 PSI(3BAR) B6>=200
BYPASS 45PSI(3.1BAR)
BY PASS
500PSI
(34.5BAR)
4000PSI L1
(275.9BAR) APU
2800PSI
B L
(193BAR)
A VARIABLE PUMP
3.1 in3(51CC)
LOAD SENSE 500PSI
PRESSURE COMP
4000PSI
8 7 6 5
Figure 5-153. Hydraulic Schematic - Sheet 1 of 8
5-156 – JLG Lift – 3121619

4 3 2 1
SWING
DRIVES
SWING
B A
SWING
BRAKES
SWING
B A D
2 2A MS2 MS3 3 3A
2000PSI
(138BAR)
2000PSI
(138BAR) C
SWING
DIRECTIONAL A B
P TO JIB
a b
P T
VALVE
PLATFORM
FILTER
SWING RELIEF
3550 psi B10>=1000
FLOW
(245 BAR) 43 PSI(3BAR)
CONTROL
BYPASS
MP4
P4
15 psi PLATFORM
SUPPLY
CHASSIS
ENABLE B
MAIN PT1 MP5 P3 SWIVEL
CONTROL PORT 2
VALVE
1001149709 D
4 3 2 1
3121619 – JLG Lift – 5-157

8 7 6 5
SWIVEL SWIVEL FRONT DEPLOY CYLS

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

CYLINDERS BORE: 4.75 IN 17.72 SQ.IN
BORE: 5 IN 19.63 SQ.IN ROD: 1.75 IN 2.4 SQ.IN
A ROD:2 IN 3.14 SQ.IN ANNULAR: 15.32 SQ.IN
ANNULAR: 16.49 SQ.IN STROKE: 9.8 IN
STROKE: 14.24 IN
8 7 6 5
5-158 – JLG Lift – 3121619

4 3 2 1
SWIVEL SWIVEL
PORT#2 PORT#1 REAR DEPLOY CYLS
P T
2500 psi MA1 V2
(172.4bar)
A3
V2
A1
p a V1 V1
A14
t b
2500 psi
(172.4bar)
MA2
A2
C
2600 psi
(179.3bar)
S1
MS1
p a
RIGHT
MS2 FRONT
t b
STEER
S2
A9
2000 psi
(138bar)
2600 psi
(179.3bar)
S3 B
MS3
p a
RIGHT
MS4
t b REAR
S4 STEER
A10
2000 psi
(138bar)
RIGHT VALVE
PAGE 2.
AXLE/STEER CONTROL
1001149709 D
4 3 2 1
3121619 – JLG Lift – 5-159

8 7 6 5
M14
C1
FRONT
DRIVE
PUMP
D M3 MB MC
F00B F00A
L1
CW
L2
M5 M4 MA A B C D MD
C TO PORT P3, MAIN TO PORT T4, MAIN

CONTROL
CONTROL
VALVE PAGE 1 VALVE PAGE 1
PORT PORT
PORT PORT PORT #2 #1 SWIVEL PORT PORT
#7 #6 #5 PORTS #4 #3
D MP
REAR AXLE
A3
300 PSI
(20.7 BAR)
LEFT B
G
A G1
B3
B
TRACTION MANIFOLD
A5
RIGHT
B
G
A
G1
B1
BRAKE 2 SPEED
B6
B5 TS
BR TS A1
MBR
REAR DRIVE BRAKES
8 7 6 5
5-160 – JLG Lift – 3121619

4 3 2 1
M14
REAR
C2 C1 DRIVE CHARGE PUMP FILTER
PUMP B6>=200
BYPASS 50PSI
CHARGE PUMP
1.025 IN3
OIL COOLER OPTION

PORT L3 OF THE PUMP D
TO THE INLET OF THE
COOLER. COOLER OUTLET
FCOB FCOA
BACK TO TANK.
L3
CW
M5 M4
FRONT AXLE
LRFT
B
G
G1 A
RIGHT
B
G
G1 A
PAGE 3
DRIVE SYSTEM
SAUER DANFOSS
PUMPS
FRONT DRIVE BRAKES
1001149709 D
4 3 2 1
3121619 – JLG Lift – 5-161

8 7 6 5
D JIB ROTATOR
SPRING 3300 PSI
JIB LEVEL CYLINDERS JIB LIFT CYLINDER
BORE: 5.5” BORE: 5”
ROD: 2.5” ROD: 2.5”
STROKE: 16.59” STROKE: 25.15”
JIB TELESCOPE CYLINDER V1 T V2

BORE: 2.5”
ROD: 1.5”
V2 STROKE: 84.06” V2
V1
V1
C V2 V1
MLA LA LB MLB MTA TA TB MTB SA SB MJA JA JB MJB
2850 psi 1200 psi 2800 psi

1500 psi 2600 psi (196.6BAR) 2850 psi (82.8BAR)
(103.5BAR) (179.3BAR) (193.1BAR)
(196.6BAR)
T3
T2 0.3
GPM 2.0
B TO GR PORT ON
MAIN CONTROL GPM
VALVE
T1
MP
P1
TO PORT ON
HIGH PRESSURE
FILTER
P2 JIB CONTROL VALVE
8 7 6 5
5-162 – JLG Lift – 3121619

4 3 2 1
PLATFORM ROTATOR
SPRING 3000 PSI
D
BORE: 3.55”
ROD: 1.5”
STROKE: 14.79”
V1 T V2
JIB LOCK CYLINDER

BORE: 2.5”
ROD: 1.75”
STROKE: 13.375”
C
V1 V2
ML1 L1 L2 ML2 R1 R2 S1 S2
2500 psi 2000 psi 2500 psi

(172.4BAR) (172.4BAR)
(138BAR)
?
T2
T1
B
0.2
GPM
MP
2.0
GPM
P
PLAT FORM CONTROL
VALVE
PAGE 4
JIB BOOM FUNCTIONS
1001149709 D
4 3 2 1
3121619 – JLG Lift – 5-163

NOTES:
5-164 – JLG Lift – 3121619

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

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

Up & Down Arrow Keys
Used to move between Top Level, Sub
Value Selector
Level, and item menus
Figure 6-1. Hand Held Analyzer
3121619 – JLG Lift – 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 – JLG Lift – 3121619

The top level menus are as follows: When a top level menu is selected, a new set of menu items
may be offered: for example:
HELP
DIAGNOSTICS DRIVE
ACTIVATE TEST BOOM
ACCESS LEVEL SYSTEM
PERSONALITIES DATALOG
MACHINE SETUP VERSIONS
LEVEL VEHICLE (level 1 only)
CALIBRATIONS (view only)
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected menu. In
If you press ENTER , at the HELP: PRESS ENTER display, some cases, such as DRIVE, the next level is the parameter or
and a fault is present, the analyzer display will scroll the fault information to be changed. Refer to the flow chart for what
across the screen. If there was no fault detected, the display menus are available within the top level menus. You may only
will read: HELP: EVERYTHING OK. If powered up at the view the personality settings for selected menus while in
ground station, the display will read: GROUND OK. access level 2. Remember, you may always cancel a selected
If ENTER is pressed again, the display moves to the fol- 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 access level
2 which enables you to only view most settings which cannot
be changed until you enter a password to advance to a lower
level. This ensures that a setting cannot be accidentally
altered. To change the access level, the correct password must
be entered. To enter the password, scroll to the ACCESS LEVEL
menu. For example:
LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the last fault the system
has seen, if any are present. You may scroll through the fault
logs to view what the last 25 faults were. Use the right and left
arrow keys to scroll through the fault logs. To return to the
beginning, press ESCAPE two times. STARTUP (2/1)

indicates a power up.
ACCESS LEVEL:
CODE 00000
3121619 – JLG Lift – 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 – JLG Lift – 3121619

Machine Setup There is a setting that JLG strongly recommends that you do
not change. This setting is so noted below:
ELEVATION CUTBACK
When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:

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

TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES
INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI-
MUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM THESE COMPONENTS. IF
ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT
BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
Level Vehicle Description
DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.
GROUND ALARM:
2 = DRIVE
The effect of the machine digit value is displayed along with
its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
sound when driving. There are certain settings allowed to
install optional features or select the machine model.
When selection the machine model to match the size of the
machine, the personality settings will all default to the factory
recommended setting.
NOTE: Refer to Personality Ranges/Defaults for the recommended

factory settings.
NOTE: Password 33271 will give you access to level 1, which will
permit you to change all machine personality settings.
LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2 ENTER confirms that

vehicle is currently level, and zeroes the tilt sensor measure-
ments
3121619 – JLG Lift – 6-5

Ground Control Console Display Gauge - Machines

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

from the JLG Control System on the screen. An asterisk (*)
will be displayed to show active faults.
Figure 6-3. Diagnostic Screen
6-6 – JLG Lift – 3121619

INDICATOR LAMP
ENGINE HOURS FUEL LEVEL
NAVIGATE BACK ARROW NAVIGATE FORWARD ARROW
NAVIGATION BUTTONS
Figure 6-5. Ground Control Console Display Gauge
3121619 – JLG Lift – 6-7

Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations
ABBREVIATION MEANING ABBREVIATION MEANING

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

Table 6-1. Analyzer Abbreviations

ABBREVIATION MEANING
S/C SHORT CIRCUIT
SEL SELECTOR
SN SERIAL NUMBER
SPD SPEED
STOW STOWED
STOWD STOWED
SW SWITCH or SOFTWARE
TELE TELESCOPE
TEMP TEMPERATURE
TORQ. TORQUE
TRN TRANSPORT
T/T TURNTABLE
T TOWER
TURNTBL TURNTABLE
TWR TOWER
U UPPER or UP
V VOLT
VER VERSION
VLV VALVE
WIT WITNESS
YEL YELLOW
3121619 – JLG Lift – 6-9

Table 6-2. Machine Configuration Programming Information
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
The items marked in BOLD bold text on this sheet represent a new board that has never been configured.
MODEL NUMBER: 0 No Model 0

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

2
1 1850SJ: 185’ MAX
Note: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial default setting.
MARKET: 0 ANSI USA 0

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

4
2 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)
3 DEUTZ ECM: Engine Control Module
4 CAT Engine
5 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.
6-10 – JLG Lift – 3121619

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
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more 1
9 than 5 degrees and above elevation; also reduces drive speed to creep.
2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees
and above elevation; also reduces drive speed to creep.
3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees
and above elevation; also reduces drive speed to creep.
4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
and main lift up.
and main lift up.
Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the machine is also above elevation.
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.
3121619 – JLG Lift – 6-11

Default
Number
DRIVE: 0 2WD drive mode enabled. 1

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

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 0
NO: No load sensor installed.
17*
1
WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
2
CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
sec ON, 2 sec OFF).
3
SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform
alarm beeps (5 sec ON, 2 sec OFF).
4
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
6-12 – JLG Lift – 3121619

Default
Number
FUNCTION CUTOUT: 0 NO: No drive cutout. 0

18*
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

19*
1 DRIVE: Travel alarm sounds when the drive function is active (Option).
2 DESCENT: Descent alarm sounds when lift down is active (Option).
3 MOTION: Motion alarm sounds when any function is active (Option).
* Certain market selections will alter default setting.
OSCILLATING AXLE: 0 NO: No oscillating axle system installed. 1

20
1 YES: Oscillating axle system installed.
TEMPERATURE: 0 CELSIUS: Celsius unit selection. 1

21*
1 FAHRENHEIT: Fahrenheit unit selection.
* Certain market selections will alter default setting.
LEVELING MODE: 0 LIFT: Platform leveling during lift only. 1

22
1 ALL: Platform leveling during all functions.
CLEARSKY: 0 NO: ClearSky Telematics system not installed. 0

23
1 YES: ClearSky Telematics system installed.
FUEL TANK: 0 52 Gallon Fuel tank. 0

24
1 41 Gallon Fuel tank.
ALERT BEACON: 0 OFF FOR CREEP. 0

25
1 20FPS FOR CREEP.
3121619 – JLG Lift – 6-13

Default
Number
LANGUAGE: 0 ENGLISH 0
26
1 SPANISH
2 EURO PORTUGUESE
3 BRAZILIAN PORTUGUESE
4 FRENCH
5 GERMAN
6 DUTCH
7 ITALIAN
8 SIMPLIFIED CHINESE
9 JAPANESE
10 KOREAN
1001128802--C
6-14 – JLG Lift – 3121619

Table 6-3. Machine Configuration Programming Settings
ANSI Export
Table 6-3. Machine Configuration Programming Settings
Australia
ANSI USA
Japan
CSA
1850SJ
CE
ANSI Export
Australia
ANSI USA
Japan
CSA
1850SJ
CE
Load System 0 0 0 0 0 0
X 1 X 1 1 1
Model Number 2 2 2 2 2 2
X 2 X 2 2 2
Envelope Height 1 1 1 1 1 1
X 3 X 3 3 3
Market 0 1 2 3 4 5
X 4 X X 4 4
Engine 5 5 5 5 5 5
Function Cutout X X X X X X
Glow Plug 0 0 0 0 0 0
X X X X X X
1 1 1 1 1 1
X X X X X X
2 2 2 2 2 2
3 3 3 3 3 3
Starter Lockout 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
Engine Shutdown 0 0 0 0 0 0
2 2 2 2 2 2
1 1 1 1 1 1
3 3 3 3 3 3
Fuel Cutout 0 0 0 0 0 0
Oscillating Axle 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
Display Units 0 0 0 0 0 0
Tilt 1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
Leveling Mode 0 0 0 0 0 0
3 3 3 3 3 3
1 1 1 1 1 1
4 4 4 4 4 4
Clearsky 0 0 0 0 0 0
5 5 5 5 5 5
1 1 1 1 1 1
Jib 0 0 0 0 0 0
Fuel Tank 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
Alert Beacon 0 0 0 0 0 0
4 Wheel Steer 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
BOLD TEXT indicates the default setting. Plain text indicates another available selec-
Drive Type 0 0 0 0 0 0 tion. ITALIC TEXT indicates the default when option is factory installed. SHADED CELLS
1 1 1 1 1 1 indicate hidden menu or selection.
Soft Touch/Skyguard 0 0 0 0 0 0
1 1 1 1 1 1
2 2 2 2 2 2
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
Gen Set Cutout 0 0 0 0 0 0
1 1 1 1 1 1
Head & Taillights 0 0 0 0 0 0
1 1 1 1 1 1
3121619 – JLG Lift – 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 54-58 (see orientation)
MIN reverse XX% Displays/adjusts minimum reverse drive speed 0 to 35% 1
MAX reverse XXX% Displays/adjusts maximum reverse drive speed 0 to 100% 100 54-58 (see orientation)
ELEV. MAX XX% Displays/adjusts maximum drive speed 0 to 50% 25 110-112 (see orientation)
NOTE: used when elevation cutout switches are

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

active
STEER: MAX SPEED XXX% Displays/adjusts maximum steer speed. 0 to 100% 100
MAIN LIFT: ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1
DECEL X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1
MIN UP XX% Displays/adjusts minimum main lift up speed 0 to 60% 20
MAX UP XX% Displays/adjusts maximum main lift up speed 0 to 100% 80 75-100 (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
6-16 – JLG Lift – 3121619

SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 3

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

active
MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 22
MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 100% 81 110-130 (see orientation)
CREEP RIGHT XX% Displays/adjusts maximum swing right speed 0 to 65% 47
MAN TELESCOPE: ACCEL X.Xs Displays/adjusts main telescope acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts main telescope deceleration 0.1 to 3.0 sec 1
MIN IN XX% Displays/adjusts minimum main telescope in 0 to 65% 15
speed. Same as Creep speed
MAX IN XXX% Displays/adjusts maximum main telescope in 0 to 100% 65 65-75 (see orientation)
speed
MIN OUT XX% Displays/adjusts minimum main telescope out 0 to 65% 15
MAX OUT XXX% Displays/adjusts maximum main telescope out 0 to 100% 60 50-60 (see orientation)
speed
PLATFORM ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5
LEVEL: DECEL X.Xs Displays/adjusts basket level deceleration 0.1 to 3.0 sec 0.5
MIN UP XX% Displays/adjusts minimum basket level up 0 to 65% 55
MAX UP XXX% Displays/adjusts maximum basket level up 0 to 100% 70
speed
MIN DOWN XX% Displays/adjusts minimum basket level down 0 to 65% 50
MAX DOWN XXX% Displays/adjusts maximum basket level down 0 to 100% 70
speed
3121619 – JLG Lift – 6-17

SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
PLATFORM ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1
ROTATE: DECEL X.Xs Displays/adjusts basket rotate deceleration 0.1 to 3.0 sec 0.5
MIN LEFT XX% Displays/adjusts minimum basket rotate left 0 to 100% 60
MAX LEFT XXX% Displays/adjusts maximum basket rotate left 0 to 100% 60 15-20 (180)
speed
MIN RIGHT XX% Displays/adjusts minimum basket rotate right 0 to 100% 60
MAX RIGHT XXX% Displays/adjusts maximum basket rotate right 0 to 100% 60 15-20 (180)
speed
JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1
MIN UP XX% Displays/adjusts minimum jib up speed. Same 0 to 65% 46
as Creep speed
MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 65 70-120
MIN DOWN XX% Displays/adjusts minimum jib down speed. 0 to 65% 46
Same as Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 76 65-100
JIB SWING: ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5
MIN LEFT XX% Displays/adjusts minimum jib left speed. Same 0 to 65% 48
as Creep speed
MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 60-68 (180)
MIN RIGHT XX% Displays/adjusts minimum jib right speed. 0 to 65% 55
Same as Creep speed
MAX RIGHT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 60-68 (180)
JIB TELESCOPE: ACCEL X.Xs Displays/adjusts jib tele acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib tele deceleration 0.1 to 3.0 sec 1
MIN IN XX% Displays/adjusts minimum jib tele in speed. 0 to 65% 45
Same as Creep speed
MAX IN XXX% Displays/adjusts maximum jib tele in speed 0 to 100% 70 20-25 (see orientation)
MIN OUT XX% Displays/adjusts minimum jib right speed. 0 to 65% 40
Same as Creep speed
MAX OUT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 20-25 (see orientation)
6-18 – JLG Lift – 3121619

SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
JIB LEVEL: ACCEL X.Xs Displays/adjusts jib level acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib level deceleration 0.1 to 3.0 sec 0.5
MIN UP XX% Displays/adjusts minimum jib level up speed. 0 to 65% 60
Same as Creep speed
MAX UP XXX% Displays/adjusts maximum jib level up speed 0 to 100% 100
MIN DOWN XX% Displays/adjusts minimum jib level down 0 to 65% 60
MAX DOWN XXX% Displays/adjusts maximum jib level down 0 to 100% 100
speed
GROUND M. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 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 1800 for 60Hz ,1900 for 50Hz
GEN SET/WELDER = 0
1001172159-A
3121619 – JLG Lift – 6-19

6.3 MACHINE ORIENTATION WHEN SETTING DRIVE FORWARD (Elevated Max - Boom Beyond
FUNCTION SPEEDS Transport), high speed - low torque setting, plat-
form speed knob out of creep, Lift boom above
LIFT UP, from platform control, lowest elevation transport, drive forward 50 ft.
up to maximum elevation, boom retracted, jib
retracted. DRIVE REVERSE (Elevated Max - Boom Beyond
Transport), high speed - low torque setting, plat-
LIFT DOWN, from platform control, maximum ele- form speed knob out of creep, Lift boom above
vation down to minimum elevation, boom transport, drive backward 50 ft.
retracted, jib retracted.
Test Notes
JIB LIFT UP, from platform control, lowest jib ele-
vation up to maximum jib elevation, boom 1. Personality settings can be adjusted anywhere within
the adjustment range in order to achieve optimum
machine performance
JIB LIFT DOWN, from platform control, maximum 2. Stop watch should start when the function is acti-
jib elevation down to minimum jib elevation, vated.Not with the controller or switch.
boom retracted, jib retracted. 3. Unless noted, function speeds should be measured from
SWING RIGHT(Max),360 Degrees, from platform platform.
control, boom approximately 45° elevation, boom 4. Platform speed knob must be at full speed (fully clock-
retracted, jib retracted. wise).
5. All test should be done with the oil temp above 100° F
SWING LEFT(Max),360 Degrees, from platform (38° C).
control, boom approximately 45° elevation, boom
TELESCOPE OUT, from platform control, boom @
0 degrees, 500 lb. capacity selected.
TELESCOPE IN, from platform control, boom @ 0
degrees, 500 lb. capacity selected.
JIB TELESCOPE IN, from platform control, boom
horizontal, jib horizontal, 500 lb. capacity selected.
JIB TELESCOPE OUT, from platform control, boom
horizontal, jib horizontal, 500 lb. capacity selected.
DRIVE FORWARD (Max), high speed - low torque
setting, drive 200 ft. front wheels to front wheels.
Timed after machine has obtained maximum
speed.
DRIVE REVERSE (Max), high speed - low torque
setting,drive 200 ft. front wheels to front wheels
Timed after machine has obtained maximum
speed.
DRIVE FORWARD (Creep Max), high torque - low
speed setting, platform speed knob at full creep
DRIVE REVERSE (Creep Max), high torque - low
speed setting, platform speed knob at full creep
6-20 – JLG Lift – 3121619

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.
3121619 – JLG Lift – 6-21

MS83
3X4 B us s Bar
Be low U GM
C hassi s LSS Module
U GM Shie ld
6 Groun d X468
J2 -4
J2 -9
J2 -5
YEL Ca n Hig h
2
GRN C an Lo C an 2 Buss Bar
J7 -24 4 MS83 She et 5 , D1
Broken C abl e Prox

Sen sor 1 Sh ee t 4, G2
Gr aphic Display
YEL C an Hi gh
MDI 4 8 1 BL U Hig h 5 8
GR N Can L o 10 3 12
X77 3 7 3
X327 a t UGM Chas sis Module 9 BLK Lo 4 10
X43
Shie ld M12 Te e with
5 J7-6 LSS Option
120 OHM
YEL Can H igh J7-1 7

11 White
GRN C an Lo
9
J7-1 8
Ma in Boom
1 3 2 J7-2 4
Cable X 81 SN29 2 Pla tfor m
J7-1 3
RED C an Hi gh
Le vel Cylinder
BLK Ca n Lo
Angle Se ns or
Shie ld
10 Gra y Shi eld

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

MS158 -1 Cy linde r Angle
Sensor 3 4 5
J1 -7
J1-6
Platf orm Module

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

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

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

B B 3
YEL Can H igh J1-6 J4-3 A A YEL Hi gh 3 BLK Lo 3 YEL Can H igh 1
Shi eld J1-8 J4-5 Sh ie ld Sh iel d
C C 1 1 5
MS261 -1
MS26 2-3
X2 28
X3 3
MS41
J ib Module 3x 4 Buss
Bar
Figure 6-6. Control System CAN Circuit 1
6-22 – JLG Lift – 3121619

120 OHM
MS83
3X4 Buss Bar
Below UGM MS1000-3 A B C
MS1000-1
MS1000-2
UGM MODULE
YEL Can High
12 Deutz ECM
120 OHM
54
76
53
75
GRN Can Lo
J12-4 10 J1 Connector
6
J12-7 Shield from Can A A
J12-6 White 1 Bus Bar Sheet B B
5 Zone H3 C C
Tee Connector
under ECM
MS1001-1 AB C
A A
120 OHM
B B
Tee Connector Tee Connector
JLG Diagnostic E Shiel d 7 A C C
120 OHM be hind Drive
MS1002-1
GRN Can Lo B under De utz
MS1002-3
Connector D 4 Pumps
YEL Can High C ECM
Beside UGM C 11
MS1001-3
A B C MS1002-2
MS10 01-2A B C
GRN Can Lo
YEL Can High
Shield
Sh ield
5
GRN Can Lo
3
YEL Can Hi gh
1
MS999-2 AB C
G
H
YEL Ca n High YEL Can High
3 A A 1 M
GRN Can Lo GRN Can Lo
4 B B 2 F
Shi eld Shield
6 C C 3
MS999 -1
MS999 -3
Engine Deutz
Connector #1 Te e Connector Diagnostic
X218 under drive Connector
On T/T side pumps Behind Engine
shee t behind
char ge pump
Figure 6-7. Control System CAN Circuit 2
3121619 – JLG Lift – 6-23

6.5 CALIBRATION INSTRUCTIONS Table 6-5. Calibration Instructions
This machine incorporates a variety of sensors and a high Telescope Crack Point Cali- Ground module replacement
degree of function interaction. For safety and proper machine bration Telescope proportional valve replacement
functionality, the calibration procedures must be repeated for Erratic controlled arc operation
any control module replacement, system calibration related Erratic controlled boom angle operation
fault, or removal or replacement of any sensors, valves, coils,
motors, or pumps. The chart below lists the calibrations Chassis Tilt Ground module removal or replacement
required and potential reasons for re-calibration. All calibra- Calibration Main terminal box removal or replacement
tion procedures are menu driven through the use of the stan- Tilt indication inaccuracy
dard analyzer. With the exception of steering calibration, no
Boom Sensors Ground module removal or replacement
external tools are required to complete the calibration proce-
Calibration BLAM module removal or replacement
dures. The user is prompted to exercise the machine in a spe-
Boom angle sensor removal or replacement
cific order to use the machines physical properties to
Boom length sensor removal or replacement
consistently establish sensor response and the interaction of
Moment pin removal or replacement
valves, pumps, and motors. Steering calibration also uses the
Boom angle sensor calibration fault
analyzer and is performed on one side of the machine at a
Boom length sensor calibration fault
time requiring the use of a string or other means to determine
Moment pin fault
when the tires are in line with each other. With the exception
Failed BCS functional check
of the load control calibration, all calibrations are accessed by
Boom control system inaccuracies
connecting the analyzer into the control system inside the
Installing or removing approved accessories
main terminal box or on the bottom of the platform control
Changing Platform Size
box.
Table 6-5. Calibration Instructions
Calibration Reasons for Re-calibration

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

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

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

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

Calibration Lift proportional valve/coil replacement
Erratic controlled arc operation
Erratic controlled boom angle operation
6-24 – JLG Lift – 3121619

3121619
ACCESS LEVEL: MENU: MENU: MENU: MENU: MENU: MENU: MENU: MENU:
CODE 33271 ACCESS LEVEL 1 PERSONALITIES MACHINE SETUP CALIBRATIONS SERVICE MODE HELP:PRESS ENTER DIAGNOSTICS SYSTEM TEST
ACCESS LEVEL: SERVICE MODE: HELP: SYSTEM TEST:

(See Figure 6-9.) (See Figure 6-10.) (See Figure 6-11.) JIB & SWING? GROUND MODE OK (See Figure 6-12.) ACTIVATE?
CODE 00000
or
JIB & SWING: (See Figure 6-13.)
JIB LEVEL? or
(See Figure 6-14.)
JIB & SWING:
JIB LOCK PIN?
JIB & SWING:

SWING ENVELOPE?
JIB & SWING:

BOOM RECOVERY?
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine con-
figuration.
Figure 6-8. Analyzer Flow Chart
6-25
6-26
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some
screens may not be available depending upon machine configuration.
Figure 6-9. Analyzer Flow Chart - Personalities (Software Version 7.X)
3121619
3121619
– JLG Lift –
NOTE: The layout shown includes all possible ana-
lyzer screens. Please note that some screens
may not be available depending upon
machine configuration.
Figure 6-10. Analyzer Flow Chart - Machine Setup (Software Version 7.X)
6-27
6-28
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
Figure 6-11. Analyzer Flow Chart - Calibrations (Software Version 7.X)
3121619
3121619
– JLG Lift –
NOTE: The layout shown includes all possible analyzer
screens. Please note that some screens may not be
available depending upon machine configuration.
Figure 6-12. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 1 of 3
6-29
6-30
– JLG Lift –
3121619
3121619
– JLG Lift –
6-31
Connector Pin Function Type

1 THROTTLE ACTUATOR (DIESEL ONLY) DIGITAL OUTPUT
2 SPARE (LP NOT USED) DIGITAL OUTPUT
3 TOWER BOOM LIFT POWER DIGITAL OUTPUT
4 GROUND GROUND INPUT
6 TOWER TELESCOPE ENABLE DIGITAL OUTPUT
7 SPARE (LP NOT USED) DIGITAL OUTPUT
10 IGNITION ON RELAY DIGITAL OUTPUT
11 START SOLENOID (DIESEL ONLY) DIGITAL OUTPUT
12 GLOW PLUG (DIESEL ONLY OPTION) DIGITAL OUTPUT
13 AUXILIARY POWER DIGITAL OUTPUT
14 COOLANT TEMP (DIESEL ONLY) ANALOG INPUT
15 OIL PRESSURE (DIESEL ONLY) ANALOG INPUT
16 FLYWHEEL SPEED PICKUP (DIESEL ONLY) FREQUENCY INPUT
J1
18 SPARE GROUND GROUND INPUT
(Natural)
19 SPARE GROUND GROUND INPUT
20 TWO SPEED DIGITAL OUTPUT
21 MAIN LIFT PILOT PRESSURE SWITCH DIGITAL INPUT
22 GENERATOR/WELDER (OPTION) DIGITAL OUTPUT
23 PARKING BRAKE DIGITAL OUTPUT
24 CONSTANT BATTERY N/C N/C
25 RS-485 HI SERIAL I/O
26 RS-485 LO SERIAL I/O
28 ANALYZER POWER VOLTAGE OUTPUT
29 ANALYZER RS-232 Rx SERIAL INPUT
30 ANALYZER RS-232 Tx SERIAL OUTPUT
31 ANALYZER GROUND GROUND INPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT
33 GROUND SHIELD GROUND INPUT
34 SPARE DIGITAL INPUT
35 HYDRAULIC OIL TEMPERATURE SWITCH DIGITAL INPUT

1 MAIN LIFT PILOT DIGITAL OUTPUT
2 HORN DIGITAL OUTPUT
3 PLATFORM CONTROL VALVE DIGITAL OUTPUT
4 UPPER TELESCOPE IN DIGITAL OUTPUT
5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT
7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT
8 TOWER TELESCOPE POWER DIGITAL OUTPUT
9 TELESCOPE FLOW CONTROL DIGITAL OUTPUT
10 LIFT PILOT DIGITAL OUTPUT
11 UPPER LIFT UP DIGITAL OUTPUT
12 LIFT DOWN AUXILIARY DIGITAL OUTPUT
13 MAIN DUMP DIGITAL OUTPUT
15 NOT CONNECTEDRS232 BACKUP COMM. ENABLE DIGITAL OUTPUT
16 UPPER TELESCOPE OUT DIGITAL OUTPUT
J2
18 SPARE PIN GROUND INPUT
(Gray)
19 LIFT FLOW CONTROL DIGITAL OUTPUT
20 SPARE OUTPUT DIGITAL OUTPUT
21 MAIN BOOM ANGLE SENSOR #2 POWER DIGITAL OUTPUT
22 UPPER LIFT DOWN DIGITAL OUTPUT
23 MAIN BOOM LIFT ENABLE DIGITAL OUTPUT
24 TOWER CYLINDER TYPE DIGITAL INPUT
25 FUEL SENSOR ANALOG INPUT
26 HEAD/TAIL LIGHT DIGITAL OUTPUT
27 ALARM DIGITAL OUTPUT
31 PVG ENABLE DIGITAL OUTPUT
32 TOWER BOOM TELESCOPE PILOT DIGITAL OUTPUT
33 TOWER BOOM LIFT ENABLE DIGITAL OUTPUT
34 SWING LEFT DIGITAL OUTPUT
35 SWING RIGHT DIGITAL OUTPUT

1 SPARE VAVLE RETURN 1 GROUND INPUT
J3 7 VBAT VBAT OUTPUT
(Black) 8 SPARE HS DIGITAL IN (FREQ. CAPABLE) DIGITAL INPUT
9 ALTERNATOR EXCITATION INPUT DIGITAL INPUT
10 SPARE HS SWITCH INPUT (MODEL INPUT FOR 1100S) DIGITAL INPUT
11 SPARE LS DIGITAL INPUT DIGITAL INPUT
12 ANALOG REF. VOLTAGE VOLTAGE OUTPUT
13 SPARE ANALOG INPUT 8 ANALOG INPUT
14 SPARE VALVE RETURN 3 GROUND INPUT
1001119509A
Figure 6-15. Ground Control Module - Sheet 1 of 3
6-32 – JLG Lift – 3121619


1 PLATFORM EMS DIGITAL INPUT
2 PLATFORM MODE DIGITAL INPUT
3 GROUND MODE DIGITAL INPUT
4 TOWER CYLINDER PRESSURE ANALOG INPUT
5 REFERENCE VOLTAGE VOLTAGE OUTPUT
6 CAN TERMINATION TERM I/O
7 SPARE ANALOG INPUT
11 BOOM RETRACTED CLOSED DIGITAL INPUT
12 BROKEN CABLE SWITCH INPUT
13 CAN HI SERIAL I/O
14 GROUND MODE OUT TO PLATFORM DIGITAL INPUT
15 FOOTSWITCH ENGAGE DIGITAL INPUT
17 CAN TERMINATION TERM I/O
J7
18 CAN SHEILD GROUND INPUT
(Black)
21 PUSH TO TEST DIGITAL INPUT
22 TOWER BOOM TRANSPORT ANGLE DIGITAL INPUT
23 GROUND CONTROL ENABLE DIGITAL INPUT
24 CAN LO SERIAL I/O
29 VBAT VBAT OUTPUT
30 VBAT VBAT OUTPUT
31 VBAT VBAT OUTPUT
32 VBAT VBAT OUTPUT
33 VBAT VBAT OUTPUT
34 CLEARSKY POWER (VBAT) VBAT OUTPUT
35 BOOM RETRACT OPEN DIGITAL INPUT

1 FREQUENCY INPUT 2 FREQUENCY INPUT
2 FREQUENCY INPUT 2 RETURN FREQUENCY INPUT
3 CAN 2 H SERIAL I/O
J12 4 CAN 2 L SERIAL I/O
(Black) 5 CAN 2 SHIELD GROUND INPUT
6 CAN 2 TERMINATOR TERM I/O
7 CAN 2 TERMINATOR TERM I/O
8 SPARE LS DIGITAL INPUT DIGITAL INPUT
1001119509A
3121619 – JLG Lift – 6-33


1 GROUND FROM BATTERY GROUND INPUT
J8 2 GROUND EMS GROUND INPUT
(Black) 3 GROUND TO PLATFORM GROUND OUTPUT
4 GROUND EMS OUT TO PLATFORM GROUND OUTPUT

1 AXLES SET LAMP DIGITAL OUTPUT
2 500# CAPACITY LAMP DIGITAL OUTPUT
3 BOOM CONTROL SYSTEM LAMP DIGITAL OUTPUT
4 START SWITCH DIGITAL INPUT
5 BASKET LEVEL DOWN DIGITAL INPUT
6 BASKET LEVEL DOWN DIGITAL INPUT
7 UPPER TELESCOPE IN DIGITAL INPUT
8 JIB DOWN DIGITAL INPUT
9 JIB LEFT DIGITAL INPUT
10 TOWER UP DIGITAL INPUT
11 MAIN TOWER TRANSPORT ANGLE OPEN DIGITAL INPUT
12 HOUR METER DIGITAL OUTPUT
13 BCS CALIBRATED LAMP DIGITAL OUTPUT
14 OVERLOAD LAMP DIGITAL OUTPUT
15 SPARE DIGITAL OUTPUT
16 AUXILIARY POWER DIGITAL INPUT
17 BASKET LEVEL UP DIGITAL INPUT
J4
18 BASKET ROTATE RIGHT DIGITAL INPUT
(Blue)
19 JIB UP DIGITAL INPUT
20 JIB RIGHT DIGITAL INPUT
21 TOWER DOWN DIGITAL INPUT
22 MAIN BOOM TRANSPORT ANGLE CLOSED DIGITAL INPUT
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
28 ENGINE HIGH TEMPERATURE LENGTH DIGITAL OUTPUT
29 ENGINE LOW OIL PRESSURE LAMP DIGITAL OUTPUT
30 UPPER TELESCOPE OUT DIGITAL INPUT
33 UPPER LIFT DOWN DIGITAL INPUT
34 SWING LEFT DIGITAL INPUT
35 SWING RIGHT DIGITAL INPUT
1001119509A
6-34 – JLG Lift – 3121619

Connector Pin FUNCTION Type

1 Power Feed Thru to J1-1 Power I/O
1 Power Feed Thru to J2-1 Power I/O 2 Power Feed Thru to J1-2 Power I/O
2 Power Feed Thru to J2-2 Power I/O 3 Ground Power Output
3 Signal Feed Thru to J2-4 Digital Input 1 Ignition Power Output
4 Front Axles Limit Switch Digital Input
4 Master Ground Connect Power Input 2 Ground Power Output
5 Rear Axles Limit Switch Digital Input
5 Master Ignition Connect Power Input 3 CANbus High Serial I/O
6 Drive Orientation Switch Digital Input
6 CANbus High Serial I/O 4 CANbus Low Serial I/O J2 (Black)
J1 (Grey) J4 (Grey) 7 Oscillating Axle Pres Sw Digital Input
7 CANbus Low Serial I/O 5 CANbus Shield Power Input
6 Bootstrap Mode Digital Input 8 Turntable Angle Sensor #1 Digital Input
8 CANbus Shield Serial I/O
7 Ignition Power Output 9 Turntable Angle Sensor #2 Digital Input
9 CANbus Terminator Serial I/O
10 CANbus Terminator Serial I/O 8 Ground Power Output 10 Spare Analog Analog Input
11 Ignition Power Output 11 Front/Rear Axle Extend Digital Output
12 Ground Power Output 12 Front/Rear Axle Retract Digital Output
Connector Pin FUNCTION Type Connector Pin FUNCTION Type

1 +5V Analog Reference Power Output 1 Right Front Steer Right Digital Output
2 Front Right Steer Angle Analog Input 2 Right Front Steer Left Digital Output
3 Ground Power Output 3 Left Front Steer Right Digital Output
4 +5V Analog Reference Power Output 4 Left Front Steer Left Digital Output
5 Front Left Steer Angle Analog Input 5 Right Rear Steer Right Digital Output
6 Ground Power Output 6 Right Rear Steer Left Digital Output
J3 (Green) J5 (Brown)
7 +5V Analog Reference Power Output 7 Left Rear Steer Right Digital Output
8 Rear Right Steer Angle Analog Input 8 Left Rear Steer Left Digital Output
9 Ground Power Output 9 Ignition Power Output
10 +5V Analog Reference Power Output 10 RS232 Receive Serial Input
11 Rear Left Steer Angle Analog Input 11 RS232 Transmit Serial Output
12 Ground Power Output 12 Ground Power Output
1001112758-C
Figure 6-18. Chassis Control Module
3121619 – JLG Lift – 6-35


1 Power Feed Thru to J1-1 Power I/O
2 Power Feed Thru to J2-2 Power I/O 3 Ground Power Output
3 Signal Feed Thru to J2-4 Digital Input 1 Ignition Power Output
4 Spare Input Digital Input
4 Master Ground Connect Power Input 2 Ground Power Output
5 Master Ignition Connect Power Input 3 CANbus High Serial I/O
6 CANbus High Serial I/O 4 CANbus Low Serial I/O J2 (Black)
J1 (Grey) J4 (Grey) 7 Spare Input Digital Input
7 CANbus Low Serial I/O 5 CANbus Shield Power Input
6 Bootstrap Mode Digital Input 8 Main Boom Ang 1 (Gravity) Digital Input
8 CANbus Shield Serial I/O
9 CANbus Terminator Serial I/O 7 Ignition Power Output 9 Main Boom Ang 2 (Gravity) Digital Input
10 CANbus Terminator Serial I/O 8 Ground Power Output 10 Spare Analog Analog Input
11 Ignition Power Output 11 Right Drive Pump Forward Digital Output
12 Ground Power Output 12 Right Drive Pump Reverse Digital Output

1 +5V Analog Reference Power Output 1 Left Drive Pump Forward Digital Output
2 Ref Voltage from J3-1 Analog Input 2 Left Drive Pump Forward Digital Output
3 Ground Power Output 3 Oscillating Axles Digital Output
4 +5V Analog Reference Power Output 4 Spare Output - D005 Digital Output
5 Main Cyl Angle #1(Absolute) Analog Input 5 Spare Output - D006 Digital Output
6 Ground Power Output 6 Spare Output - D007 Digital Output
7 +5V Analog Reference Power Output 7 Spare Output - D008 Digital Output
8 Boom Length Sensor Analog Input 8 Spare Output - D009 Digital Output
11 Main Cyl Angle #2(Absolute) Analog Input 11 RS232 Transmit Serial Output
1001112757-C
Figure 6-19. BLAM Control Module
6-36 – JLG Lift – 3121619

2 Power Feed Thru to J2-2 Power I/O Connector Pin FUNCTION Type 2 Power Feed Thru to J1-2 Power I/O
3 Signal Feed Thru to J2-4 Digital Input 1 Ignition Power Output 3 Ground Power Output
4 Master Ground Connect Power Input 2 Ground Power Output 4 Lock Pin NO Contact Digital Input
5 Master Ignition Connect Power Input 3 CANbus High Serial I/O 5 Lock Pin NC Contact Digital Input
6 CANbus High Serial I/O 4 CANbus Low Serial I/O 6 Jib Transport #1 NO Contact Digital Input
J1 (Grey) J4 (Grey) J2 (Black)
7 CANbus Low Serial I/O 5 CANbus Shield Power Input 7 Jib Transport #1 NC Contact Digital Input
8 CANbus Shield Serial I/O 6 Bootstrap Mode Digital Input 8 Spare Input Digital Input
9 CANbus Terminator Serial I/O 7 Ignition Power Output 9 Spare Input Digital Input
10 CANbus Terminator Serial I/O 8 Ground Power Output 10 Spare Analog Input Analog Input
11 Ignition Power Output 11 Jib Level Up Digital Output
12 Ground Power Output 12 Jib Level Down Digital Output
1 +5V Analog Reference Power Output 1 Jib Lift Up Digital Output

2 Jib Level Angle #1 Analog Input 2 Jib Lift Down Digital Output
3 Ground Power Output 3 Jib Swing Right Digital Output
4 +5V Analog Reference Power Output 4 Jib Swing Left Digital Output
5 Jib level Angle #2 Analog Input 5 Jib Telescope In Digital Output
6 Ground Power Output 6 Jib Telescope Out Digital Output
7 +5V Analog Reference Power Output 7 Spare Output Digital Output
8 Jib Swing Angle #1 Analog Input 8 Spare Output Digital Output
11 Jib Swing Angle #2 Analog Input 11 RS232 Transmit Serial Output
1001119262-A
Figure 6-20. Jib Control Module
3121619 – JLG Lift – 6-37

PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 6-21. Analyzer Connecting Points
6-38 – JLG Lift – 3121619

6.6 CONTROL SYSTEM BOOM SENSORS Sensor #3 - Main Boom Length Sensor (1)
The Boom Control System (BCS) requires the use of multiple
sensors to measure the position of the boom. The sensors
used to determine main boom and jib boom position are
shown in the following figures.
THE CONTROL SYSTEM MUST BE RECALIBRATED AFTER REPLACING OF ANY

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

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

See (See Figure 6-22.)
These sensors measure Main Boom angle with respect to grav-
ity. They are located in the rear of the Section #1boom and
mounted such that they generate opposing signals with
respect to boom movement.
3121619 – JLG Lift – 6-39

Figure 6-22. Main Boom Angle Sensors
6-40 – JLG Lift – 3121619

Sensor #4 - Main Boom Cylinder Angle Sensor (1) table and attached to the Main Lift cylinder of the base boom.
It is a dual output sensor in a single mechanical body with
See (See Figure 6-23.) electrically opposing signals.
This sensor's function is to measure Main Boom angle relative
to the Turntable. A rotary type sensor is mounted to the Turn-
ANGLE SENSOR
LINK
ADAPTER
BASE TERMINAL
BEI ANGLE
SENSOR ANGLE SENSOR
PIN
BOLT,
BOLT, THREADLOCKER
P/N-0100035
THREADLOCKER
P/N-0100011
Torque 12 Nm BOLT,
THREADLOCKER
P/N-0100035
ANGLE SENSOR
Torque 3.4 Nm
ANGLE SENSOR LINK
PIN WASHER RING
ADAPTER
BEI ANGLE
SENSOR
Figure 6-23. Main Boom Cylinder Angle (Protractor) Sensor
Sensor #5 - Main Boom Transport Length Switch (1)

This switch is used to indicate Main Boom retracted position
for transport. This is a mechanical limit switch.
3121619 – JLG Lift – 6-41

TRANSPORT LIMIT SWITCH WIRING
13 14
21 22
BL ACK
WHITE
TOP OF SENSOR
R ED
LIMIT SWITCH
BLACK
+1°
RED 90° -10°
WHITE
SECTION E-E
LIMIT SWITCH ADJUSTMENT
LIMIT SWITCH COVER

RUBBER PAD, BOLT, WASHER,
ADHESIVE LIMIT SWITCH THREADLOCKER
P/N-0100081 P/N-0100011
Torque 25ft.lbs. (34 Nm)
TORQUE BOLT TO 55 NM
CABLE
BOLT,
ADHESIVE
P/N-0100035
Figure 6-24. Main Boom Transport Length Switch
6-42 – JLG Lift – 3121619

Sensor #6 - Jib Level Angle Sensor (1) ing bracket. The LED on the sensor will light when power is
applied and the sensor is within range.
This sensor is used to measure Jib Level angle relative to the
20
Main Boom. A rotary type sensor is mounted between the
Main Boom Fly nose and the Jib Pivot weldment. It is a dual
output sensor in a single mechanical body with electrically
opposing signals.
SENSOR INSTALLATION
1. Attach the sensor to the mounting plate.
2. Attach the link to the sensor arm.
3. Install the sensor subassembly onto the boom.
4. Connect the sensor wiring.
Sensor #7 - Jib Lock Pin Proximity Sensor (1)
BOLT, WASHER, BOTTOM VIEW OF ROTATOR

THREADLOCKER
P/N-0100011
PROXMITY SENSOR
BRACKET
Figure 6-25. Jib Lock Pin Proximity Sensor
This sensor is used to indicate the Jib Lock Pin is fully engaged.
This is a proximity switch mounted to the Jib Pivot weldment.
LOCK PIN SENSOR ADJUSTMENT

Adjust the proximity sensor to 20 mm from the front face of
the proximity sensor to the front mounting face of the mount-
3121619 – JLG Lift – 6-43

SPACER
NUT
BOLT SCREW, WASHER,

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

SCREW, NUT THREADLOCKER
TORQUE UNTIL SNUG P/N-0100011
5 NM MAX
SENSOR
MOUNT
SENSOR
LINK
SENSOR COVER
SHOWN IN PHANTOM
FOR CLARITY
Figure 6-26. Jib Level Angle Sensor
6-44 – JLG Lift – 3121619

Sensor #8 - Jib Stow Angle Sensor (1)

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

This sensor's function is to measure the Jib angle relative to
the Main Boom Pivot weldment. A linear position sensor is
located inside the Jib lift cylinder to measure cylinder stroke.
SCREW, WASHER,
THREADLOCKER
P/N-0100035
ANGLE
SENSOR
ADAPTER
SENSOR
BRACKET
BOLT, WASHER
THREADLOCKER
P/N-0100011
ANGLE Torque 34 Nm
SENSOR PIN
SCREW,
THREADLOCKER
P/N-0100035
SENSOR MOUNT
Figure 6-27. Jib Stow Angle Sensor
3121619 – JLG Lift – 6-45

Sensor #10 - Dual Capacity / Jib Transport Length Sensor #11 - Platform Level Angle Sensor (1)
Switches (2) This sensor is used to measure Platform angle relative to the
Jib. A linear position sensor is located inside the Platform Level
See (See Figure 6-28.) cylinder to measure cylinder stroke.
These switches are located on the Jib Base Boom and are used
to measure transport position and 1000# length limit. These
are proximity switches mounted such that they generate
opposing signals.
ADJUSTMENT
Adjust the Proximity Sensors so the front sensing face is flush
to 0.75 mm below the surface of the mounting face.
PROX SENSOR
BELOW MOUNT FACE
SENSOR
COVER
PROXIMITY SENSOR
SENSOR
MOUNT
BOLT, WASHER
THREADLOCKER
P/N-0100011
Figure 6-28. Jib Transport Length Sensors
6-46 – JLG Lift – 3121619

Sensor #12 - Platform Level Angle Gravity Sensors Sensor #17 - Chassis Tilt Sensor (Externally
(2) mounted) (1)
See (See Figure 6-29.) This sensor is the primary tilt sensor and measures the tilted
angle of the turntable relative to gravity. It is mounted on a
These sensors are located on the Platform Support and are bracket on the left side of the turntable adjacent to the UGM
used to measure platform angle with respect to gravity. They and BLAM module. It is a dual axis output sensor in a single
are mounted such that they generate opposing signals. body.
Sensor #13 - Turntable Swing Angle (1) Sensor #18 - Tilt Sensor (1)
This sensor is used to determine turntable swing angle. It is This sensor is integral to the UGM. This sensor is the secondary
used for turntable swing control when the boom is in trans- tilt sensor and measures the tilted angle of the chassis relative
port position (Axles Retracted). It is a dual output sensor in a to gravity. It is used to check plausibility of the primary chassis
single mechanical body with electrically opposing signals tilt sensor reading (See Sensor #17).
mounted integral to the electrical collector ring.
Sensor #19 - Warm up Switch (1)
Sensor #14 - Steer Angle Sensor (4) This switch is located on Main Control valve. It monitors the
temperature of the main control valve.
These sensors are used to measure wheel steer angles. These
rotary sensors are mounted on top of each king pin. Sensor #20 - Main Valve Pressure Transducer (1)
Sensor #15 - Axle extend/retract Sensor (4) This pressure transducer is located on the main control valve.
It is used to monitor pressure of the lower pressure functions
These sensors are used to measure axle rotation between the of the machine (all control valve functions except Lift and Tele-
retracted and extended positions. Each sensor is mounted scope), to assure that they are within the regulated range.
between the frame and an axle.
Sensor #16 - Brake-Two Speed Pressure Sensor (1)

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

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

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

PIN # D ESC SEN SOR H AR N ESS
P IN #1 P OWE R RE D ORA NGE
P IN #2 P WM OUT WHITE Y E LLOW
P IN #3 GROUND B LA CK B LA CK
Figure 6-29. Platform Level Sensor
3121619 – JLG Lift – 6-47

Sensor #21 - Main Lift Cylinder Pressure Transducer 3. Plug the analyzer into the connector at the base of the
platform control box.
(1)
This pressure transducer is located on the port block of the
main boom lift cylinder. This is used for the diagnostics of the
lift cylinder.
6.7 SYSTEM TEST

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

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

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

trol Station.
6-48 – JLG Lift – 3121619

5. Pull out the Emergency Stop switch and Start the 7. Use the arrow button to reach SYSTEM TEST. Hit Enter.
engine. The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
8. Follow the flow path in Figure 6-30., System Test Flow
Chart - Platform Tests - Sheet 1 of 2 and Figure 6-31., Sys-
tem Test Flow Chart - Platform Tests - Sheet 2 of 2 and go
through the component tests. Hit the ESC key during
any part of the test to return to the main menu without
completing all tests or wait until all tests are complete.
During the TEST ALL INPUTS sequence, the analyzer
allows control switches to be operated and shows if they
are closed (CL) or open (OP).
6. The analyzer screen should read:
3121619 – JLG Lift – 6-49

Figure 6-30. System Test Flow Chart - Platform Tests - Sheet 1 of 2
6-50 – JLG Lift – 3121619

Figure 6-31. System Test Flow Chart - Platform Tests - Sheet 2 of 2
3121619 – JLG Lift – 6-51

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.
4. The analyzer screen should read:

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 6-32., 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).
6-52 – JLG Lift – 3121619

Figure 6-32. System Test Flow Chart - Ground Station Tests
3121619 – JLG Lift – 6-53

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.
6-54 – JLG Lift – 3121619


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.
3121619 – JLG Lift – 6-55


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.
6-56 – JLG Lift – 3121619

6.8 CALIBRATION PROCEDURES General notes:

During all controller lag times the controller should display
Axle Calibration “CALIBRATING…”
The axle angle sensors need to be calibrated to ensure that the After each operator “ENTER” input preceding the recording of
axle angle can be accurately calculated. The machine must be sensor values, the controller will wait 10 seconds for the boom
in transport position to perform an axle calibration. If the steer dynamics to settle down before readings are taken.
sensors have not been calibrated, they will be calibrated as
part of the axle calibration procedure. During the calibration if the ESC key is pressed after the cali-
bration procedure is started, the calibration will be aborted
Axle Calibration is available under AXLE SWING under the CAL- and “CAL FAILED” will be displayed on the bottom line of the
IBRATIONS menu using the analyzer. analyzer and the previous calibration values will be used for
the boom sensors.
When performing a calibration, the first prompt will be to
RETRACT AXLES. 1. With the analyzer, put the vehicle into Access Level 1
and enter the “BOOM SENSORS” calibration. The Con-
The analyzer will prompt to move to the next sequence once
troller will display “CAL. POSITION 1” on the top line and
the axle retract conditions are met and retract values are
“CHECK SYSTEM?” on the bottom line.
stored in the Control System.
2. After the operator presses the ENTER key, the controller
If the steer sensors have not been calibrated when an axle cali-
will verify:
bration is attempted, the system shall require the steer sensors
be calibrated. If this is the case, the analyzer prompt shall auto- • the angle sensors and length sensors are reporting valid
matically redirect to the steer sensor calibration section after data,
the axle retract position is calibrated (Refer to steer sensor cali-
bration). If the steer sensors have been calibrated, this step • the axles are completely extended,
shall be skipped. • the wheels are straight within 10°,
The analyzer will prompt to EXTEND AXLES. • the Boom Length Limit switch is in the retracted position,
The analyzer shall prompt to move after the extend conditions • the drive orientation switch is indicating the turntable is
are met and extend values are stored in the Control System. between the rear tires,
The axle calibration is complete at this point.
• the Jib aligned switch is on if equipped,
Boom Sensor Calibration • the chassis tilt sensor reads less than 1.5° out of level,
Initial conditions prior to initiating boom sensor calibration: • the machine is in Ground Mode and the steering, tilt sensor
calibrations have been successfully completed,
• Steering sensor, tilt sensor, and telescope crack point cali-
brations are complete • Jib Transport sensors are healthy,
• Axle calibration is complete • the Jib Level, Jib Swing, Main Cylinder Angle, Jib Lift, Plat-
form Level Cylinder Position and turntable sensors are
• Chassis tilt calibration is complete healthy,
• Ensure the axles are completely extended and axle set • the Jib is fully retracted and the Jib Pin is Locked,
lamp is ON
• if Model 1850 the axle calibration has been performed.
• Ensure the wheels are straight
• Ensure the platform is unloaded and boom is clean
• Ensure the jib is horizontal
• Ensure the jib swing is centered if Jib swing is configured
• Ensure the platform is level
• Ensure the platform is not rotated
• Ensure the turntable is centered between the rear tires
• Ensure the boom is fully retracted
• Ensure the machine indicates that it is on a level surface +/-
1.5°
• Ensure Ground Mode is selected
3121619 – JLG Lift – 6-57

3. If the initial conditions are not met, the controller will 6. The controller shall display “LIFT UP TO STOP”. After the
prompt the operator with analyzer messages “BLAM operator presses the ENTER key, the controller shall dis-
CAN LOST”, “AXLE VALVE FAULT”, OSC AXL SW FAULT”, play “CAL POSITION 3” and “SWING 180 DEG”. After the
“PARK BRAKE FAULT”, “ANGL SNSR1 FAULT”, “ANGL SNSR2 operator presses the ENTER key, the controller must see
FAULT”, “MOMENT PIN FAULT”, “LEN SNSR FAULT”, “CAL a change in the drive orientation switch or “CAL FAILED”
STEERING”, “CAL TILT SENSOR”, “CAL UPPER TELE”, and “DRIVE ORNT SW” shall be displayed. The boom
“EXTEND AXLES”, “LEVEL MACHINE”, “CENTER WHEELS”, angle sensors must also be within 10° of 40.6° (80.6° -
“TELE IN”, “ALIGN TURNTABLE”, “CENTER JIB SWING”, 40.0° = 40.6° equals rough angle sensor mounting off-
“SELECT GRND MODE”, “JIB TRANSPORT SENSOR FAULT”, set) or “CAL FAILED” and “ANGL SNSR# FAULT” will be
“JIB LEVEL SENOSR FAULT”, JIB SWING SENSOR FAULT”, displayed. The controller shall also check that the Main
“MAIN CYL ANGLE SENSOR FAULT”, “JIB LIFT SENSOR Cylinder Angle 1 sensor counts are between 15000 and
FAULT”, “PLATFORM LEVEL SENSOR FAULT”, “TURN TABLE 32767 and that sensor 2 is between 100 and 14000
SENSOR FAULT”, “JIB TELE IN”, “LOCK JIB PIN” and counts or “CAL FAILED” and “CYLN SNSR1 FAULT” or
“REMOVE DONGLE” to satisfy the initial conditions. The “CYLN SNSR2 FAULT” will be displayed.
controller will then prompt with “UNLOAD PLATFORM?”,
7. The controller at this point shall disable lift down. The
“JIB HORIZONTAL?”, “LEVEL PLATFORM?”, “CENTER PLAT- controller will record the following: moment value
FORM?” and “TELE IN TO STOP?”. based on load-pin output, both boom angle sensor raw
outputs, both main cylinder angle counts and the
4. Once the initial conditions are verified, the controller will
retracted length of the boom. The retracted length will
display “SKY WELDER NO”. If a sky welder is installed, the
be set at 539.7”. The raw length sensor A/D counts must
operator presses an ARROW key to switch to “SKY between 100 and 1311 counts or “CAL FAILED” and “LEN
WELDER YES. A similar set of menus will prompt the SNSR FAULT” shall be displayed.
operator to select sky cutter, sky glazier, sky bright, pipe
racks and camera mount. 8. The controller will display “CAL POSITION 4” on the first
line and “SWING 180 DEG”. After the operator presses
5. If the operator selects sky bright the controller will dis- the ENTER key, the controller must see a change in the
play “CAL FAILED” and “REMOVE SKYBRIGHT”. If more drive orientation switch or “CAL FAILED” and “DRIVE
than one accessory is selected except for the combina- ORNT SW” will be displayed. The controller will record
tion of sky welder/sky cutter the controller will display moment value based on load-pin output and both
“CAL FAILED” and “# OF ACCESSORIES”. If a valid acces- boom angle sensor raw outputs. If the change in right
sory option has been selected after the camera mount boom angle sensor readings is more than 1.0° from the
selection and the operator presses the ENTER key, the change in left boom angle sensor readings, “CAL
controller will display “CALIBRATE?”. After the operator FAILED” and “ANGL SNSR FAILED” will be displayed. If
presses the ENTER key, the controller will check that the this moment falls outside the expected calibration
Main Cylinder Angle 1 sensor counts are between 100 moment range of 1.288E+06 to 1.932E+06, “CAL FAILED”
and 14000 counts and that Main Cylinder Angle 2 sensor and “MOMENT PIN FAULT” will be displayed.
counts are between 15000 and 32767 counts. If they are
not in the given ranges, the controller shall display “CAL 9. If no failures have occurred, The controller will enable
FAILED” and “CYLN SNSR1 FAULT” or “CYLN SNSR2 telescope out, disable swing, and display “CAL POSITION
FAULT”. If the sensors are in range, the controller will dis- 5” on the first line and “TELE OUT TO STOP”.
able Envelope and Moment control, Telescope out, Jib
10. After the operator presses the ENTER key, the controller
Lift/Swing, Jib Telescope and Basket Level/Rotate func-
will establish this length as 1911.7”. The raw length sen-
tions and display “CAL POSITION 2” on the first line. sor A/D counts must between 29220 and 31220 counts
or “CAL FAILED” and “LEN SNSR FAULT” will be displayed.
6-58 – JLG Lift – 3121619

11. The controller will disable telescope out, enable tele- 17. The controller shall display “CAL POSITION 9” on the first
scope in and display “CAL POSITION 6” on the first line line and “JIB OUT TO STOP” on the second. When the
and “TELE IN TO STOP”. The controller will monitor the operator reaches the stopping point with the Jib and
length sensor reading at which the length limit switch is presses enter, the controller will record the moment for
tripped. The switch should change state at 553 +3.5”/- the 500# forward calibration. If this moment falls outside
5.5”. If the switch changes state in the wrong length the expected calibration moment range of 8.11E+06 to
range for the selected model, “CAL FAILED” and “CHECK 10.81E+06 lb-in “CAL FAILED” and “MOMENT PIN FAULT”
MODEL” will be displayed. If the switch does not change shall be displayed.
state at all, the calibration should be aborted and “CAL
18. The controller shall then display “CAL POSITION 10” on
FAILED” and “LENGTH SW FAILED” will be displayed.
the first line and “JIB IN TO STOP” on the second. When
The length sensor reading at the precise switch trip
the operator reaches the retracted position for the Jib,
point will be recorded for operational length calibration
the menu will automatically advance.
checks each time the boom passes through that point.
19. The controller will enable telescope in and display “CAL
12. If no failures have occurred, the controller will enable lift POSITION 10” on the first line and “TELE IN TO GREEN”.
functions, disable telescope out functions and display When Telescope In is commanded, boom length will be
“CAL POSITION 7” on the first line and “LIFT DN TO controlled to 762.0” +/-0.5”.
STOP”.
20. When the operator presses the ENTER key, the controller
13. When operator presses ENTER controller will record will verify the measured length matches the expected
angle 7. The controller must see a moment reading less green witness mark location, otherwise the controller
than 50,000 lb-in, or “CAL FAILED” and “LIFT DN TO will display “CAL FAILED” and “TELE TO GREEN” each
STOP” will be displayed each time the ENTER key is time the ENTER key is pressed and the measured length
pressed and the moment reading is too high. does not match the expected length. The controller will
calculate and record the 1000# forward calibration
14. The Control system establishes the low angle calibration moment and validate the moment is within the
point by taking into account ground slope in the direc- expected range of 7.658E+06 to 10.21E+06 lb-in. If the
tion of the boom. Low Angle Calibration value = -1.3° +/ Moment is not in this range the controller shall display
- Ground Slope. If either of the angle sensors are not “CAL FAILED” and “MOMENT PIN FAULT”. The controller
within 10.0° of –39.3° (-1.3° - 38.0° = –39.3° equals rough will also revalidate the length switch trip point using the
angle sensor mounting offset) then “CAL FAILED” and retracted and yellow witness mark to calculate length. If
“ANGL SNSR# FAULT” will be displayed. the length switch trip point is not 553 +3.5”/-5.5”, the
controller shall display “CAL FAILED” and “LEN SNSR
15. The controller shall enable telescope out and display FAULT”. Otherwise, the controller shall display “BOOM
“CAL POSITION 8” on the first line and “LIFT UNTIL STOP”. SENSORS” on the first line and “CAL COMPLETE” on the
The controller will disable Lift functions when the boom second line.
angle reaches 0°. When the operator presses the ENTER
key, the controller will verify the measured angle is 0° +/
-1°. If not, The controller will display “CAL FAILED” and
“LIFT UP(DOWN) STOP” each time the ENTER key is
pressed and the angle does not match 0° +/-1°.
16. The controller shall display “CAL POSITION 9” on the first

line and “TELE TO YELLOW”. The swing function will be
enabled and the telescope functions will be disabled
when the measured length reaches 810.0” until the
function is cycled. While the boom is in this state the
telescope functions will be allowed to extend or retract
the boom 1.0” at a time. This can be repeated until the
length reading deviates from the expected witness mark
by more than +/-14”, when “CAL FAILED” and “LENGTH
FAILED” will be displayed. When the operator presses
the ENTER key, the controller will calculate and record
the 500# verification moment value. If this moment falls
outside the expected calibration moment value of
10.720E+06 lb-in, “CAL FAILED” and “MOMENT PIN
FAULT” will be displayed. The raw length sensor A/D
counts must between 5220 and 7220 counts or “CAL
FAILED” and “LEN SNSR FAULT” will be displayed.
3121619 – JLG Lift – 6-59

6.9 ELECTRONIC PLATFORM LEVELING VALVE DRIVER ERRORS

There are three possible level valve driver errors, short to bat-
Platform Leveling Fault Warning tery, short to ground, and open circuit.
The JLG Control System takes a snapshot of the two sensor val- 1. In the case of a short to ground or an open circuit, the
ues and records the difference once on each power up. The platform valve cannot be turned on and the following
will occur:
Control system allows a ±5 degree difference from those val-
ues. For example, if Sensor 1 is at 5 degrees and Sensor 2 is at a. All interactions with platform leveling shall cease
11 degrees, the difference is 6 degrees and the DTC is trig-
b. The Electronic Leveling System Fault Lamp shall
gered when the sensors are 1 degree (or less) apart or 11
flash (to indicate that the leveling function has been
degrees (or more) apart.
lost).
If a fault occurs in the platform leveling system the following c. The platform alarm will sound.
will occur:
d. A system fault will be logged.
1. Automatic platform leveling will stop (except when e. All function speeds (lift, swing, telescope and drive)
there is a fault in only one sensor automatic leveling will will be placed in creep mode (except when the plat-
remain active as the control system will use the other form is in the transport position).
sensor to control leveling)
2. In the case of a short to battery on one of the platform
2. The level fault lamp will flash
leveling valves, the valve cannot be turned off and the
3. The audible alarm will sound following will occur:
4. All functions will default to creep speed if the platform is a. The platform dump valve will be turned off to pre-
out of the transport position. vent unintended tilting of the platform.
To reset the fault the emergency stop switch should be recy- b. All interactions with platform leveling shall cease.
cled. c. The Electronic Leveling System Fault Lamp shall
lost).
IF THE FAULT PERSISTS BRING THE PLATFORM TO THE GROUND POSITION, d. The platform alarm will sound.
SWITCH THE MACHINE OFF AND CONTACT A QUALIFIED SERVICE REPRESEN- e. A system fault will be logged.
TATIVE TO INVESTIGATE THE FAULT.
f. All function speeds (lift, swing, telescope and drive)
will be placed in creep mode (except when the plat-
Fault Response form is in the transport position)
ERROR RESPONSE 3. In the case of a short to battery on the platform dump

If basket level varies from the current setpoint by ± 5.5º for valve, the valve cannot be turned off. The controllability
more than 1.5 seconds when the platform is not in the trans- of the platform leveling function will be impaired and
port position, the following events will occur: the following will occur:
1. The platform dump valve will be disabled (level, rotate a. All interactions with platform leveling shall cease.
and jib functions disabled). b. The Electronic Leveling System Fault Lamp shall
2. The level system fault lamp will flash (to indicate that lost).
the leveling function has been lost).
c. The platform alarm will sound.
3. The platform alarm will sound.
d. A system fault will be logged.
4. A system fault will be logged. e. All function speeds (lift, swing, telescope and drive)
5. All function speeds (lift, swing, telescope and drive) will will be placed in creep mode (except when the plat-
be placed in creep mode (except when the platform is in form is in the transport position).
the transport position see below). Lift, swing, drive and telescope will continue to operate
When the unit is in the transport position and driving and the In each of the cases above it shall be necessary to re-cycle the
current setpoint varies by ± 5.5º for more than 8 seconds the EMS to clear the fault. Operable functions shall be in the creep
events 1,2,3 & 4 above will occur. (note function speeds will mode except while below elevation.
operate normally). Cycling the EMS will clear the fault and
allow the operator to operate the machine as a new level set-
point is taken.
6-60 – JLG Lift – 3121619

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).
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
is in the transport position).
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).
4. A system fault will be logged.
5. All function speeds (lift, swing, telescope and drive) will

be placed in creep mode (except when the platform is in
the transport position)
At this point, the operator must use the level up and down
toggle switch to manually level during descent. It shall be nec-
essary to re-cycle the EMS to clear the fault.
3121619 – JLG Lift – 6-61

Table 6-7. Diagnostic Fault Code Chart
Fault Text Flash 1 Flash 2 DTC 1350 1200 1250 1500 1850
EVERYTHING OK 0 0 1 ✔ ✔ ✔ ✔ ✔
RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0 0 10 ✔ ✔ ✔ ✔ ✔
FSW OPEN 0 0 11 ✔ ✔ ✔ ✔ ✔
RUNNING AT CREEP - CREEP SWITCH OPEN 0 0 12 ✔ ✔ ✔ ✔ ✔
RUNNING AT CREEP - TILTED AND ABOVE ELEVATION 0 0 13 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT SENSOR OUT OF RANGE 0 0 14 ✔ ✔ ✔ ✔ ✔
LOAD SENSOR READING UNDER WEIGHT 0 0 15 ✔ ✔ ✔ ✔ ✔
ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 0 0 16 ✔ ✔ ✔ ✔ ✔
OVER MOMENT - HYDRAULICS SUSPENDED 0 0 17 ✔ ✔ ✔ ✔ ✔
UNDER MOMENT - HYDRAULICS SUSPENDED 0 0 18 ✔ ✔ ✔ ✔ ✔
MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 0 0 19 ✔ ✔ ✔ ✔ ✔
TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 0 0 20 -- -- ✔ -- --
ADS1213 REINITIALIZED 0 0 21 ✔ ✔ ✔ ✔ ✔
RUNNING AT CREEP - PLATFORM STOWED 0 0 30 ✔ ✔ ✔ ✔ ✔
FUEL LEVEL LOW - ENGINE SHUTDOWN 0 0 31 ✔ ✔ ✔ ✔ ✔
APU ACTIVE 0 0 35 ✔ ✔ ✔ ✔ ✔
JIB UNLOCKED OUT OF TRANSPORT - HYDRAULICS SUSPENDED 0 0 37 -- -- -- ✔ ✔
SWING ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 0 0 38 -- -- -- ✔ ✔
SKYGUARD ACTIVE - FUNCTIONS CUTOUT 0 0 39 ✔ ✔ ✔ ✔ ✔
KEYSWITCH FAULTY 2 1 212 ✔ ✔ ✔ ✔ ✔
FSW FAULTY 2 1 213 ✔ ✔ ✔ ✔ ✔
STEER SWITCHES FAULTY 2 2 227 ✔ ✔ ✔ ✔ ✔
FSW INTERLOCK TRIPPED 2 2 2211 ✔ ✔ ✔ ✔ ✔
DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH 2 2 2212 ✔ ✔ ✔ ✔ ✔
STEER LOCKED - SELECTED BEFORE FOOTSWITCH 2 2 2213 ✔ ✔ ✔ ✔ ✔
D/S JOY. OUT OF RANGE LOW 2 2 2215 ✔ ✔ ✔ ✔ ✔
D/S JOY. OUT OF RANGE HIGH 2 2 2216 ✔ ✔ ✔ ✔ ✔
D/S JOY. CENTER TAP BAD 2 2 2217 ✔ ✔ ✔ ✔ ✔
L/S JOY. OUT OF RANGE LOW 2 2 2218 ✔ ✔ ✔ ✔ ✔
L/S JOY. OUT OF RANGE HIGH 2 2 2219 ✔ ✔ ✔ ✔ ✔
L/S JOY. CENTER TAP BAD 2 2 2220 ✔ ✔ ✔ ✔ ✔
LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH 2 2 2221 ✔ ✔ ✔ ✔ ✔
WAITING FOR FSW TO BE OPEN 2 2 2222 ✔ ✔ ✔ ✔ ✔
FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE 2 2 2223 ✔ ✔ ✔ ✔ ✔
FOOTSWITCH SELECTED BEFORE START 2 2 2224 ✔ ✔ ✔ ✔ ✔
6-62 – JLG Lift – 3121619

FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM 2 3 234 ✔ ✔ ✔ ✔ ✔
FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER 2 3 235 ✔ ✔ ✔ ✔ ✔
FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH 2 3 236 ✔ ✔ ✔ ✔ ✔
START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH 2 3 237 ✔ ✔ ✔ ✔ ✔
TOWER LIFT PRESSURE SENSOR - OUT OF RANGE HIGH 2 3 23100 -- -- ✔ -- --
TOWER LIFT PRESSURE SENSOR - OUT OF RANGE LOW 2 3 23101 -- -- ✔ -- --
TOWER LIFT PRESSURE SENSOR - NOT DETECTING CHANGE 2 3 23102 -- -- ✔ -- --
TOWER LIFT CYLINDER - OVER PRESSURE 2 3 23103 -- -- ✔ -- --
LIFT PRESSURE SENSOR - OUT OF RANGE LOW 2 3 23124 -- -- -- -- ✔
LIFT PRESSURE SENSOR - OUT OF RANGE HIGH 2 3 23125 -- -- -- -- ✔
LIFT PRESSURE SENSOR - NOT DETECTING CHANGE 2 3 23126 -- -- -- -- ✔
LIFT CYLINDER - OVER PRESSURE 2 3 23127 -- -- -- -- ✔
REDUCTION CHECK PRESSURE SENSOR - OUT OF RANGE LOW 2 3 23128 -- -- -- -- ✔
REDUCTION CHECK PRESSURE SENSOR - OUT OF RANGE HIGH 2 3 23129 -- -- -- -- ✔
REDUCTION CHECK PRESSURE SENSOR - HIGH 2 3 23130 -- -- -- -- ✔
REDUCTION CHECK PRESSURE SENSOR - LOW 2 3 23131 -- -- -- -- ✔
MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS 2 5 259 ✔ ✔ ✔ ✔ ✔
GENERATOR MOTION CUTOUT ACTIVE 2 5 2513 ✔ ✔ ✔ ✔ ✔
BOOM PREVENTED - DRIVE SELECTED 2 5 2514 ✔ ✔ ✔ ✔ ✔
DRIVE PREVENTED - BOOM SELECTED 2 5 2515 ✔ ✔ ✔ ✔ ✔
DRIVE PREVENTED - ABOVE ELEVATION 2 5 2516 ✔ ✔ ✔ ✔ ✔
DRIVE PREVENTED - TILTED & ABOVE ELEVATION 2 5 2517 ✔ ✔ ✔ ✔ ✔
JIB SWING PREVENTED - IN 1000# MODE 2 5 2521 ✔ ✔ ✔ ✔ ✔
CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED 2 5 2522 ✔ ✔ ✔ ✔ ✔
BACKUP BLAM COMMUNICATIONS ACTIVE 2 5 2523 -- -- ✔ -- --
DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL 2 5 2524 -- -- ✔ -- --
MACHINE SETUP FAULT - JIB SWING 2 5 2546 ✔ ✔ ✔ ✔ ✔
MACHINE SETUP FAULT - MODEL 2 5 2547 ✔ ✔ ✔ ✔ ✔
SYSTEM TEST MODE ACTIVE 2 5 2548 ✔ ✔ ✔ ✔ ✔
SKYGUARD SW - DISAGREEMENT 2 5 2563 ✔ ✔ ✔ ✔ ✔
FRONT LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 261 -- -- -- -- ✔
FRONT LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH 2 6 262 -- -- -- -- ✔
FRONT RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 263 -- -- -- -- ✔
FRONT RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH 2 6 264 -- -- -- -- ✔
REAR LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 265 -- -- -- -- ✔
3121619 – JLG Lift – 6-63

REAR LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH 2 6 266 -- -- -- -- ✔
REAR RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 267 -- -- -- -- ✔
REAR RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH 2 6 268 -- -- -- -- ✔
FRONT LEFT AXLE SENSOR - NOT RESPONDING 2 6 2611 -- -- -- -- ✔
FRONT RIGHT AXLE SENSOR - NOT RESPONDING 2 6 2612 -- -- -- -- ✔
REAR LEFT AXLE SENSOR - NOT RESPONDING 2 6 2613 -- -- -- -- ✔
REAR RIGHT AXLE SENSOR - NOT RESPONDING 2 6 2614 -- -- -- -- ✔
AXLE RETRACT POSITION - NOT CALIBRATED 2 6 2615 -- -- -- -- ✔
AXLE DEPLOY POSITION - NOT CALIBRATED 2 6 2616 -- -- -- -- ✔
BRAKE - SHORT TO BATTERY 3 3 331 ✔ ✔ ✔ ✔ ✔
BRAKE - OPEN CIRCUIT 3 3 332 ✔ ✔ ✔ ✔ ✔
GROUND ALARM - SHORT TO BATTERY 3 3 3311 ✔ ✔ ✔ ✔ ✔
RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND 3 3 3316 ✔ ✔ ✔ ✔ ✔
RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT 3 3 3317 ✔ ✔ ✔ ✔ ✔
RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY 3 3 3318 ✔ ✔ ✔ ✔ ✔
RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND 3 3 3320 ✔ ✔ ✔ ✔ ✔
RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT 3 3 3321 ✔ ✔ ✔ ✔ ✔
RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY 3 3 3322 ✔ ✔ ✔ ✔ ✔
LEFT FORWARD DRIVE PUMP - SHORT TO GROUND 3 3 3324 ✔ ✔ ✔ ✔ ✔
LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT 3 3 3325 ✔ ✔ ✔ ✔ ✔
LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY 3 3 3326 ✔ ✔ ✔ ✔ ✔
LEFT REVERSE DRIVE PUMP - SHORT TO GROUND 3 3 3328 ✔ ✔ ✔ ✔ ✔
LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT 3 3 3329 ✔ ✔ ✔ ✔ ✔
LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY 3 3 3330 ✔ ✔ ✔ ✔ ✔
ALTERNATOR/ECM POWER - SHORT TO GROUND 3 3 3336 ✔ ✔ ✔ ✔ ✔
ALTERNATOR POWER - OPEN CIRCUIT 3 3 3338 ✔ ✔ ✔ ✔ ✔
ALTERNATOR POWER - SHORT TO BATTERY 3 3 3339 ✔ ✔ ✔ ✔ ✔
AUX POWER - SHORT TO GROUND 3 3 3340 ✔ ✔ ✔ ✔ ✔
AUX POWER - OPEN CIRCUIT 3 3 3341 ✔ ✔ ✔ ✔ ✔
AUX POWER - SHORT TO BATTERY 3 3 3342 ✔ ✔ ✔ ✔ ✔
COLD START ADVANCE SOLENOID - SHORT TO GROUND 3 3 3343 ✔ ✔ ✔ ✔ ✔
COLD START ADVANCE SOLENOID - OPEN CIRCUIT 3 3 3344 ✔ ✔ ✔ ✔ ✔
COLD START ADVANCE SOLENOID - SHORT TO BATTERY 3 3 3345 ✔ ✔ ✔ ✔ ✔
ELECTRIC PUMP - SHORT TO GROUND 3 3 3349 ✔ ✔ ✔ ✔ ✔
ELECTRIC PUMP - OPEN CIRCUIT 3 3 3350 ✔ ✔ ✔ ✔ ✔
6-64 – JLG Lift – 3121619

ELECTRIC PUMP - SHORT TO BATTERY 3 3 3351 ✔ ✔ ✔ ✔ ✔
MAIN DUMP VALVE - SHORT TO GROUND 3 3 3358 ✔ ✔ ✔ ✔ ✔
MAIN DUMP VALVE - OPEN CIRCUIT 3 3 3359 ✔ ✔ ✔ ✔ ✔
MAIN DUMP VALVE - SHORT TO BATTERY 3 3 3360 ✔ ✔ ✔ ✔ ✔
BRAKE - SHORT TO GROUND 3 3 3361 ✔ ✔ ✔ ✔ ✔
START SOLENOID - SHORT TO GROUND 3 3 3362 ✔ ✔ ✔ ✔ ✔
START SOLENOID - OPEN CIRCUIT 3 3 3363 ✔ ✔ ✔ ✔ ✔
START SOLENOID - SHORT TO BATTERY 3 3 3364 ✔ ✔ ✔ ✔ ✔
TWO SPEED VALVE - SHORT TO GROUND 3 3 3368 ✔ ✔ ✔ ✔ ✔
TWO SPEED VALVE - OPEN CIRCUIT 3 3 3369 ✔ ✔ ✔ ✔ ✔
TWO SPEED VALVE - SHORT TO BATTERY 3 3 3370 ✔ ✔ ✔ ✔ ✔
GROUND ALARM - SHORT TO GROUND 3 3 3371 ✔ ✔ ✔ ✔ ✔
GROUND ALARM - OPEN CIRCUIT 3 3 3372 ✔ ✔ ✔ ✔ ✔
GEN SET/WELDER - SHORT TO GROUND 3 3 3373 ✔ ✔ ✔ ✔ ✔
GEN SET/WELDER - OPEN CIRCUIT 3 3 3374 ✔ ✔ ✔ ✔ ✔
GEN SET/WELDER - SHORT TO BATTERY 3 3 3375 ✔ ✔ ✔ ✔ ✔
HEAD TAIL LIGHT - SHORT TO GROUND 3 3 3376 ✔ ✔ ✔ ✔ ✔
HEAD TAIL LIGHT - OPEN CIRCUIT 3 3 3377 ✔ ✔ ✔ ✔ ✔
HEAD TAIL LIGHT - SHORT TO BATTERY 3 3 3378 ✔ ✔ ✔ ✔ ✔
HOUR METER - SHORT TO GROUND 3 3 3379 ✔ ✔ ✔ ✔ ✔
HOUR METER - OPEN CIRCUIT 3 3 3380 ✔ ✔ ✔ ✔ ✔
HOUR METER - SHORT TO BATTERY 3 3 3381 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND 3 3 3385 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT 3 3 3386 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY 3 3 3387 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND 3 3 3391 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT 3 3 3392 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY 3 3 3393 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND 3 3 3394 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT 3 3 3395 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY 3 3 3396 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND 3 3 3397 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT 3 3 3398 ✔ ✔ ✔ ✔ ✔
PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY 3 3 3399 ✔ ✔ ✔ ✔ ✔
JIB LIFT UP VALVE - SHORT TO GROUND 3 3 33100 ✔ ✔ ✔ -- --
3121619 – JLG Lift – 6-65

JIB LIFT UP VALVE - OPEN CIRCUIT 3 3 33101 ✔ ✔ ✔ -- --
JIB LIFT UP VALVE - SHORT TO BATTERY 3 3 33102 ✔ ✔ ✔ -- --
JIB LIFT DOWN VALVE - SHORT TO GROUND 3 3 33103 ✔ ✔ ✔ -- --
JIB LIFT DOWN VALVE - OPEN CIRCUIT 3 3 33104 ✔ ✔ ✔ -- --
JIB LIFT DOWN VALVE - SHORT TO BATTERY 3 3 33105 ✔ ✔ ✔ -- --
SWING RIGHT VALVE - SHORT TO GROUND 3 3 33118 ✔ ✔ ✔ ✔ ✔
SWING RIGHT VALVE - OPEN CIRCUIT 3 3 33119 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE IN VALVE - SHORT TO BATTERY 3 3 33120 ✔ ✔ ✔ ✔ ✔
SWING RIGHT VALVE - SHORT TO BATTERY 3 3 33121 ✔ ✔ ✔ ✔ ✔

SWING LEFT VALVE - SHORT TO GROUND 3 3 33122 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY 3 3 33123 ✔ ✔ ✔ ✔ ✔
THROTTLE ACTUATOR - SHORT TO GROUND 3 3 33130 ✔ ✔ ✔ ✔ ✔
THROTTLE ACTUATOR - OPEN CIRCUIT 3 3 33131 ✔ ✔ ✔ ✔ ✔
THROTTLE ACTUATOR - SHORT TO BATTERY 3 3 33132 ✔ ✔ ✔ ✔ ✔
PLATFORM CONTROL VALVE - SHORT TO GROUND 3 3 33133 ✔ ✔ ✔ ✔ ✔
PLATFORM CONTROL VALVE - OPEN CIRCUIT 3 3 33134 ✔ ✔ ✔ ✔ ✔
PLATFORM CONTROL VALVE - SHORT TO BATTERY 3 3 33135 ✔ ✔ ✔ ✔ ✔
MAIN LIFT APU VALVE - SHORT TO GROUND 3 3 33136 -- -- ✔ -- --
MAIN LIFT APU VALVE - OPEN CIRCUIT 3 3 33137 -- -- ✔ -- --
MAIN LIFT APU VALVE - SHORT TO BATTERY 3 3 33138 -- -- ✔ -- --
MAIN LIFT PILOT - PRESSURE FAILURE 3 3 33139 -- -- ✔ -- --
MAIN LIFT PILOT - NO PRESSURE 3 3 33140 -- -- ✔ -- --
MAIN LIFT PILOT - PRESSURE SWITCH FAILURE 3 3 33141 -- -- ✔ -- --
TOWER LIFT APU VALVE - STUCK OPEN 3 3 33142 -- -- ✔ -- --
TOWER LIFT ENABLE VALVE - STUCK OPEN 3 3 33143 -- -- ✔ -- --
TOWER LIFT ENABLE VALVE - SHORT TO GROUND 3 3 33144 -- -- ✔ -- --
TOWER LIFT ENABLE VALVE - OPEN CIRCUIT 3 3 33145 -- -- ✔ -- --
TOWER LIFT ENABLE VALVE - SHORT TO BATTERY 3 3 33146 -- -- ✔ -- --
TOWER TELESCOPE APU VALVE - SHORT TO GROUND 3 3 33147 -- -- ✔ -- --
TOWER TELESCOPE APU VALVE - OPEN CIRCUIT 3 3 33148 -- -- ✔ -- --
TOWER TELESCOPE APU VALVE - SHORT TO BATTERY 3 3 33149 -- -- ✔ -- --
LIFT PILOT VALVE - SHORT TO GROUND 3 3 33150 ✔ ✔ -- ✔ ✔
LIFT PILOT VALVE - OPEN CIRCUIT 3 3 33151 ✔ ✔ -- ✔ ✔
LIFT PILOT VALVE - SHORT TO BATTERY 3 3 33152 ✔ ✔ -- ✔ ✔
LIFT DOWN AUX VALVE - SHORT TO GROUND 3 3 33153 ✔ ✔ -- ✔ ✔
6-66 – JLG Lift – 3121619

LIFT DOWN AUX VALVE - OPEN CIRCUIT 3 3 33154 ✔ ✔ -- ✔ ✔
LIFT DOWN AUX VALVE - SHORT TO BATTERY 3 3 33155 ✔ ✔ -- ✔ ✔
TOWER LIFT APU VALVE - SHORT TO GROUND 3 3 33156 -- -- ✔ -- --
TOWER LIFT APU VALVE - OPEN CIRCUIT 3 3 33157 -- -- ✔ -- --
TOWER LIFT APU VALVE - SHORT TO BATTERY 3 3 33158 -- -- ✔ -- --
MAIN LIFT ENABLE VALVE - SHORT TO GROUND 3 3 33159 -- -- ✔ -- ✔
MAIN LIFT ENABLE VALVE - OPEN CIRCUIT 3 3 33160 -- -- ✔ -- ✔
MAIN LIFT ENABLE VALVE - SHORT TO BATTERY 3 3 33161 -- -- ✔ -- ✔
TOWER TELESCOPE APU VALVE - STUCK OPEN 3 3 33162 -- -- ✔ -- --
TOWER TELESCOPE ENABLE VALVE - STUCK OPEN 3 3 33163 -- -- ✔ -- --
TOWER TELESCOPE ENABLE VALVE - SHORT TO GROUND 3 3 33164 -- -- ✔ -- --
TOWER TELESCOPE ENABLE VALVE - OPEN CIRCUIT 3 3 33165 -- -- ✔ -- --
TOWER TELESCOPE ENABLE VALVE - SHORT TO BATTERY 3 3 33166 -- -- ✔ -- --
PVG ENABLE VALVE - SHORT TO GROUND 3 3 33167 -- -- ✔ -- --
PVG ENABLE VALVE - OPEN CIRCUIT 3 3 33168 -- -- ✔ -- --
PVG ENABLE VALVE - SHORT TO BATTERY 3 3 33169 -- -- ✔ -- --
RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY 3 3 33173 ✔ ✔ ✔ ✔ ✔
OR OPEN CIRCUIT
RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIR- 3 3 33174 ✔ ✔ ✔ ✔ ✔
CUIT
JIB ROTATE LEFT VALVE - OPEN CIRCUIT 3 3 33175 ✔ ✔ ✔ -- --
JIB ROTATE LEFT VALVE - SHORT TO BATTERY 3 3 33176 ✔ ✔ ✔ -- --
JIB ROTATE LEFT VALVE - SHORT TO GROUND 3 3 33177 ✔ ✔ ✔ -- --
JIB ROTATE RIGHT VALVE - OPEN CIRCUIT 3 3 33178 ✔ ✔ ✔ -- --
JIB ROTATE RIGHT VALVE - SHORT TO BATTERY 3 3 33179 ✔ ✔ ✔ -- --
JIB ROTATE RIGHT VALVE - SHORT TO GROUND 3 3 33180 ✔ ✔ ✔ -- --
MAIN LIFT UP VALVE - OPEN CIRCUIT 3 3 33181 ✔ ✔ -- ✔ ✔
MAIN LIFT UP VALVE - SHORT TO BATTERY 3 3 33329 ✔ ✔ -- ✔ ✔
MAIN LIFT UP VALVE - SHORT TO GROUND 3 3 33183 ✔ ✔ -- ✔ ✔
MAIN LIFT DOWN VALVE - OPEN CIRCUIT 3 3 33184 ✔ ✔ -- ✔ ✔
MAIN LIFT DOWN VALVE - SHORT TO GROUND 3 3 33185 ✔ ✔ -- ✔ ✔
MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT 3 3 33186 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE OUT VALVE - SHORT TO GROUND 3 3 33188 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE IN VALVE - OPEN CIRCUIT 3 3 33189 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE IN VALVE - SHORT TO GROUND 3 3 33190 ✔ ✔ ✔ ✔ ✔
HORN - OPEN CIRCUIT 3 3 33207 ✔ ✔ ✔ ✔ ✔
3121619 – JLG Lift – 6-67

HORN - SHORT TO BATTERY 3 3 33208 ✔ ✔ ✔ ✔ ✔
HORN - SHORT TO GROUND 3 3 33209 ✔ ✔ ✔ ✔ ✔
GLOWPLUG - OPEN CIRCUIT 3 3 33279 ✔ ✔ ✔ ✔ ✔
GLOWPLUG - SHORT TO BATTERY 3 3 33280 ✔ ✔ ✔ ✔ ✔
GLOWPLUG - SHORT TO GROUND 3 3 33281 ✔ ✔ ✔ ✔ ✔
ALTERNATOR EXCITATION LINE - SHORT TO BATTERY 3 3 33285 ✔ ✔ ✔ ✔ ✔
SWING LEFT VALVE - OPEN CIRCUIT 3 3 33295 ✔ ✔ ✔ ✔ ✔
SWING LEFT VALVE - SHORT TO BATTERY 3 3 33306 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND 3 3 33307 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT 3 3 33308 ✔ ✔ ✔ ✔ ✔
MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY 3 3 33309 ✔ ✔ ✔ ✔ ✔
MAIN LIFT DOWN VALVE - SHORT TO BATTERY 3 3 33310 ✔ ✔ -- ✔ ✔
MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND 3 3 33311 ✔ ✔ -- ✔ ✔
MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT 3 3 33312 ✔ ✔ -- ✔ ✔
MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY 3 3 33313 ✔ ✔ -- ✔ ✔
LIFT UP VALVE - SHORT TO BATTERY 3 3 33329 -- -- -- -- ✔
SWING - CURRENT FEEDBACK READING TOO LOW 3 3 33414 -- -- -- -- ✔
SWING - CURRENT FEEDBACK READING LOST 3 3 33418 -- -- -- -- ✔
JIB LIFT UP OVERRIDE VALVE - SHORT TO GROUND 3 3 33429 -- -- -- ✔ ✔
JIB LIFT UP OVERRIDE VALVE - OPEN CIRCUIT 3 3 33430 -- -- -- ✔ ✔
JIB LIFT UP OVERRIDE VALVE - SHORT TO BATTERY 3 3 33431 -- -- -- ✔ ✔
JIB LIFT DOWN OVERRIDE VALVE - SHORT TO GROUND 3 3 33432 -- -- -- ✔ ✔
JIB LIFT DOWN OVERRIDE VALVE - OPEN CIRCUIT 3 3 33433 -- -- -- ✔ ✔
JIB LIFT DOWN OVERRIDE VALVE - SHORT TO BATTERY 3 3 33434 -- -- -- ✔ ✔
JIB CONTROL VALVE - SHORT TO GROUND 3 3 33435 -- -- -- ✔ ✔
JIB CONTROL VALVE - OPEN CIRCUIT 3 3 33436 -- -- -- ✔ ✔
JIB CONTROL VALVE - SHORT TO BATTERY 3 3 33437 -- -- -- ✔ ✔
MAIN LIFT FLOW CONTROL VALVE - CURRENT FEEDBACK READING LOST 3 3 33456 -- -- -- -- ✔
MAIN LIFT FLOW CONTROL VALVE - CURRENT FEEDBACK READING TOO 3 3 33457 -- -- -- -- ✔
LOW
TELESCOPE FLOW CONTROL VALVE - CURRENT FEEDBACK READING LOST 3 3 33460 -- -- -- -- ✔
TELESCOPE FLOW CONTROL VALVE - CURRENT FEEDBACK READING TOO 3 3 33461 -- -- -- -- ✔
LOW
WARM UP VALVE - SHORT TO BATTERY 3 3 33462 -- -- -- -- ✔
WARM UP VALVE - OPEN CIRCUIT 3 3 33463 -- -- -- -- ✔
WARM UP VALVE - SHORT TO GROUND 3 3 33464 -- -- -- -- ✔
6-68 – JLG Lift – 3121619

CHASSIS ENABLE VALVE - SHORT TO BATTERY 3 3 33465 -- -- -- -- ✔
CHASSIS ENABLE VALVE - OPEN CIRCUIT 3 3 33466 -- -- -- -- ✔
CHASSIS ENABLE VALVE - SHORT TO GROUND 3 3 33467 -- -- -- -- ✔
TWO SPEED OR BRAKE VALVE - STUCK OPEN 3 3 33487 -- -- -- -- ✔
SWING FLOW CONTROL VALVE - SHORT TO GROUND 3 3 33488 -- -- -- -- ✔
SWING FLOW CONTROL VALVE - OPEN CIRCUIT 3 3 33489 -- -- -- -- ✔
SWING FLOW CONTROL VALVE - SHORT TO BATTERY 3 3 33490 -- -- -- -- ✔
LIFT ENABLE VALVE - STUCK OPEN 3 3 33563 -- -- -- -- ✔
COUNTER BALANCE VALVE - STUCK OPEN 3 3 33564 -- -- -- -- ✔
LIFT ENABLE - CURRENT FEEDBACK READING LOST 3 3 33565 -- -- -- -- ✔
LIFT ENABLE - CURRENT FEEDBACK READING TOO LOW 3 3 33566 -- -- -- -- ✔
JIB LOCK VALVE - OPEN CIRCUIT 3 4 3427 -- -- -- ✔ ✔
JIB LOCK VALVE - SHORT TO BATTERY 3 4 3428 -- -- -- ✔ ✔
JIB LOCK VALVE - SHORT TO GROUND 3 4 3429 -- -- -- ✔ ✔
JIB UNLOCK VALVE - OPEN CIRCUIT 3 4 3430 -- -- -- ✔ ✔
JIB UNLOCK VALVE - SHORT TO BATTERY 3 4 3431 -- -- -- ✔ ✔
JIB UNLOCK VALVE - SHORT TO GROUND 3 4 3432 -- -- -- ✔ ✔
PLATFORM LEVEL UP VALVE - SHORT TO GROUND 3 4 343 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 4 344 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND 3 4 347 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 4 348 ✔ ✔ ✔ ✔ ✔
JIB LEVEL UP VALVE - SHORT TO GROUND 3 5 351 -- -- -- ✔ ✔
JIB LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 352 -- -- -- ✔ ✔
JIB LEVEL DOWN VALVE - SHORT TO GROUND 3 5 353 -- -- -- ✔ ✔
JIB LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 354 -- -- -- ✔ ✔
JIB LIFT UP VALVE - SHORT TO GROUND 3 5 355 -- -- -- ✔ ✔
JIB LIFT UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 356 -- -- -- ✔ ✔
JIB LIFT DOWN VALVE - SHORT TO GROUND 3 5 357 -- -- -- ✔ ✔
JIB LIFT DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 358 -- -- -- ✔ ✔
JIB ROTATE LEFT VALVE - SHORT TO GROUND 3 5 359 -- -- -- ✔ ✔
JIB ROTATE LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3510 -- -- -- ✔ ✔
JIB ROTATE RIGHT VALVE - SHORT TO GROUND 3 5 3511 -- -- -- ✔ ✔
JIB ROTATE RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3512 -- -- -- ✔ ✔
JIB TELESCOPE IN VALVE - SHORT TO GROUND 3 5 3513 -- -- -- ✔ ✔
JIB TELESCOPE IN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3514 -- -- -- ✔ ✔
3121619 – JLG Lift – 6-69

JIB TELESCOPE OUT VALVE - SHORT TO GROUND 3 5 3515 -- -- -- ✔ ✔
JIB TELESCOPE OUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3516 -- -- -- ✔ ✔
FRONT AXLE EXTEND VALVE - SHORT TO BATTERY 3 6 361 -- -- -- -- ✔
FRONT AXLE EXTEND VALVE - SHORT TO GROUND 3 6 362 -- -- -- -- ✔
FRONT AXLE RETRACT VALVE - SHORT TO BATTERY 3 6 363 -- -- -- -- ✔
FRONT AXLE RETRACT VALVE - SHORT TO GROUND 3 6 364 -- -- -- -- ✔
REAR AXLE EXTEND VALVE - SHORT TO BATTERY 3 6 365 -- -- -- -- ✔
REAR AXLE EXTEND VALVE - SHORT TO GROUND 3 6 366 -- -- -- -- ✔
REAR AXLE RETRACT VALVE - SHORT TO BATTERY 3 6 367 -- -- -- -- ✔
REAR AXLE RETRACT VALVE - SHORT TO GROUND 3 6 368 -- -- -- -- ✔
FRONT AXLE EXTEND VALVE - OPEN CIRCUIT 3 6 369 -- -- -- -- ✔
FRONT AXLE VALVE - CURRENT FEEDBACK READING LOST 3 6 3610 -- -- -- -- ✔
FRONT AXLE RETRACT VALVE - OPEN CIRCUIT 3 6 3611 -- -- -- -- ✔
REAR AXLE VALVE - CURRENT FEEDBACK READING LOST 3 6 3612 -- -- -- -- ✔
REAR AXLE EXTEND VALVE - OPEN CIRCUIT 3 6 3613 -- -- -- -- ✔
FRONT AXLE VALVE - CURRENT FEEDBACK READING TOO LOW 3 6 3514 -- -- -- -- ✔
REAR AXLE RETRACT VALVE - OPEN CIRCUIT 3 6 3615 -- -- -- -- ✔
REAR AXLE VALVE - CURRENT FEEDBACK READING TOO LOW 3 6 3616 -- -- -- -- ✔
CHASSIS BRAKE - OPEN CIRCUIT 3 6 3617 -- -- -- -- ✔
CHASSIS BRAKE - SHORT TO BATTERY 3 6 3618 -- -- -- -- ✔
CHASSIS BRAKE - SHORT TO GROUND 3 6 3619 -- -- -- -- ✔
FRONT AXLE VALVE - SHORT TO BATTERY 3 6 3620 -- -- -- -- ✔
REAR AXLE VAVE - SHORT TO BATTERY 3 6 3621 -- -- -- -- ✔
FUEL SENSOR SHORT TO BATTERY 4 3 431 ✔ ✔ ✔ ✔ ✔
FUEL SENSOR SHORT TO GROUND 4 3 432 ✔ ✔ ✔ ✔ ✔
OIL PRESSURE SHORT TO BATTERY 4 3 433 ✔ ✔ ✔ ✔ ✔
OIL PRESSURE SHORT TO GROUND 4 3 434 ✔ ✔ ✔ ✔ ✔
COOLANT TEMPERATURE SHORT TO GROUND 4 3 435 ✔ ✔ ✔ ✔ ✔
ENGINE TROUBLE CODE 4 3 437 ✔ ✔ ✔ ✔ ✔
HIGH ENGINE TEMP 4 3 438 ✔ ✔ ✔ ✔ ✔
AIR FILTER BYPASSED 4 3 439 ✔ ✔ ✔ ✔ ✔
NO ALTERNATOR OUTPUT 4 3 4310 ✔ ✔ ✔ ✔ ✔
LOW OIL PRESSURE 4 3 4311 ✔ ✔ ✔ ✔ ✔
THROTTLE ACTUATOR FAILURE 4 3 4313 ✔ ✔ ✔ ✔ ✔
WRONG ENGINE SELECTED - ECM DETECTED 4 3 4314 ✔ ✔ ✔ ✔ ✔
6-70 – JLG Lift – 3121619

LOSS OF ENGINE SPEED SENSOR 4 3 4322 ✔ ✔ ✔ ✔ ✔
SPEED SENSOR READING INVALID SPEED 4 3 4323 ✔ ✔ ✔ ✔ ✔
SOOT LOAD WARNING - LOW 4 3 4331 ✔ ✔ ✔ ✔ ✔
SOOT LOAD WARNING - HIGH 4 3 4332 ✔ ✔ ✔ ✔ ✔
SOOT LOAD WARNING - SEVERE 4 3 4333 ✔ ✔ ✔ ✔ ✔
ENGINE COOLANT - LOW LEVEL 4 3 4334 ✔ ✔ ✔ ✔ ✔
BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN 4 4 441 ✔ ✔ ✔ ✔ ✔
BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN 4 4 442 ✔ ✔ ✔ ✔ ✔
LSS BATTERY VOLTAGE TOO HIGH 4 4 443 ✔ ✔ ✔ ✔ ✔
LSS BATTERY VOLTAGE TOO LOW 4 4 444 ✔ ✔ ✔ ✔ ✔
BATTERY VOLTAGE LOW 4 4 445 ✔ ✔ ✔ ✔ ✔
MAIN LIFT PVG VALVE - INTERNAL FAULT 4 5 451 -- -- ✔ -- --
TOWER LIFT PVG VALVE - INTERNAL FAULT 4 5 452 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - INTERNAL FAULT 4 5 453 -- -- ✔ -- --
MAIN LIFT PVG VALVE - HIGH VOLTAGE 4 5 454 -- -- ✔ -- --
TOWER LIFT PVG VALVE - HIGH VOLTAGE 4 5 455 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - HIGH VOLTAGE 4 5 456 -- -- ✔ -- --
MAIN LIFT PVG VALVE - LOW VOLTAGE 4 5 457 -- -- ✔ -- --

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

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

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

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

TOWER LIFT PVG VALVE - OBSTRUCTED 4 5 4520 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - OBSTRUCTED 4 5 4521 -- -- ✔ -- --
MAIN LIFT PVG VALVE - COMMAND IMPROPER 4 5 4522 -- -- ✔ -- --
3121619 – JLG Lift – 6-71

TOWER LIFT PVG VALVE - COMMAND IMPROPER 4 5 4523 -- -- ✔ -- --
TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER 4 5 4524 -- -- ✔ -- --
MAIN LIFT PVG VALVE - TIMEOUT 4 5 4525 -- -- ✔ -- --

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

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

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

CANBUS FAILURE - LOAD SENSING SYSTEM MODULE 6 6 663 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - ENGINE CONTROLLER 6 6 666 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - MAIN LIFT PVG 6 6 667 -- -- ✔ -- --
CANBUS FAILURE - TOWER LIFT PVG 6 6 668 -- -- ✔ -- --
CANBUS FAILURE - TOWER TELESCOPE PVG 6 6 669 -- -- ✔ -- --
6-72 – JLG Lift – 3121619

CANBUS FAILURE - BLAM 6 6 6610 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - CHASSIS MODULE 6 6 6611 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - CYLINDER LOAD PIN 6 6 6612 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - EXCESSIVE CANBUS ERRORS 6 6 6613 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - MAIN ANGLE SENSOR #1 6 6 6614 -- -- ✔ -- --
CANBUS FAILURE - MAIN ANGLE SENSOR #2 6 6 6615 -- -- ✔ -- --
CANBUS FAILURE - TCU MODULE 6 6 6622 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - TELEMATICS CANBUS LOADING TOO HIGH 6 6 6629 ✔ ✔ ✔ ✔ ✔
CANBUS FAILURE - GATEWAY MODULE 6 6 6623 ✔ ✔ ✔ ✔ ✔

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

CHASSIS TILT SENSOR OUT OF RANGE 8 1 814 -- -- -- -- ✔
CHASSIS TILT SENSOR DISAGREEMENT 8 1 815 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT READING DISAGREEMENT 8 1 8111 -- -- -- -- ✔
LSS CELL #1 ERROR 8 2 821 ✔ ✔ ✔ ✔ ✔
LSS CELL #2 ERROR 8 2 822 ✔ ✔ ✔ ✔ ✔
LSS CELL #3 ERROR 8 2 823 ✔ ✔ ✔ ✔ ✔
LSS CELL #4 ERROR 8 2 824 ✔ ✔ ✔ ✔ ✔
LSS HAS NOT BEEN CALIBRATED 8 2 825 ✔ ✔ ✔ ✔ ✔
RUNNING AT CREEP - PLATFORM OVERLOADED 8 2 826 ✔ ✔ ✔ ✔ ✔
DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED 8 2 827 ✔ ✔ ✔ ✔ ✔
LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED 8 2 828 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVELING OVERRIDE ON 8 3 831 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVELING OVERRIDE OFF 8 3 832 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED 8 3 833 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED 8 3 834 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY 8 3 8311 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT 8 3 8312 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE 8 3 8313 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE 8 3 8314 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVELING SENSOR - DISAGREEMENT 8 3 8315 ✔ ✔ ✔ ✔ ✔
3121619 – JLG Lift – 6-73

PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST 8 3 8316 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST 8 3 8317 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVELING SYSTEM TIMEOUT 8 3 8318 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY 8 3 837 ✔ ✔ ✔ ✔ ✔
PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT 8 3 838 ✔ ✔ ✔ ✔ ✔
JIB LEVEL SENSOR #1 - OUT OF RANGE LOW 8 3 8319 -- -- -- ✔ ✔
JIB LEVEL SENSOR #1 - OUT OF RANGE HIGH 8 3 8320 -- -- -- ✔ ✔
JIB LEVEL SENSOR #2 - OUT OF RANGE LOW 8 3 8321 -- -- -- ✔ ✔
JIB LEVEL SENSOR #2 - OUT OF RANGE HIGH 8 3 8322 -- -- -- ✔ ✔
JIB LEVEL SENSORS - NOT CALIBRATED 8 3 8323 -- -- -- ✔ ✔
JIB LEVEL SENSORS - DISAGREEMENT 8 3 8324 -- -- -- ✔ ✔
JIB SWING SENSOR #1 - OUT OF RANGE LOW 8 3 8325 -- -- -- ✔ ✔
JIB SWING SENSOR #1 - OUT OF RANGE HIGH 8 3 8326 -- -- -- ✔ ✔
JIB SWING SENSOR #2 - OUT OF RANGE LOW 8 3 8327 -- -- -- ✔ ✔
JIB SWING SENSOR #2 - OUT OF RANGE HIGH 8 3 8328 -- -- -- ✔ ✔
JIB SWING SENSORS - NOT CALIBRATED 8 3 8329 -- -- -- ✔ ✔
JIB SWING SENSORS - DISAGREEMENT 8 3 8330 -- -- -- ✔ ✔
JIB LOCK PIN SENSOR - DISAGREEMENT 8 3 8331 -- -- -- ✔ ✔
JIB TRANSPORT SENSOR #1 - DISAGREEMENT 8 3 8332 -- -- -- ✔ ✔
JIB TRANSPORT SENSOR #2 - DISAGREEMENT 8 3 8333 -- -- -- ✔ ✔
JIB LIFT ANGLE SENSOR - NOT CALIBRATED 8 3 8334 -- -- -- ✔ ✔
JIB LEVEL UP CRACKPOINT - NOT CALIBRATED 8 3 8335 -- -- -- ✔ ✔
JIB LEVEL DOWN CRACKPOINT - NOT CALIBRATED 8 3 8336 -- -- -- ✔ ✔
JIB LEVELING SYSTEM TIMEOUT 8 3 8337 -- -- -- ✔ ✔
WRONG JIB LOCK PIN RESPONSE 8 3 8338 -- -- -- ✔ ✔
PLATFORM LEVEL ANGLE SENSOR - NOT CALIBRATED 8 3 8339 -- -- -- ✔ ✔
BOOM ANGLE SENSOR DISAGREEMENT 8 4 841 ✔ ✔ -- ✔ ✔
BOOM LENGTH SWITCH FAILED 8 4 842 ✔ ✔ -- ✔ ✔
BOOM LENGTH SWITCH/SENSOR DISAGREEMENT 8 4 843 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE 8 4 844 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR - OUT OF RANGE HIGH 8 4 845 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR - OUT OF RANGE LOW 8 4 846 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH 8 4 847 ✔ ✔ -- ✔ ✔
BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW 8 4 848 ✔ ✔ -- ✔ ✔
BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT 8 4 849 ✔ ✔ ✔ ✔ ✔
6-74 – JLG Lift – 3121619

BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT 8 4 8410 ✔ ✔ ✔ ✔ ✔
BOOM ANGLE SENSOR #1 - INVALID ANGLE 8 4 8411 ✔ ✔ -- ✔ ✔
BOOM ANGLE SENSOR #2 - INVALID ANGLE 8 4 8412 ✔ ✔ -- ✔ ✔
WRONG TELESCOPE RESPONSE 8 4 8413 ✔ ✔ -- ✔ ✔
WRONG LIFT RESPONSE 8 4 8414 ✔ ✔ -- ✔ ✔
TOWER ANGLE SENSOR DISAGREEMENT 8 4 8415 -- -- ✔ -- --
TOWER LENGTH SENSOR DISAGREEMENT 8 4 8416 -- -- ✔ -- --
MAIN ANGLE SENSOR DISAGREEMENT 8 4 8417 -- -- ✔ -- --
TOWER LENGTH SENSOR #1 - OUT OF RANGE HIGH 8 4 8418 -- -- ✔ -- --
TOWER LENGTH SENSOR #1 - OUT OF RANGE LOW 8 4 8419 -- -- ✔ -- --
TOWER LENGTH SENSOR - NOT DETECTING LENGTH CHANGE 8 4 8422 -- -- ✔ -- --
TOWER LENGTH MOVEMENT WITHOUT COMMAND 8 4 8423 -- -- ✔ -- --
TOWER ANGLE SENSOR #1 - INVALID ANGLE 8 4 8428 -- -- ✔ -- --
TOWER ANGLE SENSOR #2 - INVALID ANGLE 8 4 8429 -- -- ✔ -- --
TOWER ANGLE SENSOR #1 - INVALID MODEL 8 4 8430 -- -- ✔ -- --
TOWER ANGLE SENSOR #2 - INVALID MODEL 8 4 8431 -- -- ✔ -- --
MAIN ANGLE SENSOR #1 - INVALID ANGLE 8 4 8432 -- -- ✔ -- --
MAIN ANGLE SENSOR #2 - INVALID ANGLE 8 4 8433 -- -- ✔ -- --
MAIN ANGLE SENSOR - NOT DETECTING ANGLE CHANGE 8 4 8434 -- -- ✔ -- --
MAIN ANGLE MOVEMENT WITHOUT CMD 8 4 8435 -- -- ✔ -- --
WRONG TOWER TELESCOPE RESPONSE 8 4 8436 -- -- ✔ -- --
WRONG TOWER LIFT RESPONSE 8 4 8437 -- -- ✔ -- --
TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE HIGH 8 4 8438 -- -- ✔ -- --
TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE LOW 8 4 8439 -- -- ✔ -- --
TOWER CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE 8 4 8440 -- -- ✔ -- --
TOWER CYLINDER ANGLE MOVEMENT WITHOUT COMMAND 8 4 8441 -- -- ✔ -- --
MAIN TRANSPORT ANGLE SWITCH FAILED 8 4 8442 -- -- ✔ -- --
TWR TRANSPORT SWITCH DISAGREEMENT 8 4 8443 -- -- ✔ -- --
TRANSPORT DUAL CAPACITY SWITCHES BAD 8 4 8444 -- -- ✔ -- --
3121619 – JLG Lift – 6-75

TRANSPORT DUAL CAPACITY BAD TRANSITION 8 4 8445 -- -- ✔ -- --
MAIN TRANSPORT LENGTH SWITCH DISAGREEMENT 8 4 8446 -- -- ✔ -- --
MAIN DUAL CAPACITY LENGTH SWITCH DISAGREEMENT 8 4 8447 -- -- ✔ -- --
MAIN TRANSPORT ANGLE SWITCH/SENSOR DISAGREEMENT 8 4 8448 -- -- ✔ -- --
TOWER CYLINDER ANGLE SWITCH/SENSOR DISAGREEMENT 8 4 8449 -- -- ✔ -- --
NEW MAIN ANGLE SENSOR #1 DETECTED 8 4 8450 -- -- ✔ -- --
NEW MAIN ANGLE SENSOR #2 DETECTED 8 4 8451 -- -- ✔ -- --
TOWER LENGTH SWITCH/SENSOR DISAGREEMENT 8 4 8452 -- -- ✔ -- --
WRONG MAIN TELE RESPONSE 8 4 8453 -- -- ✔ -- --
WRONG MAIN LIFT RESPONSE 8 4 8454 -- -- ✔ -- --
MAIN CYLINDER ANGLE SENSOR #1 - OUT OF RANGE LOW 8 4 8479 -- -- -- ✔ ✔
MAIN CYLINDER ANGLE SENSOR #1 - OUT OF RANGE HIGH 8 4 8480 -- -- -- ✔ ✔
TOWER ENVELOPE MASSIVELY ENCROACHED 8 4 8482 -- -- ✔ -- --
TOWER ENVELOPE MULTIPLE ENCROACHMENTS 8 4 8483 -- -- ✔ -- --
BCS VIOLATION - BOOM LOCKED 8 4 8484 -- -- ✔ -- --
BCS - HYDRAULIC RETRIEVAL ACTIVE 8 4 8485 -- -- ✔ -- --
BCS - ELECTRICAL RETRIEVAL ACTIVE 8 4 8486 -- -- ✔ -- --
BCS - MULTIPLE FAILURES ACTIVE 8 4 8487 -- -- ✔ -- --
MAIN CYLINDER ANGLE SENSOR #2 - OUT OF RANGE LOW 8 4 8492 -- -- -- ✔ ✔
MAIN CYLINDER ANGLE SENSOR #2 - OUT OF RANGE HIGH 8 4 8493 -- -- -- ✔ ✔
MAIN CYLINDER ANGLE SENSORS - DISAGREEMENT 8 4 8494 -- -- -- ✔ ✔
TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE LOW 8 4 8495 -- -- -- ✔ ✔
TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE HIGH 8 4 8496 -- -- -- ✔ ✔
TURN TABLE SENSOR #2 - FREQUENCY OUT OF RANGE LOW 8 4 8497 -- -- -- ✔ ✔
TURN TABLE SENSOR #2 - FREQUENCY OUT OF RANGE HIGH 8 4 8498 -- -- -- ✔ ✔
CHASSIS TURN TABLE SENSORS - DISAGREEMENT 8 4 8499 -- -- -- ✔ ✔
CHASSIS TURN TABLE SENSORS AND DRIVE ORIENTATION SWITCH - DIS- 8 4 84100 -- -- -- ✔ ✔
AGREEMENT
CHASSIS TURN TABLE SENSORS - NOT CALIBRATED 8 4 84101 -- -- -- ✔ ✔
MAIN CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE 8 4 84102 -- -- -- ✔ ✔
JIB LEVEL ANGLE SENSOR - NOT DETECTING CHANGE 8 4 84103 -- -- -- ✔ ✔
JIB LIFT ANGLE SENSOR - NOT DETECTING CHANGE 8 4 84104 -- -- -- ✔ ✔
PLATFORM LEVEL ANGLE SENSOR - NOT DETECTING CHANGE 8 4 84105 -- -- -- ✔ ✔
JIB LEVEL MOVEMENT WITHOUT COMMAND 8 4 84106 -- -- -- ✔ ✔
JIB LIFT MOVEMENT WITHOUT COMMAND 8 4 84107 -- -- -- ✔ ✔
PLATFORM LEVEL MOVEMENT WITHOUT COMMAND 8 4 84108 -- -- -- ✔ ✔
6-76 – JLG Lift – 3121619

WRONG SWING RESPONSE 8 4 84109 -- -- -- -- ✔
MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE 8 5 851 ✔ ✔ -- ✔ ✔
MOMENT PIN - VERTICAL FORCE OUT OF RANGE 8 5 852 ✔ ✔ -- ✔ ✔
LOAD PIN - HORIZONTAL FORCE OUT OF RANGE 8 5 853 -- -- ✔ -- --
LOAD PIN - VERTICAL FORCE OUT OF RANGE 8 5 854 -- -- ✔ -- --
MOMENT PIN - SENSOR FAULT 8 5 855 ✔ ✔ -- ✔ ✔
LOAD PIN - SENSOR FAULT 8 5 856 -- -- ✔ -- --
NEW MOMENT PIN DETECTED 8 5 857 ✔ ✔ -- ✔ ✔
NEW LOAD PIN DETECTED 8 5 858 -- -- ✔ -- --
LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT 8 5 859 -- -- ✔ -- --
LOAD PIN - FORCE VALUES NOT CHANGING 8 5 8510 -- -- ✔ -- --
LOAD PIN - FORCE TOO LOW OVER TOWER ANGLE CHANGE 8 5 8511 -- -- ✔ -- --
LOAD PIN - FORCE TOO LOW OVER MAIN ANGLE CHANGE 8 5 8512 -- -- ✔ -- --
LOAD PIN - FORCE TOO LOW OVER MAIN LENGTH TRANSITION 8 5 8513 -- -- ✔ -- --
RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH DIS- 8 6 861 ✔ ✔ ✔ ✔ ✔
AGREEMENT
AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 862 ✔ ✔ ✔ ✔ --
AXLE EXTEND VALVE - SHORT TO GROUND 8 6 863 ✔ ✔ ✔ ✔ --
AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 864 ✔ ✔ ✔ ✔ --
AXLE RETRACT VALVE - SHORT TO GROUND 8 6 865 ✔ ✔ ✔ ✔ --
RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 866 ✔ ✔ ✔ ✔ --
RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND 8 6 867 ✔ ✔ ✔ ✔ ✔
RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 868 ✔ ✔ ✔ ✔ --
RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND 8 6 869 ✔ ✔ ✔ ✔ ✔
LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8610 ✔ ✔ ✔ ✔ --
LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND 8 6 8611 ✔ ✔ ✔ ✔ ✔
LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8612 ✔ ✔ ✔ ✔ --
LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND 8 6 8613 ✔ ✔ ✔ ✔ ✔
RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8614 ✔ ✔ ✔ ✔ --
RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND 8 6 8615 ✔ ✔ ✔ ✔ ✔
RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8616 ✔ ✔ ✔ ✔ --
RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND 8 6 8617 ✔ ✔ ✔ ✔ ✔
LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8618 ✔ ✔ ✔ ✔ --
LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND 8 6 8619 ✔ ✔ ✔ ✔ ✔
LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 8 6 8620 ✔ ✔ ✔ ✔ --
LEFT REAR STEER LEFT VALVE - SHORT TO GROUND 8 6 8621 ✔ ✔ ✔ ✔ ✔
3121619 – JLG Lift – 6-77

FRONT RIGHT STEER SENSOR - DECOUPLED 8 6 8622 ✔ ✔ ✔ ✔ ✔
FRONT LEFT STEER SENSOR - DECOUPLED 8 6 8623 ✔ ✔ ✔ ✔ ✔
REAR RIGHT STEER SENSOR - DECOUPLED 8 6 8624 ✔ ✔ ✔ ✔ ✔
REAR LEFT STEER SENSOR - DECOUPLED 8 6 8625 ✔ ✔ ✔ ✔ ✔
FRONT LEFT STEER SENSOR - NOT RESPONDING 8 6 8626 ✔ ✔ ✔ ✔ ✔
FRONT RIGHT STEER SENSOR - NOT RESPONDING 8 6 8627 ✔ ✔ ✔ ✔ ✔
REAR LEFT STEER SENSOR - NOT RESPONDING 8 6 8628 ✔ ✔ ✔ ✔ ✔
REAR RIGHT STEER SENSOR - NOT RESPONDING 8 6 8629 ✔ ✔ ✔ ✔ ✔
FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT 8 6 8630 ✔ ✔ ✔ ✔ ✔
FRONT RIGHT STEER SENSOR - SHORT TO BATTERY 8 6 8631 ✔ ✔ ✔ ✔ ✔
FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT 8 6 8632 ✔ ✔ ✔ ✔ ✔
FRONT LEFT STEER SENSOR - SHORT TO BATTERY 8 6 8633 ✔ ✔ ✔ ✔ ✔
REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT 8 6 8634 ✔ ✔ ✔ ✔ ✔
REAR RIGHT STEER SENSOR - SHORT TO BATTERY 8 6 8635 ✔ ✔ ✔ ✔ ✔
REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT 8 6 8636 ✔ ✔ ✔ ✔ ✔
REAR LEFT STEER SENSOR - SHORT TO BATTERY 8 6 8637 ✔ ✔ ✔ ✔ ✔
ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT 8 6 8651 ✔ ✔ ✔ ✔ ✔
RIGHT FRONT STEER RIGHT VALVE - OPEN CIRCUIT 8 6 8670 -- -- -- -- ✔
RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY 8 6 8671 -- -- -- -- ✔
RIGHT FRONT STEER LEFT VALVE - OPEN CIRCUIT 8 6 8672 -- -- -- -- ✔
RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY 8 6 8673 -- -- -- -- ✔
LEFT FRONT STEER RIGHT VALVE - OPEN CIRCUIT 8 6 8674 -- -- -- -- ✔
LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY 8 6 8675 -- -- -- -- ✔
LEFT FRONT STEER LEFT VALVE - OPEN CIRCUIT 8 6 8676 -- -- -- -- ✔
LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY 8 6 8677 -- -- -- -- ✔
RIGHT REAR STEER RIGHT VALVE - OPEN CIRCUIT 8 6 8678 -- -- -- -- ✔
RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY 8 6 8679 -- -- -- -- ✔
RIGHT REAR STEER LEFT VALVE - OPEN CIRCUIT 8 6 8680 -- -- -- -- ✔
RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY 8 6 8681 -- -- -- -- ✔
LEFT REAR STEER RIGHT VALVE - OPEN CIRCUIT 8 6 8682 -- -- -- -- ✔
LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY 8 6 8683 -- -- -- -- ✔
LEFT REAR STEER LEFT VALVE - OPEN CIRCUIT 8 6 8684 -- -- -- -- ✔
LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY 8 6 8685 -- -- -- -- ✔
FRONT LEFT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8686 -- -- -- -- ✔
FRONT RIGHT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8687 -- -- -- -- ✔
6-78 – JLG Lift – 3121619

REAR RIGHT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8688 -- -- -- -- ✔
REAR LEFT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8689 -- -- -- -- ✔
MACHINE SAFTEY SYSTEM OVERRIDE OCCURRED 8 7 873 -- -- -- -- ✔
LSS WATCHDOG RESET 9 9 991 ✔ ✔ ✔ ✔ ✔
LSS EEPROM ERROR 9 9 992 ✔ ✔ ✔ ✔ ✔
LSS INTERNAL ERROR - PIN EXCITATION 9 9 993 ✔ ✔ ✔ ✔ ✔
LSS INTERNAL ERROR - DRDY MISSING FROM A/D 9 9 994 ✔ ✔ ✔ ✔ ✔
EEPROM FAILURE - CHECK ALL SETTINGS 9 9 998 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER 9 9 9911 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION 9 9 9910 ✔ ✔ ✔ ✔ ✔
IMPROPER
PLATFORM MODULE SOFTWARE UPDATE REQUIRED 9 9 9914 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT SENSOR NOT GAIN CALIBRATED 9 9 9915 ✔ ✔ ✔ ✔ ✔
CHASSIS TILT SENSOR GAIN OUT OF RANGE 9 9 9916 ✔ ✔ ✔ ✔ ✔
HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST 9 9 9917 ✔ ✔ ✔ ✔ ✔
HIGH RESOLUTION A2D FAILURE - REINIT LIMIT 9 9 9918 ✔ ✔ ✔ ✔ ✔
GROUND SENSOR REF VOLTAGE OUT OF RANGE 9 9 9919 ✔ ✔ ✔ ✔ ✔
PLATFORM SENSOR REF VOLTAGE OUT OF RANGE 9 9 9920 ✔ ✔ ✔ ✔ ✔
GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY 9 9 9921 ✔ ✔ ✔ ✔ ✔
PLATFORM MODULE FAILURE - HWFS CODE 1 9 9 9922 ✔ ✔ ✔ ✔ ✔
GROUND MODULE FAILURE - HWFS CODE 1 9 9 9923 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED 9 9 9924 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION 9 9 9925 ✔ ✔ ✔ ✔ ✔
IMPROPER
FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION 9 9 9926 ✔ ✔ ✔ ✔ ✔
IMPROPER
GROUND MODULE CONSTANT DATA UPDATE REQUIRED 9 9 9927 ✔ ✔ ✔ ✔ ✔
ENVELOPE CONTROL DISABLED 9 9 9928 ✔ ✔ ✔ ✔ ✔
MOMENT CONTROL DISABLED 9 9 9929 ✔ ✔ ✔ ✔ ✔
STEER SENSORS NOT CALIBRATED 9 9 9930 ✔ ✔ ✔ ✔ ✔
BOOM SENSORS NOT CALIBRATED 9 9 9931 ✔ ✔ ✔ ✔ ✔
LIFT CRACKPOINTS NOT CALIBRATED 9 9 9932 ✔ ✔ -- ✔ ✔
TELESCOPE CRACKPOINTS NOT CALIBRATED 9 9 9933 ✔ ✔ -- ✔ ✔
DRIVE CRACKPOINTS NOT CALIBRATED 9 9 9934 ✔ ✔ ✔ ✔ ✔
BLAM SENSOR SUPPLY OUT OF RANGE HIGH 9 9 9935 ✔ ✔ ✔ ✔ ✔
BLAM SENSOR SUPPLY OUT OF RANGE LOW 9 9 9936 ✔ ✔ ✔ ✔ ✔
LENGTH SENSOR REF VOLTAGE HIGH 9 9 9937 ✔ ✔ ✔ ✔ ✔
3121619 – JLG Lift – 6-79

LENGTH SENSOR REF VOLTAGE LOW 9 9 9938 ✔ ✔ ✔ ✔ ✔
BLAM HIGH RES A/D FAILURE 9 9 9939 ✔ ✔ ✔ ✔ ✔
CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH 9 9 9940 ✔ ✔ ✔ ✔ ✔
CHASSIS SENSOR SUPPLY OUT OF RANGE LOW 9 9 9941 ✔ ✔ ✔ ✔ ✔
BLAM BACKUP COMMUNICATIONS LINK FAULTY 9 9 9942 -- -- ✔ -- --
BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED 9 9 9943 -- -- ✔ -- --
CURRENT FEEDBACK GAINS OUT OF RANGE 9 9 9944 ✔ ✔ ✔ ✔ ✔
CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT 9 9 9945 ✔ ✔ ✔ ✔ ✔
LOAD PIN NOT CALIBRATED 9 9 9975 -- -- ✔ -- --
LSS CORRUPT EEPROM 9 9 9977 ✔ ✔ ✔ ✔ ✔
FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION 9 9 9979 ✔ ✔ ✔ ✔ ✔
IMPROPER
JIB CONTROL MODULE - HIGH RESOLUTION A2D FAILURE 9 9 99155 -- -- -- ✔ ✔
JIB CONTROL MODULE - HIGH RESOLUTION A2D REFERENCE LOW 9 9 99156 -- -- -- ✔ ✔
JIB CONTROL MODULE - HIGH RESOLUTION A2D REFERENCE HIGH 9 9 99157 -- -- -- ✔ ✔
PLATFORM LEVEL ANGLE SENSOR - INTERNAL ERROR 9 9 99158 -- -- -- ✔ ✔
JIB LIFT ANGLE SENSOR - INTERNAL ERROR 9 9 99159 -- -- -- ✔ ✔
FUNCTIONS LOCKED OUT - JIB CONTROL MODULE SOFTWARE VERSION 9 9 99160 -- -- -- ✔ ✔
IMPROPER
6-80 – JLG Lift – 3121619

Table 6-8. Diagnostic Trouble Code Chart
Flash
DTC Sequence Fault Message Fault Description Check
Code
1 0 1 EVERYTHING OK The normal help message in Platform
Mode.
2 0 2 GROUND MODE OK The normal help message in Ground Mode.
10 0 10 RUNNING AT CUTBACK - OUT OF TRANSPORT Drive speed is limited to "ELEVATED MAX"

POSITION while the vehicle is out of transport posi-
tion.
49 0 0 SCR CLEANING REQUIRED SCR Cleaning for regular maintenance
(engine controlled)
50 0 0 BOOM UNLOCK REQUIRED Triggers if machine is 1850SJ and DTC 23127
and DTC 8413 become active
0 0 0 <<< HELP COMMENT >>>
11 0 11 FSW OPEN A drive / boom function was selected with
the Footswitch open.
12 0 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the
Creep Switch is open.
13 0 13 RUNNING AT CREEP - TILTED AND ABOVE All functions at creep while the Platform is
ELEVATION elevated and the Chassis is tilted.
14 0 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 degrees for more - Not reported during power-up.
then 4 seconds.
16 0 16 ENVELOPE ENCROACHED - HYDRAULICS There is an envelope violation. - Envelope control system equipped vehicle only.
SUSPENDED
17 0 17 OVER MOMENT - HYDRAULICS SUSPENDED There is an over moment violation. - Envelope control system equipped vehicle only.
18 0 18 UNDER MOMENT - HYDRAULICS SUS- There is an under moment violation. - Envelope control system equipped vehicle only.
PENDED
21 0 21 ADS 1213 REINITIALIZED
30 0 30 RUNNING AT CREEP - PLATFORM STOWED
31 0 31 FUEL LEVEL LOW - ENGINE SHUTDOWN
35 0 35 APU ACTIVE
37 0 37 JIB UNLOCKED OUT OF TRANSPORT -
38 0 38 SWING ENVELOPE ENCROACHED - HYDRAU-
LICS SUSPENDED
210 21 0 <<< POWER-UP >>>
211 21 1 POWER CYCLE The normal help message is issued at each
power cycle.
212 21 2 KEYSWITCH FAULTY Both Platform and Ground modes are
selected simultaneously.
213 21 3 FSW FAULTY Both Footswitches are closed for more then
one second.
3121619 – JLG Lift – 6-81

Flash
Code
220 22 0 <<< PLATFORM CONTROLS >>>
227 22 7 STEER SWITCHES FAULTY Both Steer Left and Steer Right inputs are
closed simultaneously.
2211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed for more then - Can be reported during power- up.
seven seconds.
2212 22 12 DRIVE LOCKED - JOYSTICK MOVED BEFORE A drive function was selected with Foot- - Can be reported during power- up.
FOOTSWITCH switch open.
2213 22 13 STEER LOCKED - SELECTED BEFORE FOOT- A steer function was selected with Foot-
SWITCH switch open.
2215 22 15 D/S JOY. OUT OF RANGE LOW The D/S Joystick reference voltage is low. - Resistive joysticks, these faults do not occur.
2216 22 16 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference voltage is > - Resistive joysticks.
8.1V. - If the reference voltage is > 7.7V then the reference
voltage is out of tolerance of a short to battery has
occurred.
2217 22 17 D/S JOY. CENTER TAP BAD The D/S Joystick center tap voltage is < - Resistive joysticks.
3.08V or > 3.83V. - There is a +/- .1V range. around these values due to
resistor tolerances
2218 22 18 L/S JOY. OUT OF RANGE LOW The L/S Joystick reference voltage is low. - Resistive joysticks, these faults do not occur.
2219 22 19 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference voltage is > - Resistive joysticks.
8.1V. - If the reference voltage is > 7.7V then the reference
voltage is out of tolerance of a short to battery has
occurred.
2220 22 20 L/S JOY. CENTER TAP BAD The L/S Joystick center tap voltage is < - Resistive joysticks.
3.08V or > 3.83V. - There is a +/- .1V range. around these values due to
resistor tolerances
2221 22 21 LIFT/SWING LOCKED - JOYSTICK MOVED A lift / swing function was selected with
BEFORE FOOTSWITCH Footswitch open.
2222 22 22 WAITING FOR FSW TO BE OPEN The Footswitch was closed during Platform - Can be reported during power- up.
selection.
2223 22 23 FUNCTION SWITCHES LOCKED - SELECTED A boom function was selected with Foot-
BEFORE ENABLE switch open.
2224 22 24 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed during engine
start.
230 23 0 <<<Ground Inputs >>>
23124 2 3 LIFT PRESSURE SENSOR - OUT OF RANGE Pressure transducer sensor voltage output Check sensor hardware and wiring
LOW < 0.4V for 240ms
23125 2 3 LIFT PRESSURE SENSOR - OUT OF RANGE Pressure transducer sensor voltage output Check sensor hardware and wiring
HIGH > 4.5V for 240ms
23126 2 3 LIFT PRESSURE SENSOR - NOT DETECTING Lift down is commanded and pressure does Check sensor hardware and wiring
CHANGE not change by 20psi within 10seconds. This
is only evaluated when rod-side pressure
starts out below a threshold value
6-82 – JLG Lift – 3121619

Flash
Code
23127 2 3 LIFT CYLINDER - OVER PRESSURE At the end of a lift up event if pressure is Check lift cylinder seal across piston, fault detects a
greater than 2200 psi for 3seconds hardware failure
23128 2 3 REDUCTION CHECK PRESSURE SENSOR - Pressure sensor voltage output < 0.4V for Check sensor hardware and wiring
23129 2 3 REDUCTION CHECK PRESSURE SENSOR - Pressure sensor voltage output > 4.5V for Check sensor hardware and wiring
23130 2 3 REDUCTION CHECK PRESSURE SENSOR - Pressure transducer reads > 3250 psi for 2 Check sensor hardware and wiring and check relief
HIGH seconds while main dump valve energized setttings
and engine is running
23131 2 3 REDUCTION CHECK PRESSURE SENSOR - Pressure transducer reads < 1500 psi for 2
LOW seconds while main dump valve energized
and engine is running
240 24 0 <<< OTHER CONTROLS >>>
250 25 0 <<< FUNCTION PREVENTED >>>
259 25 9 MODEL CHANGED - HYDRAULICS SUS- The model selection has been changed.
PENDED - CYCLE EMS
2513 25 13 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the vehicle
generator is running AND is configured to
prevent drive.
2514 25 14 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the
vehicle is being driven AND is configured to
not allow simultaneous drive & boom oper-
ation.
2515 25 15 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the vehicle
above elevation AND is configured to pre-
vent drive while above elevation.
2516 25 16 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while Boom func-
tions are selected AND is configured to not
allow simultaneous drive & boom opera-
tion.
2517 25 17 DRIVE PREVENTED - TILTED & ABOVE ELEVA- Driving is not possible while the vehicle is
TION tilted and above elevation AND is config-
ured to prevent drive while tilted and
above elevation.
2521 25 21 JIB SWING PREVENTED - IN 1000# MODE JIB Swing is not possible while the vehicle is
in 1000 LB Mode.
2522 25 22 CAN DONGLE ATTACHED - HYDRAULICS NOT CAN Dongle attached. Very limited restric-
RESTRICTED tions for all hydraulics systems.
2546 25 46 MACHINE SETUP FAULT - JIB SWING

2547 25 47 MACHINE SETUP FAULT - MODEL
260 26 0 <<<Chassis Inputs >>>
261 2 6 FRONT LEFT AXLE SWING SENSOR - VOLTAGE Sensor output < 0.1V Check sensor hardware and wiring
OUT OF RANGE LOW
3121619 – JLG Lift – 6-83

Flash
Code
262 2 6 FRONT LEFT AXLE SWING SENSOR - VOLTAGE Sensor output >4.9V Check sensor hardware and wiring
OUT OF RANGE HIGH
263 2 6 FRONT RIGHT AXLE SWING SENSOR - VOLT- Sensor output < 0.1V Check sensor hardware and wiring
AGE OUT OF RANGE LOW
264 2 6 FRONT RIGHT AXLE SWING SENSOR - VOLT- Sensor output >4.9V Check sensor hardware and wiring
AGE OUT OF RANGE HIGH
265 2 6 REAR LEFT AXLE SWING SENSOR - VOLTAGE Sensor output < 0.1V Check sensor hardware and wiring
OUT OF RANGE LOW
266 2 6 REAR LEFT AXLE SWING SENSOR - VOLTAGE Sensor output >4.9V Check sensor hardware and wiring
OUT OF RANGE HIGH
267 2 6 REAR RIGHT AXLE SWING SENSOR - VOLT- Sensor output < 0.1V Check sensor hardware and wiring
AGE OUT OF RANGE LOW
268 2 6 REAR RIGHT AXLE SWING SENSOR - VOLT- Sensor output >4.9V Check sensor hardware and wiring
AGE OUT OF RANGE HIGH
2611 2 6 FRONT LEFT AXLE SENSOR - NOT RESPOND- < 0.4deg travel detected for 5 seconds with Check sensor hardware and wiring
ING a deploy or retract command
2612 2 6 FRONT RIGHT AXLE SENSOR - NOT Check sensor hardware and wiring
RESPONDING
2613 2 6 REAR LEFT AXLE SENSOR - NOT RESPONDING Check sensor hardware and wiring
2614 2 6 REAR RIGHT AXLE SENSOR - NOT RESPOND- Check sensor hardware and wiring
ING
2615 2 6 AXLE RETRACT POSITION - NOT CALIBRATED Axles are not calibrated Calibrate axles
2616 2 6 AXLE DEPLOY POSITION - NOT CALIBRATED Axles are not calibrated Calibrate axles
330 33 0 <<< GROUND OUTPUT DRIVER >>>
331 33 1 BRAKE - SHORT TO BATTERY There is a Short to Battery to the Brake
Valve.
332 33 2 BRAKE - OPEN CIRCUIT There is an Open Circuit to the Brake Valve.
3311 33 11 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the Ground - Ground Alarm equipped vehicles only.
Alarm.
3316 33 16 RIGHT FORWARD DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
GROUND Right Forward Drive Valve.
3317 33 17 RIGHT FORWARD DRIVE PUMP - OPEN CIR- There is an Open Circuit to the - Chassis Module equipped vehicles only.
CUIT Right Forward Drive Valve.
3318 33 18 RIGHT FORWARD DRIVE PUMP - SHORT TO There is a Short to Battery to the - Chassis Module equipped vehicles only.
BATTERY Right Forward Drive Valve.
3320 33 20 RIGHT REVERSE DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
GROUND Right Reverse Drive Valve.
3321 33 21 RIGHT REVERSE DRIVE PUMP - OPEN CIR- There is an Open Circuit to the - Chassis Module equipped vehicles only.
CUIT Right Reverse Drive Valve.
3322 33 22 RIGHT REVERSE DRIVE PUMP - SHORT TO There is a Short to Battery to the - Chassis Module equipped vehicles only.
BATTERY Right Reverse Drive Valve.
3324 33 24 LEFT FORWARD DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
GROUND Left Forward Drive Valve.
3325 33 25 LEFT FORWARD DRIVE PUMP - OPEN CIR- There is an Open Circuit to the - Chassis Module equipped vehicles only.
CUIT Left Forward Drive Valve.
6-84 – JLG Lift – 3121619

Flash
Code
3326 33 26 LEFT FORWARD DRIVE PUMP - SHORT TO There is a Short to Battery to the - Chassis Module equipped vehicles only.
BATTERY Left Forward Drive Valve.
3328 33 28 LEFT REVERSE DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
GROUND Left Reverse Drive Valve.
3329 33 29 LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehicles only.
Left Reverse Drive Valve.
3330 33 30 LEFT REVERSE DRIVE PUMP - SHORT TO BAT- There is a Short to Battery to the - Chassis Module equipped vehicles only.
TERY Left Reverse Drive Valve.
3336 33 36 ALTERNATOR/ECM POWER - SHORT TO There is a Short to Ground to the
GROUND Alternator/ECM.
3338 33 38 ALTERNATOR POWER - OPEN CIRCUIT There is an Open Circuit to the
Alternator.
3339 33 39 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the
Alternator
3340 33 40 AUX POWER - SHORT TO GROUND There is a Short to Ground to the
Auxiliary Power Pump Relay.
3341 33 41 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the
3342 33 42 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the
3343 33 43 COLD START ADVANCE SOLENOID - SHORT There is a Short to Ground to the - CAT engines only.
TO GROUND Cold Start Advance Solenoid.
3344 33 44 COLD START ADVANCE SOLENOID - OPEN There is an Open Circuit to the - CAT engines only.
CIRCUIT Cold Start Advance Solenoid.
3345 33 45 COLD START ADVANCE SOLENOID - SHORT There is a Short to Battery to the - CAT engines only.
TO BATTERY Cold Start Advance Solenoid.
3349 33 49 ELECTRIC PUMP - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Pump Relay.
3350 33 50 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
Pump Relay.
3351 33 51 ELECTRIC PUMP - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
Pump Relay.
3358 33 58 MAIN DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Dump Valve.
3359 33 59 MAIN DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Dump Valve.
3360 33 60 MAIN DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Dump Valve.
3361 33 61 BRAKE - SHORT TO GROUND There is a Short to Ground to the
Brake Valve.
3362 33 62 START SOLENOID - SHORT TO GROUND There is a Short to Ground to the - Diesel engines only.
Start Relay.
3363 33 63 START SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - Diesel engines only.
Start Relay.
3364 33 64 START SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - Diesel engines only.
Start Relay.
3368 33 68 TWO SPEED VALVE - SHORT TO GROUND There is a Short to Ground to the
Two Speed Valve.
3121619 – JLG Lift – 6-85

Flash
Code
3369 33 69 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the
Two Speed Valve.
3370 33 70 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the
Two Speed Valve.
3371 33 71 GROUND ALARM - SHORT TO GROUND There is a Short to Ground to the Ground - Ground Alarm equipped vehicles only.
Alarm.
3372 33 72 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the Ground - Ground Alarm equipped vehicles only.
Alarm.
3373 33 73 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the Generator - Generator / Welder equipped vehicles only.
Relay.
3374 33 74 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the Generator - Generator / Welder equipped vehicles only.
Relay.
3375 33 75 GEN SET/WELDER - SHORT TO BATTERY There is a Short to Battery to the Generator - Generator / Welder equipped vehicles only.
Relay.
3376 33 76 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the Head Light - Head Light equipped vehicles only.
Relay.
3377 33 77 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the Head Light - Head Light equipped vehicles only.
Relay.
3378 33 78 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the Head Light - Head Light equipped vehicles only.
Relay.
3379 33 79 HOUR METER - SHORT TO GROUND There is a Short to Ground to the Hour
Meter.
3380 33 80 HOUR METER - OPEN CIRCUIT There is an Open Circuit to the Hour Meter. - Can be reported during power- up.
3381 33 81 HOUR METER - SHORT TO BATTERY There is a Short to Battery to the Hour
Meter.
3385 33 85 PLATFORM LEVEL UP OVERRIDE VALVE - There is a Short to Ground to the Platform - Electronic leveling system equipped vehicles only.
SHORT TO GROUND Level Up Override Valve.
3386 33 86 PLATFORM LEVEL UP OVERRIDE VALVE - There is an Open Circuit to the Platform - Electronic leveling system equipped vehicles only.
OPEN CIRCUIT Level Up Override Valve.
3387 33 87 PLATFORM LEVEL UP OVERRIDE VALVE - There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
SHORT TO BATTERY Level Up Override Valve.
3391 33 91 PLATFORM LEVEL DOWN OVERRIDE VALVE - There is a Short to Ground to the Platform - Electronic leveling system equipped vehicles only.
SHORT TO GROUND Level Down Override Valve.
3392 33 92 PLATFORM LEVEL DOWN OVERRIDE VALVE - There is an Open Circuit to the Platform - Electronic leveling system equipped vehicles only.
OPEN CIRCUIT Level Down Override Valve.
3393 33 93 PLATFORM LEVEL DOWN OVERRIDE VALVE - There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
SHORT TO BATTERY Level Down Override Valve.
3394 33 94 PLATFORM ROTATE LEFT VALVE - SHORT TO There is a Short to Ground to the Platform
GROUND Rotate Left Valve.
3395 33 95 PLATFORM ROTATE LEFT VALVE - OPEN CIR- There is an Open Circuit to the Platform
CUIT Rotate Left Valve.
6-86 – JLG Lift – 3121619

Flash
Code
3396 33 96 PLATFORM ROTATE LEFT VALVE - SHORT TO There is a Short to Battery to the Platform
BATTERY Rotate Left Valve.
3397 33 97 PLATFORM ROTATE RIGHT VALVE - SHORT TO There is a Short to Ground to the Platform
GROUND Rotate Right Valve.
3398 33 98 PLATFORM ROTATE RIGHT VALVE - OPEN There is an Open Circuit to the Platform
CIRCUIT Rotate Right Valve.
3399 33 99 PLATFORM ROTATE RIGHT VALVE - SHORT TO There is a Short to Battery to the Platform
BATTERY Rotate Right Valve.
33120 33 120 MAIN TELESCOPE IN VALVE - SHORT TO BAT- There is a Short to Battery to the Main Tele-
TERY scope In Valve.
33123 33 123 MAIN TELESCOPE OUT VALVE - SHORT TO There is a Short to Battery to the Main Tele-
BATTERY scope Out Valve.
33130 33 130 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the Throttle
Actuator.
33131 33 131 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the Throttle Actu-
ator.
33132 33 132 THROTTLE ACTUATOR - SHORT TO BATTERY There is a Short to Battery to the Throttle
Actuator.
33133 33 133 PLATFORM CONTROL VALVE - SHORT TO There is a Short to Ground to the Platform - Electronic leveling system equipped vehicles only.
GROUND Control Valve.
33134 33 134 PLATFORM CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Con- - Electronic leveling system equipped vehicles only.
trol Valve.
33135 33 135 PLATFORM CONTROL VALVE - SHORT TO There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
BATTERY Control Valve.
33150 33 150 LIFT PILOT VALVE - SHORT TO GROUND There is a Short to Ground to the Lift Pilot - Gravity Lift Down equipped vehicles only.
Valve.
33151 33 151 LIFT PILOT VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Pilot - Gravity Lift Down equipped vehicles only.
Valve.
33152 33 152 LIFT PILOT VALVE - SHORT TO BATTERY There is a Short to Battery to the Lift Pilot - Gravity Lift Down equipped vehicles only.
Valve.
33153 33 153 LIFT DOWN AUX VALVE - SHORT TO GROUND There is a Short to Ground to the Lift Down - Gravity Lift Down equipped vehicles only.
Auxiliary Valve.
33154 33 154 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Down - Gravity Lift Down equipped vehicles only.
Auxiliary Valve.
33155 33 155 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the Lift Down - Gravity Lift Down equipped vehicles only.
Auxiliary Valve.
33159 3 3 MAIN LIFT ENABLE VALVE - SHORT TO Short to Ground detected Check wiring
GROUND
33160 3 3 MAIN LIFT ENABLE VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
33173 33 173 RESTRICTED TO TRANSPORT - AXLE LOCK- There is a Short to Battery or an Open Circuit
OUT VALVE - SHORT TO BATTERY OR OPEN to the Axle Lockout Valve.
CIRCUIT
33174 33 174 RESTRICTED TO TRANSPORT - BRAKE - There is a Short to Battery or an Open Circuit
SHORT TO BATTERY OR OPEN CIRCUIT to the Brake.
33182 33 182 LIFT VALVES - SHORT TO BATTERY
33186 33 186 MAIN TELESCOPE OUT VALVE - OPEN CIRUIT There is an Open Circuit to the Main Tele-
scope Out Valve.
3121619 – JLG Lift – 6-87

Flash
Code
33188 33 188 MAIN TELESCOPE OUT VALVE - SHORT TO There is a Short to Ground to the Main Tele-
GROUND scope Out Valve.
33189 33 189 MAIN TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Tele-
scope In Valve.
33190 33 190 MAIN TELESCOPE IN VALVE - SHORT TO There is a Short to Ground to the
GROUND Main Telescope In Valve.
33207 33 207 HORN - OPEN CIRCUIT There is an Open Circuit to the
Horn.
33208 33 208 HORN - SHORT TO BATTERY There is a Short to Battery to the
Horn.
33209 33 209 HORN - SHORT TO GROUND There is a Short to Ground to the
Horn.
33279 33 279 GLOWPLUG - OPEN CIRCUIT There is an Open Circuit to the - Glowplugs equipped vehicles only.
Glow Plugs.
33280 33 280 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the - Glowplugs equipped vehicles only.
Glow Plugs.
33281 33 281 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the - Glowplugs equipped vehicles only.
Glow Plugs.
33285 33 285 ALTERNATOR EXCITATION LINE - SHORT TO
33307 33 307 MAIN TELESCOPE FLOW CONTROL VALVE - There is a Short to Ground to the Main Tele-
SHORT TO GROUND scope Flow Control Valve.
33308 33 308 MAIN TELESCOPE FLOW CONTROL VALVE - There is an Open Circuit to the Main Tele-
OPEN CIRCUIT scope Flow Control Valve.
33309 33 309 MAIN TELESCOPE FLOW CONTROL VALVE - There is a Short to Battery to the Main Tele-
SHORT TO BATTERY scope Flow Control Valve.
33311 33 311 MAIN LIFT FLOW CONTROL VALVE - SHORT There is a Short to Ground to the
TO GROUND Main Lift Flow Control Valve.
33312 33 312 MAIN LIFT FLOW CONTROL VALVE - OPEN There is an Open Circuit to the
CIRCUIT Main Lift Flow Control Valve.
33313 33 313 MAIN LIFT FLOW CONTROL VALVE - SHORT There is a Short to Battery to the
TO BATTERY Main Lift Flow Control Valve.
33414 3 3 SWING - CURRENT FEEDBACK READING TOO Current feedback into controller is below Check wiring and coil
LOW threshold value
33418 3 3 SWING - CURRENT FEEDBACK READING Current feedback into controller not Check wiring and coil
LOST detected
33429 33 429 JIB LIFT UP OVERRIDE VALVE - SHORT TO
33430 33 430 JIB LIFT UP OVERRIDE VALVE - OPEN CIRCUIT
33431 33 431 JIB LIFT UP OVERRIDE VALVE - SHORT TO
33432 33 432 JIB LIFT DOWN OVERRIDE VALVE - SHORT TO
33433 33 433 JIB LIFT DOWN OVERRRIDE VALVE - OPEN
33434 33 434 JIB LIFT DOWN OVERRIDE VALVE - SHORT TO
33435 33 435 JIB CONTROL VALVE - SHORT TO GROUND
33436 33 436 JIB CONTROL VALVE - OPEN CIRCUIT
33437 33 437 JIB CONTROL VALVE - SHORT TO BATTERY
6-88 – JLG Lift – 3121619

Flash
Code
33456 3 3 MAIN LIFT FLOW CONTROL VALVE - CUR- Current feedback into controller not Check wiring and coil
33457 3 3 MAIN LIFT FLOW CONTROL VALVE - CUR- Current feedback into controller is below
RENT FEEDBACK READING TOO LOW threshold value
33460 3 3 TELESCOPE FLOW CONTROL VALVE - CUR- Current feedback into controller not
33461 3 3 TELESCOPE FLOW CONTROL VALVE - CUR- Current feedback into controller is below
RENT FEEDBACK READING TOO LOW threshold value
33462 3 3 WARM UP VALVE - SHORT TO BATTERY Short to Battery detected Check wiring
33463 3 3 WARM UP VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
33464 3 3 WARM UP VALVE - SHORT TO GROUND Short to Ground detected Check wiring
33465 3 3 CHASSIS ENABLE VALVE - SHORT TO BAT- Short to Battery detected Check wiring
33466 3 3 CHASSIS ENABLE VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
33467 3 3 CHASSIS ENABLE VALVE - SHORT TO Short to Ground detected Check wiring
33487 3 3 TWO SPEED OR BRAKE VALVE - STUCK OPEN
33488 3 3 SWING FLOW CONTROL VALVE - SHORT TO Short to Ground detected Check wiring
33489 3 3 SWING FLOW CONTROL VALVE - OPEN CIR- Open Circuit detected Check wiring
CUIT
33490 3 3 SWING FLOW CONTROL VALVE - SHORT TO Short to Battery detected Check wiring
33563 3 3 LIFT ENABLE VALVE - STUCK OPEN Lift pilot valve is energized (during auxil- Check enable valve hardware
iary or gravity sequence) and 1deg of
motion is detected prior to the enable valve
being energized
33564 3 3 COUNTER BALANCE VALVE - STUCK OPEN Counterbalance valve test completed at the Check counterbalance valve hardware
end of a lift down command. If Lift Cylinder
angle sensor detects 2-deg motion, fault is
activated
33565 3 3 LIFT ENABLE - CURRENT FEEDBACK READ- Current feedback into controller not Check wiring and coil
ING LOST detected
33566 3 3 LIFT ENABLE - CURRENT FEEDBACK READ- Current feedback into controller is below Check wiring and coil
ING TOO LOW threshold value
340 34 0 <<< PLATFORM OUTPUT DRIVER >>>
343 34 3 PLATFORM LEVEL UP VALVE - SHORT TO There is a Short to Ground to the
GROUND Platform Level Up Valve.
344 34 4 PLATFORM LEVEL UP VALVE - SHORT TO BAT- There is a Short to Battery or an Open Circuit - Electronic leveling system equipped vehicles only.
TERY OR OPEN CIRCUIT to the Platform Level Up Valve.
347 34 7 PLATFORM LEVEL DOWN VALVE - SHORT TO There is a Short to Ground to the
GROUND Platform Level Down Valve.
348 34 8 PLATFORM LEVEL DOWN VALVE - SHORT TO There is a Short to Battery or an Open Circuit - Electronic leveling system equipped vehicles only.
BATTERY OR OPEN CIRCUIT to the Platform Level Down Valve.
3427 34 37 JIB LOCK VALVE - OPEN CIRCUIT

3428 34 38 JIB LOCK VALVE - SHORT TO BATTERY
3429 34 29 JIB LOCK VALVE - SHORT TO GROUND
3430 34 30 JIB UNLOCK VALVE - OPEN CIRCUIT
3121619 – JLG Lift – 6-89

Flash
Code
3431 34 31 JIB UNLOCK VALVE - SHORT TO BATTERY
3432 34 32 JIB UNLOCK VALVE - SHORT TO GROUND
350 35 0 <<< OTHER OUTPUT DRIVERS >>>
351 35 1 JIB LEVEL UP VALVE - SHORT TO GROUND
352 35 2 JIB LEVEL UP VALVE - SHORT TO BATTERY OR
353 35 3 JIB LEVEL DOWN VALVE - SHORT TO GROUND
354 35 4 JIB LEVEL DOWN VALVE - SHORT TO BATTERY
355 35 5 JIB LIFT UP VALVE - SHORT TO GROUND
356 35 6 JIB LIFT UP VALVE - SHORT TO BATTERY OR
357 35 7 JIB LIFT DOWN VALVE - SHORT TO GROUND
358 35 8 JIB LIFT DOWN VALVE - SHORT TO BATTERY
359 35 9 JIB ROTATE LEFT VALVE - SHORT TO GROUND
3510 35 10 JIB ROTATE LEFT VALVE - SHORT TO BATTERY
3511 35 11 JIB ROTATE RIGHT VALVE - SHORT TO
3512 35 12 JIB ROTATE RIGHT VALVE - SHORT TO BAT-
3513 35 13 JIB TELESCOPE IN VALVE - SHORT TO
3514 35 14 JIB TELESCOPE IN VALVE - SHORT TO BAT-
3515 35 15 JIB TELESCOPE OUT VALVE - SHORT TO
3516 35 16 JIB TELESCOPE OUT VALVE - SHORT TO BAT-
360 36 0 <<<Chassis Output Driver >>>
361 3 6 FRONT AXLE EXTEND VALVE - SHORT TO BAT- Short to Battery detected Check wiring
362 3 6 FRONT AXLE EXTEND VALVE - SHORT TO Short to Ground detected
363 3 6 FRONT AXLE RETRACT VALVE - SHORT TO Short to Battery detected
364 3 6 FRONT AXLE RETRACT VALVE - SHORT TO Short to Ground detected
365 3 6 REAR AXLE EXTEND VALVE - SHORT TO BAT- Short to Battery detected
366 3 6 REAR AXLE EXTEND VALVE - SHORT TO Short to Ground detected
367 3 6 REAR AXLE RETRACT VALVE - SHORT TO BAT- Short to Battery detected
368 3 6 REAR AXLE RETRACT VALVE - SHORT TO Short to Ground detected
369 3 6 FRONT AXLE EXTEND VALVE - OPEN CIRCUIT Open Circuit detected
3610 3 6 FRONT AXLE VALVE - CURRENT FEEDBACK Current feedback into controller not Check wiring and coil
3611 3 6 FRONT AXLE RETRACT VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
3612 3 6 REAR AXLE VALVE - CURRENT FEEDBACK Current feedback into controller not Check wiring and coil
READING LOST detected
3613 3 6 REAR AXLE EXTEND VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
3514 3 6 FRONT AXLE VALVE - CURRENT FEEDBACK Current feedback into controller is below Check wiring and coil
READING TOO LOW threshold value
3615 3 6 REAR AXLE RETRACT VALVE - OPEN CIRCUIT Open Circuit detected Check wiring
3616 3 6 REAR AXLE VALVE - CURRENT FEEDBACK Current feedback into controller is below Check wiring and coil
READING TOO LOW threshold value
3617 3 6 CHASSIS BRAKE - OPEN CIRCUIT Open Circuit detected Check wiring
3618 3 6 CHASSIS BRAKE - SHORT TO BATTERY Short to Battery detected Check wiring
6-90 – JLG Lift – 3121619

Flash
Code
3619 3 6 CHASSIS BRAKE - SHORT TO GROUND Short to Ground detected Check wiring
3620 3 6 FRONT AXLE VALVE - SHORT TO BATTERY Short to Battery detected Check wiring
3621 3 6 REAR AXLE VAVE - SHORT TO BATTERY Short to Battery detected Check wiring
430 43 0 <<< ENGINE >>>
431 43 1 FUEL SENSOR SHORT TO BATTERY The Fuel Sensor reading is >
4.3V.
432 43 2 FUEL SENSOR SHORT TO GROUND The Fuel Sensor reading is <
0.2V.
433 43 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading is > 6.6V. - Deutz engine only.
434 43 4 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading is < 0.1V for - Deutz engine only.
more then 5 seconds. - Not reported during engine start.
435 43 5 COOLANT TEMPERATURE SHORT TO The Coolant Temperature Sensor reading is - Deutz engine only.
GROUND < 0.1V.
437 43 7 ENGINE TROUBLE CODE Displays engine SPN FMI code.
438 43 8 HIGH ENGINE TEMP (Ford engine only) The engine temperature - Ford / Deutz engine only.
is > 117 C.
(Deutz engine only) The engine tempera-
ture is > 130 C.
439 43 9 AIR FILTER BYPASSED The Air Filter is clogged.
4310 43 10 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts for more
then 15 seconds after engine start.
4311 43 11 LOW OIL PRESSURE (Ford engine only) The ECM has reported a - Ford / Deutz engine only.
low oil pressure fault. (Deutz engine only)
Oil pressure is < 8 PSI for more then 10 sec-
onds after engine start.
4313 43 13 THROTTLE ACTUATOR FAILURE The engine RPM is > XXX for more then XX
seconds.
4314 43 14 WRONG ENGINE SELECTED - ECM DETECTED A ECM was detected with a non- ECM type
engine selected.
4322 43 22 LOSS OF ENGINE SPEED SENSOR The engine RPM sensor indicates 0 RPM - Diesel engine only.
AND the Oil Pressure Sensor indicates > 8
PSI for three seconds.
4323 43 23 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indicates > 4000 - Diesel engine only.
RPM.
4364 43 64 SCR CLEANING NOT INITIATED SCR Cleaning was requested bu not initi-
ated.
4365 43 65 RUNNING AT CREEP - ENGINE POWER Triggered by 524190:14 (engine con-
REDUCTION trolled)
4366 43 66 SCR CLEANING REQUIRED - SOOT DETECTED SCR Crystallization has been detected
(engine controlled)
4368 43 68 ALL FUNCTIONS PREVENTED - ENGINE Triggered by 524191:14 (engine con-
POWER REDUCTION SEVERE trolled)You
3121619 – JLG Lift – 6-91

Flash
Code
440 44 0 <<< BATTERY SUPPLY >>>
441 44 1 BATTERY VOLTAGE TOO LOW - SYSTEM Battery voltage is < 9V.
442 44 2 BATTERY VOLTAGE TOO HIGH - SYSTEM Battery voltage is > 16V.
443 44 3 LSS BATTERY VOLTAGE TOO HIGH
444 44 4 LSS BATTERY VOLTAGE TOO LOW
445 44 5 BATTERY VOLTAGE LOW Battery voltage is < 11V for more then 5
seconds.
660 66 0 <<< COMMUNICATION >>>
662 66 2 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN communication lost.
663 66 3 CANBUS FAILURE - LOAD SENSING SYSTEM

666 66 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped engine only.
communication lost.
6610 66 10 CANBUS FAILURE - BLAM BLAM CAN communication lost. - BLAM equipped vehicles only.
6611 66 11 CANBUS FAILURE - CHASSIS MODULE Engine Control Module CAN - ECM equipped engine only.
communication lost.
6612 66 12 CANBUS FAILURE - CYLINDER LOAD PIN Cylinder Load Pin CAN communication lost. - Cylinder Load Pin equipped engine only.
6613 66 13 CANBUS FAILURE - EXCESSIVE CANBUS There has been > 500 Bus Off errors or
ERRORS >500 Bus Passive Errors.
6622 66 22 CANBUS FAILURE - TCU MODULE Machine Setup/ Telematics=YES, No

device heartbeat for 30 sec
6623 66 23 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telematics=YES, No

device heartbeat for 30 sec
6629 66 29 CANBUS FAILURE - TELEMATICS CANBUS X -Telematics only

LOADING TOO HIGH
6639 66 39 CANBUS FAILURE - JIB CONTROL MODULE
6640 66 40 CANBUS FAILURE - JIB LIFT ANGLE SENSOR
6641 66 41 CANBUS FAILURE - PLATFORM LEVEL ANGLE
680 68 0 <<< TELEMATICS >>>
681 68 1 REMOTE CONTRACT MANAGEMENT OVER- X -Telematics only
810 81 0 <<< TILT SENSOR >>>
813 81 3 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not been cali-
brated.
814 8 1 CHASSIS TILT SENSOR OUT OF RANGE Tilt sensor out of range Check sensor hardware and wiring
815 81 5 CHASSIS TILT SENSOR DISAGREEMENT X
8111 8 1 CHASSIS TILT READING DISAGREEMENT Disagreement between internal (UGM) and Check external/internal sensor hardware and installa-
external chassis tilt sensors tion on machine
820 82 0 <<< PLATFORM LOAD SENSE >>>
821 82 1 LSS CELL #1 ERROR
822 82 2 LSS CELL #2 ERROR822822
823 82 3 LSS CELL #3 ERROR823823
824 82 4 LSS CELL #4 ERROR824824
6-92 – JLG Lift – 3121619

Flash
Code
825 82 5 LSS HAS NOT BEEN CALIBRATED The Load Sensing System Module has not
been calibrated.
826 82 6 RUNNING AT CREEP - PLATFORM OVER- All functions at creep, the Load Sensing Sys-
LOADED tem indicates the Platform is overloaded
AND is configured to warn only while the
Platform is overloaded.
827 82 7 DRIVE & BOOM PREVENTED - PLATFORM Driving and boom functions are not possi-
OVERLOADED ble while the Load Sensing System indi-
cates the Platform is overloaded AND is
configured to prevent drive and boom func-
tions while the Plat- form is overloaded.
828 82 8 LIFT UP & TELE OUT PREVENTED - PLAT- Lift up and telescope out are not possible
FORM OVERLOADED while the Load Sensing System indicates
the Platform is overloaded AND is config-
ured to prevent Lift up and telescope out
while the Platform is overloaded.
830 83 0 <<< PLATFORM LEVELING >>>

831 83 1 PLATFORM LEVELING OVERRIDE ON Platform Leveling forced on with Access
Level 0 selection.
832 83 2 PLATFORM LEVELING OVERRIDE OFF Platform Leveling forced off with Access
Level 0 selection.
833 83 3 PLATFORM LEVEL UP CRACKPOINT - NOT The Platform Level Up Valve Crackpoint has - Electronic leveling system equipped vehicles only.
CALIBRATED not been calibrated.
834 83 4 PLATFORM LEVEL DOWN CRACKPOINT - NOT The Platform Level Down Valve Crackpoint - Electronic leveling system equipped vehicles only.
CALIBRATED has not been calibrated.
837 83 7 PLATFORM LEVEL SENSOR #1 - SHORT TO There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
BATTERY Level Sensor #1.
838 83 8 PLATFORM LEVEL SENSOR #1 - SHORT TO There is a Short to Ground or an Open Circuit - Electronic leveling system equipped vehicles only.
GROUND OR OPEN CIRCUIT to the Platform Level Sensor #1.
8311 83 11 PLATFORM LEVEL SENSOR #2 - SHORT TO There is a Short to Battery to the Platform - Electronic leveling system equipped vehicles only.
BATTERY Level Sensor #2.
8312 83 12 PLATFORM LEVEL SENSOR #2 - SHORT TO There is a Short to Ground or an Open Circuit - Electronic leveling system equipped vehicles only.
GROUND OR OPEN CIRCUIT to the Platform Level Sensor #2.
8313 83 13 PLATFORM LEVEL SENSOR #1 - REFERENCE Platform Level Sensor #1 reference voltage - Electronic leveling system equipped vehicles only.
VOLTAGE OUT OF RANGE is outside acceptable range (4.9 to 5.1
volts).
8314 83 14 PLATFORM LEVEL SENSOR #2 - REFERENCE Platform Level Sensor #2 reference voltage - Electronic leveling system equipped vehicles only.
VOLTAGE OUT OF RANGE is outside acceptable range (4.9 to 5.1
volts).
3121619 – JLG Lift – 6-93

Flash
Code
8315 83 15 PLATFORM LEVELING SENSOR - DISAGREE- The Control System reads the sensor values - Electronic leveling system equipped vehicles only.
MENT at power-up. The fault is triggered when
there is a ± 5 degree difference from the ini-
tial reading.
8316 83 16 PLATFORM LEVEL SENSOR #1 - COMMUNI- Platform Level Sensor #1 serial communi-
CATIONS LOST cation lost.
8317 83 17 PLATFORM LEVEL SENSOR #2 - COMMUNI- Platform Level Sensor #2 serial communi-
CATIONS LOST cation lost.
8318 83 18 PLATFORM LEVELING SYSTEM TIMEOUT The Platform was unable to maintain
desired level within range for the allotted
time.
8319 83 19 JIB LEVEL SENSOR #1 - OUT OF RANGE LOW
8320 83 20 JIB LEVEL SENSOR #1 - OUT OF RANGE HIGH
8321 83 21 JIB LEVEL SENSOR #2 - OUT OF RANGE LOW
8322 83 22 JIB LEVEL SENSOR #2 - OUT OF RANGE HIGH
8323 83 23 JIB LEVEL SENSORS - NOT CALIBRATED
8324 83 24 JIB LEVEL SENSORS - DISAGREEMENT
8325 83 25 JIB SWING SENSOR #1 - OUT OF RANGE LOW
8326 83 26 JIB SWING SENSOR #1 - OUT OF RANGE HIGH
8327 83 27 JIB SWING SENSOR #2 - OUT OF RANGE LOW
8328 83 28 JIB SWING SENSOR #2 - OUT OF RANGE HIGH
8329 83 29 JIB SWING SENSORS - NOT CALIBRATED
8330 83 30 JIB SWING SENSORS - DISAGREEMENT
8331 83 31 JIB LOCK PIN SENSOR - DISAGREEMENT
8332 83 32 JIB TRANSPORT SENSOR #1 - DISAGREE-
8333 83 33 JIB TRANSPORT SENSOR #2 - DISAGREE-
8334 83 34 JIB LIFT ANGLE SENSOR - NOT CALIBRATED
8335 83 35 JIB LEVEL UP CRACKPOINT - NOT CALI-
8336 83 36 JIB LEVEL DOWN CRACKPOINT - NOT CALI-
8337 83 37 JIB LEVELING SYSTEM TIMEOUT
8338 83 38 WRONG JIB LOCK PIN RESPONSE
8339 83 39 PLATFORM LEVEL ANGLE SENSOR - NOT
840 84 0 <<< ENVELOPE >>>
841 84 1 BOOM ANGLE SENSOR DISAGREEMENT There is a disagreement between the Boom - Envelope Control equipped vehicles only.
Angle Sensors.
842 84 2 BOOM LENGTH SWITCH FAILED The Boom Length Switches are reporting - Envelope Control equipped vehicles only.
the same state.
843 84 3 BOOM LENGTH SWITCH/SENSOR DISAGREE- There is a disagreement between the Boom - Envelope Control equipped vehicles only.
MENT Length Switch and the Boom Length Sen-
sor.
844 84 4 BOOM LENGTH SENSOR NOT DETECTING The Boom Length Sensor is not changing - Envelope Control equipped vehicles only.
LENGTH CHANGE during a boom telescope command.
6-94 – JLG Lift – 3121619

Flash
Code
845 84 5 BOOM LENGTH SENSOR - OUT OF RANGE Boom Length Sensor out of range high. - Envelope Control equipped vehicles only.
HIGH
846 84 6 BOOM LENGTH SENSOR - OUT OF RANGE Boom Length Sensor out of range low. - Envelope Control equipped vehicles only.
LOW
847 84 7 BOOM LENGTH SENSOR - VALUE OUT OF Boom Length out of range high. - Envelope Control equipped vehicles only.
RANGE HIGH
848 84 8 BOOM LENGTH SENSOR - VALUE OUT OF Boom Length out of range low. - Envelope Control equipped vehicles only.
RANGE LOW
849 84 9 BOOM ANGLE SENSOR #1 - COMMUNICA- Boom Angle Sensor #1 communications - Envelope Control equipped vehicles only.
TIONS FAULT lost.
8410 84 10 BOOM ANGLE SENSOR #2 - COMMUNICA- Boom Angle Sensor #2 communications - Envelope Control equipped vehicles only.
TIONS FAULT lost.
8411 84 11 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of range. - Envelope Control equipped vehicles only.
8412 84 12 BOOM ANGLE SENSOR #2 - INVALID ANGLE Boom Angle Sensor #2 out of range. - Envelope Control equipped vehicles only.
8413 84 13 WRONG TELESCOPE RESPONSE Boom telescope is moving in the opposite - Envelope Control equipped vehicles only.
direction of the command.
8414 84 14 WRONG LIFT RESPONSE Boom lift is moving in the opposite direc- - Envelope Control equipped vehicles only.
tion of the command.
8479 84 79 MAIN CYLINDER ANGLE SENSOR #1 - OUT OF
8494 84 94 MAIN CYLINDER ANGLE SENSORS - DIS-
8495 84 95 TURN TABLE SENSOR #1 - FREQUENCY OUT
8499 84 99 CHASSIS TURN TABLE SENSORS - DISAGREE-
84100 84 100 CHASSIS TURN TABLE SENSORS AND DRIVE
ORIENTATION SWITCH - DIS- AGREEMENT
84101 84 101 CHASSIS TURN TABLE SENSORS - NOT CALI-
84102 84 102 MAIN CYLINDER ANGLE SENSOR - NOT
84103 84 103 JIB LEVEL ANGLE SENSOR - NOT DETECTING
84104 84 104 JIB LIFT ANGLE SENSOR - NOT DETECTING
84105 84 105 PLATFORM LEVEL ANGLE SENSOR - NOT
84106 84 106 JIB LEVEL MOVEMENT WITHOUT COMMAND
84107 84 107 JIB LIFT MOVEMENT WITHOUT COMMAND
84108 84 108 PLATFORM LEVEL MOVEMENT WITHOUT
850 85 0 <<< MOMENT / LOAD PINS >>>
851 85 1 MOMENT PIN - HORIZONTAL FORCE OUT OF The Moment Pin horizontal force is out of
RANGE range.
852 85 2 MOMENT PIN - VERTICAL FORCE OUT OF The Moment Pin vertical force is out of
RANGE range.
3121619 – JLG Lift – 6-95

Flash
Code
855 85 5 MOMENT PIN - SENSOR FAULT The Moment Pin has reported a fault.
857 85 7 NEW MOMENT PIN DETECTED A new Moment Pin has been detected.
860 86 0 <<< STEERING / AXLE >>>

861 86 1 RESTRICTED TO TRANSPORT - OSCILLATING The Oscillating Axle Pressure Switch indi- - Electrically released Oscillated
AXLE PRESSURE SWITCH DIS- AGREEMENT cates pressure while not driving or does not Axles equipped vehicles only.
indicate pressure while driving and
restricted to transport.
862 86 2 AXLE EXTEND VALVE - SHORT TO BATTERY OR There is a Short to Battery or an Open Circuit
OPEN CIRCUIT to the Axle Extend Valve.
863 86 3 AXLE EXTEND VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Extend Valve.
864 86 4 AXLE RETRACT VALVE - SHORT TO BATTERY There is a Short to Battery or an Open Circuit
OR OPEN CIRCUIT to the Axle Retract Valve.
865 86 5 AXLE RETRACT VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Retract Valve.
866 86 6 RIGHT FRONT STEER RIGHT VALVE - SHORT There is a Short to Battery or an Open Circuit
TO BATTERY OR OPEN CIRCUIT to the Right Front Steer Right Valve.
867 86 7 RIGHT FRONT STEER RIGHT VALVE - SHORT There is a Short to Ground to the
TO GROUND Right Front Steer Right Valve.
868 86 8 RIGHT FRONT STEER LEFT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Right Front Steer Left Valve.
869 86 9 RIGHT FRONT STEER LEFT VALVE - SHORT TO There is a Short to Ground to the
GROUND Right Front Steer Left Valve.
8610 86 10 LEFT FRONT STEER RIGHT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Left Front Steer Right Valve.
8611 86 11 LEFT FRONT STEER RIGHT VALVE - SHORT TO There is a Short to Ground to the
GROUND Left Front Steer Right Valve.
8612 86 12 LEFT FRONT STEER LEFT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Left Front Steer Left Valve.
8613 86 13 LEFT FRONT STEER LEFT VALVE - SHORT TO There is a Short to Ground to the
GROUND Left Front Steer Left Valve.
8614 86 14 RIGHT REAR STEER RIGHT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Right Rear Steer Right Valve.
8615 86 15 RIGHT REAR STEER RIGHT VALVE - SHORT TO There is a Short to Ground to the
GROUND Right Rear Steer Right Valve.
8616 86 16 RIGHT REAR STEER LEFT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Right Rear Steer Left Valve.
6-96 – JLG Lift – 3121619

Flash
Code
8617 86 17 RIGHT REAR STEER LEFT VALVE - SHORT TO There is a Short to Ground to the
GROUND Right Rear Steer Left Valve.
8618 86 18 LEFT REAR STEER RIGHT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Left Rear Steer Right Valve.
8619 86 19 LEFT REAR STEER RIGHT VALVE - SHORT TO There is a Short to Ground to the
GROUND Left Rear Steer Right Valve.
8620 86 20 LEFT REAR STEER LEFT VALVE - SHORT TO There is a Short to Battery or an Open Circuit
BATTERY OR OPEN CIRCUIT to the Left Rear Steer Left Valve.
8621 86 21 LEFT REAR STEER LEFT VALVE - SHORT TO There is a Short to Ground to the
GROUND Left Rear Steer Left Valve.
8622 86 22 FRONT RIGHT STEER SENSOR - DECOUPLED The Front Right Steer Sensor has become
decoupled.
8623 86 23 FRONT LEFT STEER SENSOR - DECOUPLED The Front Left Steer Sensor has become
decoupled.
8624 86 24 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has become
decoupled.
8625 86 25 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has become
decoupled.
8626 86 26 FRONT LEFT STEER SENSOR - NOT RESPOND- The Front Right Steer Sensor is not respond-
ING ing to steer commands.
8627 86 27 FRONT RIGHT STEER SENSOR - NOT The Front Left Steer Sensor is not respond-
RESPONDING ing to steer commands.
8628 86 28 REAR LEFT STEER SENSOR - NOT RESPOND- The Rear Right Steer Sensor is not respond-
ING ing to steer commands.
8629 86 29 REAR RIGHT STEER SENSOR - NOT RESPOND- The Rear Left Steer Sensor is not responding
ING to steer commands.
8630 86 30 FRONT RIGHT STEER SENSOR - SHORT TO There is a Short to Ground or an Open Circuit
GROUND OR OPEN CIRCUIT to the Front Right Steer Sensor.
8631 86 31 FRONT RIGHT STEER SENSOR - SHORT TO There is a Short to Battery to the
BATTERY Front Right Steer Sensor.
8632 86 32 FRONT LEFT STEER SENSOR - SHORT TO There is a Short to Ground or an Open Circuit
GROUND OR OPEN CIRCUIT to the Front Left Steer Sensor.
8633 86 33 FRONT LEFT STEER SENSOR - SHORT TO BAT- There is a Short to Battery to the
TERY Front Left Steer Sensor.
8634 86 34 REAR RIGHT STEER SENSOR - SHORT TO There is a Short to Ground or an Open Circuit
GROUND OR OPEN CIRCUIT to the Rear Right Steer Sensor.
8635 86 35 REAR RIGHT STEER SENSOR - SHORT TO BAT- There is a Short to Battery to the
TERY Rear Right Steer Sensor.
8636 86 36 REAR LEFT STEER SENSOR - SHORT TO There is a Short to Ground or an Open Circuit
GROUND OR OPEN CIRCUIT to the Rear Left Steer Sensor.
3121619 – JLG Lift – 6-97

Flash
Code
8637 86 37 REAR LEFT STEER SENSOR - SHORT TO BAT- There is a Short to Battery to the
TERY Rear Left Steer Sensor.
8651 86 51 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE Engine Start is prevented while there is an
FAULT Oscillating Axle fault and vehicle is out of
transport position
8670 8 6 RIGHT FRONT STEER RIGHT VALVE - OPEN Open Circuit detected Check wiring
CIRCUIT
8671 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT Short to Battery detected
TO BATTERY
8672 8 6 RIGHT FRONT STEER LEFT VALVE - OPEN Open Circuit detected
CIRCUIT
8673 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO Short to Battery detected
BATTERY
8674 8 6 LEFT FRONT STEER RIGHT VALVE - OPEN Open Circuit detected
CIRCUIT
8675 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO Short to Battery detected
BATTERY
8676 8 6 LEFT FRONT STEER LEFT VALVE - OPEN CIR- Open Circuit detected
CUIT
8677 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO Short to Battery detected
BATTERY
8678 8 6 RIGHT REAR STEER RIGHT VALVE - OPEN Open Circuit detected
CIRCUIT
8679 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO Short to Battery detected
BATTERY
8680 8 6 RIGHT REAR STEER LEFT VALVE - OPEN CIR- Open Circuit detected
CUIT
8681 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO Short to Battery detected
BATTERY
8682 8 6 LEFT REAR STEER RIGHT VALVE - OPEN CIR- Open Circuit detected
CUIT
8683 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO Short to Battery detected
BATTERY
8684 8 6 LEFT REAR STEER LEFT VALVE - OPEN CIR- Open Circuit detected
CUIT
8685 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO Short to Battery detected
BATTERY
8686 8 6 FRONT LEFT AXLE - MOVEMENT WITHOUT Axle is set to extend position, no axle retract Check sensor hardware and hydraulics
COMMAND or extend is demanded by the operator and
8687 8 6 FRONT RIGHT AXLE - MOVEMENT WITHOUT one or more of the axle sensors detects
COMMAND motion
8688 8 6 REAR RIGHT AXLE - MOVEMENT WITHOUT
COMMAND
8689 8 6 REAR LEFT AXLE - MOVEMENT WITHOUT
COMMAND
6-98 – JLG Lift – 3121619

Flash
Code
990 99 0 <<< HARDWARE >>>
991 99 1 LSS WATCHDOG RESET
992 99 2 LSS EEPROM ERROR
993 99 3 LSS INTERNAL ERROR - PIN EXCITATION
994 99 4 LSS INTERNAL ERROR - DRDY MISSING
998 99 8 EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has reported an
EEPROM failure.
9910 99 10 FUNCTIONS LOCKED OUT - PLATFORM MOD- The Platform Module software version is
ULE SOFTWARE VERSION IMPROPER not compatible with the rest of the system.
9911 99 11 FUNCTIONS LOCKED OUT - LSS MODULE

9914 99 14 PLATFORM MODULE SOFTWARE UPDATE The Platform Module software requires an
REQUIRED updated.
9915 99 15 CHASSIS TILT SENSOR NOT GAIN CALI- The Chassis Tilt Sensor gain calibration has
BRATED been lost.
9916 99 16 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain calibration has
become corrupted.
9917 99 17 HIGH RESOLUTION A2D FAILURE - INTER- The Platform Module has reported that its
RUPT LOST ADS1213 chip has stopped asserting its
interrupt.
9918 99 18 HIGH RESOLUTION A2D FAILURE - REINIT The Platform Module has reported that its
LIMIT ADS1213 chip had to be reset 3 or more
times.
9919 99 19 GROUND SENSOR REF VOLTAGE OUT OF The Ground Module has reported that its - Not reported during power-up.
RANGE sensor reference voltage is outside accept-
able range.
9920 99 20 PLATFORM SENSOR REF VOLTAGE OUT OF The Platform Module has reported that its - Not reported during power-up.
RANGE sensor reference voltage is outside accept-
able range.
9921 99 21 GROUND MODULE FAILURE - HIGH SIDE The Ground Module has reported that its
DRIVER CUTOUT FAULTY high side driver cutout failed.
9922 99 22 PLATFORM MODULE FAILURE - HWFS CODE The Platform Module has reported that the
1 V(Low) FET has failed.
9923 99 23 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has reported that the
V(Low) FET has failed.
9924 99 24 FUNCTIONS LOCKED OUT - MACHINE NOT

9925 99 25 FUNCTIONS LOCKED OUT - CHASSIS MOD- The Chassis Module software version is not
ULE SOFTWARE VERSION IMPROPER compatible with the rest of the system.
9926 99 26 FUNCTIONS LOCKED OUT - BLAM MODULE The BLAM software version is not compati-
SOFTWARE VERSION IMPROPER ble with the rest of the system.
3121619 – JLG Lift – 6-99

Flash
Code
9927 99 27 GROUND MODULE CONSTANT DATA UPDATE The Ground Module constant data requires
REQUIRED an updated.
9928 99 28 ENVELOPE CONTROL DISABLED Envelope Control has been disabled by the - Envelope Control equipped vehicles only.
user from Access Level 0.
99282 99 282 GROUND DISPLAY SOFTWARE VERSION IS 1850SJ T4F machines with Ground Display
IMPROPER must have software version P1.1 or greater
to work.
9929 99 29 MOMENT CONTROL DISABLED Moment Control has been disabled by the - Envelope Control equipped vehicles only.
user from Access Level 0.
9930 99 30 STEER SENSORS NOT CALIBRATED The Steer Sensors have not been calibrated.
9931 99 31 BOOM SENSORS NOT CALIBRATED The Boom Sensors have not been cali- - BLAM equipped vehicles only.
brated.
9932 99 32 LIFT CRACKPOINTS NOT CALIBRATED The Lift Crackpoints have not been cali-
brated.
9933 99 33 TELESCOPE CRACKPOINTS NOT CALIBRATED The Telescope Crackpoints have not been
calibrated.
9934 99 34 DRIVE CRACKPOINTS NOT CALIBRATED The Drive Crackpoints have not been cali-
brated.
9935 99 35 BLAM SENSOR SUPPLY OUT OF RANGE HIGH The Boom Angle Sensors supply voltage is - BLAM equipped vehicles only.
high.
9936 99 36 BLAM SENSOR SUPPLY OUT OF RANGE LOW The Boom Angle Sensors supply voltage is - BLAM equipped vehicles only.
low.
9937 99 37 LENGTH SENSOR REF VOLTAGE HIGH The Boom Length Sensors supply voltage is
high.
9938 99 38 LENGTH SENSOR REF VOLTAGE LOW The Boom Length Sensors supply voltage is
low.
9939 99 39 BLAM HIGH RES A/D FAILURE The BLAM high resolution analog to digital - BLAM equipped vehicles only.
converter has failed.
9940 99 40 CHASSIS SENSOR SUPPLY OUT OF RANGE The Chassis Sensors supply voltage is high.
HIGH
9941 99 41 CHASSIS SENSOR SUPPLY OUT OF RANGE The Chassis Sensors supply voltage is low.
LOW
9944 99 44 CURRENT FEEDBACK GAINS OUT OF RANGE The factory set current feedback gains are
out of range.
9945 99 45 CURRENT FEEDBACK CALIBRATION CHECK- The factory set current feedback checksum
SUM INCORRECT is not correct.
99155 99 155 JIB CONTROL MODULE - HIGH RESOLUTION
99158 99 158 PLATFORM LEVEL ANGLE SENSOR - INTER-
99159 99 159 JIB LIFT ANGLE SENSOR - INTERNAL ERROR
99160 99 160 FUNCTIONS LOCKED OUT - JIB CONTROL
MODULE SOFTWARE VERSION IMPROPER
6-100 – JLG Lift – 3121619

SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 GENERAL that the leads are connected to the device under test correctly.
Also check that the lead on the "COM" port goes to the Ground
This section contains basic electrical information and sche- or negative side of the signal and the lead on the other port
matics to be used for locating and correcting most of the oper- goes to the positive side of the signal.
ating problems which may develop. If a problem should
develop which is not presented in this section or which is not Scale
corrected by listed corrective actions, technically qualified
guidance should be obtained before proceeding with any M = Mega = 1,000,000 * (Displayed Number)
maintenance. k = kilo = 1,000 * (Displayed Number)
NOTE: Some of the procedures/connectors shown in this section m = milli = (Displayed Number) / 1,000
may not be applicable to all models.
μ = micro = (Displayed Number) / 1,000,000
7.2 MULTIMETER BASICS Example: 1.2 kW = 1200 W
Example: 50 mA = 0.05 A
A wide variety of multimeters or Volt Ohm Meters (VOM) can
be used for troubleshooting your equipment. This section Voltage Measurement
shows diagrams of a common, digital VOM configured for sev-
eral different circuit measurements. Instructions for your VOM
may vary. Please consult the meter operator’s manual for more
information.
Grounding
"Grounding the meter" means to take the black lead (which is
connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the Voltage source.
Backprobing
To "backprobe" means to take the measurement by accessing
a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining cir-
cuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around
the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gen- Figure 7-1. Voltage Measurement (DC)
tle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector. • If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
Min/Max • Use firm contact with meter leads
Use of the "Min/Max" recording feature of some meters can
help when taking measurements of intermittent conditions
while alone. For example, you can read the Voltage applied to
a solenoid when it is only operational while a switch, far from
the solenoid and meter, is held down.
Polarity
Getting a negative Voltage or current reading when expecting
a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and
3121619 – JLG Lift – 7-1

Resistance Measurement Continuity Measurement
Figure 7-3. Continuity Measurement
• Some meters require a separate button press to enable

audible continuity testing
• Circuit power must be turned OFF before testing conti-
Figure 7-2. Resistance Measurement nuity
• First test meter and leads by touching leads together. • Disconnect component from circuit before testing
Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads
tance)
• First test meter and leads by touching leads together.
• Circuit power must be turned OFF before testing resis-
Meter should produce an audible alarm, indicating
tance
continuity
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
7-2 – JLG Lift – 3121619

Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND

TO ELECTRICAL CONNECTIONS
NOTE: This section is not applicable for battery terminals.
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE-
RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.
NOTE: Do NOT apply dielectric grease to the following connec-

tions:
• Main Boom Rotary sensor connections (on Celesco Sensor),
• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electrical

connections except for those mentioned above for the follow-
ing reasons:
• To prevent oxidation at the mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level con-

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

• Set up the meter for the expected current range
pound to the electrical connectors. This procedure applies to
• Be sure to connect the meter leads to the correct jacks all plug connections not enclosed in a box. Silicone grease
should not be applied to connectors with external seals.
for the current range you have selected
1. To prevent oxidation, silicone grease must be packed
• If meter is not auto ranging, set it to the correct range
completely around male and female pins on the inside
(See multi meter’s operation manual) of the connector prior to assembly. This is most easily
achieved by using a syringe.
NOTE: Over a period of time, oxidation increases electrical resis-
tance at the connection, eventually causing circuit failure.
2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connec-
tors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
should also be sealed.
NOTE: This condition is especially common when machines are

pressure washed since the washing solution is much more
conductive than water.
3121619 – JLG Lift – 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 Female Contacts
7-4 – JLG Lift – 3121619

DIN Connectors
This connector is typically used on hydraulic valves. Follow the
installation instructions.
Figure 7-6. Use of Seal Plugs

Exclusions
AMP Mate-N-Lok A limited number of connectors do not benefit from dielectric
grease, or may be permanently damaged by application.
Follow the installation instructions. Dielectric grease may not be required in properly sealed
enclosures.
3121619 – JLG Lift – 7-5

BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER

The connector uses gold contact material to resist corrosion This type of connector uses back-seals for moisture integrity.
and an o-ring seal for moisture integrity. If dielectric grease is However, the low-force contacts cannot displace dielectric
mistakenly applied to this connector system, the low-force
grease and create electrical contact. It is possible to use sol-
contacts cannot displace the grease to achieve electrical con-
vents (i.e. contact cleaner or mineral spirits) for the removal of
tact. Once contaminated, there is no practical way to remove
improperly applied dielectric grease. The EMR2 engine control
the dielectric grease (replacement of female contacts
module from Deutz employs this connector system (for exam-
required). The JLG Load Sensing System and 1250AJP Rotary
ple).
Angle Sensors are examples of components with the M12 con-
nector system.
7-6 – JLG Lift – 3121619

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 7-9.).
Check to be sure the wedge lock is in the open, or as-shipped,

position (See Figure 7-7.). Proceed as follows:
Figure 7-7. 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 7-9.).
Figure 7-8. AMP Connector
3121619 – JLG Lift – 7-7

3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).
Release the locking latches by squeezing them inward
(See Figure 7-10.).
7-8 – JLG Lift – 3121619

Figure 7-12. Connector Disassembly
Disassembly Service - Voltage Reading

1. Insert a 4.8 mm (3/16") wide screwdriver blade between
the mating seal and one of the red wedge lock tabs.
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
2. Pry open the wedge lock to the open position.
It has been common practice in electrical troubleshooting to
3. While rotating the wire back and forth over a half turn probe wires by piercing the insulation with a sharp point. This
(1/4 turn in each direction), gently pull the wire until the practice should be discouraged when dealing with the
contact is removed. AMPSEAL plug assembly, or any other sealed connector sys-
tem. The resulting pinholes in the insulation will allow mois-
NOTE: The wedge lock should never be removed from the housing
ture to invade the system by traveling along the wire strands.
for insertion or removal of the contacts.
This nullifies the effectiveness of the connector seals and
could result in system failure.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.
3121619 – JLG Lift – 7-9

Figure 7-13. Connector Installation
7-10 – JLG Lift – 3121619

7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-14. DT/DTP Contact Installation Figure 7-15. DT/DTP Contact Removal
1. Remove wedgelock using needlenose pliers or a hook

1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.
barrel.
2. To remove the contacts, gently pull wire backwards,
2. Hold connector with rear grommet facing you. while at the same time releasing the locking finger by
3. Push contact straight into connector grommet until a moving it away from the contact with a screwdriver.
click is felt. A slight tug will confirm that it is properly 3. Hold the rear seal in place, as removing the contact may
locked in place. displace the seal.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
3121619 – JLG Lift – 7-11

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal
1. Grasp contact about 25mm behind the contact crimp

1. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
2. Hold connector with rear grommet facing you.
2. Slide tool along into the insert cavity until it engages
3. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm that it is
3. Pull contact-wire assembly out of connector.
properly locked in place.
Figure 7-19. HD/HDP Unlocking Contacts

Figure 7-17. 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
7-12 – JLG Lift – 3121619

7.6 WIRING HARNESS CONNECTOR LABELS Table 7-1. Wiring Harness Connector Labels
Connector Labels Component Category Label

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

Platform
X65A, X65B connect to different portions of one device
Engine Alternator EC
X163 connects to X163A in ANSI and X163B in CE machines Cold Start
Component Labels Controller
Coolant Temp
Every component on the vehicle has a unique identification. A
Fuel Pump
standard prefix letter is assigned according to the table below,
followed by a unique sequential number. An optional suffix Fuel Solenoid
(letters & numbers) may be added when multiple terminations Glow Plugs
occur at one device. Oil Pressure
Terminals that are not loaded into connectors are considered Starter
independent components and labeled in the same fashion. Fuse & CB Fuse FC Fuse FC
Fusible Link FC
Circuit Breaker CB
Gauge & Display Board GD
Cluster
Hour meter
LMI
Speedometer
Inline Resistor R
Diode D
Joystick & Steering Electronic JS
Hydraulic
Lights Dome LB
Headlights
Simple
Taillights
Membrane Panel MP
Miscellaneous Radio MS
Speakers
Splice Blocks
T-Connectors
3121619 – JLG Lift – 7-13

Table 7-1. Wiring Harness Connector Labels
Component Category Label

Other Switches Disconnect SW
EMS
Foot
HVAC WH
Key SW
Park brake
Pump pot
Push
Shifter
Turn signal
Relay 5 Pin RL
4 Pin
Contactor
Power module
Rocker Switch SW
Sensor Angle SN
Fuel
Length
Limit
Load
Pressure
Proximity
Speed
Temperature
Terminals Pins T
Sockets
Male Blades
Female Blades
Rings
Forks
Toggle Switch DPDT SW
DPST
SPDT
SPST
Special
Valves Simple HV
Suppression
Examples:
T67 is a ring terminal connected during installation.
CO1-J3 is the J3 connector for a UGM control module.
EC9 is a glow plug supplied with the engine
7-14 – JLG Lift – 3121619

3121619
SW2 3
M AIN BO OM T ELE
SW 22- 2
SW2 2- 1
SW 21
JIB L IF T SW2 0- 1
SW 19
SW2 0- 2
JIB SWI NG
SW1 4
J IB T EL E L B1 2- M S41
* MU ST I NCL UDE:
BUSSBAR J LG P/N: 100 111 90 20
M OUN TI NG C LIP JL G P/N: 1 00 112 03 28
SW 13 LB1 2+
PLT FM R OTAT E
X3 8A
LB32 0+ CO 01 -J7
CO0 1- J8
LB32 0- X39 0
X4 3A
G D04 -J1 GD 04- J3 SW10
SW3 5- 1A
SW26
SW08 -2 X39 2
CAPACIT Y SEL
X38 5
SW08 -1
X38 8
S46
DRIVE ORIENT
S4 5
S40
– JLG Lift –
SW2 5
SW35 -2 A
STRT /AU X PWR
GD 04 -J2
X38 7 X4 4A
G D04 -J4 AH 30-
SW1 5
HIG H DR IVE CO0 1- J1
SW24 SW18
BO OM CON TR OL AXL E EXT/ RET AH 30+ X3 6A
CO 01 -J2
*M UST INC LUDE:
X39 9
SW17 WASHER J LG P/N: 446 04 96
X3 98
PL TF M LEVEL X32 NUT JLG P/N: 44 60 49 7
SW1 6
X3 3A
ST EER M ODE
* M UST INCL UDE:
WASHER JL G P/ N: 4 46 04 71
X39 1
NU T JLG P/N: 44 604 70
1001149976-D
X3 84
Figure 7-20. Platform Box Wiring Harness - Sheet 1 of 2
7-15
CONN WIRE WIRE GAUGE JACKET TO

POS COLOR LABEL
1 WHT 52-4 GEN 18 AWG GXL CO01-J7 (9)
SW16 2 YEL 2-7 18 AWG GXL CO01-J2 (33)
STEER MODE 3 WHT 49-24 SFTCH 18 AWG GXL CO01-J7 (18)
4 WHT 49-27 18 AWG GXL X38A (5)
CONN WIRE WIRE 5 WHT 49-27 18 AWG GXL X38A (4)
POS COLOR LABEL GAUGE JACKET TO
6 YEL 2-8-1 18 AWG GXL X38A (8)
1 WHT 55-2 CRB STR 18 AWG GXL CO01-J1 (16) 7 WHT 49-25 FTSW OPEN 18 AWG GXL CO01-J7 (8)
2 YEL 2-1-1 18 AWG GXL SW15 (2) YEL
8 2-8 18 AWG GXL CO01-J2 (3)
2 YEL 2-1-2 18 AWG GXL SW17 (2) 8 YEL 2-8-1 18 AWG GXL X38A (6)
3 WHT 55-3 CRD STR 18 AWG GXL CO01-J1 (17)
4
5 AH30+
6
POS COLOR LABEL
1 WHT 49-26 ALARM 18 AWG GXL CO01-J7 (19)
SW15
HIGH DRIVE AH30-
CONN WIRE WIRE CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL GAUGE JACKET TO POS COLOR LABEL
1 WHT 48-1 ENG SPD 18 AWG GXL CO01-J1 (28) 1 BLK 0-5 18 AWG GXL CO01-J7 (20)
2 YEL 2-1 18 AWG GXL CO01-J1 (18)
2 YEL 2-1-1 18 AWG GXL SW16 (2)
3 WHT 48-2 2 SPD 18 AWG GXL CO01-J1 (27) MS41
4 CONN WIRE WIRE GAUGE JACKET TO
5 POS COLOR LABEL
6 1 YEL CAN HI 20 AWG J1939 CABLE X33A (3)
2 YEL CAN HI 20 AWG J1939 CABLE CO01-J7 (31)
SW10 3 GRN
GRN
CAN LOW 20 AWG J1939 CABLE X33A (2)
4 CAN LOW 20 AWG J1939 CABLE CO01-J7 (30)
5 SHLD CAN SHIELD 20 AWG J1939 CABLE X33A (1)
CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO 6 SHLD CAN SHIELD 20 AWG J1939 CABLE CO01-J7 (32)
1 7 GRY CAN SHIELD 20 AWG CABLE X44A (5)
2 WHT 49-14 CREEP 18 AWG GXL CO01-J1 (32) 8 GRY CAN SHIELD 20 AWG CABLE X43A (5)
3 YEL 2-1-5 18 AWG GXL SW08-1 (1) 9 BLK CAN LOW 20 AWG CABLE X44A (4)
3 YEL 2-1-7 18 AWG GXL SW13 (2) 10 BLK CAN LOW 20 AWG CABLE X43A (4)
4 WHT 55-4 POT REF 18 AWG GXL CO01-J1 (34) 11 BLU CAN HI 20 AWG CABLE X44A (3)
5 BLK 0-3 18 AWG GXL CO01-J1 (13) 12 BLU CAN HI 20 AWG CABLE X43A (3)
6 WHT 55-5 PUMP POT 18 AWG GXL CO01-J1 (35)
X32
X384 CONN WIRE WIRE
POS COLOR LABEL 1 WHT 49-9 ANALPWR 18 AWG GXL CO01-J2 (26)
1 BLK 0-40 12 AWG GXL X33A (16) 2 WHT 49-8 RX 18 AWG GXL CO01-J2 (28)
3 WHT 49-7 TX 18 AWG GXL CO01-J2 (29)
4 WHT 49-6 ANALGND 18 AWG GXL CO01-J2 (27)
X391
CONN WIRE WIRE GAUGE JACKET TO CO01-J2
POS COLOR LABEL
1 BLK 0-41 12 AWG GXL X33A (18)
POS COLOR LABEL
1 WHT 59-1 JSWG RT 18 AWG GXL SW19 (1)
X398 2 WHT 59-2 JSWG LT 18 AWG GXL SW19 (3)
3 YEL 2-8 18 AWG GXL X38A (8)
POS COLOR LABEL 4 WHT 55-6 DOS 18 AWG GXL SW27 (1)
1 YEL 2-25 12 AWG GXL X33A (10) 5
6 WHT 49-1 TILT 18 AWG GXL GD04-J4 (5)
7 YEL 2-2 ENABLE 18 AWG GXL GD04-J2 (2)
X399 8 WHT 47-2 SYS FAIL 18 AWG GXL GD04-J3 (6)
9 WHT 49-5 CREEP 18 AWG GXL GD04-J2 (1)
CONN WIRE WIRE GAUGE JACKET TO WHT
POS COLOR LABEL 10 49-3 BRKN CABLE 18 AWG GXL GD04-J3 (5)
1 YEL 2-26 12 AWG GXL X33A (12) 11 WHT 49-2 OVERLOAD 18 AWG GXL GD04-J4 (3)
12 WHT 54-1 500LB MODE 18 AWG GXL GD04-J4 (4)
13 WHT 54-2 1000LB MODE 18 AWG GXL GD04-J3 (4)
X387 14 WHT 39-1 AXL SET 18 AWG GXL GD04-J3 (2)
15 WHT 52-1 GEN 18 AWG GXL GD04-J4 (2)
CONN WIRE WIRE GAUGE JACKET TO 16 WHT 49-21 SFTCH LT 18 AWG GXL LB12+ (1)
POS COLOR LABEL 17 WHT 48-1 ENG PREHEAT 18 AWG GXL GD04-J4 (6)
1 YEL 2-25-1 12 AWG GXL CO01-J8 (2) 18 BLK 0-2 18 AWG GXL GD04-J2 (6)
19 WHT 49-4 BCS 18 AWG GXL GD04-J3 (1)
WHT
X388 20
21 WHT
47-1 PLTFM LVL FAIL
47-5 LOW FUL
18
18
AWG
AWG
GXL
GXL
GD04-J4 (1)
GD04-J2 (3)
CONN WIRE WIRE GAUGE JACKET TO 22 WHT 47-1 FUL 1/4 18 AWG GXL GD04-J1 (1)
POS COLOR LABEL 23 WHT 47-3 FUL 3/4 18 AWG GXL GD04-J1 (3)
1 BLK 0-7 16 AWG TXL X36A (19) 24 WHT 47-2 FUL 1/2 18 AWG GXL GD04-J1 (2)
1 BLK 0-8 18 AWG GXL X36A (5) 25 BLK 0-1 18 AWG GXL GD04-J1 (4)
26 WHT 49-9 ANALPWR 18 AWG GXL X32 (1)
27 WHT 49-6 ANALGND 18 AWG GXL X32 (4)
X385 28 WHT 49-8 RX 18 AWG GXL X32 (2)
29 WHT 49-7 TX 18 AWG GXL X32 (3)
CONN WIRE WIRE GAUGE JACKET TO 30 WHT 55-1 DRV ORNT 18 AWG GXL GD04-J3 (3)
POS COLOR LABEL
1 BLK 0-40-3 16 AWG GXL X392 (1) 31 WHT 59-6 JIB LOK 18 AWG GXL LB320+ (1)
1 BLK 0-41-3 16 AWG GXL X392 (3) 32 YEL 2-6 18 AWG GXL S40 (1)
33 YEL 2-7 18 AWG GXL X38A (2)
34
X390 35 WHT 47-4 FUL FULL 18 AWG GXL GD04-J1 (6)
CONN WIRE WIRE

POS COLOR LABEL
GAUGE JACKET TO
CO01-J8
1 BLK 0-41-2 12 AWG GXL CO01-J8 (1)
POS COLOR LABEL
1 BLK 0-41-2 12 AWG GXL X390 (1)
2 YEL 2-25-1 12 AWG GXL X387 (1)
7-16 – JLG Lift – 3121619

CO01-J1 X33A
CONN WIRE WIRE GAUGE JACKET TO CONN WIRE WIRE
POS COLOR LABEL POS COLOR LABEL GAUGE JACKET TO
1 WHT 49-20 PROX NC 18 AWG GXL X33A (15) SHLD
1 CAN SHIELD 20 AWG J1939 CABLE MS41 (5)
2 GRN
2 CAN LOW 20 AWG J1939 CABLE MS41 (3)
3 WHT 29-1 JT ELE IN 18 AWG GXL SW14 (1) 3 YEL CAN HI 20 AWG J1939 CABLE MS41 (1)
4 WHT 29-2 JT ELE OUT 18 AWG GXL SW14 (3) 4 YEL 2-4 18 AWG GXL CO01-J7 (3)
5 WHT 13-1 MT ELE IN 18 AWG GXL SW23 (1) RED
5 1-4-3 18 AWG GXL SW35-2A (2A)
6 WHT 13-2 MT ELE OUT 18 AWG GXL SW23 (3)
6
7 WHT 23-1 P ROT RT 18 AWG GXL SW13 (1) 7 WHT 25-5 PLVL DN O/R 18 AWG GXL S46 (2)
8 WHT 23-2 P ROT LT 18 AWG GXL SW13 (3)
8
9 WHT 25-1 PLVL UP 18 AWG GXL SW17 (1) WHT
9 25-6 PLVL UP O/R 18 AWG GXL S45 (2)
10 WHT 25-2 PLVL DN 18 AWG GXL SW17 (3) 10 YEL 2-25 12 AWG GXL X398 (1)
11 WHT 27-1 JIB UP 18 AWG GXL SW21 (1) 11 YEL 2-5 18 AWG GXL CO01-J7 (1)
12 WHT 27-2 JIB DN 18 AWG GXL SW21 (3) 12 YEL 2-26 12 AWG GXL X399 (1)
13 BLK 0-3 18 AWG GXL SW10 (5) 13 WHT 49-19 PROX NO 18 AWG GXL CO01-J1 (33)
14 WHT 48-3 ST RT 18 AWG GXL SW25 (1) 14
15 WHT 53-1 AUX 18 AWG GXL SW25 (3) 15 WHT 49-20 PROX NC 18 AWG GXL CO01-J1 (1)
16 WHT 55-2 CRB ST R 18 AWG GXL SW16 (1) 16 BLK 0-40 12 AWG GXL X384 (1)
17 WHT 55-3 CRD ST R 18 AWG GXL SW16 (3) 17
18 YEL 2-1 18 AWG GXL SW15 (2) 18 BLK 0-41 12 AWG GXL X391 (1)
19 19
20 WHT 49-50 PROX NC 18 AWG GXL X36A (4)
21 WHT 54-3 CPCIT Y SW 18 AWG GXL SW26 (3)
22 WHT
WHT
49-16 ENVLP 18 AWG GXL SW24 (3) X43A
23 39-2 AXL EXT 18 AWG GXL SW18 (1)
24 WHT 39-3 AXL RET 18 AWG GXL SW18 (3) CONN WIRE WIRE
25 WHT 49-18 PLVL 1 18 AWG GXL X36A (2)
WHT 1 BRN 49-11 X43 PWR 20 AWG CABLE CO01-J7 (4)
26 49-17 PLVL 2 18 AWG GXL X36A (16)
WHT 2 WHT 49-10 X43 GND 20 AWG CABLE CO01-J7 (14)
27 48-2 2 SPD 18 AWG GXL SW15 (3)
3 BLU CAN HI 20 AWG CABLE MS41 (12)
28 WHT 48-1 ENG SPD 18 AWG GXL SW15 (1)
4 BLK CAN LOW 20 AWG CABLE MS41 (10)
29 WHT 49-15 SF T TOUCH 18 AWG GXL SW20-2 (1)
30 WHT 52-3 HEAD/TAIL LT 18 AWG GXL SW22-2 (1) 5 GRY CAN SHIELD 20 AWG CABLE MS41 (8)
31 WHT 52-2 HORN 18 AWG GXL SW08-2 (1)
32 WHT 49-14 CREEP 18 AWG GXL SW10 (2)
33 WHT 49-19 PROX NO 18 AWG GXL X33A (13) X44A
34 WHT 55-4 POT REF 18 AWG GXL SW10 (4)
CONN WIRE WIRE
35 WHT 55-5 PUMP POT 18 AWG GXL SW10 (6) GAUGE JACKET TO
POS COLOR LABEL
1 BRN 49-13 X44 PWR 20 AWG CABLE CO01-J7 (7)
2 WHT 49-12 X44 GND 20 AWG CABLE CO01-J7 (14)
CO01-J7 3 BLU CAN HI 20 AWG CABLE MS41 (11)
4 BLK CAN LOW 20 AWG CABLE MS41 (9)
CONN WIRE WIRE GRY
GAUGE JACKET TO 5 CAN SHIELD 20 AWG CABLE MS41 (7)
POS COLOR LABEL
1 YEL 2-5 18 AWG GXL X33A (11)
2 RED 1-4-3 PLT F MODE 18 AWG GXL SW35-1A (1A)
3 YEL 2-4 18 AWG GXL X33A (4) X392
4 BRN 49-11 X43 PWR 20 AWG CABLE X43A (1) CONN WIRE WIRE
5 WHT 23-3 PROT LT 18 AWG GXL X36A (8) POS COLOR LABEL GAUGE JACKET TO
6 WHT 23-4 PROT RT 18 AWG GXL X36A (9) 1 BLK 0-40-3 16 AWG GXL X385 (1)
7 BRN 49-13 X44 PWR 20 AWG CABLE X44A (1) 2 ORG 1-7-1 WK LT PWR 16 AWG T XL X36A (13)
8 WHT 49-25 F T SW OPEN 18 AWG GXL X38A (7) 3 BLK 0-41-3 16 AWG GXL X385 (1)
9 WHT 52-4 GEN 18 AWG GXL X38A (1) ORG
4 1-7-2 WK LT PWR 16 AWG T XL X36A (20)
10
11
12
13
14 WHT 49-10 X43 GND 20 AWG CABLE X43A (2) CONN WIRE WIRE
14 WHT 49-12 X44 GND 20 AWG CABLE X44A (2)
1 YEL 2-6-1 18 AWG GXL S40 (2)
15 WHT 25-3 PLVL UP 18 AWG GXL S45 (1)
2 WHT 49-18 PLVL 1 18 AWG GXL CO01-J1 (25)
16 WHT 25-4 PLVL DN 18 AWG GXL S46 (1)
3 WHT 49-22 GND 18 AWG GXL CO01-J7 (21)
17
4 WHT 49-50 PROX NC 18 AWG GXL CO01-J1 (20)
18 WHT 49-24 SF T CH 18 AWG GXL X38A (3)
5 BLK 0-8 18 AWG GXL X388 (1)
19 WHT 49-26 ALARM 18 AWG GXL AH30+ (1)
6 WHT 25-4-1 PLVL DN 18 AWG GXL S46 (2)
20 BLK 0-5 18 AWG GXL AH30- (1) WHT
7 25-3-1 PLVL UP 18 AWG GXL S45 (2)
21 WHT 49-22 GND 18 AWG GXL X36A (3) WHT
8 23-3 PROT LT 18 AWG GXL CO01-J7 (5)
22
9 WHT 23-4 PROT RT 18 AWG GXL CO01-J7 (6)
23
10 WHT 55-26 JLOCK IN 18 AWG GXL CO01-J7 (25)
24 WHT
11 55-25 JLOCK OUT 18 AWG GXL CO01-J7 (26)
25 WHT 55-26 JLOCK IN 18 AWG GXL X36A (10)
12 BLK 0-4 18 AWG GXL CO01-J7 (29)
26 WHT 55-25 JLOCK OUT 18 AWG GXL X36A (11)
13 ORG 1-7-1 WK LT PWR 16 AWG T XL X392 (2)
27 WHT
14 50-2 P DUMP 16 AWG T XL X36A (18)
28 YEL
15 2-6-2 18 AWG GXL S40 (2)
29 BLK 0-4 18 AWG GXL X36A (12)
16 WHT 49-17 PLVL 2 18 AWG GXL CO01-J1 (26)
30 GRN CAN LOW 20 AWG J1939 CABLE MS41 (4)
17 WHT 49-23 GND 18 AWG GXL CO01-J7 (33)
31 YEL CAN HI 20 AWG J1939 CABLE MS41 (2) 18 WHT 50-2 P DUMP 16 AWG T XL X36A (14)
32 SHLD CAN SHIELD 20 AWG J1939 CABLE MS41 (6)
19 BLK 0-7 16 AWG T XL X388 (1)
33 WHT 49-23 GND 18 AWG GXL X36A (17)
20 ORG 1-7-2 WK LT PWR 16 AWG T XL X392 (4)
34 21
35
3121619 – JLG Lift – 7-17

7-18
MS437
X36B
X365B
HV343
– JLG Lift –
JLOCK OUT
HV342
JLOCK IN
HV277
HV278 P-ROT LFT
P-ROT RHT HV276 SN273
HV275 P-LVL DN
P-LVL UP
HV281 1001149977-D
PLTFM ENABLE
Figure 7-23. Platform Valve Wiring Harness - Sheet 1 of 2
3121619
X36B HV343
CONN WIRE WIRE
GA UGE JA CK E T TO
JLOCK OUT
P OS COLOR LA B E L
1 RE D CA B LE 18 AWG CA B LE S N274 (1) CONN WIRE WIRE
GA UGE JA CK E T TO
P OS COLOR LA B E L
2 B LU CA B LE 18 AWG CA B LE S N274 (2)
1 WHT 55-25 JLOCK OUT 18 AWG GX L X 36B (11)
3 B LK CA B LE 18 AWG CA B LE S N274 (3)
2 B LK 0-4-6 18 AWG GX L MS 437 (6)
4 B LU CA B LE 16 AWG CA B LE X 365B (3)
5 S HIE LD S HIE LD 18 AWG S HLD NC ()
6 WHT 25-4-2 P LV L DN 18 AWG GX L HV 276 (1)
7 WHT 25-3-2 P LV L UP 18 AWG GX L HV 275 (1)
8 WHT 23-3 P ROT LT 18 AWG GX L HV 277 (1)
9 WHT 23-4 P ROT RT 18 AWG GX L HV 278 (1)
HV277
10 WHT 55-26 JLOCK IN 18 AWG GX L HV 342 (1) P-ROT LFT
11 WHT 55-25 J LOCK OUT 18 AWG GX L HV 343 (1)
12 B LK 0-4 18 AWG GX L MS 437 (8) CONN WIRE WIRE
GA UGE JA CK E T TO
P OS COLOR LA B E L
13 ORG CA B LE 16 AWG CA B LE X 365B (2)
1 WHT 23-3 P ROT LT 18 AWG GX L X 36B (8)
14 B LK CA B LE 16 AWG CA B LE X 365B (4)
2 B LK 0-4-3 18 AWG GX L MS 437 (2)
15 ORG CA B LE 18 AWG CA B LE S N273 (1)
16 YEL CA B LE 18 AWG CA B LE S N273 (2)
17 B LK CA B LE 18 AWG CA B LE S N273 (3)
WHT
18
19 B LK
25-5 P LTFRM DUMP
0-7
16 AWG
16 AWG
GX L
GX L
HV 281 (1)
HV 281 (2)
SN274
20 RE D CA B LE 16 AWG CA B LE X 365B (1) CONN WIRE WIRE
GA UGE JA CK E T TO
21 P OS COLOR LA B E L
1 RE D CA B LE 18 AWG CA B LE X 36B (1)
2 B LU CA B LE 18 AWG CA B LE X 36B (2)
3 B LK CA B LE 18 AWG CA B LE X 36B (3)
MS437
CONN WIRE WIRE
P OS COLOR LA B E L GA UGE J A CK E T TO
1 B LK 0-4-4 18 AWG GX L HV 278 (2) X365B

2 B LK 0-4-3 18 AWG GX L HV 277 (2)
CONN WIRE WIRE
3 B LK 0-4-1 18 AWG GX L HV 275 (2) GA UGE JA CK E T TO
P OS COLOR LA B E L
4 B LK 0-4-2 18 AWG GX L HV 276 (2) 1 RE D CA B LE 16 AWG CA B LE X 36B (20)
5 2 ORG CA B LE 16 AWG CA B LE X 36B (13)
6 B LK 0-4-6 18 AWG GX L HV 343 (2) 3 B LU CA B LE 16 AWG CA B LE X 36B (4)
7 B LK 0-4-5 18 AWG GX L HV 342 (2) 4 B LK CA B LE 16 AWG CA B LE X 36B (14)
8 B LK 0-4 18 AWG GX L X 36B (12)
SN273
CONN WIRE WIRE
HV342 P OS COLOR LA B E L
GA UGE JA CK E T TO
JLOCK IN 1 ORG CA B LE 18 AWG CA B LE X 36B (15)

2 YEL CA B LE 18 AWG CA B LE X 36B (16)
CONN WIRE WIRE 3 B LK CA B LE 18 AWG CA B LE X 36B (17)
GA UGE JA CK E T TO
P OS COLOR LA B E L
1 WHT 55-26 JLOCK IN 18 AWG GX L X 36B (10)
2 B LK 0-4-5 18 AWG GX L MS 437 (7)
HV281
HV278 PLTFM ENABLE
P-ROT RHT CONN WIRE WIRE
CONN WIRE WIRE
GA UGE J A CK E T TO 1 WHT 25-5 P LTFRM DUMP 16 AWG GX L X 36B (18)
P OS COLOR LA B E L
1 WHT 23-4 P ROT RT 18 AWG GX L X 36B (9) 2 B LK 0-7 16 AWG GX L X 36B (19)
2 B LK 0-4-4 18 AWG GX L MS 437 (1)
HV276
HV275 P-LVL DN
P-LVL UP
CONN WIRE WIRE
GA UGE JA CK E T TO
CONN WIRE WIRE P OS COLOR LA B E L
GA UGE JA CK E T TO
P OS COLOR LA B E L 1 WHT 25-4-2 P LV L DN 18 AWG GX L X 36B (6)
1 WHT 25-3-2 P LV L UP 18 AWG GX L X 36B (7) 2 B LK 0-4-2 18 AWG GX L MS 437 (4)
2 B LK 0-4-1 18 AWG GX L MS 437 (3)
Figure 7-24. Platform Valve Wiring Harness - Sheet 2 of 2
3121619 – JLG Lift – 7-19

7-20
MS 262-2
X230A
MS 262-3
CO245-J5
SN260
CO245-J 2
CO245-J4 SN259
JIB TRA NS 2
CO245-J3
X228B MS262-1
SN246
S264 S383
S265
CO245-J1
S N257
X365A SN258
X364B
JI B TRA NS 1
MS380 S N247
MS 347

P OS COLOR LA BEL
1 WHT 27-5-1 JIB UP 18 A WG GXL CO245-J 5 (1)
HV250
J IB S WG RHT 1 WHT 27-6-1 J -UP O/R 18 A WG GXL CO245-J 2 (2)
2 WHT 27-5-2 JIB UP 18 A WG GXL HV254 (1)
HV256
JI B LVL UP
HV255
– JLG Lift –
JIB LV L DN
S265
HV 249 CONN WI RE WIRE
JI B S WG LFT GA UGE J ACK ET TO
POS COLOR LABEL
1 WHT 27-3-1 JIB DN O/R 18 AWG GXL CO245-J2 (1)
HV248 1 WHT 27-4-1 JIB DN 18 AWG GXL CO245-J5 (2)
JIB ENAB LE 2 WHT 27-4-2 JIB DN 18 AWG GXL HV253 (1)
S383
CONN WIRE WIRE

GAUGE J ACK ET TO
P OS COLOR LABEL
1 BLK 0-27 18 AWG GX L MS380 (12)
2 BLK 0-27-1 18 AWG GX L SN259 (3)
2 BLK 0-47 16 AWG GX L HV248 (2)
HV252
JI B TELE IN
HV251
J IB TELE OUT
HV 254
JI B LI FT UP
HV 253 1001149978-D
JI B LI FT DN
Figure 7-25. Jib Valve Wiring Harness - Sheet 1 of 3
3121619
SN246 HV256
JIB LVL UP
CONN WIRE WIRE
CONN WIRE WIRE
A BLK GROUND 18 AWG CABLE CO245-J3 (12) POS COLOR LABEL GAUGE JACKET TO
B RED 5V PWR 18 AWG CABLE CO245-J3 (10) 1 WHT 55-20 JLVL UP 18 AWG GXL CO245-J2 (11)
C BLU SIGNAL 18 AWG CABLE CO245-J3 (8) 2 BLK 0-25-1 18 AWG GXL MS347 (8)
D WHT SIGNAL 18 AWG CABLE CO245-J3 (11)
E GRN GROUND 18 AWG CABLE CO245-J3 (9)
F ORG 5V PWR 18 AWG CABLE CO245-J3 (7)
HV250
JIB SWG RHT
CONN WIRE WIRE
SN257 POS COLOR LABEL
GAUGE JACKET TO
1 WHT 59-1-1 JSWG RT 18 AWG GXL CO245-J5 (3)

CONN WIRE WIRE
GAUGE JACKET TO 2 BLK 0-26-5 18 AWG GXL MS347 (2)
POS COLOR LABEL
1 YEL 2-22 18 AWG GXL CO245-J4 (1)
2 WHT 49-42 LOCK NC 18 AWG GXL CO245-J2 (5)
3 BLK 0-23 18 AWG GXL CO245-J4 (2) SN258
4 WHT 49-41 LOCK NO 18 AWG GXL CO245-J2 (4)
JIB TRANS 1
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
SN247 1 YEL 2-21 18 AWG GXL CO245-J4 (7)
CONN WIRE WIRE 2 WHT 49-44 PROX 1NC 18 AWG GXL CO245-J2 (7)
GAUGE JACKET TO
POS COLOR LABEL 3 BLK 0-24 18 AWG GXL CO245-J4 (8)
A BLK GROUND 18 AWG CABLE CO245-J3 (6) 4 WHT 49-43 PROX 1NO 18 AWG GXL CO245-J2 (6)
B RED 5V PWR 18 AWG CABLE CO245-J3 (4)
C BLU SIGNAL 18 AWG CABLE CO245-J3 (2)
D WHT SIGNAL 18 AWG CABLE CO245-J3 (5) SN259
E GRN GROUND 18 AWG CABLE CO245-J3 (3)
F ORG 5V PWR 18 AWG CABLE CO245-J3 (1)
JIB TRANS 2
CONN WIRE WIRE
HV252 1 YEL 2-19 18 AWG GXL MS380 (9)

2 WHT 49-20 PROX NC 18 AWG GXL X228B (15)
JIB TELE IN 3 BLK 0-27-1 18 AWG GXL S383 (2)
4 WHT 49-19 PROX NO 18 AWG GXL X228B (13)
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 29-3-1 JIB IN 18 AWG GXL CO245-J5 (5)
2 BLK 0-26-3 18 AWG GXL MS347 (4) MS262-1
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
HV253 A YEL CAN HI 20 AWG J1939 CABLE X228B (3)
B GRN CAN LOW 20 AWG J1939 CABLE X228B (2)
JIB LIFT DN C SHLD SHIELD 20 AWG J1939 CABLE X228B (1)
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 27-4-2 JIB DN 18 AWG GXL S265 (2) MS262-3
2 BLK 0-26-2 18 AWG GXL MS347 (9)
CONN WIRE WIRE
A YEL CAN HI 20 AWG J1939 CABLE CO245-J4 (3)
HV254 B GRN CAN LOW 20 AWG J1939 CABLE CO245-J4 (4)
JIB LIFT UP C SHLD SHIELD 20 AWG J1939 CABLE CO245-J4 (5)
CONN WIRE WIRE

GAUGE JACKET TO
POS COLOR
WHT
LABEL
MS262-2
1 27-5-2 JIB UP 18 AWG GXL S264 (2)
2 BLK 0-26-1 18 AWG GXL MS347 (10) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
A YEL CAN HI 20 AWG J1939 CABLE SN260 (3)
B GRN CAN LOW 20 AWG J1939 CABLE SN260 (4)
HV251 C SHLD SHIELD 20 AWG J1939 CABLE SN260 (5)
JIB TELE OUT
CONN WIRE
POS COLOR
WIRE
LABEL
GAUGE JACKET TO X364B
1 WHT 29-4-1 JIB OUT 18 AWG GXL CO245-J5 (6) CONN WIRE WIRE
GAUGE JACKET TO
2 BLK 0-26-4 18 AWG GXL MS347 (3) POS COLOR LABEL
1 RED 1-7-2 WK LT PWR 16 AWG GXL X365A (1)
2 RED 1-7-1 WK LT PWR 16 AWG GXL X365A (2)
3 WHT 50-3 JIB DUMP 16 AWG GXL HV248 (1)
HV248 4 WHT 50-2 PLTFM DUMP 16 AWG GXL X365A (4)
JIB ENABLE
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR
1 WHT
LABEL
50-3 JIB DUMP 16 AWG GXL X364B (3)
X230A
2 BLK 0-47 16 AWG GXL S383 (2) CONN WIRE WIRE
1 SHLD SHIELD 20 AWG J1939 CABLE CO245-J1 (8)
2 GRN CAN LOW 20 AWG J1939 CABLE CO245-J1 (7)
HV249 3 YEL CAN HI 20 AWG J1939 CABLE CO245-J1 (6)
JIB SWG LFT 4 YEL 2-4 18 AWG GXL X228B (4)
5 RED 1-4-3 18 AWG GXL X228B (5)
CONN WIRE WIRE 6 YEL 2-15 18 AWG GXL X228B (6)
7 WHT 25-5 PLVL DN O/R 18 AWG GXL X228B (7)
1 WHT 59-2-1 JSWG LT 18 AWG GXL CO245-J5 (4)
8
2 BLK 0-26-6 18 AWG GXL MS347 (1)
9 WHT 25-6 PLVL UP O/R 18 AWG GXL X228B (9)
10 YEL 2-25 12 AWG GXL MS380 (7)
11 YEL 2-5 18 AWG GXL X228B (11)
HV255 12 YEL 2-26 12 AWG GXL MS380 (6)
JIB LVL DN 13
14
WHT 27-6 J-UP O/R 18 AWG GXL CO245-J1 (2)
CONN WIRE WIRE 15 WHT 27-3 JIB DN O/R 18 AWG GXL CO245-J1 (1)
GAUGE JACKET TO
POS COLOR LABEL 16 BLK 0-40 12 AWG GXL MS380 (10)
1 WHT 55-19 JLVL DN 18 AWG GXL CO245-J2 (12) 17
2 BLK 0-25-2 18 AWG GXL MS347 (7) 18 BLK 0-41 12 AWG GXL MS380 (3)
19
3121619 – JLG Lift – 7-21

CO245-J3
POS COLOR LABEL CO245-J5
1 ORG 5V PWR 18 AWG CABLE SN247 (F)
2 BLU SIGNAL 18 AWG CABLE SN247 (C) CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL
3 GRN GROUND 18 AWG CABLE SN247 (E) 1 WHT 27-5-1 JIB UP 18 AWG GXL S264 (1)
4 RED 5V PWR 18 AWG CABLE SN247 (B)
2 WHT 27-4-1 JIB DN 18 AWG GXL S265 (1)
5 WHT SIGNAL 18 AWG CABLE SN247 (D) WHT
3 59-1-1 JSWG RT 18 AWG GXL HV250 (1)
6 BLK GROUND 18 AWG CABLE SN247 (A) WHT
4 59-2-1 JSWG LT 18 AWG GXL HV249 (1)
7 ORG 5V PWR 18 AWG CABLE SN246 (F) WHT
BLU 5 29-3-1 JIB IN 18 AWG GXL HV252 (1)
8 SIGNAL 18 AWG CABLE SN246 (C) 6 WHT 29-4-1 JIB OUT 18 AWG GXL HV251 (1)
9 GRN GROUND 18 AWG CABLE SN246 (E) 7
10 RED 5V PWR 18 AWG CABLE SN246 (B) 8
11 WHT SIGNAL 18 AWG CABLE SN246 (D)
9
12 BLK GROUND 18 AWG CABLE SN246 (A)
10
11
BLK
MS347 12 0-26 18 AWG GXL MS347 (12)

POS COLOR LABEL SN260
1 BLK 0-26-6 18 AWG GXL HV249 (2)
2 BLK 0-26-5 18 AWG GXL HV250 (2) CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL
3 BLK 0-26-4 18 AWG GXL HV251 (2) 1 YEL 2-20 18 AWG GXL CO245-J1 (11)
4 BLK 0-26-3 18 AWG GXL HV252 (2) 2 BLK 0-29 18 AWG GXL CO245-J1 (12)
5 3 YEL CAN HI 20 AWG J1939 CABLE MS262-2 (A)
6
4 GRN CAN LOW 20 AWG J1939 CABLE MS262-2 (B)
7 BLK 0-25-2 18 AWG GXL HV255 (2) SHLD
5 SHIELD 20 AWG J1939 CABLE MS262-2 (C)
8 BLK 0-25-1 18 AWG GXL HV256 (2)
9 BLK 0-26-2 18 AWG GXL HV253 (2)
10 BLK 0-26-1 18 AWG GXL HV254 (2) MS380
11 BLK 0-25 18 AWG GXL CO245-J2 (3)
BLK CONN WIRE WIRE
12 0-26 18 AWG GXL CO245-J5 (12) POS COLOR LABEL GAUGE JACKET TO
1 BLK 0-41 12 AWG GXL X228B (18)
2 BLK 0-40 12 AWG GXL X228B (10)
CO245-J1 3 BLK 0-41 12 AWG GXL X230A (18)
CONN WIRE WIRE GAUGE JACKET TO 4 YEL 2-25 12 AWG GXL X228B (16)
POS COLOR LABEL 5 YEL 2-26 12 AWG GXL X228B (12)
1 WHT 27-3 JIB DN O/R 18 AWG GXL X230A (15) 6 YEL 2-26 12 AWG GXL X230A (12)
2 WHT 27-6 J-UP O/R 18 AWG GXL X230A (13) 7 YEL 2-25 12 AWG GXL X230A (10)
3 8 YEL 2-18 14 AWG GXL CO245-J1 (5)
4 BLK 0-28 14 AWG GXL MS380 (11) 9 YEL 2-19 18 AWG GXL SN259 (1)
5 YEL 2-18 14 AWG GXL MS380 (8) 10 BLK 0-40 12 AWG GXL X230A (16)
6 YEL CAN HI 20 AWG J1939 CABLE X230A (3) 11 BLK 0-28 14 AWG GXL CO245-J1 (4)
7 GRN CAN LOW 20 AWG J1939 CABLE X230A (2) 12 BLK 0-27 18 AWG GXL S383 (1)
8 SHLD SHIELD 20 AWG J1939 CABLE X230A (1)
9
10 X365A
11 YEL 2-20 18 AWG GXL SN260 (1) CONN WIRE WIRE
12 BLK 0-29 18 AWG GXL SN260 (2) POS COLOR LABEL GAUGE JACKET TO
1 RED 1-7-2 WK LT PWR 16 AWG GXL X364B (1)
2 RED 1-7-1 WK LT PWR 16 AWG GXL X364B (2)
CO245-J4 3
4 WHT 50-2 PLTFM DUMP 16 AWG GXL X364B (4)
CONN WIRE WIRE
1 YEL 2-22 18 AWG GXL SN257 (1)
2 BLK 0-23 18 AWG GXL SN257 (3)
3 YEL CAN HI 20 AWG J1939 CABLE MS262-3 (A)
4 GRN CAN LOW 20 AWG J1939 CABLE MS262-3 (B) CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL
5 SHLD SHIELD 20 AWG J1939 CABLE MS262-3 (C)
6
YEL 2 GRN CAN LOW 20 AWG J1939 CABLE MS262-1 (B)
7 2-21 18 AWG GXL SN258 (1) YEL
BLK 3 CAN HI 20 AWG J1939 CABLE MS262-1 (A)
8 0-24 18 AWG GXL SN258 (3) YEL
4 2-4 18 AWG GXL X230A (4)
5 RED 1-4-3 18 AWG GXL X230A (5)
6 YEL 2-15 18 AWG GXL X230A (6)
CO245-J2 7 WHT 25-5 PLVL DN O/R 18 AWG GXL X230A (7)
CONN WIRE WIRE 8
9 WHT 25-6 PLVL UP O/R 18 AWG GXL X230A (9)
1 WHT 27-3-1 JIB DN O/R 18 AWG GXL S265 (1) 10 YEL 2-25 12 AWG GXL MS380 (4)
2 WHT 27-6-1 J-UP O/R 18 AWG GXL S264 (1) 11 YEL 2-5 18 AWG GXL X230A (11)
3 BLK 0-25 18 AWG GXL MS347 (11) 12 YEL 2-26 12 AWG GXL MS380 (5)
4 WHT 49-41 LOCK NO 18 AWG GXL SN257 (4) 13 WHT 49-19 PROX NO 18 AWG GXL SN259 (4)
5 WHT 49-42 LOCK NC 18 AWG GXL SN257 (2) 14
6 WHT 49-43 PROX 1NO 18 AWG GXL SN258 (4) 15 WHT 49-20 PROX NC 18 AWG GXL SN259 (2)
7 WHT 49-44 PROX 1NC 18 AWG GXL SN258 (2) 16 BLK 0-40 12 AWG GXL MS380 (2)
8 17
9 18 BLK 0-41 12 AWG GXL MS380 (1)
10 19
11 WHT 55-20 JLVL UP 18 AWG GXL HV256 (1)
12 WHT 55-19 JLVL DN 18 AWG GXL HV255 (1)
7-22 – JLG Lift – 3121619

3121619
CO12 8-J1
CO1 28-J2
X4 06A
MS1 48-1
X2 22B
X411
X4 13
C O1 28-J5 X421
CO128 -J3
– JLG Lift –
1001149979-B
SN13 0
Figure 7-28. BLAM Module Wiring Harness - Sheet 1 of 2
7-23
X404B
CONN WIRE WIRE
MS148-1
CONN WIRE WIRE
RED GAUGE JACKET TO
1 B LNGTH 18 AWG CABLE CO128-J3 (7) POS COLOR LABEL
2 BLU B LNGTH 18 AWG CABLE CO128-J3 (8) A YEL CAN HIGH 18 AWG GXL CO128-J1 (6)
3 BLK B LNGTH 18 AWG CABLE CO128-J3 (9) B GRN CAN LOW 18 AWG GXL CO128-J1 (7)
4 C
5 RED BRKN CBL PROX 18 AWG CABLE X411 (5)
6 BLU BRKN CBL PROX 18 AWG CABLE X411 (3)
7 BLK BRKN CBL PROX 18 AWG CABLE X411 (4)
8 SHIELD BRKN CBL PROX 18 AWG SHLD X411 (6)
X411
CONN WIRE WIRE
GAUGE JACKET TO
X406A POS COLOR
BLK
LABEL
1 0-22 14 AWG GXL CO128-J1 (4)
CONN WIRE WIRE 2 YEL 2-10 14 AWG GXL CO128-J1 (5)
GAUGE JACKET TO
POS COLOR LABEL
3 BLU BRKN CBL PROX 18 AWG CABLE X404B (6)
1 YEL 1-10 18 AWG GXL CO128-J5 (9)
4 BLK BRKN CBL PROX 18 AWG CABLE X404B (7)
2 WHT 49-60 GRVTY SEN1 18 AWG GXL CO128-J2 (8)
5 RED BRKN CBL PROX 18 AWG CABLE X404B (5)
3 BLK 0-55 18 AWG GXL CO128-J2 (3)
6 SHIELD BRKN CBL PROX 18 AWG SHLD X404B (8)
4
5 YEL 1-11 18 AWG GXL CO128-J2 (1)
6 WHT 49-61 GRVTY SEN2 18 AWG GXL CO128-J2 (9)
7 BLK 0-56 18 AWG GXL CO128-J2 (2)
8
CO128-J1
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 YEL IGN JUMP 18 AWG GXL CO128-J1 (11)
CO128-J2 2 BLK GND JUMP 18 AWG GXL CO128-J1 (12)
CONN WIRE WIRE 3
GAUGE JACKET TO
POS COLOR LABEL 4 BLK 0-22 14 AWG GXL X411 (1)
1 YEL 1-11 18 AWG GXL X406A (5) 5 YEL 2-10 14 AWG GXL X411 (2)
2 BLK 0-56 18 AWG GXL X406A (7) YEL
6 CAN HIGH 18 AWG GXL MS148-1 (A)
3 BLK 0-55 18 AWG GXL X406A (3) GRN
7 CAN LOW 18 AWG GXL MS148-1 (B)
4 8
5 9
6 10
7 11 YEL IGN JUMP 18 AWG GXL CO128-J1 (1)
8 WHT 49-60 GRVTY SEN1 18 AWG GXL X406A (2) BLK
12 GND JUMP 18 AWG GXL CO128-J1 (2)
9 WHT 49-61 GRVTY SEN2 18 AWG GXL X406A (6)
10
11 WHT 7-1 RDRV PFWD 18 AWG GXL X222B (1)
12 WHT 7-2 RDRV PREV 18 AWG GXL X222B (2)
CONN WIRE WIRE

GAUGE JACKET TO
POS COLOR LABEL
CO128-J5 1 WHT 5V 18 AWG GXL CO128-J3 (2)
CONN WIRE WIRE 2 WHT 5V 18 AWG GXL CO128-J3 (1)
POS COLOR LABEL GAUGE JACKET TO 3
1 WHT 7-4 LDRV PFWD 18 AWG GXL X222B (6) 4 RED BANG 1 18 AWG CABLE SN130 (5)
2 WHT 7-3 LDRV PREV 18 AWG GXL X222B (5) 5 BLU BANG 2 18 AWG CABLE SN130 (3)
3 6 BLK BANG 1 18 AWG CABLE SN130 (4)
4 7 RED B LNGTH 18 AWG CABLE X404B (1)
5 8 BLU B LNGTH 18 AWG CABLE X404B (2)
6 9 BLK B LNGTH 18 AWG CABLE X404B (3)
7 10 RED BANG 2 18 AWG CABLE SN130 (2)
8 11 BLU BANG 1 18 AWG CABLE SN130 (6)
9 YEL 1-10 18 AWG GXL X406A (1) 12 BLK BANG 2 18 AWG CABLE SN130 (1)
10
11
12 BLK 0-15 18 AWG GXL X222B (3)
X421
CONN WIRE WIRE
X222B POS COLOR LABEL
GAUGE JACKET TO
1 SHIELD B LNGTH 18 AWG SHLD X404B (NC)
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 7-1 RDRV PFWD 18 AWG GXL CO128-J2 (11)
2 WHT 7-2 RDRV PREV 18 AWG GXL CO128-J2 (12)
3 BLK 0-15 18 AWG GXL CO128-J5 (12) X413
4
5 WHT 7-3 LDRV PREV 18 AWG GXL CO128-J5 (2) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
6 WHT 7-4 LDRV PFWD 18 AWG GXL CO128-J5 (1)
1 SHIELD CABLE SHIELD 18 AWG SHLD SN130 (NC)
1 SHIELD CABLE SHIELD 18 AWG SHLD SN130 (NC2)
SN130
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 BLK BANG 2 18 AWG CABLE CO128-J3 (12)
2 RED BANG 2 18 AWG CABLE CO128-J3 (10)
3 BLU BANG 2 18 AWG CABLE CO128-J3 (5)
4 BLK BANG 1 18 AWG CABLE CO128-J3 (6)
5 RED BANG 1 18 AWG CABLE CO128-J3 (4)
6 BLU BANG 1 18 AWG CABLE CO128-J3 (11)
Figure 7-29. BLAM Module Wiring Harness - Sheet 2 of 2
7-24 – JLG Lift – 3121619

CO128-J4
CONN WIRE WIRE
GAUGE JACKET
POS COLOR LABEL
1 RED +B PWR SUP 22 PVC

2 BLK -B GND SUP 22 PVC
3 GRN CAN HI 22 PVC
4 WHT CAN LO 22 PVC
5 SHLD SHIELD 22 PVC
6 -- --- -- --
7 -- --- -- --
8 -- --- -- --
CONN WIRE WIRE

GAUGE JACKET
POS COLOR LABEL
A RED +B PWR SUP 22 PVC

B BLK -B GND SUP 22 PVC
C -- --- -- --
D GRN CAN HI 22 PVC
E WHT CAN LO 22 PVC
F -- --- -- --
001157646-A
Figure 7-30. Load Sensing Pin Cable
3121619 – JLG Lift – 7-25

X406B
CONN WIRE WIRE GAUGE JACKET
POS COLOR LABEL
1 RED #1 ANGLE PWR 18 AWG CABLE
2 BLUE #1 ANGLE SIG 18 AWG CABLE
3 BLACK #1 ANGLE GND 18 AWG CABLE
4 RED/BLACK --- 18 AWG CABLE
5 YELLOW #2 ANGLE PWR 18 AWG CABLE
6 ORANGE #2 ANGLE SIG 18 AWG CABLE
7 BROWN #2 ANGLE GND 18 AWG CABLE
8 BLUE/BLACK --- 18 AWG CABLE
X422
CONN WIRE WIRE
GAUGE JACKET
POS COLOR LABEL
1 BRN/BLK CABLE SHIELD 18 AWG CABLE
SN136
POS COLOR LABEL
A RED #1 ANGLE PWR 18 AWG CABLE
B BLUE #1 ANGLE SIG 18 AWG CABLE
C BLACK #1 ANGLE GND 18 AWG CABLE

POS COLOR LABEL
A YELLOW #2 ANGLE PWR 18 AWG CABLE
B ORANGE #2 ANGLE SIG 18 AWG CABLE
1001158015-C
C BROWN #2 ANGLE GND 18 AWG CABLE
Figure 7-31. Base Boom Sensor Cable - Sheet 1 of 2
7-26 – JLG Lift – 3121619

X404A
CONN WIRE WIRE
GAUGE J ACKET
POS COLOR LABEL
1 RED B LNTH PWR 18 AWG CABLE
2 BLUE B LNTH SIG 18 AWG CABLE
3 BLACK B LNTH GND 18 AWG CABLE
5 YELLOW BRKN CBL PWR 18 AWG CABLE
6 ORANGE BRKN CBL SIG 18 AWG CABLE
7 BROWN BRKN CBL GND 18 AWG CABLE
8 SHIELD CABLE SHLD 18 AWG CABLE
CONN WIRE WIRE

POS COLOR LABEL GAUGE JACKET

5 YELLOW BRKN CBL PWR 18 AWG CABLE
6 ORANGE BRKN CBL SIG 18 AWG CABLE
7 BROWN BRKN CBL GND 18 AWG CABLE
8 SHIELD CABLE SHIELD 18 AWG CABLE
Figure 7-32. Base Boom Sensor Cable - Sheet 2 of 2
3121619 – JLG Lift – 7-27

SN221
CONN WIRE WIRE
1 BROWN BRKN CBL PWR 22 AWG CABLE
2 WHITE --- 22 AWG CABLE
3 BLUE BRKN CBL GND 1 22 AWG CABLE
4 BLACK BRKN CBL SIG 1 22 AWG CABLE
S409
CONN WIRE WIRE
SN221
1 BLACK BRKN CBL SIG 1 22 AWG CABLE
1 BROWN BRKN CBL PWR 1 22 AWG CABLE
S410
CONN WIRE WIRE
1 BLUE BRKN CBL GND 1 22 AWG CABLE SN401
2 BLUE BRKN CBL GND 22 AWG CABLE CONN WIRE WIRE GAUGE JACKET
POS COLOR LABEL
1 BROWN BRKN CBL PWR 1 22 AWG CABLE
2 WHITE --- 22 AWG CABLE
S410 4 BLACK BRKN CBL SIG 22 AWG CABLE
S409
SN401
SN131
CONN WIRE WIRE
SN131
A RED B LNTH PWR 18 AWG CABLE
C BLUE B LNTH SIG 18 AWG CABLE
X407B
B BLACK B LNTH GND 18 AWG CABLE
CONN WIRE WIRE

GAUGE JACKET
POS COLOR LABEL
4 --- --- --- ---
5 BROWN BRKN CBL PWR 22 AWG CABLE
6 BLACK BRKN CBL SIG 22 AWG CABLE
7 BLUE BRKN CBL GND 22 AWG CABLE
8 --- --- --- ---
1001158411-B
Figure 7-33. Base Boom Harness - Sheet 1 of 2
7-28 – JLG Lift – 3121619

7-29 – JLG Lift – 3121619
BRKN CBL SIG 1
SN221
1 4 3 2
BRKN CBL GND 1

S40 9
BRKN CBL PWR

X407B
S4 10
BRKN CBL GND

BRKN CBL SIG
BRKN CBL PWR 1
B LNTH PWR
SN401
1 4 3 2
B LNTH SIG
BRKN CBL GND 2
B LNTH GND
Figure 7-34. Base Boom Harness - Sheet 2 of 2

SN131
A C B
BEACON SIDE CONNECTION

POS COLOR LABEL
1 WHT B E A CON P WR 16 AWG CA B LE HA RNE S S S I DE CONNE CTI ON
2 B LK B E A CON GND 16 AWG CA B LE HA RNE S S S I DE CONNE CTI ON

POS COLOR LABEL
1 WHT B E CON P WR 16 AWG CA B LE B E A CON S I DE CONNE CTI ON
2 B LK B E CON GND 16 AWG CA B LE B E A CON S I DE CONNE CTI ON
001158989-A
Figure 7-35. Beacon/Strobe Harness
7-30 – JLG Lift – 3121619

3121619
EC958-
C ONN WIRE WIRE GAUG E J ACKET TO EC958+

POS COLOR LABEL
1 BLK 0 0 0-4 8 -1 ENG G ND 14 AWG GXL X9 42 (4)
EC958+
CON N WIRE WIRE GAUGE JAC KET TO
POS CO LO R LABEL
1 WHT 48-9 6 FUEL PUM P 1 4 AWG GXL X94 2 (3 )
– JLG Lift –
X942
SN959
X94 2
SN959 CONN WIRE WIR E
POS COLOR L ABEL G AUGE JACKET TO
CONN WIRE WIRE GAUG E J ACKET TO
POS COL OR LABEL 1 BLK 14 8-64 WTR/FUL SW 16 AWG GXL SN95 9 (1 )
1 BL K 14 8 -64 WTR/FUL SW 1 6 AWG GXL X9 42 (1) 2 BLK 1 48-5 7 WTR /F UL RTN 16 AWG GXL SN95 9 (2 )
2 BL K 148 -57 WTR /F UL RTN 1 6 AWG GXL X9 42 (2) 3 WHT 48-96 FUEL PUMP 14 AWG GXL EC9 58+ (1 )
4 BLK 0 00 -48-1 ENG GND 14 AWG GXL EC958 - (1 )
001156135-C
Figure 7-36. Fuel Pump & Water-In-Fuel Harness
7-31
7-32
X457
IP414
IP415 BT361+
RL235-R
X353 IP379
RL235-Y
IP90 S371 S239

IP91
RL360-85
RL360-86
X378
R L127-86 X373
RL127-85 X376 X159B
RL234-85 X362
RL234-86 X419
X418
X377 S372
X375
X237
RL236-Y
RL236-R
IP90, IP91 DIODE DETAILS
PIN 2 = ANODE
X147A
– JLG Lift –
X149A
X217A
001149972-D
X218A
Figure 7-37. Turntable Wiring Harness - Sheet 1 of 9
3121619
RL360-85 X457
1 WHT 55-35 AUX B+ DISC 18 AWG GXL CO02-J1 (2) 1 RED 1-15 18 AWG GXL IP414 (2)
1 RED 1-5 16 AWG GXL IP415 (2)
RL360-86
IP415
POS COLOR LABEL
BLK CONN WIRE WIRE GAUGE JACKET TO
1 0-45 18 AWG GXL X373 (1) POS COLOR LABEL
1 RED 1-5 16 AWG GXL X327B (1)
2 RED 1-5 16 AWG GXL X457 (1)
RL127-86
POS COLOR LABEL TO
1 WHT 53-3 AUX PMP 18 AWG GXL CO02-J1 (13) CONN WIRE WIRE
1 RED 1-15 18 AWG GXL X84 (2)
2 RED 1-15 18 AWG GXL X457 (1)
RL127-85
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL X378
1 BLK 0-70 18 AWG GXL RL234-85 (1)
POS COLOR LABEL
1 BLK 0-40 12 AWG GXL X81 (16)
RL234-85
CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO X373
1 BLK 0-21 18 AWG GXL X373 (1) CONN WIRE WIRE
BLK POS COLOR LABEL GAUGE JACKET TO
1 0-70 18 AWG GXL RL127-85 (1)
1 BLK 0-21 18 AWG GXL RL234-85 (1)
1 BLK 0-45 18 AWG GXL RL360-86 (1)
RL234-86
X419
POS COLOR LABEL
RED CONN WIRE WIRE GAUGE JACKET TO
1 1-4-2-1 18 AWG GXL IP91 (1) POS COLOR LABEL
1 YEL 2-4-2-1 18 AWG GXL IP90 (1) BLK
1 0-50 16 AWG GXL S456 (1)
IP91 X376
1 RED 1-4-2-1 18 AWG GXL RL234-86 (1) 1 BLK 0-20 12 AWG GXL CO02-J8 (1)
2 RED 1-4-2 18 AWG GXL X327B (4)
X362
IP90 CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL
CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO 1 BLK 0-19 16 AWG GXL S239 (1)
1 YEL 2-4-2-1 18 AWG GXL RL234-86 (1)
2 YEL 2-4-2 18 AWG GXL S89 (1)
3121619 – JLG Lift – 7-33

RL235-R
CONN WI RE WI RE CONN WI RE WI RE
GA UGE J A CK E T TO GA UGE J A CK E T TO
P OS COLOR LA B E L P OS COLOR LA B E L
1 B LK 00-11 10 AWG GX L X 149A (2) 1 YEL 2-1-99 I GNI TI ON 16 AWG GX L S 372 (1)
1 YEL 2-13 16 AWG GX L X 217A (5)
X377 X147A
CONN WI RE WI RE
GA UGE J A CK E T TO
P OS COLOR LA B E L CONN WI RE WI RE
1 B LK 0-41 12 AWG GX L X 81 (18)
1 YEL CA N HI 18 AWG J 1939 CA B LE M S 148-2 (A )
2 GRN CA N LO 18 AWG J 1939 CA B LE M S 148-2 (B )
3 S HLD CA N S HLD 18 AWG J 1939 CA B LE M S 148-2 (C)
4
X375 5
CONN WI RE WI RE 6
P OS COLOR LA B E L 7 WHT 55-14 B RA K E 18 AWG GX L CO02-J 1 (23)
1 B LK 0-22 14 AWG GX L X 412 (1) 8
9
10
X237 11
12
CONN WI RE WI RE
P OS COLOR LA B E L
1 B LK 0-14 18 AWG GX L X 159B (11) X149A
1 B LK 0-16 18 AWG GX L LB 417 (2)
CONN WI RE WI RE
P OS COLOR LA B E L
1 YEL 02-6 10 AWG GX L RL236-R (1)
B LK
RL236-Y 2 00-11 10 AWG GX L X 418 (1)
CONN WI RE WI RE
P OS COLOR LA B E L
1 YEL 2-10 14 AWG GX L X 412 (2)
1 YEL 2-11 12 AWG GX L CO02-J8 (2) IP379
CONN WI RE WI RE
P OS COLOR LA B E L
1 RE D 1-7 WK LT P WR 12 AWG GX L B T361+ (1)
RL236-R 2 RE D 1-7-1 WK LT P WR 16 AWG GX L X 341A (2)
CONN WI RE WI RE 2 RE D 1-7-2 WK LT P WR 16 AWG GX L X 341A (1)
P OS COLOR LA B E L
1 YEL 02-6 10 AWG GX L X 149A (1)
BT361+
RL235-Y CONN WI RE WI RE
P OS COLOR LA B E L
CONN WI RE WI RE
GA UGE J A CK E T TO 1 RE D 1-7 WK LT P WR 12 AWG GX L I P 379 (1)
P OS COLOR LA B E L
1 YEL 2-25 12 AWG GX L X 81 (10)
1 YEL 2-26 12 AWG GX L X 81 (12)
X353
CONN WI RE WI RE
P OS COLOR LA B E L
1 YEL 2-12 18 AWG GX L X 327B (5)
1 YEL 2-17 18 AWG GX L LB 417 (1)
7-34 – JLG Lift – 3121619

CONN WIRE WIRE

GAUGE JACKET TO
POS COLOR LABEL
1 WHT 27-3 JIB DN O/R 18 AWG GXL X81 (15)
2 WHT 25-6 PLVL UP O/R 18 AWG GXL X81 (9)
3 WHT 25-5 PLVL DN O/R 18 AWG GXL X81 (7)
4 WHT 50-2 PLTFM DUMP 16 AWG GXL X341A (4)
5 WHT 50-3 JIB DUMP 16 AWG GXL X341A (3)
6 WHT 49-45 HYD OIL TEMP 18 AWG GXL CO02-J1 (35)
7 BLK 0-31 18 AWG GXL CO02-J1 (27)
8
9
10
11 BLK 0-14 18 AWG GXL X237 (1)
12 WHT 47-6 ALT EXC 18 AWG GXL S371 (2)
S372
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 YEL 2-1-99 IGNITION 16 AWG GXL RL235-R (1)
2 YEL 2-1-99 IGNITION 18 AWG GXL X218A (1)
2 YEL 2-1-99 IGNITION 18 AWG GXL X217A (1)
X217A
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 YEL 2-1-99 IGNITION 18 AWG GXL S372 (2)
2 BLK 0-17 16 AWG GXL CO02-J1 (8)
3 WHT 52-9 GEN 18 AWG GXL CO02-J1 (22)
4 WHT 48-7 GLOW 18 AWG GXL CO02-J1 (12)
5 YEL 2-13 16 AWG GXL RL235-R (1)
6 BLK 0-18 18 AWG GXL CO02-J1 (9)
7 WHT 48-8 SP 18 AWG GXL CO02-J1 (7)
8
X218A
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 YEL 2-1-99 IGNITION 18 AWG GXL S372 (2)
2 WHT 48-6 STRT 18 AWG GXL CO02-J1 (11)
3 YEL CAN HI 20 AWG J1939 CABLE MS83 (1)
4 GRN CAN LO 20 AWG J1939 CABLE MS83 (3)
5 WHT 47-6-1 ALT EXC 18 AWG GXL S371 (2)
6 SHLD CAN SHLD 20 AWG J1939 CABLE MS83 (5)
S371
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 47-6-2 ALT EXC 18 AWG GXL CO02-J1 (32)
2 WHT 47-6 ALT EXC 18 AWG GXL X159B (12)
2 WHT 47-6-1 ALT EXC 18 AWG GXL X218A (5)
S239
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 BLK 0-19 16 AWG GXL X362 (1)
2 BLK 0-19-1 18 AWG GXL X327B (6)
2 BLK 0-19-2 18 AWG GXL X84 (1)
3121619 – JLG Lift – 7-35

7-36
X84
MS148-3
MS148-2
X81 X327B
MS83
X468 CO02-J12
CO02-J7
SN123
X420 X412
S469 X395
S89 S456
CO02-J8
IP85
– JLG Lift –
LB417 X440B X467
X88
CO02-J1
MS82
Figure 7-41. Turntable Wiring Harness - Sheet5 of 9
3121619
X81
GAUGE JACKET TO POS COLOR LABEL
POS COLOR LABEL
1 SHLD CAN SHLD 20 AWG J1939 CABLE M S82 (5)
1 RED 1-7-2 WK LT PWR 16 AWG GXL IP379 (2)
2 GRN CAN LO 20 AWG J1939 CABLE M S82 (9)
2 RED 1-7-1 WK LT PWR 16 AWG GXL IP379 (2)
3 YEL CAN HI 20 AWG J1939 CABLE M S82 (11)
3 WHT 50-3 JIB DUM P 16 AWG GXL X159B (5)
WHT 4 YEL 2-4 18 AWG GXL S89 (1)
4 50-2 PLT F M DUM P 16 AWG GXL X159B (4)
5 RED 1-4-3 18 AWG GXL X327B (3)
6 YEL 2-15 18 AWG GXL CO02-J7 (15)
7 WHT 25-5 PLVL DN O/R 18 AWG GXL X159B (3)
8
9 WHT 25-6 PLVL UP O/R 18 AWG GXL X159B (2)
SN123 10 YEL 2-25 12 AWG GXL RL235-Y (1)
CONN WIRE WIRE 11 YEL 2-5 18 AWG GXL CO02-J7 (14)
GAUGE JACKET TO
POS COLOR LABEL 12 YEL 2-26 12 AWG GXL RL235-Y (1)
1 RED B LNT H CBL 18 AWG CABLE CO02-J7 (35) 13 WHT 27-6 J-UP O/R 18 AWG GXL CO02-J1 (3)
2 BLK B LNT H CBL 18 AWG CABLE CO02-J7 (11) 14
3 15 WHT 27-3 JIB DN O/R 18 AWG GXL X159B (1)
4 WHT B LNT H CBL 18 AWG CABLE CO02-J7 (29) BLK
16 0-40 12 AWG GXL X378 (1)
17
18 BLK 0-41 12 AWG GXL X377 (1)
19
S456
CONN WIRE WIRE
POS COLOR LABEL
GAUGE JACKET TO
S89
1 BLK 0-50 16 AWG GXL X419 (1)
CONN WIRE WIRE
1 BLK 0-50-2 16 AWG GXL X440B (8) POS COLOR LABEL GAUGE JACKET TO
2 BLK 0-50-1 16 AWG GXL X420 (1) 1 YEL 2-4 18 AWG GXL X81 (4)
1 YEL 2-4-2 18 AWG GXL IP90 (2)
2 YEL 2-4-3 18 AWG GXL CO02-J7 (2)
2 YEL 2-4-4 18 AWG GXL CO02-J7 (1)
X440B
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL LB417
1 WHT 55-30 LF T ENABLE 18 AWG GXL CO02-J1 (1)
2 WHT 49-77 P C PWR 20 AWG GXL CO02-J7 (26) CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL
3 WHT 49-76 P C GND 20 AWG GXL CO02-J7 (10)
1 YEL 2-17 18 AWG GXL X353 (1)
4 WHT 49-75 PRS CHK 20 AWG GXL CO02-J7 (7)
2 BLK 0-16 18 AWG GXL X237 (1)
5 WHT 49-73 L P PWR 20 AWG GXL CO02-J7 (16)
6 WHT 49-74 L P GND 20 AWG GXL CO02-J7 (9)
7 WHT 49-72 LIF T PRS 20 AWG GXL CO02-J7 (4)
8 BLK 0-50-2 16 AWG GXL S456 (1) X420
POS COLOR LABEL
1 BLK 0-50-1 16 AWG GXL S456 (2)
X84
POS COLOR LABEL
1 BLK 0-19-2 18 AWG GXL S239 (2)
2 RED 1-15 18 AWG GXL IP414 (1)
3 YEL CAN HI 20 AWG J1939 CABLE M S83 (11)
4 GRN CAN LO 20 AWG J1939 CABLE M S83 (4)
5 SHLD CAN SHLD 20 AWG J1939 CABLE M S83 (7)
6
7
8 YEL 2-11-1 18 AWG GXL IP85 (1)
9
MS148-3
POS COLOR LABEL
A YEL CAN HI 20 AWG J1939 CABLE M S82 (12)
B GRN CAN LO 20 AWG J1939 CABLE M S82 (10)
C SHLD CAN SHLD 20 AWG J1939 CABLE M S82 (7)
MS148-2
POS COLOR LABEL
A YEL CAN HI 18 AWG J1939 CABLE X147A (1)
B GRN CAN LO 18 AWG J1939 CABLE X147A (2)
C SHLD CAN SHLD 18 AWG J1939 CABLE X147A (3)
3121619 – JLG Lift – 7-37

CO02-J1
CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO CONN WIRE WIRE
1 RED 1-5 16 AWG GXL IP415 (1)
1 WHT 55-30 LFT ENABLE 18 AWG GXL X440B (1)
2 RED 1-4-1 18 AWG GXL CO02-J7 (3) WHT
2 55-35 AUX B+ DISC 18 AWG GXL RL360-85 (1)
3 RED 1-4-3 18 AWG GXL X81 (5)
3 WHT 27-6 J-UP O/R 18 AWG GXL X81 (13)
4 RED 1-4-2 18 AWG GXL IP91 (2)
4
5 YEL 2-12 18 AWG GXL X353 (1) 5
6 BLK 0-19-1 18 AWG GXL S239 (2)
6
7 WHT 48-8 SP 18 AWG GXL X217A (7)
8 BLK 0-17 16 AWG GXL X217A (2)
9 WHT 49-46M CNTRL 18 AWG GXL CO02-J7 (21)
9 BLK 0-18 18 AWG GXL X217A (6)
10
10
11 WHT
11 48-6 STRT 18 AWG GXL X218A (2)
12 WHT
12 48-7GLOW 18 AWG GXL X217A (4)
13 WHT 53-3 AUX PMP 18 AWG GXL RL127-86 (1)
14
15
X412 16
CONN WIRE WIRE 17
GAUGE JACKET TO
POS COLOR LABEL 18
1 BLK 0-22 14 AWG GXL X375 (1) 19
2 YEL 2-10 14 AWG GXL RL236-Y (1) 20
3 BLU CABLE 18 AWG CABLE CO02-J7 (12) 21
4 BLK CABLE 18 AWG CABLE CO02-J7 (19) 22 WHT 52-9 GEN 18 AWG GXL X217A (3)
5 RED CABLE 18 AWG CABLE CO02-J7 (32) 23 WHT 55-14 BRAKE 18 AWG GXL X147A (7)
6 SHIELD BRKN CBL PROX 18 AWG SHLD S469 (2) 24
25
26
27 BLK 0-31 18 AWG GXL X159B (7)
MS83 28 WHT 49-34 A-PWR 18 AWG GXL X88 (1)
CONN WIRE WIRE 29 WHT 49-35 A-RX 18 AWG GXL X88 (2)
30 WHT 49-36 A-TX 18 AWG GXL X88 (3)
1 YEL CAN HI 20 AWG J1939 CABLE X218A (3) 31 WHT 49-37 A-GND 18 AWG GXL X88 (4)
2 32 WHT 47-6-2 ALT EXC 18 AWG GXL S371 (1)
3 GRN CAN LO 20 AWG J1939 CABLE X218A (4) 33
4 GRN CAN LO 20 AWG J1939 CABLE X84 (4) 34
5 SHLD CAN SHLD 20 AWG J1939 CABLE X218A (6) 35 WHT 49-45 HYD OIL TEMP 18 AWG GXL X159B (6)
6 SHLD CAN SHLD 20 AWG J1939 CABLE S469 (2)
7 SHLD CAN SHLD 20 AWG J1939 CABLE X84 (5)
8
9 X88
10 GRN CAN LO 20 AWG J1939 CABLE CO02-J12 (4) CONN WIRE WIRE
11 YEL CAN HI 20 AWG J1939 CABLE X84 (3) POS COLOR LABEL GAUGE JACKET TO
12 YEL CAN HI 20 AWG J1939 CABLE CO02-J12 (3) 1 WHT 49-34 A-PWR 18 AWG GXL CO02-J1 (28)
2 WHT 49-35 A-RX 18 AWG GXL CO02-J1 (29)
3 WHT 49-36 A-TX 18 AWG GXL CO02-J1 (30)
4 WHT 49-37 A-GND 18 AWG GXL CO02-J1 (31)
MS82
POS COLOR LABEL
1 YEL CAN HI 20 AWG J1939 CABLE X327B (8)
CO02-J12
2 YEL CAN HI 20 AWG J1939 CABLE CO02-J7 (13) CONN WIRE WIRE
3 GRN CAN LO 20 AWG J1939 CABLE X327B (7)
4 GRN CAN LO 20 AWG J1939 CABLE CO02-J7 (24) 1
5 SHLD CAN SHLD 20 AWG J1939 CABLE X81 (1) 2
6 SHLD CAN SHLD 20 AWG J1939 CABLE S469 (2) 3 YEL CAN HI 20 AWG J1939 CABLE MS83 (12)
7 SHLD CAN SHLD 20 AWG J1939 CABLE MS148-3 (C) 4 GRN CAN LO 20 AWG J1939 CABLE MS83 (10)
8 5
9 GRN CAN LO 20 AWG J1939 CABLE X81 (2) 6 WHT JUMPER 18 AWG GXL CO02-J12 (7)
10 GRN CAN LO 20 AWG J1939 CABLE MS148-3 (B) 7 WHT JUMPER 18 AWG GXL CO02-J12 (6)
11 YEL CAN HI 20 AWG J1939 CABLE X81 (3) 8
IP85
CONN WIRE WIRE
1 YEL 2-11-1 18 AWG GXL X84 (8)
2 YEL 2-11 18 AWG GXL CO02-J7 (34)
7-38 – JLG Lift – 3121619

X467 CONN WIRE WIRE

GAUGE JACKET TO
CONN WIRE WIRE POS COLOR LABEL
POS COLOR LABEL GAUGE JACKET TO 1 YEL 2-4-4 18 AWG GXL S89 (2)
1 N/A UGM TO CHASSIS GND 4 AWG BRAID CO02-J8 (3) 2 YEL 2-4-3 18 AWG GXL S89 (2)
3 RED 1-4-1 18 AWG GXL X327B (2)
4 WHT 49-72 LIFT PRS 20 AWG GXL X440B (7)
5
S469 6 WHT JUMPER2 18 AWG GXL CO02-J7 (17)
7 WHT 49-75 PRS CHK 20 AWG GXL X440B (4)
CONN WIRE WIRE GAUGE JACKET TO 8 WHT 49-66 Y AXIS 18 AWG GXL X395 (4)
POS COLOR LABEL
9 WHT 49-74 L P GND 20 AWG GXL X440B (6)
1 N/A CAN SHIELD TO CHASSIS GND 4 AWG BRAID X468 (1)
10 WHT 49-76 P C GND 20 AWG GXL X440B (3)
2 SHIELD BRKN CBL PROX 18 AWG SHLD X412 (6)
11 BLK B LNTH CBL 18 AWG CABLE SN123 (2)
12 BLU CABLE 18 AWG CABLE X412 (3)
14 YEL 2-5 18 AWG GXL X81 (11)
15 YEL 2-15 18 AWG GXL X81 (6)
16 WHT 49-73 L P PWR 20 AWG GXL X440B (5)
X468 17 WHT JUMPER2 18 AWG GXL CO02-J7 (6)
18
CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO 19 BLK CABLE 18 AWG CABLE X412 (4)
1 N/A CAN SHIELD TO CHASSIS GND 4 AWG BRAID S469 (1) 20 WHT 49-65 X AXIS 18 AWG GXL X395 (3)
21 WHT 49-46 M CNTRL 18 AWG GXL X327B (9)
22
23 WHT JUMPER3 18 AWG GXL CO02-J7 (30)
25 BLK 0-60 18 AWG GXL X395 (2)
26 WHT 49-77 P C PWR 20 AWG GXL X440B (2)
27 WHT 49-64 TILT PWR 18 AWG GXL X395 (1)
28
29 WHT B LNTH CBL 18 AWG CABLE SN123 (4)
30 WHT JUMPER3 18 AWG GXL CO02-J7 (23)
31
32 RED CABLE 18 AWG CABLE X412 (5)
33
34 YEL 2-11 18 AWG GXL IP85 (2)
35 RED B LNTH CBL 18 AWG CABLE SN123 (1)
CO02-J8
CONN WIRE WIRE
1 BLK 0-20 12 AWG GXL X376 (1)
2 YEL 2-11 12 AWG GXL RL236-Y (1)
3 N/A UGM TO CHASSIS GND 4 AWG BRAID X467 (1)
4
X395
POS COLOR LABEL
1 WHT 49-64 TILT PWR 18 AWG GXL CO02-J7 (27)
2 BLK 0-60 18 AWG GXL CO02-J7 (25)
3 WHT 49-65 X AXIS 18 AWG GXL CO02-J7 (20)
4 WHT 49-66 Y AXIS 18 AWG GXL CO02-J7 (8)
3121619 – JLG Lift – 7-39


MS148-2
MS82
X395
MS83
7-40 – JLG Lift – 3121619

3121619
SW 60
MAIN TELE
LB 76
SW 58 SW 61 1000 CAP
TURNTABLE SWING JIB TELE
LB 6 8
AXLE SET
X327 LB 75
PLATF OVRLD
SW 5 6-1 SW 62 LB 73
GND MODE JIB LIFT MOMNT CNTRL
SW 59
SW 56-3 LB 71
MAIN LIFT
PLATF MODE LO OIL
LB 72
SW 56-B NO ALT
E-STOP B+ SW 64 ZIP TIE
SW 65 ASSHOWN
CO 02-J4 PLATF LVL
STRT/AUX
SW66-1
SW66-2
X77 LB 70
M.D.I. HI TEMP
SW 63 LB 74
PLATF ROT BOOM CNTRL
– JLG Lift –
SW 55-2B
E-STOP B+ SW 55-1B LB 69
BAT B+ GL OW PLUG
L B 67
5 00 CAP
001149973-C
Figure 7-46. Ground Console Wiring Harness - Sheet 1 of 3
7-41
LB69
CONN WIRE WIRE GAUGE JACKET TO CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL POS COLOR LABEL
1 WHT 39-4 AXLE 18 AWG GXL LB68 (1) 1 WHT 48-5 GLOW 18 AWG GXL CO02-J4 (15)
2 WHT 54-4 500# 18 AWG GXL LB67 (1) 2 BLK 0-12-7 18 AWG GXL LB70 (2)
3 WHT 49-29 BCS 18 AWG GXL LB74 (1) 2 BLK 0-12-8 18 AWG GXL LB68 (2)
4 WHT 48-4 STRT 18 AWG GXL SW65 (1)
5 WHT 25-8 P-LVL DN 18 AWG GXL SW64 (3)
6 WHT 23-6 P-ROT LFT 18 AWG GXL SW63 (3) LB74
7 WHT 13-5 TELE IN 18 AWG GXL SW60 (1)
8 WHT 27-4 JIB DN 18 AWG GXL SW62 (1) CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL
9 1 WHT 49-29 BCS 18 AWG GXL CO02-J4 (3)
10 2 BLK 0-12-2 18 AWG GXL LB75 (2)
11 WHT 29-3 JIB IN 18 AWG GXL SW61 (1) 2 BLK 0-12-3 18 AWG GXL LB73 (2)
12
13 WHT 49-28 MNT CNTRL 18 AWG GXL LB73 (1)
14 WHT 49-30OVERLOAD 18 AWG GXL LB75 (1) LB70
15 WHT 48-5 GLOW 18 AWG GXL LB69 (1)
16 WHT 53-2 AUX 18 AWG GXL SW65 (3) CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL
17 WHT 25-7 P-LVL UP 18 AWG GXL SW64 (1) 1 WHT 47-7 TEMP 18 AWG GXL CO02-J4 (28)
18 WHT 23-5 P-ROT RHT 18 AWG GXL SW63 (1) BLK
2 0-12-6 18 AWG GXL LB71 (2)
19 WHT 27-5 JIB UP 18 AWG GXL SW62 (3) BLK
2 0-12-7 18 AWG GXL LB69 (2)
20
21
22
23
WHT
WHT
29-4 JIB OUT
3-3 LIFT UP
18
18
AWG
AWG
GXL
GXL
SW61 (3)
SW59 (1)
SW66-2
24 YEL 2-23 18 AWG GXL X327 (10) CONN WIRE WIRE
25 YEL 2-9 18 AWG GXL SW58 (2)
26 WHT 47-9 ALT 18 AWG GXL LB72 (1) 1 WHT 49-46 M CNTRL 18 AWG GXL X327 (9)
27 WHT 54-5 1000# 18 AWG GXL LB76 (1)
WHT
28
29 WHT
47-7 TEMP
47-8 OIL PRS
18
18
AWG
AWG
GXL
GXL
LB70 (1)
LB71 (1)
SW66-1
30 WHT 13-6 TELE OUT 18 AWG GXL SW60 (3) CONN WIRE WIRE
31 BLK 0-12 18 AWG GXL LB76 (2)
32 1 YEL 2-9-3 18 AWG GXL SW60 (2)
33 WHT 3-4 LIFT DN 18 AWG GXL SW59 (3) 1 YEL 2-9-4 18 AWG GXL SW61 (2)
34 WHT 21-3 SWG LFT 18 AWG GXL SW58 (1)
35 WHT 21-4 SWG RHT 18 AWG GXL SW58 (3)
LB72
X327 CONN WIRE
POS COLOR
WIRE
LABEL GAUGE JACKET TO
1 WHT 47-9 ALT 18 AWG GXL CO02-J4 (26)
POS COLOR LABEL 2 BLK 0-12-4 18 AWG GXL LB73 (2)
1 RED 1-5-1-1 16 AWG GXL SW55-1B (1B) 2 BLK 0-12-5 18 AWG GXL LB71 (2)
2 RED 1-4-1 18 AWG GXL SW56-3 (1)
3 RED 1-4-3 18 AWG GXL SW56-1 (1)
4 RED 1-4-2 16 AWG GXL SW56-3 (1) LB71
5 YEL 2-12-1 18 AWG GXL X77 (1)
BLK CONN WIRE WIRE GAUGE JACKET TO
6 0-19-3 18 AWG GXL X77 (2) POS COLOR LABEL
7 GRN 20 AWG J1939 CABLE X77 (3) 1 WHT 47-8 OIL PRS 18 AWG GXL CO02-J4 (29)
8 YEL 20 AWG J1939 CABLE X77 (4) 2 BLK 0-12-5 18 AWG GXL LB72 (2)
9 WHT 49-46 M CNTRL 18 AWG GXL SW66-2 (1) 2 BLK 0-12-6 18 AWG GXL LB70 (2)
10 YEL 2-23 18 AWG GXL CO02-J4 (24)
11
12
LB73
CONN WIRE WIRE
X77 POS COLOR LABEL GAUGE JACKET TO
CONN WIRE WIRE 1 WHT 49-28 MNT CNTRL 18 AWG GXL CO02-J4 (13)
POS COLOR LABEL GAUGE JACKET TO 2 BLK 0-12-3 18 AWG GXL LB74 (2)
1 YEL 2-12-1 18 AWG GXL X327 (5) 2 BLK 0-12-4 18 AWG GXL LB72 (2)
2 BLK 0-19-3 18 AWG GXL X327 (6)
3 GRN 20 AWG J1939 CABLE X327 (7)
4 YEL 20 AWG J1939 CABLE X327 (8)
LB75
5
POS COLOR LABEL
1 WHT 49-30OVERLOAD 18 AWG GXL CO02-J4 (14)
SW55-2B 2 BLK 0-12-1 18 AWG GXL LB76 (2)
2 BLK 0-12-2 18 AWG GXL LB74 (2)
POS COLOR LABEL
2B RED 1-4 16 AWG GXL SW56-B (1) LB68
CONN WIRE WIRE
SW55-1B POS COLOR LABEL GAUGE JACKET TO
1 WHT 39-4 AXLE 18 AWG GXL CO02-J4 (1)
CONN WIRE WIRE 2 BLK 0-12-8 18 AWG GXL LB69 (2)
POS COLOR LABEL GAUGE JACKET TO 2 BLK 0-12-9 18 AWG GXL LB67 (2)
1B RED 1-5-1-1 16 AWG GXL X327 (1)
LB76
SW63 CONN WIRE WIRE
POS COLOR LABEL 1 WHT 54-5 1000# 18 AWG GXL CO02-J4 (27)
1 WHT 23-5 P-ROT RHT 18 AWG GXL CO02-J4 (18) 2 BLK 0-12 18 AWG GXL CO02-J4 (31)
2 YEL 2-9-6 18 AWG GXL SW62 (2) 2 BLK 0-12-1 18 AWG GXL LB75 (2)
2 YEL 2-9-8 18 AWG GXL SW64 (2)
3 WHT 23-6 P-ROT LFT 18 AWG GXL CO02-J4 (6)
SW64
CONN WIRE WIRE
LB67 POS COLOR LABEL GAUGE JACKET TO
1 WHT 25-7 P-LVL UP 18 AWG GXL CO02-J4 (17)
POS COLOR LABEL 2 YEL 2-9-8 18 AWG GXL SW63 (2)
1 WHT 54-4 500# 18 AWG GXL CO02-J4 (2) 2 YEL 2-9-9 18 AWG GXL SW65 (2)
2 BLK 0-12-9 18 AWG GXL LB68 (2) 3 WHT 25-8 P-LVL DN 18 AWG GXL CO02-J4 (5)
Figure 7-47. Ground Concole Wiring Harness - Sheet 2 of 3
7-42 – JLG Lift – 3121619

SW56-1
CONN WIRE WIRE CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO GAUGE JACKET TO
POS COLOR LABEL
1 WHT 48-4 STRT 18 AWG GXL CO02-J4 (4) 1 RED 1-4-3 18 AWG GXL X327 (3)
2 YEL 2-9-9 18 AWG GXL SW64 (2)
3 WHT 53-2 AUX 18 AWG GXL CO02-J4 (16)
SW56-3
CONN WIRE WIRE
SW59 POS COLOR LABEL GAUGE JACKET TO
CONN WIRE WIRE 1 RED 1-4-1 18 AWG GXL X327 (2)

POS COLOR LABEL GAUGE JACKET TO 1 RED 1-4-2 16 AWG GXL X327 (4)
1 WHT 3-3 LIFT UP 18 AWG GXL CO02-J4 (23)
2 YEL 2-9-1 18 AWG GXL SW58 (2)
2 YEL 2-9-2 18 AWG GXL SW60 (2)
3 WHT 3-4 LIFT DN 18 AWG GXL CO02-J4 (33) SW56-B
CONN WIRE WIRE
1 RED 1-4 16 AWG GXL SW55-2B (2B)

SW62
POS COLOR LABEL
1 WHT 27-4 JIB DN 18 AWG GXL CO02-J4 (8)
SW58
2 YEL 2-9-5 18 AWG GXL SW61 (2) CONN WIRE WIRE
YEL POS COLOR LABEL GAUGE JACKET TO
2 2-9-6 18 AWG GXL SW63 (2)
3 WHT 27-5 JIB UP 18 AWG GXL CO02-J4 (19) 1 WHT 21-3 SWG LFT 18 AWG GXL CO02-J4 (34)
2 YEL 2-9 18 AWG GXL CO02-J4 (25)
2 YEL 2-9-1 18 AWG GXL SW59 (2)
3 WHT 21-4 SWG RHT 18 AWG GXL CO02-J4 (35)
SW61
POS COLOR LABEL
1 WHT 29-3 JIB IN 18 AWG GXL CO02-J4 (11)
2 YEL 2-9-4 18 AWG GXL SW66-1 (1)
2 YEL 2-9-5 18 AWG GXL SW62 (2)
3 WHT 29-4 JIB OUT 18 AWG GXL CO02-J4 (22)
SW60
POS COLOR LABEL
1 WHT 13-5 TELE IN 18 AWG GXL CO02-J4 (7)
2 YEL 2-9-2 18 AWG GXL SW59 (2)
2 YEL 2-9-3 18 AWG GXL SW66-1 (1)
3 WHT 13-6 TELE OUT 18 AWG GXL CO02-J4 (30)
Figure 7-48. Ground Concole Wiring Harness - Sheet 3 of 3
3121619 – JLG Lift – 7-43

7-44
CO03-J1
CO03 -J2
M S 244
CO 03-J3
449B
S N243 S195
S 424
X 147B
CO03-J4 X 425
CO 03-J12
CO03-J7
S181
442A
445A
448B HV 179
HV 178
B RA KE
T WO SP E ED
X3 38A
X340A
S 167
HV161 S N423
S 205
F RONT A X LE S WG EX T.
S2 03
HV 171
RIGHT FRO NT S TR LFT
HV 175
RI GHT REA R S TR LFT
HV 162
FRONT AX LE S WG RET.
HV1 70
RIGHT FRO NT S TR RHT
– JLG Lift –
HV 174
RIG HT RE A R S TR RHT
X3 37A
X33 9A
HV 163 S 204
RE AR AX LE S WG EX T. S 202
S168
HV 172
LEF T FRONT S TR RHT
HV 176
LE FT RE AR ST R RHT
HV 164
RE AR AX LE S WG RET.
HV 173
LE FT FRONT S TR LFT
HV 177 001149975-E
LE FT REA R ST R LFT
Figure 7-49. Chassis Harness - Sheet 1 of 6
3121619
HV164 - REAR AXLE SWG RET.

POS COLOR LABEL
S195 1 WHT 38-6 RAXS RET 18 AWG GXL CO03-J2 (7)
CONN WIRE WIRE 2 WHT 60-5-2 RAXS RT N 18 AWG GXL S168 (2)
GAUGE JACKET TO
POS COLOR LABEL
1 BLK 00-8 18 AWG GXL CO03-J1 (9)
2 BLK 00-8-1 18 AWG GXL X448B (3)
2 BLK 00-8-2 18 AWG GXL X449B (3) HV176 - LEFT REAR STR RHT
POS COLOR LABEL
1 WHT 9-7 LREAR ST RR 18 AWG GXL CO03-J2 (9)
2 BLK 00-6-1 18 AWG GXL S204 (2)
CO03-J12
POS COLOR LABEL HV172 - LEFT FRONT STR RHT
1
2 WHT 55-18 T TABLE ANG2 18 AWG GXL SN243 (D) CONN WIRE WIRE GAUGE JACKET TO
3 POS COLOR LABEL
1 WHT 9-2 LF RNT ST RR 18 AWG GXL CO03-J2 (35)
4
2 BLK 00-4-1 18 AWG GXL S202 (2)
5
6
7
8 HV163 - REAR AXLE SWG EXT.
POS COLOR LABEL
CO03-J7 1 WHT 38-4 RAXS EXT 18 AWG GXL CO03-J2 (5)
2 WHT 60-5-1 RAXS RT N 18 AWG GXL S168 (2)
POS COLOR LABEL
1
2
3 WHT 49-100 ENABLE 18 AWG GXL CO03-J7 (34) S168
4 BLU RHT F RNT ST R 18 AWG CABLE X340A (3)
5 RED LF T REAR ST R 18 AWG CABLE X339A (2) POS COLOR LABEL
6 WHT 120 OHM 18 AWG GXL CO03-J7 (17) 1 WHT 60-5 RAXS RT N 18 AWG GXL CO03-J3 (2)
7 BLU LF T F RNT ST R 18 AWG CABLE X337A (3) 2 WHT 60-5-1 RAXS RT N 18 AWG GXL HV163 (2)
8 BLU LF T REAR ST R 18 AWG CABLE X339A (3) 2 WHT 60-5-2 RAXS RT N 18 AWG GXL HV164 (2)
9 BLK RHT F RNT ST R 18 AWG CABLE X340A (1)
10 BLK LF T F RNT ST R 18 AWG CABLE X337A (1)
11 WHT 55-17 DOS 18 AWG GXL X147B (11)
12 WHT 49-70 HYD. OC 18 AWG GXL SN423 (2)
S202
13 YEL CAN HI 18 AWG J1939 CABLE X147B (1) CONN WIRE WIRE GAUGE JACKET TO
14 POS COLOR LABEL
1 BLK 00-4 18 AWG GXL CO03-J2 (28)
15 WHT 55-14 BRAKE 18 AWG GXL X147B (7)
16 RED RHT F RNT ST R 18 AWG CABLE X340A (2) 2 BLK 00-4-1 18 AWG GXL HV172 (2)
17 WHT 120 OHM 18 AWG GXL CO03-J7 (6) 2 BLK 00-4-2 18 AWG GXL HV173 (2)
18 SHLD CAN SHLD 18 AWG J1939 CABLE X147B (3)

19
20 BLU RHT REAR ST R 18 AWG CABLE X338A (3) S204
21
POS COLOR LABEL
23 BLK
1 00-6 18 AWG GXL CO03-J2 (30)
24 GRN CAN LOW 18 AWG J1939 CABLE X147B (2) WHT
1 60-4 FAXS RT N 18 AWG GXL ()
25 BLK RHT REAR ST R 18 AWG CABLE X338A (1)
2 BLK 00-6-1 18 AWG GXL HV176 (2)
26 RED LF T F RNT ST R 18 AWG CABLE X337A (2) 2 BLK 00-6-2 18 AWG GXL HV177 (2)
27 RED RHT REAR ST R 18 AWG CABLE X338A (2)
28 BLK LF T REAR ST R 18 AWG CABLE X339A (1)
29 YEL 02-4 18 AWG GXL X147B (12) X339A
30
CONN WIRE WIRE
31 POS COLOR LABEL GAUGE JACKET TO
32 WHT 49-71 HYD. OC RT N 18 AWG GXL SN423 (1) BLK
1 LF T REAR ST R 18 AWG CABLE CO03-J7 (28)
33
2 RED LF T REAR ST R 18 AWG CABLE CO03-J7 (5)
34 WHT 49-100 ENABLE 18 AWG GXL CO03-J7 (3) 3 BLU LF T REAR ST R 18 AWG CABLE CO03-J7 (8)
35 4 SHIELD SHLD 18 AWG SHLD S424 (2)
5
6
X425
POS COLOR LABEL X337A
1 BLK 00-12 16 AWG GXL S424 (1)
CONN WIRE WIRE
1 BLK LF T F RNT ST R 18 AWG CABLE CO03-J7 (10)

S424 2 RED LF T F RNT ST R 18 AWG CABLE CO03-J7 (26)
3 BLU LF T F RNT ST R 18 AWG CABLE CO03-J7 (7)
CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO 4 SHIELD SHLD 18 AWG SHLD S424 (2)
1 BLK 00-12 16 AWG GXL X425 (1) 5
2 SHIELD SHLD 18 AWG SHLD X337A (4) 6

2 SHIELD SHLD 18 AWG SHLD X338A (4)
2 SHIELD SHLD 18 AWG SHLD X339A (4)
2 SHIELD SHLD 18 AWG SHLD X340A (4) X445A
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
HV177 - LEFT REAR STR LFT 1 WHT 61-1-2 5V 18 AWG GXL M S244 (8)
2 WHT 38-1 RLF T ASWG 18 AWG GXL CO03-J3 (13)
CONN WIRE WIRE GAUGE JACKET TO 3 BLK 00-15 18 AWG GXL CO03-J3 (3)
POS COLOR LABEL
1 WHT 9-8 LREAR ST RL 18 AWG GXL CO03-J2 (20)
2 BLK 00-6-2 18 AWG GXL S204 (2)
HV173 - LEFT FRONT STR LFT

CONN WIRE WIRE POS COLOR LABEL
1 WHT 61-1-3 5V 18 AWG GXL M S244 (4)
1 WHT 9-3 LF RNT ST RL 18 AWG GXL CO03-J2 (34) 2 WHT 38-9 RAXS RHT 18 AWG GXL CO03-J1 (15)
2 BLK 00-4-2 18 AWG GXL S202 (2) 3 BLK 00-8-1 18 AWG GXL S195 (2)
3121619 – JLG Lift – 7-45

HV174 - RIGHT REAR STR RHT X340A

CONN WIRE WIRE CONN WIRE WIRE
GAUGE JACKET TO GAUGE JACKET TO
POS COLOR LABEL POS COLOR LABEL
1 WHT 9-5 RREAR ST RR 18 AWG GXL CO03-J2 (8) BLK
1 RHT F RNT ST R 18 AWG CABLE CO03-J7 (9)
2 BLK 00-5-1 18 AWG GXL S203 (2) 2 RED RHT F RNT ST R 18 AWG CABLE CO03-J7 (16)
3 BLU RHT F RNT ST R 18 AWG CABLE CO03-J7 (4)
4 SHIELD SHLD 18 AWG SHLD S424 (2)
HV170 - RIGHT FRONT STR RHT 5
6
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 9-4 RF RNT ST RR 18 AWG GXL CO03-J2 (11)
2 BLK 00-3-1 18 AWG GXL S205 (2) X338A
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
HV162 - FRO NT AXLE SWG RET. 1 BLK RHT REAR ST R 18 AWG CABLE CO03-J7 (25)
CONNECT OR PART NUM BER: 4460891 2 RED RHT REAR ST R 18 AWG CABLE CO03-J7 (27)
CONN WIRE WIRE 3 BLU RHT REAR ST R 18 AWG CABLE CO03-J7 (20)
GAUGE JACKET TO
POS COLOR LABEL 4 SHIELD SHLD 18 AWG SHLD S424 (2)
1 WHT 38-3 FAXS RET 18 AWG GXL CO03-J2 (16) 5
2 WHT 60-4-2 FAXS RT N 18 AWG GXL S167 (2)
6
HV175 - RIG HT REAR STR LFT X442A

CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL CONN WIRE WIRE
GAUGE JACKET TO
1 WHT 9-6 RREAR ST RL 18 AWG GXL CO03-J2 (19) POS COLOR LABEL
2 BLK 00-5-2 18 AWG GXL S203 (2) 1 WHT 61-1-1 5V 18 AWG GXL M S244 (7)
2 WHT 38-5 FAXS RHT 18 AWG GXL CO03-J2 (25)
3 BLK 00-2 18 AWG GXL CO03-J2 (6)
HV171 - RIGHT FRONT STR LFT HV178 - TWO SPEED

GAUGE JACKET TO
POS COLOR LABEL
1 WHT 9-1 RF RNT ST RL 18 AWG GXL CO03-J2 (22)
1 WHT 55-13 2 SPD 18 AWG GXL CO03-J2 (1)
2 BLK 00-3-2 18 AWG GXL S205 (2)
2 BLK 00-1-1 18 AWG GXL S181 (2)
HV161 - FRO NT AXLE SWG EXT.

CONN WIRE WIRE
SN423
GAUGE JACKET TO
POS COLOR LABEL
CONN WIRE WIRE
1 WHT 38-2 FAXS EXT 18 AWG GXL CO03-J2 (4) GAUGE JACKET TO
POS COLOR LABEL
2 WHT 60-4-1 FAXS RT N 18 AWG GXL S167 (2) 1 WHT 49-71 HYD. OC RT N 18 AWG GXL CO03-J7 (32)
2 WHT 49-70 HYD. OC 18 AWG GXL CO03-J7 (12)
3
S203
CONN WIRE WIRE
GAUGE JACKET TO
HV179 - BRAKE
POS COLOR LABEL
1 BLK 00-5 18 AWG GXL CO03-J2 (18) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
2 BLK 00-5-1 18 AWG GXL HV174 (2)
1 WHT 55-14 BRAKE 18 AWG GXL CO03-J2 (13)
2 BLK 00-5-2 18 AWG GXL HV175 (2)
2 BLK 00-1-2 18 AWG GXL S181 (2)
S205
CONN WIRE WIRE
S181
GAUGE JACKET TO
POS COLOR LABEL
CONN WIRE WIRE
GAUGE JACKET TO
1 BLK 00-3 18 AWG GXL CO03-J2 (17) POS COLOR LABEL
2 BLK 00-3-1 18 AWG GXL HV170 (2) 1 BLK 00-1 18 AWG GXL CO03-J2 (14)
2 BLK 00-3-2 18 AWG GXL HV171 (2) 2 BLK 00-1-1 18 AWG GXL HV178 (2)
2 BLK 00-1-2 18 AWG GXL HV179 (2)
S167
GAUGE JACKET TO
WHT POS COLOR LABEL
1 60-4 FAXS RT N 18 AWG GXL CO03-J3 (1)
1 WHT 61-1-4 5V 18 AWG GXL M S244 (3)
2 WHT 60-4-1 FAXS RT N 18 AWG GXL HV161 (2)
2 WHT 38-10 FAXS LF T 18 AWG GXL CO03-J1 (14)
2 WHT 60-4-2 FAXS RT N 18 AWG GXL HV162 (2)
3 BLK 00-8-2 18 AWG GXL S195 (2)
7-46 – JLG Lift – 3121619

CO03-J4 CO03-J3
CONN WI RE WI RE CONN WI RE WI RE
GA UGE JA CK E T TO GA UGE JA CK E T TO
P OS COLOR LA B E L P OS COLOR LA B E L
1 1 WHT 60-4 FA X S RTN 18 AWG GX L S 167 (1)
2 2 WHT 60-5 RA X S RTN 18 AWG GX L S 168 (1)
3 3 B LK 00-15 18 AWG GX L X 445A (3)
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12 WHT 61-1 5V 16 AWG GX L M S 244 (6)
13 13 WHT 38-1 RLFT A S WG 18 AWG GX L X 445A (2)
14 14
15
16
17
18 CO03-J2
19
CONN WI RE WI RE
20 GA UGE JA CK E T TO
P OS COLOR LA B E L
21
1 WHT 55-13 2 S P D 18 AWG GX L HV 178 (1)
22
2
23
3
24 WHT JUM P E R 18 AWG GX L CO03-J4 (25) WHT
4 38-2 FA X S E X T 18 AWG GX L HV 161 (1)
25 WHT JUM P E R 18 AWG GX L CO03-J4 (24)
5 WHT 38-4 RA X S E X T 18 AWG GX L HV 163 (1)
26 B LK
6 00-2 18 AWG GX L X 442A (3)
27 7 WHT 38-6 RA X S RE T 18 AWG GX L HV 164 (1)
28 8 WHT 9-5 RRE A R S TRR 18 AWG GX L HV 174 (1)
29
9 WHT 9-7 LRE A R S TRR 18 AWG GX L HV 176 (1)
30
10
11 WHT 9-4 RFRNT S TRR 18 AWG GX L HV 170 (1)
12
33 WHT
13 55-14 B RA K E 18 AWG GX L HV 179 (1)
34 B LK
14 00-1 18 AWG GX L S 181 (1)
35
15
16 WHT 38-3 FA X S RE T 18 AWG GX L HV 162 (1)
17 B LK 00-3 18 AWG GX L S 205 (1)
18 B LK 00-5 18 AWG GX L S 203 (1)
19 WHT 9-6 RRE A R S TRL 18 AWG GX L HV 175 (1)
CONN WI RE WI RE
GA UGE JA CK E T TO 20 WHT 9-8 LRE A R S TRL 18 AWG GX L HV 177 (1)
P OS COLOR LA B E L
A B LK 00-14 18 AWG GX L CO03-J1 (18) 21
B WHT 61-1-6 5V 18 AWG GX L M S 244 (1) 22 WHT 9-1 RFRNT S TRL 18 AWG GX L HV 171 (1)
C WHT 55-15 TTA B LE A NG 18 AWG GX L CO03-J1 (16) 23
D WHT 55-18 TTA B LE A NG2 18 AWG GX L CO03-J12 (2) 24
E B LK 00-9 18 AWG GX L CO03-J1 (8) 25 WHT 38-5 FA X S RHT 18 AWG GX L X 442A (2)
F WHT 61-1-5 5V 18 AWG GX L M S 244 (2) 26
27
28 B LK 00-4 18 AWG GX L S 202 (1)
X160 29
30 B LK 00-6 18 AWG GX L S 204 (1)
CONN WI RE WI RE
GA UGE JA CK E T TO 31
P OS COLOR LA B E L
WHT 32
1 49-40 A -P WR 18 AWG GX L CO03-J1 (28)
WHT 33
2 49-39 A -RX 18 AWG GX L CO03-J1 (29)
34 WHT 9-3 LFRNT S TRL 18 AWG GX L HV 173 (1)
3 WHT 49-38 A -TX 18 AWG GX L CO03-J1 (30)
35 WHT 9-2 LFRNT S TRR 18 AWG GX L HV 172 (1)
4 B LK 00-7 18 AWG GX L CO03-J1 (31)
3121619 – JLG Lift – 7-47

CO03-J1
CONN WIRE WIRE
1
2
3
4
5
6
7
8 BLK 00-9 18 AWG GXL SN243 (E)
9 BLK 00-8 18 AWG GXL S195 (1)
10
11
12
13
14 WHT 38-10 FAXS LFT 18 AWG GXL X449B (2)
15 WHT 38-9 RAXS RHT 18 AWG GXL X448B (2)
16 WHT 55-15 TTABLE ANG 18 AWG GXL SN243 (C)
17
18 BLK 00-14 18 AWG GXL SN243 (A)
19
20
21
22
23
24
25
26
27
28 WHT 49-40 A-PWR 18 AWG GXL X160 (1)
29 WHT 49-39 A-RX 18 AWG GXL X160 (2)
30 WHT 49-38 A-TX 18 AWG GXL X160 (3)
31 BLK 00-7 18 AWG GXL X160 (4)
32
33
34
35
MS244
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 61-1-6 5V 18 AWG GXL SN243 (B)
2 WHT 61-1-5 5V 18 AWG GXL SN243 (F)
3 WHT 61-1-4 5V 18 AWG GXL X449B (1)
4 WHT 61-1-3 5V 18 AWG GXL X448B (1)
5
6 WHT 61-1 5V 16 AWG GXL CO03-J3 (12)
7 WHT 61-1-1 5V 18 AWG GXL X442A (1)
8 WHT 61-1-2 5V 18 AWG GXL X445A (1)

POS COLOR LABEL
1 YEL CAN HI 18 AWG J1939 CABLE CO03-J7 (13)
2 GRN CAN LOW 18 AWG J1939 CABLE CO03-J7 (24)
3 SHLD CAN SHLD 18 AWG J1939 CABLE CO03-J7 (18)
4
5
6
7 WHT 55-14 BRAKE 18 AWG GXL CO03-J7 (15)
8
9
10
11 WHT 55-17 DOS 18 AWG GXL CO03-J7 (11)
12 YEL 02-4 18 AWG GXL CO03-J7 (29)
7-48 – JLG Lift – 3121619

3121619 – JLG Lift – 7-49

7-50
AD HESIVE L INED
HEAT SHR IN K
H V316
BRN
WARM UP VLV
SHL D RTN
BL U SOLDER
SHL
HV10 8 BRN D
TEL E FLOW CN TR L BL K LD
SH
BL U
HV10 2 X158
BLK
LIFT FL OW CNTRL
AH 318 SH IEL D TER MIN ATION D IAGRAM
HV3 48
SWG FL OW CNTRL
SN 438
S1 56 S154 CO02 -J2
S45 5
S15 7 S1 55 S1 53
X159 A
H V314
X440 A
C HASSIS EN ABLE C O0 2-J3
H V104
MAIN DU MP
H V103
MAIN TELE OU T
SN11 4
H V106 FUEL LEVEL
MAIN LIFT UP
– JLG Lift –
HV9 9
SWG RH T
HV1 05
LIFT DN AUX
HV1 07
LIFT PILOT
H V100
SWG LFT
HV1 01
MAIN LIFT DN H V315
LIFT EN ABLE
H V1 09
MAIN TEL E IN
001149974-C
H YD OIL TEMP SN43 9
Figure 7-55. Hydraulic Valve Bank Harness - Sheet 1 of 3
3121619
HV102
LIFT FLOW CNTRL LIFT DN AUX
CONN WIRE WIRE
CONN WIRE WIRE GAUGE JACKET TO POS COLOR LABEL GAUGE JACKET TO
POS COLOR LABEL
1 WHT 55-10 LFT DN AUX 18 AWG GXL CO02-J2 (12)
1 WHT 55-9 LFT FCNTRL 18 AWG GXL CO02-J2 (19)
2 BLK 0-6-3 18 AWG GXL S155 (2)
2 WHT 60-1 LFCNTRL RTN 18 AWG GXL CO02-J3 (1)
HV348 HV107
SWG FLOW CNTRL LIFT PILOT
CONN WIRE WIRE
CONN WIRE WIRE POS COLOR LABEL GAUGE JACKET TO
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 55-11 LFT PLT 18 AWG GXL CO02-J2 (10)
1 WHT 55-32 SWG F.C. 18 AWG GXL CO02-J2 (35)
2 BLK 0-10-1 18 AWG GXL S154 (2)
2 WHT 60-3 SWG RTN 18 AWG GXL CO02-J3 (4)
S157 HV99
SWG RHT
POS COLOR LABEL CONN WIRE WIRE GAUGE JACKET TO
1 BLK 0-14 16 AWG GXL X159A (11) POS COLOR LABEL
2 BLK 0-14-2 18 AWG GXL AH318 (C) 1 WHT 22-1 SWG RHT 18 AWG GXL CO02-J2 (32)
2 BLK 0-14-3 18 AWG GXL SN114 (2) 2 BLK 0-30-2 18 AWG GXL S153 (2)
X159A HV101
MAIN LIFT DN
CONN WIRE WIRE
GAUGE JACKET TO CONN WIRE WIRE
1 WHT 27-3 JIB DN O/R 18 AWG GXL CO02-J2 (31) POS COLOR LABEL
1 WHT 3-1 MLIFT DN 18 AWG GXL CO02-J2 (22)
2 WHT 25-6 PLVL UP O/R 18 AWG GXL CO02-J2 (5)
2 BLK 0-6-2 18 AWG GXL S155 (2)
3 WHT 25-5 PLVL DN O/R 18 AWG GXL CO02-J2 (7)
4 WHT 50-2 PLTFRM DUMP 16 AWG GXL CO02-J2 (3)
5 WHT 50-3 JIB DUMP 16 AWG GXL CO02-J2 (1)
6 WHT 49-45 HYD OIL TEMP 18 AWG GXL SN416 (1) HV103
7 BLK 0-31 18 AWG GXL SN416 (2)
8
MAIN TELE OUT
9 CONN WIRE WIRE
10
11 BLK 0-14 16 AWG GXL S157 (1) 1 WHT 13-3 MTELE OUT 18 AWG GXL CO02-J2 (16)
12 WHT 47-6 ALT EXC 18 AWG GXL CO02-J3 (9) 2 BLK 0-11-2 18 AWG GXL S156 (2)
SN439 SN416
CONN WIRE WIRE
HYD OIL TEMP
GAUGE JACKET TO
1 BRN 49-73 L P PWR 20 AWG CABLE X440A (5) POS COLOR LABEL GAUGE JACKET TO
2 1 WHT 49-45 HYD OIL TEMP 18 AWG GXL X159A (6)
3 BLU 49-72 LIFT PRS 20 AWG CABLE X440A (7) 2 BLK 0-31 18 AWG GXL X159A (7)
4 BLK 49-74 L P GND 20 AWG CABLE X440A (6)
SHLD SHLD P LIFT SN 20 AWG CABLE S455 (2)
AH318
SN438 CONN WIRE
POS COLOR
WIRE
LABEL GAUGE JACKET TO
CONN WIRE WIRE GAUGE JACKET TO A WHT 52-8ALRM PWR 18 AWG GXL CO02-J3 (7)
POS COLOR LABEL B WHT 52-6MOT ALRM 18 AWG GXL CO02-J2 (27)
1 BRN 49-77 P C PWR 20 AWG CABLE X440A (2) C BLK 0-14-2 18 AWG GXL S157 (2)
2
3 BLU 49-75 PRS CHK 20 AWG CABLE X440A (4)
4 BLK 49-76 P C GND 20 AWG CABLE X440A (3)
SHLD SHLD P CHK SN 20 AWG CABLE S455 (2) X158
CONN WIRE WIRE
S455 1 WHT 52-7 H&T LT SIG 18 AWG GXL CO02-J2 (26)
CONN WIRE WIRE

1 SHLD RTN 20 AWG CABLE X440A (8)
2 SHLD P CHK SN 20 AWG CABLE SN438 (SHLD)
HV316
2 SHLD P LIFT SN 20 AWG CABLE SN439 (SHLD) WARM UP VLV
CONN WIRE WIRE
X440A 1 WHT 55-33WARM UP 18 AWG GXL CO02-J2 (33)

2 WHT 60-6WARM UP RTN 18 AWG GXL CO02-J3 (5)
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 55-30 LFT ENABLE 18 AWG GXL HV315 (1)
2 BRN 49-77 P C PWR 20 AWG CABLE SN438 (1) HV108
3 BLK 49-76 P C GND 20 AWG CABLE SN438 (4)
4 BLU 49-75 PRS CHK 20 AWG CABLE SN438 (3)
TELE FLOW CNTRL
5 BRN 49-73 L P PWR 20 AWG CABLE SN439 (1) CONN WIRE WIRE
GAUGE JACKET TO
6 BLK 49-74 L P GND 20 AWG CABLE SN439 (4) POS COLOR LABEL
7 BLU 49-72 LIFT PRS 20 AWG CABLE SN439 (3) 1 WHT 55-12 TELE FCNTRL 18 AWG GXL CO02-J2 (9)
8 SHLD 20 AWG CABLE S455 (1) 2 WHT 60-2 TFCNTRL RTN 18 AWG GXL CO02-J3 (2)
3121619 – JLG Lift – 7-51

S153
CONNECT OR PART NUM BER: SPLICE
CONN WIRE WIRE T ERM INAL CONN WIRE WIRE GAUGE JACKET TO
POS COLOR LABEL GAUGE JACKET P/N TO POS COLOR LABEL
1 BLK 0-30 18 AWG GXL N/A CO02-J2 (18) 1 WHT 50-3 JIB DUM P 16 AWG GXL X159A (5)
2 BLK 0-30-1 18 AWG GXL N/A HV100 (2) 2 WHT 55-31 CHS ENABLE 18 AWG GXL HV314 (1)
2 BLK 0-30-2 18 AWG GXL N/A HV99 (2) 3 WHT 50-2 PLT F RM DUM P 16 AWG GXL X159A (4)
4 WHT 13-4 M T ELE IN 18 AWG GXL HV109 (1)
5 WHT 25-6 PLVL UP O/R 18 AWG GXL X159A (2)
6 BLK 0-11 16 AWG GXL S156 (1)
S154 7 WHT 25-5 PLVL DN O/R 18 AWG GXL X159A (3)
CONNECT OR PART NUM BER: SPLICE 8
CONN WIRE WIRE T ERM INAL WHT
GAUGE JACKET TO 9 55-12 T ELE F CNT RL 18 AWG GXL HV108 (1)
POS COLOR LABEL P/N
10 WHT 55-11 LF T PLT 18 AWG GXL HV107 (1)
1 BLK 0-10 16 AWG GXL N/A CO02-J2 (14)
11 WHT 3-2 M LIF T UP 18 AWG GXL HV106 (1)
2 BLK 0-10-1 18 AWG GXL N/A HV107 (2)
12 WHT 55-10 LF T DN AUX 18 AWG GXL HV105 (1)
2 BLK 0-10-2 18 AWG GXL N/A HV104 (2)
13 WHT 50-1 M AIN DUM P 18 AWG GXL HV104 (1)
14 BLK 0-10 16 AWG GXL S154 (1)
15 WHT 22-2 SWG LF T 18 AWG GXL HV100 (1)
S155 16 WHT 13-3 M T ELE OUT 18 AWG GXL HV103 (1)
CONNECT OR PART NUM BER: SPLICE 17 BLK 0-36 18 AWG GXL HV314 (2)
CONN WIRE WIRE T ERM INAL
GAUGE JACKET TO 18 BLK 0-30 18 AWG GXL S153 (1)
POS COLOR LABEL P/N
19 WHT 55-9 LF T F CNT RL 18 AWG GXL HV102 (1)
1 BLK 0-6 16 AWG GXL N/A CO02-J2 (30)
20
2 BLK 0-6-1 18 AWG GXL N/A HV106 (2)
21
2 BLK 0-6-2 18 AWG GXL N/A HV101 (2)
22 WHT 3-1 M LIF T DN 18 AWG GXL HV101 (1)
2 BLK 0-6-3 18 AWG GXL N/A HV105 (2)
23
24
25 WHT 47-10 F UL SEN 18 AWG GXL SN114 (1)
S156 26 WHT 52-7 H&T LT SIG 18 AWG GXL X158 (1)
CONNECT OR PART NUM BER: SPLICE 27 WHT 52-6 M OT ALRM 18 AWG GXL AH318 (B)
CONN WIRE WIRE T ERM INAL 28
POS COLOR LABEL GAUGE JACKET P/N TO
29
1 BLK 0-11 16 AWG GXL N/A CO02-J2 (6)
30 BLK 0-6 16 AWG GXL S155 (1)
2 BLK 0-11-1 18 AWG GXL N/A HV109 (2)
31 WHT 27-3 JIB DN O/R 18 AWG GXL X159A (1)
2 BLK 0-11-2 18 AWG GXL N/A HV103 (2)
32 WHT 22-1 SWG RHT 18 AWG GXL HV99 (1)
33 WHT 55-33 WARM UP 18 AWG GXL HV316 (1)
34
HV314 35 WHT 55-32 SWG F.C. 18 AWG GXL HV348 (1)
CHASSIS ENABLE
CONNECT OR PART NUM BER: 4460891
CONN WIRE WIRE
GAUGE JACKET
T ERM INAL
TO
CO02-J3
POS COLOR LABEL P/N
1 WHT 55-31 CHS ENABLE 18 AWG GXL 4460465 CO02-J2 (2) CONN WIRE WIRE
GAUGE JACKET TO
BLK POS COLOR LABEL
2 0-36 18 AWG GXL 4460465 CO02-J2 (17)
1 WHT 60-1 LF CNT RL RT N 18 AWG GXL HV102 (2)
2 WHT 60-2 T F CNT RL RT N 18 AWG GXL HV108 (2)
HV104 3
WHT
4 60-3 SWG RT N 18 AWG GXL HV348 (2)
MAIN DUMP 5 WHT 60-6 WARM UP RT N 18 AWG GXL HV316 (2)
CONNECT OR PART NUM BER: 4460891 6
CONN WIRE WIRE T ERM INAL 7 WHT 52-8 ALRM PWR 18 AWG GXL AH318 (A)
GAUGE JACKET TO
POS COLOR LABEL P/N 8
1 WHT 50-1 M AIN DUM P 18 AWG GXL 4460465 CO02-J2 (13) 9 WHT 47-6 ALT EXC 18 AWG GXL X159A (12)
2 BLK 0-10-2 18 AWG GXL 4460465 S154 (2)
10
11
12
HV100 13
SWG LFT 14 WHT 60-7 LENABLE RT N 18 AWG GXL HV315 (2)
POS COLOR LABEL GAUGE JACKET P/N TO
1 WHT 22-2 SWG LF T 18 AWG GXL 4460465 CO02-J2 (15) HV315

2 BLK 0-30-1 18 AWG GXL 4460465 S153 (2) LIFT ENABLE
CONN WIRE WIRE
HV106 1 WHT 55-30 LF T ENABLE 18 AWG GXL X440A (1)
MAIN LIFT UP 2 WHT 60-7 LENABLE RT N 18 AWG GXL CO02-J3 (14)

CONN WIRE WIRE GAUGE JACKET T ERM INAL TO
POS COLOR LABEL P/N
1 WHT 3-2 M LIF T UP 18 AWG GXL 4460465 CO02-J2 (11) SN114
2 BLK 0-6-1 18 AWG GXL 4460465 S155 (2)
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
WHT
HV109 1
2 BLK
47-10 F UL SEN
0-14-3
18 AWG
18 AWG
GXL
GXL
CO02-J2 (25)
S157 (2)
MAIN TELE IN
GAUGE JACKET TO
POS COLOR LABEL P/N
1 WHT 13-4 M T ELE IN 18 AWG GXL 4460465 CO02-J2 (4)
2 BLK 0-11-1 18 AWG GXL 4460465 S156 (2)
7-52 – JLG Lift – 3121619

HV142
HV144 RHT DRV PUMP FWD
LFT DRV PUMP REV
X222A
S146
HV143
RHT DRV PUMP REV
HV145
LFT DRV PUMP FWD 001149970-B

POS COLOR LABEL
1 WHT 7-4 RDRV PFWD 18 AWG GXL HV142 (1)
2 WHT 7-3 RDRV PREV 18 AWG GXL HV143 (1)
3 BLK 0-15 18 AWG GXL S146 (1)
4
5 WHT 7-2 LDRV PREV 18 AWG GXL HV144 (1)
6 WHT 7-1 LDRV PFWD 18 AWG GXL HV145 (1)
HV144 - LFT DRV PUMP REV

CONN WIRE WIRE
1 WHT 7-2 LDRV PREV 18 AWG GXL X222A (5)
2 BLK 0-15-3 18 AWG GXL S146 (1)
S146
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 BLK 0-15 18 AWG GXL X222A (3)
1 BLK 0-15-3 18 AWG GXL HV144 (2)
1 BLK 0-15-4 18 AWG GXL HV145 (2)
2 BLK 0-15-1 18 AWG GXL HV142 (2)
2 BLK 0-15-2 18 AWG GXL HV143 (2)
HV142 - RHT DRV PUMP FWD

CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 7-4 RDRV PFWD 18 AWG GXL X222A (1)
2 BLK 0-15-1 18 AWG GXL S146 (2)
HV143 - RHT DRV PUMP REV

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

CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 WHT 7-1 LDRV PFWD 18 AWG GXL X222A (6)
2 BLK 0-15-4 18 AWG GXL S146 (1)
Figure 7-58. Drive Pump Harness
3121619 – JLG Lift – 7-53

7-54
EC241-L
X218B
X941
X217B
MS999-1 MS 1000-1
X1009
S1011 S945 S944
– JLG Lift –
S 1008 MS1002-2
S 946 E CM-J1
X950 MS1001-1
RL930
X 1006
FC1004 ECM-J2
FC1003
RL930-2
T920 RL930-1
RL931-85 RL931-87
RL931-86
001149971-C
SN939
Figure 7-59. T4i Engine Harness - Sheet 1 of 4
3121619
CONN WIRE WIRE

GAUGE JACKET TO
POS COLOR LABEL
1 RED 148-1 ECM PWR 2.5 mm² FLRYW S944 (2)
2 BLK 148-2 ECM GND 2.5 mm² FLRYW S945 (2)
7
8
9
10
11
12
13 BLK 148-13 COOLANT LEVEL SIG 0.75 mm² FLRYW SN939 (3)
14
15 BLK 148-15-68 CLUTCH SWITCH 0.75 mm² FLRYW ECM-J1 (68)
16
17
18
19
20
21
22
23
24
25
26 BLK 148-26FUEL PUMP RELAY CONTROL GND 0.75 mm² FLRYW RL930 (2)
27
28 BLK 148-70 STRT GND 0.75 mm² FLRYW EIC (2)
29 BLK 148-29 COOLANT LEVEL PWR 0.75 mm² FLRYW SN939 (1)
30
31
32
33
34
35 BLK 148-35-3 STRT REQ 0.75 mm² FLRYW S1011 (1)
36
37
38 BLK 148-38 THROTTLE FLAP 4 0.75 mm² FLRYW EIC (52)
39
40
41
42
43
44 BLK 148-44EHXAUST GAS RECIRCULATION 0.75 mm² FLRYW EIC (50)
45
46
47
48
49
50
51
52
53 GRN CAN LOW 0.75 mm² FLRYW MS1000-1 (B)
54 YEL CAN HIGH 0.75 mm² FLRYW MS1001-1 (A)
55
56 BLK 148-56 AIR INLET TEMP 0.75 mm² FLRYW EIC (34)
57 BLK 148-57 WATER IN FUEL SW RTN 0.75 mm² FLRYW X941 (2)
58
59
60
61 BLK 148-61FUEL LOW PRESSURE 0.75 mm² FLRYW EIC (17)
62
63
64 BLK 148-64 WATER IN FUEL SW 0.75 mm² FLRYW X941 (1)
65
66
67
68 BLK 148-15-68 CLUTCH SWITCH 0.75 mm² FLRYW ECM-J1 (15)
69
70
71
72 BLK 148-72 THROTTLE FLAP 3 0.75 mm² FLRYW EIC (49)
73 BLK 148-71 STRT SIG 0.75 mm² FLRYW EIC (3)
74
75 YEL CAN HIGH 0.75 mm² FLRYW MS1000-1 (A)
76 GRN CAN LOW 0.75 mm² FLRYW MS1001-1 (B)
77
78
79
80
81
83
84
86
87 BLK 148-87 COOLANT LEVEL GND 0.75 mm² FLRYW SN939 (2)
88 BLK 148-88 IGNITION 0.75 mm² FLRYW S946 (2)
89
90
91
92
93
94
Figure 7-60. T4i Engine Harness - Sheet 2of 4
3121619 – JLG Lift – 7-55

CONN WIRE WIRE

GAUGE JACKET TO
POS COLOR LABEL
1 SHLD 248-38ENGINE SPEED CRANKSHAFT 0.75 mm² SHLD ECM-J2 (38)
2 BLK 148-70 STRT GND 0.75 mm² FLRYW ECM-J1 (28)
3 BLK 148-71 STRT SIG 0.75 mm² FLRYW ECM-J1 (73)
4
5
6
7
8
9 SHLD 248-53ENGINE SPEED CAMSHAFT 0.75 mm² SHLD ECM-J2 (53)
10
11
12
13 BLK 248-52ENGINE SPEED CAMSHAFT 0.75 mm² FLRYW ECM-J2 (52)
14 BLK 248-37ENGINE SPEED CAMSHAFT 0.75 mm² FLRYW ECM-J2 (37)
15 BLK 248-39ENGINE SPEED CRANKSHAFT 0.75 mm² FLRYW ECM-J2 (39)
16
17 BLK 148-61FUEL LOW PRESSURE 0.75 mm² FLRYW ECM-J1 (61)
18
19 BLK 248-4MPROP ACTUATOR 1.5 mm² FLRYW ECM-J2 (4)
20 BLK 248-5MPROP ACTUATOR 1.5 mm² FLRYW ECM-J2 (5)
21 BLK 248-54ENGINE SPEED CRANKSHAFT 0.75 mm² FLRYW ECM-J2 (54)
22 BLK 248-24 BOOST PRESSURE / TEMP 0.75 mm² FLRYW ECM-J2 (24)
23 BLK 248-43 OIL PRESSURE 0.75 mm² FLRYW ECM-J2 (43)
24 BLK 248-28COOLING TEMPERATURE 0.75 mm² FLRYW ECM-J2 (28)
25 BLK 248-26 RAIL PRESSURE FUEL 0.75 mm² FLRYW ECM-J2 (26)
28 BLK 248-40 AIR INLET TEMP 0.75 mm² FLRYW ECM-J2 (40)
29 BLK 248-27 BOOST PRESSURE / TEMP 0.75 mm² FLRYW ECM-J2 (27)
30
33
34 BLK 148-56 AIR INLET TEMP 0.75 mm² FLRYW ECM-J1 (56)
35 BLK 248-16 INJECTOR 1 1.5 mm² FLRYW ECM-J2 (16)
36
39
43
44
45
46 BLK 148-85EHXAUST GAS RECIRCULATION 0.75 mm² FLRYW ECM-J1 (85)
49 BLK 148-72 THROTTLE FLAP 3 0.75 mm² FLRYW ECM-J1 (72)
52 BLK 148-38 THROTTLE FLAP 4 0.75 mm² FLRYW ECM-J1 (38)
53
54
55
56
57
58
59
60
7-56 – JLG Lift – 3121619

CONN WIRE WIRE

1
2 BLK 248-2 INJECTOR 3 1.5 mm² FLRYW EIC (61)
4 BLK 248-4MPROP ACTUATOR 1.5 mm² FLRYW EIC (19)
5 BLK 248-5MPROP ACTUATOR 1.5 mm² FLRYW EIC (20)
6
7 BLK 248-7 RAIL PRESSURE FUEL 0.75 mm² FLRYW EIC (32)
8
9
10
11
12
13
14
15
17
21
22
23 BLK 248-23 GLOW SENSE 0.75 mm² FLRYW FC1003 (1)
24 BLK 248-24 BOOST PRESSURE / TEMP 0.75 mm² FLRYW EIC (22)
27 BLK 248-27 BOOST PRESSURE / TEMP 0.75 mm² FLRYW EIC (29)
28 BLK 248-28COOLING TEMPERATURE 0.75 mm² FLRYW EIC (24)
29 BLK 248-29 OIL PRESSURE 0.75 mm² FLRYW EIC (27)
30
31
34
35 BLK 248-35GLOW RELAY CONTROL GND 0.75 mm² FLRYW RL931-85 (1)
36
37 BLK 248-37ENGINE SPEED CAMSHAFT 0.75 mm² FLRYW EIC (14)
38 SHLD 248-38ENGINE SPEED CRANKSHAFT 0.75 mm² SHLD EIC (1)
39 BLK 248-39ENGINE SPEED CRANKSHAFT 0.75 mm² FLRYW EIC (15)
40 BLK 248-40 AIR INLET TEMP 0.75 mm² FLRYW EIC (28)
41
42
45
47
49
50
51
52 BLK 248-52ENGINE SPEED CAMSHAFT 0.75 mm² FLRYW EIC (13)
53 SHLD 248-53ENGINE SPEED CAMSHAFT 0.75 mm² SHLD EIC (9)
54 BLK 248-54ENGINE SPEED CRANKSHAFT 0.75 mm² FLRYW EIC (21)
55
56
57
58
59
60
3121619 – JLG Lift – 7-57

7-58
MS999-2
CONN WIRE WIRE
MS999-2 GAUGE JACKET TO
POS COLOR LABEL
A YEL CAN HI 20 AWG J1939 CABLE MS1001-2 (A)
B GRN CAN LOW 20 AWG J1939 CABLE MS1001-2 (B)
C SHLD SHIELD 20 AWG J1939 CABLE MS1001-2 (C)
X1005
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
2 GRN CAN LOW 20 AWG J1939 CABLE MS999-3 (B)
X1005 MS1000-2
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
C SHLD SHIELD 20 AWG J1939 CABLE MS1002-1 (C)
MS1000-2
MS1002-1
– JLG Lift –
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
C SHLD SHIELD 20 AWG J1939 CABLE MS1000-2 (C) MS1001-2
MS1001-2
POS COLOR LABEL
SHLD
C SHIELD 20 AWG J1939 CABLE MS999-2 (C)
MS999-3
CONN WIRE WIRE
GAUGE JACKET TO
MS999-3 POS COLOR LABEL
A YEL CAN HI 20 AWG J1939 CABLE X1005 (1)
B GRN CAN LOW 20 AWG J1939 CABLE X1005 (2) 001156001-B
C SHLD SHIELD 20 AWG J1939 CABLE X1005 (3)
Figure 7-63. CAN Engine Harness - Sheet 1 of 2
3121619
MS1000-2
Figure 7-64. CAN Engine Harness - Sheet 2 of 2

X1005
MS1002-1
MS999-3
MS999-2
3121619 – JLG Lift – 7-59

Figure 7-65. Generator Enable Harness - Sheet 1 of 2
7-60 – JLG Lift – 3121619

Figure 7-66. Generator Enable Harness - Sheet 1 of 2
3121619 – JLG Lift – 7-61

Figure 7-67. T4F Engine Harness - Sheet 1 of 14
7-62 – JLG Lift – 3121619

3121619 – JLG Lift – 7-63

7-64 – JLG Lift – 3121619

3121619 – JLG Lift – 7-65

7-66 – JLG Lift – 3121619

3121619 – JLG Lift – 7-67

7-68 – JLG Lift – 3121619

3121619 – JLG Lift – 7-69

7-70 – JLG Lift – 3121619

3121619 – JLG Lift – 7-71

7-72 – JLG Lift – 3121619

3121619 – JLG Lift – 7-73

7-74 – JLG Lift – 3121619

3121619 – JLG Lift – 7-75

Figure 7-81. Urea Tank/Supply Module Harness - Sheet 1 of 2
7-76 – JLG Lift – 3121619

Figure 7-82. Urea Tank/Supply Module Harness - Sheet 2 of 2
3121619 – JLG Lift – 7-77

001156522-H
Figure 7-83. Electrical Installation - Sheet 1 of 10
7-78 – JLG Lift – 3121619

1001156522-H
3121619 – JLG Lift – 7-79

1001156522-H
7-80 – JLG Lift – 3121619

1001156522-H
3121619 – JLG Lift – 7-81

1001156522-H
7-82 – JLG Lift – 3121619

1001156522-H
3121619 – JLG Lift – 7-83

1001156522-H
7-84 – JLG Lift – 3121619

1001156522-H
3121619 – JLG Lift – 7-85

1001156216-H
7-86 – JLG Lift – 3121619

1001156216-H
3121619 – JLG Lift – 7-87

THIS MACHINE UTILIZES A 12-VOLT ELECTRICAL SYSTEM. TO PREVENT DAMAGE

WHEN JUMP-STARTING THE MACHINE, CONNECT THE JUMP-START EQUIPMENT
ONLY TO THE BATTERY SHOWN TO PREVENT DAMAGE TO THE MACHINE'S ELEC-
TRICAL SYSTEM.
Figure 7-93. Battery Jump-Start Hookup
7-88 – JLG Lift – 3121619

Figure 7-94. Battery Installation - Sheet 1 of 2
3121619 – JLG Lift – 7-89

Figure 7-95. Battery Installation - Sheet 2 of 2
7-90 – JLG Lift – 3121619

Figure 7-96. Electrical Schematic - Sheet 1 of 20
3121619 – JLG Lift – 7-91

7-92
SG #2 SG #1
RELAY RELAY
WHT 47-1 FUL 1/4

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

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

WHT 52-1 GEN
YEL 2-2 ENABLE

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

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

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

WHT 54-2 1000LB MODE
WHT 48-1 ENG PREHEAT
WHT 49-21 SFTCH LT
WHT 47-1 PLTFM LVL FAIL

WHT 59-2 JSWG LT
WHT 59-1 JSWG RT
BLK
BLK
BLU
BLU
RED
BRN
RED
BRN
GRN
WHT
BLK 0-5
WHT 25-1 PLVL UP
BLU/YEL
WHT/YEL
ORN/YEL
WHT/RED
WHT/GRN
1
YEL 2-1-2
2
WHT 49-26 ALARM
– JLG Lift –
WHT 25-2 PLVL DN
3
YEL 2-1-3
4
5
6
GRN
GROUND
GROUND
BRN
SOFT TOUCH
RED WHT 39-2 AXL EXT
ANALYZER TX
ANALYZER RX
LIGHT SYSTEM
1
FAILURE LIGHT
LEVEL FAILURE
JIB LOCK LIGHT

JIB SWING LEFT
AXLE SET LIGHT

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

3
GENERATOR ENABLE
FUEL LEVEL 1/4 LIGHT

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

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

5
TOGGLE SWITCH
WHT
6
CONNECTOR IN CONSOLE BOX

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

WHT/GRN
10 10
YEL 2-8-1 WHT/RED

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

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

GROUND PLATFORM ROTATE RIGHT LB320-
WHT 25-4 PLVL DN WHT 55-5 PUMP POT YEL 2-1-7
PLATFORM LEVEL DOWN PUMP POT
WHT 25-3 PLVL UP WHT 23-2 P ROT LT WHT 23-2 P ROT LT
PLATFORM LEVEL UP PLATFORM ROTATE LEFT
YEL 2-5
IGNITION GROUND
BLK 0-3 YEL 2-1-8 SILVER PIN
YEL 2-4 WHT 49-15 SFT TOUCH
IGNITION SOFT TOUCH
1
3
2
4
RED 1-4-3 PLTF MODE WHT 27-1 JIB UP
[7,E] PLATFORM MODE JIB UP
BRN 49-13 X44 PWR WHT 27-2 JIB DN
X392
M12 POWER JIB DOWN
WHT 52-3 HEAD/TAIL LT
HEAD & TAIL LIGHT
BRN 49-11 X43 PWR
PLATFORM CONTROL MODULE - 1600343
WHT 29-1 JTELE IN WHT 29-1 JTELE IN

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

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

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

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

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

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

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

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

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

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

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

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

PUSH BUTTON
6-POSITION TERM.BLOCK
X384
HEAD/TAIL LIGHT
X388
YEL
GRN
SHLD
BLK 0-7 (16)
1 1
BLK 0-8 BLK 0-41 (12) WHT 13-1 MTELE IN
[2,D]
X391 1
YEL 2-1-13
2
WHT 13-2 MTELE OUT
WHT 25-3 PLVL UP

X472B
3
1
2
3
YEL 2-1-14
4
1
2
3
5
TOGGLE SWITCH
X472A
6
BRN 49-11 X43 PWR
BRN 49-13 X44 PWR

WHT 49-12 X44 GND
WHT 49-10 X43 GND
MAIN BOOM TELESCOPE
SW23
BLU CAN HI
BLU CAN HI
BLK CAN LOW

BLK CAN LOW
GRY CAN SHIELD

GRY CAN SHIELD
YEL 2-6
1
YEL 2-1-14
X44A
X43A
2
1
2
3
4
5
1
2
3
4
5
WHT 49-16 ENVLP
3
1
2
3
4
5
1
2
3
4
5
YEL 2-1-15
S45 WHT 25-4 PLVL DN

4
X44B
X43B
5
TOGGLE SWITCH
WHT 25-3-1 PLVL UP

WHT 25-6 PLVL UP O/R
6
YEL 2-6
BOOM CONTROL SELECT
1001145974_3-[1,A]
SW24
S46
WHT 48-3 STRT

1
YEL 2-1-15
2
S40
[5,B]
WHT 53-1 AUX

3
GRN
YEL 2-1-16
S481
S480
4
YEL
GRN
SHLD
5
TOGGLE SWITCH
WHT 25-4-1 PLVL DN

START/AUX POWER
WHT 25-5 PLVL DN O/R

6
SW25
YEL 2-6-2
YEL 2-6-1
1
YEL 2-1-16
2
WHT 54-3 CPCITY SW
3
YEL 2-1-17
4
BLK 0-4
YEL 2-6-2
YEL 2-6-1
5
BLK 0-7 (16)

TOGGLE SWITCH
CAPACITY SELECT
WHT 49-23 GND

WHT 49-22 GND
6
WHT 23-3 PROT LT

2-26 FUSIBLE LINK (12)
WHT 23-4 PROT RT

2-25 FUSIBLE LINK (12)
WHT 25-3-1 PLVL UP

WHT 25-4-1 PLVL DN
WHT 55-26 JLOCK IN

YEL 2-5
YEL 2-4
BLK 0-8
RED 1-4-3 PLTF MODE
WHT 55-25 JLOCK OUT

RED 1-4-3
SW26
WHT 50-2 P DUMP(16)

WHT 50-2 P DUMP(16)
BLK 0-41 (12)
BLK 0-40 (12)
GRN
WHT 49-20 PROX NC

WHT 49-19 PROX NO
WHT 55-6 DOS

RED 1-4-3
[2,E] 1
YEL 2-1-17
X36A
2
1
9
8
3
6
7
5
4
2
SW35-2B
SW35-2A
SW35-1A
SW35-1B
11
13
20
15
17
12
10
21
14
18
19
16
2B
2A
1A
1B
WHT 49-17 PLVL 2

WHT 49-18 PLVL 1
3
X33A
7
4
9
3
2
1
8
6
5
11
11
13
20
15
17
12
10
21
14
18
19
16
15
13
19
17
14
18
16
12
10
1
9
8
3
6
7
4
5
2
5
TOGGLE SWITCH
X36B
DRIVE ORIENTATION
11
15
13
19
17
14
18
16
12
10
7
4
9
3
2
1
8
6
5
SW27
X33B
EMS
SWITCH
ZONE C-1
SHEET 2
SEE SHEET 3
BOOM CABLE
CONNECTION
ZONE G&F-1
SEE SHEET 3
PLATFORM VALVE
BANK FUNCTIONS
7-93
JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN

SENSOR #2 (LH) SENSOR #1 (RH) ANGLE SENSOR
PROXIMITY SENSOR PROXIMITY SENSOR PROXIMITY SENSOR
PLATFORM LEVEL SENSOR PLATFORM LEVEL SENSOR JIB LIFT
JIB LOCK JIB LOCK PLATF LVL PLATF LVL PLATF ROT PLATF ROT PLATFORM IGNITION/GROUND
PIN-IN PIN-OUT UP DOWN LEFT RIGHT DUMP 2x6 BUSS BAR
10
12
11
1
2
3
4
5
6
7
8
9
1
2
4
3
1
2
4
3
5
4
3
2
1
1
2
4
3
MS380
SN259
SN258
SN260
SN257
1
2
3
1
2
3
1
2
1
2
1
2
1
2
1
2
1
2
1
2
SN273
SN274
HV342
HV343
HV275
HV276
HV277
HV278
HV281
YEL 2-25 (12)

BLK 0-28 (14)
BLK 0-27-1
BLK 0-27
BLK 0-24
BLK 0-23
WHT 49-44 PROX 1NC
WHT 49-43 PROX 1NO
YEL 2-19
YEL 2-19
YEL 2-21
YEL 2-22
WHT 49-19 PROX NO
ORG CABLE
WHT 49-20 PROX NC
WHT 49-41 LOCK NO

WHT 49-42 LOCK NC
RED CABLE
BLK CABLE
BLU CABLE
BLK CABLE
YEL CABLE
BLK CAN LOW(20)

YEL 2-18 (14)
GRY SHIELD(20)
BLU CAN HI(20)

WHT 55-25 JLOCK OUT
BLK 0-4-5
BLK 0-4-6
BLK 0-4-1
BLK 0-4-2
BLK 0-4-3
BLK 0-4-4
WHT 25-5 PLTFRM DUMP (16)
WHT 0-29 (20)

BRN 2-20 (20)
BLK 0-41 (12)
BLK 0-40 (12)

WHT 55-26 JLOCK IN
BLK 0-40 (12)
YEL 2-25 (12)

YEL 2-26 (12)
WHT 25-4-2 PLVL DN
WHT 25-3-2 PLVL UP
WHT 23-4 PROT RT

WHT 23-3 PROT LT
BLK 0-7 (16)
YEL 2-26 (12)

BLK 0-41 (12)
S383 BLK 0-47 (16)
[8,G]
[4,C]
[4,D]
[4,D]
[4,C]
X36A
ORG CABLE
15 15
YEL CABLE
16 16
BLK CABLE
17 17
RED CABLE
1 1
BLU CABLE
2 2
BLK CABLE
3 3
WHT 55-26 JLOCK IN
10 10
WHT 55-25 JLOCK OUT
11 11
WHT 25-3-2 PLVL UP
7 7
WHT 25-4-2 PLVL DN
6 6
WHT 23-3 PROT LT
8 8
WHT 23-4 PROT RT
9 9 LSS MODULE
21 21 MOUNTED UNDER CONSOLE BOX
SHIELD SHIELD
5 5
BLK 0-4
12 12
18 18
BLK 0-4-2
BLK 0-4-1
BLK 0-4-3
BLK 0-4-4
BLK 0-4
BLK 0-7 (16)

19 19
BLK CABLE (16)
14 14
BLU CABLE (16)
4 4
ORG CABLE (16)
MS437
13 13
RED CABLE (16)
20 20
8
7
6
5
4
3
2
1
X36B
10
12
10
12
CO285-J1
CO285-J2
11
11
1
2
3
4
5
6
7
8
9
4
9
5
1
2
3
6
7
8
1 x 8 Buss Bar
VALVE GROUNDING
WHT
BRN
GRY
BLU
BLK
BLK CAN LOW(20)

GRY SHIELD(20)
BLU CAN HI(20)
GRN CAN LOW

X289
SHLD SHIELD
YEL CAN HI
WHT
1 1
BRN
GRY
BLU
BLK
2 2
3 3
4 4
X287
5 5
1
2
3
4
5
6 6
MS262-2
MS262-3
BRN
X43B 7 7
GRY
5 5 8 8
C
B
A
C
B
A
BLK BLK
4 4 9 9
BLU BLU
3 3 10 10
WHT WHT
2 2 11 11
BRN BRN
1 1 12 12
S291
X286 X290
MS262-1
C
A
B
X44A
BRN BRN
PLATFORM LEVEL
ANGLE SENSOR
1 1 1
WHT WHT
2 2 2
BLU BLU
3 3 3
BLK BLK
4 4 4
GRN CAN LOW

SHLD SHIELD
YEL CAN HI
GRY GRY
5 5 5
X44B SN292
ORN 12 AWG ORN 12 AWG BLK 0-40 (12)

16 [3,G]
BLK 12 AWG BLK 12 AWG YEL 2-25 (12)
10 [4,G]
RED 18 AWG RED 18 AWG YEL CAN HI
3
GRN CAN LOW
2
SHLD SHIELD
1
19
BLK/WHT 12 AWG BLK/WHT 12 AWG BLK 0-41 (12)
18 [3,G]
17
YEL/BLK 18 AWG YEL/BLK 18 AWG WHT 49-20 PROX NC
15
14
ORN/BLK 18 AWG ORN/BLK 18 AWG WHT 49-19 PROX NO
13
RED 12 AWG RED 12 AWG YEL 2-26 (12)
12 [4,G]
BLU/BLK 18 AWG BLU/BLK 18 AWG YEL 2-5
11
RED/BLK 18 AWG RED/BLK 18 AWG WHT 25-6 PLVL UP O/R
9
8
BRN 18 AWG BRN 18 AWG WHT 25-5 PLVL DN O/R
7
YEL 18 AWG YEL 18 AWG YEL 2-15
6
BLU 18 AWG BLU 18 AWG RED 1-4-3
5
ORN 18 AWG YEL 2-4
4
X228B
X365B
BLK CABLE (16)
4
BLU CABLE (16)
3
ORG CABLE (16)
2
RED CABLE (16)
1
WHT P1 WHT P1
1001145974_2-[1,C]
WHT P8
WHT P8
GRN
1001145974_2-[7,D]
GRN
7-94 – JLG Lift – 3121619

JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN JIB LEVEL JIB LEVEL JIB LIFT JIB LIFT JIB TELE JIB TELE JIB SWING JIB SWING JIB
PROXIMITY SENSOR PROXIMITY SENSOR ANGLE SENSOR PROXIMITY SENSOR UP DOWN UP DOWN IN OUT RIGHT LEFT DUMP
JIB LIFT
1
2
1
2
1
2
2
1
1
2
1
2
1
2
1
2
1
2
HV256
HV255
HV254
HV253
HV252
HV251
HV250
HV248
HV249
WHT 55-20 JLVL UP
4
5
6
7
8
9
1
2
4
3
1
2
4
3
5
4
3
2
1
1
2
4
3
SN259
SN258
SN260
SN257
BLK 0-25-1
BLK 0-25-2
BLK 0-26-1
BLK 0-26-2
BLK 0-26-3
BLK 0-26-4
BLK 0-26-5
BLK 0-26-6
WHT 59-1-1 JSWG RT
WHT 29-4-1 JIB OUT
WHT 59-2-1 JSWG LT

WHT 55-19 JLVL DN
WHT 27-4-2 JIB DN

WHT 27-5-2 JIB UP
WHT 29-3-1 JIB IN
WHT 50-3 JIB DUMP(16)

BLK 0-47 (16)
YEL 2-25 (12)
BLK 0-27-1
BLK 0-24
BLK 0-23
WHT 49-44 PROX 1NC
WHT 49-43 PROX 1NO
YEL 2-19
YEL 2-19
YEL 2-21
YEL 2-22
WHT 49-19 PROX NO
WHT 49-20 PROX NC
WHT 49-41 LOCK NO

WHT 49-42 LOCK NC
BLK CAN LOW(20)
YEL 2-18 (14)
GRY SHIELD(20)
BLU CAN HI(20)

WHT 0-29 (20)
BRN 2-20 (20)
YEL 2-25 (12)
YEL 2-26 (12)
YEL 2-26 (12)
WHT 55-19 JLVL DN

WHT 27-3-1 JIB DN O/R
WHT 27-6-1 J-UP O/R
S383 BLK 0-47 (16)

[8,G]
CO245-J2
2 1
S264
1 2
WHT 29-3-1 JIB IN S265
12 5
[4,G]
BLK 0-25 WHT 29-4-1 JIB OUT
3 6
WHT 55-20 JLVL UP WHT 59-1-1 JSWG RT
11 3
[4,D]
[4,C]
WHT 49-41 LOCK NO WHT 59-2-1 JSWG LT

4 4
WHT 49-42 LOCK NC
5 7
WHT 49-43 PROX 1NO
6 8
WHT 49-44 PROX 1NC
7 9
8 10
9 11
BLK 0-26
10 12
CO245-J5
CO245-J4
BLK 0-23
2
YEL 2-22
MS347
LSS MODULE 1
SHLD SHIELD
MOUNTED UNDER CONSOLE BOX 5
9
8
7
6
5
4
3
2
1
12
10
11
GRN CAN LOW
4
YEL CAN HI
3
6
BLK 0-24
8
YEL 2-21 JIB VALVE
7
GND BUSS
SN246
JIB SWING ANGLE SENSOR

CO245-J1
DUAL OUTPUT ROTARY

BRN 2-20 (20) RED 5V PWR RED 5V PWR
11 10 B
WHT 0-29 (20) WHT SIGNAL WHT SIGNAL
12 11 D
10
12
10
12
CO285-J1
CO285-J2
11
11
WHT 27-6 J-UP O/R BLK GROUND BLK GROUND

9
4
9
5
1
2
3
6
7
8
2 12 A
WHT 27-3 JIB DN O/R ORG 5V PWR ORG 5V PWR
1 7 F
BLU SIGNAL BLU SIGNAL
3 8 C
YEL 2-18 (14) GRN GROUND GRN GROUND
5 9 E
BLK 0-28 (14) RED 5V PWR
4 4
GRY
BLU
BLK
YEL CAN HI WHT SIGNAL

6 5
GRN CAN LOW BLK GROUND
7 6
SHLD SHIELD ORG 5V PWR
8 1
BLU SIGNAL
9 2
JIB LEVEL ANGLE SENSOR

DUAL OUTPUT ROTARY
GRN GROUND RED 5V PWR
10 3 B
CO245-J3 WHT SIGNAL
D
BLK GROUND
A
ORG 5V PWR
F
BLU SIGNAL
C
GRN GROUND
BLK CAN LOW(20)
GRY SHIELD(20)
BLU CAN HI(20)
E
GRN CAN LOW
SHLD SHIELD
YEL CAN HI
1 SN247
2
3
4
5
6
MS262-2
MS262-3
7
8
C
B
A
C
B
A
9
10
11
12
X290
MS262-1
C
A
B
GRN CAN LOW
SHLD SHIELD
YEL CAN HI
X230A X231A
BLK 0-40 (12) BLK 12 AWG BLK 12 AWG
[3,G] 16 16 16 16
YEL 2-25 (12) ORN 12 AWG ORN 12 AWG
[4,G] 10 10 10 10
SHLD SHIELD SHIELD 18 AWG SHIELD 18 AWG
1 1 1 1
GRN CAN LOW BLK 18 AWG BLK 18 AWG
2 2 2 2
YEL CAN HI RED 18 AWG RED 18 AWG
3 3 3 3
19 19 19 19
BLK 0-41 (12) BLK/WHT 12 AWG BLK/WHT 12 AWG
[3,G] 18 18 18 18
17 17 17 17
WHT 27-3 JIB DN O/R YEL/BLK 18 AWG YEL/BLK 18 AWG
15 15 15 15
14 14 14 14
WHT 27-6 J-UP O/R ORN/BLK 18 AWG ORN/BLK 18 AWG
13 13 13 13
YEL 2-26 (12) RED 12 AWG RED 12 AWG
[4,G] 12 12 12 12
YEL 2-5 BLU/BLK 18 AWG BLU/BLK 18 AWG
11 11 11 11
WHT 25-6 PLVL UP O/R RED/BLK 18 AWG RED/BLK 18 AWG
9 9 9 9
8 8 8 8
WHT 25-5 PLVL DN O/R BRN 18 AWG BRN 18 AWG
7 7 7 7
YEL 2-15 YEL 18 AWG YEL 18 AWG
6 6 6 6
RED 1-4-3 BLU 18 AWG BLU 18 AWG
5 5 5 5
YEL 2-4 ORN 18 AWG ORN 18 AWG
4 4 4 4
X230B X81
X365B X364B
BLK CABLE (16) WHT 50-2 PLTFM DUMP(16) WHT 50-2 PLTFM DUMP(16) BLK (16)
4 4 4 4 1001145974_5-[8,B]
BLU CABLE (16) WHT 50-3 JIB DUMP(16) BLU (16)
3 3 3 3 1001145974_5-[8,B]
ORG CABLE (16) RED 1-7-1 WK LT PWR(16) RED 1-7-1 WK LT PWR(16) ORG (16)
2 2 2 2 1001145974_5-[8,B]
RED CABLE (16) RED 1-7-2 WK LT PWR(16) RED 1-7-2 WK LT PWR(16) RED (16)
1 1 1 1 1001145974_5-[8,B]
X365A X364A
3121619 – JLG Lift – 7-95

7-96
1
1
1
SHIELD CABLE SHIELD SHIELD CABLE SHIELD
1
X422
X420
X421
X413
SHIELD
WHT 7-4 LDRV PFWD
6
WHT 7-3 LDRV PREV SHIELD CABLE SHIELD SHIELD CABLE SHIELD
5
BLK 0-50-1 (16)

SHIELD B LNGTH
4
BLK 0-15
3
WHT 7-1 RDRV PFWD
1
WHT 7-2 RDRV PREV
2
X222B
[6,C]
BLK 0-15
SHIELD B LNGTH
WHT 7-3 LDRV PREV

WHT 7-4 LDRV PFWD
YEL 1-10
X404B
BLK B LNGTH
BLU B LNGTH
RED B LNGTH
NC SN221
RED B LNGTH RED YEL BRN BRKN CBL PWR (22)
1 1 5 5 1
BLU B LNGTH BLU SHIELD
2 2 8 8 4
BLK B LNGTH BLK BRN BLU BRKN CBL GND1 (22)
3 3 7 7 3
RED/BLK ORG S410
BROKEN CABLE
4 4 6 6
SHIELD BRKN CBL PROX SHIELD RED/BLK
BLK PROX SIG (22)
PROXIMITY SENSOR #1
8 8 4 4
RED BRKN CBL PROX YEL RED
5 5 1 1
BLK BRKN CBL PROX BRN BLU
7 7 2 2
S409
ORG BLK
6 6 3 3
X404A X407A X407B
BLK BRKN CBL SIG (22)
BRN PROX PWR (22)
SN401
BLU BRKN CBL GND2 (22)
1
4
3
RED
BROKEN CABLE
BLU BRKN CBL PROX

PROXIMITY SENSOR #2
BLU
BLK
YEL 1-11
BLK 0-55
BLK 0-56
YEL 2-10 (14)
BLK 0-22 (14)
YEL CAN HIGH
GRN CAN LOW
WHT 7-2 RDRV PREV

WHT 7-1 RDRV PFWD
WHT 49-60 GRVTY SEN1

WHT 49-61 GRVTY SEN2
SHIELD
SHLD X406B
BLK CABLE BLK CABLE BLK 0-55
3 3 3
BLU CABLE BLU CABLE WHT 49-60 GRVTY SEN1
2 2
RED CABLE RED CABLE YEL 1-10
1 1
B
A
C
MS148-1
4 4
8 8
BRN CABLE BLK 0-56
7 7
ORG CABLE WHT 49-61 GRVTY SEN2
6 6 X147A
YEL CABLE YEL 1-11
5 5 4
C
C
A
B
A
B
SHLD X406A 5
BRN CABLE
3 6
MS148-2
MS148-3
ORG CABLE WHT 55-14 BRAKE WHT 55-14 BRAKE
2 1001145974_5-[7,D] 7
YEL CABLE SHLD CAN SHLD
1 3
#2 LEFT SIDE
GRN CAN LO
SN137 2
YEL
GRN
SHLD
YEL CAN HI
BOOM ANGLE SENSOR

1
– JLG Lift –
9
10
11
12
8
X149A
YEL 02-6 (10)
1
BLK 00-11 (10)
2

BLK BRKN CBL PROX

BLU BRKN CBL PROX
RED BRKN CBL PROX

SHIELD BRKN CBL PROX
YEL 2-10 (14)
BLK 0-22 (14)
YEL
GRN
SHLD
X411
6
5
4
3
2
1
6
5
4
3
2
1
X412
BLK CABLE
BLU CABLE
RED CABLE
1001145974_5-[3,F]
1001145974_5-[3,F]
1001145974_5-[3,F]
BLK (1/0)
BLK (1/0)
YEL 2-10 (14)
BLK 0-22 (14)
RED (1/0)
SHIELD BRKN CBL PROX
RED (1/0) RED (1/0)

RED (1/0)
BLK 0-70
WHT 55-35 AUX B+ DISC
1 1001145974_5-[7,D]
WHT 53-3 AUX PMP WHT 53-3 AUX PMP
RL360-85 1001145974_5-[7,C]
BLK 0-45
1
RED (1/0)
RL360-86
RED (1/0)
1
SOLENOID
RED (1/0)
RL360-30
RED (1/0)
BATTERY DISCONNECT
1
RL360-87
IP379
RED 1-7-1 WK LT PWR(16) RED 1-7 WK LT PWR(12)
RED (1/0)
1001145974_5-[8,E]
RED 1-7-2 WK LT PWR(16)
1001145974_5-[8,E]
BLK (1/0)
BLK (1/0)
RED (1/0)
BT361-
1
1
BT361+
RED (1/0)
1001145974_5-[2,E]
1001145974_5-[3,A]
12 VOLT BATTERY
BLK (1/0)
SHEET 4
AUX POWER/ENGINE POWER
3121619
STROBE
LIGHT
2
1
LB417
RED (1/0)
RED (1/0)
BLK (1/0)
WHT 53-3 AUX PMP
WHT B LNTH CBL

RED B LNTH CBL
BLK B LNTH CBL
RED (1/0)
BLK 0-70
BLK 0-16
YEL 2-17
WHT 53-3 AUX PMP
WHT B LNTH CBL

1001145974_5-[3,C]
BLK B LNTH CBL
1001145974_5-[3,C]
RED B LNTH CBL
1001145974_5-[3,D]
1001145974_5-[7,C]
SHLD
1001145974_5-[3,F]
GRN
1001145974_5-[3,F]
YEL
1001145974_5-[3,F]
X411
BLK 0-22 (14) BLK 0-22 (14)
1 1
YEL 2-10 (14) YEL 2-10 (14)
2 2
BLU BRKN CBL PROX BLU CABLE BLU CABLE
3 3 1001145974_5-[3,D]
BLK BRKN CBL PROX BLK CABLE BLK CABLE
4 4 1001145974_5-[3,C]
RED BRKN CBL PROX RED CABLE RED CABLE
5 5 1001145974_5-[3,D]
SHIELD BRKN CBL PROX SHIELD BRKN CBL PROX SHIELD BRKN CBL PROX
6 6 1001145974_5-[3,E]
X412
RED 1-15 RED 1-15
1001145974_5-[2,C]
IP414
X457
RED 1-5 (16) RED 1-5 (16)
1001145974_5-[1,E] 1
IP415
YEL 02-6 (10)
1
YEL 2-10 (14)
??RL236-R_2-R
YEL 2-11 (12) YEL 2-11 (12)
1001145974_5-[4,B] 1
??RL236-Y_2-Y
BUSSBAR
1
??RL236-B+_2-B+
??RLGeneric power relay-B+_1-B+

BUSSBAR
1
RED 2/0 EPDM
YEL 2-25 (12)

1001145974_5-[4,A] ??RL235-Y_1-Y
YEL 2-26 (12)
1001145974_5-[4,A] 1
1001145974_5-[7,D]
RL235-R
YEL 2-1-99 IGNITION(12) YEL 2-1-99 IGNITION(12)
1001145974_5-[6,C] 1
YEL 2-13 (16) YEL 2-13 (16)
1001145974_5-[6,C] X353
YEL 2-12 YEL 2-12
1001145974_5-[2,E] 1
YEL 2-17
RL234-87
RED 2/0 EPDM
1
RL234-30
RED (1/0)
SOLENOID
IGNITION
1
IP90 RL234-86
YEL 2-4-2 YEL 2-4-2-1 YEL 2-4-2-1
RED (1/0)
1001145974_5-[3,A] IP91 1
RED 1-4-2 RED 1-4-2-1 RED 1-4-2-1 RED 1-4-2-1
1001145974_5-[2,E] RL234-85
BLK 0-21
1
BLK 0-70
[1,E]
BLK 0-50-1 (16)
BLK (1/0)
1001145974_5-[8,D]
1001145974_5-[4,A]
1001145974_5-[4,A]
BLK (1/0)
1
BT361-
RED (1/0)
RED (1/0)
1
S456
BT361+
12 VOLT BATTERY
RED 1-7 WK LT PWR(12)
BLK 0-50-2 (16)

1001145974_5-[2,B]
AUX POWER/ENGINE POWER
BLK 0-41 (12)
BLK 0-40 (12)

BLK 0-14
BLK 0-19 (16AWG)

1001145974_5-[2,A]
BLK 0-20 (12)

1001145974_5-[5,B]
RED (1/0)
RED (1/0)
BLK (1/0)
BLK 0-45
BLK 0-19 (16AWG)

BLK 00-11 (10)
BLK 0-22 (14)
BLK 0-50 (16)
BLK 0-20 (12)

RED (1/0)
RED (1/0)
RED (1/0)
BLK (1/0)
BLK (1/0)
IP379
BLK 0-45
BLK 0-21
BLK 0-16
BLK 0-14
RL360-86
RL360-30
RL360-87
RL360-85

1
X373
X374
X375
X237
X377
X378
X418
X419
X362
X376
1
BATTERY DISCONNECT
SOLENOID
1001145974_5-[8,E]
1001145974_5-[8,E]
3121619 – JLG Lift – 7-97

7-98
SW55-1B
SW55-1A
2
1
4
3
RED 1-5-1-1 (16)
CAN CHANNEL #2 1B
X06
3 x 4 Buss Bar 1A
EMS
H
D
C
G
F
A
E
B
J
1
2
3
4
2A
EMERGENCY
X84
RED 1-4 (16)
X395
2B
SW55-2A
11
12
10
1
2
3
4
9
5
6
7
8
SW55-2B
MS83
BLK 0-19-2
YEL 2-11-1B
BLK 0-60
RED 1-4-3
BLK 0-19-3
SHLD CAN SHLD
RED 1-15-2
RED 1-15-1
RED 1-4-3A
YEL 2-11-1A
1
WHT 49-66 Y AXIS

WHT 49-65 X AXIS
SW56-1
YEL CAN HI
GRN CAN LO
RED 1-4 (16)
1
YEL CAN HI
YEL CAN HI
YEL CAN HI
GRN CAN LO
GRN CAN LO
GRN CAN LO
WHT 49-64 TILT PWR

S09
SHLD CAN SHLD
SHLD CAN SHLD
SW56-B
SHLD CAN SHLD

YEL CAN HI RED 1-4-1
[6,C] 1
GRN CAN LO RED 1-4-2
[6,C] SW56-3 KEY
SHLD CAN SHLD
SWITCH
YEL 2-11-1A
[6,C] 1
SW56-2
YEL 2-11-1
1
SW56-B1
RED 1-4-3A
1
SW56-4
X327B
RED 1-5 (16) RED 1-5-1-1 (16)
1001145974_4-[6,E] 1 1
RED 1-4-1 RED 1-4-1
2 2
S07
RED 1-4-3 RED 1-4-3B RED 1-4-3
[4,A] 3 3
RED 1-4-2 S11 RED 1-4-2 RED 1-4-2
IP85
1001145974_4-[5,C] 4 4 X77
YEL 2-12 YEL 2-12 YEL 2-12-1
1001145974_4-[7,C] 5 5 1
BLK 0-19-1 BLK 0-19-1 S31 BLK 0-19-3
5A
6 6 2
GRN CAN LO GRN (20) S42 GRN (20)
7 7 3
RED 1-15
YEL CAN HI YEL (20) YEL (20)
8 8 4
WHT 49-46 M CNTRL WHT 49-46 M CNTRL
9 9 5
10 10 6
WHT 44-1 MSSO WHT 44-1 MSSO
11 11
BLK 0-44 BLK 0-44
12 12
X327 SW471-1
WHT 44-1 MSSO
1
SW471-2
1001145974_4-[6,E]
MSSO
BLK 0-44
SWITCH
BLK 0-19-3
BLK 0-19 (16) S239 BLK 0-19-1
1001145974_4-[7,B] X483
BLK 0-19-2 BLK 0-19-2
X487A 1
YEL 2-12-2
C C 2
GRN CAN LO GRN CAN LO GRN CAN LO
B B 4
BLK 0-50-2 (16) YEL CAN HI YEL CAN HI YEL CAN HI
8 1001145974_4-[7,B] A A 3
WHT 49-72 LIFT PRS (20)
7 X487B 5
WHT 49-74 L P GND (20)
6 6
WHT 49-73 L P PWR (20)
5
WHT 49-75 PRS CHK (20)
4
WHT 49-76 P C GND (20)
1001145974_4-[7,G]
1001145974_4-[7,G]
1001145974_4-[7,E]
1001145974_4-[7,E]
1001145974_4-[7,E]
1001145974_4-[7,F]
3
WHT 49-77 P C PWR (20)
2 MS82
WHT 55-30 LFT ENABLE YEL CAN HI
1 1
YEL CAN HI
X440B 2
YEL CAN HI
11
YEL 2-4-2 YEL 2-4-2 YEL 2-4-4 YEL CAN HI YEL CAN HI
1001145974_4-[5,C] 1001145974_4-[4,E] 12
YEL 2-4 YEL 2-4-3 GRN CAN LO
3
BLK CABLE
BLU CABLE
RED CABLE
S89 GRN CAN LO
4
BLK B LNTH CBL

RED B LNTH CBL
WHT B LNTH CBL

GRN CAN LO
9
3 x 4 Buss Bar
GRN CAN LO GRN CAN LO

1001145974_4-[4,E] 10
CAN CHANNEL #1
SHLD CAN SHLD

5
SHLD CAN SHLD
6
SHLD CAN SHLD SHLD CAN SHLD
S469 X468 1001145974_4-[4,E] 7
SHLD CAN SHLD CAN SHIELD TO CHASSIS GND
1 8
SHLD CAN SHLD
1001145974_4-[7,E]
BLK 0-44
YEL CAN HI
YEL CAN HI
GRN CAN LO
GRN CAN LO
WHT 49-74 L P GND (20)
WHT 49-77 P C PWR (20)
BLK 0-60
WHT 44-1 MSSO
WHT 49-75 PRS CHK (20)
– JLG Lift –
SW482-1
WHT 49-64 TILT PWR

WHT 49-46 M CNTRL
YEL 2-5
YEL 2-11
WHT 49-73 L P PWR (20)
YEL 2-15
WHT 49-76 P C GND (20)
WHT 148-5 REGEN
WHT 49-72 LIFT PRS (20)
YEL 2-4-3
YEL 2-4-4
RED 1-4-1
1
BLK B LNTH CBL

WHT B LNTH CBL
WHT 49-66 Y AXIS

WHT 49-65 X AXIS
WHT JUMPER
WHT JUMPER
BLK CABLE
BLU CABLE
RED CABLE
WHT JUMPER3
WHT JUMPER3
SW482-2
RED B LNTH CBL

YEL 2-9-10
ENGINE
WHT 55-30 LFT ENABLE

1
REGENERATION
1
12
WHT 21-3 SWG LFT WHT 21-3 SWG LFT
X467
34 1
YEL 2-9 YEL 2-9
25 2
WHT 21-4 SWG RHT WHT 21-4 SWG RHT
35 3
WHT 29-3 JIB IN YEL 2-9-1
1001145974_4-[7,D]
11 4
SWING
WHT 29-4 JIB OUT

TURNTABLE
22 5
WHT 27-4 JIB DN
8 6
WHT 27-5 JIB UP
19 SW58
WHT 23-5 P-ROT RHT
18
WHT 148-5 REGEN
UGM TO CHASSIS GND

9
20
YEL 2-11 (12)

WHT 23-6 P-ROT LFT
6
WHT 3-3 LIFT UP WHT 3-3 LIFT UP
23 1
WHT 25-7 P-LVL UP YEL 2-9-1
17 2

WHT 3-4 LIFT DN WHT 3-4 LIFT DN
33 3
WHT 25-8 P-LVL DN YEL 2-9-2
LIFT
1001145974_4-[7,D]
1001145974_4-[7,D]
1001145974_4-[6,B]
1001145974_4-[6,B]
MAIN
5 4
[2,E]
WHT 48-4 STRT
4 5
WHT 53-2 AUX
16 6
WHT 54-4 500#
2 SW59
WHT 39-4 AXLE
WHT 48-5 GLOW
CO02-J8 15
WHT 13-5 TELE IN WHT 13-5 TELE IN
RED 1-4-3
4 7 1
WHT HRC-WARN/ LRC-TEMP YEL 2-9-2
3 28 2
WHT 13-6 TELE OUT WHT 13-6 TELE OUT
2 30 3
YEL 2-26 (12)

YEL 2-25 (12)
BLK 0-41 (12)
BLK 0-40 (12)
WHT 47-8 OIL PRS YEL 2-9-3
MAIN
1 29 4
WHT HRC-HEST/ LRC-ALT
TELESCOPE
26 5
13 6
3 SW60
14 SW66-1
YEL 2-9-3
27 1
YEL 2-9-4
31 SW66-2
WHT 49-46 M CNTRL
32 1
PUSH BUTTON
MOMNT CNTRL
21
10
WHT 49-29 BCS
24
WHT 29-3 JIB IN
WHT 54-5 1000#
WHT 49-28 MNT CNTRL
12 1
YEL 2-9-4
WHT 49-30 OVERLOAD
10 2
WHT 29-4 JIB OUT
18 3
JIB
YEL 2-9-5
16 4
BLK 0-20 (12)

TELESCOPE
19 14 5
RED 1-4-3
5 13 6
17 12 SW61
14 11
8 10
SHLD CAN SHLD WHT 27-4 JIB DN
1 8 1
YEL CAN HI YEL 2-9-5
3 7 2
GRN CAN LO WHT 27-5 JIB UP
2 6 3
JIB
1001145974_4-[7,B]
YEL 2-4 YEL 2-9-6
LIFT
4 5 4
YEL 2-5
11 4 5
YEL 2-15
6 3 6
WHT 27-6 J-UP O/R
13 2 SW62
WHT 27-3 JIB DN O/R
15 1
9 9
WHT 25-5 PLVL DN O/R WHT 23-5 P-ROT RHT
7 CO02-J3 1
X81 YEL 2-9-6
2
WHT 23-6 P-ROT LFT
3
YEL 2-9-8
3121619
WHT 21-4 SWG RHT WHT 21-4 SWG RHT
35 3
WHT 29-3 JIB IN YEL 2-9-1
11 4
WHT 29-4 JIB OUT
SWING
22 5
WHT 27-4 JIB DN
TURNTABLE
8 6
WHT 27-5 JIB UP SW58
19
WHT 23-5 P-ROT RHT
18
WHT 148-5 REGEN
9
3121619
UGM TO CHASSIS GND
20
YEL 2-11 (12)

WHT 23-6 P-ROT LFT
6
WHT 3-3 LIFT UP WHT 3-3 LIFT UP
23 1
WHT 25-7 P-LVL UP YEL 2-9-1
17 2
WHT 3-4 LIFT DN WHT 3-4 LIFT DN
33 3
WHT 25-8 P-LVL DN YEL 2-9-2
LIFT
1001145974_4-[7,D]
1001145974_4-[7,D]
1001145974_4-[6,B]
1001145974_4-[6,B]
MAIN
5 4
[2,E]
WHT 48-4 STRT
4 5
WHT 53-2 AUX
16 6
WHT 54-4 500#
2 SW59
WHT 39-4 AXLE
WHT 48-5 GLOW
CO02-J8 15
WHT 13-5 TELE IN WHT 13-5 TELE IN
RED 1-4-3
4 7 1
WHT HRC-WARN/ LRC-TEMP YEL 2-9-2
3 28 2
WHT 13-6 TELE OUT WHT 13-6 TELE OUT
2 30 3
YEL 2-26 (12)

YEL 2-25 (12)
BLK 0-41 (12)
BLK 0-40 (12)
WHT 47-8 OIL PRS YEL 2-9-3
MAIN
1 29 4
TELESCOPE
26 5
13 6
3 SW60
14 SW66-1
YEL 2-9-3
27 1
YEL 2-9-4
31 SW66-2
WHT 49-46 M CNTRL
32 1
PUSH BUTTON
MOMNT CNTRL
21
10
WHT 49-29 BCS

24
WHT 29-3 JIB IN
WHT 54-5 1000#

WHT 49-28 MNT CNTRL
12 1
YEL 2-9-4
WHT 49-30 OVERLOAD

10 2
WHT 29-4 JIB OUT
18 3
JIB
YEL 2-9-5
16 4
BLK 0-20 (12)

TELESCOPE
19 14 5
RED 1-4-3
5 13 6
17 12 SW61
14 11
8 10
SHLD CAN SHLD WHT 27-4 JIB DN
1 8 1
YEL CAN HI YEL 2-9-5
3 7 2
GRN CAN LO WHT 27-5 JIB UP
2 6 3
JIB
1001145974_4-[7,B]
YEL 2-4 YEL 2-9-6
LIFT
4 5 4
YEL 2-5
11 4 5
YEL 2-15
6 3 6
WHT 27-6 J-UP O/R
13 2 SW62
WHT 27-3 JIB DN O/R
15 1
9 9
WHT 25-5 PLVL DN O/R WHT 23-5 P-ROT RHT
7 CO02-J3 1
YEL 2-9-6
X81 2
WHT 23-6 P-ROT LFT
3
YEL 2-9-8
4
ROTATE
PLATFORM
5
6
SW63
WHT 25-7 P-LVL UP

1
YEL 2-9-8
BLK 0-18
WHT 49-36 A-TX
WHT 49-35 A-RX
BLK 0-31
2
WHT 49-37 A-GND

WHT 49-34 A-PWR
WHT 27-6 J-UP O/R

WHT 48-8 SP
BLK 0-17 (16)
WHT 52-9 GEN
WHT 25-8 P-LVL DN
WHT 48-6 STRT
WHT 48-7 GLOW

3
WHT 55-14 BRAKE
WHT 53-3 AUX PMP
WHT 47-6-2 ALT EXC

YEL 2-9-9

LEVEL
WHT 49-45 HYD OIL TEMP

PLATFORM
1001145974_4-[7,D]
6
[1,D]
[1,D]
[1,D]
SW64
WHT 48-4 STRT

1
YEL 2-9-9
2
WHT 53-2 AUX
3
YEL CAN HI
S372
GRN CAN LO
YEL 2-9-10
S371
4
SHLD CAN SHLD

START/
AUX PWR
– JLG Lift –
6
SW65
1001145974_4-[7,C]
WHT 47-6 ALT EXC
YEL 2-1-99 IGNITION (14)
WHT 54-4 500#
WHT 49-36 A-TX

WHT 49-35 A-RX
1
WHT 49-37 A-GND

WHT 49-34 A-PWR
LIGHT
BLK 0-12-9
WHT 48-6 STRT

500# CAP.
YEL 2-1-99 IGNITION (14)

2
WHT 47-6-1 ALT EXC

LB67
YEL CAN HI
YEL 2-13 (16)

GRN CAN LO
SHLD CAN SHLD

X88
4
3
2
1
WHT 39-4 AXLE
X218A
1
6
5
4
3
2
1
BLK 0-12-9
LIGHT
2
AXLE SET
BLK 0-12-8
LB68
WHT 48-5 GLOW

1
BLK 0-12-8
2
LIGHT
BLK 0-12-7 LB69

GLOW PLUG

BLK 0-18
WHT 48-8 SP
BLK 0-17 (16)
YEL 2-13 (16)

WHT 52-9 GEN
WHT 48-7 GLOW
WHT HRC-WARN/ LRC-TEMP
1
BLK 0-12-7
2
BLK 0-12-6
LB70
/ENG WARN LT
HIGH COOLANT
8
7
6
5
4
3
2
WHT 47-8 OIL PRS
1
1 X217A
BLK 0-12-6
2
BLK 0-12-5
LOW OIL
LB71
PRES. LIGHT
1001145974_4-[5,F]
1001145974_4-[5,C]
1001145974_4-[3,G]
1
BLK 0-12-5
2
BLK 0-12-4
/HEST LIGHT
X159B LB72
NO ALTERNATOR
WHT 47-6 ALT EXC

12
8
WHT 49-28 MNT CNTRL
9 1
BLK 0-12-4
10 2
WHT 27-3 JIB DN O/R BLK 0-12-3
1 LB73
TEST LIGHT

MOMENT CNTRL
2
3
BLK 0-14 BLK 0-14 WHT 49-29 BCS
1001145974_4-[6,B] 11 1
WHT 49-45 HYD OIL TEMP BLK 0-12-3
6 2
BLK 0-31 BLK 0-12-2 LB74
7
SYSTEM LIGHT
BOOM CONTROL
BLK (16) BLK (16) WHT 50-2 PLTFM DUMP (16) WHT 50-2 PLTFM DUMP (16)
1001145974_3-[8,C] 4 4 4
BLU (16) BLU (16) WHT 50-3 JIB DUMP (16) WHT 50-3 JIB DUMP (16)
1001145974_3-[8,B] 3 3 5
ORG (16) ORG (16) RED 1-7-1 WK LT PWR(16) WHT 49-30 OVERLOAD
1001145974_3-[8,B] 2 2 1001145974_4-[5,A] 1
LIGHT
RED (16) RED (16) RED 1-7-2 WK LT PWR(16) BLK 0-12-2

1001145974_3-[8,B] 1 1 1001145974_4-[5,A] 2
BLK 0-12-1
X341B X341A LB75
PLATFORM OVERLOAD
WHT 54-5 1000#

1
BLK 0-12-1
LIGHT
2
1000# CAP.
BLK 0-12
LB76
7-99
MTS LINEAR SENSOR

DEUTSCH REAR LFT AXLE SWG
1 x 8 Buss Bar
1
2
3
4
5
6
7
8
MS244
1
2
3
SN349
WHT 61-1-6 5V
WHT 61-1-5 5V
WHT 61-1-4 5V
WHT 61-1-3 5V
WHT 61-1-1 5V
WHT 61-1-2 5V
WHT 61-1 5V
BLU RETURN
BRN SUPPLY
WHT SIGNAL
X445B
1
2
3
X445A
WHT 38-1 RLFT ASWG

[6,C]
[6,C]
[6,C]
[7,C]
WHT 61-1 5V
BLK 00-15
WHT JUMPER
WHT JUMPER
WHT JUMPER
WHT JUMPER
GE TN
LTA G R RTN
F. VO SW G G D
RE AX SW SW GN
NT AX AX
FR EAR LF
T
R AR
RE
FRNT AXLE SWG EXT.
TWO SPEED
FRNT AXLE SWG RET.
REAR AXLE SWG EXT.

GND
BRAKE
FRNT RHT AXLE SWG
OPEN HYD. CIRCUIT GND
PRESSURE SENSOR REAR AXLE SWG RET.
1
3
2
SN423
GND
GND
WHT 49-71 HYD. OC RTN
GND
WHT 49-70 HYD. OC
WHT 55-18 TTABLE ANG2

GND
RHT FRNT STR LFT
TURNTABLE ANGLE 2 LFT FRNT STR RHT
LFT FRNT STR LFT
RHT FRNT STR RHT
RHT REAR STR RHT
RHT REAR STR LFT
LFT REAR STR RHT
LFT REAR STR LFT
WHT 120 OHM
WHT 120 OHM
WHT 55-14 BRAKE

ANALYZER GND
SHIELD SHLD
ANALYZER TX
NC X-CHASSIS SIDE
SHLD CAN SHLD
ANALYZER RX
6 6 6
GRN CAN LOW
ANALYZER PWR
5 5 5
LFT REAR
SHIELD SHLD SHIELD SHLD YEL CAN HI

STEER
4 4 4
RED STR PWR RED STR PWR RED LFT REAR STR RED LFT REAR STR
2 2 2
BLU STR SIG BLU STR SIG BLU LFT REAR STR BLU LFT REAR STR
3 3 3
BLK STR GND BLK STR GND BLK LFT REAR STR BLK LFT REAR STR
1 1 1
SN-SENSOR SIDE YEL 02-4
X339A
SHIELD SHLD WHT 55-17 DOS
NC X338B
6 6 6
5 5 5
RHT REAR\
SHIELD SHLD SHIELD SHLD

STEER
4 4 4
RED STR PWR RED STR PWR RED RHT REAR STR RED RHT REAR STR
2 2 2
BLU STR SIG BLU STR SIG BLU RHT REAR STR BLU RHT REAR STR
3 3 3
BLK STR GND BLK STR GND BLK RHT REAR STR BLK RHT REAR STR
1 1 1 RIGHT REAR AXLE SWG
SN330
SHIELD SHLD
X338A
WHT 49-70 HYD. OC
LFT FRNT AXLE SWG
NC X337B
WHT 49-71 HYD. OC RTN
6 6 6
5 5 5
LFT FRNT

STEER
4 4 4
RED STR PWR RED STR PWR RED LFT FRNT STR RED LFT FRNT STR
2
BLU STR SIG BLU STR SIG
2 2
BLU LFT FRNT STR BLU LFT FRNT STR
GND
3
BLK STR GND BLK STR GND
3 3
BLK LFT FRNT STR BLK LFT FRNT STR
TURNTABLE ANG
1 1 1
WHT 49-100 ENABLE
GND
SN331 X337A GND
WHT 49-100 ENABLE
X340B
BLK STR GND BLK STR GND BLK RHT FRNT STR BLK RHT FRNT STR
1 1 1
BLU STR SIG BLU STR SIG BLU RHT FRNT STR
3 3 3
RHT FRNT
RED STR PWR RED STR PWR RED RHT FRNT STR
STEER
2 2 2
4 4 4
5 5 5
1
6 6 6
X425
SHIELD SHLD
NC X340A
S424
SN332
BLK 00-12 (16)
BLK 00-11 (10)

YEL 02-6 (10)
BLK 00-12 (16)
WHT 55-14 BRAKE
SHLD CAN SHLD

GRN CAN LOW
WHT 55-17 DOS
YEL CAN HI
YEL 02-4
X147B
9
8
7
6
5
4
3
2
1
12
10
11
12
10
11
9
8
7
6
5
4
3
2
1
X309
BLK 00-11 (10)

YEL 02-6 (10)
ORG
GRN
BLK
YEL
ORIENTATION
SN312
BLK
DRIVE
1
BLK
2
X149B
X311
9
8
7
6
5
4
3
2
1
1
2
12
10
11
12
10
11
9
8
7
6
5
4
3
2
1
1
2
X147A
X149A
7-100 – JLG Lift – 3121619

MTS LINEAR SENSOR MTS LINEAR SENSOR

DEUTSCH REAR LFT AXLE SWG FRNT RHT AXLE SWG
1 x 8 Buss Bar
1
2
3
4
5
6
7
8
MS244
1
2
3
1
2
3
SN349
SN350
WHT 61-1-6 5V
WHT 61-1-5 5V
WHT 61-1-4 5V
WHT 61-1-3 5V
WHT 61-1-1 5V
WHT 61-1-2 5V
WHT 61-1 5V
WHT 55-14 BRAKE

BLU RETURN
BLU RETURN
WHT SIGNAL
WHT SIGNAL
BRN SUPPLY
BRN SUPPLY
BLK 00-1-1
X445B
X442B
1
2
3
1
2
3
X445A
1
2
3
X442A
WHT 38-1 RLFT ASWG
[6,C]
[6,C]
[6,C]
[7,C]
WHT 38-5 FAXS RHT

WHT 61-1 5V
BLK 00-15
BLK 00-2
WHT JUMPER
WHT JUMPER
GE TN
TA G R RTN
OL SW G
F. V AX SW
G D
SW GN
RE NT R AX AX
R
F EA T
R LF
AR
RE
FRNT AXLE SWG EXT.
TWO SPEED
FRNT AXLE SWG RET.
REAR AXLE SWG EXT. BLK 00-1

GND WHT 55-14 BRAKE
BRAKE WHT 38-5 FAXS RHT
FRNT RHT AXLE SWG BLK 00-2
GND
REAR AXLE SWG RET.
BLK 00-3
GND BLK 00-4
GND BLK 00-5
GND
BLK 00-6
GND
RHT FRNT STR LFT
LFT FRNT STR RHT
LFT FRNT STR LFT
RHT FRNT STR RHT BLK 00-3 BLK 00-3-1
RHT REAR STR RHT S205
RHT REAR STR LFT
LFT REAR STR RHT
LFT REAR STR LFT BLK 00-3-2
BLK 00-4 BLK 00-4-1

ANALYZER GND S202
ANALYZER TX
ANALYZER RX
ANALYZER PWR BLK 00-4-2
BLK 00-5 BLK 00-5-1

S203
BLK 00-5-2
WHT 38-9 RAXS RHT

RIGHT REAR AXLE SWG WHT 38-10 FAXS LFT
LFT FRNT AXLE SWG
BLK 00-6 BLK 00-6-1

S204
BLK 00-8
GND BLK 00-9 S195
TURNTABLE ANG WHT 55-15 TTABLE ANG BLK 00-6-2
[5,H]
GND BLK 00-14

GND WHT 61-1-3 5V
[5,H]
WHT 38-10 FAXS LFT
WHT 38-9 RAXS RHT

[5,H]
[5,H]
1
X425
WHT 61-1-4 5V
WHT 61-1-3 5V
BLK 00-8-2
BLK 00-8-1
WHT 61-1-6 5V
WHT 61-1-5 5V
BLK 00-12 (16)
BLK 00-11 (10)

YEL 02-6 (10)
X449B
X448B
3
2
1
3
2
1
3
2
1
3
2
1
X449A
X448A
WHT 55-18 TTABLE ANG2
WHT 55-15 TTABLE ANG
BLU RETURN
BRN SUPPLY
WHT SIGNAL
BLU RETURN
BRN SUPPLY
WHT SIGNAL
BLK 00-14
BLK 00-9
WHT 61-1-6 5V
WHT 61-1-5 5V
SN352
SN351
SN243
F
3
2
1
A
D
B
E
C
3
2
1
TURNTABLE
ANGLE SENSOR
MTS LINEAR SENSOR MTS LINEAR SENSOR

LFT FRNT AXLE SWG RHT REAR AXLE SWG
3121619 – JLG Lift – 7-101

HYDRAULIC
OIL TEMP. WARM UP LIFT CHASSIS
VALVE ENABLE ENABLE
1
2
1
2
2
1
2
1
SN416
HV316
HV315
HV314
WHT 60-6 WARM UP RTN
WHT 55-31 CHS ENABLE

WHT 60-7 LENABLE RTN
BLK 0-31
WHT 55-33 WARM UP
BLK 0-36
WHT 7-4 RDRV PFWD
1
BLK 0-15-1 RIGHT DRV
2
PUMP FWD
HV142
WHT 7-4 RDRV PFWD

1
WHT 7-3 RDRV PREV WHT 7-3 RDRV PREV
2 1
BLK 0-15 BLK 0-15 BLK 0-15-2 BLK 0-15-2 RIGHT DRV
3 2
S146 PUMP REV
4 HV143
WHT 7-2 LDRV PREV
5
WHT 7-1 LDRV PFWD
6
X222A
WHT 7-2 LDRV PREV
1
BLK 0-15-3 LEFT DRV
2
PUMP REV
HV144
BLK 0-15-4
2
WHT 7-1 LDRV PFWD LEFT DRV
1
PUMP FWD
HV145
BLK 0-30
WHT 52-7 H&T LT SIG
1
X158
WHT 27-3 JIB DN O/R

1
2
3
4
WHT 50-3 JIB DUMP (16)
5
6
BLK 0-31
7
8
9
10
BLK 0-14
11
WHT 47-6 ALT EXC
12
X159A

1
BRN 49-77 P C PWR (20)
2
BLK 49-76 P C GND (20)
3
BLU 49-75 PRS CHK (20)
4
SHLD RTN (20) SHLD RTN (20)
8
BRN 49-73 L P PWR (20) S455
5
BLK 49-74 L P GND (20)
6
BLU 49-72 LIFT PRS (20)
7
SHLD P CHK SN (20)

SHLD P LIFT SN (20)
X440A
SN439
SN438
2
3
4
1
2
3
4
1
SHLD
SHLD
LIFT PRESSURE PRESSURE CHECK

SENSOR SENSOR
7-102 – JLG Lift – 3121619

3121619
1
BLK 0-31
2
SN416
OIL TEMP.
HYDRAULIC
WHT 55-33 WARM UP

1
BLU 49-72 LIFT PRS (20)

2
VALVE
BLK 49-74 L P GND (20)

HV316
WARM UP
BRN 49-73 L P PWR (20)

BLU 49-75 PRS CHK (20)
BLK 49-76 P C GND (20)
BRN 49-77 P C PWR (20)
SHLD RTN (20)

BLK 0-30
S455
SHLD P LIFT SN (20)
SHLD
2
3
4
SENSOR
1
LIFT PRESSURE
SN439

2
1
LIFT
SHLD P CHK SN (20)

ENABLE
SHLD HV315
2
3
4
BLK 0-36
SENSOR
1 2
SN438 1
PRESSURE CHECK
ENABLE
CHASSIS
HV314
WHT 47-6 ALT EXC

WHT 52-8 ALRM PWR

WHT 60-3 SWG RTN
BLK 0-46
X05B
BLK 0-46 BLK 0-46
2 2
BLK 0-46 BLK 0-46
1 1
X05A
– JLG Lift –
BLK 0-30
BLK 0-46
WHT 50-3 JIB DUMP (16)

WHT 27-3 JIB DN O/R
WHT 52-7 H&T LT SIG
WHT 55-33 WARM UP

BLK 0-36

WHT 55-32 SWG F.C. WHT 55-32 SWG F.C.
1
WHT 60-3 SWG RTN
2
SWING
HV348
FLOW CONTROL
WHT 52-6 MOT ALRM

WHT 47-10 FUL SEN
WHT 52-8 ALRM PWR

A
WHT 52-6 MOT ALRM
B
HORN
BLK 0-14 BLK 0-14-2 BLK 0-14-2

C
S157
MOTION ALARM/
AH318
WHT 47-10 FUL SEN

1
BLK 0-14-3
2
SN114
7-103
1 2 3 4 5
GLOW PLUG SENSOR IGNITION

FUSE FUSE
5A 10A
H BLK 148-70 STRT RTN
FC1003
FC1004
1
2
1
2
RED EPDM 2/0AWG

SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm²
FUSIBLE LINK 12AWG

RED EPDM 2/0AWG
RED EPDM 2/0AWG
BLK 148-71 STRT SIG
SHLD SHIELD
MS999-1
A
B
C
MS999-2
MS999-3
C
C
B
A
B
A
GRN CAN LOW (J1939 CABLE 20)

SHLD SHIELD (J1939 CABLE 20)

YEL CAN HI (J1939 CABLE 20)

E
BLK 148-15-68 CLUTCH SWITCH
BLK 148-70 STRT RTN

BLK 148-35-3 STRT REQ
BLK 148-71 STRT SIG
MS1000-3
A
D B
120 OHM
C C
GRN CAN LOW GRN CAN LOW
B
YEL CAN HIGH YEL CAN HIGH YEL CAN HI (J1939 CABLE 20)
A A
MS1000-1 B
C
MS1000-2

C
MS1001-1 B
YEL CAN HIGH YEL CAN HIGH YEL CAN HI (J1939 CABLE 20)
A A
GRN CAN LOW GRN CAN LOW
B MS1001-2
C C
B
A
MS1001-3 120 OHM
C
BLK 148-15-68 CLUTCH SWITCH
1 2 3 4 5
7-104 – JLG Lift – 3121619

4 5 6 7 8
GLOW
GLOW PLUG SENSOR IGNITION PLUGS
FUSE FUSE
5A 10A
FC1003
FC1004
1
2
1
2
RL931-87
EC1010
1
1
RED EPDM 2/0AWG
FUSIBLE LINK 12AWG
FUSIBLE LINK 12AWG

RED EPDM 2/0AWG
RED EPDM 2/0AWG
RED 4AWG
G
150 A
EC971-B+
DEUTZ CONTROLLED
RED EPDM 2/0AWG
STARTER MOTOR
1
EC971
1
EC971-B-
1
X1008
BLK 000-148-2 1.5 K OHM
1
BLK 148-35-4 STRT REQ
2
BLK 148-35-3 STRT REQ BLK 148-35-2 STRT REQ BLK 148-35-2 STRT REQ
S1007 YEL CAN HIGH
GRN CAN LOW
F
SHLD SHIELD
SHLD SHIELD
X217B
1
2
MS999-1
3
4
A
B
C
5
6
7
8
MS999-2
MS999-3
C
C
B
A
B
A


YEL 2-48-2 IGNITION

BLK 000-48-2 ENG GND
B
X1005 C
YEL CAN HI (J1939 CABLE 20) YEL CAN HIGH
MS1000-3 1 1 M
GRN CAN LOW (J1939 CABLE 20) GRN CAN LOW
A 2 2 F
B
120 OHM SHLD SHIELD (J1939 CABLE 20)
3 3 J
D
C C X1006 K
GRN CAN LOW
MS1002-1 B G
YEL CAN HI (J1939 CABLE 20) YEL CAN HI (J1939 CABLE 20) YEL CAN HIGH
A A A H
GRN CAN LOW (J1939 CABLE 20) GRN CAN LOW (J1939 CABLE 20)
B B MS1002-2 L
SHLD SHIELD (J1939 CABLE 20) SHLD SHIELD (J1939 CABLE 20)
C C C E
MS1000-2 B D
A
120 OHM
MS1002-3

C
B
A
MS1001-2
C
B
A
MS1001-3 120 OHM
C
WIF SWITCH
1
2
SN959
EC958+
FUEL PUMP
1
EC958-
1
BLK 000-148-2
BLK 000-48-2 ENG GND
4 5 6 7 8
3121619 – JLG Lift – 7-105

7-106 – JLG Lift – 3121619

3121619 – JLG Lift – 7-107

DEUTZ EMR4 91 WAY CONNECTOR (D2.2)
TIER 4 FINAL
WHT 148-15 CLUTCH SW

WHT 148-15 CLUTCH SW
DEUTZ TD3.6L
CYLINDER 1
WHT 64-35 INJCTR RTN (1.5mm²)
INJECTOR
WHT 45-40 INJCTR (1.5mm²)
CYLINDER 2
INJECTOR
CYLINDER 3
INJECTOR
CYLINDER 4
INJECTOR
WHT 25-20 MPROP (1.5mm²)
ACTUATOR
WHT 46-19 MPROP RTN (1.5mm²)
MPROP
BLK 99-13 CAM ENG SPD
ENGINE SPEED
WHT 100-14 CAM ENG SPD
CAMSHAFT DPF PRESSURE
WHT 75-S214 SHLD RTN SHLD S214-9
WIRE SHIELD DS DPF
S214 SHLD S214-1 AMBIENT AIR
WIRE SHIELD COOLANT LEVEL
BLK 101-21 CRK ENG SPD TEMP. SENSOR
ENGINE SPEED SENSOR
WHT 102-15 CRK ENG SPD
CRANKSHAFT
WHT 67-48 EXH GAS REC (1.5mm²)
EXHAUST GAS
WHT 2-47 EXH GAS REC (1.5mm²)
RECIRCULATION
WHT 18-50 5V
5 VOLT SUPPLY
WHT 76-51 GND RTN
GROUND
WHT 55-46 E GAS REC SIG
EXHAUST GAS SIGNAL
WHT 36-31 RAIL PRS FUL
FUEL
RAIL
PRESSURE
WHT 13-24 COOL TEMP
COOLING TEMPERATURE
WHT 74-28 BST PRS TEMP
BOOST
PRESSURE
TEMPERATURE
WHT 21-22 PRS RTN
GROUND
WHT 72-26 OIL PRS
OIL PRESSURE
WHT 35-27 TEMP/PRS RTN
GROUND
WHT 54-17 FUL LOW PRS
LOW FUEL PRESSURE
WHT 95-2 STRT SIG
START SIGNAL
WHT 94-3 STRT RTN
START RETURN
WHT 8-7 EGR TEMP
BLK 0-60-7-3
EGR TEMPERATURE BEHIND VENTURI
WHT 7-52 INTAKE THRTLE
AIR INTAKE
WHT 38-49 INTAKE THRTLE
THROTTLE
WHT 51-6 DELTA VNTRI
DELTA p VENTURI
DEUTZ ENGINE 62 WAY
CONNECTOR (X17)
DEUTZ DIAGNOSTIC
CONNECTOR
PLUGS
GLOW
DEUTZ
CAN BUSS
BLK 0-60-9-2 (1mm²) GROUND

IGNITION
CAN HIGH (DEUTZ TERM)

CAN LOW (DEUTZ TERM)
CAN HIGH (DEUTZ)

CAN LOW (DEUTZ)
X233
C
GRN CN L (DEUTZ)
B
YEL CN H (DEUTZ)
A
GRN CN L (DEUTZ)
GRN CN L (DEUTZ)
GRN CN L (DEUTZ)
YEL CN H (DEUTZ)
YEL CN H (DEUTZ)
YEL CN H (DEUTZ)
SN237*
SN236
2
1
3
4
2
1
3
4
DOSING UREA TANK NOx SENSOR NOx SENSOR

VALVE
UREA TANK HARNESS AFTER SCR CAT SCR CAT UREA TANK HARNESS
HEATING
SHEET #11 SHEET #11
VALVE
ZONE H-2 ZONE H-2/3
SCR EXHAUST GAS EXHAUST GAS
TEMPERATURE TEMPERATURE
(BEFORE SCR) (BEFORE OXY CAT)
7-108 – JLG Lift – 3121619

FUEL PUMP
AUXILIARY AUXILIARY
RELAY
RELAY PUMP
WHT 48-95 FUL RLY 86

WHT 148-35-3 STRT REQ
ENGINE/AUX PUMP
BATTERY
BATTERY ISOLATOR
140 AMP
FUEL
PUMP
DPF PRESSURE
AMBIENT AIR DS DPF
TEMP. SENSOR
WATER IN
FUEL SWITCH
EMR4 IGNITION
GROUND
GENERATOR ENABLE
GLOW
GENERATOR POWER
GENERATOR GROUND
PLUGGED
PLUGGED
S285* IGNITION
START REQUEST
CAN HIGH CHANNEL #2
CAN LOW CHANNEL #2
ALTERNATOR EXCITE
BLK 0-60-7-3
CAN SHIELD
DEUTZ
120 AMP
DEUTZ DIAGNOSTIC
CONNECTOR
RELAY
PLUGS
GLOW PLUG
GLOW
DEUTZ
CAN BUSS DEUTZ
STARTER
ENGINE POWER
DISTRIBUTION MODULE
PULL DOWN RESISTOR
AIR INTAKE THROTTLE POWER

5 AMP FUSE
NOx SENSORS POWER
15 AMP FUSE
UREA SENSOR POWER
5 AMP FUSE
FUEL PUMP RELAY
25 AMP FUSE
SCR CONTROL POWER
30 AMP FUSE
RELAY, SUPPLY
MODULE HEATER
RELAY, HEATER 1
SUCTION LINE
RELAY, HEATER 2
THROTTLE LINE
RELAY, HEATER 3
PRESSURE LINE
RELAY, SCR CONTROL

S284
SYSTEM B+ ON BATTERY ISOLATER

BLK 0-60-9 (2.5mm²)
GROUND STUD
GRN CN L (DEUTZ)
GRN CN L (DEUTZ)
GRN CN L (DEUTZ)
YEL CN H (DEUTZ)
YEL CN H (DEUTZ)
YEL CN H (DEUTZ)
SN237*
SN236
2
1
3
4
2
1
3
4
UREA TANK NOx SENSOR NOx SENSOR

AFTER SCR CAT SCR CAT UREA TANK HARNESS BUSS BAR BUSS BAR
HEATING
VALVE
SHEET #11
ZONE H-2/3
RELAY POWER ENGINE GROUND
ENGINE TIER 4 FINAL
3121619 – JLG Lift – 7-109

ENGINE HARNESS ENGINE HARNESS

SHEET #10 SHEET #10
ZONE A-2/3 ZONE A-4/5
AFTERTREATMENT SECTION
UREA TANK/ SUPPLY MODULE
LOCATED ON LEFT SIDE OF MACHINE
UREA QUALITY, 1 3
N6 CONNECTION LEVEL AND TEMP. SUCTION LINE PRESSURELINE
2
UREA PUMP HEATER HEATER
UREA PURGE VALVE THROTTLE LINE
SUPPLY MODULE HEATER HEATER
UREA PRESSURE AFTER PUMP
TANK/ SUPPLY MODULE
7-110 – JLG Lift – 3121619

Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65813058 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte Ltd
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 29 Tuas Ave 4,
Germany Sheung Shui N. T. Italy Jurong Industrial Estate
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Singapore, 639379
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +65-6591 9030
(852) 2639 5797 +65-6591 9031
Oshkosh-JLG (Tianjin) Equipment Plataformas Elevadoras JLG Sverige AB

Technology., Ltd JLG Iberica, S.L. Enkopingsvagen 150
Pudong Kerry Parkside Trapadella, 2 Box 704
Room 3705 P.I. Castellbisbal Sur SE - 176 27 Jarfalla
1155 Fang Dian Road 08755 Castellbisbal, Barcelona Sweden
Pudong, Shanghai 201204 Spain +46 (0)850 659 500
+0086 21 60311575 +34 93 772 4700 +46 (0)850 659 534
+0086 21 60311599 +34 93 771 1762
www.jlg.com

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Service and Maintenance Manual

January 27, 2016

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-

3121619 – JLG Lift – A-1

Original Issue - June 18, 2014

A-2 – JLG Lift – 3121619

SECTION NO. TITLE PAGE NO.

3121619 – JLG Lift – i

SECTION NO. TITLE PAGE NO.

ii – JLG Lift – 3121619

SECTION NO. TITLE PAGE NO.

3121619 – JLG Lift – iii

SECTION NO. TITLE PAGE NO.

iv – JLG Lift – 3121619

SECTION NO. TITLE PAGE NO.

3121619 – JLG Lift – v

SECTION NO. TITLE PAGE NO.

vi – JLG Lift – 3121619

FIGURE NO. TITLE PAGE NO.

3121619 – JLG Lift – vii

FIGURE NO. TITLE PAGE NO.

viii – JLG Lift – 3121619

FIGURE NO. TITLE PAGE NO.

3121619 – JLG Lift – ix

FIGURE NO. TITLE PAGE NO.

x – JLG Lift – 3121619

FIGURE NO. TITLE PAGE NO.

3121619 – JLG Lift – xi

FIGURE NO. TITLE PAGE NO.

xii – JLG Lift – 3121619

FIGURE NO. TITLE PAGE NO.

3121619 – JLG Lift – xiii

FIGURE NO. TITLE PAGE NO.

xiv – JLG Lift – 3121619

FIGURE NO. TITLE PAGE NO.

3121619 – JLG Lift – xv

TABLE NO. TITLE PAGE NO.

xvi – JLG Lift – 3121619

TABLE NO. TITLE PAGE NO.

3121619 – JLG Lift – xvii

TABLE NO. TITLE PAGE NO.

This page left blank intentionally.

xviii – JLG Lift – 3121619

Horizontal Reach over end

Swing Gearbox 3 qt. (2.8 L)

Horizontal Reach from centerline of rota-

3121619 – JLG Lift – 1-1

1.5 ENGINE DATA 1.7 HYDRAULIC OIL

Type Turbo-charged Diesel Hydraulic System

NOTE: Aside from JLG recommendations, it is not advisable to

1-2 – JLG Lift – 3121619

Table 1-10. UCon Hydrolube HP-5046

Type Synthetic Biodegradable

Table 1-11. Mobil EAL H 46 Specs

Type Synthetic Biodegradable

3121619 – JLG Lift – 1-3

Figure 1-1. Maintenance and Lubrication Diagram

1-4 – JLG Lift – 3121619

1.8 MAINTENANCE AND LUBRICATION 2. Swing Gearbox