A 1200SJP 1350SJP JLG Service English

Service & Maintenance Manual
Model
1200SJP, 1350SJP
PVC 2207
31220396
July 11, 2022 - Rev A
ANSI ©
Copyright
AS/NZS MOL70
INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS
GENERAL
This section contains the general safety precautions which must be observed during maintenance of the mobile elevating work
platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible
injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is
safe to operate.
WARNING
Modification or alteration of a mobile elevating work platform shall be made only
with written permission from the manufacturer.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are,
for the most part, those that apply when servicing hydraulic and larger machine component parts.
Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of
weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable
position. When raising a portion of the equipment, ensure that adequate support is provided.
WARNING
Since the machine manufacturer has no direct control over the field inspection and
maintenance, safety in this area responsibility of the owner/operator.
HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should
be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Do not use your hand to check for
leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.
1200SJP , 1350SJP 31220396 3

Introduction Maintenance Safety Precautions
MAINTENANCE
WARNING
Failure to comply with safety precautions listed in this section could result in ma-
chine damage, personnel injury or death and is a safety violation.
• USE ONLY REPLACEMENT PARTS OR COMPONENTS THAT ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, REPLACEMENT
PARTS OR COMPONENTS MUST BE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL
OTHER TIMES.
• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON
OR ENTANGLED IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR
OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.
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REVISION LOG
DATE REVISION DESCRIPTION

July 11, 2022 A Original Issue
1200SJP , 1350SJP 31220396 5

This Page is intentionally left blank
6
SECTION CONTENTS
Section Subject Page
INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS........................................................................ 3
REVISION LOG ............................................................................................................................................... 5

SECTION 1
SPECIFICATIONS ......................................................................................................................................... 11
1.1 Capacities .......................................................................................................................... 11
1.2 Tires.................................................................................................................................. 11
1.3 Engine Data ....................................................................................................................... 11
1.4 Specifications and Performance Data ..................................................................................... 13
1.5 Torque Requirements .......................................................................................................... 16
1.6 Hydraulic Oil Specifications .................................................................................................. 16
1.7 Major Component Weights .................................................................................................. 19
1.8 Pressure Settings ................................................................................................................ 20
1.9 Engine Oil Specifications ...................................................................................................... 20
1.10 Lubrication and Maintenance ............................................................................................... 23
1.11 Threadlocking Compound.................................................................................................... 32
1.12 Torque Charts..................................................................................................................... 33
SECTION 2
GENERAL ...................................................................................................................................................... 49
2.1 Machine Preparation, Inspection, and Maintenance ................................................................. 49
2.2 Service and Guidelines......................................................................................................... 50
2.3 Lubrication and Information ................................................................................................. 52
2.4 Cylinder Drift...................................................................................................................... 53
2.5 Pins and Composite Bearing Repair Guidelines........................................................................ 54
2.6 Welding on JLG Equipment .................................................................................................. 54
SECTION 3
CHASSIS AND TURNTABLE ........................................................................................................................ 61
3.1 Tires and Wheels................................................................................................................. 61
3.2 Extending Axles .................................................................................................................. 62
3.3 Axle Limit Switch Adjustment Procedure ................................................................................ 62
3.4 Drive System ...................................................................................................................... 63
3.5 Steering Control System ...................................................................................................... 63
3.6 Drive/Steering Speed Control ............................................................................................... 64
3.7 Traction Control System....................................................................................................... 65
3.8 Drive Orientation System ..................................................................................................... 65
3.9 Oscillating Axle System ........................................................................................................ 74
3.10 Oscillating Axle Bleeding Procedure and Lockout Test.............................................................. 75
3.11 Wheel Drive Assembly ......................................................................................................... 76
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Section Contents
3.12 Drive Hub .......................................................................................................................... 77

3.13 Drive Motor........................................................................................................................ 78
3.14 Drive Hub - If Equipped With Reggiana Riduttori ..................................................................... 81
3.15 Swing Drive. ....................................................................................................................... 98
3.16 Swing Brake ....................................................................................................................... 99
3.17 Swing Motor ...................................................................................................................... 99
3.18 Procedure for Setting Gear Backlash ...................................................................................... 99
3.19 Swing Drive Lubrication ..................................................................................................... 101
3.20 Swing Bearing .................................................................................................................. 101
3.21 Swing Speed Proportioning................................................................................................ 109
3.22 Chassis Tilt Indicator System ............................................................................................... 110
3.23 Rotary Coupling................................................................................................................ 110
3.24 Generator ........................................................................................................................ 115
3.25 Auxiliary Power System...................................................................................................... 124
3.26 Cold Weather Package ....................................................................................................... 125
3.27 Deutz TD2011L04 Engine ................................................................................................... 126
3.28 Deutz TCD2.9L4 (Guo III) Engine.......................................................................................... 183
3.29 Deutz TCD2.9L4 Engine...................................................................................................... 185
3.30 Deutz Engine TCD2.9L4 (Stage V) ........................................................................................ 194
3.31 HRC Engine Emission Characteristics.................................................................................... 233
3.32 Diesel Particulate Filter (If Equipped).................................................................................... 233
3.33 Bio Fuel in Deutz Engines................................................................................................... 239
SECTION 4
BOOM AND PLATFORM ...........................................................................................................................243
4.1 Boom Systems .................................................................................................................. 243
4.2 Platform .......................................................................................................................... 248
4.3 Boom Removal, Disassembly/Assembly, & Cable Replacement ................................................ 251
4.4 Rotator ............................................................................................................................ 299
4.5 Boom Lubrication Application............................................................................................. 300
4.6 Boom Shimming Procedure................................................................................................ 300
4.7 JIB Rotator Orientation....................................................................................................... 301
4.8 JIB Lift End of Stroke Dampening ........................................................................................ 301
4.9 Load Sensing Pin Removal and Installation ........................................................................... 301
4.10 Powertrack Maintenance.................................................................................................... 315
4.11 Hose Routing Procedure .................................................................................................... 328
4.12 Wire Rope ........................................................................................................................ 328
4.13 Wire Rope Tensioning Adjustment ...................................................................................... 330
4.14 Broken Boom Cable Proximity Switch .................................................................................. 340
4.15 Electronic Platform Leveling ............................................................................................... 341
4.16 Rotary Actuator ................................................................................................................ 343
4.17 Bolt-on External Fall Arrest ................................................................................................. 359
4.18 Skyguard ......................................................................................................................... 362
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Section Contents
SECTION 5
BASIC HYDRAULIC INFORMATION AND SCHEMATICS .......................................................................365
5.1 Lubricating O-Rings In The Hydraulic System ........................................................................ 365
5.2 Hydraulic Connection Assembly And Torque Specification...................................................... 367
5.3 Cylinder Repair ................................................................................................................. 441
5.4 Hydraulic Tank.................................................................................................................. 473
5.5 Pressure Setting Procedure................................................................................................. 473
5.6 Drive Pumps (Rexroth) ....................................................................................................... 481
5.7 Function Pump (Rexroth) ................................................................................................... 492
5.8 Drive Pumps (SAUER)......................................................................................................... 506
5.9 Function Pump (SAUER)..................................................................................................... 527
5.10 Gear pump (Sauer) ............................................................................................................ 540
5.11 Drive & Function Pump Start Up Procedures ......................................................................... 554
5.12 Hydraulic Schematics. ........................................................................................................ 556
SECTION 6
JLG CONTROL SYSTEM.............................................................................................................................561
6.1 Introduction ..................................................................................................................... 561
6.2 CANbus Communications................................................................................................... 562
6.3 Calibration Instructions ...................................................................................................... 564
6.4 To Connect the JLG Control System Analyzer ........................................................................ 586
6.5 Using the Analyzer ............................................................................................................ 586
6.6 Changing the Access Level Of The Hand Held Analyzer .......................................................... 587
6.7 Adjusting Parameters Using The Hand Held Analyzer ............................................................. 589
6.8 Machine Setup ................................................................................................................. 590
6.9 Machine Personality Settings/Function Speeds...................................................................... 602
6.10 Machine Orientation When Setting Function Speeds.............................................................. 605
6.11 System Test...................................................................................................................... 606
6.12 Calibrating Steer ............................................................................................................... 619
6.13 Calibrating Drive ............................................................................................................... 623
6.14 Load Sensing System (LSS) ................................................................................................. 627
6.15 Resetting the MSSO System................................................................................................ 634
6.16 Electronic Platform Leveling ............................................................................................... 635
6.17 Calibrating Platform Level .................................................................................................. 640
6.18 Calibrating Lift Crack Point ................................................................................................. 646
6.19 Calibrating Telescope Crack point ....................................................................................... 650
6.20 Calibrating Tilt Sensor........................................................................................................ 654
6.21 Drive Cutout Override Service Mode .................................................................................... 656
6.22 Calibrating the Boom Sensors ............................................................................................. 657
6.23 CANbus Troubleshooting ................................................................................................... 710
SECTION 7
BASIC ELECTRICAL INFORMATION AND SCHEMATICS .......................................................................733
7.1 General ........................................................................................................................... 733
7.2 Multimeter Basics.............................................................................................................. 733
7.3 Applying Silicone Dielectric Compound to Electrical Connections ............................................ 736
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Section Contents
7.4 Dielectric Grease Application .............................................................................................. 736

7.5 AMP Connector ................................................................................................................ 738
7.6 Deutsch Connectors .......................................................................................................... 743
7.7 Telematics Gateway .......................................................................................................... 745
7.8 Electrical Schematics ......................................................................................................... 760
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SECTION 1
SPECIFICATIONS
1.1 CAPACITIES
Hydraulic Tank 55 Gallon (208 L)
Fuel Tank
Standard 31 Gallon (117 L)
Optional 52.8 Gallon (200 L)
Hydraulic System 66 Gallon (250 L)
Wheel Drive Hub

Bonfiglioli TBD
Reggiana Riduttori 1.59 Quarts (1.5 L)
1.2 TIRES
Size 445/50D710
Load Range J
Ply Rating 18
Load Rating 26,500 lb @ 100 psi (12020 kg @ 6.9 Bar)
Foam Fill Poly urethane HD (55 Durometer) Foam
Max Tire Load

1200SJP 25,000 lb (11,340 kg)
1350SJP 26,250 lb (11,907 kg)
Max Tire Load (Non-Marking Tire)
@6 km/h 33,000 lb (15,000 kg)

@10km/h 29,700 lb (13,500 kg)
@25km/h 25,300 lb (11,500 kg)
1.3 ENGINE DATA
1.3.1 Deutz TD2011L04

Type Liquid Cooled
Number of Cylinders 4
Bore 3.7 in. (94 mm)

Stroke 4.4 in. (112 mm)
Total Displacement 190 cu. in. (3108 cm³)
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Specifications
Compression Ratio 17.5:1
Firing Order 1-3-4-2
Output 75 hp (56 kW)
Oil Capacity
Cooling System 5 Quarts (4.5 L)
w/Filter 11 Quarts (10.5 L)

Total Capacity 16 Quarts (15 L)
Average Fuel Consumption 1.1 gph (4.1 lph)
Idle Engine RPM 1200
Mid Engine RPM 1800
High Engine RPM 2475
1.3.2 Deutz TCD2.9L4

Type Liquid Cooled
Output Power 74.2 hp (55.4 kW)
Output Torque 192 ft. lbs. (260 Nm) @ 1800 rpm
Max High Engine RPM 2500
Min Low Engine RPM 900
High RPM set 2500 ±50 RPM
Low RPM set 1200 ± 50 RPM

Engine Oil Capacity 2.4 Gallon (8.9 L)
Coolant Capacity (Engine Only) 0.79 Gallon (3 L)
Acceptable Fuel Grades Ultra Low Sulfur (15 ppm)
(Dependent upon Regulated Area) Up to 5% Biodiesel
1.3.3 Deutz TCD2.9L4 GUOIII

Type Liquid Cooled
Output Power 74.2 hp (55.4 kW)
High RPM set 2500 ±50 RPM
Low RPM set 1200 ± 50 RPM

Coolant Capacity (Engine Only) 0.9 2 Gallon (3.5 L)
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Specifications
1.3.4 Deutz TCD2.9L4 Stage V

Type Liquid Cooled
Output Power 74.2 hp (55.4 kW) @ 2600 rpm
High RPM set 2500 ±50 rpm
Low RPM set 1200 ± 50 rpm

Coolant Capacity (Engine Only) 0.92 Gallon (3.5 L)
1.4 SPECIFICATIONS AND PERFORMANCE DATA
1.4.1 Reach Specifications

Maximum Work Load (Capacity)
Unrestricted 500 lb (227 kg)
Restricted 1000 lb (450 kg)
Max.Vertical Platform Height (Unrestricted)

1200SJP 120 ft. (36.6 m)
1350SJP 135 ft. (41.15 m)
Max.Vertical Platform Height (Restricted)
1200SJP 115 ft. 8 in. (35.26 m)
1350SJP 125 ft. 10 in. (38.35 m)
Max.Horizontal Platform Reach (Unrestricted)
1200SJP 75 ft. (22.9 m)
1350SJP 80 ft. (24.4 m)
Max.Horizontal Platform Reach (Restricted)
1200SJP 65 ft. (19.8 m)
1350SJP 70 ft. (21.3 m)
1200SJP , 1350SJP 31220396 13

Specifications
Jib PLUS
Length 8 ft. (2.44 m)
Horizontal Motion 180° working, 244°

stowed
Vertical Motion 130° (+75/-55)
Maximum Operating Slope 5°
Maximum Travel Grade With boom in stowed position 45%
(Gradeability)
Maximum Travel Grade With boom in stowed position 5°

(Side Slope)
Turning Radius (Axles Retracted)
Outside 22 ft. 6 in. (6.8 m)

Inside 14 ft. 5 in. (4.4 m)
Turning Radius (Axles Extended)
Inside 8 ft. (2.4 m)

Max Tire Load
1200SJP 25,000 lb (11,340 kg)
1350SJP 26,250 lb (11,907 kg)
Max Ground Bearing Pressure

1200SJP 100 psi (7.03 kg/cm2)
1350SJP 105 psi (7.38 kg/cm2)
Maximum Drive Speed 3.25 mph (5.2 km/h)

Max. Hydraulic System Pressure 4600 psi (317 Bar)
Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 400 N
Electrical System Voltage 12 V
Gross Machine Weight (Platform Empty)
1200SJP 41,100 lb (18,643 kg)
1350SJP 44,750 lb (20,298 kg)
1.4.2 Dimensional Data

Overall Width
Axles Retracted 8 ft. 2 in. (2.49 m)
Axles Extended 12 ft. 6 in. (3.8 m)

Stowed Height 10 ft. (3.04 m)
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Specifications
Stowed Length (Transport Mode)

1200SJP 34 ft. 11 in. (10.64 m)
1350SJP 38 ft. 11 in. (11.86 m)
Stowed Length (Working Mode)
1200SJP 44 ft. 11 in. (13.69 m)
1350SJP 48 ft. 11 in. (14.91 m)
Wheelbase 12 ft. 6 in. (3.81 m)
Tailswing 5 ft. 6 in. (1.6 m)
Ground Clearance (Axle) 12 in. (30.4 cm)

Ground Clearance (Chassis) 25.5 in. (64.7 cm)
1.4.3 Chassis Specifications

Maximum Travel Grade With boom in stowed position (Gradeability) 45%
Maximum Travel Grade With boom in stowed position (Side Slope) 5°

Turning Radius (Axles Retracted)

Inside 14 ft. 5 in. (4.4 m)
Turning Radius (Axles Extended)
Inside 8 ft. (2.4 m)

Max Tire Load
1200SJP 25,000 lb (11,340 kg)
1350SJP 26,250 lb (11,907 kg)
Max Ground Bearing Pressure

1200SJP 100 psi (7.03 kg/cm 2)
1350SJP 105 psi (7.38 kg/cm 2)
Maximum Drive Speed 3.25 mph (5.2 kph)

Max. Hydraulic System Pressure 4600 psi (317 bar)
Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 400 N
Electrical System Voltage 12 V
Gross Machine Weight (Platform Empty)
1200SJP 41,100 lb (18,643 kg)

1350SJP 44,750 lb (20,298 kg)
1200SJP , 1350SJP 31220396 15

Specifications
1.5 TORQUE REQUIREMENTS
Description Torque Value (Dry) Interval Hours

180 ft. lbs.
Wheel Bolts 150
(244 Nm)
190 ft. lbs.
Swing Bearing Bolts 50/600*
(258 Nm)
Tele Cylinder 13 ft. lbs.
As required
Regen Valve Mounting Bolts (18 Nm)
Starter Solenoid
Contacts 95 in. lbs. (9.5 Nm) As required
Coil 40 in. lbs. (4 Nm)
*Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter. (Refer to Section — Swing Bearing, page 101 in Section 3.)
Note: When maintenance becomes necessary or a fastener has loosened, refer to Section — Torque Chart , page 33 to determine proper torque value.
1.6 HYDRAULIC OIL SPECIFICATIONS
Hydraulic System Operating Temperature Range S.A.E. Viscosity Grade
+0° to + 180° F 10W

(-18° to +83° C)
+0° to + 210° F 10W-20, 10W30
(-18° to +99° C)
+50° to + 210° F 20W-20
(+10° to +99° C)
Note: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile
hydraulic system service. JLG Industries recommends standard UTTO fluid which has an SAE viscosity index of 152.
Note: When temperatures remain consistently below 20 degrees F. (-7 degrees C.), JLG Industries recommends the use of premium hy-
draulic fluid.
Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same re-
quired additives or be of comparable viscosities.
Table 1. Standard UTTO Hydraulic Fluid Specs

Inspection Data Recommended SHELL SPIRAX S4 TXM Optional MOBILFLUID 424
ISO Viscosity Grade 68 68
Specific Gravity 0.882 0.880
Pour Point -43.6° F (-42° C) -45.4° F (-43° C)
Flash Point 428° F (220° C) 442.4° F (228° C)
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Specifications
Table 1. Standard UTTO Hydraulic Fluid Specs (continued)

Inspection Data Recommended SHELL SPIRAX S4 TXM Optional MOBILFLUID 424
Base Oil Type HV HV
Viscosity
Brookfield, at -20° C - 4300 cP

Brookfield, at -5° C - -
Viscosity at 40° C 66.93 cSt 60.21 cSt
Viscosity at 100° C 10.53 cSt 9.26 cSt
Viscosity Index 146 134
Table 2. Premium Hydraulic Fluid (VG 32) Specs

Inspection Data Recommended SHELL TELLUS S2 VX 32 Optional MOBIL DTE 10 EXCEL 32
Pour Point -38.2° F (-39° C) -65.2° F (-54° C)
Flash Point 419° F (215° C) 482° F (250° C)
Base Oil Type HV HV
Viscosity
Brookfield, at -30°C - 3360 cP

Brookfield, at -20°C 1090 cP
Brookfield, at -5°C - -
Viscosity at 40°C 33.01 cSt 32.76 cSt
Table 3. Fire Resistant Hydraulic Fluid (HP-5046D) Specs

Type Synthetic Biodegradable
ISO Viscosity Grade 46

Specific Gravity at 25° C 1.088
Pour Point, Max -81.4° F (-63° C)
Flash Point -
pH 9.0 - 10.0
Base Oil Type DIETHYLENE WATER-GLYCOL
Viscosity
Viscosity at -20° C -
Viscosity at 0° C 340 cSt
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Specifications
Table 3. Fire Resistant Hydraulic Fluid (HP-5046D) Specs (continued)

Viscosity Index 192
Table 4. Biodegradable Synthetic Hydraulic Fluid (VG 46) Specs

Inspection Data Recommended SHELL NATURELLE HF-E46 Optional MOBIL EAL ENVIROSYN H46
Pour Point -43.6° F (-42° C) -49° F (-45° C)
Flash Point 611.6° F (322° C) 500° F (260° C)
POLYOL ESTER FATTY ACID ESTER
Base Oil Type HEES -
HFDU -
Auto Ignition Temperature >752° F (>400° C) -
Biodegradability (% 28 Days) 76% >60%
Viscosity
Brookfield at -20°C - -
Brookfield at -5°C - -
Brookfield at 100°C 9.41 7.69
Table 5. Premium Hydraulic Fluid (All Weather) Specs

Inspection Data Recommended SHELL TELLUS S4 VX 32 Optional MOBIL UNIVIS HVI 26
UNSHEARED SHEARED UNSHEARED SHEARED
Specific Gravity 0.866 - 0.89 -
Pour Point -76° F (-60° C) -76° F (-60° C)

Flash Point >212° F (>100° C) >201.2° F (>94° C)
Base Oil Type HV HV
Viscosity
Brookfield at -40° C - - - -
Viscosity at 40° C 31.41 cSt 21.64 cSt 25.78 cSt 15.28 cSt
Relative Viscosity Loss* 31.1% 40.7%
Viscosity at 100°C 9.17 cSt 6.10 cSt 8.74 cSt 5.02 cSt
18 31220396 1200SJP , 1350SJP

Specifications
Table 5. Premium Hydraulic Fluid (All Weather) Specs (continued)

Inspection Data Recommended SHELL TELLUS S4 VX 32 Optional MOBIL UNIVIS HVI 26
Relative Viscosity Loss* 33.5% 42.6%
Viscosity Index 296 258 352 304
*Fluid is subjected to 20 hours in the CEC L-45-A-99 test to be mechanically degraded.
Table 6. Fluid Gear 80W-90

Inspection Data Recommended SPIRAX S4 AX 80W-90 Optional MOBILUBE GX 80W-90
Appearance — —
SAE Grade 80W-90 80W-90
Density @ 15°C, kg/L 0.887 0.89
Flash Point 424.4° F (218° C) 464° F (240° C)
Pour Point -16.6° F (-27° C) -27.4° F (-33° C)
Viscosity
Viscosity at 40° C 139 cSt 135 cSt

Viscosity at 100° C 14.8 cSt 14.5cSt
API Classification GL-4,GL-5 GL-4
1.7 MAJOR COMPONENT WEIGHTS
Component Pound Kilograms
Tire & Wheel (Foam Filled) 867 393

Tire & Wheel (Solid) 990 449
Drive Hub & Motor 275.5 123
Swing Drive 290 132
Engine Assembly 1275 579
1350 Boom (Complete) 11850 5375
1200 Boom (Complete) 11100 5035
Lift Cylinder 787 357
1350 Tele Cylinder 1322 600
1200 Tele Cylinder 1170 531
Jib Cylinder 69 31
Axle Oscillation Cylinder 74 34
Axle Extend Cylinder 92 42
Level Cylinder 89 40
Platform 36 x 96 245 111
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Specifications
Component Pound Kilograms
Platform 36 x 72 195 89
1350 Counterweight 8500 3856
1200 Counterweight 5494 2492
T/T Assy. (less Cwt) 9450 4286
1.8 PRESSURE SETTINGS
Circuit PSI Bar

Function Pump, High 3400 234.4
Function Pump, Low 300 20.6
Drive, Pre-Set 5000 344.7
Lift Up 2750 189.6
Lift Down 1500 103.4
Swing 1500 103.4
Tele Out 3000 206.8
Telescope In 3200 220.6
Steer Right 2000 137.9
Steer Left 2600 172.3
Platform Level Up 2500 172.3
Platform Level Down 1500 103.4
Jib Up 2750 189.6
Jib Down 2750 189.6
Extendable Axles 2500 172.3
1.9 ENGINE OIL SPECIFICATIONS
Table 7. Engine Diesel Fluid 15W-40 Specs

Inspection Data Recommended SHELL Optional MOBIL
ROTELLA T3 FLEET 15W-40 RIMULA R4 L 15W-40 (CE/ DELVAC 1300 SUPER 15W-40 DELVAC MX ESP 15W-40
(US) UKCA) (US) (CE/UKCA)
SAE Grade 15W-40
Viscosity, cST at 104°F (40°C) 115 109
Viscosity, cST at 212°F (100°C) 15.3 14 14.1
Total Base Number, mg KOH/g 10 9.4 9.8
Density at 59°F (15°C) kg/l 0.876 0.875 —
Ash, Sulfated, Mass% Low Ash 1 0.9 0.98
API Classification CK-4 CK-4 CJ-4
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Specifications
Table 7. Engine Diesel Fluid 15W-40 Specs (continued)

Inspection Data Recommended SHELL Optional MOBIL
ACEA Classification E9
Fluid Requirements
Deutz Specification DQC 111-10 LA DQC 11-10 LA
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Specifications
Figure 1. Lubrication and Maintenance Diagram
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Specifications
1.10 LUBRICATION AND MAINTENANCE
Note: The following numbers correspond to those in Figure — Lubrication and Maintenance Diagram, page 22.
Table 8. 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 lb minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.
NOTICE
Lubrication intervals are based on machine operation under normal conditions. For
machines used in multi-shift operations and/or exposed to hostile environments or
conditions, lubrication frequencies must be increased accordingly.
Note: It is recommended as a good practice to replace all filters at the same time.
1. Swing Bearing - Remote Lube
• Lube Point(s) - 2 Grease Fitting
• Capacity - A/R
• Lube - MPG
• Interval - Every 3 months or 150 hours of operation.
1200SJP , 1350SJP 31220396 23

Specifications
2. Swing Gearbox
• Lube Point(s) - Fill Plug
• Capacity - 79 ounces (2.3 L)
• Lube - GL-5
• Interval - Check level every 150 hrs/Change every 1200 hours of operation. Fill to cover ring gear.
3. Swing Brake
• Lube Point(s) - Fill Plug
• Capacity - 2.7 ounces (80 ml)
• Lube - DTE24
• Interval - Check level every 150 hrs/Change every 1200 hours of operation.
Note: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs.
24 31220396 1200SJP , 1350SJP

Specifications
4. A. Wheel Drive Hub - Rexroth
• Lube Point(s) - Level/Fill Plug
• Capacity - 0.5 L (1/2 full)
• Lube - EPGL
• Interval - Change after first 150 hours then every 1200 hours of operation
• Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position. Pour lubricant into fill port until it just
starts to flow out of check port.
B: Wheel Drive Hub - Reggiana Riduttori
• Lube Point(s) - Level/Fill Plug
• Capacity - 0.5 Quarts (0.5 L) ± 10%
• Lube - EPGL
• Interval - Change after first 150 hours then every 1200 hours of operation
• Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position. Pour lubricant into fill port until it just
starts to flow out of check port.
1200SJP , 1350SJP 31220396 25

Specifications
5. Hydraulic Return Filter
• Lube Point(s) - Replaceable Element
• Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator.
6. Hydraulic Charge Filter
• Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator.
7. Hydraulic Oil
• Lube Point(s) - Fill Cap
• Capacity - 55 Gallon (208 L) Tank
• Lube - HO
• Interval - Check level daily. Change every 2 years or 1200 hours of operation.
26 31220396 1200SJP , 1350SJP

Specifications
8. Suction Strainers (In Tank)
• Lube Point(s) - 2
• Interval - Every 2 years or 1200 hours of operation. Remove and clean at time of hydraulic oil change.
1200SJP , 1350SJP 31220396 27

Specifications
9. A. Oil Change w/Filter - Deutz TD2011L04
• Lube Point(s) - Fill Cap/Spin-on Element
• Capacity -
5 Quarts (4.5 L) Cooling System
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L) Total Capacity
• Lube - EO
• Interval - Check level daily; change every 500 hours or six months, whichever comes first. Adjust final oil level by mark on
dipstick.
B. Oil Change w/Filter - Deutz TCD2.9L4
• Lube Point(s) - Fill Cap/Spin-on Element
• Capacity - 2.4 Gallon (8.9 L)
• Lube - EO
• Interval - Check level daily; change every 500 hours or six months, whichever comes first. Adjust final oil level by mark on
dipstick.
28 31220396 1200SJP , 1350SJP

Specifications
Figure 2. Deutz Engine Dipstick
10. A. Fuel Filter - Deutz TD2011L04
• Interval - Every year or 600 hours of operation.
B. Fuel Filter - Deutz TCD2.9L4
1200SJP , 1350SJP 31220396 29

Specifications
11. Fuel Strainer - Deutz TD2011L04
12. Fuel Pre-Filter TCD2.9L4
• Interval - Drain water daily; Change every year or 600 hours of operation.
13. Radiator Coolant TCD2.9L4
• Lube Point(s) - Fill Cap
• Capacity - 3.2 Gallon (12.1 L)
• Lube - Anti-Freeze
• Interval - Check level daily; change every 1000 hours or 2 years, whichever comes first.
30 31220396 1200SJP , 1350SJP

Specifications
14. A. Air Filter - Deutz TD2011L04
• Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator.
B. Air Filter - Deutz TCD2.9L4
• Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator
• Comments - Check Dust Valve daily.
15. Platform Filter
• Interval - Change after first 50 hours and then every year or 600 hours of operation thereafter.
1200SJP , 1350SJP 31220396 31

Specifications
16. Optional Fuel Filter/Water Separator
• Interval - Drain water daily; Change every year or 600 hours of operation.
1.11 THREADLOCKING COMPOUND
JLG PN Loctite® ND Industries Description
0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue)
1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue)
0100019 271™ Vibra-TITE™140 High Strength (Red)
0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red)
Note: Loctite®243™can be substituted in place of Loctite® 242™. Vibra-TITE™122 can be substituted in place of Vibra-TITE™ 121.
32 31220396 1200SJP , 1350SJP

Specifications
1.12 TORQUE CHARTS
1.12.1 SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Tensile Torque (Loctite® Torque (Loctite®
Clamp Torque (Dry) Torque Lubricated 242™ or 271™ or Vi- 262™ or Vibra-TITE™
Size TPI Bolt Dia Stress
Load bra-TITE™ 111 or 140) 111)
Area
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
5000059K

Area
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
1200SJP , 1350SJP 31220396 33

Specifications

Area
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
5000059K
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
34 31220396 1200SJP , 1350SJP

Specifications
SAE Fastener Torque Chart (Continued)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque (Loctite® 242™ or
Tensile Torque(Dry or Loctite® Torque(Loctite® 262™ or
Size TPI Bolt Dia Clamp Load 271™ or Vibra-TITE™ 111
Stress Area 263) K=0.20 Vibra-TITE™ 131) K=0.15
or 140) K=0.18
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
5000059K

or 140) K=0.18
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1200SJP , 1350SJP 31220396 35

Specifications

or 140) K=0.18

1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
5000059K

36 31220396 1200SJP , 1350SJP

Specifications
Values for Magni Coating Fasteners (Ref 4150701)

Torque (Loctite® 242™ or Torque(Loctite® 262™ or
Tensile Clamp Load Torque (Dry) K=0.17
Size TPI Bolt Dia 271™ or 111 or 140) K= Vibra-TITE™ 131) K=0.15
Stress Area
0.16
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
5000059K

Stress Area
0.16
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1200SJP , 1350SJP 31220396 37

Specifications

Stress Area
0.16
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
5000059K

38 31220396 1200SJP , 1350SJP

Specifications
Torque(Dry or Loctite® Torque (Loctite® 242™ or Torque or Vibra-TITE™

Tensile Clamp Load
Size TPI Bolt Dia 263) K=0.17 271™ or 111 or 140) K= 131) K=0.15
Stress Area
0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5000059K


Tensile Clamp Load
Stress Area
0.16
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1200SJP , 1350SJP 31220396 39

Specifications


Tensile Clamp Load
Stress Area
0.16
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
5000059K

40 31220396 1200SJP , 1350SJP

Specifications

SOCKET HEAD CAPSCREWS
Tensile Clamp Load Torque (Dry or Loctite® 271™ orVibra-TITE™ 111 Torque(Loctite® 262™ or
Size TPI Bolt Dia 263) K=0.17 Vibra-TITE™ 131) K=0.15
Stress Area See Note 4 or 140) or Precoat® 85 K=
0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5000059K

0.16
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
1200SJP , 1350SJP 31220396 41

Specifications

0.16
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
5000059K

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
42 31220396 1200SJP , 1350SJP

Specifications
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

Size TPI Bolt Dia 271™ or 111 or 140) or Vibra-TITE™ 131) K=0.15
Stress Area See Note 4
Precoat® 85 K=0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5000059K

Precoat® 85 K=0.16
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1200SJP , 1350SJP 31220396 43

Specifications

Precoat® 85 K=0.16
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
5000059K

44 31220396 1200SJP , 1350SJP

Specifications
1.12.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque (Loctite®
Torque (Loctite®
Tensile Stress Clamp Load See Torque (Dry or 242™ or 271™ or
Size Pitch Torque (Lube) 262™ or 271™ or
Area Note 4 Loctite® 263™) Vibra-TITE™ 111
Vibra-TITE™ 131)
or 141)
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
5000059K

1200SJP , 1350SJP 31220396 45

Specifications
Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5*
Torque (Lube or
Torque (Loctite®
Clamp Load See Torque (Dry or Loc- Loctite® 242™ or
Size Pitch Tensile Stress Area 262™ or Vibra-TITE™
Note 4 tite® 263™) K=0.20 271™ or Vibra-TITE™
131) K=0.15
111 or 140) K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
5000059K

46 31220396 1200SJP , 1350SJP

Specifications
Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

Torque or 271™
(Lube or Loctite® Torque (Loctite®
Clamp Load See Torque (Dry or Loc-
Size Pitch Tensile Stress Area 242™ or 271™ or Vi- 262™ Vibra-TITE™
Note 4 tite® 263™) K=0.17
bra-TITE™ 111 or or 131) K=0.15
140) K=0.16
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070
5000059K

1200SJP , 1350SJP 31220396 47

Specifications
Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE*
Torque (Lube or
Torque (Loctite®
Clamp Load See Torque (Dry or Loc- Loctite® 242™ or
Size Pitch Tensile Stress Area 262™ or Vibra-TITE™
Note 4 tite® 263™) K=0.17 271™ or Vibra-TITE™
131) K=0.15
111 or 140) K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
5000059K

48 31220396 1200SJP , 1350SJP

SECTION 2
GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
2.1.1 General
This section provides the necessary information needed by those personnel that are responsible to place the machine in operation
readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary
inspections and maintenance have been completed before placing the machine into service. With proper care, maintenance, and
inspections performed per JLG's recommendations, and with any and all discrepancies corrected, this product will be fit for continued
use.
2.1.2 Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table
outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or
local regulations for further requirements for Mobile Elevating Work Platform. The frequency of inspections and maintenance must be
increased as environment, severity and frequency of usage requires.
2.1.3 Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use daily or at each change
of operator. Reference the Operation and Safety Manual for completion procedures for the Pre-Start Inspection. The Operation and
Safety Manual must be read in its entirety and understood prior to performing the Pre-Start Inspection.
2.1.4 Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc.
recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive
knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject
JLG product model.
The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-
Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for
each machine in service for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items
requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and
maintenance procedures.
2.1.5 Annual Machine Inspection

The Annual Machine Inspection must be performed on an annual basis, no later than thirteen (13) months from the date of the prior
Annual Machine Inspection. JLG Industries recommends this task be performed by a Factory-Trained Service Technician. JLG Industries,
Inc. recognizes a Factory-Trained Service Technician as a person who has successfully completed the JLG Service Training School for the
subject JLG product model. Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for
performance of this inspection.
Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring
inspection during the performance of this inspection. Reference the appropriate areas of this manual for servicing and maintenance
procedures.
For the purpose of receiving safety-related bulletins, it is important that JLG Industries, Inc. has updated ownership information for each
machine. When performing each Annual Machine Inspection, notify JLG Industries, Inc. of the current machine ownership.
1200SJP , 1350SJP 31220396 49

General
2.1.6 Preventative Maintenance

In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries,
Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive
knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject
JLG product model.
Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures.
The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.
Table 9. Inspection and Maintenance

Type Frequency Primary Responsibility Service Qualification Reference
Prior to use each day; or At each
Pre-Start Inspection User or Operator User or Operator Operation and Safety Manual
Operator change.
Prior to each sale, lease, or rent- Service and Maintenance Manual

Pre-Delivery Inspection Owner, Dealer, or User Qualified JLG Mechanic and applicable JLG inspection
al delivery.
form.
In service for 3 months or 150
hours, whichever comes first; or Service and Maintenance Manual
Frequent Inspection Owner, Dealer, or User Qualified JLG Mechanic and applicable JLG inspection
Out of service for a period of
more than 3 months; or pur- form.
chased used.
Annually, no later than 13 Service and Maintenance Manual
Factory Trained Service Techni-
Annual Machine Inspection months from the date of the Owner, Dealer, or User and applicable JLG inspection
cian (Recommended)
prior inspection. form.
At intervals as specified in the
Owner, Dealer, or User Service and Maintenance
Preventive Maintenance Service and Maintenance Qualified JLG Mechanic
Manual
Manual.
2.2 SERVICE AND GUIDELINES
2.2.1 General
The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this
book.
2.2.2 Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of
weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable
position. When raising a portion of the equipment, ensure that adequate support is provided.
2.2.3 Cleanliness
1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital
components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel,
and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.
2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As
soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.
3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all
parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until
they are ready to be used.
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2.2.4 Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be
parallel to each other and as near perpendicular as possible to top of part being lifted.
2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket
lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.
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.
2.2.5 Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or
assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any
adjustments, other than those recommended, without obtaining proper approval.
2.2.6 Pressure-Fit Parts

When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface.
2.2.7 Bearings
1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to
drip dry. Compressed air can be used but do not spin the bearing.
2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.
3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new
bearings until they are ready to install.
4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to
the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.
2.2.8 Gaskets
Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket
material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious
system damage.
2.2.9 Bolt Usage and Torque Application
NOTICE
Self locking fasteners, such as nylon insert and thread deforming locknuts, are not
intended to be reinstalled after removal.
1. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too
short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the
same specifications of the original, or one which is equivalent.
2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs,
and steel nuts, in accordance with recommended shop practices. Refer to Section — Torque Chart, page 33 in Section 1.
2.2.10 Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit.
This will assure that they are correctly reinstalled.
2.2.11 Hydraulic System

1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.
1200SJP , 1350SJP 31220396 51

General
2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate
components, as required, to aid assembly.
2.2.12 Lubrication
Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals.
When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications
listed.
2.2.13 Battery
Clean battery, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry
battery and coat terminals with an anti corrosion compound.
2.2.14 Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Section — Lubrication Specifications, page 23 in Section
1.
2.3 LUBRICATION AND INFORMATION
2.3.1 Hydraulic System

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e. g., using
inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing
maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction)
lines.
2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of
dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation.
Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be
checked, cleaned, and/or replaced as necessary, at the specified intervals required in the Section — Lubrication Specifications, page
23 in Section 1. Always examine filters for evidence of metal particles.
3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition
occurs, the system must be drained, flushed, and refilled with clean oil.
4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable
viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are
recommended for use.
Note: Metal particles may appear in the oil or filters of new machines due to the wear-in of meshing components.
2.3.2 Hydraulic Oil

1. Refer to Section — Hydraulic Oil Specifications , page 16 for recommendations for viscosity ranges.
2. JLG recommends Standard UTTO Fluid, which has an SAE viscosity of 10W-30 and a viscosity index of 152.
Note: Start-up of hydraulic system with oil temperatures below -15° F (-26° C) is not recommended. If it is necessary to start the system
in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of
-15° F (-26° C).
3. The only exception to the above is to drain and fill the system with premium hydraulic fluid oil or its equivalent. This will allow
start up at temperatures down to -20° F (-29° C). However, use of this oil will give poor performance at temperatures above 120° F
(49° C). Systems using premium hydraulic fluid should not be operated at temperatures above 200° F (94° C) under any condition.
2.3.3 Changing Hydraulic Oil

1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless specified otherwise) thereafter. If
it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to
obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent.
Avoid mixing petroleum and synthetic base oils.
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General
2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to
clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge
any time the system oil is changed.
3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic
components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.
2.3.4 Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multipurpose greases
usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of
greases in maintenance stock, consult your local supplier for evaluation. Refer to Section — Lubrication Specifications, page 23 for an
explanation of the lubricant key designations appearing in the Lubrication Chart.
2.4 CYLINDER DRIFT
2.4.1 Theory
When a hydraulic cylinder is supporting a load, cylinder drift may occur as a result of any of the circumstances below:
• Normal leakage of load holding valves or malfunction of load holding valves. Refer to Section — Cylinder Leakage Test, page 53 and
Table — Cylinder Drift, page 53 below for evaluation.
• Damaged or worn piston seals.
• Normal thermal expansion or contraction of the hydraulic oil within cylinders (Refer to Section — Cylinder Thermal Drift, page 54
below).
The first two circumstances may result in cylinder movement due to oil leaking out of the cylinder externally or by leaking back to tank
or due to oil leaking internally from one cylinder chamber to the other.
Thermal expansion or contraction of oil in hydraulic cylinders is a normal occurrence and does not result in oil leaking out of the cylinder
or leaking internally from one cylinder chamber to the other. Thermal expansion or contraction is the tendency for materials to change
size in response to a change in temperature.
2.4.2 Cylinder Leakage Test

Cylinder oil must be at stabilized ambient temperature before beginning this test.
Measure drift at cylinder rod with a calibrated dial indicator.
In an area free of obstructions, cylinder must have load applied and appropriately positioned to detect drift.
Cylinder leakage is acceptable if it passes this test.
Table 10. Cylinder Drift

Cylinder Bore Diameter Max. Acceptable Drift in 10 Minutes
inches mm inches mm
3 76.2 0.026 0.66
3.5 89 0.019 0.48
4 101.6 0.015 0.38
5 127 0.009 0.22
6 152.4 0.006 0.15
7 177.8 0.005 0.13
8 203.2 0.004 0.10
9 228.6 0.003 0.08
Note: This information is based on 6 drops per minute cylinder leakage.
1200SJP , 1350SJP 31220396 53

General
2.4.3 Cylinder Thermal Drift

The oil in all hydraulic cylinders will expand or contract due to thermal effects over time and may result in changes to the boom and/or
platform position while the machine is stationary. These effects occur as the cylinder oil changes temperature, usually from a higher oil
temperature as it cools and approaches the ambient air temperature. Results of these effects are related to several factors including
cylinder length and change in temperature over the time the cylinder remains stationary.
2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES
Filament wound bearings.
1. Pinned joints should be disassembled and inspected if the following occurs:

a. Excessive sloppiness in joints.
b. Noise originating from the joint during operation.
2. Filament wound bearings should be replaced if any of the following is observed:

a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their housing.
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 surface.
c. Rusting of the pin in the bearing area.
4. Re-assembly of pinned joints using filament wound bearings.

a. Housing should be blown out to remove all dirt and debris bearings and bearing housings must be free of all contamination.
b. Bearing / pins should be cleaned with a solvent to remove all grease and oil filament wound bearing are a dry joint and
should not be lubricated unless otherwise instructed (i.e. sheave pins).
c. Pins should be inspected to ensure it is free of burrs, nicks, and scratches which would damage the bearing during installation
and operation.
2.6 WELDING ON JLG EQUIPMENT
Note: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on an external
structure, or component.
2.6.1 DO the Following When Welding on JLG Equipment

• Disconnect the battery.
• Disconnect the moment pin connection (where fitted).
• Ground only to structure being welded.
2.6.2 DO NOT Do the Following When Welding on JLG Equipment

• Ground on frame and weld on any other area than the chassis.
• Ground on turntable and weld on any other area than the turntable.
• Ground on the platform/support and weld on any other area than the platform/support.
• Ground on a specific boom section and weld on any other area than that specific boom section.
54 31220396 1200SJP , 1350SJP

General
• Allow pins, wear pads, wire ropes, bearings, gearing, seals, valves, electrical wiring, or hoses to be between the grounding position
and the welded area.
NOTICE
Failure to comply with the above requirements may result in component damage (i.
e. Electronic modules, swing bearing, collector ring, boom wire ropes etc.)
Table 11. Inspection and Preventive Maintenance Schedule

INTERVAL
AREA Pre-Delivery 1 or
Fre- Annual 3 (Yearly)
quent 2 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
Platform Assembly
Platform 1,2 1,2

Railing 1,2 1,2
Gate 1,5 1,5
Floor 1,2 1,2
Rotator 9,5,15 9,5,15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly
Swing Bearing or Worm Gear 1,2,14 1,2,3,13,14

Oil Coupling 9,11,23 9,11,23
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 1,16,17,18 1,16,17,18
Wheel Nuts/Bolts 1,15 1,15
Wheel Bearings 14,24 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8 5,8
1200SJP , 1350SJP 31220396 55

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Table 11. Inspection and Preventive Maintenance Schedule (continued)

INTERVAL
AREA Pre-Delivery 1 or Fre- Annual 3 (Yearly)
Outrigger or Extendable Axle Systems 5,8 5,8
Steer Components 1,2,3,4,16 1,2,3,4,16
Drive Motors 1,2,5,6,7,9,23 1,2,5,6,7,9,23
Drive Hubs 11 11
Functions/Controls
Platform Controls 5,6 5,6
Ground Controls 5,6 5,6
Function Control Locks, Guards, or Detents 1,5 1,5
Footswitch 1,5 1,5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems 5 5
Capacity Indicator 5 5
Drive Brakes 5 5
Swing Brakes 5 5
Boom Synchronization/Sequencing Systems 5 5
Manual Descent or Auxiliary Power 5 5
Power System
Engine Idle, Throttle, and RPM 3 3

Engine Fluids (Oil, Coolant, Fuel) 9,11 9,11
Air/Fuel Filter 1,7 1,7
Exhaust System 1,9 1,9
Batteries 1,5,9 1,5,9
Battery Fluid 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 1,2,5,9,11 1,2,5,9,11
Hydraulic/Electric System
Hydraulic Pumps 1,2,9 1,2,9

Hydraulic Cylinders 1,2,7,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,2,9 1,2
Hydraulic Hoses, Lines, and Fittings 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1,2,5,9,11 1,5
Hydraulic Filter 1,7,9 7
56 31220396 1200SJP , 1350SJP

General

INTERVAL
Hydraulic Fluid 7,11 7,11
Electrical Connections 1,20 20
Instruments, Gauges, Switches, Lights, Horn 1 1,5,23
General
Operators and Safety Manuals in Storage Box 21 21
ANSI Manual of Responsibilities and AEM Safety Manual in Storage Box (ANSI only) 21 21
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
Walk-Around Inspection Performed 21 21
Annual Machine Inspection Due 21 21
No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4

All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21,22
Paint and Appearance 7 7
Stamp Inspection Date on Frame - 22
Notify JLG of Machine Ownership - 22
Footnotes:
1 Prior to each sale, lease, or delivery
2 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
3 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds

5 - Operates Properly
6 - Returns to neutral or "off " position when released
7 - Clean and free of debris

8 - Interlocks function properly
9 - Check for signs of leakage
1200SJP , 1350SJP 31220396 57

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INTERVAL
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
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
Figure 3. Engine Operating Temperature Specifications - Deutz
58 31220396 1200SJP , 1350SJP

General
Figure 4. Hydraulic Operating Temperature Specifications
1200SJP , 1350SJP 31220396 59

60
SECTION 3
CHASSIS AND TURNTABLE
3.1 TIRES AND WHEELS
For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be
taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly.
• a smooth, even cut through the cord plies which exceeds 3 in. (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies which exceeds 1 in. (2.5 cm) in any direction
• any punctures which exceed 1 inch in diameter
• any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to insure the damage hasn’t
propagated beyond the allowable criteria.
3.1.1 Wheel and Tire Replacement

The rims installed on each product model have been designed 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 written factory
recommendations, may result in an unsafe condition regarding stability.
3.1.2 Wheel Installation

It is extremely important to apply and maintain proper wheel mounting torque.
WARNING
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 fasteners. 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-tightening will result in breaking the studs or permanently deforming the mounting stud holes in the
wheels.
The proper procedure for attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.
1200SJP , 1350SJP 31220396 61

Chassis and Turntable
2. Tighten nuts in the following sequence:
3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart.
Table 12. Wheel Torque Chart

TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
45 ft. lbs. (61 Nm) 100 ft. lbs. (136 Nm) 180 ft. lbs. (244 Nm)
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.
3.2 EXTENDING AXLES
The Axle Extension System allows each of the four axles to be extended and retracted together while maintaining full steering control as
the machine is driven. The system allows the axles to extend or retract only while the boom is in the transport position and in order to
minimize wheel scrubbing during axle movement, a minimum drive speed must be attained before axle extension/retraction will be
permitted. The system uses four limit switches (one at each axle) to sense when the axles are fully extended. If any of the switches are
not made, the control system considers the axles retracted. To extend/retract the axles, the user engages the axle extend/retract switch
on the platform console and the drive control at the same time. The axle set indicator will be off when the axles are not fully extended
and the axle extend/retract switch is not engaged. It will flash while the axles are extending or retracting and will be on constantly when
the axles are fully extended. With the axles not fully extended, the boom is restricted to operation within the transport position. If a
signal from any axle extend sensing switch is lost when the boom beyond the transport position, the axle set indicator will flash and
drive/steer functions will be disabled until the boom is brought back into the transport position. The steering angle will be automatically
limited to +/- 25 degrees anytime the axles are not fully extended. If the wheel angle is more than +/- 25 degrees when the axle retract
command is engaged, the control system will automatically reduce the wheel angle to 25 degrees during axle retraction.
Note: For more detailed information concerning system adjustment and operation, refer to Section - JLG Control System, page 561.
3.3 AXLE LIMIT SWITCH ADJUSTMENT PROCEDURE
1. Fully extend the axles.
2. Initially position the limit switch arm straight.
3. Select the mounting plate bolt pattern to position the switch roller within 0.125 inches (3.1 mm) from the edge of the axle cutout.
It may be necessary to reposition the switch arm ±10° to accomplish this.
4. Ensure the arm will clear the axle (without bottoming out to 70° stroke of the switch) in the retracted position.
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5. Check for proper operation. Axle set light is to deactivate when the axle is retracted 0.625 inches (16 mm) maximum from fully
extended.
Figure 5. Axle Limit Switch Adjustment
3.4 DRIVE SYSTEM
The drive system utilizes 2 traction pumps so each side is powered individually. This produces maximum tractive effort to wheels by
minimizing flow divider losses. The maximum drive speed is modulated with the steered angle of the wheels to eliminate the whiplash
effect of driving at full speed and maximum steering lock.
3.5 STEERING CONTROL SYSTEM
Each wheel is individually steered by means of a closed circuit control system utilizing a steer sensor on each wheel, 4 steer cylinders,
and proportional valves.
The control system senses the wheel position in relation to the steering command (direction and steering mode) and automatically
synchronizes the movement of all 4 wheels to the desired position.
There are three different modes of steering selectable by the position of the steer select switch on the platform control panel:
conventional two wheel steering, crab and coordinated. These are shown below.
Figure 6. Conventional Two Wheel Steer Mode
1200SJP , 1350SJP 31220396 63

Figure 7. Crab Steer Mode
Figure 8. Coordinated Steer Mode

Each wheel has its own steer cylinder, wheel angle sensor, and proportional valve, allowing the control system to position each wheel to
the ideal angle for all steering modes and all steering commands. Changes in steering modes while the footswitch is depressed 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 +/- 25 degrees anytime
the axles are not fully extended. If a wheel cannot achieve its commanded angle within a specified time, it is considered jammed. When
a wheel is considered jammed during steering, a fault is reported and the remaining wheels will continue to their commanded position.
The fault is cleared when the footswitch is cycled. If a wheel is jammed making it significantly out of position, with regard to the other
wheels, the drive motors are restricted to their maximum displacement (slow speed). Wheel angle sensor failures will result in an
approximated steering control logic that will allow the operator to move the machine until it can be repaired. The wheel at the failed
sensor will be driven based on the information available from the other sensors. This wheel will not track perfectly and will become
farther out of position over time. When the wheel becomes prohibitively out of position, the wheels can be re synchronized by fully
steering against the mechanical stops.
3.6 DRIVE/STEERING SPEED CONTROL
The Drive/Steering Speed Control system uses the steering sensors from the steering control system to increase operator control and
comfort by reducing the effect of turning the chassis on the resulting lateral platform speed. The system proportionally varies the drive
speed based on the predicted turning radius of the chassis for both coordinated and conventional 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.
Note: For more detailed information concerning system adjustment and operation, refer to Section - JLG Control System, page 561
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3.7 TRACTION CONTROL SYSTEM
The traction control system uses the steering sensors from the steering control system to optimize the performance of the drive system.
This is especially important due to the disparity 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 path and therefore the required wheel
speed of each wheel as the steering angles change and steering modes change. The control system can then command the ideal flow
from each of the two drive pumps, one for the right side of the machine and one for he left side. Two flow dividers, one for the right side
front to back and one for the left side front to back absorb the variation in wheel speed front to back.
3.8 DRIVE ORIENTATION SYSTEM
The Drive Orientation System (DOS) is intended to indicate to the operator conditions that could make the direction of movement of the
chassis different than the direction of movement of the drive/steer control handle. The system indicates to the operator the need to
match the black and white directional arrows on the platform control panel to the arrows on the chassis. The system uses a proximity
switch mounted on the hydraulic swivel, an indicator light and an override switch on the platform display panel. The proximity switch
trips when the turntable is swung +/- 45 degrees off center of the normal driving position. This occurs roughly when the boom is swung
past a rear tire. When the turntable is in the normal drive position with the boom between the rear tires, no indications or interlocks are
made. When the machine is actively driving when the turntable is swung past the switch point, the system is ignored until drive/steer is
released. When drive is initiated with the boom swung past the switch point, the DOS indicator will flash and the drive/steer functions
will be disabled. The operator must engage the DOS override switch to enable Drive/steer (high drive will remain disabled). When the
DOS is enabled, the DOS indicator will be illuminated continuously and a 3-second enable timer will be started and will continue for 3
seconds after the end the last drive/steer command. If the timer expires, the DOS override switch must be re-engaged to enable drive/
steer.
1200SJP , 1350SJP 31220396 65

Figure 9. Chassis Component Location
1. Axle Limit Switch (Right Front) 9. Axle Limit Switch (Left Rear)
2. Steer Angle Sensor (Right Front) 10. Steer Angle Sensor (Left Rear)
3. Steer Valve (Front) 11. Chassis Module

4. Axle Lockout Valve 12. Swivel/Collector Ring
5. Traction Valve 13. Axle Lockout Pressure Switch

6. Steer Valve (Rear) 14. Steer Angle Sensor (Left Front)
7. Steer Angle Sensor (Right Rear) 15. Axle Limit Switch (Left Front)
8. Axle Limit Switch (Right Rear)
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Figure 10. Turntable and Boom Component Location
1200SJP , 1350SJP 31220396 67

Note: Refer to Figure — Turntable and Boom Component Location, page 67 for below table.
1. Platform Control Valve 23. Headlight

2. Jib Stow Switch 24. Deutz EMR2 Module
3. Platform Level Sensor (Secondary - Left) 25. 110V / 220V Generator
4. Tail Lights 26. Generator Control Box
5. Skypower Generator 27. Alternator
6. Alarm 28. Throttle Actuator

7. Main Control Valve 29. Oil Temperature Switch
8. Auxiliary Power Pump 30. Oil Pressure Switch
9. Auxiliary Power Relay 31. Intake Heaters
10. Chassis Power Distribution Relay 32. In Head Glow Plug
11. Headlight/Tail Light Relay 33. Engine Speed Sensor

12. Horn 34. Starter
13. Lift Cylinder Pivot Pin 35. Drive Pump (Right Side)
14. Fuel Level Sensor 36. Drive Pump (Left Side)
15. B.L.A.M. Module 37. Function Pump

16. Strobe Light 38. Starter Relay
17. Headlight 39. Glow Plug Relay
18. Ground Control Box 40. Swivel/Collector Ring
19. Boom Angle Sensor (Left) 41. Transport Limit Switch
20. Broken Cable Proximity Switch 42. Platform Level Sensor (Primary - Right)
21. Boom Length Sensor 43. Jib Position Switches
22. Boom Angle Sensor (Right)
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9
SEE DETAIL A
3 8
1
SEE DETAIL B
5
1001173913-I
MAF27141I
Figure 11. Axle Installation - Oscillating - Sheet 1 of 2
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3
ASSEMBLE TO SIDE PLATES

OF AXLE WELDMENTS
TYP 16 PLACES, 4 AXLES
DETAIL A
2
5 DETAIL B
1001173913-I
MAF27151I
Figure 12. Axle Installation - Oscillating - Sheet 2 of 2
1. Axle 4. Axle Pivot Pin 7. Hose Bundle Bracket

2. Hose Bundle Sleeve 5. Extension Cylinder 8. Axle Box Weldment
3. Axle Limit Switch 6. Axle Extend Stop Pin 9. Axle Lockout Cylinder
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2
SEE DETAIL A
1 3 6
SEE DETAIL B
5 AXLE AND AXLE BOX FRONT PLATES
1001173914-I
MAE35941I
Figure 13. Axle Installation - Fixed - Sheet 1 of 2
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3
2
DETAIL A
DETAIL B
5
1001173914-I
MAE35951I
Figure 14. Axle Installation - Fixed - Sheet 2 of 2
1. Axle 3. Axle Limit Switch 5. Extension Cylinder 7. Axle Extend Stop Pin
2. Hose Bundle Sleeve 4. Axle Attach Pin 6. Axle Box Weldment 8. Axle Stop Block
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Figure 15. Axle Threadlocking Compound Application
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Figure 16. Steering Installation
1. Spindle 3. Steer Cylinder 5. King Pin
2. Angle Sensor Assembly 4. Steer Cylinder Pivot Pin 6. Axle
3.9 OSCILLATING AXLE SYSTEM
The oscillating front axle is attached to the frame by a pivot pin, which allows all four wheels to remain on the ground when traveling on
rough terrain. The oscillating axle also incorporates two lockout cylinders connected between the frame and the axle. The lockout
cylinders permit axle oscillation when the boom is in the transport position and drive is commanded. The lockout cylinders will lock and
hold the axle when drive is not commanded or when the boom is outside the transport position. The cylinders unlock when pilot
pressure is applied to the holding valves mounted on the cylinders and lock when pilot pressure is removed. Pilot pressure is available
from brake pressure and is controlled by a solenoid operated NC lockout valve mounted in the frame. To ensure the lockout valve is
functioning correctly, a NO pressure switch is mounted between the lockout valve and the holding valves. The system is “healthy” when
pressure trips the pressure switch when the lockout valve is commanded to be open and conversely is healthy when the lack of pressure
resets the pressure switch when the lockout valve is commanded to be closed. Failures in the oscillating axle system will cause the
control system to disallow lift up and telescope out when the boom is within the transport position and will disallow drive/steer, lift up
and telescope out when the boom is beyond the transport position.
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3.10 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST
3.10.1 Lockout Cylinder Bleeding

To start the test, the axle must be fully oscillated in one direction. Start with oscillating the axle so that the left lock-out cylinder. is fully
retracted (left front tire up), and the right lock-out cylinder Is fully extended (right front tire down).
NOTICE
Ensure platform is fully lowered and boom is centered over rear axle prior to begin-
ning bleeding procedure. Making sure machine is on a level surface and rear wheels
are blocked, brake wire is disconnected.
1. Making sure machine is on a level surface and rear wheels are blocked, machine is in transport mode.
2. Disengage the drive hubs.
3. Use suitable container to catch any residual hydraulic fluid, place container under the lockout cylinder.
4. With the left lock-out cyl. retracted, open the bleeder on top of the cylinder, then have an operator from the platform (on high
engine) feather drive. Activate drive fully.
5. Close the bleeder when there is a steady stream of oil and not air.
6. With the axle in the same position, go to the right lockout cylinder and open the bleeder at the rod end. Activate drive in the same
manner and close when all air has been purged.
7. Close the bleeder when there is a steady stream of oil and not air.
8. Oscillate the axle the other direction, left lock-out cylinder extended (tire down), right lock-out cylinder retracted (tire up). Use the
same procedure for the bleeder in the rod end of the left lock-out cylinder, Then the piston end of the right lock-out cylinder then
close.
9. Repeat this process one more time to ensure that all air has been purged from the system.
10. Perform oscillating axle lockout test.
11. If necessary, repeat steps 1 thru 9.
Note: Bleeding of the oscillating axles is an infrequent operation performed after hydraulic line failure and or lock-out cylinder repair.
3.10.2 Oscillating Axle Lockout Test

The front axles will oscillate when the boom is in the transport position (i.e. when the boom is less than 15° above horizontal and not
extended beyond 12 in. [30.4 cm] on the 1350SJP or 24 in. [60.9 cm] on the 1200SJP) and drive is selected.
NOTICE
Lockout system test must be performed quarterly, any time a system component is
replaced, or when improper system operation is suspected.
Note: Ensure boom is fully retracted, lowered, and centered between drive wheels prior to beginning lockout cylinder test. The axles
must also be fully extended.
1. Place a 6 in. (15.2 cm) high block with ascension ramp in front of left front wheel.
2. From platform control station, activate machine hydraulic system.
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/ TORQUE SELECT control switches to their respective LOW positions.
1200SJP , 1350SJP 31220396 75

4. Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of
block.
5. Telescope the boom out of the transport position.
6. Drive machine off of block and ramp back onto the level surface.
7. Have an assistant check to see that left front wheel remains locked in position off of ground.
8. Retract the boom back in to the transport position. Activate drive and the lockout cylinders should release.
9. Place the 6 in. (15.2 cm) high block with ascension ramp in front of right front wheel.
10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block.
11. Telescope the boom out of the transport position
12. Drive machine off of block and ramp back onto the level surface.
13. Have an assistant check to see that right front wheel remains locked in position off of ground.
14. Retract the boom back in to the transport position. Activate drive and the lockout cylinders should release.
15. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.
3.11 WHEEL DRIVE ASSEMBLY
3.11.1 Removal
Note: The drive motor can be removed through the axle flange as part of the wheel drive assembly or they can be removed separately
through the bottom of the frame while leaving the torque hub bolted to the axle.
1. Use a jack to lift the frame enough so the tire and wheel assembly is off of the ground. Place blocking strong enough to support
the weight of the machine under the frame and remove the jack.
Note: The solid tire & wheel assembly weighs approximately 990 lb (449 kg). The foam-filled tire & wheel assembly weighs approxi-
mately 867 lb (393 kg).
2. Remove hardware securing wheel and remove wheel assembly.
3. Using suitable lifting device lift the wheel assembly and place in a suitable area.
3.11.2 Installation
1. Use a jack to lift the frame enough so the tire and wheel assembly is off of the ground. Place blocking strong enough to support
the weight of the machine under the frame and remove the jack.
2. Using adequate support, install wheel into wheel assembly and secure with bolts and washers.
Note: Torque the bolts to 180 ft. lbs. (244 Nm).
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Figure 17. Wheel Drive Removal and Installation
3.12 DRIVE HUB
3.12.1 Removal
1. Place machine on the firm level surface.
2. Disconnect the battery power and all electrical connections from the drive motor assembly.
3. Use suitable lifting device to support the drive hub.
Note: The drive hub weighs approximately 182.5 lb (82.5 kg).
4. Remove twelve bolts attached drive hub to the frame.
5. Remove the hub from machine and place in a clean work area.
3.12.2 Installation
1. Use suitable lifting device to support the drive hub.
Note: The drive hub weighs approximately 182.5 lb (82.5 kg).
2. Install the drive hub to the machine.
3. Use twelve bolts and attach the drive hub to the machine.
4. Install previously removed hydraulic hoses to drive motor.
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Figure 18. Drive Hub Removal and Installation
3.13 DRIVE MOTOR
3.13.1 Removal
1. Place machine on the firm level surface.
2. Disconnect the battery power and all electrical connections from the drive motor.
3. Use suitable lifting device to support the drive motor.
Note: The drive motor weighs approximately 34 lb (15.4 kg).
4. Remove two bolts attached drive motor to the drive hub.
5. Remove the motor from machine and place in a clean work area.
6. Clean the motor for dirt. Remove rust or corrosion from coupling shaft.
3.13.2 Installation
1. Use suitable lifting device to support the drive motor.
Note: The drive motor weighs approximately 34 lb (15.4 kg).
2. Install the drive motor to the drive hub.
CAUTION
Incorrect shaft alignment may result in damage to drive shaft, bearings, or seal
which can cause external oil leakage.
3. Make sure that the pump shaft is properly aligned.
4. Use the bolts and attach the drive motor to the machine.
5. Reconnect all electrical connections to the drive motor.
6. Start the machine and check the motor for proper functioning.
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Figure 19. Drive Motor Removal and Installation
1200SJP , 1350SJP 31220396 79

Figure 20. Drive Motor Assembly
1. Bolt 9. Snap ring 17. Cylinder Piston 25. Gasket 33. Snap ring
2. End cap motor 10. Spring Retainer 18. Piston Ring 26. Plug 34. Snap ring
3. Locating pin 11. Spring 19. O- ring 27. O-ring 35. Seal
4. O- ring 12. Washer 20. Piston 28. Plug 36. Washer
5. Plug 13. Cylinder block 21. Spring 29. O- ring

6. Dower pin 14. Slipper Pin 22. Pin 30. Housing
7. Needle Bearing 15. Guide 23. Swash Plate 31. Shaft
8. Valve Plate 16. Slip Retainer 24. Kit Bearing 32. Bearing
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3.14 DRIVE HUB - IF EQUIPPED WITH REGGIANA RIDUTTORI
3.14.1 Symbol Nomenclature
= ADHESIVE
= LUBRICANT
= GREASE
= TORQUE WRENCH
= DISPOSAL
3.14.2 Tools
Tools required for assembling and disassembling the wheel gear RRTD1701TB
1. Hammer;
2. Clamps for inner retention rings;
3. Clamps for outer retention rings;
4. Electric or pneumatic screwdriver;
5. Special spacer mounting;
6. Torque wrench;
7. Hydraulic press;
8. Wrench for M6, M8, M10 socket head screws and 1/4"G plug.
9. Socket wrench for M6 hexagonal screw.
1200SJP , 1350SJP 31220396 81

Figure 21. Bearing Track Spacer Mounting C016117
Figure 22. Oil Seal Spacer Mounting C125049
Figure 23. Bearing Spacer Mounting C016117
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Figure 24. Assembly Diagram 1
M- 1316
30
Ø 34
M- 1317
45°
45 °
8 M- 1317
R 45°
N° 4 45°
50
M- 1317
216.5
12
Ø230
20
M- 1316 10x45°
Ø 16
90
70
55
38
M- 1317
M- 1317
M- 1317
16 n° 8 Routing to 45°
Ø205
BM110101A
Figure 25. Wrench for Ring Nut
1200SJP , 1350SJP 31220396 83

M- 1125
Ø180
n° 12 Fori a 30° Ø35
Ø80
Ø20 H7 ( +0.021
) n °12 Hole to 30°
10.5
0
20
n° 12 Hole to 30° Ø6.5
32
n° 12 Spot-facing to 30° Ø10.5
T.U.15
6.5
n° 4 Hole to 90° M10
Ø50
Ø275
Ø305
30° 30 °
30
0
°
°
3 0°
3 0°
A A
BM110102A
Figure 26. Anti-rotation Flange
M- 1020
35 35
10
10 10
35
70
A A
35
50
70
Ø
10
Ø11
60
Ø17
11
BM110141A
Figure 27. Anti-rotation Block
M- 1126
Ø20
Ø12
T.U.9
30
50
M6
BM110142A
Figure 28. Anti-rotation Pin
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Figure 29. Assembly Diagram 2
1200SJP , 1350SJP 31220396 85

Figure 30. Tools for Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram
3.14.3 Disassembly
1. Remove the plugs and pour the lubricant in a container.
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2. Release the screws to disassemble the motor flange taking care not to damage the O-Ring.
3. Release the screws from the release cover and pull the pin out.
4. Remove the BR250 ring and pull the cover out avoiding to damage the O-Ring.
1200SJP , 1350SJP 31220396 87

5. Pull the reduction gears out.
Figure 31. Reggiana Riduttori Hub
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Note: Refer to Figure— Reggiana Riduttori Hub, page 88 for below table.
1. Screw 13. Iron Brake Disc 25. Tapered Roller Bearing 37. O-ring
2. Motor Support 14. Plastic Plug 26. Bearing Support 38. Crown Gear
3. O-ring 15. Spindle 27. Ring Nut 39. Crown Gear Screw
4. Inner Retention Ring 16. Planet Wheel 28. Sphere 40. O-ring
5. Brake Spring Spacer 17. Bearing 29. Screw 41. Support Table
6. Brake Spring 18. Outer Retention Ring 30. Pinion 42. O-ring
7. Brake Piston 19. Input Shaft 31. Reduction Gears 43. Cover
8. Parbak 20. Input Shaft Bearing 32. Outer Retention Ring 44. Steel Plug
9. O-ring 21. Ring 33. Pinion 45. Cover Retaining Ring

10. O-ring 22. Disengagement Spring 34. Reduction Gears 46. Disengagement Stud
11. Parbak 23. Disengagement Shaft 35. Outer Retention Ring 47. Disengagement Cap
12. Sintered Brake Disc 24. Spindle Oil Seal 36. Pinion 48. Disengagement Screw
6. Loosen the M10x25 flathead socket screws and remove the planetary ring without damaging the O-Ring.
7. Remove the release joint together with the spring.
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8. Disassemble the Ø40 outer snap rings and using an extractor remove the planetary gears from the spindle pins.
9. Loosen the M6x6 socket headless screws and also remove the 3/16" balls.
10. Loosen the ring nut using the special wrench.
11. Remove the hub support together with the roller bearing inner track.
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12. Disassemble the Ø160 inner snap ring and pull the spring holder spacer out. Remove the springs and using a compressed air jet in
the brake control hole pull the piston out of the spindle.
13. Remove the brake discs and seals.
14. Fit the ball bearing into the input shaft and lock it with a Ø40 outer snap ring. Then mount the motor shaft in the spindle and lock
with a BR68 ring. Lubricate the bearing.
3.14.4 Assembly
1. Make sure all the component parts of the wheel gear are devoid of burrs, machining residues and that they are correctly washed.
2. Fit the ball bearing in the input shaft and lock with a Ø40 outer snap ring.
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3. Mount the motor shaft in the spindle and lock with BR68 ring. Lubricate the bearing.
4. Fit the brake sealing rings O-Ring and PARBAK (lubricated with grease) in the respective spindle seats. Place the brake discs
making sure to centre them on the spindle and on the input shaft.
5. Insert the brake piston and place the springs into the piston holes. Close the brake fitting the spring holder plate, then lock with
the Ø160 inner snap ring. Check the brake leakage, if any, as well as the static torque and minimum opening pressure.
6. Prepare the hub support, mounting on it the two roller bearing outer tracks. Place the first roller bearing inner track.
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7. Fit the oil seal lubricated with grease onto the support with the special spacer mounting (Refer to figure A).
8. Place the hub support already assembled on the spindle making sure that the first roller bearing inner track goes correctly against
it; then fit the second roller bearing inner track by means of the spacer mounting. Tighten the ring nut.
9. Now check the unit roll torque and proceed in the following order:
10. 7.) By keeping the spindle locked, apply a setting preload by tightening the ring nut at 40daNm, turn completely the hub support
twice using the special wrench to recover any bearing cage misalignments. Release and tighten the ring nut at the final torque of
30daNm (alternate tightening and some setting turns). Check the roll torque with seal which must be within 1÷1,5 daNm.
Note: Place the ring nut with its convex part facing the roller bearing as shown below.
1200SJP , 1350SJP 31220396 93

11. Using the special tool and hammer make four dents on the spindle thread by the M6 holes of the ring nut.
12. Fit the 4 3/16" balls and tighten with Medium Strength Threadlocking Compound the 4 M6x6 socket headless screws at the torque
of 1daNm.
13. Fit the bearings onto the 3rd stage planetary gears and using a spacer mounting mount everything on the spindle pins. Lock with
a ÿ40 outer snap ring. Lubricate the bearings.
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14. Using a marking pen, make a mark between the snap ring and the bearing. Fit the greased spring and the release joint. Use grease
to fit the O-Ring 2-275 in the hub support seat.
15. Place the hub onto the support making the two holes coincide for tightening the M10x25 flathead socket screws at the torque of
5daNm.
16. Fit the reduction gears and the pinion in the unit.
17. Prepare the closing cover fitting the O-ring 5-582 suitably greased and lock it with the shimming ring. Lubricate the bearings.
1200SJP , 1350SJP 31220396 95

18. Fit the O-Ring 2-177 suitably greased, mount the cover locking it with the BR250 ring.
19. Fit the O-Ring 2-163 suitably greased, onto the motor coupling flange S-D LC/KC. Mount the flange on the spindle with 6 M8x25
socket capscrews at the torque of 2.4daNm with Medium Strength Threadlocking Compound Insert the pin and carry out the
rotation test according to PGQ-22 standard.
20. Mount the release cover fastening it with 2 M6x20 hexagonal screws at the torque of 1daNm. Mount the 1/4"GAS plugs on the
cover at the torque of 1daNm.
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Figure 32. Swing System
1. Swing Drive 3. Swing Bearing 5. Turntable Lock Pin

2. Inner Race Bearing Bolt 4. Outer Race Bearing Bolt 6. Remote Bearing Lubrication Fittings
1200SJP , 1350SJP 31220396 97

3.15 SWING DRIVE
Figure 33. Swing Motor
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Note: Refer to Figure — Swing Drive, page 98 for below table.
1. Shaft 11. Spacer 21. Pinion 31. Seal 41. O-Ring

2. Ring 12. O-Ring 22. Ring 32. O-Ring 42. Cover
3. Oil Seal 13. Planetory Gear 23. Spacer 33. Steel Disc 43. Screw
4. Bearing 14. Spacer 24. Spacer 34. Disc 44. O-Ring
5. Support 15. O-Ring Plug 25. Pinion 35. Disc 45. Motor
6. O-Ring Plug 16. Spring 26. Ring 36. Seal 46. Lung Lifting
7. O-Ring Plug 17. Capscrew 27. Washer 37. O-Ring 47. Capscrew
8. Nut Ring 18. O-Ring 28. Brake Housing 38. Piston Brake 48. Brake Valve Adapter
9. Reduction Gear 19. Planetory Ring 29. Plug 39. Spring Brake 49. Valve
10. Pinion 20. Reduction Gear 30. Capscrew 40. Shaft Input
3.16 SWING BRAKE
Note:
SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION.
3.17 SWING MOTOR
Note:
SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION.
3.18 PROCEDURE FOR SETTING GEAR BACKLASH
1. Set backlash to 0.010 to 0.015" using the following procedure.
2. Place shim (JLG PN 4071041) between pinion and bearing on bearing high spot. The bearing high spot should be stamped with an
“X” on the surface below the teeth and marked with yellow paint in the tooth space.
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3. Torque the shoulder screw (shown below) to 205 ft. lbs. (280 Nm) with High Strength Threadlocking Compound.
4. Remove turntable lock pin.
5. Pre-torque the capscrews (shown below) to 90 ft. lbs. (122 Nm) with High Strength Threadlocking Compound.
6. Tighten setscrew (shown below) until pinion is completely snug against shim and bearing, then back off the setscrew.
7. Torque setscrew to 50 ft. lbs. (68 Nm).
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8. Tighten jam nut (shown below) with High Strength Threadlocking Compound.
9. Torque capscrews shown in step 5 to 545 ft. lbs. (738.92 Nm).
10. Remove shim and discard.
3.19 SWING DRIVE LUBRICATION
Figure 34. Swing Drive Ports
1. Swing Gearbox/Brake Fill Port 2. Swing Gearbox/Brake Drain Port
The brake on swing drive uses same oil cavity as gearbox. Remove the swing gearbox/brake fill plug and fill the unit with 105 ounces
(3.1 L) of ISO VG 150 oil, until oil reaches halfway of the plug opening. Close the swing gearbox/brake fill port (1) immediately. Drain oil
through the swing gearbox/brake drain port (2).
3.20 SWING BEARING
3.20.1 Turntable Bearing Mounting Bolt Condition Check

Note: This check must be performed after first 50 hours of machine operation and every 600 hours of machine operation thereafter. If
during this check any bolts are found to be missing or loose, replace missing or loose bolts with new bolts and torque to the val-
ue specified in the torque chart, after lubricating the bolt threads with High Strength Threadlocking Compound. After replacing
and retorquing bolt or bolts recheck all existing bolts for looseness.
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1. Check the bolts attaching the swing bearing to the frame as follows, Refer to Figure — Swing Bearing Attaching Bolt Configuration,
page 102
Note: These bolts engage the swing bearing from underneath
a. Position boom as Boom Fully Retracted and Elevated. Refer to Figure — Swing Bearing Tolerance Measurement Location and
Boom Placement, page 105, Position 2.
b. Check the quadrant of bolts that are toward the turntable counterweight by inserting a 0.0015 in. (0.0381 mm) feeler gauge
between the bolts and hardened washers. Refer to Figure — Frame Side Bearing Bolt Feeler Gauge Check, page 103.
c. Ensure that the feeler gauge will not penetrate under the bolt head to the bolt shank.
d. Rotate the turntable 90 degrees, and check the next quadrant of bolts.
e. Continue rotating the turntable at 90 degree intervals until all bolts have been checked.
2. Check the bolts attaching the swing bearing to the turntable as follows, Refer to Figure — Swing Bearing Attaching Bolt
Configuration, page 102
a. Position boom as Boom Fully Retracted and Elevated. Refer to Figure — Swing Bearing Tolerance Measurement Location and
Boom Placement, page 105, Position 2.
b. Check the semi-circle of bolts that are toward the turntable counterweight by inserting a 0.0015 in. (0.0381 mm) feeler gauge
between the bolts and hardened washers. Refer to Figure — Turntable Side Bearing Bolt Feeler Gauge Check, page 103.
c. Ensure that the feeler gauge will not penetrate under the bolt head to the bolt shank.
d. Reposition boom as shown in Figure —Swing Bearing Tolerance Measurement Location and Boom Placement, page 105, Position
1.
e. Check the remaining semi-circle of bolts.
Figure 35. Swing Bearing Attaching Bolt Configuration
1. Turntable Side Bearing Bolt 4. Turntable Bearing Inner Race
2. Turntable Bearing Outer Race 5. Turntable

3. Frame Side Bearing Bolt 6. Frame
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Figure 36. Frame Side Bearing Bolt Feeler Gauge Check
7. Feeler Gauge, 0.0015 In. (0.0381 mm)
BM109394A
Figure 37. Turntable Side Bearing Bolt Feeler Gauge Check
8. Feeler Gauge, 0.0015 In. (0.0381 mm)
3.20.2 Wear Tolerance
NOTICE
The swing bearing is one of the most critical points on a mobile elevating work plat-
form. It is here that the stresses of lifting are concentrated, at the center of rotation.
Because of this, proper maintenance of the swing bearing is a must for safe
operation.
1. Position machine as shown in Figure — Swing Bearing Tolerance Measurement Location and Boom Placement, page 105, Position 1.
2. Set up a dial indicator as follows:

a. Dial indicator is to be located next to the swing bearing, in-line with the boom's centerline, opposite the turntable
counterweight. Refer to Figure — Dial Indicator Setup, page 104 and Figure — Dial Indicator Pointer Location, page 104.
b. Position the magnetic base of the dial indicator on the frame.
c. Position the indicator point to touch the underside of the turntable base plate 2.5 in. (64 mm) from root of gear tooth.
3. Zero the dial indicator.
4. Check dial indicator accuracy using a feeler gauge. Ensure dial indicator reading is same as thickness of feeler gauge.
5. Do not swing the turntable. Reposition boom as shown in Figure — Swing Bearing Tolerance Measurement Location and Boom
Placement, page 105, Position 2
6. Verify that the dial indicator has not shifted, & then record the indicator value for bearing play.
7. Return the boom to Position 1. The dial indicator should return to zero. If dial indicator does not return to zero, take corrective
action and repeat the test.
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8. If the measurement is more than 0.094 in. (2.4 mm), replace the bearing. If the measurement is less, and any of the following
conditions exist, the bearing should be removed, disassembled, and inspected:
a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation
9. If bearing inspection shows no defects, reassemble and return to service.
Figure 38. Dial Indicator Setup
2.5 in.
(64 mm)
BM109408A
Figure 39. Dial Indicator Pointer Location
9. Dial Indicator Point
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12
10
POSITION 2
10 11
BM109407A
POSITION 1
Figure 40. Swing Bearing Tolerance Measurement Location and Boom Placement
10. Dial Indicator Measuring Point
11. Boom Fully Extended Horizontal (Zero Degrees)
12. Boom Fully Retracted and Elevated
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3.20.3 Swing Bearing Removal

1. From Ground Control station, operate the boom adequately to provide access to frame opening to rotary coupling.
DANGER
Never work beneath the boom without first engaging boom safety prop or provid-
ing adequate overhead sling support and/or blocking.
2. Attach an adequate support sling to the boom and draw all slack from sling. Prop or block the boom if feasible.
NOTICE
Hydraulic lines and ports should be capped immediately after disconnecting lines
to avoid the entry of contaminants into the system.
3. Tag and disconnect the hydraulic lines from the fittings on the top of the rotary coupling. Use a suitable container to retain any
residual hydraulic fluid. Immediately cap lines and ports.
NOTICE
Hydraulic lines and ports should be capped immediately after disconnecting lines
to avoid the entry of contaminants into the system.
4. From inside turntable, remove mounting hardware which attach rotary coupling retaining yoke brackets to turntable.
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Figure 41. Swing Bearing Removal
5. At the rear of the main valve, remove the lift hose from port #4. Immediately cap the line and port.
6. Attach suitable overhead lifting equipment to the machine. Refer to Figure — Swing Bearing Removal, page 107.
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7. Use a suitable tool to scribe a line on the inner race of the swing bearing and on the underside of the turntable. This will aid in
aligning the bearing upon installation. Remove the bolts and washers which attach the turntable to the bearing inner race. Discard
the bolts.
8. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing. Ensure that no damage occurs to the
turntable, bearing or frame-mounted components.
9. Carefully place the turntable on a suitably supported trestle.
Note: The swing bearing weighs approximately 300 lb (136 kg).
10. Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame. This line will aid in aligning the bearing
upon installation. Remove the bolts and washers which attach the outer race of the bearing to the frame. Discard the bolts. Use
suitable lifting equipment to remove the bearing from the frame, then move the bearing to a clean, suitably supported work area.
3.20.4 Swing Bearing Installation

Note: The swing bearing weighs approximately 300 lb (136 kg).
1. Using suitable lifting equipment, carefully lower the swing bearing into position on the frame. Ensure the scribed line of the outer
race of the bearing aligns with the scribed line on the frame. If a new swing bearing is used, ensure that the spot with minimum
gear backlash (marked with yellow paint) is towards the centerline of the swing drive (as close as the bolt pattern will allow).
NOTICE
JLG industries recommends that all removed bearing bolts be discarded and re-
placed with new bolts. Since the swing bearing is the only structural link between
the frame and turntable, it is imperative that such replacement hardware meets JLG
specifications. Use of genuine JLG hardware is highly recommended.
2. Apply a light coating of High Strength Threadlocking Compound to the new bearing bolts, and loosely install the bolts and
washers through the frame and outer race of bearing.
NOTICE
If compressed air or electrically operated impact wrench is used for tightening the
bearing attachment bolts, the torque setting accuracy of the tool should be
checked prior to use.
3. Refer to the Torque Sequence diagram as shown in Figure — Swing Bearing Torque Sequence, page 109. Spray a light coat of Safety
Solvent 13 on the new bearing bolts. Then apply a light coating of High Strength Threadlocking Compound to the new bearing
bolts, and install the bolts and washers through the frame and outer race of the bearing. Tighten the bolts to an initial torque of
190 ft. lbs. (258 Nm) w/Threadlocking.
4. Remove the lifting equipment from the bearing.
5. Using suitable lifting equipment, carefully position the turntable assembly above the machine frame.
6. Carefully lower the turntable onto the swing bearing, ensuring that the scribed line of the inner race of the bearing aligns with
scribed line on the turntable. If a new swing bearing is used, ensure that the filler plug fitting is at 90 degrees from the fore and aft
center line of the turntable.
7. Spray a light coat of Safety Solvent 13 on the new bearing bolts. Then apply a light coating of High Strength Threadlocking
Compound to the new bearing bolts, and install the bolts and washers through the turntable and inner race of the bearing.
8. Following the Torque Sequence diagram shown in Figure — Swing Bearing Torque Sequence, page 109, tighten the bolts to a
torque of 190 ft. lbs. (258 Nm) w/Threadlocking.
9. Connect the hydraulic lines to the rotary coupling as tagged prior to removal.
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10. Install the rotary coupling retaining yoke brackets, apply a light coating of Medium Strength Threadlocking Compound to the
attaching bolts and secure the yoke to the turntable with the mounting hardware.
11. Connect the hydraulic line disconnected during removal back to port #4 on the back of the main hydraulic valve.
12. Remove the lifting equipment.
13. At ground control station, use boom lift control to lower boom to stowed position.
14. Using all applicable safety precautions, activate the hydraulic system and check the swing system for proper and safe operation.
3.20.5 Swing Bearing Torque Values

1. Outer Race - 190 ft. lbs. (258 Nm) w/Threadlocking.
2. Inner Race - 190 ft. lbs. (258 Nm) w/Threadlocking.
3. Refer to Swing Bearing Torquing Sequence.
WARNING
Check the inner and outer swing bearing bolts for missing or looseness after first 50
hours of operation, and every 600 hours thereafter.
Figure 42. Swing Bearing Torque Sequence
Note: Swing Bearing Torque Sequence is typical for both inner and outer races.
3.21 SWING SPEED PROPORTIONING
Swing Speed Proportioning uses the boom length and angle sensors to improve the comfort, speed and control of the turntable swing
function. Turntable swing speed is increased as the distance of the platform to the center of rotation is decreased. This results in
approximately constant platform speeds regardless of boom position. Swing speed proportioning is disabled with any envelope sensors
failure. Disabling of swing speed proportioning will default to the slowest swing speed setting.
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3.22 CHASSIS TILT INDICATOR SYSTEM
The Chassis Tilt Indicator System measures the turntable angle with respect to level ground. The tilt sensor (which is an integral part of
the ground module) has two settings; 5.0 and 8.0 degrees. The smaller angle is used for the purpose of warning the operator by means
of the chassis tilt light in the platform display panel. Additionally when used in conjunction with the 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. With the
exception of the speed cutback, this is a warning system only. The machine will continue to function. The operator is responsible to
prevent the machine from attaining an unstable position. The 8.0 degree angle is used exclusively for the purpose of automatically
shifting the drive motors to the maximum displacement position (slow speed). The control system responds to indicated angle readings
0.5 degrees smaller than the required angles to account for calibration and sensor variation.
3.23 ROTARY COUPLING
Use the following procedure to for installing the seal kit.
1. Remove snap ring (7) from end.
2. Remove thrust ring (3) from same end.
3. Remove center body (1) from housing (3).
4. Cut off old seals (2, 3, 5).
5. Assemble lip seals (2) in direction shown in Figure — Rotary Coupling Seal Installation, page 111.
6. Reassemble O-ring (4).
7. Heat cap seals (5) in hydraulic oil for 5 minutes at 300° F (149° C).
8. Assemble cap seals over O-rings.
9. Reinsert center body into housing (lube with hydraulic oil).
10. Replace thrust ring and snap ring.
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Figure 43. Rotary Coupling Seal Installation
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Figure 44. Rotary Coupling Cutaway
1. Center Body 3. Housing 5. Seal 7. Snap Ring
2. Seal 4. O-ring 6. Thrust Ring
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Figure 45. Rotary Coupling Installation
1. Medium Strength Threadlocking Compound 5. Rotary Coupling & Collector Ring Assembly 7. Not Used
2. Bolt 5A. Rotary Coupling 8. Flatwasher
3. Bolt 5B. Rotary Circuit Contactor 9. Nut
4. Swivel Bracket 6. Locknut
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Figure 46. Rotary Coupling Port Location
Table 13. Coupling Port Information Table

Operating Pressure PSI
Port No. Outlets Port Size Description Proof Pressure PSI (Bar)
(Bar)
1 2 -12 Steer/Axle Extend (Tank) 250 (17) 375 (26)
Steer/Axle Extend
2 2 -10 3000 (207) 4500 (310)
(Pressure)
3 1 -10 Drive A 3000 (207) 4500 (310)
4 1 -10 Drive B 3000 (207) 4500 (310)
5 1 -10 Drive A 3000 (207) 4500 (310)
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Table 13. Coupling Port Information Table (continued)

Operating Pressure PSI
Port No. Outlets Port Size Description Proof Pressure PSI (Bar)
(Bar)
6 1 -10 Drive B 3000 (207) 4500 (310)
7 2 -12 Case Drain 250 (17) 375 (26)
3.24 GENERATOR
3.24.1 Every 250 hours

Every 250 hours of operation, check the drive belt for proper tension.
3.24.2 Every 500 hours

Every 500 hours of operation, service the generator brushes and slip rings. Hostile environments may require more frequent service.
Every 500 hours of service, blow out the inside of the generator. If operating in a hostile environment, clean monthly.
3.24.3 Overload Protection
CAUTION
Stop the engine whenever checking or inspecting the circuit breaker.
The circuit breaker protects the generator windings from overload. If the circuit breaker opens, generator output stops. If the circuit
breaker continues to open, check for faulty equipment connected to the platform receptacles.
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3.24.4 Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings

Refer to Figure — Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings, page 117.
INSPECTING BRUSH POSITION
Inspect brush alignment with slip rings. View alignment through the air vents in the stator barrel. The brushes must ride completely on
the slip rings.
INSPECTING BRUSHES
Remove the end panel. Inspect the wires. Remove the brush holder assembly. Pull the brushes from the holders.
Replace the brushes if damaged, or if the brush is at or near minimum length.
CLEANING SLIP RINGS
Visually inspect the slip rings. Under normal use, the rings turn dark brown.
If the slip rings are corroded or their surface is uneven, remove the belt to turn the shaft by hand for cleaning.
Clean the rings with 220 grit emery paper. Remove as little material as possible. If the rings are deeply pitted and do not clean up,
consult generator factory service.
Reinstall the belt, brush holder assembly, and end panel.
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Figure 47. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
1. Brush Holder Assembly
2. Brushes
3. Slip Rings
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3.24.5 Generator Disassembly and Assembly

Refer to Figure — Generator Troubleshooting Circuit, page 119 Diagram to determine if trouble is in stator, rotor, control box, or
combination of these components.
1. Rotor
2. Stator Assembly
CAUTION
DO NOT damage rotor or stator windings during disassembly and assembly
procedure.
DISASSEMBLY
1. Mark and disconnect all electrical leads, secure using cable ties.
2. Remove brush holder assembly.
3. Disassemble generator parts shown in Figure — Generator Disassembly and Assembly, page 118.
4. Clean all parts with approved solvent and dry with compressed air, If applicable.
5. Inspect all part for damage. Replace if necessary.
Figure 48. Generator Disassembly and Assembly

ASSEMBLY
1. Assemble generator parts using torque values in table.
2. Reconnect all leads. Use cable ties to secure leads away from moving or hot parts.
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1200SJP , 1350SJP
Voltage Readings
a) Tolerance − ± 10% unless
Voltage readings taken with PLG31 Voltage readings taken with PLG4/RC4 connected.
connected to RC31 on PC1. Resistance readings taken with PLG4/RC4 disconnected.
b) Condition − 70 ° F (21 ° C); cold
1 ohm machine (no warm-up); no load
PLG31 Ridge denotes Pin 1 V9
Pin1 c) Power rpm (3600 at 60 Hz, 3000 at
V11 d) Reference − single arrow :

reference to circuit common
(lead 42); double arrow :
V10
Pin 7 Circuit Common referenceto points indicated
RC31
e) Wiring Diagram
V7
26 ohms
I1 = 1 amps DC (60 Hz) V1 Thru V6 Taken At Basket Receptacle
No greater than 3.5 amps V8 V1 X to Y − 240 volts A C ±10%
DC under load
V2 X to Z − 240 volts AC ±10%
See Section 8-4
V3 Y to Z − 240 volts AC ±10%
for PC1 data
I1
V4 X to G − 120 volts A C ±10%
V5 Y to G − 120 volts A C ±10%
V6 Z to G − 208 volts A C ±10%
V7 Rotor:
20 volts DC at no load ±20%
70 volts DC at full load ±10%
V8 Exciter:
138 volts AC at no load ±10%
155 volts AC at full load ±10%
I2 = 1 amps DC (60 Hz)
No greater than 3.5 amps V9 Voltage Feedback:
DC under load 240 volts A C ±10%
V10 Shutdown Signal:
I2 0 volts DC during normal oper a
V11 PWM Signal: 0 to +15 volts DC
1.5 volts DC normal no load
31220396
4.3 volts DC at full load
V12 Generator Enable:
Battery voltage when gener ator is
enabled (on)
0 volts DC when gener ator is not en-
SeeSection 8-6 abled (off )
for PC2 data V13 Batter y Voltage
RC1 * If 12 volts DC is present, check rotor

and if r ot or checks ok, replace con-
trol boar d PC1.
V12 SeeSection 8-3 for
Figure 49. Generator Troubleshooting Circuit Diagram

waveforms A,B Measure Output Voltages V1
Waveform A Thru V6 At Basket Receptacle
V13 Check Resistance atTE1

C to D,
C to E,
Test Equipmen t Needed: C to F,
Ridge denotes Pin 1 Pin 5 - Circuit Common
PLG1 E to F,
D to F
Voltage readings taken with All readings should be 1
PLG1 connected to RC1 on PC2. ohm. Check with lead 42 lift-
ed. Replace generator if
windings are shorted to case
or open.
MAF46940
119
MAF46950
Figure 50. Generator Electrical Circuit Diagram
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MAF46960
Figure 51. Power Board PC1 Electrical Circuit Diagram
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MAF46970
Figure 52. Power Board PC2 Electrical Circuit Diagram
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3.24.6 Lead Connection List

Note: Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Note: Apply small amount of dielectric grade, non-conductive electric grease to connectors where factory-applied grease had been
present.
Table 14. Lead Connection List for Generator

Leads Connections
1A STATOR TO CB1
2A STATOR TO CB1
3A STATOR TO CB1
4A STATOR TO TE1 (C)
5A STATOR TO RC4 (3)
5B PLG2 (C) TO PLG4 (3)
5C RC2 (C) PLG31 (8)
6A STATOR TO RC4 (4)
6B PLG2 (D) TO PLG4 (4)
6C RC2 (D) PLG31 (9)
9A RC5 (B) TO PLG3 (B) (Customer Supplied)
9B RC3 (B) PLG1 (8)
12A PLG2 (E) TO PLG4 (5)
12B RC2 (E) PLG1 (9)
12C RC4 (5) TO BRUSH
13A PLG2 (F) TO PLG4 (6)
13B RC2 (F) PLG31 (4)
13C RC4 (6) TO BRUSH
15A PLG1 (6) TO PLG31 (6)
16A PLG1 (3) TO PLG31 (1)
17A PLG1 (4) TO PLG31 (2)
21A CB1 TO TE1 (F)
21B PLG2 (A) TO PLG4 (1)
21C PLG1 (1) TO RC2 (A)
21D RC4 (1) TO CB1
22A CB1 TO TE1 (E)
22B PLG2 (B) TO PLG4 (2)
22C PLG1 (2) TO RC2 (B)
22D RC4 (2) TO CB1
23A CB1 TO TE1 (D)
42A RC5 (C) TO PLG3 (C) (Customer Supplied)
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Table 14. Lead Connection List for Generator (continued)

42B RC3 (C) TO CONNECTION POINT 1
42C PLG31 (7) TO CONNECTION POINT 1
42D PLG1 (5) TO CONNECTION POINT 1
42F END BELL SHROUD TO ENGINE MOUNT
42G CHASSIS TO TE1 (B)
43A RC5 (A) TO PLG3 (A) (Customer Supplied)
43B RC3 (A) TO CONNECTION POINT 2
43C PLG31 (3) TO CONNECTION POINT 2
43D PLG1 (7) TO CONNECTION POINT 2
3.25 AUXILIARY POWER SYSTEM
The auxiliary power system is intended as a secondary means of moving the boom in the event of primary power loss. This system uses
an electric motor/pump unit powered by a 12V battery capable of operating all functions except drive, controlled arc, controlled boom
angle, and envelope tracking. During lift up or down functions, no other functions are permitted and during lift up functions, automatic
platform leveling is not active. To reduce the demand on the battery and therefore extend the run time of the system, the auxiliary
power functionality differs from the primary power functionality. The auxiliary power lift down function supplies pilot pressure to the lift
cylinder allowing gravity to lower the boom. The system redirects discharge oil from the lift cylinder to retract the telescope cylinder.
When the boom is retracted to the transport length, the telescope in valve is dropped out and lift down is operated alone allowing the
platform to reach the ground. This not only greatly reduces the power required for these functions but also lowers the boom within the
envelope regardless of starting position. Envelope control and moment control remain active during the auxiliary power function.
Figure 53. Auxiliary Pump Installation
1. Auxiliary Pump 3. Battery
2. Power Relay
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Figure 54. Cold Weather Package
3.26 COLD WEATHER PACKAGE
As an option, a cold weather package is available to allow the machine to be operated in lower temperatures. The package consists of
battery heaters, a hydraulic tank heater, Exxon Univis hydraulic oil, and diesel fuel conditioner. Refer to Figure — Cold Weather Package,
page 125.
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3.27 DEUTZ TD2011L04 ENGINE
Figure 55. Detuz TD2011L04 Engine Installation
1. Fan 6. Hose, Oil Cooler 11. Oil Drain 16. Muffler Bracket
2. Shroud, Fan 7. Muffler 12. Lanyard 17. Motor Mount
3. Exhaust 8. Air Cleaner Assembly 13. Front Engine Mounting Plate 18. Generator Mount
4. Air Intake 9. Pump Assembly 14. Rear Engine Mounting Plate 19. Pump Coupling Kit
5. Heater 10. Cooler 15. Pulley 20. Engine Tray
Note: Refer to the engine manufacturer’s manual for detailed operating and maintenance instructions.
3.27.1 Glow Plugs

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

1. Switch the engine off before checking oil level.
2. Make sure the machine and engine are level.
3. Remove the oil dipstick.
4. Wipe the dipstick with non-fibrous, clean cloth.
5. Insert the dipstick to the stop and remove again.
Check the oil level, and if necessary, top the oil level up to the MAX mark with an approved grade and type of oil as outlined in the
engine manufacturer’s operator’s manual. Refer to Figure — Deutz Engine Dipstick, page 127.
6. Replace the dipstick making sure that it is fully seated in the dipstick tube to seal off the crankcase.
3.27.3 Changing Engine Oil

1. Allow the engine to warm up. The engine oil should reach approximately 176° F (80° C).
2. Make sure the machine and engine are level.
3. Switch off the engine.
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4. Place an oil tray under the engine.
5. Open the oil drain valve.
WARNING
When draining hot engine oil there is a risk of scalding.
NOTICE
do not let used oil run into the soil; collect the used oil in a container suitable for
disposal or recycling. Dispose of the used engine oil in accordance with environ-
mental regulations.
6. Drain the oil.
7. Close the oil drain valve.
8. Pour in new engine oil. Refer to Section —Specifications, page 11 for capacity and refer to Figure – Engine Oil Viscosity, page 128 for
the proper grade.
Figure 57. Engine Oil Viscosity
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3.27.4 Changing the Oil Filter
1. Wipe the area around the filter to clean any dirt from the area.
2. Using a suitable oil filter removal tool, loosen the lube oil filter cartridge and spin off.
3. Catch any escaping oil.
4. Clean any dirt from the filter carrier sealing surface.
5. Lightly oil the rubber gasket on the new oil filter.
6. Manually screw in the new filter until the gasket is flush.
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7. Tighten the filter another half-turn.
8. Check the oil level.
9. Check the oil pressure.
10. Check the oil filter cartridge and make sure there are no leaks.
3.27.5 Replacing the Fuel Filter
WARNING
When working on the fuel system, make sure there are no open flames or sparks in
the area. do not smoke when working on the fuel system.
2. Undo the fuel filter cartridge and spin off.
3. Catch any escaping fuel.
4. Clean any dirt from the filter carrier sealing surface.
5. Apply a light film of oil or diesel fuel to the rubber gasket of the new filter cartridge.
6. Manually screw in the new filter until the gasket is flush.
7. Tighten the fuel filter cartridge with a final half-turn.
8. Open the fuel shut-off valve.
9. Check for leaks.
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3.27.6 Cleaning the Fuel Strainer
WARNING
the area. do not smoke when working on the fuel system.
1. Unscrew the hexagonal nut (1).
2. Remove the fuel strainer cover (2).
3. Clean the fuel strainer with diesel fuel, replace if necessary.
4. Place the seal (3) in position.
5. Install the fuel strainer cover (2) in position and tighten the hexagonal screw (1).
6. Check for leaks.
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3.27.7 Deutz EMR 2
The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control System are
connected by means of separate cable harnesses to the EMR control unit.
The sensors attached to the engine provide the electronics in the control unit with all the relevant physical parameters In accordance
with the information of the current condition of the engine and the preconditions (throttle position etc.), the EMR2 controls an actuator
that operates the control rod of the injection pump and thus doses the fuel quantity in accordance with the performance requirements.
The exact position of the regulating rod is reported back and, if necessary, is corrected, by means of the control rod travel sensor,
situated together with the rotation magnets in a housing of the actuator.
The EMR2 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running (Limp
home) functions.
In order to switch the engine off, the EMR2 is switched in a de-energized fashion over the ignition switch. A strong spring in the actuator
presses the control rod in the de-energized condition into the zero position. As a redundancy measure, an additional solenoid serves for
switching off and this, independently of the actuator, also moves the control rod in the de-energized condition into the zero position.
After the programming, that is carried out over the ISO9141 interface, the EMR2 is possesses a motor-specific data set and this is then
fixedly assigned to the engine. Included in this are the various application cases as well as the customer’s wishes regarding a particular
scope of function.
Each EMR2 module is matched by serial number to the engine. Modules cannot be swapped between engines.
Figure 58. EMR 2 Engine Side Equipment
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Figure 59. Deutz EMR 2 Troubleshooting Flow Chart
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Figure 60. Deutz EMR 2 Vehicle Side Connection Diagram
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Figure 61. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
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Figure 62. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
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Figure 63. EMR 2 Engine Plug Pin Identification
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Figure 64. EMR 2 Vehicle Plug Pin Identification
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Figure 65. EMR2 Fault Codes - Sheet 1 of 5
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3.27.8 Engine Fault Codes

Table 15. Detuz TD2011L04 Fault Codes
De-
utz Blink Description
SPN FMI Possible Cause Action
Cod- Code
e
Short circuit to battery error of actuator Suspected Components :1- Lamps K57: Check wiring harness and connected loads
relay 2. Components on Pin A88, K57 Warn Ash Charge, Diagnostic, Warn Coolant on pins A88, K57.
cannot be activated .Internal ECU power Temp/Level, Warn Oil, Warn Boost Air,
38 731 523925 3 stage switched off. Warn Air Filter, Warn Water in Fuel, SCR,
Regeneration, Engine Running. 2- Relay
Preheat A883- Exhaust Flap A88
Short circuit to battery error of actuator Suspected Components :1- Urea Pump Check wiring harness and connected loads
relay 2. Components on Pin A04, A05 A042- SCR Heater A05 on pins A04, A05.
40 733 523927 3 cannot be activated. Internal ECU power
stage switched off.
Overload at Pins O_V_RH2x: A01, K74, Suspected components: 1- Pin K91:Clutch Threshold for error detection is an internal
K91. Components on A01, K74, K91 cannot switch, Brake switch, Engine brake demand, ECU threshold. Check wiring harness and
be activated. Internal ECU power stage Regeneration activation, Parkingbrake, connected loads on pins A01, K74, K91
42 167 523924 4 switched off. Gearbox N, Fan control 12- Pin K74: Boost and/or reflash ECU. If error is still present,
air cooler bypass or electrical fuel pump exchange ECU.
relay, Fan control 2/fuel valve for flamestar
Short circuit to ground actuator relais 3 Suspected components: 1- Pin A88: Preheat Threshold for error detection is an internal
Overload at Pins O_V_RH3x: A88, K57 relay, Exhaust flap2- Pin K 57:- control ECU threshold. Check wiring harness and
lamps:- OBD, preheat lamp, warning temp., connected loads on pinsA88, K57. If error
43 731 523925 4 warning oil, maintenance lamp, is still present, exchange ECU.
regeneration indicator, alternator
management, engine running, diagnostic
Short circuit to ground aktuator relais 4. Suspected components: Fan, Wiring harness Threshold for error detection is an internal
Overload at Pins O_V_PCV: A90 ECU threshold. Check wiring harness and
44 732 523926 4 connected loads on pin A90.If error is still
present, exchange ECU.
Battery voltage: the voltage measured by Battery voltage above warning threshold Check wiring harness and connected
45 318 168 3 ECU is out of the target range, system (~38,9Volt), Short cut to battery possible. alternator.
reaction is initiated
Battery voltage: the voltage measured by Battery voltage below warning threshold, Check wiring harness and connected
46 318 168 4 ECU is out of the target range, system Short cut to ground alternator.
reaction is initiated
Battery voltage: the voltage measured by If Battery voltage (Ubatt_U) > 17V or 31V Check wiring harness and connected
ECU is out of the target range, system for mor than = 0.5sec a warning is alternator.
47 318 168 2
reaction is initiated generated Battery voltage above warning
threshold
@ engines < 4l: Throttle valve error, Open The sensed raw voltage value is below the The sensed raw voltage value DPM_
Load or Short cut to Battery, blocked valve minimum threshold. uRawBrnDVDsP is above the minimum
73 7-2-2 523912 4 or wrong control signal for valve.@ threshold DPM_SRCBrnDVDsP.uMin_C@
engines with Burner T4i:Pressure Sensor CRT < 4l: check throttle valve@ engines
error after valve (DV2), lower limit reached with Burner T4i: check back-pressure valve
CAN bus 0: the ECU is not allowed to send CAN BusOff error; CAN 0 (Customer CAN) Threshold for error detection is an internal
messages, because the status "BusOff" is ECU threshold. BusOff bit for CAN A node
detected. is set. Check wiring of CAN bus and if
84 271 639 14
necessary repair it, check connection cable
and if necessary repair or replace it, check
resistance in CAN lines (120 Ohm)
CAN bus 1: the ECU is not allowed to send CAN Bus Off error; CAN 1 (Diagnostic CAN) Threshold for error detection is an internal
85 271 1231 14 messages, because the status "BusOff" is ECU threshold. BusOff bit for CAN B node is
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Table 15. Detuz TD2011L04 Fault Codes (continued)

De-
Cod- Code
e
detected Warning, no diagnostic with set. Check wiring of CAN bus and if
SERDIA2010 possible necessary repair it, check connection cable
CAN bus 2: the ECU is not allowed to send CAN BusOff error; CAN 2 (Engine CAN) Threshold for error detection is an internal
messages, because the status "BusOff" is ECU threshold. BusOff bit for CAN C node is
detected. Warning, depends on engine, set. Check wiring of CAN bus and if
86 271 1235 14
EAT. necessary repair it, check connection cable
Charge air pressure messured by sensor is Charged air cooler pressure below Check waste gate system if necessary
88 223 102 2 above the shut off threshold. threshold. replace TC, check CAC if all channels are
clean, check charge air piping if necessary.
Charge air pressure messured by sensor is Charge air pressure above shut off threshold Check waste gate system if necessary
89 223 102 2 above the warning threshold replace TC, check CAC if all channels are
clean, check charge air piping if necessary.
Coolant temperature sensor: the voltage of Suspected components: wiring harness, Check wiring harness and connected
93 225 110 1 the sensor measured by ECU is out of the coolant temperature sensor. Coolant Temp Sens.
target range.
Coolant temperature sensor: the voltage of Short cut to battery or open load. Check sensor and if necessary replace it,
96 225 110 3 the sensor measured by ECU is out of the check connection cable and if necessary
target range repair or replace it.
Coolant temperature sensor: the voltage of Voltage Surveillance has found shortcut to Check sensor and if necessary replace it,
the sensor measured by ECU is out of the Ground at Coolant Temperature Sensor. check connection cable and if necessary
97 225 110 4 target range repair or replace itMeasure Voltage at
Coolant Temperature Sensor and renew
harness if needed.
Coolant temperature: the coolant Cooling temperature too high. Coolant Clean radiator, check fan drive, check
temperature calculated by ECU is above temperature above warning threshold coolant level, check cooling system in
98 232 110 0 the target range; the ECU activates a general, check thermostat function, check
system reaction water pump
Coolant temperature: the coolant Coolant temperature above shut off Clean radiator, check fan drive, check
temperature calculated by ECU is above threshold. coolant level, check cooling system in
99 232 110 0 the target range. The ECU activates a general, check thermostat function, check
system reaction water pump
Coolant level: the coolant level calculated Coolant level too low, leakage in cooling Check coolant level, inspect cooling system
101 235 111 1 by ECU is underneath the allowed system, sensor defective, wiring damaged. for leakage and if necessary repair it, heck
minimum. sensor and wiring
Request of engine shut off: the operator Engine Shut Off demand has been ignored Depending on error requested a shut off.
121 341 1109 2 ignores the engine shut off request within by the user
an allowed period.
Shut off request from supervisory Engine Shut Off due to supervisory function Threshold for error detection is an internal
monitoring function ECU threshold. heck error memory for
122 591 523698 11 additional error ode to find root cause.
depending on additional error folow the
documented "Take action for repair".
DLC Error of CAN-Receive-Frame AT1IG1Vol Not Used Threshold for error detection is an internal
129 596 3224 2 NOX Sensor (SCR-system upstream cat; ECU threshold. Check Nox-Sensor and the
wiring from CAN-BUS.
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De-
Cod- Code
e
DPF-ystem downstream cat); length of
frame incorrect
Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX sensor and sensor connection check
AT1IG1Vol; NOX sensor (SCR-system
130 597 3224 9
upstream cat; DPF-system downstream
cat)
Timeout Error (BAM to packet) for CAN- Failure of the CAN Bus message NOX sensor and sensor connection check
Receive-Frame AT1IGCVol1 information;
133 766 523938 9 factors & Sensorcalibration for NOX Sensor
(SCR-system upstream cat; DPF-
systemdownstream cat)
Broadcast Announce Message of the Defective Nox sensor, faulty NOX sensor and sensor connection check
calibration messageof the upstream parameterization
catalytic NOx sensor has failed.Timeout
Error (BAM to BAM) for CAN-Receive-
134 766 523939 9
Frame AT1IGCVol1 information.factors &
Sensorcalibration for NOX Sensor (SCR-
system upstream cat, DPF-system
downstream cat).
Timeout Error (PCK2PCK) for CAN-Receive- Failure of the CAN Bus message NOX sensor and sensor connection check
Frame AT1IGCVol1 information; factors &
135 766 523940 9 Sensorcalibration for NOX Sensor (SCR-
system upstream cat; DPF-
DLC Error of CAN-Receive-Frame AT1O1Vol Failure of the CAN Bus message NOX downstream sensor and sensor
NOX Sensor (SCR-system downstream cat; connection check
138 114 3234 2
DPF-system downstream cat); length of
frame incorrect
Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX downstream sensor and sensor
AT1OG1Vol; NOX sensor (SCR-system connection check
139 117 3234 9
downstream cat; DPF-system downstream
cat)
Timeout Error (BAM to packet) for CAN- Timeout Error (Missing CAN Bus message) NOX downstream sensor and sensor
Receive-Frame AT1OGCVol2 information; connection check
140 767 523941 9 factors & Sensorcalibration for NOX Sensor
(SCR-system downstream cat; DPF-
Timeout Error (BAM to BAM) for CAN- Defective Nox sensor, faulty NOX downstream sensor and sensor
Receive-Frame AT1OGCVol2 information, parameterization. connection check.
Calibration message 1 of the after catalyst
141 767 523942 9 NOx sensor has failed.Factors &
Sensorcalibration for NOX Sensor (SCR-
system downstream cat, DPF-system
downstream cat)
Timeout Error (PCK2PCK) for CAN-Receive- The fault is detected when a timeout error NOX downstream sensor and sensor
Frame AT1OGCVol2 information; factors & in packet 2 of NOxSenVol2Rx frame occurs. connection check
142 767 523943 9 Sensorcalibration for NOX Sensor (SCR-
system downstream cat; DPF-
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De-
Cod- Code
e
Timeout Error of CAN-Transmit-Frame Fault is detected if a TimeOut of the Check wiring harness and customer nodes
168 763 523935 12 EEC3VOL1; Engine send messages EEC3VOL1 frame has occured.
Timeout Error of CAN-Transmit-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
169 764 523936 12 EEC3VOL2; Engine send messages
Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer devices
171 3-3-3 523212 9 ComEngPrt; Engine Protection
Timeout CAN-message FunModCtl; Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling,
Function Mode Control polarity, short circuit, power interrupt),
179 527 523240 9 testprotocol of receiver, check CAN
functional range.
Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Threshold for error detection is an internal
TSC1TE - active ECU threshold.Check CAN Bus cabling (Bus
291 119 523776 9 sheduling, polarity, short circuit, power
interrupt), testprotocol of receiver, check
CAN functional range.
Message TSC1-TE has been missing Passive timeout Error (Missing CAN Bus Check CAN Bus cabling (Bus scheduling,
(passive) message) polarity, short circuit, power interrupt),
functional range, check actuator
Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling,
TSC1TE - active polarity, short circuit, power interrupt),
functional range.
Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated Check wiring, check alternator, check
360 737 523982 0 that battery voltage is not high. due to too high battery voltage. cables and repair or replace if necessary.
Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated Check wiring, check alternator, check
361 737 523982 1 that battery voltage is not low. due to too low battery voltage. cables and repair or replace if necessary.
Internal hardware monitoring: the ECU Section could not be erased Threshold for error detection is an internal
finds an error during the access to its ECU threshold.There is no healing possible
EEPROM memory or works with an for the error. In the every new
376 281 630 12 alternative value initialization phase, thedebounce level is
set to zero.If not programmed, EEPROM is
defect –> ECU is defect, reprogramm ECU
and ifnecessary replace it.
Internal hardware monitoring: the ECU Minimum 3 blocks could not be readed, There is no healing possible for the error.
finds an error during the access to its EEPROM has Checksum Error In the every new initialization phase,
EEPROM memory or works with an thedebounce level is set to zero.If not
377 281 630 12 alternative value programmed, EEPROM is defect –>ECU is
defect, reprogramm ECU and ifnecessary
replace it
Internal hardware monitoring: the ECU Block could not be written for minimum 3 Threshold for error detection is an internal
finds an error during the access to it's times ECU threshold.If not programmed, EEPROM
378 281 630 12 EEPROM memory or works with an is defect –> ECU is defect, reprogramm
alternative value ECU and ifnecessary replace it.
Range check cannot be done or EGR or wiring defect Check wiring harness and connected EGR.
381 693 411 4 interrupted.
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De-
Cod- Code
e
Internal hardware monitoring: the CPU of Injector shut off demand for the ICO Threshold for error detection is an internal
the ECU is reset and the cause is logged coordinatorSystem responses:not ECU threshold.Caution ! Sequence error,
387 555 523612 12 internally; no item will be created in error check error memory for other errors.
memory
Engine speed: the engine speed calculated Overspeed monitoring during 1 level of FOC check powertrain settings regarding
389 214 190 0 by ECU is above the target range; the ECU (Failure overrun condition) if engine overspeed
activates a system reaction speedwas over Limit.
Engine speed: the engine speed calculated Overspeed monitoring during 2 level of FOC check powertrain settings regarding
390 214 190 11 by ECU is above the target range; the ECU (Failure overrun condition) if engine overspeed
activates a system reaction speedwas over limit.
Engine speed: the engine speed calculated Overspeed monitoring during ORC (Override check powertrain settings regarding
391 214 190 14 by ECU is above the target range; the ECU conditions) if engine speed was overspeed
activates a system reaction over2900rpm
Sensor error SCR-System environment open loop to sensor Check cabling, if environment temperature
temperature; DPF-System air inlet sensor is not working, check sensorand if
417 312 171 3 temperature; signal range check high necessary replace it, check connection
cable and if necessary repair or replace it.
Sensor error SCR-System environment short circuit to Ground Check cabling, if environment temperature
temperature; DPF-System air inlet sensor is not working, check sensorand if
418 312 171 4 temperature; signal range check low necessary replace it, check connection
cable and if necessary repair or replace it
Camshaft speed sensor: the ECU receives When disturbed camshaft signal detected. Threshold for error detection is an internal
no signal and uses the signal from Error in sensor or wiring. ECU threshold, occurs by
crankshaft speed sensor as alternative to disturbedcamshaft signal.Check increment
419 212 190 8 calculate the engine speed wheel position, clean and adjust if
necessary, check sensor postition.Check
Camshaft Sensor or wiring.
Camshaft speed sensor: the ECU receives Error in sensor or wiring. Threshold for error detection is an internal
no signal and uses the signal from ECU threshold, occurs by disturbed or
camshaft speed sensor as alternative to nocamshaft signal.Check increment wheel
420 212 190 12 calculate the engine speedThreshold: position, clean and adjust if necessary,
check sensor postition.Check Camshaft
Sensor or wiring.
ECU measures a deviation between Offset error between crankshaft and Threshold for error detection is an internal
camshaft and crankshaft angle to target. camshaft. ECU threshold, occurs by offset
betweencrankshaft and camshaft.Check
421 213 190 2 increment wheel position, clean and adjust
if necessary, check sensor postition.Check
Camshaft and Crankshaft senor or wiring.
Sensor crankshaft speed; disturbed signal Error in sensor or wiring.Crankshaft sensor Threshold for error detection is an internal
defect. ECU threshold, occurs by
disturbedcrankshaft signal.Check increment
422 212 190 8 wheel position, clean and adjust if
necessary, check sensor postition.Check
Crankshaft Sensor or wiring.
Crankshaft speed sensor: the ECU receives Error in sensor or wiring. Threshold for error detection is an internal
no signal and uses the signal from ECU threshold, occurs by disturbed or
423 212 190 12 camshaft speed sensor as alternative to noCrankshaft signal.Check increment wheel
calculate the engine speed. position, clean and adjust if necessary,
check Crankshaftsensor postition or wiring.
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De-
Cod- Code
e
Fuel filter water level sensor: the voltage Sensor not connected or sensor defect. Check of wiring and water in fuel sensor.
of sensor measured by ECU is out of the Check cabling, if charge Water in Fuel
464 228 97 3 target range sensor is not working, check sensor and
ifnecessary replace it,check connection
Fuel filter water level sensor: the voltage cable break or short circuit, sensor Check sensor and if necessary replace it,
465 228 97 4 of sensor measured by ECU is out of the defective, connection cable damaged.Short check connection cableand if necessary
target range. cut to ground. repair or replace it.
Low fuel pressure sensor: the voltage of cable break or short circuit, sensor Check cabling, if sensor not working, check
sensor measured by ECU is out of the defective, connection cable damagedShort sensor and if necessary replace it,
472 216 94 3 target range cut to battery or open loop checkconnection cable and if necessary
repair or replace it
Low fuel pressure sensor: the voltage of cable break or short circuit, sensor Check cabling, if sensor not working, check
sensor measured by ECU is out of the defective, connection cable damagedshort sensor and if necessary replace it,
473 216 94 4 target range cut to ground checkconnection cable and if necessary
Low fuel pressure: the low fuel pressure Fuel pressure below warning threshold Check low fuel pressure system (fuel feed
474 216 94 1 calculated by ECU is underneath the target pump, relay , fuse, wiring, sensor) and
range; the ECU activates a system reaction ifnecessary repair or replace it.
Cold start aid relay error. Relay defect or wire harness problem Threshold for error detection is an internal
543 263 676 11 ECU threshold.check wire harness, replace
relay
Cold start aid relay open load Relay or wire harness Threshold for error detection is an internal
544 263 676 11 threshold.check wire harness, replace relay
The cold start aid relay is according to Relay defect or wire harness problem Threshold for error detection is an internal
545 263 729 5 wiring faulty. ECU threshold.Electrical error, check wires
The cold start aid relay is overheated, High temperature around the cold start Check the functionality of relay and
which causes this error relay. replace it if needed.Check the temperature
547 263 729 12 around the cold start relay during worst
case operation.
wiring to the intake air heater device is Intake Air Heater Device: overload, short- Threshold for error detection is an internal
549 263 729 3 faulty. circuit ECU threshold.Electrical error, Check wiring
to the intake air heater device.
wiring to the air intake heater is faulty Relay (for cold start aid) cable break or Threshold for error detection is an internal
551 263 729 4 short to ground: ECU threshold.Electrical error, check wiring
to the air intake heater.
Missing or wrong injector adjustment Missing or wrong injector adjustment value Threshold for error detection is an internal
value programming (IMA) injector 1 (in for cyl. 1. ECU threshold.Check correct injector
559 1-5-8 523895 13
firing order). adjustment value (IMA). Use SERDIA
UseCase to check it.
value programming (IMA) injector 2 (in for cyl. 2 ECU threshold.check dataset and flash
560 1-5-8 523896 13
firing order). correct injector adjustement value (IMA).
Use SERDIAUseCase to check it.
Missing or wrong injector adjustment Missing or wrong parametrisation of Threshold for error detection is an internal
561 1-5-8 523897 13 value programming (IMA) injector 3 (in injector adjustment cyl. 3. ECU threshold.Check correct injector
firing order). adjustment value (IMA).
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De-
Cod- Code
e
562 1-5-8 523898 13 value programming (IMA) injector 4 (in for cyl. 4. ECU threshold.Check correct injector
Injector cylinder bank 1: the current drop Short circuit injection bank 1 (all injectors Threshold for error detection is an internal
565 151 523350 4 measured by ECU is above the target of this bank can be affected) ECU threshold.Check wiring harness,
range injectors and if necessary repair/replace it.
Injector cylinder bank 2: the current drop Short circuit injection bank 2 (all injectors Threshold for error detection is an internal
566 152 523352 4 measured by ECU is above the target of this bank can be affected) ECU threshold.Check wiring harness,
range injectors and if necessary repair/replace it.
Internal hardware monitoring: the ECU Defective powerstage in ECU Threshold for error detection is an internal
detects an error of its injector high current ECU threshold.If error is not removable,
567 153 523354 12 output. Chip of CY33x defect power stage change ECU.
components
Injector cyl. 1: interruption of electrical Interruption of electronic connection Threshold for error detection is an internal
568 154 651 5 connection Injector cyl. 1 ECU threshold.Check wiring harness,
injectors and if necessary repair/replace it.
Injector cyl. 1: the current drop measured Suspected Components:injector cylinder Threshold for error detection is an internal
by ECU is above the target range 1wiring harness, cable break or short circuit, ECU threshold.Check wiring harness,
580 154 651 3 sensor defective, connection cabledamaged injectors and if necessary repair/replace it.
Use SerDia Injectortest for diagnosis.
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De-
Cod- Code
e
583 161 654 3 sensor defective, connection cable injectors and if necessary repair/replace it.
Detecting an open load fault in the wiring harness defective, cable break Threshold for error detection is an internal
592 135 523615 5 metering unit ECU threshold.Check wiring harness and
metering unit if necessary repair/replace it.
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.
593 135 523615 12 Check temperature of metering unit and
improve the installation in case of
overheating.
Fuel metering unit: the current drain short circuit to battery high side Threshold for error detection is an internal
594 135 523615 3 measured by ECU is above the target ECU threshold.Check wiring harness and
range metering unit if necessary repair/replace it.
Fuel metering unit: the current drain short circuit to ground high side Threshold for error detection is an internal
Fuel metering unit: the current drain short circuit to battery low side Threshold for error detection is an internal
Fuel metering unit: the current drain short circuit to ground low side Threshold for error detection is an internal
Internal hardware monitoring: the CPU of Plausibility check failed (MoCADC_uNTP_ Threshold for error detection is an internal
the ECU is reset and the cause is logged mp is higher than MoCADC_uNTPMax_C). ECU threshold.If error is still present,
612 555 523612 12 internally; no item will be created in error exchange ECU.
memory.
Internal hardware monitoring: the CPU of Analysis of test voltage (Value is out of the Threshold for error detection is an internal
the ECU is reset and the cause is logged target -> ECU internal error) ECU threshold.Check wiring, check
613 555 523612 12 internally; no item will be created in error connected sensors actuators.If error is still
memory present, exchange ECU.
Internal hardware monitoring: the CPU of Analysis of the ratiometric correction (Value Threshold for error detection is an internal
614 555 523612 12 the ECU is reset and the cause is logged is out of the target -> ECU internal error) ECU threshold.Check wiring, check
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De-
Cod- Code
e
internally;no item will be created in error connected sensors actuators.If error is still
memory present, exchange ECU.
Internal hardware monitoring: the CPU of Error report due to an error in the Threshold for error detection is an internal
the ECU is reset and the cause is logged plausbility of Function Coordination(FC) ECU threshold.If error is still present,
615 555 523612 12 internally;no item will be created in error andMonitoring Modul(MM)(ECU internal exchange ECU.
memory error)
Internal hardware monitoring: the CPU of Error report due to an interrupted SPI Threshold for error detection is an internal
the ECU is reset and the cause is logged communication (ECU internal error) ECU threshold.If error is still present,
memory
Internal hardware monitoring: the CPU of multiple error in complete ROM-test during Threshold for error detection is an internal
the ECU is reset and the cause is logged postdrive detected (ECU internal error) ECU threshold.If error is still present,
memory
Internal hardware monitoring: the CPU of Too less bytes received by monitoring Threshold for error detection is an internal
the ECU is reset and the cause is logged memory from CPU as response (ECU ECU threshold.If error is still present,
618 555 523612 12 internally; no item will be created in error internalerror). Loss of synchronization exchange ECU.
memory sending bytes to the monitoring memory
from CPU
Internal hardware monitoring: the CPU of Suspected components:InjectorECUwiring Threshold for error detection is an internal
the ECU is reset and the cause is logged harness/connector ECU threshold.If error is still present,
memory
Internal hardware monitoring: the CPU of Error trying to set MM Response time (ECU Threshold for error detection is an internal
the ECU is reset and the cause is logged internal error) ECU threshold.If error is still present,
memory
Internal hardware monitoring: the CPU of Error detected in the internal ECU Threshold for error detection is an internal
the ECU is reset and the cause is logged communication, Too many SPI errors ECU threshold.If error is still present,
621 555 523612 12 internally; no item will be created in error duringMoCSOP execution exchange ECU.
memory
Internal hardware monitoring: the CPU of Error in the check of the shut-off path test Threshold for error detection is an internal
the ECU is reset and the cause is logged of the under voltage detection (ECU ECU threshold.If error is still present,
623 555 523612 12 internally; no item will be created in error internalerror). Diagnostic fault check to exchange ECU.
memory report the error in undervoltage monitoring
Internal hardware monitoring: the CPU of Error in the check of the shut-off path of Threshold for error detection is an internal
the ECU is reset and the cause is logged the monitoring module (ECU internal error). ECU threshold.If error is still present,
memory
Internal hardware monitoring: the CPU of Time out error trying to set or cancelling Threshold for error detection is an internal
the ECU is reset and the cause is logged the alarm task (ECU internal error). ECU threshold.If error is still present,
625 555 523612 12 internally; no item will be created in error Failuresetting the alarm task period exchange ECU.
memory
Internal hardware monitoring: the CPU of Error in time monitoring of the shut-off Threshold for error detection is an internal
the ECU is reset and the cause is logged path test (ECU internal error). Diagnostic ECU threshold.If error is still present,
627 555 523612 12 internally; no item will be created in error faultcheck to report the timeout in the exchange ECU.
memory shutoff path test
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Internal hardware monitoring: the CPU of Error in the check of the shut-off path test Threshold for error detection is an internal
the ECU is reset and the cause is logged of the over voltage detection (ECU ECU threshold.If error is still present,
628 555 523612 12 internally; no item will be created in error internalerror). Diagnostic fault check to exchange ECU.
memory report the error in overvoltage monitoring
The two voltage values (ADC_VAL1, ADC_ Defect pedal or wiring Threshold for error detection is an internal
VAL2), detected bythe accelerator pedal, ECU threshold.Check Pedal, repair or
629 555 523612 12 are not plausible to each other. exchange the Pedal. Check wiring.If error
is still present, exchange ECU.
Impermissible offset between the engine Calculated engine speed in level 1/2 Threshold for error detection is an internal
630 555 523612 12 speed of level 2 and level 1 implausible (-> ECU internal error). ECU threshold.If error is still present,
exchange ECU.
Diagnostic fault check to report the Implausible injection energizing time for Threshold for error detection is an internal
631 555 523612 12 plausibility error between level 1 either PiIx or MI1 or PoIx. ECU threshold.If error is still present,
energizing time and level 2 information exchange ECU.
Error in the plausibility of the start of Implausible start of energising of either PiIx Threshold for error detection is an internal
632 555 523612 12 energising angles or MI1 or PoIx. ECU threshold.If error is still present,
exchange ECU.
Error in the plausibility of the energising The energising times of the zero fuel Threshold for error detection is an internal
633 555 523612 12 times of the zero fuel quantity calibration quantity calibration ZFC is out of the target. ECU threshold.If error is still present,
(->ECU internal error) exchange ECU.
Error in the plausibility of PoI2 efficiency. Error in the plausibility of PoI2 efficiency. Threshold for error detection is an internal
634 555 523612 12 ECU threshold.If error is still present,
exchange ECU.
Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an internal
exchange ECU.
Error in the plausibility of PoI3 efficiency. Error in the plausibility of PoI3 efficiency. Threshold for error detection is an internal
exchange ECU.
Engine speed: the engine speed calculated Error in the plausibility of current energising Threshold for error detection is an internal
by ECU is above the target range; the ECU time with maximum permitted ECU threshold.If error is still present,
637 555 523612 12 activates a system reaction energisingtime. Diagnostic fault check to exchange ECU.
report the error due to OverRun
Error in the plausibility of the wave Error in the plausibility of the wave Threshold for error detection is an internal
638 555 523612 12 correction parts correction parts ECU threshold.If error is still present,
exchange ECU.
Plausibility error of the Rail pressure sensor In case the gradient of rail pressure is larger Threshold for error detection is an internal
than the max threshold or lesser than ECU threshold.Check metering unit or
639 555 523612 12 themin threshold.Rail metering unit defect. cable.Check Rail pressure. Check the Rail
Leakge in the Rail System. System of leakage.
Error in the torque comparison between Error in the torque comparison between the Threshold for error detection is an internal
640 555 523612 12 permissible engine torque and current permissible inner engine torque and ECU threshold.If error is still present,
actual torque thecurrent plausible actual torque. exchange ECU.
Diagnosis of curr path limitation forced by The torque comparison is not plausible with Threshold for error detection is an internal
641 555 523612 12 ECU monitoring level 2 the torque monitoring. ECU threshold.If error is still present,
exchange ECU.
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Diagnosis of lead path limitation forced by The setpoint path of the air system is Threshold for error detection is an internal
642 555 523612 12 ECU monitoring level 2 limited by the limitation torque of the ECU threshold.If error is still present,
functionalcontrol unit monitoring. exchange ECU.
Diagnosis of set path limitation forced by If the quantity setpoint is exceeds the limit Threshold for error detection is an internal
643 555 523612 12 ECU monitoring level 2. of the torque function. ECU threshold.If error is still present,
exchange ECU.
supply voltage too high not used Threshold for error detection is an internal
644 555 523612 3
ECU threshold.
supply voltage too low not used Threshold for error detection is an internal
646 555 523612 4
ECU threshold.
Error report "WDA wire is active" due to a Error detection by monitoring module Threshold for error detection is an internal
714 555 523612 12 defect query/response communication ECU threshold.Software reset.
Error report "ABE wire is active" due to The reason is that a slow dropping of the Threshold for error detection is an internal
undervoltage detection vehicle electrical system voltage ECU threshold.Software reset.
(defectiveautobattery)should not lead the
715 555 523612 12 ECU OCWDA's diagnose to enter an error in
the fault memory dueto an
undervoltagerecognition.
Error report "ABE wire is active" due to If the ABE/WDA powerstage shut-off is Threshold for error detection is an internal
716 555 523612 12 overvoltage detection active due to an overvoltage detection. ECU threshold.software reset.
Error report "ABE/WDA active" due to an The reason is that a slow dropping of the Threshold for error detection is an internal
unknown reason vehicle electrical system voltage ECU threshold.Software reset.
(defectiveautobattery)should not lead the
717 555 523612 12 ECU OCWDA's diagnose to enter an error in
the fault memory dueto an
undervoltagerecognition.
Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiringCheck cabling. If
measured by ECU is out of the target sensor not working, check sensor and if
732 224 100 3 range necessary replace it,check connection cable
and if necessary repair or replace it.
Oil pressure sensor: the voltage of sensor Short circuit to ground The sensed raw voltage value Oil_
measured by ECU is out of the target uRawPSwmp is above Oil_SRCPSwmp.
range uMin_CCheck cabling, if sensor not
733 224 100 4 working, check sensor and if necessary
replace it, checkconnection cable and if
necessary repair or replace itNo detail
informationen!
Oil pressure is below the target range Oilpressure too low (pressure below Threshold for error detection is an internal
(warning threshold) warning threshold) ECU threshold.Check oil level, check engine
736 231 100 1
for oil leckage, measure oil pressure
external to evaluatesensor value
Oil pressure is below the target range Oilpressure too low (pressure below shut off Threshold for error detection is an internal
(shut off threshold) threshold). ECU threshold.Check oil level, check engine
737 231 100 1
for oil leckage, measure oil pressure
external to evaluatesensor value.
Override switch switch: the ECU receives a Switch is blocked, taster locked, connection If the Block Button is pressed shorter than
permanent signal. cable damagedplausbility error "override the Maximum Plausible pressing Time.
747 145 1237 2 switch > 250ms pressed". Check cabling, if sensor is not working,
check switch and if necessary replace it,
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checkconnection cable and if necessary
repair or replace it.
Air filter differential pressure: the pressure Pressure loss above target range with Check airfilter and if necessary clean or
difference of the intake air between the system reaction, air filter clogged or renew it, check cabling, check sensor and
752 136 107 0 filter inlet and outlet calculated by ECU is defective,sensor not working, connection ifnecessary replace it, check connection
above the target range and the ECU cable damagedPressure value above cable and if necessary repair or replace it
activates asystem reaction warning threshold
Deviation between sensed intake manifold deviation between ambient pressure sensor 1) Exchange boost pressure sensor2)
pressure is not plausible compared to and charge air pressure sensor at Exchange ECU
772 223 102 2 environment pressure. Which sensor is not notrunning engine to high
okay can not be said.
charge air pressure below lower limit measured charge air pressure below the Check complete air system of engine for
threshold. massive leakage, especially from
774 223 102 1 compressorto intake air manifold.Check air
filter.Exchange charge air presure sensor.
Charge air pressure sensor: the measured The Sensor Voltage is above the Threshold. Check cabling, if charge air pressure/
voltage of sensor by ECU is out of the temperature sensor is not working, check
776 223 102 3 target range sensorand if necessary replace it, check
connection cable and if necessary repair or
replace it.
Charge air pressure sensor: the measured The Sensor Voltage is below the Threshold. Check cabling, if charge air pressure/
voltage of sensor by ECU is out of the temperature sensor is not working, check
777 223 102 4 target range sensorandif necessary replace it, check
replace it
delta pressure across venturi in EGR line sensed value of venturi difference pressure Threshold for error detection is an internal
above physical high limit > high limit ECU threshold.EGR-Valve blocked openEGR-
Valve actuator defectEGR-cooler defect
(check for coolant water)Reed Valve
791 693 411 0 defectIntake throttle blocked in closed
position => Check intake throttleExhaust
pressure too high => Check Exhaust
pressureCheck Nox-sensor upstream SCR
catalystdp venturi sensor defect
delta pressure across venturi in EGR line sensed value of venturi difference pressure Threshold for error detection is an internal
below physical low limit < low limit ECU threshold.Check correct mounting of
792 693 411 1 difference pressure sensor at venturi
tubeExchange difference pressure sensor
broken
DFC is stored in EEPROM and status kept deviation between desired O2 concentration Threshold for error detection is an internal
until check is allowedto be carried out in intake air manifoldand the real O2- ECU threshold.EGR-Valve mechanically
againDFC can be reset by service routine concentration within intake air manifold > blocked open or closedEGR-pipe blocked
216 limit with metall plate instead sealing
downstream EGR-ValveEGR-Valve actuator
defectEGR-cooler defect (check for coolant
793 693 411 11
water)Reed Valve defectIntake throttle
blocked in closed position => Check
intake throttleExhaust pressure too high
=> Check Exhaust pressureCheck Nox-
sensor upstream SCR catalystdp venturi
sensor defect
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The sensed raw voltage Air_ EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure
uRawPEGRDeltaP is above the maximum sensor is not working, check sensor andif
795 693 411 3 threshold. necessary replace it, check connection
The sensed raw voltage value Air_ EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta pressure
uRawPEGRDeltaP is above the minimum sensor is not working, check sensor andif
796 693 411 4 threshold. necessary replace it, check connection
The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger Replace pressure relief valve (PRV) and
825 253 523009 9 the number of allowed activations. threshold of the pressure limiting valve. reset fault with Serdia.
The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger Threshold for error detection is an internal
826 146 523470 2 opened due to excessive pressure. threshold of the pressure limiting valve. ECU threshold.Reset the fault and at
reappearance check injection system.
The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger Threshold for error detection is an internal
827 146 523470 2 opened due to excessive pressure. threshold of the pressure limiting valve. ECU threshold.Reset the fault and at
reappearance check injection system.
Rail pressure relief valve: is open.Shutoff Shut Off after PRV Open Threshold for error detection is an internal
conditions. ECU threshold.Check PRV opening counter
and if necessary replace PRV,check rail-
828 146 523470 12 pressure sensor for plausibility and if
necessary replace it,check FCU and if
necessary replace it.
Rail pressure relief valve is open.Warning Warning PRV open Threshold for error detection is an internal
conditions. ECU threshold.Check PRV opening counter
and if necessary replace PRV,check rail-
829 146 523470 12 pressure sensor for plausibility and if
necessary replace it,check FCU and if
Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal
ECU threshold.Only after ECU reset.Check
PRV opening counter and if necessary
830 146 523470 14 replace it,check rail-pressure sensor for
plausibility and if necessary replace it,
check FCU and if necessary replace it.
Rail pressure relief valve can not be Railpressure out of tolerance range (PRV Threshold for error detection is an internal
831 146 523470 11 opened due to the railpressure. can not be opened by a pressure peak in ECU threshold.Check railpressure, check rail
thisoperating point) pressure sensor for plausibility, check FCU.
Rail pressure is out of the expected Averaged rail pressure is outside the Threshold for error detection is an internal
average range.The PRV can not be opened expected tolerance range. ECU threshold.Check PRV and replace if
832 146 523470 11
at this operating point with a pressure necessary.
shock.
The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger Replace pressure relief valve (PRV) and
833 2-5-3 523009 10 the allowed opening time. threshold of the pressure limiting valve. reset fault with Serdia.
Diagnostic fault check for min error of COM The sensed raw value is less than the Check cabling, check sensor and if
839 1-4-3 523450 4 message. threshold. necessary replace it,check connection cable
and if necessary repair or replace it.
Rail pressure: the fuel pressure in rail Pressure governor deviation exceeds the Threshold for error detection is an internal
856 134 523613 0 calculated by ECU is below the target limiting value based on the engine speed. ECU threshold.(A) Check for leakage(B)
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range which is dependant on the engine Check fuel-primary pressure(C) Change
speed. components, check sensor and if necessary
replace it, check fuel systemand if
necessary repair it
Rail pressure: the fuel pressure in rail maximum positive deviation of rail pressure Threshold for error detection is an internal
calculated by ECU is below the target exceeded concerning set flow of fuel. ECU threshold.(A) Check for leakage(B)
range which is dependant on the engine Check fuel-primary pressure(C) Change
857 134 523613 0 speed. components, check sensor and if necessary
replace it, check fuel systemand if
necessary repair it
Rail pressure: the fuel pressure in rail leakage is detected based on fuel quantity Threshold for error detection is an internal
calculated by ECU is above the target balance. ECU threshold.(A) Check backflow pressure
858 134 523613 0 range which is dependant on the engine (B) Check Injector function with SerDia(C)
speed. Change components (metering unit,
injector) if necessary
Rail pressure: the fuel pressure in rail Maximum negative rail pressure deviation Threshold for error detection is an internal
calculated by ECU is above the target with metering unit on lower limit is ECU threshold.(A) Check backflow pressure
859 134 523613 0 range which is dependant on the engine exceeded. (B) Check Injector function with SerDia(C)
Rail pressure: the fuel pressure in rail Rail pressure falls below the limiting value Threshold for error detection is an internal
calculated by ECU is below the target based on the engine speed. ECU threshold.(A) Check backflow pressure
861 134 523613 1 rangewhich is dependant on the engine (B) Check Injector function with SerDia(C)
Rail pressure: the fuel pressure in rail Rail pressure exceeds the limiting value. (A) Check backflow pressure(B) Check
862 134 523613 0 calculated by ECU is above the target pressure relief valve and metering unit.(C)
range. Change components if necessary
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 exceeds the threshold based on thepressure. threshold.(A) Check backflow pressure(B)
864 134 523613 2 plausible. Check pressure relief valve and metering
unit.(C) Change components if necessary
Rail pressure is out of the expected Rail pressure is out of the expected average (A) Check railpressure relief valve and
average range. range.PRV can not be opened. replace if necessary.(B) Check high
876 146 523470 7 pressure pumps, pressure relief valve and
metering unit.(C) Change components if
necessary
Rail pressure sensor: the voltage of sensor Short cut to battery.Damaged rail pressure Check cabling, check rail pressure sensor
measured by ECU is out of the target sensor. and if necessary replace it,check
877 147 157 3 range. connection cable and if necessary repair or
replace it.
Rail pressure sensor: the voltage of sensor Check cabling, check rail pressure sensor Check cabling, check rail pressure sensor
measured by ECU is out of the target and if necessary replace it,check connection and if necessary replace it,check
878 147 157 4 range. cable and if necessary repair or replace it. connection cable and if necessary repair or
replace it.
Supply module heater: Duration of switch uty cycle for temperature readout from When the received supply module heater
on is too long. supply module heater to the control unit is temperature duty cycle SCR_rSMT is out
925 148 523720 8 outof range; Supply modul defect, fault in ofthe failurerange (SCR_rSMFailMax_C <
the wiring. SCR_rSMHtrT < SCR_rSMFailMin_C)Supply
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module check and replace if necessary.
Check the wiring.
Supply module heater: Dutycycle timing Duty cycle for temperature readout from When the received supply module heater
over error threshold. supply module heater to the control unit is duty cycle SCR_rSMHtrT is in the valid
926 148 523720 8 notvalid.Supply modul defect, fault in the range(SCR_r-Supply module check and
wiring. replace if necessary.Check the wiring.
Supply module heater: temperature Duty cycle for temperature readout from Threshold for detection is an internal ECU
measurement not available. supply module heater to the control unit is threshold.No erasing in the current driving
927 689 523721 11 notavailable.Supply modul defect, fault in cycle.Supply module check and replace if
the wiring. necessary. Check the wiring.
Supply module heater: PWM time periode PWM signal for temperature readout from The Time period of the received PWM
out of valid range. supply module to the control unit is out signal SCR_tiSMPerPwm is within the
928 928 691 8 ofrange.Supply modul defect, fault in the specifiedrange of150ms to 250msSupply
wiring. module check and replace if necessary.
Check the wiring.
Supply module heater: Faulty PWM signal PWM Signal for temperature readout from Threshold for error detection is an internal
from supply module. supply module to the control unit is not ECU threshold.When valid Sync followed
valid.Supply modul defect, fault in the by temperature information signal is
wiring. received AND valid syncand
929 691 523722 8 temperaturesignal for both information is
received one after the other.Supply
module check and replace if necessary.
Check the wiring.
Supply module heater: Dutycycle timing Duty cycle for temperature readout from Supply module check and replace if
over error threshold. supply module to the control unit is out necessary.Check the wiring.
930 689 523721 8 ofrange.Supply modul defect, fault in the
wiring.
Supply module heater: Dutycycle timing Duty cycle for temperature readout from When the received supply module duty
out of valid range. supply module to the control unit is not cycle SCR_rSMT is in the valid range(SCR_
valid.Supply modul defect, fault in the rSMTVld-Min_C <= SCR_rSMT <= SCR_
931 689 523721 8 wiring. rSMTVldMax_C), OR in the failurerange
(SCR_rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C)Supply module check
and replace if necessary.Check wiring.
Diagnostic fault check of short circuit to The signal exceeds the applicatable If the signal is below the applicatable
supply voltage(signal range check high) of threshold; signal range violation threshold APP_uRawSRCHiHTLIS_C, the
acceleration pedal signal. signalrange violation is resetafter the
healing debouncing.In case when the CCP
932 1-2-6 29 3 is active (CCP_stActive = 1)and the
reading from the EEPROMmemory is
successful, thesignal is below the threshold
APP_uHTLISCCPHi[1], a signal range
violation is resetafter debouncing.
Analog accelerator pedal sensor 1 or Sensor defect.Short cut to battery or open Check cabling, check accelerator pedal
double accelerator pedal sensor: the loop. sensor and if necessary replace it,
voltage measured by ECU is out of the checkconnection cable and if necessary
target range or the calculated pedal repair or replace it.If the signal is below
935 2-2-6 91 3 position is implausiblecompared with the the applicatable threshold APP_
position of the second pedal uRaw1SRCHigh_C, the signalrange
violation is reset afterthe healing
debouncing.
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Diagnostic fault check of short circuit to The signal is below the applicatable If the signal exceeds the applicatable
ground (signal range check low) of threshold; signal range violation threshold APP_uRawSRCLoHTLIS_C, the
acceleration pedal signal signalrange violation is resetafter the
healing debouncing.In case when the CCP
937 1-2-6 29 4 is active (CCP_stActive = 1)and the
reading from the EEPROMmemory is
successful, thesignal exceeds the threshold
APP_uHTLISCCPLo[1], a signal range
violation is resetafter debouncing.
Analog accelerator pedal sensor 1 or Short circuit to ground. Check cabling, check accelerator pedal
double accelerator pedal sensor: the sensor and if necessary replace it,
voltage measured by ECU is out of the checkconnection cable and if necessary
940 2-2-6 91 4 target range or the calculated pedal repair or replace itIf the signal exceeds the
position is implausiblecompared with the applicatable threshold APP_
position of the second pedal uRaw1SRCLow_C, the signalrange violation
is reset after thehealing
Internal hardware monitoring: the ECU Suspected components EDC17cv52Pin A19: Check cabling of external components,
detects a deviation of the target range of DEF press / Exh.PressBeforeTurb (P3) / Air check working voltage and if necessary
the power supply voltage of sensor output Pump Press/BrnFuelPressAfterDV2 Pin K19: correctit,check connection cable and if
1. Fan Speed SensorPin A21: LDF6T / OilPress / necessary repair or replace it,if error is not
LowFuelPress Pin A17: Rail Pressure removable, change ECU.
SensorSuspected components EDC17cv54Pin
A21: CAM speed Pin K44: Delta Press
946 282 1079 13 Venturi / Poti EGR or Inlet ThrottlePin A24:
LDF6T / OilPress / LowFuelPressPin K43:
Reserve 5V Sensor SupplyPin A09: second
footpedalSuspected components
EDC17cv56Pin A21: Cam speed Pin K44: DEF
press / Air FilterDiffPressPin A24: LDF6T /
OilPress / LowFuelPress Pin K43: second
footpedalPin A09: Delta Press Venturi
Internal hardware monitoring: the ECU Suspected components EDC17cv52Pin K16: Check cabling of external components,
detects a deviation of the target range of second footpedalPin A20: Exh. check working voltage and if necessary
the power supply voltage of sensor output PressAfterTurb/DPFDiffPress/BrnDV1Press/ correctit, check connection cable and if
2. HCIPressDV1DV2Suspected components necessary repair or replace it, if error is not
EDC17cv54Pin K45: DPF Diff Press / Exh. removable,change ECU.
947 282 1080 13 Press After Turb / Fan Speed SensorPin A46:
first footpedalSuspected components
EDC17cv56Pin A22: Fan Speed SensorPin
K45: Position EGR or Intake throttle flapPin
K46: First footpedal
Internal hardware monitoring: the ECU Suspected components EDC17cv52Pin A18: Check cabling of external components,
detects a deviation of the target range of DeltaPressVenturi / Position intake throttle check working voltage and if necessary
948 282 523601 13 the power supply voltage of sensor output flapPin K20: First footpedalPin K21: Air correctit,check connection cable and if
3. FilterDiffPressSuspected components necessary repair or replace it,if error is not
EDC17cv54 and cv56Pin A07: Rail pressure removable, change ECU.
Start relay (high side power stage): the Short cut HighSide-output to battery. Threshold for error detection is an internal
current drop measured by ECU is above the ECU threshold.Check cabling and start relay
956 512 677 3 target range. and if necessary replace it,check
replace it.
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Start relay (high side power stage):the Shortcut HighSide-output to ground. Threshold for error detection is an internal
current drain measured by ECU is above ECU threshold.Check cabling and start relay
957 512 677 4 the target range. and if necessary replace it,check
replace it.
Start relay (low side power stage): the Open circuit/disconnection LowSide-Output. Threshold for error detection is an internal
958 512 677 5 target range and if necessary replace it,check
replace it.
Start relay (low side power stage): the Temperature over limit. Threshold for error detection is an internal
replace it.
Start relay (low side power stage): the Shortcut LowSide-Output to battery. Threshold for error detection is an internal
current drain measured by ECU is above ECU threshold.Check cabling and start relay
960 512 677 3 the target range. and if necessary replace it,check
replace it.
Start relay (low side power stage): the Shortcut LowSide-Output to ground. Threshold for error detection is an internal
connection cable of terminal 50 and if
necessary repair or replace it.
Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal
the ECU is reset and the cause is logged ECU threshold.
973 555 523612 14 internally;no item will be created in error
memory.
Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal
the ECU is reset and the cause is logged ECU threshold.
974 555 523612 14 internally;no item will be created in error
memory.
Internal hardware monitoring: the CPU of Visibility of SoftwareResets in DSM Threshold for error detection is an internal
the ECU is reset and the cause is logged ECU threshold.If possible the software
975 555 523612 14 internally;no item will be created in error update has to be done. Replace the ECU.
memory
Diagnostic fault check of synchronism of Measured voltage of accelerator pedal 1 is Threshold for error detection is an internal
single potentiometer and Low idle switch out of plausible range. ECU threshold.Check cabling, check
(LIS). accelerator pedal and pedal sensor and if
necessary replace it,check connection cable
976 2-2-6 91 11
and if necessary repair or replace it.When
the PWM period APP_tiPWMPer is in
between APP_tiSRCLoPWMPer_C andAPP_
tiSRCHiPWMPer_C .
Diagnostic fault check of synchronism of Plausibility error between sensor and idle Threshold for error detection is an internal
hand throttle and Low idle switch(LIS). switch ECU threshold.The accelerator pedal must
978 1-2-6 29 2
have detected full load and idle plausibility
at least once.
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Terminal 50 was operated for more than 2 Startinformation to Starter (T50-switch) Threshold for error detection is an internal
minutes. This may happen due to short to erratic/defect. ECU threshold.Check cabling, if sensor not
980 515 523550 12 battery or wrong usage of Terminal 50. working, check start switch and if
Starter control is disabled until this error is necessary replace it,check connection cable
healed. and if necessary repair or replace it.
Charged Air cooler down stream Sensed temperature within intake air actual temperature below -40°C?exchange
992 128 105 1 temperature.Temperature below lower manifold < threshold. sensor
physical threshold.
Charge air temperature sensor: the voltage Short circuit to battery.sensor voltage > The sensor raw signal Air_uRawTCACDs
of sensor measured by ECU is out of the limit (voltage) > Air_SRCTCACDs.uMin_C.Check
994 128 105 3 target range. CAC-sensor and if necessary replace it,
check connection cable and ifnecessary
Charge air temperature sensor: the voltage Short circuit to ground or open load.sensor The sensor raw signal Air_uRawTCACDs
of sensor measured by ECU is out of the voltage < limit. (voltage) is below Air_SRCTCACDs.uMin_C.
995 128 105 4 target range. Check CAC-sensor and if necessary replace
it, check connection cable and ifnecessary
Charge air temperature downstream Charge air temperature (downstream) over Check CAC system and clean it. Check fan
996 233 105 0 calculated by ECU is above the target warning threshold. functionality.Check cooling perfomance
range.The ECU activates a system reaction. with temperature measurement.
Charge air temperature downstream Charge air temperature (downstream) over Check CAC system and clean it. Check fan
calculated by ECU is under the shut down the low threshold. functionality. Check cooling
997 233 105 0
threshold.The ECU activates a system perfomancewith temperature
reaction. measurement.
EGR downstream temperature sensor: the Short circuit to battery.sensor voltage > Check wiring harness to TEGR-sensor.
1007 682 412 3 voltage of sensor measured by ECU is out limit Exchange TEGR-sensor.
of the target range.
EGR downstream temperature sensor: the Short circuit to ground or open load.sensor Check wiring harness to TEGR-sensor.
1008 682 412 4 voltage of sensor measured by ECU is out voltage < limit Exchange TEGR-sensor.
of the target range.
Physical range check high for EGR cooler Sensed temperature downstream EGR-cooler EGR-Valve blocked openEGR-Valve actuator
downstream temperature. > limit. defectEGR-cooler defect (check for coolant
1011 771 523960 0 blocked in closed positionExhaust pressure
too highCheck Nox-sensor upstream SCR
Physical range check low for EGR cooler sensor voltage > lower limit EGR-Valve blocked openEGR-Valve actuator
downstream temperature. defectEGR-cooler defect (check for coolant
1012 771 523960 1 blocked in closed positionExhaust pressure
too highCheck Nox-sensor upstream SCR
Actuator error EGR-Valve.Signal range Short cut to batterie. Check wiring and repair or replace if
1014 594 5763 6 check high. necessary, check actuator with SERDIA test
forEGR and if necessary replace it.
Actuator error EGR-Valve.Signal range Short cut to ground. Check wiring and repair or replace if
1015 594 520521 5 check low. necessary, check actuator with SERDIA test
forEGR and if necessary replace it.
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Actuator position for EGR valve is not Position error of throttle flap (deviation > Threshold for error detection is an internal
plausible, internal error, angular 7%). ECU threshold.Threshold for error
1016 594 5763 7 misalignement of the flap. detection, deviation from setpoint > 7%.
Troubleshooting with SERDIA 2010 Use
Case "EGR Diagnostic".
Actuator error EGR-Valve; signal range Short circuit to battery or open circuit. Check cabling, actuator defect, check
check high, measured current by ECU is actuator and if necessary replace it,
1022 5-9-4 5763 6 over target checkconnection cable and if necessary
Actuator error EGR-Valve; signal range Short circuit to ground. Check wiring, check cabels and repair or
check low, measured current is below replace if necessary, check actuator
1023 5-9-4 5763 5 target withSERDIA 2010 test for EGR and if
Actuator of the external EGR valve: the Short cut to battery or open loop. Check cabling, actuator defect, check
ECU detects a short circuit to battery or actuator and if necessary replace it,
1024 594 5763 3 open load. checkconnection cable and if necessary
Actuator of the external EGR valve: the Short cut to ground Check cabling, actuator defect, check
ECU detects a short circuit to ground. actuator and if necessary replace it,
1025 594 5763 4 checkconnection cable and if necessary
Static plausibility check:The exhaust Static plausibility check:The exhaust Check ambient temperature => value
temperature value from the sensor before temperature value from the sensor before plausible?upstream DOC sensor mounted
DOC, the exhaust temperature value from DOC, the exhaust temperaturevalue from within exhaust line?T upstream DOC sensor
the sensor after DOC, the temperature the sensor after DOC, the temperature value physically mounted in correct position
value from the sensor beforeSCR-Cat, the from the sensor beforeSCR-Cat, the upstream DOC? (notupstream SCR or
environment temperature and the coolant environment temperature and the coolant downstream DOC?)Check T upstream DOC
engine temperature their ratios to each engine temperature their ratiosto each sensorCheck other T-sensors within EAT-
other exceed their related thresholds. other exceed their related thresholds. system (Exh_tOxiCatDs & UCatUsT_tFlt_
Dynamic plausibility check with (difference between temperature after DOC mp showplausible values? No errors on
environment temperature sensor value:The and temperature before DOC > Threshold them?
exhaust temperature value from the sensor 1difference between temperature befor DOC
before DOC is lower than an applicable and before SCR > Threshold 2difference
1036 683 4768 2 environment temperature threshold between temperature after DOC and before
SCR < Threshold 3difference between
temperature after DOC and ambinet
temperature < Threshold 4differnece
between temperatur ambient temperature
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
applicableenvironment temperature
threshold (< environmental temperature +
Threshold 6)
The exhaust temperature value from the sensed temperature upstream DOC > shut- Check air path of engine: EGR-Valve,
sensor befor DOCis above an applicable off limit Intake-Throttle,Check Turbocharger and
upper shutoff thresholdTOxiCatUs_ Piping each for leakage and correct
1039 683 4765 0 tShOffThresHiAds_C = Threshold 1 in functionCheck injectors: is an injector got
Normal andHeatmodes (TOxiCatUs_ stuck?Exchange temperature sensor
tShOffThresHiRgn_C = Threshold 2in upstream DOC
stand-still)
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The exhaust temperature value from the Sensed temperature upstream DOC > Check air path of engine: EGR-Valve,
sensor befor DOCis above an applicable warning limit Intake-Throttle, Turbocharger and Piping
1040 683 4765 0 upper warning thresholdTOxiCatUs_ eachfor leakage and correct functionCheck
tWarnThresHi_C = Threshold injectors: is an injector got stuck?Exchange
temperature sensor upstream DOC
Oxidation catalyst upstream temperature The sensed raw voltage value Exh_ Check wiring harness to temperature
1044 683 4768 3 sensor: the voltage of sensor measured by uRawTOxiCatUs is aboveExh_SRCTOxiCatUs. sensor upstream DOCExchange
ECU is out of the target range uMax_CShortcut to battery temperature sensor upstream DOC
Oxidation catalyst upstream temperature The sensed raw voltage value Exh_ Check wiring harness to temperature
1045 683 4768 4 sensor: the voltage of sensor measured by uRawTOxiCatUs isbelow Exh_SRCTOxiCatUs. sensor upstream DOCExchange
ECU is out of the target range uMin_CShortcut to ground temperature sensor upstream DOC
The filtered urea cat upstream temperature Sensed temperature upstream SCR > Check temperature difference across DOC
is greater than an applicable maximum physical high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at
temperature threshold higherengine load =>high difference >
100 K?If yes, the engine emitts too many
Hydrocarbons => check injectors: is an
injector gotstuck?=> Check EGR ValveIf
difference normal the exhaust out of the
engie itself is too hot:=> Check air path
1069 668 4360 0 of engine: EGR-Valve, Intake-Throttle,
Turbocharger and Pipingeach for leakage
and correct functionIf that error was set
while stand-still operation the error source
could be exothermalsoot burn off in DPF
(which should not happen) => Dismount
DPF and check it visuallyexchange
temperature sensor upstream SCR
The filtered temperature before urea cat is Sensed temperature upstream SCR catalyst Cold start and ambient temperature <
less than an applicable minimum < than physical low limit Threshold? Missdetection?Check wiring
1070 668 4360 1
temperature threshold harness to UCatUsT-sensorExchange
UCatUsT-sensor
Urea catalyst upstream temperature Voltage of temperature sensor upstream Check sensorCheck wiringReplace UCatUsT-
1072 668 4361 3 sensor: the voltage of sensor measured by SCR catalyst > maximum limitShort circuit sensor
ECU is out of the target range to battery
Urea catalyst upstream temperature Voltage of temperature sensor upstream Check sensorCheck wiringReplace UCatUsT-
1073 668 4361 4 sensor: the voltage of sensor measured by SCR catalyst < minimum limitShort circuit sensor
ECU is out of the target range to ground
Urea dosing valve: the current measured Fault in the wiriingDefect urea dosing Check wiringCheck the urea dosing
1075 677 3361 6 value by ECU at the end of the injection is injection valve injection valve
too high
Urea dosing valve (low side power stage): Fault in the wiring Threshold for error detection is an internal
1077 677 3361 3 the current drain measured by ECU is ECU thresholdSee substitute functionCheck
above the target range the wiring
Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal
1078 677 3361 3 the current drain measured by ECU is ECU thresholdCheck the wiring
above the target range
Urea dosing valve (low side power stage): Fault in the wiring Check the wiring
1079 677 3361 4 the current drain measured by ECU is
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Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal
1080 677 3361 4 the current drain measured by ECU is ECU thresholdCheck the wiring
Urea backflow line heater: the current Open loadIf this error detected during the Threshold for error detection is an internal
drain measured by ECU is above the target heating phase is a result error: KWP ECU thresholdCheck wiringCheck heating
1090 674 4345 5
range 1089Broken wiring, broken heating element element
in backflow line
Urea backflow line heater: the current Shortcut to batteryIf this error detected Threshold for error detection is an internal
drain measured by ECU is above the target during the heating phase is a result error: ECU thresholdCheck wiringCheck heating
1092 674 4345 3 range KWP 1089Short cut to battery or broken element
wiring, broken heating element in backflow
line
Urea backflow line heater: the current Shortcut to groundIf this error detected Threshold for error detection is an internal
drain measured by ECU is above the target during the heating phase is a result error: ECU thresholdCheck wiringCheck heating
1093 674 4345 4 range KWP 1089Short cut to ground or broken element
wiring, broken heating element in backflow
line
Urea pressure line heater: the current drain Open loadIf this error detected during the Threshold for error detection is an internal
measured by ECU is above the target heating phase is a result error: KWP ECU thresholdCheck wiringCheck heating
1094 673 4343 5 range 1089Broken wiring, broken heating element element
in pressure line
Urea pressure line heater: the current drain shortcut to batteryIf this error detected Threshold for error detection is an internal
measured by ECU is above the target during the heating phase is a result error: ECU thresholdCheck wiringCheck heating
1096 673 4343 3 range KWP 1089broken heating element in element
pressure line
Urea pressure line heater: the current drain Shortcut to groundIf this error detected Threshold for error detection is an internal
measured by ECU is above the target during the heating phase is a result error: ECU thresholdCheck wiringCheck heating
1097 673 4343 4 range KWP 1089Short cut to ground or broken element
wiring, broken heating element in pressure
line
Urea heater relay: the current drain Open loadIf this error detected during the Threshold for error detection is an internal
1098 676 523718 5 measured by ECU is above the target heating phase it is a result error: KWP ECU thresholdTest SCR main relayCheck
range 1089Broken wiringbroken relay cabling, if necessary replace relay.
Urea heater relay: the current drain Shortcut to batteryIf this error detected Threshold for error detection is an internal
1100 676 523718 3 measured by ECU is above the target during the heating phase it is a result error: ECU thresholdCheck wiringCheck SCR main
range KWP 1089Broken wiring, broken relay relay
Urea heater relay: the current drain Shortcut to groundIf this error detected Threshold for error detection is an internal
1101 676 523718 4 measured by ECU is above the target during the heating phase it is a result error: ECU thresholdCheck wiringCheck SCR main
range KWP 1089Broken wiring, broken relay relay
Urea heater supply line: the current drain electrical error Threshold for error detection is an internal
1102 675 4341 5 measured by ECU is above the target ECU thresholdCheck wire harnessCheck
range supply line
range supply line
range supply line
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Urea supply module heater: the current Open loadIf this error detected during the Threshold for error detection is an internal
drain measured by ECU is above the target heating phase is a result error: KWP ECU thresholdCheck wiringCheck cabling, if
1106 672 523719 5 range 1089Broken wiringHeating element in necessary replace supply module
supply module defect
Urea supply module heater: the current Short circuit to batteryIf this error detected Threshold for error detection is an internal
52327- drain measured by ECU is above the target during the heating phase it is a result error: ECU thresholdCheck wiringCheck cabling, if
1108 672 3 range KWP 1089Broken wiringHeating element in necessary replace supply module
19
Urea supply module heater: the current Shortcut to groundIf this error detected Threshold for error detection is an internal
drain measured by ECU is above the target during the heating phase it is a result error: ECU thresholdCheck wiringCheck cabling, if
1109 672 523719 4 range KWP 1089Broken wiringHeating element in necessary replace supply module
Urea tank heating valve: the current drain Open loadIf this error detected during the Threshold for error detection is an internal
measured by ECU is above the target heating phase is a result error: KWP ECU thresholdCheck wiringCheck urea tank
1110 671 4366 5
range 1089Broken wiringUrea tank heating valve heating valve
defect
Urea tank heating valve: the current drain Shortcut to batteryIf this error detected Threshold for error detection is an internal
measured by ECU is above the target during the heating phase is a result error: ECU thresholdCheck wiringCheck urea tank
1112 671 4366 3
range KWP 1089Broken wiringUrea tank heating heating valve
valve defect
Urea tank heating valve: the current drain Shortcut to groundIf this error detected Threshold for error detection is an internal
measured by ECU is above the target during the heating phase is a result error: ECU thresholdCheck wiringCheck urea tank
1113 671 4366 4
range KWP 1089Broken wiringUrea tank heating heating valve
valve defect
Urea supply module pump: the current When the pump motor does not switch to Threshold for error is an internal ECU
drain measured by ECU is above the target pump actuation mode after threshold
1117 666 523632 11
range temperaturemeasurement hasbeen carried
out.
Urea supply module pump: the ECU can Open loadBroken wiringPump in urea Threshold for error detection is an internal
not measure any reaction during pump supply module defect ECU thresholdThe hardware detects the
control presence of load on the PWM output
1118 666 4375 5 power stage for theurea pump module
actuator.Check wiringCheck pump in the
urea supply module
Urea supply module pump: the current Shortcut to batteryIf this error detected Threshold for error detection is an internal
drain measured by ECU is above the target during the heating phase is a result error: ECU thresholdThe hardware detects
range KWP 1089Broken wiringPump in urea absence of any short circuit to battery on
1120 666 4375 3 supply module defect the PWM output powerstage for the urea
pump module actuatorCheck wiringCheck
pump in the urea supply module
Urea supply module pump: the current Shortcut to groundIf this error detected Threshold for error detection is an internal
drain measured by ECU is above the target during the heating phase is a result error: ECU thresholdThe hardware detects a short
range KWP 1089Broken wiringPump in urea circuit to ground error on the PWM output
supply module defect power stagefor the UreaPump Module
1121 666 4375 4 Motor Actuator. The error is updated by
setting bit 1 ofmeasuring point UPmp-
Mot_stPrevTstRslt_mpCheck wiringCheck
pump in the urea supply module
The absolute pressure value of the urea Suspected Components:Urea pump Check the urea pumpCheck the supply
1122 665 4334 0 pump is greater than an applicable defectSupply module pressure sensor module pressur sensorClean the urea pump
maximal filtered pressure threshold defectPump contains dirty parts (filter)
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Urea supply module pressure sensor: The Check the urea pumpCheck the supply Check the urea pumpCheck the supply
absolute pressure value of the urea pump module pressur sensorClean the urea pump module pressur sensorClean the urea pump
1123 665 4334 1 is less than an applicable minimal filtered (filter) (filter)
pressure threshold
Urea supply module pressure sensor: the Shortcut to batteryBroken wiringPressure Check wiringCheck pressure sensor in urea
1127 665 523632 3 current drain measured by ECU is above sensor in urea supply module defect supply module
the target range
Urea supply module pressure sensor: the Shortcut to groundBroken wiringPressure Check wiringCheck pressure sensor in urea
current drain measured by ECU is above sensor in urea supply module defect supply module
1128 665 523632 4 the target rangeThe sensed raw voltage
value SCR_uRawUPmpP is above SCR_
SRCUPmpP.uMin_C
Urea supply module reversal valve: the Open loadFault in the wiringReversal valve Threshold for error detection is an internal
1129 667 4376 5 current drain measured by ECU is above in the urea supply module defect ECU thresholdCheck wiringCheck urea
the target range supply modul
Urea supply module reversal valve: the Shortcut to batteryFault in the Threshold for error detection is an internal
1131 667 4376 3 current drain measured by ECU is above wiringReversal valve in the urea supply ECU thresholdCheck wiringCheck urea
the target range module defect supply modul
Urea supply module reversal valve: the Shortcut to groundFault in the Threshold for error detection is an internal
1132 667 4376 4 current drain measured by ECU is above wiringReversal valve in the urea supply ECU thresholdCheck wiringCheck urea
the target range module defect supply modul
The urea tank temperature sensor detects Sensed urea tank temperature > physical Case "CANBUS sensor":Check urea tank
a value above the maximum allowed range high limit temperature: really hot?Check CANBus-
threshold message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2Compare it
to Com_dRxSCR1Byt1 (urea temperature at
quality sensor) identical?Tank heater
permantly on?Check wiring of DEF-quality
1135 669 3031 0 sensorCase "analog DEF T & Level sensor":
Check urea tank temperature: really hot?
Check urea tank temperature SCR_
tSensUTnkTCompare urea tank temperature
to EnvT_t or to SCR_tSMT (the urea
temperatureinside the supply module)
identical?Tank heater permantly on?Check
wiring of analog DEF T & Level sensor
The urea tank temperature sensor detects sensed urea tank temperature < physical Case "CANBUS sensor":Check ambient
a value lower than the minimum allowed range low limit temperature EnvT_t => About -40 °C? If
threshold. yes Error could be plausibleCheck CANBus-
message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2Compare it
to Com_dRxSCR1Byt1 (urea temperature at
quality sensor) identical?Check wiring of
DEF-quality sensorCheck quality sensorCase
1136 669 3031 1
"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 plausibleCheck
urea tank temperature SCR_
tSensUTnkTCheck wiring of analog DEF T &
Level sensorCheck analog DEF T & Level
sensor
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Signal error in case of Urea tank CAN message is not send properly. Check sensor connectorCheck CANbus
1137 6-6-9 4365 2 temperature trnasmitted via CAN-signal
Com_tUTnkT.
Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal
drain measured by ECU is above the target ECU threshold.The Sensed raw voltage
1138 6-6-9 4365 3 range. value SCR_uRawUTnkT is below SCR_
SRCUTnkT.uMax_C.Check wiring.
Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal
drain measured by ECU is above the target ECU threshold.The sensed raw voltage
1139 6-6-9 4365 4 range. value SCR_uRawUTnkT is above SCR_
SRCUTnkT.uMin_C.Check wiring.
Fuel filter water level sensor: the Water level in fuel pre-filter reservoir over Measure Voltage at Water in Fuel Sensor
1157 228 97 12 maximum level is exceeded limit (bad fuel quality) and renew harness if needed.
Internal hardware monitoring: the CPU of Error during positive test (ECU internal Threshold for error detection is an internal
the ECU is reset and the cause is logged error). Diagnostic fault check to report that ECU threshold.Reflash ECU. If error is still
1170 555 523612 12 internally; no item will be created in error thepositive test failed activ replace ECU.
memory
Battery voltage: the voltage measured by Battery voltage over limit Check alternator, regulator of alternator
1180 318 168 0 ECU is out of the target range and if necessary replace it, check wiring
andvoltage of alternator
Battery voltage: the voltage measured by Battery voltage below limit Check alternator, cabling, contact
ECU is out of the target range resistance, safety fuses, too high load in
1181 318 168 1 energysystem, check battery and if
necessary replace it
sensed air temperature within air intake sensed air temperature within air intake Cold start and ambient temperature <
1183 226 172 1 path of engine below physical low limit path of engine below physical low limit thresholdCheck wiring harness to AFST-
sensorExchange AFST-sensor
Camshaft- and Crankshaft speed sensor Sensors for engine speed are defect. Threshold for error detection is an internal
1222 2-1-2 190 14 signal not available on CAN or defect. ECU threshold.Check wiring, check cabels
and repair or replace if necessary.
Actuator EGR-Valve: Open load on ECU Open circuit on component wiring Threshold for error detection is an internal
1223 594 5763 6 output is detected ECU threshold.Check wiring, component,
ECUCheck repair with SerDia 2010 use case
Actuator EGR-valve: too high curent is Overload on component wiring Threshold for error detection is an internal
1224 594 5763 6 going into the actuator. Output is switched ECU threshold.Check wiring, component,
off ECUCheck repair with SerDia 2010 use case
Actuator EGR-valve: short cut to battery is Short-Circuit to battery on component Threshold for error detection is an internal
1226 594 5763 3 detected wiring ECU threshold.Check wiring, component,
Actuator EGR-valve: short cut to battery on Short-Circuit to battery on component Threshold for error detection is an internal
1227 594 5763 3 ECU pin is detected wiring ECU threshold.Check wiring, component,
Actuator EGR-valve: short cut to ground on Short-Circuit to ground on component Threshold for error detection is an internal
1228 594 5763 4 ECU pin is detected wiring ECU threshold.Check wiring, component,
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Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal
1229 594 5763 4 ECU pin is detected ECU threshold.Check wiring, component,
Actuator error EGR-valve; Overload by Short Circuit over Load Threshold for error detection is an internal
1230 5-9-4 5763 6 short-circuit ECU threshold.Check wiring, component
Power stage overtemperature due to high Temperature dependent Over Current Threshold for error detection is an internal
1231 5-9-4 5763 11 current. ECU threshold.Check wiring, component
Actuator error EGR-Valve (2.9;3.6) or Monitoring for CY146 Under Voltage. Threshold for error detection is an internal
Throttle-Valve (4.1;6.1;7.8); Voltage below ECU threshold.Check wiring, component
1232 5-9-4 5763 4 threshold3.6) Drosselklappe (4.1;6.1;7.8);
Voltage below threshold;
Actuator relay 5: the voltage measured by Short-Circuit to battery to component Threshold for error detection is an internal
1239 788 523984 3 ECU is out of the target range ECU threshold.Check wiring, component,
ECU
Actuator relay 4: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal
ECU
Actuator relay 5: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal
ECU
Injector diagnosis: Timeout of Injetor Short-Circuit to ground on component Threshold for error detection is an internal
detection cylinder bank 0 wiring ECU threshold.Check wiring, component,
1337 565 2797 4 ECUNote: affected injector has to be
evaluated according to firing order
Injector diagnosis: Timeout of Injetor Short-Circuit to ground on component Threshold for error detection is an internal
detection cylinder bank 1 wiring ECU threshold.Check wiring, component,
1338 566 2798 4 ECUNote: affected injector has to be
evaluated according to firing order
Injector test: Short cut to ground on Short-Circuit to ground on component Check wiring, component, ECUNote:
1339 565 2797 4 cylinder bank 0 wiring affected injector has to be evaluated
according to firing order
Injector test: Short cut to ground on Short-Circuit to ground on component Check wiring, component, ECUNote:
1340 566 2798 4 cylinder bank 1 wiring affected injector has to be evaluated
according to firing order
Rail pressure safety function is not Rail pressure is still above threshold. Threshold for error detection is an internal
executed correctly ECU threshold.Reset the fault and at
1381 839 164 2 reappearance check ECU and injection
system
ECU internal temperature; temperature Short-Circuit in ECU, ECU heated by hot air Close warm air circuits, replace ECU
1398 681 1136 0 measured by ECU is out of the target
range
sensed intake air temperature at air filter sensed intake air temperature at air filter > Check outside conditions:Temperature >
> physical high limit physical high limit Threshold within the intake air system of
the engine?E.G: engine sucks in air from
1425 226 172 0 hot asphalt out of paver bucketSensor
positioned within black air filter housing
above engine lid at hot
environmentalconditions and idling or
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similar?=> if yes check with application
team to adapt limitsif not check sensor
and wiring harnessexchange 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
Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted Check temperature upstream DOC Exh_
DPF temperature < Threshold DPF temperature, is below or abovethe tSensOxiCatUs within Stand-still: > 450 °C?
1Temperature Phy_tPfWgh, the weighted target temperature towards the end of the Ifnot:=> Check air path of engine: EGR-
DPF temperature > Threshold 2towards stand-still main phase. Valve, Intake-Throttle, Turbocharger and
the end of the stand-still main phase. Pipingeach for leakage and correct
functionCheck 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
1455 711 3711 12 injector got stuck?Too many hydrocarbons
in exhaust? White smoke (at hot EAT
system, not at coldstart)?Check air path of
engine: EGR-Valve, Intake-Throttle,
Turbocharger and Piping eachfor leakage
and correct functionCheck exhaust gas
temperature sensors within EAT-system: T
upstream DOCC, Tdownstream DOC & T
upstream SCR catalystall three of them can
influence Phy_tPfWgh
Low fuel pressure: the low fuel pressure Fuel pressure below warning threshold Threshold for error detection is an internal
calculated by ECU is underneath the target ECU threshold.Check low fuel pressure
1505 8-4-3 524057 2 range; the ECU activates a system reaction system (fuel feed pump, relay , fuse,
wiring, sensor) and ifnecessary repair or
replace it.
Open load sensor internally at NOx-sensor Open load sensor internally at NOx-sensor Threshold for error detection is an internal
downstream SCR downstream SCR ECU threshold.Check NOx-Sensor
downstream SCR catalyst: water inside?
Shake out sensor afterdismounting. => If
1533 246 524074 9 water inside, replace sensor.Check
mounting position of sensor and judge it
regarding condense water formation
/agglomeration.Check wiring
harnessExchange sensor
Short circuit sensor internally at NOx- Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal
sensor downstream SCR downstream SCR ECU threshold.Check NOx-Sensor
downstream SCR catalyst: water inside?
Shake out sensor afterdismounting. => If
water inside, replace sensor.Check
1534 247 524075 11
mounting position of sensor and judge it
regarding condense water formation
/agglomeration? Rearrange if critical and
possibleCheck wiring harnessExchange
sensor
Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal
downstream SCRNOx Sensors are CAN downstream SCR ECU threshold.Check NOx-Sensor upstream
1535 248 524076 9 Sensors –> no HW Pin on the ECU SCR catalyst: water inside? Shake out
sensor afterdismounting. => If water
1200SJP , 1350SJP 31220396 169


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inside, replace sensor.Check mounting
position of sensor and judge it regarding
condense water formation /agglomeration.
Check wiring harnessExchange sensor
Short circuit sensor internally at NOx- Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal
sensor downstream SCRNOx Sensors are downstream SCR ECU threshold.Check NOx-Sensor upstream
CAN Sensors –> no HW Pin on the ECU SCR catalyst: water inside? Shake out
sensor afterdismounting. => If water
1536 249 524077 11 inside, replace sensor.Check mounting
position of sensor and judge it regarding
condense water formation /agglomeration.
Check wiring harnessExchange sensor
Lambda value of NOx-Sensor downstream sensed lambda value of Nox-sensor Check whether NOx-sensor downstream
SCR is out of range.When the filtered downstream SCR catalyst is > physical high SCR catalyst is physically mounted within
Lambda concentration value at the sensor limitComRxSCR_rCanLamDs_mp > theexhaust lineCheck Lambda values of
(ComRxSCR_rFltLamDs_mp) is greater threshold NOx-sensor downstream SCR catalystat at
than the physical range check max. idle conditions,ComRxSCR_rCanLamDs_mp
lambda threshold > threshold?Compare to ComRxSCR_
1537 255 524078 9 rCanLamUs_mp. Values must be almost
identicalCheck CANBus of NOx-sensor
downstream SCR catalystCheck NOx-sensor
downstream SCR catalyst wiringCheck NOx-
sensor downstream SCR catalyst
itselfReplace NOx-sensor downstream SCR
catalyst
sensed lambda value of NOx-sensor sensed lambda value of NOx-sensor Compare to ComRxSCR_rCanLamUs_mp.
downstream SCR catalyst is < physical low downstream SCR catalyst is < physical low ComRxSCR_rCanLamDs_mp must bealmost
limitComRxSCR_rCanLamDs_mp < limitComRxSCR_rCanLamDs_mp < identical!If almost identical,Check air path
threshold threshold of engine: EGR-Valve, Intake-Throttle,
Turbocharger and Piping eachfor leakage
and correct functionCheck injection system
of engine. Injector stuck?if sensed lambda
1538 256 524079 9 upstream SCR higher (ComRxSCR_
rCanLamUs_mp) : Diesel inUrea-tank?
Check CANBus of NOx-sensor downstream
SCR catalystCheck NOx-sensor downstream
SCR catalyst wiringCheck NOx-sensor
downstream SCR catalyst itselfReplace
NOx-sensor downstream SCR catalyst
sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor Check whether NOx-sensor upstream SCR
upstream SCR catalyst is > physical high upstream SCR catalyst is > physical high catalyst is physically mounted within
limitComRxSCR_rCanLamUs_mp > limitComRxSCR_rCanLamUs_mp > theexhaust lineCheck Lambda values of
Threshold Threshold NOx-sensor upstream SCR catalystat at idle
conditions,ComRxSCR_rCanLamUs_mp <
Threshold?Compare to ComRxSCR_
1539 257 524080 9 rCanLamDs_mp. Must be almost
identicalCheck CANBus of NOx-sensor
upstream SCR catalystCheck NOx-sensor
upstream SCR catalyst wiringCheck NOx-
sensor upstream SCR catalyst itselfReplace
NOx-sensor upstream SCR catalyst
sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor Check air path of engine: EGR-Valve,
1540 258 524081 9 upstream SCR catalyst is < physical low upstream SCR catalyst is < physical low Intake-Throttle, Turbocharger and Piping
eachfor leakage and correct functionCheck
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limitComRxSCR_rCanLamUs_mp < limitComRxSCR_rCanLamUs_mp < injection system of engine. Injector stuck?
Threshold Threshold Check CANBus of NOx-sensor upstream SCR
catalystCheck NOx-sensor upstream SCR
catalyst wiringCheck NOx-sensor upstream
SCR catalyst itselfReplace NOx-sensor
upstream SCR catalyst
sensed NOx-value of NOx-sensor sensed Nox-value of Nox-sensor Check CANBus of NOx-sensor downstream
downstream SCR catalyst < Threshold downstream SCR catalyst < physical low SCR catalystCheck NOx-sensor downstream
1542 261 524083 9 limit SCR catalyst wiringCheck NOx-sensor
downstream SCR catalyst itselfReplace
NOx-sensor downstream SCR catalyst
sensed Nox-value of Nox-sensor upstream sensed Nox-value of Nox-sensor upstream Check CANBus of NOx-sensor upstream SCR
SCR catalyst < Threshold SCR catalyst < physical low limit catalystCheck NOx-sensor upstream SCR
1544 912 524085 9 catalyst wiringCheck NOx-sensor upstream
SCR catalyst itselfReplace NOx-sensor
upstream SCR catalyst
Urea backflow line heater: broken wiring Open Load on wiring to component Check wiring, component
1555 869 524063 5 detectedThreshold 1 < SCRHtr_
rUHtrMeasRatio_mp < Threshold 2
Urea main relay: broken wiring relay defectrelay not connectedwiring Check wiring, component
1556 869 524063 5 detectedThreshold 1 < SCRHtr_ harness brokenproblems with supply
rUHtrMeasRatio_mp < Threshold 2 voltage
Urea pressure line heater: broken wiring Open load on wiring to component Check wiring, component
1557 869 524063 5 detectedThreshold 1 < SCRHtr_
SCR heater mainrelay; short circuit to Short-Circuit to battery on wiring to Check wiring, component
1558 869 524063 3 batteryThreshold 1 < SCRHtr_ component
Connection between heating valve (Y31) Faulty wiring, faulty heater relay (K27-K31), Disconnect plug from heating valve (Y31)
on the control unit Pin A:92 andLoad side defective heating valve (Y31),broken and reset fault.If fault is still present you
SCR heater main relay (K31) is a short cut element in heating. have to look in the wiring of Y31 to the
1559 869 524063 4 to ground.Threshold 1 < SCRHtr_ control unit Pin A:92.If error is no longer
rUHtrMeasRatio_mp < Threshold 2 present, you have to check the wiring of
Y31 via relay K31and possibly the heating
cables and relay (K27-K30).
SCR relay for suction line not relay defectrelay not connectedwiring Check wiring, component
1560 869 524063 5 connectedThreshold 1 < SCRHtr_ harness brokenproblems with supply
rUHtrMeasRatio_mp < Threshold 2 voltage
Open load on wiring to Open load on wiring to component Check wiring, component
1561 869 524063 5 componentThreshold 1 < SCRHtr_
1562 869 524063 5 SCR heater tank; open load Open load on wiring to component Check wiring, component
The relativ pressure value of the exhaust sensed presure upstream SCR catalyst > Check for crystallisation in exhaust line
gas from the urea cat upstreamsensor is physical high range limit f(exhaust upstream SCR and dwnstream of urea
greater than an applicable maximum volumeflow)UCatUsP_pRelFlt_mp > injectorCheck correct connection from
1565 892 524065 0 pressure threshold UCatUsP_pMax_mp exhaust line to pressure sensor upstream
SCR catalyst:syphons?, water in tube?,
water in sensor?Check that exhaust pipe
outlet is free (downstream SCR catalyst)
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Check wiring of pressure sensor upstream
SCR catalystCheck pressure sensor
upstream SCR catalyst:sensor has no
connection to vehicle body? => Ensure
that sensor is freeDoes sensor oscillate
heavely at engine low idle / high idle? =>
try to supress theoscillatingExchange
pressure sensor upstream SCR
catalystCheck calculated exhaust volume
flow of engine within EDC: SCR_
dvolSCRUspausible? If not:Check T sensor
upstream SCR catalyst, check complete
engine air path: EGR-Valve,Intake throttle,
turbocharger, piping for leakage and
functionCheck SCR catalyst: Broken?
Exchange SCR-Catalyst
The relativ pressure value of the exhaust sensed presure upstream SCR catalyst > Check correct connection from exhaust line
gas from the urea cat upstream sensor is physical high range limit f(exhaust to pressure sensor upstream SCR catalyst:
less than an applicable minimum pressure volumeflow)UCatUsP_pRelFlt_mp < leakage?Check electric connector: 4h pin
threshold UCatUsP_pMin_mp open / new connector type used? pressure
exchangefrom inside electrical connector
with the environemt possibleCheck exhaust
line: any leakages upstream of SCR
catalyst?Check wiring of pressure sensor
1566 892 524065 1 upstream SCR catalystExchange pressure
sensor upstream SCR catalystCheck
calculated exhaust volume flow of engine
within EDC: SCR_dvolSCRUspausible? If
not:Check T sensor upstream SCR catalyst,
check complete engine air path: EGR-
Valve,Intake throttle, turbocharger, piping
for leakage and functionCheck SCR
catalyst: Broken? Exchange SCR-Catalyst
voltage of pressure sensor upstream SCR > voltage of pressure sensor upstream SCR > Check wiring of pressure sensor upstream
voltage high limit voltage high limit SCR catalystCheck pressure sensor
1569 892 524065 3 upstream SCR catalystExchange pressure
sensor upstream SCR catalyst
voltage of pressure sensor upstream SCR < voltage of pressure sensor upstream SCR < Check wiring of pressure sensor upstream
voltage low limit voltage low limit SCR catalyst. Check pressure
1570 892 524065 4 sensorupstream SCR catalyst. Exchange
pressure sensor upstream SCR catalyst
Filtered urea supply module heater sensed temperature of supply module Compare SCR_tSMT with SCR_tSMHtrT.
temperature value is above an applicable heater > physical high range limit Both show the same value?Check urea
maximum heater temperature threshold of tank temperature (SCR_tAdapUTnkT). Very
the supply moduleThe temperature is read hot (> 70°C), urea tank heaterpermanet
out via the PWM signal of the urea pump. on?Does the pump never stop working?
That is only possible in status init of the Check wiring to supply moduleCompare
1581 894 524067 0 SCR-system short after ignition was SCR_tSMT with SCR_tSMHtrT. Both show
switched on. When that state isleft the different values or urea tanktemperature
sensed temperature value is frozen. (SCR_tAdapUTnkT) is cold:exchange urea
pump unitSupply module heater
temperature sensor defectSupply module
heater defectSupply module defect
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Filtered urea supply module heater sensed temperature of supply module Check ambient temperature EnvT_t <
temperature value is below an applicable heater < threshold Threshold?Compare SCR_tSMT with SCR_
minimum heater temperature threshold of tSMHtrTCheck wiring with regard to supply
the supply moduleThe temperature is read modul heaterexchange urea pump
1582 894 524067 1 out via the PWM signal of the urea pump. unitSupply module heater temperature
That is only possible in status init of the sensor defectSupply module defect
SCR-system short after ignition was
switched on. When that state isleft the
sensed temperature value is frozen.
Filtered urea supply module temperature sensed temperature of urea within supply Compare SCR_tSMT with SCR_tSMHtrT.
value (SCR_tSMT) is above an applicable module > physical high range limit Both show the same value?Check urea
maximum temperature threshold of the tank temperature (SCR_tAdapUTnkT). Very
supply moduleThe temperature is read out hot (> 70°C), ure tank heaterpermanet
via the PWM signal of the urea pump. on?Does the pump never stop working?
That is only possible in status init of the Check wiring to supply moduleCompare
1585 894 524067 0 SCR-system short after ignition was SCR_tSMT with SCR_tSMHtrT. Both show
switched on. When that state isleft the different values or urea tanktemperature
sensed temperature value is frozen. (SCR_tAdapUTnkT) is cold:exchange urea
pump unitSupply module temperature
sensor defectSupply module heater
defectSupply module defect
Filtered urea supply module temperature sensed temperature of urea within supply Check ambient temperature EnvT_t <
(SCR_tSMT) value is below an applicable module < physical low range limit threshold?Compare SCR_tSMT with SCR_
minimum temperature threshold of the tSMHtrTCheck wiring with regard to supply
supply moduleThe temperature is read out modul heaterexchange urea pump
1586 894 524067 1 via the PWM signal of the urea pump. unitSupply module temperature sensor
That is only possible in status init of the defectSupply module defect
SCR-system short after ignition was
switched on. When that state isleft the
sensed temperature value is frozen.
The urea tank level sensor detects a value Suspected components:Urea Quality Sensor Check level sensor and float gauge
1593 129 1761 0 higher than the maximum allowed defectmechanical defect at the float gauge
threshold
The DEF tank level sensor detects a value Suspected components:Urea Quality Sensor Check level sensor and float gauge
1594 129 1761 1 lower than the minimum allowed defectmechanical defect at the float gauge
threshold
Comparison of urea cat upstream exhaust absolut value of difference between sensed Check electric connector: 4h pin open /
gas- and environment pressure, the pressure upstream SCR catalyst new connector type used?pressure
difference should not exceed a certain andenvironmental pressure > limitabs exchange from inside electrical connector
limitabs(UCatUsP_pDiffEnvCat_mp) > (UCatUsP_pDiffEnvCat_mp) > Threshold with the environemt possible?water in
Threshold sensor?sensor frozen?Check wiring of
1598 892 524065 2 pressure sensor upstream SCR
catalystExchange pressure sensor upstream
SCR catalystCheck intake manifold pressure
sensor (Air_pCACDs)Check ambient
pressure sensor (EnvP_p)
No proper urea pressure level could be This error shows up, if no proper urea Make sure that frozen lines, pump or tank
build up within the SCR system state "Fill pressure level could be build up within the can be excluded!Check whether there is
Lines" => SCRCo_stStatus_mp = 1 within SCRsystem state "Fill Lines" => SCRCo_ urea in the urea tankCheck urea lines:All
some miuntes stStatus_mp = 1 within some minutesOnce lines connected? The right lines connected
1639 966 524147 13 the urea pump pressure has exceeded the to the correct places?Suction line blocked?
threshold the error is declared asokay. No leakage? Not also urea to the outside
Suspected components:Suction line but also air into the lines, especially in
blockedPWM Powerstage has a defect and a thesuction line!Perform service routine
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default value which leads not to a rising "pressure test":Does the urea pump work?
pressurePump Pressure sensor defectpump => check wiring harness & PWM signal
filter contains dirty partsreverting valve for pumpDoes the urea pressure rise?DFC
continously open 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_
SCRCoRevVlvBlkCheck pump filter: dirt
inside?Suspected components:Urea pump
brokenReverting valve continously
openUrea suction line, backflow line
broken or connection swappedPWM
Powerstage has a defectPump Pressure
sensor broken
SCR supply module temperature is not Suspected components:Enviroment CheckEnvironment temperature sensorSCR
reaching a threshold before a calibratable temperature sensor defectSCR supply supply module temperature sensorSCR
time is exceeded.Corresponding to the module temperature sensor defectSCR supply module electrical heater
environmental Temperature a specific supply module electrical heater defect
defrosting time is given. After starting the
defrosting a clock counter is starting. Does
the counter reach the givendefrosting time
1646 869 524063 12 limit, an error will be detected. Is the
temperature reached in time the clock
counter will be resetExample: by using the
calibrated temperature/time curve –>
environmental temperature 0°C –>
defrosting time limit 6000s –> if the clock
counter reaches 6000s the error willbe
detected
The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp Check urea level => if empty, then fill in
threshold of <5% [%] is below applicable threshold 5% ureaCheck DEF level sensor.If there is urea
in the tank, then move the floater of the
level sensor. The floater mustbe free. If
1655 138 1761 14 you lift the sensor body, then SCRUTnk_
rVol_mp must change.Exchange DEF level
sensor, if no change of value or it's
implausible.
The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp Check urea level => if empty, then fill in
threshold of <2.5% [%] is below 2.5% ureaCheck DEF level sensor.If there is urea
in the tank, then move the floater of the
level sensor. The floater mustbe free. If
1656 138 1761 14 you lift the sensor body, then SCRUTnk_
rVol_mp must change.Exchange DEF level
sensor, if no change of value or it's
implausible.
Timeout error of CAN-Transmit-Frame Open load on CANBUS wiring. Check wiring, component.
1666 924 524100 9
ComDPFHisDat.
Timeout error of CAN-Receive-Frame If the frame CM1 message is not Check CAN Bus cabling (Bus sheduling,
ComRxCM1 transmitted successfully polarity, short circuit, power interrupt),
1672 9-4-2 524118 9 testprotocol of receiver, check CAN
functional range.
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Timeout error of CAN-Receive-Frame Time out of Check CANBUS EAT Control Threshold for error detection is an internal
ComRxDPFCtl. CM1 Module Customer Receive Message, PGN65348.The message is ECU threshold.Check CANBUS EAT Control
1676 928 524104 9 Recieve Message. not received. Receive Message, PGN65348.CM1 Module
Customer Recieve Message.
Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling,
ComRxTrbChActr polarity, short circuit, power interrupt),
functional range.
ComTxTrbChActr polarity, short circuit, power interrupt),
functional range.
ComRxEBC2 from wheel speed sensor. Defect on wheel speed sensor. polarity, short circuit, power interrupt),
functional range.Replace the wheel speed
sensor.
EGR actuator is mechanically blocked. EGR actuator faulty or blocked. Threshold for error detection is an internal
ECU threshold.Check the EGR actuator and
1752 415 2791 7 EGR valve to mechanical blockage / clean.
Check for free movement of the valve. If
it'S blocked, then exchange the EGR valve.
corrupted CAN communication with CAN bus error or faulty EGR actuator. Threshold for error detection is an internal
actuator. ECU threshold.Check other CAN bus
1753 415 2791 2 components. If no message is sent, fix the
wiring.If o.k. exchange EGR actuaror.
EGR actuator can not learn stop positions. Error detection during the learning process. Threshold for error detection is an internal
Possibly only second failure if other EGRTV ECU threshold.Start Serdia Usecase to reset
1754 415 2791 13 failures occure. EGR actuator.Check EGR valve and
mounting situation. If o.k. change EGR
actuator.
Internal electrical fault of EGR actuator. Internal damage of EGR actuator due to Threshold for error detection is an internal
1755 415 2791 12 high temperature or electrical wiring issue. ECU threshold.Exchange EGR actuator.
EGR actuator can not learn stop positions Interruption of learning process due to Threshold for error detection is an internal
1756 415 2791 13 because procedure was interrupted. mechanical damage. ECU threshold.Start Serdia Usecase to reset
EGR actuator.
Overcurrent to EGR actuator. High voltage from battery.EGR actuator is Check battery voltage. Check if EGR is
1757 415 2791 6 blocked or moving very hard. blocked or 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.
Stop positions of EGR valve not o.k. Mechanical damage of EGR actuator.EGR Threshold for error detection is an internal
1760 415 2791 13 valve is blocked or moving very hard. ECU threshold.Start Serdia Usecase to reset
EGR actuator.
EGR actuator spring broken. mechanical damage of spring due to Threshold for error detection is an internal
1761 415 2791 7 overstress. ECU threshold.Exchange EGR actuator.
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Internal actuator temperature above overheating of EGR actuator Let EGR actuator cool down, check heat
1762 415 2791 16 threshold. accumulation during worst case operation.
Internal actuator temperature is above Overheating of EGR actuator during Let EGR actuator cool down and check
1763 415 2791 0 threshold. operation. heat accumulation during worst case
operation.
DEF dosing valve is blocked with While SCR system is starting up and fter Check electrical connection of urea
crystalized urea or other deposits. urea pressure reaches 10000 hPa, the injector:- wiring harness-
DEFdosing module is tested. Expectation is connectorConduct SERDIA use-case
that urea pressure drops below 1500 hPa "injection test". If it is faulty:- remove urea
ifinjector works properly. The test is injector from exhaust line:- check for
repeated up to 3 times before an error is crystallisation direct on injector nozzle /
1827 192 524141 7 set.SCRSysPresMon_stPresDropDet_mp = 0 plate- rinse it thoroughly in water-
while SCRCo_stStatus_mp = 16.Suspected remount urea injector and conduct SERDIA
component:wiring harnessDEF dosing use-case "injection test"If the error is still
valveThe error is stored into the EEPROM of active, then exchange urea injector.
the ECU and status at ECU shut down
isregained at ignition on.
Fault in the monitoring during the engine wiring is not according DEUTZ Threshold for error detection is an internal
start. Start requested in level 1, but not requirementsengine start conditions are not ECU threshold.check other active errors and
released in level 2 which leads to no fuel observedlow battery voltage during fix them.check all needed engine start
injection. startmalfunction of starter conditions, e.g. neutral switch.check the
1857 555 523612 12
engine speed during starting of the
engine. If it's too low, then check
thebattery voltage and then check the
starter for malfunction.
DEF dosing valve is blocked with While SCR system is starting up and fter Check electrical connection of urea
crystalized urea or other deposits. urea pressure reaches 10000 hPa, the injector:- wiring harness-
DEFdosing module is tested. Expectation is connectorConduct SERDIA use-case
that urea pressure drops below 1500 hPa "injection test". If it is faulty:- remove urea
ifinjector works properly. The test is injector from exhaust line:- check for
repeated up to 3 times before an error is crystallisation direct on injector nozzle /
1858 192 524141 7 set.SCRSysPresMon_stPresDropDet_mp = 0 plate- rinse it thoroughly in water-
while SCRCo_stStatus_mp = 16.Suspected remount urea injector and conduct SERDIA
component:wiring harnessDEF dosing use-case "injection test"If the error is still
valveThe error is stored into the EEPROM of active, then exchange urea injector.
the ECU and status at ECU shut down
isregained at ignition on.
The error shows up, if no proper urea This error shows up, if no proper urea Make sure that DEF lines, pump and tank
presure could be build up within the SCR presure could be build up within the SCR are not frozen.Check for DEF level in the
system state "Fill Lines" => SCRCo_ systemstate "Fill Lines" => SCRCo_ tank.Check DEF lines:Are all DEF lines
stStatus_mp = 1. stStatus_mp = 1.3 cases can lead to the connected?Is the suction line blocked?Is
error:Case A: increasing pressure is detected ther any leakage? Not only urea to the
within 15s the check has passed => no outside but also air into the lines,
errorCase B: The pressure threshold was not especially inthe suction line!Perform
reached within the 60s but case A was SERDIA usecase "pressure test":Does the
1863 995 524177 7 notpositiv.Case C: The minimum pressure of DEF pump work? => check wiring harness
3000 hPa was not reached within the 60s. & 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
SCR system state = 0 ("Init check"),SCR_
pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!Check DEF
pump filter: Is any dirt inside?Suspected
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components:Suction linePWM Powerstage
has a defect and a default value which
leads not to a rising pressureDEF pump
pressure sensor defectDEF pump filter
contains dirty parts
The urea pump is not able to control the The urea pump controller is not able to Make sure that DEF lines, pump and tank
urea pressure between 9bar and 11 bar. control the urea pressure between 9bar and are not frozen.Check for DEF level in the
11bar due to malfunction in the SCR tankCheck DEF lines:All lines connected?
system.Suspected components:- DEF pump The right lines connected to the correct
broken- Reverting valve continously open- places?Suction line blocked?Is there any
Urea suction line, backflow line broken or leakage? Not also urea to the outside but
connection swapped- PWM Powerstage has also air into the lines, especiallyin the
a defect- Pump Pressure sensor broken suction line!Perform SERDIA usecase
"pressure test":Does the DEF pump work
properly? => check wiring harness &
PWM signal for pumpDoes the DEF
1864 996 524178 7 pressure rise?Is the error healed?If still
unsuccessful so far:- Check DEF pressure
sensor: At ignition on and SCR system
state = 0 ("Init check"),SCR_
pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!- Check
reverting valve- Check DEF pump filter: dirt
inside?Suspected components:DEF pump
brokenReverting valve continously openDEF
suction line, backflow line broken or
connection swappedPWM Powerstage has
a defectDEF pump pressure sensor broken
Error at static plausibility check:absolut Error at static plausibility check:absolut Check whether temperature sensor
temperature difference of sensed temperature difference of sensed upstream of SCR catalyst is physically
temperature upstream SCR catalyst and temperature upstream SCR catalyst mountedwithin exhaust pipeIf cold start
ambient temperature > as static andambient temperature > as static condition can be made sure (engine was
plausibility limitat engine cold start plausibility limitat engine cold start (engine off for at least 8 h) comparevalues of
(engine was off for at least 8 h), was off for at least 8 h), temperature EnvT_t, EngDa_tEng, Exh_TOxiCatUs, Exh_
temperature upstream of SCR catalyst is upstream of SCRcatalyst is expected to be tOxiCatDs andSCR_tSensUCatUsT at
expected to be identical to ambient identical to ambient temperature => see ignition on, without starting the engine.
temperature => see enable conditions enable conditions fordetails.Error at All identical?Compare values of Exh_
fordetails.Error at dynamic plausibility dynamic plausibility check:temperature TOxiCatUs, Exh_tOxiCatDs and SCR_
1865 668 4360 2
check:temperature difference of sensed difference of sensed temperature upstream tSensUCatUsT after 15min in constant
temperature upstream SCR catalyst and SCR catalyst and ambienttemperature < as operation point: show all similar values
ambient temperature < as dynamic dynamic plausibility limitdynamic check is (30 K tolerance width). Areambient
plausibility limitdynamic check is blocked if blocked if static plausibility check is already temperature and (EnvT_t), cooling water
static plausibility check is already faulty=> faulty=> Temperature upstream SCR temperature (EngDa_tEng) plausible?
Temperature upstream SCR catalyst must catalyst must be by 40°C higher than Sensor coated with urea crystalls?
be by 40°C higher than ambient ambienttemperature if engine runs and a Dismount urea injector and inspect
temperature if engine runs and a certain certain delay time has expired. temperaturesensor upstream SCR catalyst
delay time has expired. visuallyCheck wiring of sensorReplace
sensor
absolute difference of sensed urea pump absolute difference of sensed urea pump Check environment pressure sensor (EnvP_
pressure (SCR_pAbsSensUPmpP) and pressure (SCR_pAbsSensUPmpP) p) => plausible value?Engine shut-off and
ambient pressure (EnvP_p) > limitabs andambient pressure (EnvP_p) > limitabs immediately re-started? => Shut-off
(UPmpP_pDiffPmpEnv_mp) > UPmpP_ (UPmpP_pDiffPmpEnv_mp) > UPmpP_ again. Wait until afterun ofECU has
1866 665 4334 2
pDiffPmpEnv_C (250 hPa) pDiffPmpEnv_C finished, re-Start engineBack-flow line
free? Does the urea pump pressure show
values < 1000 hPa in SCRstate emptying
(64)?Check revision valve => Does the
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urea pump pressure show values < 1000
hPa in SCRstate emptying (64)? =>
exchange supply moduleSupply module
pressure sensor defect => exchange
supply module
absolute diference of sensed temperature absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT,
of supply module heater temperature and supply module heater temperature EnvT_t and CEngTds_t andSCR_
ambient temperature UPmpT_ andambient temperature UPmpT_ tAdapUTnkT => All identical? If not:Has
tDiffPmpHtrAmb_mp > threshold tDiffPmpHtrAmb_mp > threshold the machine been brought from cold
environment into a warm one or vice
1867 894 524067 2 versawithout engine running, e.g. at
workshop?Environment temperature sensor
defectCoolant temperature sensor
defectSupply module temperature sensor
defectProblem at Supply module unit
(broken?) => exchange supply module
absolute diference of sensed temperature absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT,
of supply module temperature and supply module temperature and EnvT_t and CEngTds_t andSCR_
ambient temperature > threshold ambienttemperature UPmpT_ tAdapUTnkT => All identical? If not:Has
tDiffPmpAmb_mp > threshold the machine been brought from cold
environment into a warm one or vice
1868 894 524067 2 versawithout engine running, e.g. at
workshop?Environment temperature sensor
defectCoolant temperature sensor
defectSupply module temperature sensor
defectProblem at Supply module unit
(broken?) => exchange supply module
CAN message is not received fora definite CAN message is not received for a definite Check eletrical connection oif urea quality
time => error is set. As soon as the time => error is set. As soon as sensorCheck engine CAN busCheck urea
1874 971 524152 2
message is received the error heals. themessage is received the error heals. quality sensor itselfExchange urea quality
sensor
CAN message is not reseived for a definite CAN message is not reseived for a definite Check eletrical connection of suction unit
time => error is set. As soon as the time => error is set. As soon as sensor (combined sensor with tank level
1875 997 524153 2 message is received the error heals. themessage is received the error heals. andtank temperature)Check engine CAN
busCheck level sensor itselfExchange
suction unit
The DEF tank level is below the threshold. actual DEF tank level SCRUTnk_rVol_mp Check DEF level => if empty, refillCheck
[%] is below the threshold DEF level sensor.If there is urea in the tank
loose the sensor and move it. The floater
must be free andmove if you lift the
sensor body.SCRUTnk_rVol_mp must
1880 138 1761 14 change.Compare SCRUTnk_rVol_mp to:1 =
SCR_rawUTnkLvl2 = SCR_rAdapUtnkLvl3
= SCRUTnk_rActTnkVol *SCRUTnk_
facVolPer_mpIn case of malfunction,
exchange DEF level sensor.
At engine cold start conditions the sensed Difference temperature of exhaust gas Check whether all exhaust gas
exhaust gas temperature downstream DOC temperature downstream DOC and temperature sensors within the EAT system
(Exh_tSensTOxiCatDs)has exceeded the fixedambient temperature at ignition on aremounted properly: Within the exhaust
sum of ambient temperature (EnvT_t) + exceeds a certain limit earlier than the line and at correct positions.Check the
1881 683 4768 2 offset (40°C) earlier than the sensed differencetemperature of exhaust gas position of the sensor upstream SCR which
exhaust gastemperature upstream of DOC temperature upstream DOC and fixed might be physically mounted inthe wrong
(Exh_tSensTOxiCatUs).The check is only ambient temperatureat ignition on. position.If cold start condition can be
performed once each ignition cycle and made sure (engine was off for at least 8 h)
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only if the start is judged a cold start.Error comparevalues of EnvT_t, EngDa_tEng,
status is frozen for that ignition cycle. No Exh_TOxiCatUs, Exh_tOxiCatDs andSCR_
healing possible. tSensUCatUsT at ignition on, without
starting the engine. All identical? Then
thesensors itself are okay.Check exhaust
piping for leakage.Check wiring of
sensorsReplace sensorsCheck DOC =>
physicallly intact?
Not enough urea in tank or low urea Low DEF tank levelLow DEF Check DEF level in tank. If there is no DEF,
quality or hardware tampering failure is qualityHardware Tampering is refill up to volume above the
detected or hardware failure is detected activeHardware Failure is active warningthreshold.Check the DEF quality in
1891 272 524190 14
the tank. If wrong fluid is filled, refill with
proper DEF.Check other errors based on
hardware malfunctions.
A low DEF tank level or a low DEF quality Low DEF tank levelLow DEF Threshold for error detection is an internal
is detected or hardware tampering(system qualityHardware Tampering is ECU threshold.Check the DEF level in tank.
components are pinched off) or hardware activeHardware Failure is active If there is no DEF, refill up above the
1892 273 524191 14 failures as shortcut to battery, shortcut to warning level.Check DEF quality filled in
groundetc. are detected. the tank.Check other errors based on
hardware tampering or failure.
The total time in standstill-regeneration Stand-still mode is very often aborted by Read out stand-still statistics => see
mode exceeds the long-limit threshold the operator.Standstill mode does not reach service manual:Standstill operation finished
within last 500h total engine run time.The required temperature level and or often interrupted by driver / engine
error is activated if the engine runs to regeneration level istherefore reached after shut-off? => Runstandstill and instruct
many times in Standstill regeneartion. a short time again operatorStandstill operation required often
by soot load => Check dp DPF pressure
sensorStand-still mode does not reach
required temperature level:Check engine
air path: Intake Trottle, EGR-Valve and
turbocharger okay?Any leakage in engine
air intake sytem or exhaust gas system?
Check temperature sensors within exhaust
system: upstream DOC, downstream DOCIf
soot load level of DPf allow it:Perform
Stand-still and check reached temperature
1893 275 524193 8 level upstream and downstreamDOC: T
upstream DOC in the range of 480-550°C?
Downstream DOC after 25 minstandstill
main phase 590°C are reached?Temerature
traces are steady and even?Temperature
downstream DOC higher than upstream
DOC but difference does notexceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C
downstreamDOC are not reached) =>
exchange DOCVery big difference (>100 K
after 25 min stand-still main phase, 590 °C
downstreamDOC exceeded) => check
injection system of engine & engine air
path
The total time in standstill-regeneration Stand-still mode is aborted / interrupted Read out stand-still statistics => see
mode exceeds the long-limit threshold: too often by the operatorStand-still is service manual:Standstill operation finished
1894 276 524194 8 2,5h stand-still operation within 50h total required too often due to miscalculation in or often interrupted by driver / engine
motor run time.The error is activated if the the soot modelStand-still mode does not shut-off? => Runstand-still and instruct
reache temperature level and regeneration operatorStand-still operation required
1200SJP , 1350SJP 31220396 179


De-
Cod- Code
e
engine runs to much time in short level is thereforereached after a short time often by soot load => Check dp DPF
Standstill regeneartion. again. pressure sensorStand-still mode does not
reach required temperature level:Check
engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?Any leakage in
engine air intake sytem or exhaust gas
system?Check temperature sensors within
exhaust system: upstream DOC,
downstream DOCIf soot load level of DPF
allows it:Perform Stand-still and check
reached temperature level upstream and
downstreamDOC: T upstream DOC in the
range of 480-550°C? Downstream DOC
after 25 minstand-still main phase 590°C
are reached?Temerature traces are steady
and even?Temperature downstream DOC
higher than upstream DOC but difference
does notexceed 100 K?Very small
difference (< 10 K after 25 min stand-still
main phase, 590 °C downstreamDOC are
not reached) => exchange DOCVery big
difference (>100 K after 25 min stand-still
main phase, 590 °C downstreamDOC
exceeded) => check injection system of
engine & engine air path
The integrated temperature sensor of the Temperature sensor inside the UQS defect. Check the temperature sensor signal for
Urea Quality Sensor measures higher CAN Communication corrupted.Overheating plausibility. In case of improper signal,
temperature than threshold of the DEF tank due to malfunction of the exchange the suction unit in the tank.
heating valve.Flow direction is of coolant is Check CAN bus communication for proper
wrong due to mixed up the hoses routed to signal. In case of improper signal,
the heatingvalve.Overheating of the DEF exchangethe suction unit in the tank.Check
tank due to heat transfer from neighbor the function of heating valve and routing
1895 277 3519 12
parts. of the hoses. The coolant flow throughthe
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 duringworst case condition
and improve the installation of the DEF
tank.
The integrated diagnostic of the Urea wiring harness of UQS corruptedCAN Threshold for error detection is an internal
Quality Sensor recognized a short circuit to Communication corrupted ECU threshold.Check the wiring harness
battery from the ECU to the suction unit of the
1896 278 3520 3 DEF tankCheck the CAN bus
communication. If the signal is corrupt,
then exchange the suctionunit.
The integrated diagnostic of the Urea wiring harness to the suction unit in the Threshold for error detection is an internal
Quality Sensor recognized a short circuit to DEF tank is corruptedCAN Communication ECU threshold.Check the wiring to the
ground. corrupted suction unit in the DEF tank.Check the CAN
1897 278 3520 4
bus communication. In case the
communication is corrupt, exchangethe
suction unit in the DEF tank.
The integrated diagnostic of the Wrong diagnostic of the short circuits logic Check the wiring to the suction unit in the
temperature sensor of the Urea Quality inside the temperature sensor of the DEF tank.Check the CAN bus
1898 277 3519 3 Sensor recognized a short circuit to UQSCAN Communication corrupted communication of the suction unit. In case
battery.The UQS Sensor is an combined
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sensor of tank temperature, filling grade the communication iscorrupt, exchange the
and DEF quality and it is also an CAN suction unit.
sensor –> no PIN
The integrated diagnostic of the DEF quality sensor in the suction unit of the Check the wiring to the suction unit of the
temperature sensor of the Urea Quality DEF tank is defectCAN Communication DEF tank.Check the CAN bus
1899 277 3519 4 Sensor recognized a short circuit to ground corrupted communication from the suction unit. In
case the signal is corrupt,exchange the
suction unit in the DEF tank.
The standstill request of detected Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line
crystallization is ignored for more than 5h reached a level which and inspect visually the injector and
(>300min)This will be activated if there is indicatescrystallisation inside of exhaust theexhaust line for urea crystallisation
a standstill request activated by line.The error detection depends on the upstream of SCR catalyst:If crystallisation
Crystalisation Monitoring. sensed pressure upstream of the SCR can be clearly seen, then stand-still must
catalyst andthe calculated exhaust volume be processed.Has the engine been
flow through the mixer pipe.In case of error operated in low load for longer time? If
is set, but no crystallisation can be found in yes, then it could be thereaoson for
the mixing pipe, a possiblereason can be crystallisation.Does the NOx-Sensors work
the defect sensors:- exhaust pressure & properly? Compare ComRxSCR_rNOxUs
temperature upstream of the SCR catalyst,- toComRxSCR_rNOxDs, when ComRxSCR_
the ambient pressure- the exhaust mass stNOxRdyUs = 1 &ComRxSCR_stNOxRdyDs
flow => Check air path system at the = 1 (Warm engine and EAT-system,SCRT_
engine. tCatAvrgExhGs_mp > 250°C, SCR_stStatus
= "Dosing" = 8): sensed NOxupstream of
SCR catalyst must be higher than
downstream of SCR catalyst.Go to idle and
wait until SCR system enters status "stand-
by" (no dosing),SCRT_tCatAvrgExhGs_mp
< 225°C: ComRxSCR_rNOxUs =
1900 279 524195 14
ComRxSCR_rNOxDsClean urea injector:
rinse it thourougly under waterCheck EGR-
Path: difference pressure sensor at venturi
tube, EGR cooler, EGR-Valve,Reed-Valve,
Intake throttle regarding function and
leakage. Does the EGR-cooler leakwater in
the exhaust?Check air path for
leakageCheck turbochargerNo
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 for20 minutes?=> Run
stand-still to remove crystallisation and to
reset the DFC
Measured DEF Quality from UQS is too low. Suspected components:Urea quality sensor Check that there is liquid urea of known
Quality value received from UQS is < 22 % defectWrong installation (measuring air) quality in the tank firstCheck urea tank
for a certain time and a certain number or Urea level sensor defectNon urea filled in level. Add urea until level is at least 10 cm
for measuring conditions not observed for tankCANBUS problemsEvaluation conditions above sensor.Ensure that urea is not frozen
1904 2-7-8 3520 2
a certain time. for new quality check not fulfilled after one / sufficient urea is liquidCheck Sensor: Are
previous mal detection urea tank temperature and level
displayed? Changes the level if yourefill
urea?Check electrical connectionCheck
1200SJP , 1350SJP 31220396 181


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e
CANBusNew quality detection is carried out
if urea re-fill is detected or if an quality
evaluationwas triggered and was not
finished successfully: To provoke a quality
measurement: refillurea, at least 10 % of
tank volumeWait until quality evaluation
was carried out, can take up to 30 minutes
=> check value.It should be about 33 %
Exchange quality sensor
Urea quality at UQS out of range the Suspected componentsDEF quality Check DEF quality and/or DEF quality
1907 278 3520 13 specified thresholds; invalid quality of the sensorDEF sensor
urea qualiy
Temperature at UQS out of range the Suspected ComponentsTank heaterDEF Check temperature system and/or DEF
1908 277 3519 13 specified thresholds; invalid quality of the sensor quality sensor
temperature
The urea quality value from the sensor is Suspected Components:UQS defect Check DEF quality and/or sensor.
greater than the maximum physical range
1911 127 3532 3 thresholdComment: tank temperature is
measured by the UQS sensor
The urea quality value from the sensor is Suspected Components:UQS defect Check DEF quality and/or Sensor.
1912 127 3532 4 lower than the minimum physical range
threshold.
Internal error of DEF qualitysensor. Suspected componentes:DEF Check wiring harness and DEF
1914 669 4365 3 qualitysensorWiring harness qualitysensor
Internal error of DEF qualitysensor. Suspected componentes:DEF Check wiring harness and DEF
1915 6-6-9 4365 4 qualitysensorWiring harness qualitysensor
Standstill escalation by time. In case the Stand-still request ignored by the operator. Perform Stand-still. If soot load level of
standstill request will not be released Display / stand-still request lamp broken. DPF has increased too high already call
1917 2-8-6 3936 14 within50 h by the driver this fault code serviceto perform stand-still.In case the
will be set. DPF soot load level remove DPF =>
Exchange DPF.
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3.28 DEUTZ TCD2.9L4 (GUO III) ENGINE
Figure 70. Deutz TCD2.9L4 (GUO III) Engine Installation - Sheet 1 of 2
1. Surge Tank 3. Fan 5. Muffler 7. Engine Mount
2. Radiator 4. Alternator 6. Exhaust Tail Pipe 8. Fuel Filter
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Figure 71. Deutz TCD2.9L4 (GUO III) Engine Installation - Sheet 2 of 2
1. Generator Mount 3. Air Intake Hose 5. Air Filter 7. Upper Radiator Hose
2. Lower Radiatpr Hose 4. Air Filter Indicator 6. Coolant Level Sensor 8. Pipe Flex Assembly
184 31220396 1200SJP , 1350SJP

3.29 DEUTZ TCD2.9L4 ENGINE
Figure 72. Deutz TCD2.9L4 Engine Installation - Sheet 1 of 2
1. Fan 3. Alternator 5. Muffler 7. Radiator

2. Expansion Tank 4. Fuel Filter 6. Engine Mount 8. Generator Mount
1200SJP , 1350SJP 31220396 185

Figure 73. Deutz TCD2.9L4 Engine Installation - Sheet 2 of 2
1. Air Filter 3. Air Filter Service Indicator 5. Sensor Coolant Level 7. Engine Block Heater
2. Air Intake 4. Pipe Exhaust 6. Engine Mount 8. Engine Tray
Note: Refer to engine manufacturer's manual for detailed operating and maintenance instructions. Limited engine maintenance items
are presented here for convenience but detailed engine maintenance items and schedule are included in the engine manufactur-
er's manual.
3.29.1 Glow Plugs

Emergency Stop switch is pulled on if the ambient air temperature is less than 50°F (10°C) and the engine coolant temperature is less
than 140°F (60°C). This determination will occur one second after the Power/Emergency Stop switch has been pulled on. The lamp and
glow plugs will remain enegized for the period of time specified by the setting in the JLG Control System. Engine start shall be disabled
digit setting.
3.29.2 Check Oil Level

1. Make sure machine and engine are level and switch engine OFF before checking oil level.
2. Remove oil dipstick and wipe with clean cloth.
3. Insert dipstick to the stop and remove again.
186 31220396 1200SJP , 1350SJP

4. Check oil level. Top oil level as shown in figure below with an approved grade and type of oil outlined in engine manufacturer’s
operator’s manual.
5. Replace dipstick until fully seated.
3.29.3 Replacing Engine Oil

1. Allow engine to warm up. Engine oil should reach approximately 176°F (80°C).
2. Make sure machine and engine are level.
3. Switch off engine.
4. Place oil tray under engine.
CAUTION
Hot engine oil can cause burns. Avoid contact with hot oil when draining.
NOTICE
Collect used oil in a container suitable for disposal or recycling. Dispose of used en-
gine oil in accordance with environmental regulations.
5. Open oil drain valve and drain oil.
6. Close oil drain valve.
7. Pour in new engine oil. Refer to Section- capacity, page 11 in section 1 and Figure — Engine Oil Viscosity, page 187.
1200SJP , 1350SJP 31220396 187

3.29.4 Replacing the Oil Filter
Figure 76. Location of the Oil Filter
1. Wipe area around filter to clean any dirt from area.
2. Using a suitable oil filter removal tool, loosen lube oil filter element and spin off.
4. Clean any dirt from filter carrier sealing surface.
5. Lightly coat new oil filter rubber gasket with clean oil.
6. Screw in new filter by hand until gasket is flush.
7. Hand-tighten filter another half-turn.
8. Check oil level.
9. Check oil pressure.
10. Check oil filter cartridge for leaks.
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3.29.5 Replacing the Primary Fuel Filters
Figure 77. Location of the Primary Fuel Filter
WARNING
Fuel is flammable and can cause death or serious injury. Make sure no open flames
or sparks are in the area when working on fuel system. Do not smoke when working
on the fuel systems.
2. Fuel supply from the fuel tank may need to be blocked to prevent flow from the fuel tank.
3. Remove fuel filter cartridge.
5. Clean dirt from filter carrier sealing surface.
6. Apply light film of oil or diesel fuel to rubber gasket of new filter cartridge.
7. Screw in new filter by hand until gasket is flush. Handtighten filter another 3/4 turn.
8. Check for leaks.
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3.29.6 Replacing the Fuel Pre-Filter
Figure 78. Location of Fuel Pre-Filter
Note: Refer Figure — Components of Fuel Pre-Filters, page 190.
Figure 79. Components of Fuel Pre-Filter
1. Fuel Supply Flow to the Pump 3. Electrical Connection for Water Level Sensor 5. Filter Element
2. Venting Screw 4. Drain Plug 6. Fuel Inlet from the Fuel Tank
WARNING
the area. Do not smoke when working on the fuel system.
2. Fuel supply from the fuel tank may need to be blocked to prevent fuel flow from the tank.
3. Place suitable collecting container under drain plug.
4. Disconnect electrical connections from water sensor.
5. Loosen drain plug and drain liquid.
6. Remove filter element.
190 31220396 1200SJP , 1350SJP

8. Clean any dirt of the sealing surfaces of the new filter element and opposite side of filter head.
9. Wet the sealing surfaces of new filter element slightly with fuel.
10. Install new filter onto the filter head in clockwise direction. Torque to 12.5-13.3 ft. lbs. (17-18 Nm).
11. Install the drain plug and tighten to torque 1-1.4 ft. lbs. (1.3-1.9 Nm).
12. Connect electrical connection to water sensor.
13. Check for leaks after starting engine.
3.29.7 Water in Fuel Sensing System (Optional)

The Water in Fuel Sensing System detects when there is an excessive amount of water in the fuel and sets a DTC code in the JLG Control
System to alert the operator and/or service technician.
When Water in Fuel condition occurs, the machine will respond in the following way:
• The engine will shut down automatically.
• The JLG Control System will set DTC 4375 - Water in Fuel.
• An alarm will sound from the active control station (ground or platform).
• If in platform mode, the Low Fuel Indicator will flash.
• Engine Restart will be permitted after the machine senses the Water in Fuel condition, but will only run for 2 minutes and the engine
will shut down again. This restart process will continue until the Water in Fuel condition is corrected.
3.29.8 Draining Water

Frequency of water draining is determined by the contamination level of the fuel. Inspect or drain the collection bowl of water daily or
as necessary. The collection bowl must be drained before contaminants reach the top of the turbine or when the Water Detection
Module (optional) indicates it’s time to drain water.
PRESSURE APPLICATIONS / INSTALLATIONS:
1. Open the drain plug on the bottom of the bowl to evacuate water and contaminants with a suitable collection container in place.
2. Close the drain after all the water and contaminants have been evacuated.
Note: Do not leave the drain open too long as it may completely drain the entire filter assembly of water and fuel.
1200SJP , 1350SJP 31220396 191

3.29.9 Auxiliary Fuel Filter
Figure 80. Components of Auxiliary Fuel Filter
1. T-handle 3. Lid
2. Filter Element 4. Drain Plug
WARNING
ELEMENT REPLACEMENT
Frequency of element replacement is determined by the contamination level of the fuel. Replace the elements every 500 hours, if power
loss is noticed or annually, which ever comes first.
4. Remove the T-handle and lid.
5. Remove the element by holding the bail handles and slowly pulling upward with a twisting motion. Dispose of properly.
6. Replace old lid gasket and T-handle O-ring with new seals (supplied with new element). Lubricate both seals with motor oil or
diesel fuel before installation.
7. Refer to Priming of auxiliary fuel filter or fill the unit with clean fuel, then replace the lid and T-handle then tighten snugly by hand
only.
Note: Do not use any tool for removal and installation of T-handle.
PRIMING OF AUXILIARY FUEL FILTER

1. Remove the T-handle and lid from the top of the filter assembly.
2. Fill the filter assembly with clean fuel.
3. Lubricate lid gasket and T-handle O-ring with clean fuel or motor oil.
192 31220396 1200SJP , 1350SJP

4. Replace the lid and T-handle and tighten snugly by hand only.
Note: Do not use any tool for removal and installation of T-handle.
5. Start engine and check for fuel system leaks.
6. Correct as necessary with engine off and pressure relieved from filter assembly.
DRAINING WATER
Frequency of water draining is determined by the contamination level of the fuel. Inspect or drain the collection bowl of water daily or
as necessary. The collection bowl must be drained before contaminants reach the top of the turbine or when the Water Detection
Module (optional) indicates it’s time to drain water.
PRESSURE APPLICATIONS / INSTALLATIONS:
1. Open the self-venting drain plug on the bottom of the bowl to evacuate water and contaminants with a sui able collection
container in place. Head pressure will push any water and contaminants out of the drain while keeping the filter primed.
2. Close the drain after all the water and contaminants have been evacuated.
3. If necessary, follow priming of auxiliary fuel filter.
Note: Do not leave the drain open too long as it may completely drain the entire filter assembly of water and fuel.
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3.30 DEUTZ ENGINE TCD2.9L4 (STAGE V)
2 7
1001235151-L
MAF36980L
Figure 81. Deutz Engine TCD2.9L4 (Stage V) Installation - Sheet 1 of 9
1. Fan 3. Alternator 5. DOC & DPF 7. Radiator

2. Expansion Tank 4. Fuel Filter 6. Engine Mount
194 31220396 1200SJP , 1350SJP

4
5
7
1001235151-L
MAF36990L
1. Air Filter 3. Air Filter Service Indicator 5. Sensor Coolant Level 7. Engine Tray
2. Air Intake 4. Pipe Exhaust 6. Engine Mount
1200SJP , 1350SJP 31220396 195

3
1001235149-K
MAF37401K
4
1. Piston Pump Assembly 2. Deutz TCD2.9L4 Engine Assembly 3. Drive Pump 4. Function Pump
196 31220396 1200SJP , 1350SJP

FLOW DIRECTION
OF FILTER
FILTER, PARKER,
HYDRAULIC 5
MICRON ENGINE CONTROL
MODULE
BATTERY CABLE
ATTACH TO STARTER
BATTERY CABLE
1001237825-F
1001237826-F
MAF37111F
1200SJP , 1350SJP 31220396 197

198 31220396 1200SJP , 1350SJP

ENGINE TRAY STOP BOLT

ENGINE TRAY STOP LANYARD
TRY CLAMP PLATE
1001237825-F
1001237826-F
MAF37151F
1200SJP , 1350SJP 31220396 199

200 31220396 1200SJP , 1350SJP

1200SJP , 1350SJP 31220396 201

202 31220396 1200SJP , 1350SJP

Note: Refer to engine manufacturer's manual for detailed operating and maintenance instructions. Limited engine maintenance items
are presented here for convenience but detailed engine maintenance items and schedule are included in the engine manufactur-
er's manual.
3.30.1 Glow Plugs

Emergency Stop switch is pulled on if the ambient air temperature is less than 50°F (10°C) and the engine coolant temperature is less
than 140°F (60°C). This determination will occur one second after the Power/Emergency Stop switch has been pulled on. The lamp and
glow plugs will remain enegized for the period of time specified by the setting in the JLG Control System. Engine start shall be disabled
digit setting.
3.30.2 Check Oil Level

1. Make sure machine and engine are level and switch engine OFF before checking oil level.
2. Remove oil dipstick and wipe with clean cloth.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level as shown in figure below with an approved grade and type of oil outlined in engine manufacturer’s
operator’s manual.
5. Replace dipstick until fully seated.
3.30.3 Replacing Engine Oil

1. Allow engine to warm up. Engine oil should reach approximately 176°F (80°C).
2. Make sure machine and engine are level.
3. Switch off engine.
4. Place oil tray under engine.
CAUTION
Hot engine oil can cause burns. Avoid contact with hot oil when draining.
NOTICE
Collect used oil in a container suitable for disposal or recycling. Dispose of used en-
gine oil in accordance with environmental regulations.
5. Open oil drain valve and drain oil.
6. Close oil drain valve.
1200SJP , 1350SJP 31220396 203

7. Pour in new engine oil. Refer to Section- capacity, page 11 in section 1 and Figure — Engine Oil Viscosity, page 204.
3.30.4 Replacing the Oil Filter
Figure 92. Location of the Oil Filter
2. Using a suitable oil filter removal tool, loosen lube oil filter element and spin off.
4. Clean any dirt from filter carrier sealing surface.
5. Lightly coat new oil filter rubber gasket with clean oil.
6. Screw in new filter by hand until gasket is flush.
204 31220396 1200SJP , 1350SJP

7. Hand-tighten filter another half-turn.
8. Check oil level.
9. Check oil pressure.
10. Check oil filter cartridge for leaks.
3.30.5 Replacing the Primary Fuel Filters
Figure 93. Location of the Primary Fuel Filter
WARNING
Fuel is flammable and can cause death or serious injury. Make sure no open flames
or sparks are in the area when working on fuel system. Do not smoke when working
on the fuel systems.
2. Fuel supply from the fuel tank may need to be blocked to prevent flow from the fuel tank.
3. Remove fuel filter cartridge.
5. Clean dirt from filter carrier sealing surface.
6. Apply light film of oil or diesel fuel to rubber gasket of new filter cartridge.
1200SJP , 1350SJP 31220396 205

7. Screw in new filter by hand until gasket is flush. Handtighten filter another 3/4 turn.
8. Check for leaks.
3.30.6 Replacing the Fuel Pre-Filter
Figure 94. Location of Fuel Pre-Filter
Note: Refer Figure — Components of Fuel Pre-Filters, page 206.
Figure 95. Components of Fuel Pre-Filter
206 31220396 1200SJP , 1350SJP

1. Fuel Supply Flow to the Pump 3. Electrical Connection for Water Level Sensor 5. Filter Element
2. Venting Screw 4. Drain Plug 6. Fuel Inlet from the Fuel Tank
WARNING
3. Place suitable collecting container under drain plug.
4. Disconnect electrical connections from water sensor.
5. Loosen drain plug and drain liquid.
6. Remove filter element.
8. Clean any dirt of the sealing surfaces of the new filter element and opposite side of filter head.
9. Wet the sealing surfaces of new filter element slightly with fuel.
10. Install new filter onto the filter head in clockwise direction. Torque to 12.5-13.3 ft. lbs. (17-18 Nm).
11. Install the drain plug and tighten to torque 1-1.4 ft. lbs. (1.3-1.9 Nm).
12. Connect electrical connection to water sensor.
13. Check for leaks after starting engine.
3.30.7 Deutz EMR5

The EMR5 consists of the sensors, the control unit and the common rail injection system. Engine-side controls as well as the JLG Control
System are connected by means of separate cable harnesses to the EMR control unit.
The sensors attached to the engine provide the electronics in the control unit with all the relevant physical parameters In accordance
with the information of the current condition of the engine and the preconditions (throttle position etc.), the EMR5 controls the injection
pump and thus doses the fuel quantity in accordance with the performance requirements.
The EMR5 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running (Limp
home) functions.
In order to switch the engine off, the EMR5 is switched in a de-energized fashion over the ignition switch.
After the programming, that is carried out over the interface, the EMR5 possesses a motor-specific data set and this is then fixedly
assigned to the engine. Included in this are the various application cases as well as the customer’s wishes regarding a particular scope of
function.
Each EMR5 module is matched by serial number to the engine. Modules cannot be swapped between engines.
1200SJP , 1350SJP 31220396 207

Figure 96. EMR5 Engine Side Equipment
208 31220396 1200SJP , 1350SJP

Figure 97. Deutz EMR5 Troubleshooting Flow Chart
1200SJP , 1350SJP 31220396 209

Figure 98. Deutz EMR5 Power Harness
210 31220396 1200SJP , 1350SJP

Figure 99. Deutz EMR5 Exhaust After Treatment Harness
1200SJP , 1350SJP 31220396 211

Figure 100. Deutz EMR5 Equipment Harness - Sheet 1 of 5
212 31220396 1200SJP , 1350SJP

1200SJP , 1350SJP 31220396 213

214 31220396 1200SJP , 1350SJP

1200SJP , 1350SJP 31220396 215

216 31220396 1200SJP , 1350SJP

Figure 105. EMR5 Engine Plug Pin Identification
Pin No. Description

A01 INJS3
A02 INJS4
A03 INJS5
A04 Fuel metering unit (BAT+)
A05 Fuel metering unit (low side)

A06
A07 Rail fuel pressure supply
A08 Fan speed visco supply
A09 Boost pressure and temperature supply
A10 Customer Temperature
A11 Exhaust pressure P3
A12 EGR position sensor signal
A13 Air inlet temperature
A14 Fan speed visco
A15 Oil warning lamp

A16 INJS0
A17 INJS1
A18 INJS2
A19 EGR control pos
A20 EGR control neg
A21 DPF differential pressure sensor supply
A22 EGR feedback supply
A23 Oil level sensor (Hella)
A24 Oil pressure supply
A25 Rail fuel pressure ground
A26 Rail pressure sensor signal
A27 Boost temperature
A28 Coolant temperature
A29 Exhaust pressure P3 ground
A30 Differential pressure sensor
1200SJP , 1350SJP 31220396 217

Pin No. Description
A30 Differential pressure sensor (see analog input)

A31 INJS3
A32 INJS4
A33 INJS0
A34 Regeneration indication lamp
A35 Fan actuator
A36 Air inlet temperature ground
A37 Cam shaft speed sensor positive

A38 Crankshaft sensor shield
A39 Crank shaft speed sensor positive
A40 EGR feedback ground

A41 Starter low side
A42 Boost pressure and temperature ground
A43 Boost pressure sensor signal
A44 Oil pressure sensor input signal
A45 Switched Battery UB2

A46 INJS5
A47 INJS1
A48 INJS2
A49 After run active
A51 Customer Temperature ground
A52 Cam shaft speed sensor negative
A53 Camshaft speed sensor shield
A54 Crank shaft speed sensor negative

A55 Reserve Ground
A56 Reserve Ground
A57 Oil pressure ground
A58 Water in fuel switch
A59 Exhaust gas temperature 1
Figure 106. EMR5 Vehicle Plug Pin Identification
218 31220396 1200SJP , 1350SJP

Pin No. Description

K01 BATTERY PLUS
K02 BATTERY MINUS
K03 BATTERY PLUS
K04 BATTERY MINUS
K05 BATTERY PLUS
K06 BATTERY MINUS
K07 EGR temperature behind venturi ground
K08 ITV-H-bridge pos
K08 Intake air throttle pos
K09 Intake air throttle neg
K09 ITV-H-bridge neg

K10 Electrical connected with K9
K11 Vehicle speed sensor ground
K12 Speed switch on/off

K13 Coolant level
K14 Redundant brake switch
K15 Clutch switch
K16 Regeneration activation switch
K17 Air filter differential
K18 Speed switch (+)
K19 Gearbox neutral switch
K20 Preheat sense
K21 Low fuel pressure ground
K22 Controller parameter choise
K23 Delta P venturi supply
K24 Reserve pressure input supply
K25 Fuel pump relay
K26 Intake air throttle (PWM) low side switch

K27 Reserve
K28 Disk seperator
K29 Switched Battery UB2

K30 Reserve
K31 Engine stop switch
K32 Speed switch (hold/resume)
K33 EGR Temperature behind venturi
K34 Vehicle speed sensor
1200SJP , 1350SJP 31220396 219

Pin No. Description

K35 Terminal 50
K36 Reserve analog temperatur input
K37 Speed switch (-)
K38 Parking brake switch
K39 Ambient temperature
K40 Engine brake switch

K41 Brake main switch
K42 Override switch
K43 Low fuel pressure supply
K44 App2 supply
K45 App1 supply
K46 Air intake throttle feedback supply
K47 Exhaust flap
K48 Preheat lamp
K49 Engine speed output

K50 Reserve 2
K52 Multiple state switch 2 ground

K53 CAN2 low
K54 CAN1 high
K55 Exhaust gas temperature 2 ground
K56 Exhaust gas temperature 2
K57 Multiple state switch 2
K58 Low fuel pressure

K59 LIN bus
K61 Throttle 1a
K62 APP1 ground
K63 Throttle 2a
K65 Diagnostic lamp ground
K66 Diagnostic switch
K67 Intake air throttle (PWM) status
K69 OBD lamp
K70 Diagnostic lamp
K71 Engine running lamp
220 31220396 1200SJP , 1350SJP

Pin No. Description
K72 Prehead relay
K74 Torque / droop Line ground
K75 CAN2 high

K76 CAN1 low
K77 Reserve pressure input ground
K78 Reserve analog pressure input
K79 Torque / droop Line

K80 Feedback intake air throttle
K81 Delta p venturi
K83 Throttle 1b
K84 APP2 ground
K85 Throttle 2b
K86 Controller mode
K87 Digital ground
K88 Terminal 15

K91 Sent1
K92 Warning temperature lamp
K93 Reserve 3
K94 Reserve 1
3.30.8 Engine Trouble Codes

Table 16. EMR5 Trouble Codes
DTC-Code FTB SPN FMI Error Identification
1000 0 98 2 Engine Oil Level - Data Erratic, Intermittent or Incorrect
1001 0 98 31 Engine Oil Level - Condition Exists
1003 0 98 2 Engine Oil Level - Data Erratic, Intermittent or Incorrect
1005 0 98 14 Engine Oil Level - Special Instructions
1021 0 100 3 Engine Oil Pressure 1-VoltageAboveNormalorShortedToHighSource
1022 0 100 4 Engine Oil Pressure 1-VoltageBelowNormalorShortedToLowSource
1025 0 100 1 Engine Oil Pressure 1- Data Below Normal Operational Range (Most Severe Level)
1026 0 100 1 Engine Oil Pressure 1- Data Below Normal Operational Range (Most Severe Level)
1200SJP , 1350SJP 31220396 221

Table 16. EMR5 Trouble Codes (continued)

1043 0 107 0 Engine Air Filter 1 Differential Pressure- Data Above Normal Operational Range (Most Severe Level)
1071 0 411 2 Engine Exhaust Gas Recirculation 1 Differential Pressure- Data Erratic, Intermittent or Incorrect
1072 0 411 0 Engine Exhaust Gas Recirculation 1 Differential Pressure- Data Above Normal Operational Range
(Most Severe Level)
1073 0 411 1 Engine Exhaust Gas Recirculation 1 Differential Pressure- Data Below Normal Operational Range
(Most Severe Level)
1077 0 411 3 Engine Exhaust Gas Recirculation 1 Differential Pressure- Voltage Above Normal or Shorted To High
Source
1078 0 411 4 Engine Exhaust Gas Recirculation 1 Differential Pressure- Voltage Below Normal or Shorted To Low
Source
1079 0 108 0 Barometric Pressure- Data Above Normal Operational Range (Most Severe Level)
080 0 108 1 Barometric Pressure- Data Below Normal Operational Range (Most Severe Level)
1081 0 108 15 Barometric Pressure- Data Above Normal Operational Range (Least Severe Level)
1082 0 108 17 Barometric Pressure- Data Above Normal Operational Range (Least Severe Level)
1083 0 108 2 Barometric Pressure- Data Erratic, Intermittent or Incorrect
1084 0 3720 0 Aftertreatment 1 Diesel Particulate Filter Ash Load Percent- Data Above Normal Operational Range
(Most Severe Level)
1086 0 3734 0 Aftertreatment 1 Diesel Particulate Filter Trip Active Regeneration Time- Data Above Normal
Operational Range (Most Severe Level)
1087 0 4781 14 Aftertreatment 1 Diesel Particulate Filter Soot Mass- Special Instructions
1088 0 4781 0 Aftertreatment 1 Diesel Particulate Filter Soot Mass- Data Above Normal Operational Range (Most
Severe Level)
1089 0 4781 16 Aftertreatment 1 Diesel Particulate Filter Soot Mass- Data Above Normal Operational Range
(Moderately Sever Level)
1090 0 10156 0 DPF Active Regeneration Time Remaining- Data Above Normal Operational Range (Most Severe
Level)
1091 0 3735 16 Aftertreatment 1 Diesel Particulate Filter Trip Disabled Time- Data Above Normal Operational Range
1092 0 3735 0 Aftertreatment 1 Diesel Particulate Filter Trip Disabled Time- Data Above Normal Operational Range
(Most Severe Level)
1093 0 4766 1 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Temperature- Data Below Normal Operational
Range (Most Severe Level)
1102 0 171 2 Ambient Air Temperature- Data Erratic, Intermittent or Incorrect
1113 0 102 0 Engine Intake Manifold 1 Pressure- Data Above Normal Operational Range (Most Severe Level)
1114 0 102 1 Engine Intake Manifold 1 Pressure- Data Below Normal Operational Range (Most Severe Level)
1115 0 102 3 Engine Intake Manifold 1 Pressure- Voltage Above Normal or Shorted To High Source
1116 0 102 4 Engine Intake Manifold 1 Pressure- Voltage Below Normal or Shorted To Low Source
222 31220396 1200SJP , 1350SJP


1121 0 102 2 Engine Intake Manifold 1 Pressure- Data Erratic, Intermittent or Incorrect
1122 0 102 0 Engine Intake Manifold 1 Pressure- Data Above Normal Operational Range (Most Severe Level)
1124 0 1209 2 Engine Exhaust Pressure 1- Data Erratic, Intermittent or Incorrect
1125 0 1209 15 Engine Exhaust Pressure 1- Data Above Normal Operational Range (Least Severe Level)
1126 0 1176 1 Engine Turbocharger 1 Compressor Intake Pressure- Data Below Normal Operational Range (Most
Severe Level)
1127 0 1209 2 Engine Exhaust Pressure 1- Data Erratic, Intermittent or Incorrect
1130 0 1209 3 Engine Exhaust Pressure 1- Voltage Above Normal or Shorted To High Source
1131 0 1209 4 Engine Exhaust Pressure 1- Voltage Below Normal or Shorted To Low Source
1134 0 3251 3 Aftertreatment 1 Diesel Particulate Filter Differential Pressure- Voltage Above Normal or Shorted To
High Source
1135 0 3251 4 Aftertreatment 1 Diesel Particulate Filter Differential Pressure- Voltage Below Normal or Shorted To
Low Source
1136 0 3251 14 Aftertreatment 1 Diesel Particulate Filter Differential Pressure- Special Instructions
1149 0 3251 2 Aftertreatment 1 Diesel Particulate Filter Differential Pressure- Data Erratic, Intermittent or Incorrect
1150 0 3251 0 Aftertreatment 1 Diesel Particulate Filter Differential Pressure- Data Above Normal Operational
1151 0 3251 16 Aftertreatment 1 Diesel Particulate Filter Differential Pressure- Data Above Normal Operational
Range (Moderately Sever Level)
1152 0 3251 1 Aftertreatment 1 Diesel Particulate Filter Differential Pressure- Data Below Normal Operational
1153 0 3251 18 Aftertreatment 1 Diesel Particulate Filter Differential Pressure- Data Below Normal Operational
Range (Moderately Severe Level)
1161 0 5571 16 High Pressure Common Rail Fuel Pressure Relief Valve- Data Above Normal Operational Range
1162 0 5571 2 High Pressure Common Rail Fuel Pressure Relief Valve- Data Erratic, Intermittent or Incorrect
(Least Severe Level)
1166 0 5571 0 High Pressure Common Rail Fuel Pressure Relief Valve- Data Above Normal Operational Range (Most
Severe Level)
1200SJP , 1350SJP 31220396 223


1169 0 5571 13 High Pressure Common Rail Fuel Pressure Relief Valve- Out of Calibration
1171 0 94 1 Engine Fuel Delivery Pressure- Data Below Normal Operational Range (Most Severe Level)
1172 0 1347 5 Engine Fuel Pump Pressurizing Assembly 1- Current Below Normal or Open Circuit
1174 0 1347 3 Engine Fuel Pump Pressurizing Assembly 1- Voltage Above Normal or Shorted To High Source
1175 0 1347 4 Engine Fuel Pump Pressurizing Assembly 1- Voltage Below Normal or Shorted To Low Source
119 0 1231 14 CAN Bus 2 / Engine/Diagnose CAN- Special Instructions
1190 0 7103 13 Engine Fuel Metering Rail Pump- Out of Calibration
1195 0 7103 1 Engine Fuel Metering Rail Pump- Data Below Normal Operational Range (Most Severe Level)
1197 0 7103 0 Engine Fuel Metering Rail Pump- Data Above Normal Operational Range (Most Severe Level)
1198 0 7103 2 Engine Fuel Metering Rail Pump- Data Erratic, Intermittent or Incorrect
120 0 639 14 CAN 1 / Customer CAN (J1939)- Special Instructions
1200 0 5357 14 Engine Fuel Injection Quantity Error for Multiple Cylinders- Special Instructions
1202 0 157 0 Engine Fuel 1 Injector Metering Rail 1 Pressure- Data Above Normal Operational Range (Most
Severe Level)
1208 0 157 3 Engine Fuel 1 Injector Metering Rail 1 Pressure- Voltage Above Normal or Shorted To High Source
1209 0 157 4 Engine Fuel 1 Injector Metering Rail 1 Pressure- Voltage Below Normal or Shorted To Low Source
121 0 520252 2 CAN-Receive-Message EAT Control Checksum- Data Erratic, Intermittent or Incorrect
1212 0 629 12 Engine Control Unit (Controller 1)- Bad Intelligent Device or Component
122 0 4207 2 TSC1 Message Checksum- Data Erratic, Intermittent or Incorrect
1233 0 5826 15 Emission Control System Operator Inducement Severity (NCD Inducement)- Data Above Normal
Operational Range (Least Severe Level)
1235 0 5826 0 Emission Control System Operator Inducement Severity (NCD Inducement)- Data Above Normal
Operational Range (Most Severe Level)
1236 0 5826 14 Emission Control System Operator Inducement Severity (NCD Inducement)- Special Instructions
224 31220396 1200SJP , 1350SJP


1274 0 91 3 Accelerator Pedal Position 1- Voltage Above Normal or Shorted To High Source
1275 0 2623 3 Accelerator Pedal 1 Channel 2- Voltage Above Normal or Shorted To High Source
1276 0 29 3 Accelerator Pedal 2 Position- Voltage Above Normal or Shorted To High Source
1277 0 2625 3 Accelerator Pedal 2 Channel 2- Voltage Above Normal or Shorted To High Source
1280 0 91 4 Accelerator Pedal Position 1- Voltage Below Normal or Shorted To Low Source
1281 0 2623 4 Accelerator Pedal 1 Channel 2- Voltage Below Normal or Shorted To Low Source
1282 0 29 4 Accelerator Pedal 2 Position- Voltage Below Normal or Shorted To Low Source
1283 0 2625 4 Accelerator Pedal 2 Channel 2- Voltage Below Normal or Shorted To Low Source
1289 0 3509 14 Sensor supply voltage 1 from ECU- Special Instructions
1290 0 3509 0 Sensor supply voltage 1 from ECU- Data Above Normal Operational Range (Most Severe Level)
1291 0 3509 6 Sensor supply voltage 1 from ECU- Current Above Normal or Grounded Circuit
1292 0 3509 1 Sensor supply voltage 1 from ECU- Data Below Normal Operational Range (Most Severe Level)
1293 0 3510 14 Sensor supply voltage 2 from ECU- Special Instructions
1294 0 3510 0 Sensor supply voltage 2 from ECU- Data Above Normal Operational Range (Most Severe Level)
1295 0 3510 6 Sensor supply voltage 2 from ECU- Current Above Normal or Grounded Circuit
1296 0 3510 1 Sensor supply voltage 2 from ECU- Data Below Normal Operational Range (Most Severe Level)
1306 0 677 3 Engine Starter Motor Relay - Voltage Above Normal or Shorted To High Source
1307 0 677 4 Engine Starter Motor Relay - Voltage Below Normal or Shorted To Low Source
1308 0 677 5 Engine Starter Motor Relay - Current Below Normal or Open Circuit
1310 0 677 3 Engine Starter Motor Relay - Voltage Above Normal or Shorted To High Source
1311 0 677 4 Engine Starter Motor Relay - Voltage Below Normal or Shorted To Low Source
1323 0 91 11 Accelerator Pedal Position 1- Root Cause Not Known
1326 0 29 11 Accelerator Pedal 2 Position- Root Cause Not Known
1346 0 1041 14 Start Signal Indicator - Special Instructions
1354 0 105 0 Engine Intake Manifold 1 Temperature- Data Above Normal Operational Range (Most Severe Level)
1357 0 1136 0 Engine ECU Temperature- Data Above Normal Operational Range (Most Severe Level)
1358 0 1136 1 Engine ECU Temperature- Data Below Normal Operational Range (Most Severe Level)
1359 0 1136 15 Engine ECU Temperature- Data Above Normal Operational Range (Least Severe Level)
1360 0 1136 17 Engine ECU Temperature- Data Above Normal Operational Range (Least Severe Level)
1361 0 1136 2 Engine ECU Temperature- Data Erratic, Intermittent or Incorrect
1200SJP , 1350SJP 31220396 225


1362 0 412 15 Engine Exhaust Gas Recirculation 1 Temperature- Data Above Normal Operational Range (Least
Severe Level)
1363 0 412 17 Engine Exhaust Gas Recirculation 1 Temperature- Data Above Normal Operational Range (Least
Severe Level)
1364 0 412 3 Engine Exhaust Gas Recirculation 1 Temperature- Voltage Above Normal or Shorted To High Source
1365 0 412 4 Engine Exhaust Gas Recirculation 1 Temperature- Voltage Below Normal or Shorted To Low Source
1372 0 51 5 Engine Throttle Valve 1 Position 1- Current Below Normal or Open Circuit
1375 0 51 3 Engine Throttle Valve 1 Position 1- Voltage Above Normal or Shorted To High Source
1377 0 51 4 Engine Throttle Valve 1 Position 1- Voltage Below Normal or Shorted To Low Source
1379 0 51 6 Engine Throttle Valve 1 Position 1- Current Above Normal or Grounded Circuit
1382 0 51 7 Engine Throttle Valve 1 Position 1- Mechanical System not Responding or Out of Adjustment
1383 0 51 7 Engine Throttle Valve 1 Position 1- Mechanical System not Responding or Out of Adjustment
1398 0 105 1 Engine Intake Manifold 1 Temperature- Data Below Normal Operational Range (Most Severe Level)
1399 0 4766 2 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Temperature- Data Erratic, Intermittent or
Incorrect
1400 0 4766 2 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Temperature- Data Erratic, Intermittent or
Incorrect
1401 0 4766 15 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Temperature- Data Above Normal Operational
Range (Least Severe Level)
1402 0 4766 3 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Temperature- Voltage Above Normal or Shorted To
High Source
1403 0 4766 4 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Temperature- Voltage Below Normal or Shorted To
Low Source
1404 0 4765 2 Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature- Data Erratic, Intermittent or
Incorrect
1405 0 4765 15 Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature- Data Above Normal Operational
Range (Least Severe Level)
1406 0 4765 3 Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature- Voltage Above Normal or Shorted To
High Source
1407 0 4765 4 Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature- Voltage Below Normal or Shorted To
Low Source
1408 0 4765 2 Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature- Data Erratic, Intermittent or
Incorrect
142 0 520256 9 CAN-Receive-Message EAT Control- Abnormal Update Rate / Timeout
226 31220396 1200SJP , 1350SJP


144 0 523211 9 CAN-Receive-Message EBC1- Abnormal Update Rate / Timeout
154 0 523212 9 CAN-Receive-Message Engine Protection- Abnormal Update Rate / Timeout
1540 0 520254 8 Time in Standstill Mode- Abnormal Frequency or Pulse Width or Period
1541 0 520255 2 Hoses Connected to dp DPF SENT Sensor Inverted- Data Erratic, Intermittent or Incorrect
155 0 523741 14 Engine Shutdown Request via CAN- Special Instructions
1587 0 97 0 Water In Fuel Indicator 1- Data Above Normal Operational Range (Most Severe Level)
188 0 523240 9 CAN-Receive-Message Function Mode Control- Abnormal Update Rate / Timeout
219 0 520253 2 CAN-Receive-Message EAT Control Message Counter- Data Erratic, Intermittent or Incorrect
220 0 4206 2 TSC1 Message Counter- Data Erratic, Intermittent or Incorrect
349 0 3349 0 TSC1 Receive Timeout-Error- Data Above Normal Operational Range (Most Severe Level)
38 0 1485 3 ECM Main Relay- Voltage Above Normal or Shorted To High Source
41 0 1485 4 ECM Main Relay- Voltage Below Normal or Shorted To Low Source
48 0 168 0 Battery voltage- Data Above Normal Operational Range (Most Severe Level)
49 0 168 1 Battery voltage- Data Below Normal Operational Range (Most Severe Level)
50 0 168 3 Battery voltage- Voltage Above Normal or Shorted To High Source
1200SJP , 1350SJP 31220396 227


51 0 168 4 Battery voltage- Voltage Below Normal or Shorted To Low Source
516 0 523982 0 Powerstage Diagnosis disabled, Battery Potential- Data Above Normal Operational Range (Most
Severe Level)
517 0 523982 1 Powerstage Diagnosis disabled, Battery Potential- Data Below Normal Operational Range (Most
Severe Level)
52 0 168 0 Battery voltage- Data Above Normal Operational Range (Most Severe Level)
567 0 27 5 Engine Exhaust Gas Recirculation 1 Valve Position- Current Below Normal or Open Circuit
570 0 27 3 Engine Exhaust Gas Recirculation 1 Valve Position- Voltage Above Normal or Shorted To High Source
571 0 27 3 Engine Exhaust Gas Recirculation 1 Valve Position- Voltage Above Normal or Shorted To High Source
572 0 27 4 Engine Exhaust Gas Recirculation 1 Valve Position- Voltage Below Normal or Shorted To Low Source
573 0 27 4 Engine Exhaust Gas Recirculation 1 Valve Position- Voltage Below Normal or Shorted To Low Source
574 0 27 6 Engine Exhaust Gas Recirculation 1 Valve Position- Current Above Normal or Grounded Circuit
577 0 27 7 Engine Exhaust Gas Recirculation 1 Valve Position- Mechanical System not Responding or Out of
Adjustment
578 0 27 7 Engine Exhaust Gas Recirculation 1 Valve Position- Mechanical System not Responding or Out of
Adjustment
582 0 5763 3 Engine Exhaust Gas Recirculation 1 Actuator 1- Voltage Above Normal or Shorted To High Source
583 0 5763 4 Engine Exhaust Gas Recirculation 1 Actuator 1- Voltage Below Normal or Shorted To Low Source
586 0 3055 14 Engine Fuel System Monitor (ECU Internal Error)- Special Instructions
587 0 190 0 Engine Speed - Data Above Normal Operational Range (Most Severe Level)
610 0 171 15 Ambient Air Temperature- Data Above Normal Operational Range (Least Severe Level)
613 0 171 3 Ambient Air Temperature- Voltage Above Normal or Shorted To High Source
614 0 171 4 Ambient Air Temperature- Voltage Below Normal or Shorted To Low Source
615 0 723 8 Camshaft Speed Sensor- Abnormal Frequency or Pulse Width or Period
616 0 723 14 Camshaft Speed Sensor- Special Instructions
617 0 723 13 Camshaft Speed Sensor- Out of Calibration
618 0 4201 8 Crankshaft Speed Sensor- Abnormal Frequency or Pulse Width or Period
619 0 4201 14 Crankshaft Speed Sensor- Special Instructions
68 0 1669 14 CAN Bus ID-5- Special Instructions
70 0 110 2 Engine Coolant Temperature- Data Erratic, Intermittent or Incorrect
709 0 97 3 Water In Fuel Indicator 1- Voltage Above Normal or Shorted To High Source
710 0 97 4 Water In Fuel Indicator 1- Voltage Below Normal or Shorted To Low Source
228 31220396 1200SJP , 1350SJP


721 0 94 15 Engine Fuel Delivery Pressure- Data Above Normal Operational Range (Least Severe Level)
723 0 94 3 Engine Fuel Delivery Pressure- Voltage Above Normal or Shorted To High Source
724 0 94 4 Engine Fuel Delivery Pressure- Voltage Below Normal or Shorted To Low Source
75 0 110 3 Engine Coolant Temperature- Voltage Above Normal or Shorted To High Source
76 0 110 4 Engine Coolant Temperature- Voltage Below Normal or Shorted To Low Source
77 0 110 0 Engine Coolant Temperature- Data Above Normal Operational Range (Most Severe Level)
78 0 110 0 Engine Coolant Temperature- Data Above Normal Operational Range (Most Severe Level)
797 0 676 12 Engine Cold Start Aid Relay- Bad Intelligent Device or Component
798 0 676 5 Engine Cold Start Aid Relay- Current Below Normal or Open Circuit
799 0 676 5 Engine Cold Start Aid Relay- Current Below Normal or Open Circuit
803 0 676 3 Engine Cold Start Aid Relay- Voltage Above Normal or Shorted To High Source
805 0 676 4 Engine Cold Start Aid Relay- Voltage Below Normal or Shorted To Low Source
807 0 2797 14 Engine Fuel 1 Injector Group 1- Special Instructions
815 0 2797 4 Engine Fuel 1 Injector Group 1- Voltage Below Normal or Shorted To Low Source
816 0 5358 5 Engine Cylinder 1 Fuel Injection Quantity- Current Below Normal or Open Circuit
822 0 2797 6 Engine Fuel 1 Injector Group 1- Current Above Normal or Grounded Circuit
823 0 2798 6 Engine Fuel 1 Injector Group 2- Current Above Normal or Grounded Circuit
824 0 5358 6 Engine Cylinder 1 Fuel Injection Quantity- Current Above Normal or Grounded Circuit
83 0 111 1 Engine Coolant Level 1- Data Below Normal Operational Range (Most Severe Level)
1200SJP , 1350SJP 31220396 229


836 0 105 3 Engine Intake Manifold 1 Temperature- Voltage Above Normal or Shorted To High Source
837 0 105 4 Engine Intake Manifold 1 Temperature- Voltage Below Normal or Shorted To Low Source
853 0 0 0 Not defined- Data Above Normal Operational Range (Most Severe Level)
854 0 7103 5 Engine Fuel Metering Rail Pump- Current Below Normal or Open Circuit
855 0 7103 3 Engine Fuel Metering Rail Pump- Voltage Above Normal or Shorted To High Source
856 0 7103 3 Engine Fuel Metering Rail Pump- Voltage Above Normal or Shorted To High Source
857 0 7103 4 Engine Fuel Metering Rail Pump- Voltage Below Normal or Shorted To Low Source
858 0 7103 4 Engine Fuel Metering Rail Pump- Voltage Below Normal or Shorted To Low Source
859 0 7103 6 Engine Fuel Metering Rail Pump- Current Above Normal or Grounded Circuit
871 0 91 14 Accelerator Pedal Position 1- Special Instructions
875 0 190 2 Engine Speed - Data Erratic, Intermittent or Incorrect
876 0 5357 2 Engine Fuel Injection Quantity Error for Multiple Cylinders- Data Erratic, Intermittent or Incorrect
877 0 5441 2 Engine Fuel Injection Timing Error for Multiple Cylinders- Data Erratic, Intermittent or Incorrect
879 0 523612 12 Internal Recovery- Bad Intelligent Device or Component
88 0 598 10 Clutch Switch - Abnormal Rate of Change
884 0 5442 2 Engine Fuel Injection Pressure Error for Multiple Cylinders- Data Erratic, Intermittent or Incorrect
230 31220396 1200SJP , 1350SJP


885 0 29 2 Accelerator Pedal 2 Position- Data Erratic, Intermittent or Incorrect
886 0 677 2 Engine Starter Motor Relay - Data Erratic, Intermittent or Incorrect
887 0 513 2 Actual Engine Percent Torque- Data Erratic, Intermittent or Incorrect
888 0 513 2 Actual Engine Percent Torque- Data Erratic, Intermittent or Incorrect
889 0 520250 2 Function Monitoring: Error During Subsequent Selectable Monitoring- Data Erratic, Intermittent or
Incorrect
91 0 1109 2 Engine Protection System Approaching Shutdown- Data Erratic, Intermittent or Incorrect
1200SJP , 1350SJP 31220396 231


92 0 1109 14 Engine Protection System Approaching Shutdown- Special Instructions
232 31220396 1200SJP , 1350SJP

3.31 HRC ENGINE EMISSION CHARACTERISTICS
The Deutz engine uses multiple & different technologies in order to maintain engine emissions compliance in Highly Regulated
Countries (HRC).
All HRC regions, except for CE/UKCA, utilize an engine with Exhaust Gas Recirculation (EGR), & Diesel Oxidation Catalyst (DOC). These
systems are passive, requiring no operator input or regular maintenance. This engine meets ANSI Tier 4F.
The CE/UKCA market utilizes a similar engine, also incorporating EGR & DOC, but also includes a Diesel Particulate Filter (DPF). This
engine meets CE/UKCA Stage V. The DPF system requires monitoring & periodic maintenance. Failure to follow the DPF maintenance will
cause the engine to de‐rate & eventually shut down, if not addressed.
The DPF traps two kinds of contaminants: Soot & Ash. Soot can be burned off with heat. Ash is a byproduct of the burnt soot, & builds
up over time, eventually necessitating filter replacement after thousands of hours of engine run‐time.
3.31.1 Terminology for Removing Soot

Automatic Background Regeneration
During normal operation, if the DPF has accumulated a little too much soot, the system automatically engages a routine to increase the
exhaust temperatures to burn out the soot. It operates in the background. It does not affect operation of the machine. Long periods of
idle and/or low ambient temperatures may reduce the effectiveness of this type of regen.
Standstill Regeneration
This is supposed to be activated by the operator when the Automatic Background Regen fails to reduce the soot sufficiently. The
machine must be made stationary and no functions may be operated. The system elevates the exhaust temperatures much higher to
clean the DPF. Regen takes estimated 35 minutes every 500 hours (will vary). If the operator refuses to initiate a standstill regen when
indicated, the engine will automatically be limited to lower power and/or idle lock.
The engine’s control unit also monitors the time elapsed since the last Standstill Regen. Even if soot loading doesn’t rise high enough to
request a regen, the clock will eventually request the regen.
3.32 DIESEL PARTICULATE FILTER (IF EQUIPPED)
Diesel Particulate Filter (DPF) is an emissions control system used in diesel engines and requires operator interaction to make sure
proper operation of the system.
For peak operation, the DPF 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 excessive soot in the DPF canister). Maintenance Standstill Cleaning is cleaning requested by the engine on the regular
maintenance interval.
Note: The system will reset the maintenance interval back to zero hours after Standstill or Maintenance Standstill Cleaning events are
performed.
Table 17. DPF Operational Indicators
Indicator / Switch Meaning / Use Platform control LED Module Ground Control Module Ground Control LCD
The DPF Time‐Since‐Last‐Regen

Regen Required Clock, or Soot Loading, is calling -
for a Standstill Regeneration.
The engine is producing High

Emission TemperatureIndicator -
Exhaust System Temperatures.
The DPF Ash Loading has

Ash Overload reached levels that require DPF - -
Replacement.
The Engine's monitoring systems

have detected an issue requiring
Engine Distress Fault Codes
service. FaultCodes will be dis-
played on the LCD.
1200SJP , 1350SJP 31220396 233

Table 17. DPF Operational Indicators (continued)
Indicator / Switch Meaning / Use Platform control LED Module Ground Control Module Ground Control LCD
The Emission Controls' monitor-
ing systems have detected an is-
Emission SystemMalfunction sue requiring service. Fault - Fault Codes
Codes will be displayed on the
LCD.
Actuated by the Operator to ini-

Standstill Regen InitiationSwitch - -
tiate a Standstill Regeneration.
Switch
3.32.1 Standstill Cleaning

The following conditions must be met to perform Standstill Cleaning.
• Machine must be stationary
• Boom in the stowed position
• No personnel in platform
• Engine must be idling
• Coolant temperature must be above 104°F (40°C)
• Machine in Ground Station mode
1. The Diesel Particulate Filter (DPF) Indicator on the Platform Control Panel will flash when standstill cleaning is required.
2. Move the machine to an suitable area free of flammables and personnel that could be exposed to hot exhaust.
3. Launch the cleaning process by pressing the DPF button on the Ground Console for 3 seconds. The Indicator Gauge will display
the following screen.
234 31220396 1200SJP , 1350SJP

4. The Main Cleaning process will begin and last for approximately 30 to 60 minutes. The following screen will show that the process
has begun and includes a status bar that indicates the progress of the cleaning process.
5. After the cleaning process is complete, the engine will run for approximately 5 minutes to allow the Engine and Exhaust After
Treatment (EAT) to cool down. The Indicator Gauge will display the “Regen Complete” screen as shown and the Emissions
Temperature indicator will no longer be illuminated.
3.32.2 Maintenance Standstill Cleaning Initiation Methods

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

Maintenance Standstill Cleaning will be stopped immediately if:
• The Platform/Ground Select switch is switched from Ground to Platform mode
• Any function switch is enabled to perform a boom function
• The Engine is powered down
If Maintenance Standstill Cleaning is interrupted, it must be reinitiated and the Indicator Gauge will display the “Regen Failed” screen as
shown.
1200SJP , 1350SJP 31220396 235

3.32.4 Unsuccessful Cleaning Event

If there is an unsuccessful cleaning event, the DPF icon will show on the display gauge. Possible causes of an Unsuccessful Cleaning
Event are:
• Engine is not warmed up
• DEF tank is frozen
• Machine functions operated during cleaning event in progress
• Other engine faults are active
The Gauge will display “Regen Failed” screen as shown. If the cleaning event has failed, the process must be repeated.
3.32.5 DPF Filter Replacement due to Ash Load

The DPF collects non-burnable particulates which cannot be removed by the Standstill Cleaning process. Build up of the ash load
requires filter maintenance and/or exchange. DPF filter maintenance or exchange requirement is indicated by the DPF Exchange icon
shown on the display gauge.
236 31220396 1200SJP , 1350SJP

Table 18. Maintenance Standstill Cleaning

Machine Hours DPF Regenera- Emissions
Standstill Cleaning Levels Since Last Engine Error
tion Initiation DPF Indicator Temperature Derate Comments
Cleaning Indicator
Methods Indicator*
Serdia Tool(Lev- Between 500
el 2)+(Switch in and650 hours,
0-500 JLGmachine or cleaning cycle
JLGAnalyzer) canbe initiated
with a JLG ana-
lyzer or Switch
in machine.
Normal
0 - - None (Deutz ECM will
Operation Switch in generate DPF
JLGMachi- cleaning re-
500-650 neORJLG quired lamp at
Analyzer 500 hours. JLG
will mask this
lamp until 650
hours.)
Exhaust gastem-
Switch in perature willbe
Standstill JLGMachi- around 600°
1 650-750 - None
Required neORJLG Cduring stand-
Analyzer stillDPF
regeneration.
Switch in
DeratingStep 1 Machine placed
JLGMachi-
2 Warning Level 750-775 (25% in Creep and
neORJLG
Powerderate) DTC active
Analyzer Continuous
Must haveSerdia Idle Lock. Boom
Level 3access Functions
DeratingStep 2
3 Shut Off Level >775 +(switch in Locked Out and
(Idle Lock)
JLGmachine or trapped in
JLGanalyzer) Blinking Transport.
Idle Lock. Boom

Functions
DeratingStep 2
4 Filter Exchange DPF Regeneration NOT POSSIBLE Locked Out and
(Idle Lock)
trapped in
Blinking Transport.
*Emissions Temperature indicator continuously ON during Standstill Cleaning
Table 19. Standstill Cleaning: DPF Filled with Soot

HEST Lamp
(Possible),
Time inHeat- DPFRegener- CheckEngine- DPFCleanin- Continu-
StandstillEscalationSteps Soot Load ationInitia- Derate Comments
Mode(Hours) Lamp gLamp ouslyon dur-
tionMethods ingstandstill-
cleaning
NormalOpera- -
0 <62%
tion
If soot load
- - - None reaches56% in
50 hours of-
1 HeatMode 1 62%to78% 50 Heat Mode 1,
Systemwill au-
tomatically
1200SJP , 1350SJP 31220396 237

Table 19. Standstill Cleaning: DPF Filled with Soot (continued)

HEST Lamp
(Possible),
DPFRegener- CheckEngine- DPFCleanin- Continu-
Time inHeat-
StandstillEscalationSteps Soot Load ationInitia- Derate Comments
Mode(Hours) Lamp gLamp ouslyon dur-
tionMethods ingstandstill-
cleaning
takeit to nor-
maloperation.
If soot load
reaches56% in
250 hours of-
Heat Mode 2,
2 HeatMode 2 78%to100% 250 Systemwill au-
tomatically
takeit to nor-
maloperation.
Will remain in
Switch in JLG Standstill
Standstill mode for 100
3 100%to109% 100 Machine or - None
Required hours or until
JLG Analyzer
0.5 Hz the soot load
reaches 109%
Will remain in
Warning level
(Derate) for
Switch in JLG DeratingStep 25 hours or
Warning Level Machine or 1(25% until the soot
4 109%to125% 25
JLG Analyzer Powerderate) load reaches
Continuous 0.5 Hz 125%. Ma-
chine placed
in Creep and
DTC active
Must haveSer- Idle Lock.
dia Level 3ac- Boom Func-
cess+(switch DeratingStep tions Locked
5 Shut Off Level 125%to161% in JLGmachine Outand
2(Idle Lock)
or Blinking 3 Hz Trapped
JLGanalyzer) inTransport.
Idle Lock.
DPFRegenera-
Boom Func-
tionNOTPOSSI-
Filter DeratingStep tions Locked
6 >161% BLE.DPF
Exchange 2(Idle Lock) Outand
Filterexchan-
Blinking 3 Hz Trapped
gerequired
inTransport.
*Emissions Temperature indicator continuously ON during Standstill Cleaning
3.32.6 Ash Load

• During the lifetime of the EAT system the DPF collects also particulates that cannot be removed by regeneration process. All non‐
burnable particles stored in the filter are here summarized as ash load. This ash load leads to shortened regeneration intervals and
finally a filter maintenance or exchange is required.
• When 100'% of the rated ash load is reached, a filter exchange is required. The maintenance request is indicated by the ash lamp
(solid on) and/or by the respective CAN‐message.
• In case of continuously ignored maintenance requests the available filter volume is reduced and the need for standstill regenerations
becomes more probable.
238 31220396 1200SJP , 1350SJP

• Therefore, at higher ash loads an error paths is set and engine protection functionalities are activated. At this state the ash lamp is
flashing with 1 Hz.
• After exchanging the filter, the soot and ash load stored in the ECU must be reset with the Service Tool (SERDIA).
Table 20.
DM1 Byte1.3‐6
AT1S Byte 2 [%] DPF Test MonitorByte AshLamp Warning Lamp System reactionEU and EPA
Ash Load
3.3‐4
Symbol
xx0000xx
Normal Operation <100% 00 Off - NoDerating
-
xx0000xx
Filter Exchange Required ≥100% 01 - NoDerating
-
xx0000xx
Warning Level - NoDerating

≥105% 10
Blinking -
xx0000xx
On
Warning Level ≥110% 11 DeratingStep 1Active.
Blinking
Continuous
3.33 BIO FUEL IN DEUTZ ENGINES
3.33.1 General
Use of bio fuels is permitted for the compact engines made by DEUTZ.
Distillate fuels with residue oil percentages or mixed fuels may not be used in DEUTZ compact engines.
The DEUTZ vehicle engines are designed for diesel fuels in accordance with EN 590 with a cetane number of at least 51. DEUTZ engines
for mobile machinery are designed for a cetane number of at least 45. When using fuels of a low cetane number, disturbing white smoke
and ignition misfires are to be expected under some circumstances.
A cetane number of at least 40 is permissible for the US market, therefore special engine models have been developed to avoid starting
difficulties, extreme white smoke or increased hydrocarbon emissions (EPA specification - US EPA REGULATIONS FOR LARGE NONROAD
COMPRESSION-IGNITION ENGINES).
If the white smoke behavior is unacceptable when using a very low cetane number, the use of ignition improvers is to be recommended
as a later remedial measure.
The certification measurements for compliance with the legal emission limits are carried out with the test fuels prescribed by law. These
correspond to the diesel fuels in accordance with EN 590 and ASTM D 975. No emission values are guaranteed with the other fuels
described. It is the obligation of the owner to check the permission for use of the fuels in accordance with regional regulations.
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3.33.2 Bio Fuel

PERMITTED BIO-DIESEL FUELS
Originally only rape seed oil methylester (RME) was sold as a bio-diesel fuel in Europe but fatty acid methylester (FAME) based on other
oils have come onto the market increasingly in recent years. However, with the latter there is a risk that the limit values of EN 14214 are
not kept in the field. Anyone who uses bio-diesel fuel in DEUTZ engines must therefore choose his supplier very carefully and have him
guarantee compliance with the EN 14214 limit values. Since experience has shown that rape seed oil methylester (RME) exceeds the limit
values less often that other esters, it is expressly recommended to use only rape seed oil methyester. DEUTZ customers in Germany can
additionally ensure the quality by buying bio-diesel fuel with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Management Biodiesel
e.V.).
The use of US bio-diesel based on soy oil methylester is only permissible in mixtures with diesel fuel with a bio-diesel part of a max. 20
weight-%. The US bio-diesel used for the mixture must comply with the ASTM D6751-07a (B100) standard.
APPROVED ENGINES
The 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and 513 series are approved for bio-diesel from year of manufacture 1993
under compliance with the basic conditions specified below.
BASIC CONDITIONS TO BE OBSERVED
• A power loss of 5-9 % in relation to diesel fuel in accordance with EN 590 is possible due to the lower heating value. Blocking of the
fuel injector is not allowed.
• The lubricating oil quality must correspond to TR 0199- 99-3002. The lubricating oil change interval must be halved in relation to
operation with diesel fuel in accordance with EN 590.
• Standstills of longer than 4 to 6 weeks must be avoided with bio-diesel. Otherwise the engine must be started and stopped with
diesel fuel.
• Bio-diesels can be mixed with normal diesel fuel but the basic conditions described in this subsection apply for mixtures. Mixtures
with up to 5 % (m/m) bio-diesel (B5) which have recently been on sale at European fuel stations are excepted. These fuels must be
treated like normal diesel fuels because EN 590 expressly permits adding up to 5 % (m/m) bio-diesel in accordance with EN 14214.
• Approx. 30-50 hours after changing over from diesel fuel to bio-diesel, the fuel filter should be changed as a preventive measure to
avoid a drop in performance due to clogged fuel filters. Deposited fuel ageing products are dissolved by biodiesel and transported
into the fuel filter. They should not be changed immediately but after approx. 30 to 50 hours because the dissolving of dirt takes a
certain amount of time.
PLANT OIL
NOTICE
Pure plant oils (e. g. rape seed oil, soy oil, palm oil) are not classified as bio-diesel
and exhibit problematical properties for diesel engine operation (strong tendency
to coke, risk of piston seizure, extremely high viscosity, poor evaporation behavior.
The conversion of DEUTZ engines to rape seed oil fuel operation with conversion kits and modified tanks systems of various
manufacturers is not allowed and leads to loss of warranty rights.
3.33.3 Biological Contamination in Fuels

SYMPTOMS
The following symptoms may indicate that a fuel tank is contaminated by micro-organisms:
• Internal tank corrosion,
• Filter blockage and the associated loss of power due to gellike deposits on the fuel filter (especially after long standstills)
240 31220396 1200SJP , 1350SJP

CAUSE
Micro-organisms (bacteria, yeasts, funguses) can form bio-sludge under unfavorable conditions (favoured particularly by heat and water).
Penetration by water is usually caused by condensation of the water in the air. Water does not dissolve in fuel so that the penetrating
water collects at the bottom of the tank. The bacteria and funguses grow in the watery phase, at the phase boundary to the fuel phase,
from which they draw their nutrition. There is an increased risk especially with bio-diesel (FAME).
PREVENTIVE MEASURES
• Keep the storage tank clean, regular cleaning of the tank by specialist companies
• Installation of fuel pre-filters with water traps, especially in countries with frequently fluctuating fuel qualities and high percentage of
water.
If the fuel system and storage tank have already been attacked by micro-organisms. The biocide must be dosed according to the
manufacturer's specifications.
• Avoid direct exposure of the storage tank to sunlight
• Use smaller storage tanks with corresponding low dwell times of the stored fuel
FUEL ADDITIVES
The use of fuel additives is not permitted. The flow improvers mentioned above are an exception. Use of unsuitable additives will result
in loss of warranty.
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242
SECTION 4
BOOM AND PLATFORM
4.1 BOOM SYSTEMS
4.1.1 Broken Cable Indicator System

The boom on this model is a 4 section proportionally driven telescopic boom. The inner mid boom is driven directly by the telescope
cylinder. The outer mid and fly booms are each driven by separate wire rope systems. Each rope system contains redundant ropes that
are capable of allowing the operator to unknowingly continue use of the machine with a single rope failure. These kinds of failures with
the extend ropes are self revealing to the operator so proper action can be taken. Failures within the fly extend ropes are self revealing
as they are exposed on the exterior of the boom where a broken rope would be obvious. Failures within the outer mid ropes require the
addition of the Broken Cable Indicator System in order to be self-revealing to the operator. This system uses a proximity sensor to detect
excessive movement of the sensed rope as would be expected with a rope failure. A broken rope detection results in illuminating the
Cable Break indicator on the platform control panel. No restrictions are made to the functionality of the control system. It is the
responsibility of the operator to take the appropriate action.
4.1.2 Platform Control Enable System

The platform controls make use of a time dependent enable circuit to limit the time availability of “live” or enabled controls. To operate
any directional function, the footswitch must be depressed before activation of the function. When the footswitch is depressed, the
controls are enabled and the operator has 7 seconds to operate any control. The controls will remain enabled as long as the operator
continues to use any function and will remain enabled 7 seconds after the last function has been used. While the controls are “live”, the
enabled light will be illuminated in the platform display panel. When the time limit has been reached, the enabled light will turn off and
the controls will be “dead” or disabled. To continue use of the machine the controls must be re-enabled to start the timer system over
again. This is done by releasing all functions, then releasing and re-depressing the footswitch.
4.1.3 Transport Position Sensing System

The transport position sensing system uses the boom angle sensors and the boom length sensor mounted in the pivot end of the base
boom in addition to the boom length switch mounted on the platform end of the base boom to sense when the boom is in the position
associated with high speed travel. Above transport angle is recognized when one angle sensor reads more than 15° with respect to
gravity and resets to within transport position when both angle sensors read less than 10° with respect to gravity. Transport length is
recognized when both the length switch and length sensor read less than 1 ft extension for the 1350SJP (2 ft extension for the 1200SJP).
During failures of either the length switch or length sensor, the transport length will be determined by the remaining sensor or switch.
The position of the articulated jib is not considered.
This system is used to control the following systems:
• Beyond Transport - Drive Speed Cutback System
• Drive/Steer – Boom Function Interlock System – CE/UKCA Only
• Jib Stow System
• Axle Extension System
• Oscillating Axle System
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Boom and Platform
4.1.4 Beyond Transport - Drive Speed Cutback System

When boom is positioned beyond the Transport Position, the drive motors are automatically restricted to their maximum displacement
position (slow speed).
4.1.5 Drive/Steer – Boom Function Interlock System (CE/UKCA ONLY)

The Drive/Steer – Boom Function Interlock System uses the Transport Position Sensing System to sense when the boom is out of the
transport position. All controls are simultaneously functional when the booms are within the transport position as on the standard
machine. When the boom is beyond the transport position, the control functions are interlocked to prevent simultaneous operation of
any boom function with drive/steer. The first function set to be operated in this mode, becomes the master function set. In other words,
while operating drive/steer functions the boom functions are inoperable. Likewise, while operating boom functions drive/steer functions
are inoperable.
4.1.6 Jib Stow System

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

The Envelope Tracking System uses the envelope control sensors to enhance the control of the boom within the working envelope. Due
to the shape of the working envelope, the maximum boom angle varies with telescope length. To maintain unrestricted operation of the
boom, the lift down function is automatically introduced while telescoping in only when the boom is on the rearward edge of the
envelope. This only occurs when telescoping in along the rearward edge and is not used elsewhere within the envelope or when
telescoping out. Envelope tracking is disabled with any envelope or moment violations or failures. The envelope tracking functionality
and be turned off using the manual position of the boom control select switch. Refer to Boom Control Select.
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Boom and Platform
4.1.8 Moment Control System

The Moment Control System is the secondary means of controlling the stability of the machine. This system uses a load moment pin to
attach the lift cylinder of the boom to the turntable. This pin is instrumented with gauges allowing the forces in the pin to be monitored.
These forces are used to compare the actual boom moment (force at a distance) to a predetermined allowable boom moment. In
controlling the boom moment, the position and load of the boom is controlled. The moment control system will detect moments larger
than expected as well as those smaller than expected. This effectively controls the forward and rearward positions of the boom. The
moment control system varies the maximum allowable moment based on ground slope. On level ground and with rated load in the
platform, the allowable moments establish a working envelope slightly larger than the Envelope Control System’s envelope to minimize
interaction of the systems. With increasing ground slopes and rated load in the platform, the allowable moments may establish a
working envelope smaller than the Envelope Control System’s envelope and may result in moment violations at the extreme platform
positions. Violations of the moment control systems allowable moment will result in reduced function speeds, BCS warning light
illumination, restriction of functions, and sounding of the platform alarm and the flashing of the BCS light with attempts to operate
restricted functions. The restricted functions due to moment system violations related to forward reach are disallowing jib functions, lift
down, telescope out, swing, drive, and steer. The restricted functions due to moment system violations related to backward reach are
disallowing jib functions, lift up, telescope in, swing, drive, and steer. Recognized failures within this system will result in control by the
Envelope Control System, reduced function speeds, BCS warning light illumination. The boom will be restricted from leaving the
transport position until the failure is resolved.
4.1.9 Boom Control System (BCS) Functional Check (Push to Test) System
The machine is equipped with a system for the operator to daily verify the proper functioning of the Boom Control System (Envelope
Control System and the Moment Control System). The operator is instructed to position the boom in the position described by the
instruction decal and to then verify the control system cut out the telescope movement at the correct length. When the operator pushes
the push button mounted on the ground control panel, the control system compares the current moment reading in the moment
system and compares it to the moment expected for this position. If the current moment is within allowable tolerance for the test
position, the green BCS indicator will illuminate indicating the system is working properly. If the current moment is not within the
allowable tolerance for the test position, the red BCS indicator will illuminate indicating the machine requires service by JLG 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 responsibility to take proper action. The machine can be in either capacity mode of the dual capacity
system for this system check.
4.1.10 Controlled Arc System

The Controlled Arc System uses the envelope control sensors to enhance the control of the boom within the working envelope. The
purpose of the controlled arc system is to minimize the interaction of lift functions with envelope edges and to increase user efficiency.
This minimizes the effect of a long boom working in a comparatively narrow envelope. Because the boom is permitted to extend to
longer lengths at high angles than at it is low angles, lift commands would normally cause the boom to violate the permitted envelope
while lifting down or conversely require the operator to frequently command telescope out while lifting to high heights. The controlled
arc system optimizes the envelope shape by automatically introducing telescope in or out during "lift only" commands. Telescope flow is
regulated during lift commands to maintain a constant percentage of available boom length (0% is always fully retracted, 100% is
variable as the permitted length changes when the boom is raised). The target percentage will be maintained throughout the lift
command whether it is maintaining 0%, 100%, or any percentage in between. The target percentage is established at the start of lift
command or end of manual telescope commands when using multiple functions with lift. The telescope command can be used
independently or in combination with other functions. Manual introduction of telescope will override the controlled arc system and
result in conventional control. Controlled arc will be disabled with any sensor failure, any moment violation, any envelope violation, or
with auxiliary power functions. The controlled arc functionality and be turned off using the manual position of the boom control select
switch. Refer to Boom Control system.
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Boom and Platform
Figure 107. Controlled Arc Boom Movement
4.1.11 Controlled Boom Angle System

The Controlled Boom Angle System uses the envelope control sensors to enhance the control of the boom by minimizing the interaction
of swing and drive functions with the envelope edges. This interaction is due to two factors. First, the envelope is controlled relative to
gravity regardless of ground slope and second, the turntable/boom mounting is effected by swing and drive functions when the ground
slope varies. This can cause the boom position to vary within the envelope or even violate the envelope edges when swinging or driving
without intentionally moving the boom. The controlled boom angle system minimizes this effect by automatically introducing lift up or
down during swing and drive commands to maintain a constant boom angle relative to gravity for all boom angles greater than 9
degrees. Controlled boom angle is disabled with any envelope or moment violations or failures. The controlled boom angle functionality
4.1.12 Envelope Tracking

The Envelope Tracking System uses the envelope control sensors to enhance the control of the boom within the working envelope. Due
to the shape of the working envelope, the maximum boom angle varies with telescope length. To maintain unrestricted operation of the
boom, the lift down function is automatically introduced while telescoping in only when the boom is on the rearward edge of the
envelope. This only occurs when telescoping in along the rearward edge and is not used elsewhere within the envelope or when
telescoping out. Envelope tracking is disabled with any envelope or moment violations or failures. The envelope tracking functionality
4.1.13 Slow Down System

When the boom approaches the edges of the working envelope, all functions (except jib and platform functions, telescope in or out on
the rearward edge and telescope in on the forward edge) are automatically slowed down by the control system to reduce the machine
dynamics and improve operator control. The slow down starts within 4 feet of all edges and is at the fully reduced speeds 2 feet from all
edges. The control system indicates to the operator this automatic introduction of slow down by flashing the creep light on the platform
display panel. This feature applies to both platform and ground controls, however, no indication is made on the ground control panel.
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Boom and Platform
4.1.14 Dual Capacity System

The Dual Capacity System on this machine is a multiple envelope control system as opposed to an indication system. The control system
changes the working envelope and moment limits to match the capacity select mode to either the 500 lb (230 kg) mode or the 1000 lb
(450 kg) mode. It then displays the capacity mode on the platform and ground display panel and controls the positions of the boom
within the allowable envelope for that mode. This mode is selectable by the operator with the dual capacity select switch on the
platform control panel. The 500 lb (230 kg) mode has the largest envelope and allows the use of the side swing jib. The 1000 lb (450 kg)
mode has a smaller envelope and requires the jib to be fixed in the centered position. To select the 1000 lb (450 kg) mode the boom
must already be in the smaller 1000 lb (450 kg) envelope and the jib must be centered (+/-10 degrees) verified to the control system by
the jib centered limit switch mounted on the side swing rotator. When the operator selects the 1000 lb (450 kg) mode and these
conditions are met, the capacity light changes from 500 lb (230 kg) to 1000#, jib swing is disallowed, and the envelope and permitted
moment values are changed accordingly. When the operator selects the 1000 lb (450 kg) mode and these conditions are not met, both
capacity lights will flash, the platform alarm will sound, and all functions except jib swing will be disabled until the capacity select switch
is put back into the 500 lb (230 kg) position. Operation of jib swing in this condition can be used to find the center position of the jib as
the jib swing function will stop when the center position is reached.
4.1.15 Platform Load Sensing System (LSS)

The Platform Load Sensing System consists of single load cell mounted between the platform and platform support, and a dedicated
electronic interface module (EIM) located below the platform console. This system measures the weight in the platform.hen the capacity
is exceeded, or when there is a fault in the system, the platform overload indicator will flash, the platform alarm will sound at the
standard JLG duty cycle of 5 sec on / 2sec off and all platform controls (except emergency descent) will be disabled.
4.1.16 Electronic Platform Leveling

The electronic platform leveling system uses two tilt sensors (mounted on either side of the pivot weldment), a control valve (mounted
to the platform support), a level cylinder, and the platform control module (mounted in the platform control box) to automatically
measure and control the incline of the platform with respect to gravity. While in the automatic position of the boom control select (item
33) platform leveling is active while operating drive, telescope, lift or swing and is not active while operating any other function (e.g.
rotate, jib, or steer). While in the manual position of the boom control select, platform leveling is active while operating lift only. The
system controls the platform angle relative to gravity using a set point established during power-up (cycling of the EMS) or at the
conclusion of a manual platform level override by the operator using the platform level override switch from either the platform or the
ground control. In other words the operator can chose a platform incline other than level with gravity and the system will maintain that
incline automatically.
If a fault occurs in the platform leveling system the following will occur:
• Automatic platform leveling will stop (except when there is a fault in only one sensor)
• The platform level fault indicator will flash
• The platform alarm will sound
• All functions will default to creep speed if in platform mode and the boom is out of the transport position. Refer to Transport Position
Sensing System.
To reset the fault the emergency stop switch should be recycled.
4.1.17 Boom Control Select

The boom control select switch is mounted on the platform control panel and allows the operator the ability to select between two
different modes of boom control functionality: automatic and manual. While in either mode, the Envelope Control System and Moment
Control System remains active.
When the boom control is selected to the automatic boom control position, lift and telescope movements are coordinated by the
control system as described in the Controlled Arc, Controlled Boom Angle, and Envelope Tracking descriptions. These systems will
remain active to automatically assist the operator in keeping the boom within the envelope boundaries.
When operating in the automatic mode, the following functionality characteristics should be noted.
• While operating Lift Up, the boom may also telescope out (Controlled Arc)
1200SJP , 1350SJP 31220396 247

Boom and Platform
• While operating Lift Down, the boom may also telescope in (Controlled Arc)
• While operating Swing or Drive, the boom may lift up or lift down (Controlled Boom Angle)
• While operating Telescope In, the boom may lift down when at high boom angles and the creep light is flashing (Envelope Tracking)
In addition, when the boom control is selected to the automatic position, the automatic platform leveling feature is active during lift,
telescope, swing, and drive movements as described in the Electronic Platform Leveling System description.
When the boom control is selected to the manual position, lift and telescope movements are controlled separately by the operator
effectively turning off the controlled arc, controlled boom angle, and envelope tracking systems. Without these systems being active, the
control system will stop the movements of the boom when the envelope boundaries are reached and the functions that could violate
the envelope will be restricted. The platform alarm will sound and the BCS light will flash with attempts to operate a restricted function.
In addition, when the boom control is selected to the manual position, the automatic platform leveling feature is active only during lift
movements.
4.2 PLATFORM
4.2.1 Support Removal
1. Disconnect electrical cables from control console.
2. Remove the bolts securing the platform to the platform support, then remove the platform.
Note: The platform weighs approximately 132.2 lb (60 kg).
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Boom and Platform
3. Using a suitable lifting device, support the platform support.
Note: The platform support weighs approximately 81.6 lb (35 kg).
4. Remove the bolts securing the support to the rotator.
5. Using a suitable brass drift and hammer, remove the center bolt and locknut.
6. Remove the platform support from rotator.
4.2.2 Support Installation

1. Using a suitable device, support the platform support and position it on the rotator.
Note: The platform support weighs approximately 81.6 lb (57 kg).
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Boom and Platform
2. Install the rotator center bolt and locknut.
3. Apply Medium Strength Threadlocker Compound to the eight bolts securing the support to the rotator and install the bolts.
4. Torque the nut on the rotator center bolt to 586 ft. lbs. (795 Nm). Torque the retaining bolts to 35 ft. lbs. (50 Nm).
5. Position the platform on the platform support and install the bolts securing the platform to the platform support.
6. Connect the electrical cables to the platform control console.
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Boom and Platform
Figure 108. Platform Support Torque Values
A. Torque to 35 ft. lbs. (50 Nm) C. Torque to 586 ft. lbs. (795 Nm) E. Torque to 65 ft. lbs (88 Nm)
B. Medium Strength Threadlocking Compound D. Check torque every 150 hours of operation
4.3 BOOM REMOVAL, DISASSEMBLY/ASSEMBLY, & CABLE REPLACEMENT
4.3.1 Removal
1. Place machine on firm, level ground.
2. Slightly elevate the boom and support the fly boom with a crane or an adequate lifting device capable of handling 6 - 7 tons.
3. Place blocking under lift cylinder to hold it in place.
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Boom and Platform
4. Remove lift cylinder pin securing the lift cylinder rod to the boom.
1. Pivot Pin 2. Bolt 3. Keeper Pin
5. Remove the boom end cover.
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Boom and Platform
6. Tag and disconnect the telescope, tank, and pressure hoses as indicated below from the main valve and cap ends.
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Boom and Platform
Figure 109. Boom Assembly - Sheet 1 of 7
1. Boom Base 3. Boom Outer Mid 5. Jib Rotator 7. Platform Rotator

2. Boom Inner Mid 4. Boom Fly 6. Jib Assembly
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Boom and Platform
1. Outer Mid Extend Block 4. Retract Rope Retainer Plate 7. Retract Rope Retainer Plate
2. Outer Mid Retract Sheave 5. Rope Retainer Block 8. Lock Plate
3. Rope Retainer Block 6. Fly Retract Sheave 9. Tele Cylinder Wear Pad
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Boom and Platform
1. Upper Rear Wear Pad 4. Trunnion Keeper Block 7. Rope Support Guide
2. Shim 5. Side Wear Pad 8. Bottom Rear Wear Pad
3. Telescope Cylinder 6. Shim 9. Shim
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Boom and Platform
1. Sheave Deflector 4. Fly Extension Sheave 7. Level Cylinder
2. Sheave Deflector 5. Rope Retainer Block 8. Front Lower Wear Pad

3. Rope Retainer Block 6. Rope Retainer Block 9. Lock Plate
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Boom and Platform
1. Front Upper Wear Pad 5. Jib Cylinder 9. Front Side Wear Pad
2. Shim 6. Lower Jib Link 10. Shim

3. Pivot Assembly 7. Jib Rotator 11. Shim
4. Platform Rotator 8. Jib Rotator Cam 12. Lock Plate
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1. Outer Mid Extend Rope 3. Fly Retract Rope 5. Proximity Switch Spring
2. Fly Extend Rope 4. Outer Mid Retract Rope 6. Switch Adjustment Block
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7. Tag and disconnect the three electrical wires that run to the power track and the wire that goes to the proximity switch.
8. Unbolt the power track.
9. Remove the bolt securing the keeper pin and remove the keeper pin from boom pivot pin.
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10. Using the lifting device, support the rear of the boom to remove the load from the pivot pin.
11. Remove the boom pivot pin.
12. Move all of the hydraulic hoses and electrical wires so they are free from chassis.
13. Using the lifting device, remove boom from chassis.
14. Place boom on saw horses or other adequate supports.
4.3.2 Disassembly
It is not necessary to completely remove the entire boom assembly from the machine to replace the cables. In the following procedure,
the base boom section will remain on the machine.
WARNING
Never handle wire rope with bare hands.
1. Position the boom so that it is horizontal. If the boom is below horizontal, ensure that the boom is not on the boom rest.
2. Use an adequate lifting device to support the weight of the jib and platform assembly.
3. Tag and disconnect the hoses and electrical harnesses that run to the platform. Cap or plug all openings.
4. Pull the hoses and harnesses through the jib and lay them off to the side of the boom.
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5. Remove the bolt and keeper pin securing the platform level pivot pin and remove the pin.
6. Remove the bolt and keeper pin securing the jib pivot pin and remove the pin.
7. Remove the jib and platform assembly from the boom.
8. Attach a lifting device to the powertrack for support and unbolt the upper powertrack tube from the fly boom.
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9. Pull the disconnected tube back to allow room to disconnect the lower tube.
10. Unbolt the lower powertrack tube from the outer mid boom section and the mounting bracket from the inner mid boom section.
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11. Attach a strap or other similar device around the powertrack and boom to keep the powertrack secure throughout the cable
replacement procedure.
12. Remove the bolts securing the side wear pads to the front of the base boom and remove the pads and shims.
13. Remove the boom length plate.
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14. Remove the cover over the boom length limit switch at the front of the boom base section. Remove the switch.
15. Remove the rear boom cover.
16. Tag and disconnect the wiring harness running to the boom length sensor. Remove all the bolts and washers securing the sensor,
including those that secure the measuring cable to the telescope cylinder, and remove the length sensor.
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17. Tag and disconnect the hydraulic hoses from the telescope cylinder. Cap or plug all openings.
18. Remove the front side, top, and lower wear pads from the boom base section.
19. Remove the keepers for the outer mid retract cable adjustment nuts at the front of the boom base section.
20. Loosen and remove the outer mid retract cable adjustment nuts.
21. Remove the adjustment bolt keepers for the outer mid extend cable adjustment nuts at the rear of the boom.
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22. Remove the adjustment nuts for the for the outer mid extend cables along with the Broken Cable proximity switch, spring, and
adjustment plate.
23. Remove the cable mounting plate.
24. Remove the cover plate from the bottom of the boom and remove the sheave blocks.
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25. Remove the trunnion blocks that secure the telescope cylinder rod to the boom base section.
26. Remove the outer mid retract cables from the attachment fixtures at the front of the boom base section.
27. Attach an auxiliary hydraulic power source to the telescope cylinder and extend the cylinder rod enough to turn the trunnion in a
vertical position.
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28. Pull the inner mid, outer mid, and fly boom sections out of the base boom section. Use additional lifting devices and reposition
any lifting straps as necessary as the sections are withdrawn. It will be helpful during this step to pull the outer mid retract cable
out from the front of the base section as the other sections are being pulled out. This will prevent the cables from tangling as the
sections are withdrawn.
29. Remove the trunnion blocks that secure the telescope cylinder barrel to the inner mid boom section.
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30. Attach a lifting device to the telescope cylinder and pull the cylinder, along with the outer mid extend cables out of the inner mid
boom section. Reposition the lifting device as necessary to balance the cylinder.
31. Remove the hardware attaching the outer mid extend block and remove the block and outer mid extend cables.
32. Remove the cable retainer plate, cable retainer block, bushing, and sheave.
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33. Remove the rear bottom wear pad.
34. Remove the lock plates from the fly boom retract cable adjustment nuts and remove the adjustment nuts from the fly boom
retract cables and from the fly boom extend cables at the front of the inner mid boom section.
35. Pull the fly boom extend cables from their mounting receptacles.
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36. Remove the top, side, and bottom wear pads from the front of the inner mid boom sections.
37. Attach a strap to pull the outer mid and fly boom sections out of the inner mid boom section. Secure the rear of the inner mid
boom section so it doesn’t move as the other sections are withdrawn.
38. Pull the sections out enough to allow easy removal of the cable retainer blocks and sheave blocks for the fly boom retract cables at
the front of the inner mid boom section.
Note: When pulling the outer mid and fly boom sections out of the inner mid boom section, make sure the outer mid retract ca-
bles do not catch at the rear of the boom section.
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39. Pull the sections the rest of the way out of the inner mid boom section, pulling the fly boom retract cables out at the same time.
40. Remove the outer mid retract cables from the rear of the inner mid boom section.
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41. Remove the cable retract retainer plates, cable retainer blocks, sheaves, and bushings from the rear of the outer mid boom section.
42. Remove the front wear pads from the outer mid boom section.
43. Remove the upper rear wear pads from the fly boom section.
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44. Remove the cable retainer blocks and shims.
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45. Pull the fly boom extend cables out enough to have clearance to remove the sheave, and remove the retaining bolt, keeper pin,
pin, bushings, and sheave from the front of the outer mid boom section.
Note: When pulling the fly boom section out of the outer mid boom section, make sure the fly boom retract cables do not catch at
the rear of the boom section.
46. Attach a lifting device to the fly boom section and pull the section and fly boom extend cables from the outer mid boom section.
Secure the rear of the outer mid boom section so it doesn’t move when the fly boom section is withdrawn.
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47. Remove the tape from the fly boom section and remove the fly boom retract cables.
48. Remove the fly boom extend cables from the bottom of the fly boom section.
49. Thoroughly clean the boom sections.
4.3.3 Assembly
WARNING
Never handle wire rope with bare hands.
Note: Moderately apply Super Lube JLG Part No. 3020042 to all four inner surfaces of both ends of each boom section to a minimum
depth of 3 to 4 feet (1 to 1.25 m). The fly boom section only needs Super Lube applied to the insertion end.
Super Lube is also to be moderately applied to all outer surfaces of interior wear pads after they are installed to the insertion end
of boom sections. Care should be taken to avoid application on exposed painted surfaces of the fully extended boom.
NOTICE
Wire rope nuts are close in size and can be switched. Refer to the JLG parts Manual.
Outer Mid Retract nuts, located on bottom of base boom, will be black in color.
NOTICE
Take extra care not to cross any wire ropes during the assembly procedure.
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1. Install the fly extend wire rope button ends into the slots on the bottom of the fly boom section. Place tape over the wire ends to
keep them in place during assembly.
2. Fabricate a special fixture as shown below to keep four extend wire ropes from crossing over each other.
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3. Install the fly retract wire rope button ends into the slots in the side of the fly boom, coil the remaining lengths of wire rope and
place them into the fly boom, tape the slots to keep the rope from jumping out.
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Figure 116. Boom Assembly Torque Values - Sheet 1 of 2
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Figure 117. Boom Assembly Torque Values - Sheet 2 of 2
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4. Install the fly boom section partially into the outer mid boom section.
NOTICE
Do not allow the fly boom to rest on the four extend wire ropes while inserting it in-
to the outer mid boom.
5. Apply Medium Strength Threadlocking Compound to the bolts and install the front lower wear pads and shims to the outer mid
boom as marked during disassembly. Torque the bolts to 50 ft. lbs. (68 Nm).
6. Install the fly boom section most of the way into the outer mid boom section, leaving enough of the fly out so there is adequate
slack in the fly boom extend cables to allow for installation of the front sheave.
7. Install the sheave, bushings, pin, keeper pin, and retaining bolt to the front of the outer mid boom section.
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8. Install the cable retainer blocks and shims.
9. Apply Medium Strength Threadlocking Compound to the bolts and install the front upper, and side wear pads on the outer mid
boom section as marked during disassembly. Torque the bolts to 50 ft. lbs. (68 Nm).
10. Apply Medium Strength Threadlocking Compound to the bolts and install the rear upper and side wear pads on the outer mid
boom section as marked during disassembly. Torque the bolts to 50 ft. lbs. (68 Nm).
11. Uncoil the fly retract wire ropes from the fly boom. Route the threaded ends of the wire ropes through the holes in the outer mid
boom plates at the retract sheave locations.
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12. Apply a thin coat of moly paste lubricant to the inside diameter of the sheave composite bearings. Install the fly retract sheaves
and bushings while guiding the wire ropes into the sheave grooves. Apply moly paste lubricant on the inside diameter of the
sheave bushing cup. Ensure the sheaves move freely. Apply High Strength Threadlocking Compound to the sheave retaining bolts
and torque to 165 ft. lbs. (224 Nm). Install the cable retract retainer plates and cable retainer blocks.
13. Apply Medium Strength Threadlocking Compound to the bolts and install the lower rear wear pad onto the outer mid boom
section. Torque the bolts to 50 ft. lbs. (68 Nm).
14. Apply Medium Strength Threadlocking Compound to the bolts and install the side and upper wear pads on the rear of the inner
mid boom section. Torque the bolts to 50 ft. lbs. (68 Nm).
15. Lubricate the wear surfaces on the inside of the inner mid boom section with Super Lube.
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16. Feed the fly boom retract cable into the inner mid boom section from the front.
17. Using an adequate lifting device, align the outer mid boom section with the inner mid boom section.
18. Attach the fly boom retract cables in the inner mid boom section to the receptacles at the rear of the outer mid boom section.
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19. Put tape over the holes to keep the cable ends from jumping out.
20. Push the outer mid assembly part way into the inner mid boom section. Apply Medium Strength Threadlocking Compound to the
bolts and install the front bottom wear pad into the inner mid boom section. Torque the bolts to 50 ft. lbs. (68 Nm).
21. Push the outer mid assembly into the inner mid while pulling the boom cables out the back for the inner mid section at the same
time. Leave 3 to 4 feet of the outer mid section sticking out of the inner mid section.
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22. Push the retract cable ends into the mounting receptacles and install the cable sheaves and adjustment nuts.
23. Push the outer mid assembly almost completely into the inner mid boom section.
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24. Install the cable retainer blocks over the fly boom retract cables and insert the fly boom extend cable into the mounting
receptacles.
25. Apply Medium Strength Threadlocking Compound the bolts and install the side and top wear pads into the inner mid boom
26. Put moly paste on the sheave mounts at the rear of the inner mid boom section and install the sheaves.
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27. Apply a thin coat of moly paste lubricant to the inside diameter of the sheave composite bearings. Install the retract sheaves and
bushings while guiding the wire ropes into the sheave grooves. Apply moly paste lubricant on the inside diameter of the sheave
bushing cup. Ensure the sheaves move freely. Apply High Strength Threadlocking Compound to the sheave retaining bolts and
torque to 165 ft. lbs. (224 Nm). Install the cable retainer blocks and cable retainer plates.
28. Apply Medium Strength Threadlocking Compound to the bolts and install the rear bottom wear pad on the rear of the inner mid
boom section. Torque the bolts to 50 ft. lbs. (68 Nm).
29. Install a new sheave on the telescope cylinder.
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30. Install the outer mid extend cables into the cable pulley at the rod end of the telescope cylinder.
BM105368A
31. Install the other end of the outer mid extend cables into the cable guide block.
32. Route the cables around the sheave on the cylinder and install the cable retainer block.
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33. Using an adequate lifting device, insert the cylinder and cables part way into the inner mid boom.
34. Apply Medium Strength Threadlocking Compound to the bolts and attach the cable guide to the inner mid boom section with the
mounting hardware. Torque the bolts to 165 ft. lbs. (224 Nm).
35. Push the cylinder the rest of the way into the inner mid boom assembly.
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36. Install the cylinder trunnion blocks and shims.
37. Using Super Lube®, lubricate all wear surfaces on the inside of the boom base section and the outside of the inner mid boom
section.
38. Insert the inner mid boom section part way into the boom base section enough to be able to pull the outer mid retract cables out
through the hole at the bottom front of the boom base section.
39. Apply Medium Strength Threadlocking Compound to the bolts and install the front lower wear pads into the boom base section.
Torque the bolts to 50 ft. lbs. (68 Nm).
40. Push the inner mid boom assembly the rest of the way into the boom base section, adjusting the lifting device as necessary to
keep the weight balanced.
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41. Apply Medium Strength Threadlocking Compound to the bolts and install the side and upper wear pads into the boom base
42. Install the boom transport length sensor on the side of the boom base section.
43. Attach the powertrack tubes.
44. If necessary, attach a source of auxiliary hydraulic power and retract the boom enough to allow installation of the cable
adjustment plate at the rear of the base boom section and install the plate.
45. Install the broken cable sensor and the outer mid extend cable adjustment nuts.
46. Install the outer mid retract cable adjustment nuts at the front of the boom base section.
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47. Install the boom length sensors and angle sensors as tagged during removal.
48. Connect the hydraulic hoses to the telescope cylinder as tagged during removal.
49. Adjust the boom cables. Refer to Section — Wire Rope Tensioning Adjustment, page 330.
50. Perform a boom calibration as described in Section — Calibrating the Boom Sensors, page 657.
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Figure 118. Locations for Threadlocker Application - Sheet 1 of 4
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4.4 ROTATOR
4.4.1 Removal
1. Remove the Platform Support. Refer to Section — Platform, page 248.
2. Tag and disconnect hydraulic lines to rotator. Use suitable container to retain any residual hydraulic fluid. Cap or plug all openings
of hydraulic lines and ports.
Note: The rotator approximately weighs 50 lb (23 kg).
3. Supporting the rotator and jib lift cylinder, remove hardware from pin (1). Using a suitable brass drift and hammer remove pin (1).
4. Remove the hardware from pin (2). Using a suitable brass drift and hammer, remove pin (2) and remove the rotator.
4.4.2 Installation
1. Supporting the rotator and jib lift cylinder, align rotator with jib lift cylinder and jib. Using a soft head mallet, install pin (1) to the
jib assembly. Install hardware securing pin (1).
Note: The rotator approximately weighs 50 lb (23 kg).
2. Using a soft head mallet install pin (2) to jib assembly and install the rotator. Install hardware securing pin (2).
3. Install the platform and platform support. Refer Section — Platform, page 248.
4. Remove cap or plugs from openings of hydraulic lines and ports and connect hydraulic lines to the rotator as tagged during
removal.
Figure 122. Platform Rotator Removal and Installation
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4.5 BOOM LUBRICATION APPLICATION
This procedure applies to booms after assembly or during annual application using Super Lube® lubricant (JLG PN 3020042).
1. Position the boom on the boom rest using the 500 lb capacity setting.
2. Telescope main boom section as far as it will extend at this position, approximately 3 ft. (0.9 m).
3. From the front of the machine (boom pivot end), moderately apply lubricant to the interior surfaces of the base boom, inner mid
boom, and outer mid boom. To prevent misdiagnosis of hydraulic leaks, take care to prevent excessive application of lubrication.
4. At the rear of the machine, apply lubricant to the side, top and bottom surfaces of the fly boom, outer mid, and inner mid
specifically to wear pad contact paths. To prevent misdiagnosis of hydraulic leaks, take care to prevent excessive application of
lubrication.
5. After application of the lubricant is complete, cycle the boom through its full range of travel 2 times.
4.6 BOOM SHIMMING PROCEDURE
1. Measure and record the dimension and direction of any sweep found in the fly boom section. Measure and record the inside width
and inside height of the outer mid boom opening.
Figure 123. Measuring Boom Section Sweep
Note: Wear Pad bolt lengths should be flush to one thread below the surface of the insert. When installing wear pads in the follow-
ing steps, the wear pad bolt lengths may need to be adjusted as shim thicknesses are adjusted.
2. Install the side wear pads on the fly boom sides. Shim as necessary to match the outer mid boom dimension recorded in step 1 ±
1/32” (± 0.8 mm). Shims should be divided as evenly as possible between the side pads unless corrections are needed to
compensate for sweep recorded in step 1. If the sweep is to the left the internal side pads on the left should have more shims than
the right side pads and vise versa.
3. Install the bottom wear pad(s) and shims if applicable on the fly boom.
4. Install the top wear pad(s) on the fly boom and shim as necessary to obtain 0 - 1/16” (0 - 1.6 mm) less than the corresponding
dimension recorded in step 2.
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5. Slide the fly into the outer mid boom leaving 2 - 6 feet (0.6-1.8 m) exposed.
6. Install the bottom wear pad(s) and shims if necessary into the end of the outer mid boom.
7. Temporarily insert the side pads on one side and slide the fly boom to that side. Insert the other side pads and using shims,
measure how many will be required to fill the remaining space. Install the total amount of shims as evenly as possible between the
two sides unless corrections are needed to compensate for out-of-square booms or for corrections due to sweep recorded in step
1. Care should be taken to keep the bottom pads evenly loaded while shimming the side pads.
Note: Do not install more shims than will fit because this may result in a boom being shimmed too tight. The use of pry bars or
wedges should only be used to finish installing a shim that can be installed by hand more than ½ of its length.
8. Install the top wear pads and shims into the end of the outer mid boom leaving a gap of 0” to 1/16” between the top of the fly
boom and inside of the outer mid boom.
9. Repeat steps 1-7 to install the fly/outer mid assembly into the inner mid boom.
10. Repeat steps 1-7 to assemble the fly/out mid/inner mid assembly into the base boom.
11. Complete the boom assembly. The boom should be functionally tested and evaluated for boom sweep. Boom sweep should be
limited to no more than 5/16" (8 mm). If necessary, the boom may be re-shimmed by moving shims from one side to the other to
further correct any remaining boom sweep. There may be some instances where no shims are used under a given side pad to pass
the criteria for boom sweep at final inspection of machine.
4.7 JIB ROTATOR ORIENTATION
In order for the Jib Rotator to rotate properly, it must be installed with the timing marks running parallel to the flat rotator mounting
plate as shown below.
Figure 124. Jib Rotator Orientation
4.8 JIB LIFT END OF STROKE DAMPENING
The jib lift cylinder is constructed in a way that causes the jib lift cylinder oil flow to be restricted by an orifice while raising the jib within
5 degrees of maximum elevation. This restriction slows the jib lift speed while raising the jib. The oil flow is not restricted while lowering
the jib and therefore the speed is not altered.
4.9 LOAD SENSING PIN REMOVAL AND INSTALLATION
1. Place the machine on a firm, level surface.
Note: Replacing the load sensing pin requires the boom sensors be re-calibrated. Make sure the machine is in an area where this
can be accomplished after installation of the new pin.
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2. Swing the engine tray out to gain access to the sensing pin and retaining pin.
Note: The lift cylinder weighs 787 lb (357 kg.)
3. Run a nylon strap capable of supporting the weight of the lift cylinder around the bottom of the cylinder. Lift up on the strap to
relieve the weight of the lift cylinder on the load sensing pin.
4. Loosen and remove the bolt that secures the retaining pin and remove the retaining pin.
5. Disconnect the wiring harness from the strain relief connector at the opposite side of the load sensing pin.
6. Use the Load Pin Removal Tool (JLG PN 4846765) to prevent the pin from being damaged, and use a hammer to remove the pin.
To make the tool refer to Figure — Load Pin Removal Tool, page 304, JLG PN 4846765. If the Load Pin Removal Tool is not available,
use an arbor of the proper size (as shown below). If excessive force is necessary to move the pin, it may be necessary to carefully
activate lift using the auxiliary power switch to relieve lift cylinder weight from the load sensing pin.
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7. When installing a new pin, make sure all of the holes in the turntable and lift cylinder are aligned. If the new load sensing pin does
not push 1/2 to 3/4 of the way in by hand, remove the pin and align the holes better. Also make sure the pin is installed with the
strain relief connector opposing the pin orientation bar as shown. Refer to Figure — Pivot Pin Installation, page 314.
8. Using an oak block, carefully tap the pin until it is fully installed. Secure the pin in place with the retaining pin and retaining pin
bolt.
NOTICE
do not tap on the center of the pivot pin.
9. Connect the wiring harness to the strain relief connector and re-calibrate the boom sensors.
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Figure 125. Load Pin Removal Tool, JLG PN 4846765
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Figure 126. Boom/Jib Sensors and Switches Installation - Sheet 1 of 4
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Figure 134. Boom Wiper Installation
1. Bar A Adjust top blades 0.000 to 0.063" (0 to 1.6 mm) from top boom plate
2. Blade B Adjust side blades 0.000 to 0.063" (0 to 1.6 mm) from side boom plate
3. Mount C Apply Threadlocker PN 0100019 & torque to 50 ft.lbs. (70 Nm)
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Figure 135. Pivot Pin Installation
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4.10 POWERTRACK MAINTENANCE
4.10.1 One Piece Bracket Maintenance

1. Place the powertrack on a workbench.
2. Remove the screws from the bars on one side of the powertrack on the first link.
3. Remove the screws from the flat bar on the other side of the powertrack.
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4. Pull up on the loose side of the round bar to allow the poly roller to slide off.
5. Slide the poly roller off of the round bar.
6. Hold the round bar to remove the other screw.
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7. Slide the flat bar out.
8. Remove the snap ring from one side of the bracket.
9. Remove the snap ring from the other side of the bracket.
10. Push down with slight pressure on the link and slide the bracket side up and over the extrusion on the link.
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11. Repeat the previous step on the other side.
12. Slide the bracket off of the powertrack.
4.10.2 Two Piece Bracket Maintenance

1. Loosen the screw.
2. Slide the roller off the bar.
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3. Hold the bar tightly and remove the other screw.
4. Hold the flat bar and remove the screws.
5. Remove the snap rings and pins.
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6. Remove the screws from the bar. Remove the snap ring and pin.
7. Slide the link out.
4.10.3 Snap Rings and Screws
NOTICE
When performing maintenance on the powertrack, make sure to discard and re-
place all old screws.
Make sure screws are tight and installed properly.
Make sure that all snap rings are closed and seated.
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An open snap ring is shown below.
A snap ring that is not seated is shown below.
A seated and closed snap ring is shown below.
10-24 x 0.812 button torx socket head with blue locking patch:
• 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.
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Figure 136. Powertrack Installation - Sheet 1 of 6
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4.11 HOSE ROUTING PROCEDURE
For proper hose routing and cable wrap placement and clamping, refer to Figure — Powertrack Installation - Sheet 1 of 6, page 322, Figure
— Powertrack Installation - Sheet 2 of 6, page 323, Figure — Powertrack Installation - Sheet 3 of 6, page 324, Figure — Powertrack
Installation - Sheet 4 of 6, page 325, Figure — Powertrack Installation - Sheet 5 of 6, page 326, and Figure — Powertrack Installation - Sheet 6
of 6, page 327. It is important to periodically inspect hoses, wraps and clamps for proper slack adjustments and clamping integrity (pull
check). Any changes as a result of inspection should be verified by performing full strokes of boom functions especially lift, telescope, jib,
and platform rotate.
4.12 WIRE ROPE
WARNING
If delayed movement is detected in wire rope operation, lower platform to stowed
position, shut down machine, and have wire ropes inspected/serviced by a qualified
jlg mechanic. Loose or misadjusted wire ropes could result in serious injury or
death.
Each day before using the machine:
1. Raise the main boom to approximately horizontal.
2. Extend and retract the boom sections.
3. Check for delayed movement of the fly section, which indicates loose wire ropes.
4.12.1 Inspection
Note: The pictures in this paragraph are just samples to show the replacement criteria of the rope.
1. Inspect ropes for broken wires, particularly valley wire breaks and breaks at end terminations.
Flexing a wire rope can often expose broken wires hidden in valleys between strands.
2. Inspect ropes for corrosion.
3. Inspect ropes for kinks or abuse.
A kink is caused by pulling down a loop in a slack line during improper handling, installation, or operation.
4. Inspect sheaves for condition of bearings/pins. (See Dimension Of Sheaves for proper dimension.)
5. Inspect sheaves for condition of flanges. (See Dimension Of Sheaves for proper dimension.)
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6. Inspect sheaves with a groove wearout gauge for excessive 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.
4.12.2 Three Month Inspection

1. Remove boom covers and visually (with flashlight) inspect the ropes for rust, broken wires, frays, abuse, or any signs of
abnormalities.
2. Check rope tension by deflecting the ropes by hand properly tensioned ropes should have little or no movement.
4.12.3 Additional Inspection Required If:

1. Machine is exposed to hostile environment or conditions.
2. Erratic boom operation or unusual noise exists.
3. Machine is idle for an extended period.
4. Boom is overloaded or sustained a shock load.
5. Boom exposed to electrical arc. Wires may be fused internally.
4.12.4 12 Year or 7000 Hour Replacement

Mandatory wire rope and sheave replacement.
4.12.5 Additional Replacement Criteria

1. Sheaves and wire rope must be replaced as sets.
2. Rusted or corroded wire ropes.
3. Kinked, “bird caged”, or crushed ropes.
4. Ropes at end of adjustment range.
5. Sheaves failing wearout gage inspection.
6. Ropes with 6 total broken wires in one rope lay, 3 in one strand in one rope lay, 1 valley break, or 1 break at any end termination.
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4.13 WIRE ROPE TENSIONING ADJUSTMENT
NOTICE
Any time the wire rope tensioning has been adjusted, boom calibration should be
performed immediately afterward.
Before adjusting wire rope tension, the boom sections must be in the proper position as shown in Figure — Wire Rope Tensioning, page
337. This is so the wire ropes are equalized on both sides of the sheaves and are seated properly in the sheave grooves. This is necessary
for proper tensioning of the wire ropes.
This section covers the two major operations in tensioning the wire ropes which are as follows:
• Positioning the boom sections (so that proper tensioning can be achieved).
• Tensioning the wire rope.
4.13.1 Boom Section Re-Positioning

Note: Because the Outer Mid Boom is used to control the movement of the Fly Boom, any repositioning of the Outer Mid Boom section
will also affect the position of the Fly Boom section. Correctly position the Outer Mid Boom before repositioning the Fly Boom.
Note: Use the Telescope function of the machine to position the boom sections. Do not use the wire rope adjustment nuts to position
the booms. This may cause damage to the wire rope adjustment threads.
1. Ensure the machine is placed on firm, level ground.
2. Before making any adjustments, position the boom assembly in the fully retracted position.
3. Take preliminary measurements of the position of each boom section and compare them to Figure — Wire Rope Tensioning, page
337. If the measurements fall within the tolerances in the figure, proceed to Wire Rope Tensioning in this section.
NOTICE
Proper boom positions do not mean that the wire rope tensions are correct.
If the measurements do not fall within the tolerances in Figure — Wire Rope Tensioning, page 337, adjust the booms using the re-
positioning procedures that follow.
Inner Mid Boom Section Repositioning

The inner mid section of the boom is positioned by the hydraulic cylinder. No adjustments can be made to this section. The wire ropes
within the assembly only control the movement of the Outer Mid Boom and Fly Boom sections.
Outer Mid Boom Section Repositioning
If the Outer Mid Boom falls within the dimension and tolerance of Figure — Wire Rope Tensioning, page 337, proceed to the Fly Boom
Section Positioning procedure in this section. If the Outer Mid Boom section is outside of the tolerance as shown, perform the following
procedure.
1. Extend the boom assembly so the platform moves 5 to 6 ft. (1.5 to 1.8 m) from the fully retracted position.
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2. Remove any covers necessary to access the wire rope adjustment nuts.
3. Remove the lock plates and nylon collar locknuts from the wire rope adjustment nuts.
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4. If the Outer Mid Boom needs to be retracted:

a. Loosen the Outer Mid Boom Extend Adjustment Nuts by an amount equal to twice the distance the boom needs to move to
be in tolerance.
b. Fully retract the boom.
c. To remove the slack caused by the previous step, tighten the Outer Mid Boom Extend Adjustment Nuts until they just contact
the plate.
5. If the Outer Mid Boom needs to be extended out:

a. Loosen the Outer Mid Boom Retract Adjustment Nuts by an amount equal to twice the distance the boom needs to move to
be in tolerance.
b. Extend the boom 3-4 ft. (1-1.5 m).
c. To remove the slack caused by the previous step, tighten the Outer Mid Boom Retract Adjustment Nuts until they just contact
the plate.
6. Fully retract the boom sections.
7. Verify that the exposed boom section dimensions meet the dimensions and tolerances of Figure — Wire Rope Tensioning, page 337.
a. If the Outer Mid Boom still does not fall within the dimension and tolerance of Figure — Wire Rope Tensioning, page 337,
repeat the Outer Mid Boom positioning procedure.
b. If the Outer Mid Boom falls within the dimension and tolerance of Figure — Wire Rope Tensioning, page 337, proceed to the Fly
Boom Section Positioning procedure in this section.
Note: Because the Outer Mid Boom is used to control the movement of the Fly Boom, any repositioning of the Outer Mid Boom
Section will also affect the position of the Fly Boom section. After repositioning the Outer Mid Boom, always check the Fly
Boom position per Figure — Wire Rope Tensioning, page 337.
Fly Boom Section Repositioning

If the Fly Boom section location and the Outer Mid Boom section location are both within the dimensions and tolerances in Figure —
Wire Rope Tensioning, page 337, proceed to the Wire Rope Tensioning Procedure in this section.
If the Fly Boom section is outside of the tolerance as shown in Figure — Wire Rope Tensioning, page 337 while the boom assembly is fully
retracted, perform the following procedure:
1. Extend the boom assembly such that the platform moves 5 to 6 feet (1.5-1.8 m) from the fully retracted position.
2. Remove the lock plates and nylon collar locknuts from the wire rope adjustment nuts.
3. If the Fly Boom needs to be retracted farther in:

a. Loosen the Fly Boom Extend Adjustment Nuts by an amount equal to twice the distance the boom needs to move to be in
tolerance.
Fly Boom Extend Adjusting

Nuts and Lock Plates
BM105401A
b. Fully retract the boom.

c. To remove the slack caused by the previous step, tighten the Fly Boom Extend Adjustment Nuts until they just contact the
plate.
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4. If the Fly Boom needs extended:

a. Loosen the Fly Boom Retract Adjustment Nuts by an amount equal to twice the distance the boom needs to move to be in
tolerance.
b. Extend the boom 3-4 ft. (1-1.5 m).

c. To remove the slack caused by the previous step, tighten the Fly Boom Retract Adjustment Nuts until they just contact the
plate.
d. Fully retract the boom sections.
5. Verify that the exposed boom section dimensions meet the dimensions and tolerances of Figure — Wire Rope Tensioning, page 337.
a. If the Fly Boom still does not fall within the dimension and tolerance of Figure — Wire Rope Tensioning, page 337, repeat the
Fly Boom Section Repositioning procedure.
b. If the Fly Boom falls within the dimension and tolerance of Figure — Wire Rope Tensioning, page 337, proceed to the Wire
Rope Tensioning Procedure.
4.13.2 Wire Rope Tensioning Procedure

Note: Verification of the rope tension should be determined by proper function of the boom assembly and by the dimensions and tol-
erances of Figure — Wire Rope Tensioning, page 337.
NOTICE
Repeat Wire Rope Tensioning Procedure only as necessary to achieve proper
tension.
NOTICE
If the booms have been properly positioned and there is not enough adjustment re-
maining on the wire ropes to achieve torque, the service life of the wire ropes has
been consumed. Do not proceed with the remainder of this procedure. Replace the
wire ropes and sheaves.
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1. Remove any covers necessary to access the wire rope adjustment nuts.
2. If not already done, remove the lock plates and nylon collar locknuts from the wire rope adjustment nuts.
3. Position the boom so that it is horizontal within ±5°. If the boom is below horizontal, ensure that the boom is not on the boom
rest.
4. Extend the boom so the platform moves 5 to 6 ft. (1.5-1.8 m) from the fully retracted position. This is done to position the boom so
the ropes to be tensioned are not under load.
5. When extending the boom in the previous step, if the boom reaches the end of travel and then automatically retracts a small
amount, the ropes may still be under load. If so, perform the following steps:
a. Note where the boom hits the end of stroke.
b. Retract 3-4 ft. (1-1.3 m).
c. Extend the boom and stop just before the boom hits the end of stroke.
6. Using tool JLG PN 4120043, torque the Outer Mid Boom Retract Adjustment Nuts to 80 ft. lbs. (108 Nm), alternating between the
two ropes until both maintain the required torque.
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7. Using tool JLG PN 4120043, torque the Fly Boom Retract Adjuster Nuts to 80 ft. lbs. (108 Nm), alternating between the two ropes
until both maintain the required torque.
8. Retract the boom 2-3 ft. (0.6-1.0 m). Do not fully retract or bottom out the booms.
9. Using tool JLG PN 4120043, torque the Outer Mid Boom Extend Adjustment Nuts to 80 ft. lbs. (108 Newton meters), alternating
between the two ropes until both maintain the required torque.
10. Using tool JLG PN 4120040, torque the Fly Extend Adjustment Nuts to 10 ft. lbs. (13.5 Nm), starting with the inside ropes and doing
the outside ropes last. Refer to Figure — Torque Sequence for Fly Extend Rope, page 335, Torque Sequence for Fly Extend Rope.
Alternate between the four ropes until all maintain the required torque.
Fly Boom Extend Adjusting

Nuts and Lock Plates
BM105401A
3 1 2 4
BM105406A
Figure 142. Torque Sequence for Fly Extend Rope
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11. Repeat the following boom movement steps three times. This is to ensure that the wire rope tension has equalized on both sides
of the sheaves and the ropes are seated properly in the sheave grooves.
a. Fully retract the boom.
b. Extend the boom such that the platform moves 5 to 6 ft. (1.5-1.8 m) from fully retracted position.
12. Verify the Fly Boom and Outer Mid Boom Retract wire rope torques.
a. If the torque values are not correct, repeat the Wire Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next step.
13. Retract the boom 2-3 ft. (0.5-1 m). Do not fully retract or bottom out the boom.
14. Verify the Fly Boom and Outer Mid Boom Extend wire rope torques.
a. If the torque values are not correct, repeat the Wire Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next step.
15. Check for proper function of the boom assembly. When properly torqued and positioned, all three moving boom sections will
move simultaneously.
16. Install new nylon collar locknuts to the Fly Boom Extend wire rope fittings. Do not re-use the old nylon collar lock nuts. Torque the
locknuts to 10 ft. lbs. (13.5 Nm)
17. Reinstall the lock plates to the remaining adjuster nuts.
18. Install all covers.
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Figure 143. Wire Rope Tensioning
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Figure 144. Outer Mid Boom Extend/Retract Cables
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Figure 145. Fly Boom Extend/Retract Cables
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Figure 146. Wire Rope Adjustment Tools (Optional)
1. 2" Socket 2. 3/4” Socket 3. Retaining Bolt
4.14 BROKEN BOOM CABLE PROXIMITY SWITCH
This system uses a proximity switch to detect excessive movement 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 system. 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.
4.14.1 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.
3. Tighten the jam nut.
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Figure 147. Broken Boom Cable Proximity Switch Location
4.15 ELECTRONIC PLATFORM LEVELING
Note: For more detailed information concerning system adjustment and operation, refer to Section 6 - JLG Control System, page 561.
4.15.1 Description
Electronic platform leveling replaces the conventional hydraulic method of platform leveling.
To control electronic platform leveling the platform is equipped with a pair of tilt sensors, one primary and one secondary, mounted to
the non-rotating portion of the platform rotator. The tilt sensors are monitored regularly and the platform level up and down valves are
automatically controlled to maintain as the machine is operated.
PRIMARY AND SECONDARY TILT SENSOR INTERACTION
The secondary tilt sensor is used as a backup to the primary tilt sensor. Any time a tilt set point is reset, a value from each sensor shall
be set.
If a fault occurs with the primary sensor, control will revert to the secondary sensor. (This is discussed in more detail in the error response
section.)
Because of the mounting orientation of the tilt sensors, the primary tilt sensor will output ascending voltage values with increases in
positive platform tilt angle. The backup or secondary tilt sensor will output descending voltage values with increases in positive platform
angle.
PLATFORM VALVES
The platform specific valves are located in a manifold at the platform.
There are individual proportional control valves that control each of the four platform functions; Platform Level, Platform Rotate, Jib Lift,
and Jib Swing.
There is also a Platform Dump Valve, located in the platform valve manifold, which is used to hydraulically isolate the control valves and
to improve hydraulic response.
The Ground Module controls this valve to provide manual platform leveling in the event that the Platform Module is inoperable.
In ground mode, the platform dump valve is turned on whenever any platform or jib valve output is turned on. Whenever all platform
and jib valves are turned off, the platform dump valve is turned off.
In platform mode, the platform dump valve is turned on whenever the footswitch is depressed.
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4.15.2 Normal Operation

AUTOMATIC LEVELING
Two tilt sensors, mounted on either side of the platform support, are used to measure the incline of the platform with respect to gravity
and control the automatic leveling function, one is used as the primary sensor and one as a secondary back up sensor.
The level system shall assume a new fixed set point (fixed incline of the platform with respect to gravity) each time the control system
is powered up (cycling of the EMS).
Automatic platform leveling only functions while operating drive, telescope, lift or swing. It does not operate while operating any other
function (e.g. rotate, jib, or steer).
The proportional control for these valves varies. This is dependant on the tilt variance from target as well as on the impact coil
temperature is having on the current to the valves.
If a command from the Platform Level Up and Down toggle switch on either the platform or the ground is received, automatic platform
leveling will cease and the appropriate output will be commanded to turn on.
When the toggle switch is released, after ¼ second, the current filtered value of tilt angle will be taken as the new set point.
In order to obtain acceptable performance while performing all hydraulic functions, five sets of parameters are used. These “zones” allow
compensation for differences in how the basket level changes when doing different functions. These zones are as follows:
1. Lift up
2. Lift down
3. Other boom functions
4. Drive
5. Auxiliary
The other boom functions zone includes Swing, Telescope, Jib swing (It is not necessary to level with jib lift, since the mechanical linkage
keeps the basket level).
These zones are prioritized when multiple functions are active. The priorities are as follows.
1. Auxiliary power and any other function, zone = auxiliary power
2. Drive and any other function, zone = Drive
3. Lift up and any other function, zone = Lift up
4. Lift down and any other function, zone = Lift down
5. Other boom functions, zone = Other boom functions
During the power-up procedure, function enable, in both Platform and Ground Mode, is delayed during the 1.5 second startup lamp
test. During this 1.5 second startup period, the basket level up valve will be energized at 100% duty cycle for 0.5 second, and then the
basket level down valve energized at 100% duty cycle for 0.5 second. This will help to keep the valves from sticking.
PLATFORM LEVEL MANUAL OVERRIDE
In addition to automatic leveling the operator is able to manually adjust the platform level position by means of the level override
switches located at the platform and ground control positions (similar to a Master/Slave hydraulic system).
The level system assumes a new set point after a level override switch is operated. In other words the operator can chose a platform
level incline other than level with gravity and the system will maintain this set point during automatic leveling.
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4.16 ROTARY ACTUATOR
4.16.1 Theory of Operation

The L20 Series rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into
powerful shaft rotation. Each actuator is composed of a housing with integrated gear teeth (01) and only two moving parts: the central
shaft with integrated bearing tube and mounting flange (02), and the annular piston sleeve (03). Helical spline teeth machined on the
shaft engage matching splines on the inside diameter of the piston. The outside diameter of the piston carries a second set of splines,
of opposite hand, which engage with matching splines in the housing. As hydraulic pressure is applied, the piston is displaced axially
within the housing - similar to the operation of a hydraulic cylinder - while the splines cause the shaft to rotate. When the control valve
is closed, oil is trapped inside the actuator, preventing piston movement and locking the shaft in position.
The shaft is supported radially by the large upper radial bearing and the lower radial bearing. Axially, the shaft is separated from the
housing by the upper and lower thrust washers. The end cap is adjusted for axial clearance and locked in position by set screws or pins.
4.16.2 Required Tools

Upon assembly and disassembly of the actuator there are basic tools required. The tools and their intended functions are as follows:
1. Flashlight - helps examine timing marks, component failure and overall condition.
2. Felt Marker - match mark the timing marks and outline troubled areas.
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3. Allen wrench - removal of port plugs and set screws.
4. Box knife - removal of seals.
5. Seal tool - assembly and disassembly of seals and wear guides.
6. Pry bar - removal of end cap and manual rotation of shaft.
7. Rubber mallet- removal and installation of shaft and piston sleeve assembly.
8. Nylon drift - installation of piston sleeve.
9. End cap dowel pins - removal and installation of end cap (sold with Helac seal kit).
Figure 148. Rotary Actuator - Exploded View
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
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Figure 149. Rotary Actuator - Assembly Drawing
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring

113. Capscrew 304.1. Wiper Seal
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4.16.3 Disassembly
1. Remove the capscrews (113) over end cap lock pins (109).
2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center of each lock pin to a depth of approximately 3/16” (4.76 mm).
3. Remove the lock pins using an ”Easy Out” (a size #2 is shown).
If the pin will not come out with the ”Easy Out”, use 5/16” drill bit to a depth of 1/2” (12.7 mm) to drill out the entire pin.
4. Install the end cap (4) removal tools provided with the Helac seal kit.
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5. Using a metal bar, or something similar, unscrew the end cap (4) by turning it counter clockwise.
6. Remove the end cap (4) and set aside for later inspection.
7. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actuator.
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8. Every actuator has timing marks for proper engagement.
9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly
simplify timing during assembly.
10. Remove the shaft (2). It may be necessary to strike the threaded end of the shaft with a rubber mallet.
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11. Before removing the piston (3), mark the housing (1) ring gear in relation to the piston O. D. gear. There should now be timing
marks on the housing (1) ring gear, the piston (3) and the shaft (2).
12. To remove the piston (3) use a rubber mallet and a plastic mandrel so the piston is not damaged.
13. At the point when the piston gear teeth come out of engagement with the housing gear teeth, mark the piston and housing with
a marker as shown.
14. Remove the O-ring (204) and backup ring (207) from end cap (4) and set aside for inspection.
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15. Remove the wear guides (302) from the end cap (4) and shaft (2).
16. To remove the main pressure seals (205), it is easiest to cut them using a sharp razor blade being careful not to damage the seal
groove.
17. Remove the thrust washers (304), from the end cap (4) and shaft (2).
18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2).
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19. Remove the piston O.D. seal (202).
20. Remove the piston I.D. seal (200). You may now proceed to the inspection process.
4.16.4 Inspection
1. Clean all parts in a solvent tank and dry with compressed air prior to inspecting. Carefully inspect all critical areas for any surface
finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth.
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2. Inspect the thrust washers (304) for rough or worn edges and surfaces. Measure it’s thickness to make sure it is within
specifications (Not less than 0.092” or 2.34 mm).
3. Inspect the wear guide condition and measure thickness (not less than 0.123” or 3.12 mm).
4.16.5 Assembly
1. Gather all the components and tools into one location prior to re-assembly. Use the cut away drawing to reference the seal
orientations.
2. Install the thrust washer (304) onto shaft (2) and end cap (4).
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3. Install the wiper seal (304.1/green O-ring) into it’s groove on the shaft (2) and end cap (4) around the outside edge of the thrust
washer (304).
4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular motion.
5. Install the wear guide (302) on the end cap (4) and shaft (2).
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6. Install the inner T-seal (200) into the piston (3) using a circular motion.
Install the outer T-seal (202) by stretching it around the groove in a circular motion.
Each T-seal has 2 Backup rings (see drawing for orientation).
Beginning with the inner seal (200) insert one end of b/u ring in the lower groove and feed the rest in using a circular motion.
Make sure the wedged ends overlap correctly.
Repeat this step for the outer seal (202).
7. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the housing bore.
8. Looking from the angle shown, rotate the piston (3) until the marks you put on the piston and the housing (1) during disassembly
line up as shown. Using a rubber mallet, tap the piston into the housing up to the point where the gear teeth meet.
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9. Looking from the opposite end of the housing (1) you can see if your timing marks are lining up. When they do, tap the piston (3)
in until the gear teeth mesh together. Tap the piston into the housing the rest of the way until it bottoms out.
10. Install the shaft (2) into the piston (3). Be careful not to damage the seals. Do not engage the piston gear teeth yet.
11. Looking from the view shown, use the existing timing marks to line up the gear teeth on the shaft (2) with the gear teeth on the
inside of the piston (3). Now tap the flange end of the shaft with a rubber mallet until the gear teeth engage.
12. Install 2 bolts in the threaded holes in the flange. Using a bar, rotate the shaft in a clockwise direction until the wear guides are
seated inside the housing bore.
13. Install the stop tube onto the shaft end. Stop tube is an available option to limit the rotation of an actuator.
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14. Coat the threads on the end of the shaft with anti-seize grease to prevent galling.
15. Install the O-ring (204) and Backup ring (207) into the inner seal groove on the end cap (4).
16. Thread the end cap (4) onto the shaft (2) end. Make sure the wear guide stays in place on the end cap as it is threaded into the
housing (1).
17. Tighten the end cap (4). In most cases the original holes for the lock pins will line up.
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18. Place the lock pins (109) provided in the Helac seal kit in the holes with the dimple side up. Then, using a punch, tap the lock pins
to the bottom of the hole.
19. Insert the set screws (113) over the lock pins. Tighten them to 25 in. lbs. (2.825 Nm).
4.16.6 Installing Counterbalance Valve

Refer to Figure — Rotator Counterbalance Valve, page 359.
1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old Threadlocking
compound.
2. Make sure the new valve has the O-rings in the counterbores of the valve to seal it to the actuator housing.
3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve. Medium Strength
Threadlocking Compound should be applied to the shank of the three bolts at the time of installation.
4. Torque the 1/4 in. bolts 110 to 120 in. lbs. (12.4 to 13.5 Nm). Do not torque over 125 in. lbs. (14.1 Nm). Torque the 5/16 in. bolts 140
in. lbs. (15.8 Nm). Do not torque over 145 in. lbs. (16.3 Nm).
4.16.7 Testing the Actuator

If the equipment is available, the actuator should be tested on a hydraulic test bench. The breakaway pressure — the pressure at which
the shaft begins to rotate — should be approximately 400 psi (28 bar). Cycle the actuator at least 25 times at 3000 psi (210 bar) pressure.
After the 25 rotations, increase the pressure to 4500 psi (315 bar) to check for leaks and cracks. Perform the test again at the end of the
rotation in the opposite direction.
TESTING THE ACTUATOR FOR INTERNAL LEAKAGE
If the actuator is equipped with with a counterbalance valve, plug the valve ports. Connect the hydraulic lines to the housing ports.
Bleed all air from the actuator (see Installation and Bleeding) Rotate the shaft to the end of rotation at 3000 psi (210 bar) and maintain
pressure. Remove the hydraulic line from the non-pressurized side.
Continuous oil flow from the open housing port indicates internal leakage across the piston. Replace the line and rotate the shaft to the
end of rotation in the opposite direction. Repeat the test procedure outlined above for the other port. If there is an internal leak,
disassemble, inspect and repair.
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4.16.8 Bleeding After Installation

Note: Bleeding will be necessary if excessive backlash is displayed after the actuator is installed. To do this, bleeder valves must be in-
stalled in the actuator at the locations shown below. The following steps are recommended when a minimum of 2 Gallon (8 L) is
purged.
1. Connect a 5 ft. (1.5 m) long 3/16" inside diameter, 5/16" outside diameter clear vinyl drain tube to each of the two bleeder valves.
Secure the tubes in place with hose clamps.
2. Place the end of the tubes in a clean 5 Gallon (19 L) container to collect the purged oil. The oil can be returned to the reservoir
when the procedure is complete.
3. Open both bleeder valves 1/4 turn. Using the hydraulic system, rotate the platform to the end of rotation and maintain hydraulic
pressure. Oil with small air bubbles should be seen flowing through the tubes. Allow 1/2 Gallon (2 L) of oil to be purged from the
actuator.
4. Keep the bleeder valves open and rotate the platform in the opposite direction to the end of rotation. Maintain hydraulic pressure
until an additional 1/2 Gallon (2 L) of oil is pumped out.
5. Repeat steps 3 and 4. After the last 1/2 Gallon (2 L) of oil is purged, close both bleed nipples before rotating away from the end of
rotation.
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Boom and Platform
Figure 150. Rotator Counterbalance Valve
4.17 BOLT-ON EXTERNAL FALL ARREST
The bolt-on external fall arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside
the platform. Exit/Enter the platform through the gate area only. The system is designed for use by one person.
Personnel must use fall protection at all times. A full body harness is required with lanyard not to exceed 6 ft. (1.8 M) in length, that
limits the maximum arrest force to 900 lb (408 kg).
Bolt-On External Fall Arrest System capacity is 310 lb (140 kg) - one (1) person maximum.
Do not move the platform during use of the bolt-on external fall arrest system.
WARNING
Do not operate any machine functions while outside of platform. be careful when
entering/exiting the platform at elevation.
WARNING
If the bolt-on external fall arrest system is used to arrest a fall or is otherwise dam-
aged, the entire system must be replaced and the platform fully inspected before
returning to service. Refer to the service manual for removal and installation
procedures.
WARNING
The bolt-on external fall arrest system requires an annual inspection and certifica-
tion. The annual inspection and certification must be performed by a qualified per-
son other than the user.
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Boom and Platform
4.17.1 Inspection Before Use

The bolt-on external fall arrest system must be inspected before each use of the mobile elevating work platform. Replace components if
there are any signs of wear or damage.
Before each use, perform a visual inspection of the following components:
• Cable: Inspect cable for proper tension, broken strands, kinks, or any signs of corrosion.
Figure 151. Bolt-On External Fall Arrest Cable Tension
• Fittings & Brackets: Ensure all fittings are tight and there are no signs of fractures. Inspect brackets for any damage.
• Attachment Ring: No cracks or signs of wear are acceptable. Any signs of corrosion requires replacement.
• Attaching Hardware: Inspect all attaching hardware to ensure there are no missing components and hardware is properly tightened.
• Platform Rails: No visible damage is acceptable
4.17.2 Installation
1. Install the retaining hardware (bolts, nuts, and washers) and secure the brackets to the platform rail. Tighten the nuts but do not
torque them yet.
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Boom and Platform
2. Attach the fall arrest cable to the right hand bracket Using the attaching bolt and nut. Orient the bolt as shown below. Do not
tighten the nut so cable can still rotate.
3. Install the Attachment Ring onto the cable.
4. Without twisting the fall arrest cable, pull it thru the left hand bracket and mark the top of the swaged cable end. Install the fall
arrest cable through the left hand bracket and secure it using the belleville washers, washer, retaining nut, and jam nuts. Orient
the hardware as shown below and with the belleville washers so the gap is present at the outside diameter of the washers. install
the nuts onto the cable finger tight so the mark on the cable does not move.
5. Use the two jam nuts to prevent the cable from rotating while the nut is tightened. Tighten the nut until the belleville washers are
fully compressed and no gap is present at the outside diameter of the washers. Ensure the cable has not rotated during tightening.
6. Tighten the first jam nut against the retaining nut to keep the nut from loosening. Tighten the remaining jam nut against the first
jam nut.
7. Torque the nuts and bolts securing the brackets to 15 ft. lbs. (20 Nm).
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Boom and Platform
Figure 152. Bolt-On External Fall Arrest System
1. Belleville Washer 4. Jam Nut 7. Cable

2. Washer 5. LH Bracket 8. RH Bracket
3. Hex Nut 6. Attachment Ring 9. Decal
4.18 SKYGUARD
4.18.1 Operation
SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actuation
will reverse or cutout. The SkyGuard Function Table provides more details on these functions.
Consult the following illustrations to determine which type of SkyGuard the machine is equipped with. Regardless of the type, SkyGuard
function according to the SkyGuard Function Table does not change.
SkyGuard
SkyGuard SkyLine™
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Boom and Platform
SkyGuard SkyEye™
WARNING
The machine operator is required to perform A daily function test to ensure proper
operation of the skyguard system.
4.18.2 Function Test

SkyGuard Only
Perform this function test if SkyGuard only is selected in machine setup (refer to Table — Machine Configuration Programming
Information, page 591).
From the Platform Control Console in an area free from obstructions:
1. Operate the telescope out function, then activate SkyGuard sensor.
2. Once sensor has been activated, ensure telescope out function stops then telescope in function operates for a short duration.
Additionally, verify Soft Touch/SkyGuard indicator light flashes and horn sounds. If machine is equipped with SkyGuard beacon,
ensure it flashes when sensor activates.
3. With SkyGuard sensor still engaged, press and hold yellow Soft Touch/SkyGuard override button. Operate a function to verify
operation can be resumed.
4. Disengage SkyGuard sensor, release controls, and recycle footswitch. Ensure normal operation available.
In Ground Mode:
1. Operation is allowed regardless of SkyGuard activation.
BOTH SKYGUARD AND SOFT TOUCH

Perform this procedure if both SkyGuard and Soft Touch are selected in machine setup (refer to Table — Machine Configuration
Programming Information, page 591).
From the Platform Control Console in an area free from obstructions:
Note: Machine will treat Soft Touch/SkyGuard override switch as if it is a Soft Touch and SkyGuard switch.
1. Operate the telescope out function, then activate Sky-Guard sensor.
2. Once sensor has been activated, ensure telescope out function stops. Additionally, verify Soft Touch/SkyGuard indicator light
flashes and horn sounds. If machine is equipped with SkyGuard beacon, ensure it flashes when sensor activates.
3. With SkyGuard sensor still engaged, press and hold yellow Soft Touch/SkyGuard override button. Operate a function to verify
operation can be resumed.
4. Disengage SkyGuard sensor, release controls, and recycle footswitch. Ensure sure normal operation is available.
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Boom and Platform
In Ground Mode:
1. Operation is allowed regardless of SkyGuard activation.
Soft touch only

If is selected in machine setup (refer to Table — Machine Configuration Programming Information, page 591), machine will treat the Soft
Touch/SkyGuard override switch as if it is a Soft Touch switch.
SkyGuard not selected in machine setup
If the SkyGuard system is installed on the machine, but no option is selected in the machine setup (refer to Table — Machine
Configuration Programming Information, page 591), SkyGuard sensor status will be ignored. No function cutout or reversal will be
implemented.
4.18.3 Diagnostics & Troubleshooting

If SkyGuard does not function when the sensor is engaged, first verify the configuration under the MACHINE SETUP: SKYGUARD OPTION
menu using the handheld Analyzer. Ensure the selected configuration matches the actual system installed on the machine. If not, select
the correct configuration, then verify operation.
Additionally, use the handheld analyzer to navigate to the DIAGNOSTICS: FEATURES →KYGUARD INPUTS menu to determine additional
SkyGuard fault information.
Engage the SkyGuard sensor and observe the Analyzer to determine if the switch/relay closes.
If the status of the switch/relay remains OPEN while the SkyGuard sensor is actively engaged, it is possible the sensor has failed and
should be replaced immediately.
If the status of the switch/relay remains CLOSED while the SkyGuard sensor is actively engaged, a power or ground wire may not be
making good contact or may be loose or broken. Additionally, there is a low probability that both relays may have failed.
If the switch/relay status is in disagreement, then one may have failed or is not installed correctly. In this case, the machine will be
inoperable.
Fault Codes
Table 21. SkyGuard Function Table
Drive Drive Boom Lift Boom Lift Boom Tele Boom Tele Basket Basket
Steer Swing Jib Lift Jib Swing
Forward Reverse Up Down Out In Level Rotate
R*/
R C R R R R C C C C C
C**
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* DOS (Drive Orientation System) Enabled
* * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is
active
Note: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing
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SECTION 5
BASIC HYDRAULIC INFORMATION AND SCHEMATICS
5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEM
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 following procedures.
Note: All O-ring fittings must be pre-lubricated with hydraulic oil prior to assembly.
5.1.1 Cup and Brush

The following is needed to correctly oil the O-ring in this manner:
• A small container for hydraulic oil
• Small paint brush
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.
2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire O-ring in the fitting, making sure
the entire O-ring is completely saturated.
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Basic Hydraulic Information and Schematics
3. Turn the O-ring on the other side of the fitting and repeat the previous step, ensuring the entire O-ring is coated with hydraulic oil.
5.1.2 Dip Method

Note: This method works best with Face Seal O-rings, but will work for all O-ring fitting types.
The following is needed to correctly oil the O-ring in this manner:
• A small leak proof container
• 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.
3. O-ring Boss type fittings will require more pressure in able to immerse more of the fitting into the saturated sponge. This will also
cause more oil to be dispersed from the sponge.
BM110143A
5.1.3 Spray Method

This method requires a pump or trigger spray bottle.
1. Fill the spray bottle with hydraulic oil.
2. Hold the fitting over a suitable catch can.
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3. Spray the entire O-ring surface with a medium coat of oil.
5.1.4 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 even coat of oil.
5.2 HYDRAULIC CONNECTION ASSEMBLY AND TORQUE SPECIFICATION
5.2.1 Tapered Thread Types

NPTF = national tapered fuel (Dry Seal) per SAE J476/J512
Figure 153. NPTF Thread

BSPT = British standard pipe tapered per ISO7-1
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Figure 154. BSPT Thread
5.2.2 Straight Thread Types, Tube and Hose Connections

JIC = 37° flare per SAE J514
Figure 155. JIC Thread

SAE = 45° flare per SAE J512
Figure 156. SAE Thread

ORFS = o-ring face seal per SAE J1453
Figure 157. 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 158. MTBL-MBTS Thread

BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
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Figure 159. Bulkhead Thread
5.2.3 Straight Thread Types, Port Connections

ORB = O-ring boss per SAE J1926, ISO 11926
MPP = metric pipe parallel o-ring boss per SAE J2244, ISO 6149, DIN 3852
Figure 160. ORB-MPP Thread

MFF = metric flat face port per ISO 9974-1
BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852-2
Figure 161. MFF-BSPP Thread
5.2.4 Flange Connection Types

FL61 = code 61 flange per SAE J518, ISO 6162
FL62 = code 62 flange per SAE J518, ISO 6162
Figure 162. ORB-MPP Thread
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5.2.5 Tightening Methods

Torque = Application of a twisting force to the applicable connection by use of a precise measurement instrument (i.e. torque wrench).
Finger Tight = The point where the connector will no longer thread onto the mating part when tightened by hand or fingers. Finger
Tight is relative to user strength and will have some variance. The average torque applied by this method is 3 ft. lbs. [4 Nm] 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 (fingers) and
applying an additional rotation counted by a defined number of turns by use of a tool.
FFWR = Flats from Wrench Resistance; Application of a preload to a connection by tightening to the point of initial wrench resistance
and turning the nut a described number of ‘flats’. A ‘flat’ is one side of the hexagonal tube nut and equates to 1/6 of a turn. Also referred
to as the ‘Flats Method’.
5.2.6 Assembly and Torque Specifications

Prior to selecting the appropriate torque from the tables within this section, it is necessary to properly identify the connector being
installed. Refer to the Figures and Tables in this section.
GENERAL TUBE TYPE FITTING ASSEMBLY INSTRUCTIONS
1. Take precautions to ensure that fittings and mating components are not damaged during storage, handling or assembly. Nicks and
scratches in sealing surfaces can 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 attachment 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. Contamination can prevent
proper tightening of fittings and adapters 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 necessary before re-
installing.
c. Sealing compounds should be applied where specified; however, care should be taken not to introduce sealant into the
system.
d. Avoid applying sealant to the area of the threads where the sealant will be forced into the system. 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. Refer to Section —
O-ring Installation (Replacement), page 441 in this section.
4. Take care to identify the material of parts to apply the correct torque values.
a. Verify the material designation in the table headings.
b. If specifications are given only for steel fittings and components, the values for alternate materials shall be as follows:
Aluminum and Brass- reduce steel values by 35%; Stainless Steel- Use the upper limit for steel.
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5. To achieve the specified torque, the torque wrench is to be held perpendicular to the axis of rotation.
Figure 163. Torque Wrench Angle
6. Refer to the appropriate section in this manual for more specific instructions and procedures for each type of fitting connection.
5.2.7 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
1. Inspect components to ensure male and female port threads are free of rust, splits, dirt, foreign matter, or burrs.
2. Apply a suitable thread sealant, such as high temperature high thread sealant with PTFE to the male pipe threads if not already
applied. Ensure the first 1 to 2 threads are uncovered to prevent system contamination.
3. Assemble connection hand tight.
4. Mark fittings, male and female.
CAUTION
Over tightening may cause deformation of the pipe fitting and damage to the join-
ing 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.
5. Rotate male fitting the number of turns per Table – NPTF Pipe Thread, page 372. Refer to Section – FFWR and TFFT Methods, page
439 for TFFT procedure requirements.
Note: TFFT values provided in Table — NPTF Pipe Thread, page 372 are applicable for the following material configurations:
• STEEL fittings with STEEL mating components.
• STEEL fittings with ALUMINUM or BRASS mating components.
• ALUMINUM or BRASS fittings with STEEL mating components.
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS mating components.
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Table 22. NPTF Pipe Thread
372
TYPE/FITTING IDENTIFICATION
Thread Size ØA* Turns From Finger Tight (TFFT)**

Material Dash Size
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3

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
STEEL, ALUMINUM, OR BRASS FIT-
TINGS WITH STEEL, ALUMINUM, OR 12 3/4 - 14 1.05 26.56 2 to 3

BRASS MATING COMPONENTS
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
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32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
* ØA thread dimension for reference only.
** Refer to Section – FFWR and TFFT Methods, page 439 subsection for TFFT procedure requirements.
1200SJP , 1350SJP
5.2.8 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
1. Inspect components to ensure male and female port threads are free of rust, splits, dirt, foreign matter, or burrs.
2. Apply a suitable thread sealant, such as threadlocking compound, to the male pipe threads if not already applied. Ensure the first 1
to 2 threads are uncovered to prevent system contamination.
3. Assemble connection hand tight.
4. Mark fittings, male and female.
NOTICE
Over tightening may cause deformation of the pipe fitting and damage to the join-
ing 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.
5. Rotate male fitting the number of turns per Table – BSPT Pipe Thread, page 374. Refer to Section – FFWR and TFFT Methods, page 439
for TFFT procedure requirements.
Note: TFFT values provided in Table – BSPT Pipe Thread, page 374 are applicable for the following material configurations:
• STEEL fittings with STEEL mating components
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Table 23. BSPT Pipe Thread
374
Thread Size ØA* Turns From Finger Tight (TFFT)**

MATERIAL Dash Size
(BSPT) (in) (mm)
STEEL, ALUMINUM, OR BRASS FIT- 2 1/8 - 28 0.38 9.73 2 to 3

TINGS WITH STEEL, ALUMINUM,
OR BRASS MATING COMPONENTS 4 1/4 - 19 0.52 13.16 2 to 3
6 3/8 - 19 0.66 16.66 2 to 3
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
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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.
** Refer to Appendix B for TFFT procedure requirements.
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5.2.9 Assembly Instructions for 37° (JIC) Flare Fittings

1. Inspect the flare for obvious visual squareness and concentricity issues with the tube OD. Ensure surface is smooth, free of rust,
weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or adapter.
CAUTION
Do not force a misaligned or short hose/tube into alignment. It puts undesirable
strain onto the joint eventually leading to leakage.
2. Align tube to fitting and start threads by hand.
CAUTION
The torque method should not be used on lubricated or oily fittings. No lubrication
or sealant is required. The lubrication Would cause increased clamping force and
cause fitting damage.
3. Torque assembly to value listed in Table – 37° Flare (JIC)Thread - Steel, page 376 or Table – 37° Flare (JIC)Thread - Aluminum/Brass,
page 377 while using the Double Wrench Method per Double Wrench Method. Refer to Section – FFWR and TFFT Methods, page 439
for procedure requirements if using the FFWR method.
Note: Torque values provided in Table – 37° Flare (JIC)Thread - Steel, page 376 and Table – 37° Flare (JIC)Thread - Aluminum/Brass,
page 377 are segregated based on the material configuration of the connection.
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING COMPONENTS’ indicate either the following material configurations:
1200SJP , 1350SJP 31220396 375

Table 24. 37° Flare (JIC)Thread - Steel
376
Type/Fitting Identification Torque
Flats from Wrench
Thread Size ØA* ØB* [Ft-Lb] [N-m] Resistance (F.F.W.
MATERIAL Dash Size 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 –
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
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2
STEEL FITTINGS 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

WITH STEEL MAT-
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
ING
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COMPONENTS; 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.
** Refer to Appendix B for FFWR procedure requirements.
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Table 25. 37° Flare (JIC) Thread - Aluminum/Brass
1200SJP , 1350SJP
Flats from Wrench
Thread Size ØA* ØB* [Ft-Lb] [N-m] Resistance (F.F.W.
MATERIAL Dash Size R)**
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 –
3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 –
4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
ALUMINUM/BRASS
FITTINGS OR ALUMI- 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
NUM/BRASS MATING
10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
COMPONENTS; UN-
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LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
THREADS
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
** Refer to Section – FFWR and TFFT Methods, page 439 for FFWR procedure requirements.
377
5.2.10 Assembly Instructions for 45° SAE Flare Fittings

1. Inspect the flare for obvious visual squareness and concentricity issues with the tube OD. Ensure surface is smooth, free of rust,
weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or adapter.
CAUTION
Do not force a misaligned or short hose/tube into alignment. It puts undesirable
strain onto the joint eventually leading to leakage.
2. Align tube to fitting.
3. Tighten fitting by hand until hand tight.
CAUTION
The torque method should not be used on lubricated or oily fittings. No lubrication
or sealant is required. The lubrication would cause increased clamping force and
cause fitting damage.
4. Torque fitting to value list and Table – 45° Flare (SAE) - Aluminum/Brass, page 380 while using the Double Wrench Method outlined
in this section. Refer to Section – FFWR and TFFT Methods, page 439 for procedure requirements if using the TFFT method.
Note: Torque values provided in Table – 45° Flare (SAE) - Steel, page 379 and Table – 45° Flare (SAE) - Aluminum/Brass, page 380 are
segregated based on the material configuration of the connection.
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Table 26. 45° Flare (SAE) - Steel
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TYPE/FITTING IDENTIFICATION Torque
Thread Size ØA* ØB* [Ft-Lb] [N-m]

MATERIAL Dash Size
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33
STEEL FITTINGS WITH STEEL MATING
COMPONENTS; UN-LUBRICATED 8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
THREADS
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
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379
Table 27. 45° Flare (SAE) - Aluminum/Brass
380
TYPE/FITTING IDENTIFICATION Torque
Thread Size ØA* ØB* [Ft-Lb] [N-m]

MATERIAL Dash Size
4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12
6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20
STEEL FITTINGS WITH STEEL MATING
COMPONENTS; UN-LUBRICATED 8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41
THREADS
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
** Refer to Section – FFWR and TFFT Methods, page 439 for TFFT procedure requirements.
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1200SJP , 1350SJP
5.2.11 Assembly Instructions for O-ring Face Seal (ORFS) Fittings

1. Ensure proper O-ring is installed. If O-ring is missing install per Section – O-ring Installation (Replacement), page 441.
2. Ensure surface is smooth, free of rust, weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or
adapter.
CAUTION
Care to be taken when lubricating O-ring. Avoid adding oil to the threaded connec-
tion of the fitting. The lubrication would cause increased clamping force and cause
fitting damage.
3. Pre-lubricate the O-ring with Hydraulic Oil.
4. Place the tube assembly against the fitting body so that the flat face comes in contact with the o-ring. Hand thread the nut onto
the fitting body.
5. Torque nut to value listed in Table — O-ring Face Seal (ORFS) - Steel, page 382 or Table — O-ring Face Seal (ORFS) - Aluminum/ Brass,
page 383 while using the Double Wrench Method. Refer to Section – FFWR and TFFT Methods, page 439 for procedure requirements
if using the FFWR method.
Note: Torque values provided in Table — O-ring Face Seal (ORFS) - Steel, page 382 and Table — O-ring Face Seal (ORFS) - Aluminum/
Brass, page 383 are segregated based on the material configuration of the connection.
1200SJP , 1350SJP 31220396 381

Table 28. O-ring Face Seal (ORFS) - Steel
382
Flats from Wrench Resistance
(F.F.W.R)**
Thread [Ft-Lb] [N-m]

ØA* ØB* Swivel &
MATERIAL Dash Size Size Tube nuts
Hose 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 FITTINGS
WITH STEEL MAT- 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
ING COMPO-
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
NENTS; UN-
LUBRICATED 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
THREADS
20 111/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
31220396
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
1200SJP , 1350SJP
Table 29. O-ring Face Seal (ORFS) - Aluminum/Brass
1200SJP , 1350SJP
Flats from Wrench Resistance
(F.F.W.R)**
Thread [Ft-Lb] [N-m]

ØA* ØB* Swivel &
MATERIAL Dash Size Size Tube nuts
Hose 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
8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4
ALUMINUM/
BRASS FITTINGS 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
OR ALUMINUM/
BRASS MATING 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
COMPONENTS;
UN-LUBRICATED 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
THREADS
20 111/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
31220396
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
383
5.2.12 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
CAUTION
A non-square tube end can cause improperly seated fittings and leakage.
1. Inspect the components to ensure free of contamination, 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 collect 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 — DIN 24° Cone (MBTL & MBTS), page 385 while using the Double Wrench Method. The tube must not turn
with the nut.
384 31220396 1200SJP , 1350SJP

Table 30. DIN 24° Cone (MBTL & MBTS)
1200SJP , 1350SJP
DIN 24° CONE FLARELESS BITE FITTING
(With or Without o-ring)
Torque
Tube O.D. Thread M Size ØA* ØB* C* ØD*
[Ft-Lb] [N-m] Flats from Resist-
MATERIAL TYPE
ance(F.F.W.R)**
M-
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom
ax
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
8 M14 x 1.5 12.50 14.00 7.00 8.20 FFWR is the recommended method of fitting assembly. 1.5 to 1.75
10 M16 x 1.5 14.50 16.00 7.00 10.20 1.5 to 1.75
12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
31220396
STEEL FITTINGS DIN 24° CONE FLARE- 15 M22 x 1.5 20.50 22.00 7.00 15.20 Torque values are application specific due to variability in 1.5 to 1.75
WITH STEEL MAT- LESS BITE (MBTL) the fitting supplier, coating, lubrication, and other physical
ING COMPONENTS FITTING 18 M26 x 1.5 24.50 26.00 7.50 18.20 characteristics of the connection. 1.5 to 1.75
22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75
28 M36 x 2 33.90 36.00 7.50 28.20 1.5 to 1.75
35 M45 x 2 42.90 45.00 10.50 35.30 Refer to the specific procedure in the 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
385
DIN 24° CONE FLARELESS BITE FITTING
386
(With or Without o-ring)
Torque
Tube O.D. Thread M Size ØA* ØB* C* ØD* Flats from Re-
MATERIAL TYPE [Ft-Lb] [N-m] sistance(F.F.
W.R)**
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75
8 M16 x 1.5 14.50 16.00 7.00 8.20 FFWR is the recommended method of fitting assembly. 1.5 to 1.75
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
12 M20 x 1.5 18.50 20.00 7.50 12.20 1.5 to 1.75
STEEL FITTINGS DIN 24° CONE 14 M22 x 1.5 20.50 22.00 8.00 14.20 Torque values are application specific due to variability in the fit- 1.5 to 1.75
WITH STEEL FLARELESS BITE ting supplier, coating, lubrication, and other physical characteris-
MATING (MBTS) FITTING 16 M24 x 1.5 22.50 24.00 8.50 16.20 1.5 to 1.75
tics of the connection.
COMPONENTS
20 M30 x 2 27.90 30.00 10.50 20.20 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 1.5 to 1.75
30 M42 x 2 39.90 42.00 13.50 30.20 Refer to the specific procedure 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.
** Refer to Appendix B for FFWR procedure requirements.
31220396
1200SJP , 1350SJP
5.2.13 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 — Bulkhead Fittings (BH) - INCH, page 388 and Table — Bulkhead Fittings (BH) - METRIC, page 390
while using the Double Wrench Method.
1200SJP , 1350SJP 31220396 387

Table 31. Bulkhead Fittings (BH) - INCH
388
FASTENING JAM NUT
for Bulkhead Connectors
Torque
Thread Size
MATERIAL TYPE Dash Size [Ft-Lb] [N-m]
(UNF) Min Nom Max Min Nom Max

4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
8 13/16-16 55 58 61 75 79 83
10 1-14 85 90 94 115 122 127
O-RING FACE SEAL
STEEL FITTINGS (ORFS) BULKHEAD 12 1 3/16-12 135 142 149 183 193 202
31220396
FITTING
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
1200SJP , 1350SJP
FASTENING JAM NUT
Torque
Thread Size
MATERIAL TYPE Dash Size [Ft-Lb] [N-m]
1200SJP , 1350SJP
(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
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
37° FLARE (JIC) 10 7/8-14 85 90 94 115 122 127

STEEL FITTINGS
BULKHEAD FITTING 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
31220396
389
Table 32. Bulkhead Fittings (BH) - METRIC
390
FASTENING JAM NUT
Torque
Connecting Tube O.
Thread Size
MATERIAL TYPE 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
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
DIN 24° CONE FLARE- 15 M22 x 1.5 44 47 50 60 64 68
31220396
STEEL FITTINGS LESS BITE (MBTL)
BULKHEAD FITTING 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
1200SJP , 1350SJP
FASTENING JAM NUT
Torque
Connecting Tube O.
Thread Size
MATERIAL TYPE D. [Ft-Lb] [N-m]
1200SJP , 1350SJP
(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
DIN 24° CONE FLARE- 14 M22 x 1.5 70 47 50 60 64 68
STEEL FITTINGS LESS BITE (MBTS)
BULKHEAD FITTING 16 M24 x 1.5 115 75 80 95 102 108
20 M30 x 2 150 120 125 156 163 169
25 M36 x 2 155 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
31220396
391
5.2.14 Assembly Instructions for O-Ring Boss (ORB) Fittings

1. Inspect components to ensure that male and female port threads are free of rust, splits, dirt, foreign matter, or burrs.
2. Ensure proper O-ring is installed. If O-ring is missing install per Section – O-ring Installation (Replacement), page 441.
CAUTION
fitting damage.
4. For Non-Adjustable and Plugs, thread the fitting by hand until contact.
5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly.
6. Torque the fitting or nut to value listed in Table — O-ring Boss (ORB) - Table 1 of 6, page 393 through Table — O-ring Boss (ORB) -
Table 6 of 6, page 403 while using the Double Wrench Method.
a. The table headings identify the straight thread O-ring port and the type on the other side of the fitting. The torque will be
applied to the straight thread O-ring port.
b. Torque values provided in Table — O-ring Boss (ORB) - Table 1 of 6, page 393 through Table — O-ring Boss (ORB) - Table 6 of 6,
page 403 are segregated based on the material configuration of the connection. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/
BRASS MATING COMPONENTS’ indicate either the following material configurations:
7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port.
392 31220396 1200SJP , 1350SJP

Table 33. O-ring Boss (ORB) - Table 1 of 6
1200SJP , 1350SJP
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

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
STEEL FITTINGS WITH 8 3/4-16 0.75 19.10 52 55 57 70 75 77

STEEL MATING COM-
PONENTS; UN-LUBRI- 10 7/8-14 0.87 22.22 85 90 94 115 122 127
31220396
CATED THREADS 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
393
HEX TYPE PLUGS & STUD ENDS
394

MATERIAL Dash Size
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22

5 1/2-20 0.50 12.70 15 16 17 20 22 23
6 9/16-18 0.56 14.28 19 20 21 26 27 28
ALUMINUM/BRASS
FITTINGS OR ALU- 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MINUM/BRASS
MATING COMPO- 10 7/8-14 0.87 22.22 55 58 61 75 79 83
NENTS; UN-LUBRI- 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
CATED THREADS
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
31220396
* 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.
1200SJP , 1350SJP
1200SJP , 1350SJP
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
STEEL FITTINGS 8 3/4-16 0.75 19.10 60 63 66 80 85 89
WITH STEEL MAT-
ING COMPONENTS; 10 7/8-14 0.87 22.22 100 105 110 135 142 149
UN-LUBRICATED
31220396
THREADS 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
395
STUD ENDS
396

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
ALUMINUM/BRASS
FITTINGS OR ALU- 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MINUM/BRASS
10 7/8-14 0.87 22.22 65 69 72 88 94 98
MATING COMPO-
NENTS; UN-LUBRI- 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
CATED THREADS
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
31220396
1200SJP , 1350SJP
1200SJP , 1350SJP
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
STEEL FITTINGS 8 3/4-16 0.75 19.10 52 55 57 70 75 77
WITH STEEL MAT-
ING COMPONENTS; 10 7/8-14 0.87 22.22 85 90 94 115 122 127
UN-LUBRICATED
31220396
THREADS 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
397
ADJUSTABLE STUD END
398

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
ALUMINUM/BRASS
FITTINGS OR ALU- 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MINUM/BRASS
MATING COMPO- 10 7/8-14 0.87 22.22 55 58 61 75 79 83
NENTS; UN-LUBRI- 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
CATED THREADS
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
31220396
1200SJP , 1350SJP
1200SJP , 1350SJP
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
STEEL FITTINGS WITH 8 3/4-16 0.75 19.10 60 63 66 80 85 89

STEEL MATING COM-
10 7/8-14 0.87 22.22 100 105 110 135 142 149
PONENTS; UN-LUBRI-
31220396
CATED THREADS 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
399
ADJUSTABLE STUD END
400

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
ALUMINUM/BRASS
FITTINGS OR ALU- 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MINUM/BRASS
10 7/8-14 0.87 22.22 65 69 72 88 94 98
MATING COMPO-
NENTS; UN-LUBRI- 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
CATED THREADS
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
31220396
1200SJP , 1350SJP
1200SJP , 1350SJP
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
STEEL FITTINGS 8 3/4-16 0.75 19.10 60 63 66 80 85 89
WITH STEEL MAT-
ING COMPONENTS; 10 7/8-14 0.87 22.22 100 105 110 135 142 149
UN-LUBRICATED
THREADS 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
31220396
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
401
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
402
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
ALUMINUM/BRASS
FITTINGS OR ALU- 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MINUM/BRASS
MATING COMPO- 10 7/8-14 0.87 22.22 65 69 72 88 94 98
NENTS; UN-LUBRI- 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
CATED THREADS
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
31220396
1200SJP , 1350SJP
1200SJP , 1350SJP
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
STEEL FITTINGS 8 3/4-16 0.75 19.10 28 30 32 38 41 43
WITH STEEL MAT-
ING COMPONENTS; 10 7/8-14 0.87 22.22 46 48 50 62 65 68
31220396
UN-LUBRICATED
THREADS 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
20 1 5/8-12 1.63 41.30 Fitting size greater than -12 not typically specified on 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
403
ZERO LEAK GOLD®
404
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
ALUMINUM/BRASS
FITTINGS OR ALU- 8 3/4-16 0.75 19.10 28 30 32 38 41 43
MINUM/BRASS
10 7/8-14 0.87 22.22 46 48 50 62 65 68
MATING COMPO-
NENTS; UN-LUBRI- 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
CATED THREADS
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30

20 1 5/8-12 1.63 41.30 Fitting size greater than -12 not typically specified on 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
31220396
1200SJP , 1350SJP
5.2.15 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter or burrs.
2. If O-ring is not pre-installed, install proper size, taking care not to damage it. Refer to Section – O-ring Installation (Replacement),
page 441 for instructions.
CAUTION
fitting damage.
4. For Non-Adjustable Fittings and Plugs, thread the fitting by hand until contact.
6. Torque the fitting or nut to value listed in Table — Metric Flat Face Port (MFF) - L Series - Table 1 of 3, page 406, Table — Metric Flat
Face Port (MFF) - L Series - Table 2 of 3, page 408, Table — Metric Flat Face Port (MFF) - L Series - Table 3 of 3, page 410, Table —
Metric Flat Face Port (MFF) - S Series - Table 1 of 3, page 412, Table — Metric Flat Face Port (MFF) - S Series - Table 2 of 3, page 414 or
Table — Metric Flat Face Port (MFF) - S Series - Table 3 of 3, page 416 while using the Double Wrench Method.
a. The table headings identify the Metric port and the type on the other side of the fitting. The torque will be applied to the
Metric port.
b. Torque values provided in Table — Metric Flat Face Port (MFF) - L Series - Table 1 of 3, page 406, Table — Metric Flat Face Port
(MFF) - L Series - Table 2 of 3, page 408, Table — Metric Flat Face Port (MFF) - L Series - Table 3 of 3, page 410, Table — Metric Flat
Face Port (MFF) - S Series - Table 1 of 3, page 412, Table — Metric Flat Face Port (MFF) - S Series - Table 2 of 3, page 414 and Table
— Metric Flat Face Port (MFF) - S Series - Table 3 of 3, page 416, are segregated based on the material configuration of the
connection. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING COMPONENTS’ indicate either the following material
configurations:
1200SJP , 1350SJP 31220396 405

Table 39. Metric Flat Face Port (MFF) - L Series - Table 1 of 3
406
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
Torque Torque
Connecting
Thread M Size
MATERIAL 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
31220396
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
STEEL FIT- M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
TINGS WITH
STEEL MATING M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
COMPONENTS;
UN-LUBRI- M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
CATED
THREADS 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
1200SJP , 1350SJP

1200SJP , 1350SJP
Torque Torque
Connecting
Thread M Size
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
ALUMINUM/
BRASS FIT- M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
TINGS OR ALU-
MINUM/BRASS M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
MATING COM- M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
PONENTS; UN-
LUBRICATED M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
THREADS
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
31220396
407
408

Torque Torque
Connecting
Thread M Size
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
31220396
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
STEEL FIT- M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
TINGS WITH
STEEL MATING M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
COMPONENTS;
UN-LUBRI- M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
CATED
THREADS 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
1200SJP , 1350SJP

1200SJP , 1350SJP
Torque Torque
Connecting
Thread M Size
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
ALUMINUM/BRASS M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
FITTINGS OR ALU-
MINUM/BRASS M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
MATING COMPO- M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
NENTS; UN-LUBRI-
CATED THREADS 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
31220396
409
410
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)HOLLOW HEX PLUGS
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
Connect- Torque Torque Torque

Thread M
MATERI- ing Tube
Size [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
AL O.D.
(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
STEEL M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
FITTINGS
WITH M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
STEEL
MATING M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
31220396
COMPO- M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
NENTS;
UN-LU- M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
BRICATED
THREADS 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
1200SJP , 1350SJP
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)

Thread M
MATERI- ing Tube
Size
1200SJP , 1350SJP
O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
AL
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
ALUMI- M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
NUM/
BRASS M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
FITTINGS M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
OR ALU-
MINUM/ M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
BRASS
MATING M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
COMPO-
NENTS; M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
UN-LU- M33x2 28 – – – – – – 173 182 190 235 247 258 108 114 119 146 155 161
BRICATED
THREADS 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
31220396
411
Table 42. Metric Flat Face Port (MFF) - S Series - Table 1 of 3
412

Torque Torque
Connecting
Thread M Size
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
31220396
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
STEEL FIT- M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
TINGS WITH
STEEL MATING M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
COMPONENTS;
UN-LUBRI- M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
CATED
THREADS 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
1200SJP , 1350SJP

1200SJP , 1350SJP
Torque Torque
Connecting
Thread M Size
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
ALUMINUM/
BRASS FIT- M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
TINGS OR ALU-
MINUM/BRASS M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
MATING COM- M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
PONENTS; UN-
LUBRICATED M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
THREADS
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
31220396
413
414

Torque Torque
Connecting
Thread M Size
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
31220396
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
STEEL FIT- M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
TINGS WITH
STEEL MATING M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
COMPONENTS;
UN-LUBRI- M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
CATED
THREADS 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
1200SJP , 1350SJP

1200SJP , 1350SJP
Torque Torque
Connecting
Thread M Size
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
ALUMINUM/
BRASS FIT- M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
TINGS OR ALU-
MINUM/BRASS M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
MATING COM- M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
PONENTS; UN-
LUBRICATED M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS
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
31220396
415
416

Thread M
ing Tube
MATERIAL Size [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
O.D.
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 – – – – – –
STEEL FIT- M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 – – – – – –
TINGS WITH
STEEL MAT- M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
31220396
ING COMPO-
NENTS; UN- M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 – – – – – –
LUBRICATED
THREADS 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 – – – – – –
1200SJP , 1350SJP
Torque Torque Torque

Thread M Connecting
Size Tube O.D.
1200SJP , 1350SJP
MATERIAL [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
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 – – – – – –
ALUMINUM/ M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 – – – – – –
BRASS FIT- M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 – – – – – –
TINGS OR
ALUMINUM/ M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
BRASS MAT-
ING COMPO- M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 – – – – – –
NENTS; UN-
LUBRICATED M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 – – – – – –
THREADS M33x2 28 – – – – – – 173 182 190 235 247 258 – – – – – –
M42x2 35 – – – – – – 259 272 285 351 369 386 – – – – – –
M48x2 42 – – – – – – 335 352 369 454 477 500 – – – – – –
31220396
417
5.2.16 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
CAUTION
fitting damage.
6. Torque the fitting or nut to value listed in Table — Metric Pipe Parallel O-Ring Boss (MPP), page 419 while using the Double Wrench
Method.
a. The table headings identify the Metric port and the type on the other side of the fitting. The torque will be applied to the
Metric port.
b. Torque values provided in Table — Metric Pipe Parallel O-Ring Boss (MPP), page 419 are segregated based on the material
configuration of the connection. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING COMPONENTS’ indicate either
the following material configurations:
418 31220396 1200SJP , 1350SJP

Table 45. Metric Pipe Parallel O-ring Boss (MPP)
1200SJP , 1350SJP
STUD ENDS STUD ENDS
with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end
Torque Torque
Connecting
Thread M Size
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
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
31220396
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
STEEL FIT-
TINGS WITH M20 x 1.5 – – – – – – – 59 62 65 80 84 88
STEEL MATING
COMPONENTS; M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
UN-LUBRI-
CATED M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
THREADS
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
419
STUD ENDS STUD ENDS
420
with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end
Torque Torque
Connecting
Thread M Size
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
ALUMINUM/ M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
BRASS FIT-
TINGS OR ALU- M20 x 1.5 – – – – – – – 30 40 42 41 54 57
MINUM/BRASS
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
MATING COM-
PONENTS; UN-
M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122

LUBRICATED
THREADS 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
31220396
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
1200SJP , 1350SJP
5.2.17 Assembly instructions for Adjustable Port End (BSPP) Fittings

CAUTION
fitting damage.
6. Torque the fitting or nut to value listed in Table — British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3, page 422, Table
— British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3, page 424, Table — British Standard Parallel Pipe Port (BSPP) - L
Series - Table 3 of 3, page 426, Table — British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3, page 428, Table — British
Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3, page 430 and Table — British Standard Parallel Pipe Port (BSPP) - S Series -
Table 3 of 3, page 432 while using the Double Wrench Method.
a. The table headings identify the BSPP port and the type on the other side of the fitting. The torque will be applied to the BSPP
port.
b. Torque values provided in Table — British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3, page 422, Table — British
Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3, page 424, Table — British Standard Parallel Pipe Port (BSPP) - L Series -
Table 3 of 3, page 426, Table — British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3, page 428, Table — British
Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3, page 430 and Table — British Standard Parallel Pipe Port (BSPP) - S
Series - Table 3 of 3, page 432 are segregated based on the material configuration of the connection. ‘ALUMINUM/BRASS
FITTINGS OR ALUMINUM/BRASS MATING COMPONENTS’ indicate either the following material configurations:
1200SJP , 1350SJP 31220396 421

Table 46. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
422
BM110144A
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

Torque Torque
BSPP Thread Connecting
MATERIAL G Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
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
31220396
STEEL FIT- G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
TINGS WITH
STEEL MATING G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
COMPONENTS;
UN-LUBRI- G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
CATED
THREADS 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
1200SJP , 1350SJP
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

1200SJP , 1350SJP
Torque Torque
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
ALUMINUM/
BRASS FIT- G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
TINGS OR ALU-
MINUM/BRASS G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
MATING COM- G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
PONENTS; UN-
LUBRICATED G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
THREADS
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
31220396
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
423
424
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE

Torque Torque
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
31220396
STEEL FIT- G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
TINGS WITH
STEEL MATING G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
COMPONENTS;
UN-LUBRI- G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
CATED
THREADS 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
1200SJP , 1350SJP

1200SJP , 1350SJP
Torque Torque
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
ALUMINUM/
BRASS FIT- G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
TINGS OR ALU-
MINUM/BRASS G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
MATING COM- G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
PONENTS; UN-
LUBRICATED G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS
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
31220396
425
426
BANJO FITTINGS HIGH PRESSURE BANJO FITTING FORM E (EOLASTIC SEALING RING)
with L series DIN (MBTL) opposite end S with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
Con- Torque Torque Torque

BSPP
necting
Thread
MATERIAL Tube O. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
G Size
D.
6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/8A
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
STEEL FITTINGS WITH
31220396
STEEL MATING COMPO- G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
NENTS; UN-LUBRICATED G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
THREADS
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
1200SJP , 1350SJP
BSPP Connec- Torque Torque Torque

Thread tingTube
1200SJP , 1350SJP
MATERIAL G Size O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
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
ALUMINUM/BRASS FIT-
TINGS OR ALUMINUM/ G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
BRASS MATING COMPO-
NENTS; UN-LUBRICATED G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
THREADS
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
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Table 49. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
428
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end
Torque Torque
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
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STEEL FIT- G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
TINGS WITH
STEEL MATING G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
COMPONENTS;
UN-LUBRI- G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
CATED
THREADS 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
1200SJP , 1350SJP
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

1200SJP , 1350SJP
Torque Torque
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
ALUMINUM/ G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
BRASS FITTINGS
OR ALUMINUM/ G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
BRASS MATING
COMPONENTS; G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
UN-LUBRICATED
THREADS 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
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429
430
FORM E* (EOLASTIC SEALING RING) STUD ENDS FORM G/H*** (O-RING W/ RETAINING RING) & ADJUSTABLE
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS
Torque Torque
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
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STEEL FIT- G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
TINGS WITH
STEEL MATING G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
COMPONENTS;
UN-LUBRI- G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
CATED
THREADS 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
1200SJP , 1350SJP
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS
1200SJP , 1350SJP
Torque Torque
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
ALUMINUM/
BRASS FIT- G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
TINGS OR ALU-
MINUM/BRASS G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
MATING COM- G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
PONENTS; UN-
LUBRICATED G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
THREADS
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
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432
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
BSPP Connec- Torque Torque Torque

Thread G tingTube
MATERIAL Size O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
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
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G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
STEEL FITTINGS WITH
STEEL MATING COMPO- 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
NENTS; UN-LUBRICATED 16 66 70 73 90 95 99 89 94 98 120 127 133 to the specific procedure in this Service Manual.
G 1/2A
THREADS
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
1200SJP , 1350SJP
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
BSPP Torque Torque Torque

Connecting
Thread G
Tube O.D.
1200SJP , 1350SJP
MATERIAL Size [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
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
ALUMINUM/BRASS FIT-
TINGS OR ALUMINUM/ 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
BRASS MATING COMPO- to the specific procedure in this Service Manual.
NENTS; UN-LUBRICATED G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87
THREADS
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
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5.2.18 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. Install O-ring as per “Section – O-ring Installation (Replacement), page 441”.
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 increments to the torque listed on Table — Flange Code (FL61 & FL62) - Inch
Fasteners, page 435 and Table — Flange Code (FL61 & FL62) - Metric Fasteners, page 437.
434 31220396 1200SJP , 1350SJP

Table 52. Flange Code (FL61 & FL62) -Inch Fasteners
1200SJP , 1350SJP
TYPE/FITTING IDENTIFICATION STEEL 4-BOLT FLANGE SAE J518 (INCH FASTENERS)
Bolt Fastener Torque for Flanges Equipped with GRADE 5 Screws Fastener Torque for Flanges Equipped with GRADE 8 Screws
Inch Flange Flange Size A* Thread
TYPE SAE Dash Size [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
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
CODE 61 24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
SPLIT
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
FLANGE
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(FL61) 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
435
TYPE/FITTING IDENTIFICATION STEEL 4-BOLT FLANGE SAE J518 (INCH FASTENERS)
436
Bolt Fastener Torque for Flanges Equipped with GRADE 5 Screws Fastener Torque for Flanges Equipped with GRADE 8 Screws
Size
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
CODE 62 16 1.00 25 2.25 57.15 7/16-14 – – – – – – 68 71 75 92 97 101

SPLIT
FLANGE 20 1.25 32 2.62 66.55 1/2-13 – – – – – – 111 116 122 150 158 165
(FL62) 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.
31220396
1200SJP , 1350SJP
Table 53. Flange Code (FL61 & FL62) - Metric Fasteners
1200SJP , 1350SJP
TYPE/FITTING IDENTIFICATION STEEL 4-BOLT FLANGE SAE J518 (METRIC FASTENERS)
Bolt Fastener Torque for Flanges Equipped with CLASS 8.8 Screws Fastener Torque for Flanges Equipped with CLASS 10.9 Screws
Size
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
CODE 61 24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55

SPLIT
FLANGE 32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
31220396
(FL61) 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
437
TYPE/FITTING IDENTIFICATION STEEL 4-BOLT FLANGE SAE J518 (METRIC FASTENERS)
438
Bolt Fastener Torque for Flanges Equipped with CLASS 8.8 Screws Fastener Torque for Flanges Equipped with CLASS 10.9 Screws
Size
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
CODE 62 16 1.00 25 2.25 57.15 M12 x 1.75 – – – – – – 96 101 105 130 137 143
SPLIT
20 1.25 32 2.62 66.55 M12 x 1.75 – – – – – – 96 101 105 130 137 143
FLANGE
(FL62) 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.
31220396
1200SJP , 1350SJP
5.2.19 Double Wrench Method

To prevent undesired hose or connector rotation, two wrenches must be used; one torque wrench and one backup 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, the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually
indicates the hose is twisted. Refer to Figure — Double Wrench Method, page 439, for double wrench method requirements.
Figure 164. Double Wrench Method
5.2.20 FFWR and TFFT Methods

FFWR (FLATS FROM WRENCH RESISTANCE METHOD)
1. Tighten the swivel nut to the mating fitting until no lateral 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. Refer to Figure — FFWR
Method, page 439.
3. Use the double wrench method, turn the swivel nut to tighten as shown in Figure — FFWR Method, page 439, The nut is to be
rotated clockwise the number of hex flats 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. Refer to Figure — FFWR Method, page 439.
Figure 165. FFWR Method
1200SJP , 1350SJP 31220396 439

TFFT (TURNS FROM FINGER TIGHT METHOD)

1. Tighten the swivel nut to the mating fitting until no lateral 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 clockwise 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.
5.2.21 Adjustable Stud End Assembly

For Adjustable Stud End Connections; the following assembly steps are to be performed:
1. Lubricate the O-ring with a light coat of hydraulic oil.
2. Position #1 – The O-ring should be located in the groove adjacent to the face of the backup washer. The washer and O-ring should
be positioned at the extreme top end of the groove as shown.
3. Position #2 – Position the locknut to just touch the backup washer as shown. The locknut in this position will eliminate potential
backup washer damage during the next step.
4. Position #3 – Install the connector into the straight thread box port until the metal backup washer contacts the face of the port as
shown.
5. Position #4 – Adjust the connector to the proper position by turning out (counterclockwise) up to a maximum 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.
440 31220396 1200SJP , 1350SJP

Figure 166. Adjustable Stud End Assembly
5.2.22 O-ring Installation (Replacement)

Care must be taken when installing O-rings over threads during replacement or installation. O-rings could become nicked or torn. A
damaged O-ring could lead to leakage problems.
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 hardness, or are slightly
different diameters or widths.
3. Use a thread protector when replacing O-rings on fittings.
4. In ORB; ensure O-ring is properly seated in groove. On straight threads, ensure O-ring is seated all the way past the threads prior to
installation.
5. Inspect O-ring for any visible nicks or tears. Replace if found.
5.3 CYLINDER REPAIR
Note: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylin-
der will be so noted.
5.3.1 Disassembly
NOTICE
Disassembly of the cylinder should be performed on a clean work surface in a dirt
free work area.
1200SJP , 1350SJP 31220396 441

1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
NOTICE
Do not fully extend cylinder to the end of stroke. Retract cylinder slightly to avoid
trapping pressure.
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support
the cylinder rod, if applicable.
3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard O-rings.
4. Place cylinder barrel in a suitable holding fixture. Tap around outside of cylinder head retainer with a suitable hammer to break
thread-locking compound.
Figure 167. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the eight (8) cylinder head
retainer capscrews, and remove capscrews from cylinder barrel.
Figure 168. Capscrew Removal
NOTICE
Extreme care should be taken when removing the cylinder rod, head, and piston.
Avoid pulling the rod off-center, which could cause damage to the piston and cylin-
der barrel surfaces.
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6. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from
the cylinder barrel.
Figure 169. Cylinder Rod Support
1200SJP , 1350SJP 31220396 443

Figure 170. Axle Extension Cylinder
1. Barrel 6. U-Packing 11. Backup Ring 16. Backup Ring 21. O-ring
2. Rod 7. Back up Ring 12. O-ring 17. Set Screw 22. Plug
3. Head 8. Dust Wiper 13. Piston 18. Counterbalance Valve 23. O-ring
4. Spacer 9. Retaining Ring 14. Piston Seal 19. Dust Cap
5. Retaining Ring 10. O-ring 15. O-ring 20. Plug
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Figure 171. Axle Lockout Cylinder
1. Barrel 6. Counterbalance Valve 11. Bushing 16. Seal

2. Rod 7. Wiper 12. O-ring Plug 17. Lock Ring
3. Piston 8. Rod Seal 13. Wear Ring 18. Capscrew.
4. Tapered Bushing 9. Backup ring 14. Backup ring 19. Bleeder Valve
5. Head 10. O- ring 15. O- ring 20. Capscrew
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Figure 172. Platform Level Cylinder (With Cold Weather Plus Package)
1. Barrel 6. Retainer 11. Backup Ring 16. Spacer 21. Plug
2. Rod 7. Rod Seal 12. Piston 17. Holding Valve Cartridge 22. Tapered Bushing
3. Head 8. Backup Ring 13. Piston Seal 18. Counterbalance Valve 23. Capscrew
Cartridge
4. Cap Cylinder 9. Wear Ring 14. O- ring 19. Bushing
5. Wiper 10. O- ring 15. O- ring 20. Plug
446 31220396 1200SJP , 1350SJP

Figure 173. Platform Level Cylinder (Without Cold Weather Plus Package)
1. Barrel 6. Wear Ring 11. Lock Ring 16. Capscrew 21. Bushing
2. Rod 7. O-ring 12. O-ring 17. Capscrew 22. O-ring

3. Head 8. Backup Ring 13. Backup Ring 18. Ring washer 23. O-ring
4. Wiper 9. Piston 14. Spacer 19. Counterbalance valve
5. Rod seal 10. Guide Ring 15. Tapered Bushing 20. Cartridge Valve
1200SJP , 1350SJP 31220396 447

Figure 174. Lift Cylinder
1. Barrel 6. Wear Ring 11. Guide Ring 16. Tapered Bushing 21. Bushing
2. Rod 7. O-ring 12. Wear Ring 17. Capscrew 22. O-ring Plug
3. Head 8. Backup Ring 13. O-ring 18. Capscrew 23. O-ring Plug
4. Wiper 9. Piston 14. Back Up Ring 19. Holding Valve 24. Pressure Regulator Valve
5. Rod Seal 10. Lock Ring 15. Spacer 20. Check Valve
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Figure 175. Jib Cylinder
1. Barrel 6. Wear Ring 11. Wear Ring 16. Tapered Bushing 21. Cartridge Valve
2. Rod 7. O-ring 12. O-ring 17. Capscrew 22. Cartridge Valve
3. Head 8. Backup Rig 13. Backup Ring 18. Capscrew 23. Bushing
4. Rod Wiper 9. Piston 14. Seal 19. Ring Washer 24. O-ring
5. Seal 10. Seal 15. Spacer 20. Counterbalance valve 25. O-ring
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Figure 176. Telescope Cylinder -1200SJP
1. Barrel 8. O-ring 15. Tapered Bushing 22. Capscrew

2. Rod 9. Backup Ring 16. Spacer 23. Capscrew
3. Head 10. Piston 17. Capscrew 24. Bolt

4. Wiper 11. Seal 18. Wear Pad 25. Washer
5. Retaining Ring 12. Wear Ring 19. Valve Assembly 26. Plug
6. Rod seal 13. O-ring 20. Bracket 27. Plug

7. Wear Ring 14. Backup Ring 21. Capscrew 28. Plug
450 31220396 1200SJP , 1350SJP

Figure 177. Telescope Cylinder -1350SJP
1. Barrel 8. O-ring 15. Tapered Bushing 22. Capscrew

2. Rod 9. Backup Ring 16. Spacer 23. Capscrew
3. Head 10. Piston 17. Capscrew 24. Bolt

4. Wiper 11. Seal 18. Wear Pad 25. Washer
5. Retaining Ring 12. Wear Ring 19. Valve Assembly 26. O-ring
6. Rod seal 13. O-ring 20. Bracket 27. O-ring

7. Wear Ring 14. Backup Ring 21. Capscrew 28. O-ring
1200SJP , 1350SJP 31220396 451

7. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.
8. Loosen and remove the capscrew(s), if applicable, which attach the tapered bushing to the piston.
9. Insert the capscrew(s) in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the capscrew(s) until
the bushing is loose on the piston.
10. Remove the tapered bushing from the piston.
BM110145A
Figure 179. Tapered Bushing Removal
11. Screw the piston CCW, by hand, and remove the piston from cylinder rod.
12. Remove and discard the piston O-rings, seal rings, and backup rings.
13. Remove piston spacer, if applicable, from the rod.
14. Remove the rod from the holding fixture. Remove the cylinder head gland and retainer plate, if applicable. Discard the O-rings,
Backup rings, rod seals, and wiper seals.
5.3.2 Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent.
Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if
necessary.
5. Inspect threaded portion of barrel for damage. Dress threads as necessary.
6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.
7. Inspect threaded portion of piston for damage. Dress threads as necessary.
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8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary.
10. Inspect threaded portion of head for damage. Dress threads as necessary.
11. Inspect seal and O-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.
13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced.
c. Lubricate inside of the steel bushing with WD40 prior to bearing installation.
d. Using an arbor of the correct size, carefully press the bearing into steel bushing.
Note: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings.
Figure 180. Composite Bearing Installation
14. Inspect travel limiting collar or spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or
equivalent.
15. If applicable, inspect port block fittings and holding valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary.
5.3.3 Assembly
Note: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. Refer to your JLG Parts Manual.
Apply a light film of hydraulic oil to all components prior to assembly.
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1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.
Figure 181. Rod Seal Installation
NOTICE
When installing ‘poly-pak’ piston seals, ensure seals are installed properly. Refer to
wiper seal installation for correct seal orientation. Improper seal installation could
result in cylinder leakage and improper cylinder operation.
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable
cylinder head gland groove.
Figure 182. Poly-Pak Piston Seal Installation
Figure 183. Wiper Seal Installation
3. Place a new O-ring and Backup seal in the applicable outside diameter groove of the cylinder head.
Figure 184. Installation of Head Seal Kit
4. Install washer ring onto rod, carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or
dislodged. Push the head along the rod to the rod end, as applicable.
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5. Carefully slide the piston spacer on the rod.
Note: Main telescope cylinder piston has an O-ring installed inside the spacer.
6. If applicable, correctly place new O-ring in the inner piston diameter groove. (The backup ring side facing the O-ring is grooved.)
7. If applicable, correctly place new seals and guide lock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger
than the O.D. of the piston is recommended to install the solid seal.)
Note: The backup rings for the solid seal have a radius on one side. This side faces the solid seal.(Refer to magnified insert in Figure
4-78.)The split of seals and backup rings are to be positioned so as not to be in alignment with each other.
BM110146A
Figure 185. Piston Seal Kit Installation
8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.
9. Carefully thread the piston on the cylinder rod hand tight, ensuring that the O-ring and Backup rings are not damaged or
dislodged.
10. Thread piston onto rod until it abuts the spacer end and install the tapered bushing.
Note: When installing the tapered bushing, piston and mating end of rod must be free of oil.
NOTICE
When rebuilding the telescope, lift, jib, level, axle lockout or axle extension cylin-
ders, tighten securely. (Refer to table — Cylinder Head and Tapered Bushing Torque
Specifications, page 457).
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11. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor capscrews) through the drilled holes
in the bushing and into the tapped holes in the piston.
BM110145A
Figure 186. Tapered Bushing Installation
12. Tighten the capscrews evenly and progressively in rotation to the specified torque value. (Refer to table — Cylinder Head and
Tapered Bushing Torque Specification table — Cylinder Head and Tapered Bushing Torque Specifications, page 457).
13. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in
diameter) as follows;
a. Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews.
b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews.
Figure 187. Seating the Tapered Bearing
14. Retorque the capscrews evenly and progressively in rotation to the specified torque value. (Refer to table — Cylinder Head and
Tapered Bushing Torque Specifications, page 457).
15. Remove the cylinder rod from the holding fixture.
16. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston. (Refer to Figure — Piston Seal Kit
Installation, page 455)
17. Position the cylinder barrel in a suitable holding fixture.
NOTICE
Extreme care should be taken when installing the cylinder rod, head, and piston.
18. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that
the piston loading O-ring and seal ring are not damaged or dislodged.
19. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.
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20. Secure the cylinder head gland using the washer ring and socket head bolts. (Refer to table — Cylinder Head and Tapered Bushing
Torque Specifications, page 457 and Table 4-37, Holding Valve Torque Specifications), page 457).
Figure 188. Rod Assembly Installation
21. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any
holding valve or valves.
22. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new O-rings as applicable. (Refer to
Table — Holding Valve Torque Specifications , page 457).
Table 54. Cylinder Head and Tapered Bushing Torque Specifications

Description Head Torque Value (Wet) Tapered Bushing Torque Value (Wet)
120 ft. lbs. 30 ft. lbs.

Tele Cylinder (1200SJP)
(163 Nm) (40.5 Nm)
Tele Cylinder (1350SJP)
(163 Nm) (63 Nm)
120 ft. lbs. 9 ft. lb.s
Level Cylinder
(163 Nm) (12.6 Nm)
Jib Cylinder
(41 Nm) (9 Nm)
Lift Cylinder
(410 Nm) (168 Nm)
Axle Oscillation Cylinder
(163 Nm) (12.6 Nm)
Axle Extend Cylinder
(70 Nm) (12.6 Nm)
Table 55. Holding Valve Torque Specifications

Description Torque Value
30-35 ft. lbs.

SUN - 7/8 HEX M20 X 1.5 THDS.
(41-48 Nm)
45-50 ft. lbs.
SUN - 1 1/8 HEX 1 -14 UNS THDS.
(61-68 Nm)
150-160 ft. lbs.
SUN - 1 1/4 HEX M36 X 2 THDS.
(204-217 Nm)
RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.
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Table 55. Holding Valve Torque Specifications (continued)

Description Torque Value
(68-75 Nm)
75-80 ft. lbs.
RACINE - 1 3/8 HEX 1 3/16 - 12 THDS.
(102-109 Nm)
100-110 ft. lbs.
RACINE - 1 7/8 HEX 1 5/8 - 12 THDS.
(136-149 Nm)
5.3.4 Steer Cylinder

DISASSEMBLY
NOTICE
Disassembly of the cylinder should be performed on a clean work surface in a dirt
free work area.
1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
NOTICE
Do not fully extend cylinder to the end of stroke. Retract cylinder slightly to avoid
trapping pressure.
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support
the cylinder rod, if applicable.
3. Place cylinder barrel in a suitable holding fixture. Tap around outside of cylinder head retainer with a suitable hammer to break
thread-locking compound.
Figure 189. Cylinder Barrel Support
4. Mark cylinder cap and barrel with a center punch for easy realignment. Unscrew the cylinder cap from the barrel.
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5. Using a hook spanner, loosen the cylinder cap on Barrel. Remove the cylinder head from the barrel and the rod.
Figure 190. Cylinder Cap Removal
BM110147A
Figure 191. Cylinder Cap Removal
NOTICE
Extreme care should be taken when removing the cylinder rod, head, and piston.
6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel.
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7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible.
Figure 192. Steer Cylinder
1. Barrel 6. Piston Seal 11. Nut 16. Bushing
2. Rod 7. Wear Ring 12. Wiper 17. Plug
3. Head 8. O-ring 13. Wear Ring

4. Cylinder Cap 9. Backup Ring 14. O-ring
5. Wiper 10. Piston 15. Bushing
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8. Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible.
9. Loosen and remove the lock nut that secures the piston to the cylinder rod.
10. Remove the piston from the cylinder rod.
11. Remove and discard the piston O-rings, seal rings.
12. Remove the rod from the holding fixture. Remove the cylinder head. Discard all seals on the cylinder head.
5.3.5 Cleaning And Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent.
Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if
necessary.
5. Inspect threaded portion of barrel for damage. Dress threads as necessary.
6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.
7. Inspect threaded portion of piston for damage. Dress threads as necessary.
8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary.
10. Inspect threaded portion of head for damage. Dress threads as necessary.
11. Inspect seal and O-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.
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13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced.
c. Lubricate inside of the steel bushing with WD40 prior to bearing installation.
d. Using an arbor of the correct size, carefully press the bearing into steel bushing.
Note: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings.
Figure 194. Composite Bearing Installation
14. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.
15. If applicable, inspect piston rings for cracks or other damage. Replace as necessary.
5.3.6 Assembly
Note: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. Refer to your JLG Parts Manual.
Note: Apply a light film of hydraulic oil to all components prior to assembly.
1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.
Figure 195. Rod Seal Installation
NOTICE
When installing new seals, ensure seals are installed properly. Improper seal installa-
tion could result in cylinder leakage and improper cylinder operation.
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2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove. Install new wear rings into the cylinder head gland
groove.
Figure 196. Poly-Pak Piston Seal Installation
Figure 197. Wiper Seal Installation
3. Place a new O-ring and backup ring in the outside diameter groove of the cylinder head.
Figure 198. Installation of Head Seal Kit
4. Place the cylinder cap over the rod and carefully install the head gland on the rod, ensuring that the wiper and rod seals are not
damaged or dislodged. Push the head along the rod to the rod end.
5. Place a new O-ring in the inner piston diameter groove.
6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston threads as possible.
7. Install the piston on the cylinder rod hand tight, ensuring that the O-ring and Backup rings are not damaged or dislodged.
8. Place a new wear ring in the outer piston diameter grooves.
9. Carefully thread the lock nut onto the rod to secure the piston in place.
10. Remove the cylinder rod from the holding fixture.
11. Position the cylinder barrel in a suitable holding fixture.
NOTICE
Extreme care should be taken when installing the cylinder rod, head, and piston.
12. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that
the piston seals are not damaged or dislodged.
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13. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.
14. Secure the cylinder head using Low Strength Threadlocking Compound and the cylinder cap.
15. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted).
Figure 199. Hydraulic Tank
1. Return Filter 3. Sight/Temperature Gauge 5. Magnetic Drain Plug

2. Vented Fill Cap 4. Suction Strainer
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Figure 200. Chassis Control Valve Locations
A. Front Steer Valve/Axle Extend D. Chassis Module Controller

B. Traction Valve E. Junction Manifold Valve
C. Rear Steer Valve/Axle Extend F. Axle Oscillation Valve
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Figure 201. Platform Valve Identification - JLG PN 4641266
1. Level Up 6. Jib Swing Left 10. Level Up Relief 14. Main Pressure Check Port
2. Rotate Right 7. Jib Up 11. Jib Up/Down Relief 15. Level Up Test Port
3. Level Down 8. Jib Swing Right 12. Level Down Relief 16. Level Down Test Port
4. Rotate Left 9. Platform Dump 13. Filter or Plug 17. Jib Up/Down Test Port
5. Jib Down
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Figure 202. Platform Valve Identification - JLG PN 4641460
1. Level Up 5. Jib Down 9. Platform Dump 13. Main Pressure Check Port
2. Rotate Right 6. Jib Swing Left 10. Level Up Relief 14. Level Up Test Port
3. Level Down 7. Jib Up 11. Jib Up/Down Relief 15. Level Down Test Port
4. Rotate Left 8. Jib Swing Right 12. Level Down Relief 16. Jib Up/Down Test Port
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Figure 203. Main Valve Identification
1. Aux Lift Down 5. Dump 9. Lift Up Relief 13. Tele Out Relief
2. Tele Out 6. Swing Relief 10. Lift Down Relief 14. Tele In Relief
3. Lift Up 7. Swing Left 11. Lift Flow 15. Tele Flow
4. Swing Right 8. Lift Down 12. Tele In 16. Lift Down/Aux Select
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Figure 204. Main Valve Cartridge Torque Values
Table 56. Cartridge Torque Values

Ft-Lbs. Nm Ft-Lbs. Nm
1 20-25 27.1-33.9 9 30-35 40.6-47.4
2 25-30 33.9-40.6 10 30-35 40.6-47.4
3 30-35 40.6-47.4 11 30 40.6
4 30-35 40.6-47.4 12 30-35 40.6-47.4
5 30-35 40.6-47.4 13 30-35 40.6-47.4
6 30-35 40.6-47.4 14 30-35 40.6-47.5
7 30-35 40.6-47.4 15 30-35 40.6-47.5
8 30 40.6
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Figure 205. Main Valve Plug Torque Values
Table 57. Plug Torque Values

Ft-Lbs. Nm
1 137 185.8
2 54 73.2
3 8 10.9
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14
11
1
13 3
8
5
4
7
6
10
12
13
4641454-E
11 MAF53231E
Figure 206. Traction Valve Identification
1. Axle Lockout Cartridge 6. Brake Release Coil 11. Left Drive Flow Divider
2. Axle Lockout Coil 7. Cartridge Check Valve 12. Drive shuttle Cartridge
3. Two Speed Cartridge 8. Steer Pilot Cartridge 13. Cartridge Relief Valve
4. Two Speed Coil 9. Axle Lockout Pressure Switch 14. Pressure Check
5. Brake Release Cartridge 10. Right Drive Flow Divider
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4
5
4641268-B
MAF53241B
Figure 207. Steer Valve Identification
1. Axle Extend/Retract 4. Tank Return

2. Left Side Steer Left/Right 5. Pressure Supply
3. Right Side Steer Left/Right
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5.4 HYDRAULIC TANK
The hydraulic tank has a capacity of 55 Gallon (208 L) and includes the hydraulic return filter and two suction strainers. It is normal for
the oil level to appear low when the boom is raised and should only be checked with the machine on level ground and with the boom
fully retracted and lowered. The hydraulic oil should be maintained at the full level as shown by the decal and hydraulic oil level gauge
located on the side of the tank as shown in Figure — Hydraulic Oil Level Gauge, page 473. This decal shows the proper full level for both
hot and cold oil. Do not fill the hydraulic tank past the appropriate full mark. Overfilling can cause the oil to overflow from the top of the
hydraulic tank during emergency lowering operations.
Figure 208. Hydraulic Oil Level Gauge
5.5 PRESSURE SETTING PROCEDURE
Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the machine until the
hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the
use of a calibrated gauge. Pressure readings are acceptable if they are within ± 5% of specified pressures.
To ensure all pressures are set correctly, the following procedures must be followed in order.
1. All applicable steps in Section — Drive and Function Pump Start Up Procedures, page 554 must be followed.
2. Set up of the function pump.
3. Adjustments made at the main valve bank.
4. Adjustments made at the platform valve.
5.5.1 Set Up of the Function Pump

HIGH PRESSURE RELIEF - 3400 PSI (234.4 BAR)
1. Install a high pressure gauge at the MP port of the main valve block.
2. Using a screwdriver, remove the Din connector from the lift down coil.
3. Activate lift down. The gauge should read 3400 psi (234 bar).
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4. To make an adjustment to this pressure, go back to the engine compartment to the function pump which is the back pump. The
high pressure relief adjustment is the adjustment closest to the pump. Using a 17 mm wrench, remove the cover nut. Be careful
not to lose the O-ring washer inside the cover nut.
5. Loosen the jam nut at the setscrew with the 17 mm wrench. Using a 3 mm allen wrench, adjust clockwise to increase, or
counterclockwise to decrease.
6. After adjusting the pressure, tighten the jam nut and the cover nut. This is the maximum relief pressure for all the functions
governed by this pump.
STAND BY PRESSURE OR LOW PRESSURE RELIEF - 300 PSI (20.6 BAR)

1. Install a low pressure gauge at port MP of the main valve block capable of reading 300 psi (20.6 bar).
2. Start the engine, the gauge should read 300 psi (20.6 bar).
3. To make an adjustment to this pressure, go to the engine compartment, locate the function pump. The stand by adjustment is the
adjustment outside adjustment, closest to the turntable. Use the same tools that were used in the Hi pressure adjustment
procedure.
5.5.2 Adjustments Made at the Main Valve Bank

LIFT UP - 2750 PSI (189.6 BAR)
1. Install a high pressure gauge at the M5 port of the main valve block. Plug and cap the hose on port 5.
2. Activate lift up. The gauge should read 2750 psi (189.6 Bar).
3. The adjustment cartridge is located below the M5 gauge port. Turn clockwise to increase, counterclockwise to decrease.
LIFT DOWN - 1500 PSI (103.4 BAR)

1. Install a high pressure gauge at the M4 port of the main valve block.
2. Activate lift down to the end of the stroke. The gauge should read 1500 psi (103.4 bar).
3. The adjustment cartridge is located to the left of the M4 gauge port. Turn clockwise to increase, counterclockwise to decrease.
SWING - 1500 PSI (103.4 BAR)

Note: Left and right are done with one adjustment.
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1. Install a high pressure gauge at port MS.
2. Lock the turntable pin.
3. Activate swing, the gauge should read 1500 psi (103.4 Bar). The adjustment cartridge is located below the MS gauge port.
4. Turn clockwise to increase, counterclockwise to decrease.
TELESCOPE OUT - 3000 PSI (206.8 Bar)

1. Install a high pressure gauge at the M8 port of the main valve bank. Plug the telescope out hose either at the valve bank (port #8)
or at the inlet of the telescope cylinder (V1).
2. Activate telescope out. The gauge should read 3000 psi (206.8 Bar).
3. The adjustment cartridge is located below the M8 gauge port. Turn clockwise to increase, counterclockwise to decrease.
TELESCOPE IN - 3200 PSI (220.6 BAR)

1. Install a high pressure gauge at the M7 port of the main valve block.
2. Activate Telescope In. The gauge should read 3200 psi (220.6 Bar).
3. The adjustment cartridge is located to the left of the M7 gauge port. Turn clockwise to increase, counterclockwise to decrease.
5.5.3 Adjustments Made at the Frame Valve Bank

AXLE EXTEND AND RETRACT, FRONT AND REAR - 2500 PSI (172.3 BAR)
1. To extend the axles, drive the machine back and forth 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 (172.3 Bar) in both directions.
3. The axle extend/retract cylinders are connected hydraulically in parallel. In order to get the correct pressure of the circuit being
adjusted, unscrew the solenoid coil from the circuit not being adjusted and pull it away from the valve.
4. Turn clockwise to increase, counterclockwise to decrease.
STEERING, FRONT AND REAR

Note: The following procedure requires 2 people to perform. One is needed for verifying / adjusting pressure readings and wheel spin-
dle alignment the other for operating the steer functions and using the Analyzer from the platform.
The Analyzer is required to perform the pressure check procedure through access of the calibration menu. The calibration menu will
allow for extending and retracting the steer cylinders individually, verifying pressures, and proper steer sensor calibration. Verification of
the steer sensor calibration will require one of two types of measuring methods; using a square and ruler or using string as explained in
Section – JLG Control System. The purpose of these measuring tools is to assure that the wheel spindle is aligned “straight” with the
extended axle weldment.
1. Position the machine with both front and rear axles fully extended.
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2. Install the Analyzer in the platform control box and scroll menu’s to Access Level 2 and insert password (33271) to get into Access
Level 1.
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3. Scroll to the calibration mode. Once in the calibration mode, press “ENTER” and scroll to steer. Once in the steer calibration mode,
the Analyzer is going to ask to calibrate the steer sensors, this is going to allow extending and retracting each steer cylinder
individually during this process. The JLG control system will ask to calibrate the left front sensor, the left rear sensor, the right front
sensor and finally the right rear sensor in that order. During this calibration mode each individual steer cylinder will be extended
and retracted to verify correct pressures with the marked MS (Measure Steer) ports on the steer / axle valve that pertains to that
steer cylinder. Refer to the Hydraulic Schematic in Section - Schematics, page 760.
Figure 209. Steer Pressure Adjustments
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4. Remove the front circular steer/axle access covers at the front of the chassis, and the rear square cover at the top rear of the
chassis to gain access to the axle/steer valves.
5. Install a pressure gauge at the front axle/steer valve at MS2 port. This should be located on the left side of the valve closest to the
left front wheel spindle. Position the steer switch to activate the left front steer cylinder until the rod is in the fully extended
position and hold the switch for a few seconds after the rod has been fully extended. The MS2 port should read 2000 psi (138 Bar).
If the pressure is not 2000 psi (138 Bar) adjust relief valve mounted next to the MS2 port, CW to increase or CCW to decrease.
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6. Remove the pressure gauge from MS2 port and install on the MS1 port, which is on the right side of the front axle/steer valve,
closest to the right front wheel spindle. Position the steer switch to activate the left front steer cylinder until the rod is in the fully
retracted position and hold the switch for a few seconds after the rod has stopped. The MS1 port should read 2600 psi (179 Bar). If
the pressure is not correct, adjust relief valve next to MS1 port, CW to increase or CCW to decrease.
7. This step involves aligning the left front wheel spindle with the axle weldment. Position the left front wheel spindle “straight”
using a square and rule or string for proper alignment (Refer to Section – JLG Control System, page 561). Once the left front wheel
spindle has been properly measured, press “ENTER” on the Analyzer. This is calibrating data to the JLG Control System that the left
front steer sensor is centered.
8. Checking the left rear steer cylinder is identical to the procedure for left front steer cylinder, except now we are checking pressures
at the rear axle/steer valve location. Install pressure gauge at MS1 port. This should be located on the left side of the valve closest
to the left rear wheel spindle. MS1 port should read 2600 psi (179 Bar) when the left rear steer cylinder is activated with the rod in
the fully retracted position. If the pressure is not 2600 psi (179 Bar) adjust relief valve mounted next to MS1 port CW to increase or
CCW to decrease.
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9. Remove the gauge from MS1 port and install on MS2 port, which is on the right side of the rear axle/steer valve, closest to the
right rear wheel spindle. Position the steer switch to activate the left rear steer cylinder until the rod is in the fully extended
position and hold the steer switch for a few seconds after the rod has been fully extended. The MS2 port should read 2000 psi (179
Bar). If the pressure is not correct, adjust the relief valve mounted next to MS2 port CW to increase or CCW to decrease.
10. The next step is identical to the left front step mentioned above. Make sure the left rear wheel spindle is straight and press
“ENTER” to accept the new calibration settings, now press “ESC” (escape) and scroll to the right front steer calibration step.
11. Checking the right front steer cylinder is identical to the procedure laid out for the left front steer cylinder, except the pressures
are now checked at MS3 port of the front axle/steer valve. This should be at the right side of the valve closest to the right front
wheel spindle. Install the gauge at MS3 port. Position the steer switch to activate the right front steer cylinder until the rod is in the
fully retracted position and hold the steer switch for a few seconds after the rod has been fully retracted. If the pressure is not 2600
psi (179 Bar), adjust the relief valve mounted next to the MS3 port CW to increase or CCW to decrease.
12. Remove the gauge from MS3 port and install on MS4 port, which is on the left side of the front axle/steer valve, closest to the left
front wheel spindle. Position the steer switch to activate the right front steer cylinder until the rod is in the fully extended position
and hold the steer switch for a few seconds after the rod has stopped extending. The MS4 port should read 2000 psi (138 Bar). If
the pressure is not correct, adjust relief valve mounted next to the MS4 port CW to increase or CCW to decrease.
13. The next step is identical to the left front step mentioned above. Make sure the right front wheel spindle is straight and press
“ENTER” to accept the new calibration settings. Scroll over to right rear steer calibration step.
14. Checking the right rear steer cylinder is identical to the procedure laid out for the left rear steer cylinder. Install gauge at MS4 port
of the rear axle/steer valve. This should be at the right side of the valve closest to the right rear wheel spindle. Position the steer
switch to activate the right rear steer cylinder until the rod is in the fully extended position and hold the steer switch for a few
seconds after the rod has stopped extending. The MS4 port should read 2000 psi (138 Bar. If the pressure is not correct, adjust
relief valve next to the MS4 port CCW to increase or CCW to decrease.
15. Remove gauge from MS4 port and install on MS3 port, which is on the left side of the rear axle/steer valve, closest to the left rear
wheel spindle. Position the steer switch to activate the right rear steer cylinder until the rod is in the fully retracted position and
hold the steer switch for a few seconds after the rod stops retracting. If the pressure is not 2600 psi (179 Bar), adjust the relief valve
mounted next to the MS3 port CW to increase or CCW to decrease.
16. The next step is identical to the left front step mentioned above, make sure the right rear wheel spindle is straight and press
“ENTER” to accept the new calibration settings, now escape out of the calibration menu and remove the Analyzer and pressure
gauge.
5.5.4 Adjustments Made at the Platform Valve Bank

PLATFORM LEVEL UP - 2500 PSI (172.3 BAR)
1. Install a high pressure gauge at the gauge port M1.
2. Activate level up to the end of stroke, it should read 2500 psi (172.3 Bar).
3. All the relief valves are located on the same face. The level up relief valve is located closest to the M1 gauge port. Turn clockwise to
increase, counterclockwise to decrease.
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PLATFORM LEVEL DOWN - 1500 PSI (103.4 BAR)

1. Install a high pressure gauge at gauge port M2.
2. Activate level down to the end of stroke, it should read 1500 psi (103.4 Bar).
3. The level down relief valve is located to the left of the level up relief valve. Turn clockwise to increase, counterclockwise to
decrease.
ARTICULATING JIB UP AND DOWN - 2750 PSI (189.6 BAR)

1. Install a high pressure gauge on gauge port M3. The jib relief valve is located below the level down relief valve. Activate jib up or
down, it should read 2750 psi (189.6 Bar). Turn clockwise to increase, counterclockwise to decrease.
5.6 DRIVE PUMPS (REXROTH)
5.6.1 Troubleshooting Procedure

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

No - Proceed to step 2e
Yes - Repair damaged hose
e. Is the charge pump suction pressure/vacuum within recommended limits? (0.8 bar absolute or 6.3 inches of mercury)
Yes - Proceed to step 2.g
f. Is the suction strainer inside the reservoir blocked, clogged, restricted?
No - Proceed to step 2.g
Yes - Repair/replace with a clean suction strainer
g. Is the reservoir air breather blocked or restricted?
No - Proceed to step 2.h
Yes - Clean or replace air breather
h. Remove charge pressure relief valve from the middle pump and inspect. Is it damaged?
No - Refit cartridge and proceed to step 2.i
Yes - Clean & inspect cartridge, poppet, springs, seals to determine cause of damage. Repair or fit a new cartridge and return
to step 2.a
i. Remove and inspect charge pump assemblies. Are they damaged?
No - Proceed to step 2.j
Yes - Repair and/or replace damaged components and return to step 2.a
j. Is the charge pump installed for the clockwise rotation?
No - Refit charge pump. Return to step 2.a
Yes - With proper charge pressure and transmission still does not operate, proceed to step 3.a
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3. Transmission does not propel the machine, diesel engine running properly - Pump Control: (Insure Generator Drive option is not
turned "on")
a. Are the electrical connectors & wiring connected properly to the pump control solenoids?
No - Connect a ammeter in series with solenoid wiring. Is a current of 400 mA to 1060 mA being applied. (Current signal
varies with joystick position)
b. Are all four of the two-speed motors, mounted in the wheel drive planetary reduction gearboxes, shifted to maximum
displacement (high torque - low speed)?
No - Select maximum displacement
Yes - Proceed to step 3.c
c. Actuate the pump control in both directions. Do the pumps stroke? Do they go to full stroke?
No - Refer to the pump service manual and then proceed to step 3.d
Yes - Operate the transmission
d. Remove stroking orifices in X 1 and X 2. Install pressure gauges in X 1 and X 2 (0-500 psi [0 - 35 bar]). Stroke the pump in both
directions. Do the pressures at X 1 and X2 alternate between 30 & 250 psi (2 & 17 bar)?
No - Remove the EP control module & replace it with a new unit. Repeat step 3.c
Yes - Proceed to step 3.e.
e. Is the pressure at port "R", case pressure, less than 15 psi (1 bar) gauge pressure?
No - Correct problem restricting case drain oil flow (oil cooler blockage, pinched hoses, etc)
Yes - Proceed to step 3.f
f. Stroke pump in both directions, while measuring pressure at Ma & Mb ports of the pump. Does any pressure greater than
charge pressure alternate between ports Ma & Mb?
No - Verify that loading the pump will cause system pressure to increase above charge pressure. Proceed to step 3.a
Yes - Proceed to step 3.g
g. Is it possible to adjust high pressure relief valves using 0-6000 psi (0 - 415 bar) gauges to monitor pressure at Ma & Mb? (Refer
to relief valve adjustment)
No - Replace high pressure relief valve and return to step 3.c
Yes - Adjust high pressure relief valves to 5000 psi +50 psi, -0 psi (344.7 bar +3.4 bar, -0 bar)
h. Actuate control in both directions. Does transmission operate?
No - Check that minimum displacement stops on the wheel drive motors are adjusted properly, check that the motors stroke
between maximum to minimum.
4. Transmission Drive is Sluggish or Erratic

a. Does the "EP" proportional pump control current vary with joystick movement?
No - Rectify the problem - broken wires, electrical connector, open solenoid coil, etc.
b. Are all four (4) brakes fully released?
No - Check brake release pressure and insure each wheel receives correct release pressure.
c. Are the pumps stroking time orifices installed tight and clean?
No - Remove the Plugs in ports X 1 and X 2. Remove orifices with a 3mm allen wrench. Check that orifices are clean & re-install.
Yes - Proceed to step 4.d
d. Is an motor displacement stroking time orifice plugged or is the two-speed shift hose pinched?
Yes - Inspect and clean stroking orifice, check two-speed hose routing
e. Is a flow divider/combiner cartridge stuck in the Traction Control Manifold? Flow divider/combiner cartridge # 111 controls
the right side wheels, # 112 controls the left side wheels. Also check to insure bypass orifices #151 (right side) and # 152 (left
side are not plugged.
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5. Transmission Drives in one direction only

a. Are electrical connections to pump control proportional solenoids correct, intact and without defects?
No - Rectify the problem
b. Check hot oil flushing valve cartridge #120 located in the Traction Control Manifold.
Remove and inspect flushing valve cartridge for stuck spool or damaged cartridge "O"-ring seals & backup rings.
c. Inspect "Make-Up" check valve cartridges, #190.1-190.4, installed in the Traction Control Manifold. Is a cartridge "stuck" open
with debris or is an "O"-ring failed?
Yes - Clean/repair or replace Make-Up check cartridge.
d. Swap high pressure relief valves in the transmission. Does the transmission drive in the other direction?
No - Proceed to step 5.e
Yes - Repair/clean/adjust or replace high pressure relief valve on the non-driving side
e. Replace "EP" control module. Does pump operate properly?
No - Replace or repair pump
6. Transmission Drives in Wrong Direction

a. Check to see if electrical connectors or wiring have been swapped on the pump.
b. Check to determine want end of the machine the boom is swung over.
7. Transmission Does Not Find or Hold Neutral

a. Does pump remain in neutral with electrical connectors removed?
No - proceed to step 7.b
Yes - Check electrical system for signal problem
b. With electrical connectors removed and machines wheels jacked off the ground and engine running, momentarily apply 12
volt DC signal (battery voltage) to a pump control solenoid. Does the pump return to neutral after the 12 volt signal is
removed?
No - Apply 12 volts to opposite solenoid & recheck.
No - Replace pump control module, repeat step 7.a
Yes - Possibly dirt was dislodged from control module, re-check thoroughly to determine problem has definitely been
resolved.
c. Check mechanical centering of the pumps
8. Transmission Drives at a High Noise Level

a. Are the wheel drive planetary reduction gearboxes filled to the correct level and do they have the proper lubricant?
No - Fill gearbox with correct grade of oil to the prescribed level.
b. Is the engine flex plate and drive coupling correctly installed and aligned with the transmission pump?
No - Install flex plate and bell housing per manufacturer's instructions
Yes - proceed to step 8.c
c. Is a rigid item or object contacting the resilient mounted engine/pump assembly?
Yes - Insure no item is contacting the unit, transmitting 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 indicated by foaming or milky colored oil.
Yes - Deaerate the oil and inspect system for cause of air induction. Check for loose or missing "O"-rings on face seal
connections.
f. Is a wheel drive hydraulic motor operating at excessive speed?
Yes - Check minimum displacement stop screw adjustments on the motors. Should be 0.433" or 11mm above the stop screw
lock nut. Is one or more motors "stuck" at minimum displacement, check for plugged/blocked two-speed stroking orifice(s).
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9. Transmission Operates at a Higher than Normal Temperature

a. Is the reservoir temperature above 195°F (90.5°C)?
No - 195 o F (90.5°C) is the upper limit. If temperature is over 195°F (90.5°C), the oil cooler may need to be cleaned.
b. Are the hydraulic motor(s) stalling (wheels not turning) intermittently?
Yes - Hydraulic fluid is being heated through system pressure relief valves. Shut down system and rectify the cause of motor
stall.
c. Does oil temperature remain above 195°F (90.5°C), after cleaning the oil cooler? Proceed to step 8.a
No - Operate transmission. Check oil cooler more often.
Yes - Proceed to step 8.a
10. Transmission Operates at a Higher than Normal Temperature

a. Check for differential temperature across the oil cooler. Is there a temperature difference?
No - Check to determine if the bypass check valve (10 psi [0.7 bar] crack pressure) is stuck open. Check to determine if the oil
cooler is restricted internally, causing oil flow to pass across the bypass check valve.
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 flow rate from charge pumps. Is the flow rate 3.8 GPM (14.4 LPM) with
diesel idle speed of 1200 rpm?
No - Refer to charge pump removal & inspection procedure
11. Transmission Pump(s) Do Not Develop Maximum Horsepower (Flow & Pressure)
a. Does the charge pump pressure meet specification?
No - Return to step 2.a
b. Does the pump case pressure exceed 15 psi gauge pressure?
Yes - Check case drain hoses, oil cooler, etc. for pinched or restricted oil flow
c. Are the pump (s) high pressure cross port relief valves adjusted to the required pressure (5000 psi) so they do not bypass
prematurely?
No - Inspect/clean/adjust and or replace valve cartridge
Yes - Replace the pump, after blocking the "A" & "B" ports, running the pump and measuring pressure developed at "A" & "B".
This must be done to insure that flow & pressure loss in not elsewhere in the system. (motors, swivel coupling, etc)
d. Is the diesel engine capable of developing horsepower at design rpm? Follow recommended troubleshooting procedures to
insure the engine is developing full power at specified rpms.
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5.6.2 Charge Pressure Relief Valve Adjustment
With a low pressure (0 – 1000 psi [0 - 70 bar]) pressure gauge tee’d into the ”G” port or two (2) low pressure gauges installed into ”Ma”
and ”Mb”, run pump at engine idle speed. Do not place the pump on stroke – low pressure gauges installed in ”Ma” & ”Mb” will be
damaged! Prior to adjusting pressure, insure charge pressure relief valve is clean of any dirt or debris. The charge pressure relief valve
does not wear appreciably over time. If charge pressure was normal and then has decayed, check for other causes of low charge
pressure. If pressure is low, remove relief valve and add shim(s). If pressure is high, remove relief valve and take out shim(s).
Note: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are available in 0.3, 0.5, and 1.0 mm thickness.
5.6.3 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 connect the X 1
and X 2 ports together by means of hose or tubing. (No less than a1/4 inch ID) The port sizes are:
Pump Size Allen Wrench Wrench

28 5 mm 17 mm
With pressure gages installed at MA, and M B, and with A and B ports blocked (or motor stalled), and with the pump running, loosen the
jam nut. Turn the mechanical centering adjusting screw until 1000 psi is read on MA, or M B then turn screw opposite direction until 1000
psi is read on other pressure port. Turn the screw back, splitting the distance between the previous two positions. This should be the
neutral position. Pressure on MA, and M B should be equal.
Tighten jam nut, stop the pump drive, remove the hose connecting ports X 1 and X 2.
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5.6.4 Hydraulic Centering of Control Modules

PREPARATION FOR ADJUSTMENT
When control modules are exchanged or replaced, it is generally necessary to center the new module. This is done by running the pump
with gauges installed at ports X 1, X 2, MA, and M B Release the jam nut and turn the adjustment screw on top of the control module valve
body.
The adjustment screw is an eccentric, therefore, turning more than 90’ in either direction will have no further centering effect, and could
cause damage to the eccentric pin.
Pump Size Tool Required Wrench

28 Screwdriver 10 mm
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 X 1 and X 2.
2. The hydraulic motor does not turn when the brake is released.
3. Charge pressure is registered equally at ports M A and M B, when the flow output of the pump is deadheaded against a locked
motor or a valve.
If difficulties are encountered in obtaining neutral position of the HD or EP control modules, check that the ends of the control
spring are correctly located in the grooves near the end of the feedback lever arms.
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5.6.5 High Pressure Relief Valve Adjustments

1. Remove relief valve cover from pump (ref. item 1).
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. lbs. (7 Nm).
5. Install relief valve assembly into pump, reinstall cover (ref. item 1) to proper torque.
Table 58. Torque Specs for Relief Valves into Port Block
Pump Size Wrench Size Torque
28 32 mm 66 ft. lbs. (90 Nm)
5.6.6 Removal and Inspection of Charge Pump

Before removing capscrews, mark the position of the charge pump housing and separator plate in relation to the port block.
Loosen screws with metric allen wrench.
Pump Size Allen Wrench

28 8 mm
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Remove charge pump housing and inspect for wear or damage to gear set and O-ring seals. Grease O-rings prior to reassembly. Make
sure O-rings are completely seated in their grooves.
Withdraw pinion shaft and inspect gear teeth and bearing surfaces for abnormal wear.
When reassembling, make sure chamfer (on outer edge of driven gear and drive gear) is installed into housing per illustration.
Torque value for bolts when replacing charge pump.
Pump Size Torque
28 18 ft. lbs. (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.
5.6.7 Routine Maintenance

The Variable Displacement Hydrostatic Transmission Pumps are relatively maintenance free. Maintenance work is confined to the system,
by way of maintaining hydraulic fluid condition, the "life blood" of the machine. Oil monitoring, changes and filter renewal promote
system cleanliness. This will prevent premature breakdown and repairs. Under normal application conditions, the following maintenance
intervals are suggested:
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1. Renewal of Filter Elements

a. After commissioning or re-build.
b. At every 500 operating hours or when filter indicator 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 throwaway cartridges.
2. Hydraulic Fluid Change

a. After 2000 operating hours (1st oil change).
b. Thereafter, every 2000 operating hours or annually, irrespective of operating hours achieved.
c. Oil change should be performed with the system in warm running condition. Before re-filling, the reservoir 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
contamination.
f. The recommended interval between oil changes is based on various factors and should be carried out according to the
degree of aging, contamination and water content.
g. Under application conditions with a heavy occurrence of dust or severe temperature fluctuations, the intervals between fluid
maintenance should be shortened accordingly.
NOTICE
Practical experience shows that most fluid maintenance errors occur during an oil
change due to:
• USE OF AN UNSUITABLE HYDRAULIC FLUID
• USE OF OIL CONTAMINATED DUE TO POOR STORAGE PRACTICES
• FAILURE TO CLEAN THE RESERVOIR
• INADEQUATE CLEANLINESS WHEN FILLING THE RESERVOIR (DIRTY DRUMS, CONTAINERS, WATER, ETC)
3. Leakage Inspection
a. After commissioning.
b. The complete transmission drive system (pumps, motors, hosing, filters, valves, etc) should be checked for leakage at regular
intervals.
c. Leaking joints & connections must only be tightened when pressureless.
4. Cleanliness Inspection
a. The oil tank breather should be regularly cleaned of dirt and dust to prevent clogging. With each cylinder movement, gallons
of oil pumped, an equal amount of air exchange occurs across the reservoir breather. A dirty or clogged breather will affect all
machine functions!
b. The air/oil cooler surfaces and engine radiator should be cleaned at the same time.
c. If hose connections are disassembled, it is imperative that the utmost care be taken that no foreign bodies infiltrate the oil
circuit. Catastrophic component failure may occur.
5. Oil Level Inspection

a. Inspect oil level in the reservoir daily.
b. If "topping off" is required, use only the same Mobilfluid #424, Product #52233-4.
c. Do Not Mix Fluids.
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6. Hydraulic Fluid - The "Life Blood" of the Machine

a. The type of hydraulic fluid supplied in the machine from the factory was selected after extensive testing and development.
The fluid was selected to perform under "most" applications and conditions. Should this machine be in service for extended
time periods at the extremes (hot or cold), JLG should be consulted for assistance in selection of the most suitable fluid type
and grade for your application.
b. When operating at temperatures below 0 o F, allow a warm-up period, if at all possible, to a temperature of 40°F.
c. When beginning motion of a "cold" machine, operate all functions at reduced speeds until the "cold" oil has circulated out of
the drive loop.
5.6.8 Removal and Installation of Shaft Seal

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.
Press in shaft seal with bushing to the stop. Then replace snap ring.
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5.7 FUNCTION PUMP (REXROTH)
Figure 210. Function Pump - Sectional View
5.7.1 Spare Parts

1. Sealing kit, existing spare parts: shaft sealing ring, O-rings, and a circlip.
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2. Drive Shaft
3. Bearing set, miscellaneous parts.
4. Rotary Group complete: 9 pistons, cylinder subassembly, valve plate, retaining plate, and retaining ball.
5. Swash Plate.
6. Parts of the control valve: control piston, piston rod, plug, spring stopper max flow, hex nut, and hex head nut.
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7. DFR pilot valve.
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5.7.2 Sealing the Drive Shaft
NOTICE
Be very careful so the drive shaft is not damaged during the removal of the shaft
sealing ring.
1. Remove the snap ring.
2. Change the shaft seal and check its’ sliding surface (drive shaft) and housing. Grease the sealing ring.
3. Be careful while you seal the drive shaft. Use an adhesive tape to prevent the shaft splines from damaging the seal.
4. Assemble the sealing ring, fitting tool holds the correct position of the sealing ring in the pump housing.
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5. Assemble the snap ring.
6. Assemble the snap ring in the correct position.
5.7.3 Disassembly and Assembly of the Complete Unit

1. Disassemble the pilot valve.
2. Mark the position of the port plate and remove the socket screw of the port plate.
3. Remove the port plate together with the valve plate (hold the valve plate so the plate can’t fall down).
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4. Remove the O-ring.
5. Disassemble the taper roller bearing (nearby port plate).
6. Remove the adjustment shim.
7. Unscrew the cap nut and remove it.
8. Loosen the fixing nut of the stopper max flow and disassemble it.
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9. Turn in the stopper max flow to get swivel angle zero.
10. Disassemble the rotary group in horizontal position.
11. Disassemble the stopper max flow.
12. Remove the threaded pin.
13. Disassemble the plug.
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14. Disassemble the control piston while moving the swash plate.
15. The swash plate must be lifted a little bit to disassemble the piston rod.
16. Remove the swash plate.
17. Remove the spring.
18. Remove both bearing shells.
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19. Remove the drive shaft.
20. Disassemble the snap ring.
21. Disassemble the sealing ring.
22. The external front bearing ring is pulled out of the pump housing.
23. Remove the O-ring. Lifting of the valve plate isn’t shown.
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24. A bearing puller is used to disassemble the external bearing ring of the taper roller bearing inside the port plate. Take care of the
surface of the port plate.
25. The spring has additional pretension while you disassemble the three pressure pins inside the cylinder.
5.7.4 Assembly
1. Measurement of the taper roller bearing pretention.
2. Ensure there is a correct connection of the piston rod and the swash plate.
3. Pumps clockwise driven must have a position of the valve plate 4 degrees out of center in the same direction decentered like drive
direction.
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4. Pumps counterclockwise driven must have a position of the valve plate 4 degrees decentered in the ccw position.
5. Note the correct position of the drilling that connects high pressure to the control valve. Check control valve drilling position at
the pump housing and fit together.
5.7.5 Adjustments
TAPER ROLLER BEARING INITIAL TENSION
Cast Iron pump housing must have initial tension of the bearings: 0 to 0.05 mm.
MECHANICAL FLOW LIMITER

Differential volume if you are rotating the threaded pin - each rotation is approximately 3.1 cm.
5.7.6 Tightening Torques

For break-off plugs, use High Strength Anaerobic Retaining Compound.
For all other parts, use Medium Strength Threadlocking Compound.
Table 59. Tightening Torques

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30
8.8 2.3 5.0 8.5 21 41 72 115 176 240 350 600 1220
10.9 3.2 7.2 12 29 58 100 165 250 350 490 840 1670
12.9 4.1 8.5 14.5 35 70 121 195 300 410 590 990 2000
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Figure 211. Function Pump, Pressure and Flow Control - Sheet 1
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5.7.7 Pump Control Disassembly for Cleaning

NOTE: If the Function Pump does not perform correctly after following the pre-start, start-up procedures, it is possible that a
contaminate particle has lodged in the pump control preventing proper operation. The pump control’s internal parts are not provided as
spare parts due to the close tolerances required between the mating parts. However, the control can be disassembled, cleaned and
placed back in service should the only problem prove to be contamination. Disassembly, inspection, cleaning and reassembly MUST BE
done in a clean well-illuminated area.
Pump Control removal:
1. Disconnect plug the hose attached to the pump control Port ”X”.
2. Remove the four (4) socket head capscrews that attach the control to the pump. Insure that the three (3) ”0”-rings are also
removed with the control.
3. Hydraulic fluid may drip from the pump. Wiping the surface clean and installing some adhesive tape should prevent oil from
seeping from the pump control.
4. Work on a clean, lint free area.
Note: The pump control can be equipped with either O-rings or a sealing plate. These components are NOT interchangeable.
5. Remove the three (3) ”O”-rings (Parker # 2-011, Viton 90 shore).
6. Remove both the adjustment hex caps and bonded seal rings. (17 mm wrench)
7. Remove both the adjustment lock nuts and bonded seal rings. (17 mm wrench)
8. Remove both the adjusting screws. (3 mm Allen wrench)
9. Remove the spring cover hex cap for the ”outer” flow regulation adjustment this requires a 19 mm wrench.
10. Remove the spring disc.
11. Remove the adjusting springs (two springs, one ”nested” inside the other) and spring follower.
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12. The flow regulation spool should slide from the control housing, (a magnet should aid in removal). If it does not, remove the
hollow hex head plug at the rear of the flow regulation spool and carefully push the spool from the housing - do not scratch/mar
the spool’s bore.
13. Remove the spring cover hex cap for the ”inner” pressure compensation adjustment – this requires a 30 mm wrench.
14. Remove the spring disc.
15. Remove the adjusting springs (two springs, one ”nested” inside the other).
16. Remove the spring follower.
17. The pressure compensation spool should slide from the control housing (a magnet should aid in removal). If it does not, remove
the hollow hex head plug at the rear of the flow regulation spool and carefully push the spool from the housing - do not scratch/
mar the spool’s bore.
18. The spools are identical.
19. Wash the housing and all parts in a clean JLG approved solvent such as non-chlorinated brake cleaner, Stoddard solvent, etc.
20. Blow off all the parts with clean, dry compressed air.
21. Inspect the housing for contamination or plugged orifices. Clean orifices carefully with adead soft steel wire to insure they are
open. Inspect all parts for burrs, scoring, debris, etc.
Note: On the mounting surface of the control housing, between the oil ports is what appears to be a slotted head screw. IT IS NOT
A SCREW. This is a bleed orifice, which must be orientated to allow proper control operation. The slot in the head should be
oriented to fall in-line with the oil ports, NOT PERPENDICULAR to the oil ports. If the slot is oriented perpendicular to the
three ports, the pump pressure will not return from load pressure to stand-by pressure at the end of operating a function!
The pump pressure will remain at the last highest pressure generated.
22. After all parts are clean and dry, lightly oil a control spool and install in its bore. The spool must slide smoothly and easily within
the housing. If it does not, check for contamination. If contamination cannot be found check for ”scoring” or ”burring” of the
control housing. If the spool does not slide smoothly & freely, the control must be replaced with a new unit.
23. Lightly oil and check operation of the second spool. The spools are installed correctly when there ”pointed” end faces the spring
followers.
24. Re-assemble in reverse order.
25. Bench set the pressure adjustments as described in ”C. 4” of the Operating Instructions.
Note: The pump control can be equipped with either O-rings or a sealing plate. These components are NOT interchangeable.
26. Re-install on the Function Pump, insure the ”O-rings" are installed properly and tighten the four (4) M6 socket head capscrews to
105 in. lbs.
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5.8 DRIVE PUMPS (SAUER)
Figure 214. Piston Pump Cross Sectional View
5.8.1 Port Locations and Gauge Installation

Table 60. Port Information
Port identifier Port size Wrench size Reading Gauge size, bar [psi]
L1, L2, L3 1 1/16-12 UNF 2B 9/16 internal hex Case drain 10 bar [100 psi]
MA, MB, MC, MD 9/16-18 UNF 1/4 internal hex System pressure 600 bar [10,000 psi]
M3 9/16-18 UNF 2B 1/4 internal hex Charge pressure 50 bar [1000 psi]
M4, M5 7/16-20 UNF 2B 3/16 internal hex Servo pressure 50 bar [1000 psi]
X7 9/16-18 UNF 2B 1/4 internal hex Brake pressure 50 bar [1000 psi]
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Figure 215. Port Locations - Sheet 1 of 2
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Figure 216. Port Locations - Sheet 2 of 2
5.8.2 Initial Startup Procedures

Follow this procedure when starting-up a new pump or when restarting a pump that has been removed. Ensure the pump is thoroughly
tested on a test stand before installing.
Prior to installing the pump, inspect for damage that may have occurred during shipping.
1. Ensure that the machine hydraulic oil and system components (reservoir, hoses, valves, fittings, and heat exchanger) are clean and
free of any foreign material.
2. Install new system filter element(s) if necessary. Check that inlet line fittings are properly tightened and free of air leaks.
3. Install the pump. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port M3.
4. Fill the housing by adding filtered hydraulic fluid to the upper case drain port. If the controls are installed on top, open the
construction plugs in the top of the controls to assist in air bleed.
5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a 10-micron filler filter. Ensure construction plug
is closed after filling is complete.
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6. Disconnect the pump from all control input signals.
CAUTION
After start-up the fluid level in the reservoir may drop due to system components
filling Damage to hydraulic components may occur if the fluid supply runs out. En-
sure reservoir remains full of fluid during start-up.
CAUTION
Air entrapment in oil under high pressure may damage hydraulic components.
Check carefully for inlet line leaks.
CAUTION
Do not run at maximum pressure until system is free of air and fluid has been thor-
oughly filtered.
7. Use a common method to disable the engine to prevent it from starting. Crank the starter for several seconds. Do not to exceed
the engine manufacturer’s recommendation. Wait 30 seconds and then crank the engine a second time as stated above. This
operation helps remove air from the system lines. Refill the reservoir to recommended full oil level.
8. When the gauge begins to register charge pressure, enable and start engine. Let the engine run for a minimum of 30 seconds at
low idle to allow the air to work itself out of the system. Check for leaks at all line connections and listen for cavitation. Check for
proper fluid level in reservoir.
9. When adequate charge pressure is established (as shown in model code), increase engine speed to normal operating rpm to
further purge residual air from the system.
10. Shut the off engine. Connect the pump control signal. Start the engine, checking to be certain the pump remains in neutral. Run
the engine at normal operating speed and carefully check for forward and reverse control operation.
11. Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system contaminants out of the
system loop.
Note: Normal charge pressure fluctuation may occur during forward and reverse operation.
12. Check that the reservoir is full. Remove charge pressure gauge and cap port. The pump is now ready for operation.
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5.8.3 Troubleshooting
CAUTION
High inlet vacuum causes cavitation which can damage internal pump
components.
WARNING
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your
skin causing serious injury and/or infection and may be hot enough to cause burns.
Relieve pressure in the system before removing hoses, fittings, gauges, or compo-
nents. Seek immediate medical attention if you are cut or burned by hydraulic fluid.
CAUTION
Contamination can damage internal components. Take precautions to ensure sys-
tem cleanliness when removing and reinstalling system components and lines.
Table 61. Electrical Troubleshooting
Item Description Action

Control operates pump in one direction only Control coil failure. Measure resistance at coil pins. Resistance should be
14.2W (24V) or 3.66W (12V) at 20°C [70°F]. Replace
coil.
No pump function No power to controller. Restore power to controller.
Erratic pump function Electrical connection to pump is bad. Disconnect connection, check wires, reconnect wires.
Erratic or no machine function External controller malfunction or hydraulic system Verify external controller problem using spare controller.
problem. Replace controller. Check hydraulic system fluid level/
pressures/filters/etc. Fix hydraulic system problems.
Table 62. Neutral Difficult or Impossible to Find

Input to pump control Input to control module is operating improperly. Disconnect input and check to see if pump comes back
to neutral. If Yes, input fault, replace/repair external
controller. If No, go to next step.
Pump control neutral Neutral set improperly. Shunt servo gauge ports M4 and M5 together with
external hose and see if pump comes back to neutral. If
Yes: control neutral improperly set. If no: balance
swashplate (Refer to Mechanical neutral adjustment). If
you still cannot set neutral, replace control.
Table 63. System Operating Hot

Oil level in reservoir Insufficient hydraulic fluid will not meet cooling Fill reservoir to proper level.
demands of system.
Heat exchanger Heat exchanger not sufficiently cooling the system. Check air flow and input air temperature for heat
exchanger. Clean, repair or replace heat exchanger.
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Table 63. System Operating Hot (continued)

Charge pressure Low charge pressure will overwork system. Measure charge pressure. Inspect and adjust or replace
charge relief valve. Inspect charge pump. Repair or
replace charge pump.
Charge pump inlet vacuum High inlet vacuum will overwork system. A dirty filter Check charge inlet vacuum. If high, inspect inlet filter
will increase the inlet vacuum. Inadequate line size will and replace as necessary. Check for adequate line size,
restrict flow. length or other restrictions.
System relief pressure settings If the system relief valves are worn, contaminated, or Verify settings of high pressure relief valves and replace
valve settings are too low, the relief valves will be valves as necessary.
overworked.
System pressure Frequent or long term operation over system relief Measure system pressure. If pressure is too high, reduce
setting will create heat in system. loads.
Table 64. System Will not Operate

Oil level in reservoir Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level.
Control orifices Control orifices are blocked. Clean control orifices.

Control screens Control screens are blocked. Clean or replace control screens.
Charge pressure with pump in neutral Low charge pressure insufficient to recharge system Measure charge pressure with the pump in neutral. If
loop. pressure is low, go to next step.
Pump charge relief valve A pump charge relief valve that is leaky, contaminated, Adjust or replace pump charge relief valve as necessary.
or set too low will depressurize the system.
Charge pump inlet filter A clogged filter will under supply system loop. Inspect filter and replace if necessary.
Charge pump A malfunctioning charge pump will provide insufficient Repair or replace the charge pump.
charge flow.
System pressure Low system pressure does not provide enough power to Measure system pressure. Continue to next step.
move load.
Charge check / HPRVs Defective charge check / HPRVs cause system pressure to Repair or replace charge check / HPRVs.
be low.
Input to control Input to control module is operating improperly. Repair or replace control.
Optional control cutoff valve Control cutoff valve coil not energized. Ensure charge pressure to control via port X7. If none,
confirm control cutoff valve coil is energized. If still no
pressure, repair or replace control cutoff valve.
Table 65. System Noise or Vibration

Reservoir oil level Low oil level leads to cavitation. Fill reservoir.
Aeration of the oil/pump inlet vacuum Air in system decreases efficiency of units and controls. Find location where air is entering into the system and
Air in system is indicated by excessive noise in pump, repair. Check that inlet line is not restricted and is
foaming in oil, and hot oil. proper size.
Cold oil If oil is cold, it may be too viscous for proper function Allow the oil to warm up to its normal operating
and pump cavitates. temperature with engine at idle speed.
Pump inlet vacuum High inlet vacuum causes noise/cavitation. Check that inlet line is not restricted and is proper size.
Check filter and bypass switch.
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Table 65. System Noise or Vibration (continued)

Shaft couplings A loose input shaft to prime mover coupling will cause Replace loose shaft coupling.
excessive noise.
Shaft alignment Misaligned input and prime mover shafts create noise. Correct misalignment.
Charge/system relief valves Unusual noise may indicate sticking valves. Possible Clean/replace valves and test pump. May be a normal
contamination. condition.
Table 66. Sluggish System Response

Oil level in reservoir Low oil level will cause sluggish response. Fill reservoir.
Charge check / HPRVs Incorrect pressure settings will affect system reaction Replace charge check / HPRVs.
time.
Low prime mover speed Low engine speed will reduce system performance. Adjust engine speed.
Charge and control pressures Incorrect pressures will affect system performance. Measure and adjust charge and control pressures.
Air in system Air in system will produce sluggish system response. Fill tank to proper level. Cycle system slowly for several
minutes to remove air from system.
Contaminated control orifices Control orifices are plugged. Clean control orifices.
Contaminated control screens Control screens are plugged. Clean or replace control screens.
Pump inlet vacuum Inlet vacuum is too high resulting in reduced system Measure charge inlet vacuum. Inspect line for proper
pressure. sizing. Replace filter. Confirm proper bypass operation.
5.8.4 Adjustments
CAUTION
Contamination can damage internal components and void your warranty. Take pre-
cautions to ensure system cleanliness when removing and reinstalling system lines
1. Thoroughly clean the outside of the pump.
2. If removing the pump, tag each hydraulic line. When you disconnect hydraulic lines, cap them and plug each open port to prevent
contamination.
3. Ensure the surrounding area is clean and free of contaminants like dirt and grime.
4. Inspect the system for contamination.
5. Check the hydraulic fluid for signs of contamination: oil discoloration, foam in the oil, sludge, or metal particles.
6. If there are signs of contamination in the hydraulic fluid, replace all filters and drain the hydraulic system. Flush the lines and refill
the reservoir with the correct filtered hydraulic fluid.
7. Before reinstalling the pump, test for leaks.
CHARGE PRESSURE RELIEF VALVE

1. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3. Install a 10 bar [100 psi] gauge at case pressure port
L1, L2, or L3. Operate the system with the pump in neutral (zero displacement) when measuring charge pressure.
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2. The table below shows the acceptable pump charge pressure range for some nominal charge relief valve settings (refer to model
code located on serial number plate). These pressures assume 1800 min-1 (rpm) pump speed and a reservoir temperature of 50° C
[120° F], and are referenced to case pressure.
Note: Listed pressures assume a pump speed of 1800 min-1 (rpm) and charge flow of 26.5 l/min [7 US gal/min]. At higher pump
speeds or higher charge flows the charge pressure will rise over the rated setting.
3. Loosen the locknut and rotate the adjusting screw clockwise to increase the setting; counterclockwise to decrease it. Subtract the
case pressure reading to compute the actual charge pressure.
Note: Pressure change per turn is dependent on charge flow entering pump.
4. While holding the adjusting screw, torque locknut to 12 Nm [9 ft. lbs.].
5. When you achieve the desired charge pressure setting, remove the gauges and plug the ports.
DISPLACEMENT LIMITER ADJUSTMENT

1. Mark servo cylinder location in case it rotates during displacement limiter adjustment.
2. Loosen the locknut (E550).
3. Rotate the adjusting screw (E450) based on the following table. Rotating the adjusting screw clockwise decreases the maximum
displacement of the pump while rotating the adjusting screw counterclockwise increases the maximum displacement.
Figure 217. Charge Pressure Adjustment
4. After establishing the desired maximum displacement setting, hold adjusting screw in place and tighten the locknut. Torque to 23
Nm [17 ft. lbs.].
CAUTION
Be sure servo cylinder does not rotate when displacement limiter locknut (E550) is
torqued.
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5. One turn of the adjusting screw will change the maximum displacement approximately as follows.
Table 67. Displacement Limiter Adjustment Data

Approximate displacement change
Displacement Locknut wrench size and torque Adjusting screw size
per revolution of adjusting screw
45 13 mm 23 Nm [17 ft. lbs.] 4 mm internal hex 5.1 cc / turn
CONTROL NEUTRAL ADJUSTMENT

All functions of the Electric Displacement Control (EDC) are preset at the factory. Adjust the pump to neutral with the pump running on
a test stand or on the vehicle/machine with the prime mover operating. If adjustment fails to give satisfactory results, you may need to
replace the control or coils.
1. Install a 50 bar [1000 psi] gauge in each of the two servo gauge ports (M4 and M5). Disconnect the external control input
(electrical connections) from the control. Start the prime mover and operate at normal speed.
2. Use a 4 mm internal hex wrench to hold the neutral adjusting screw stationary while loosening the locknut with a 13 mm wrench.
3. Observe pressure gauges. If necessary, turn adjusting screw to reduce any pressure differential.
Note: Adjustment of the EDC is very sensitive. Be sure to hold the hex wrench steady while loosening the locknut. Total adjust-
ment is less than 120 degrees.
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4. Rotate the neutral adjusting screw clockwise until the pressure increases on the gauge. Note the angular position of the wrench.
Then rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge.
Again note the angular position of the wrench.
Illustration shows how eccentric cam on adjusting screw rotates to adjust neutral.
Figure 218. Control Neutral Adjustment
5. Rotate the neutral adjusting screw clockwise half the distance between the wrench positions noted above. The gauges should
read the same pressure, indicating that the control is in its neutral position.
6. Hold the neutral adjusting screw stationary and tighten the lock nut. Torque to 10 Nm [7 ft. lbs.]. Do not over torque the nut.
7. When the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs. Reconnect the
external control input.
Note: A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Zero differential is usually not possible.
MECHANICAL NEUTRAL ADJUSTMENT

Mechanical neutral is set with the pump running at 1800 min (rpm). To set neutral, you must stroke the pump in each direction.
This procedure details setting neutral for the entire pump, one side at a time. The procedure is the same for each side of each pump so
you will need to repeat it four times to set mechanical neutral for both the front and rear sections. Alternate M4/M5 and MA/MB to zero
out forward and reverse directions of the front unit, then move the gauges to M4/M5 of the rear unit and MC/MD (system gauge ports
for the rear unit). Refer to the drawing that follows to identify all ports. The front and rear sections are basically mirror images of each
other. The control solenoids C1 and C2 are marked on each control.
While performing this adjustment, you monitor the following pressures.:
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• Servo pressure at M4 and M5
• System pressure at MA and MB or MC and MD
• Pressure differential between M4 and M5 (optional)
• Pressure differential between A and B or C and D (optional)
PUMP SETUP
1. Attach a 50 bar [1000 psi] gauge to each servo pressure port M4 and M5.
2. Attach a 600 bar [10 000 psi] gauge to each system pressure port (MA and MB for front pump, MC and MD for rear pump).
3. Remove servo cylinder locking screws (E350) and plates (E300) from both sides of the pump.
4. Disconnect the control solenoids from the vehicle wiring harness.
5. If using a PWM signal to set mechanical neutral, connect the control solenoids C1 and C2 to the signal source. Ensure the source
supplies no current to the solenoids until required in the following procedure.
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Figure 219. Servo and System Pressure Gauge Port Locations

SERVO ADJUSTMENT
1. Run prime mover at 1800 min (rpm).
2. If using a PWM signal, ensure the signal is off. Check the servo pressure gauges. Ensure the differential between M4 and M5 is less
than 1.5 bar [22 psi].
3. Using a 3/4 in deep socket, unthread both servo cylinders 2-3 turns. This step ensures the servo cylinders have no contact with the
servo piston.
4. Stroke the pump by turning the control eccentric screw (or supplying current to solenoid C1) until the servo pressure at port M4 is
1 to 2 bar [14 -29 psi] greater than at port M5 and the system pressure gauges indicate displacement. Pressure should be greater
at port MA for clockwise rotation, or MB for counterclockwise rotation. This also indicates the servo piston is in contact with the
servo cylinder on side M5.
5. Slowly thread the servo cylinder on the M5 side in until the system pressure differential starts to decrease. Maintain servo pressure
differential between 1-2 bar [14-29 psi] during this step. Continue turning the servo cylinder in until the system pressure
differential (between ports MA/MB or MC/MD) is less than 1.5 bar [22 psi]. This procedure sets the servo and swashplate to
mechanical neutral on the M5 side.
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6. To complete setting neutral, repeat steps 1-5 but stroke the pump in the opposite direction by turning the eccentric screw in the
opposite direction, or by supplying current to solenoid C2. Reverse gauge locations (M4 for M5, MB for MA etc.) from those stated
above since the pump is now stroking the other direction.
7. Set neutral for the rear pump by repeating steps 1-6 on the rear pump. Remember that the rear pump is a mirror image of the
front pump and therefore the locations of the servo gauge ports (M4/M5) and the control solenoids (C1/C2) are opposite.
8. Remove all gauges and replace gauge port plugs.
5.8.5 Removing the Pump

Before working on the pump, thoroughly clean the outside. If the pump has an auxiliary pump attached, remove both pumps as a single
unit. Tag and cap all hydraulic lines as you disconnect them, and plug all open ports to ensure that dirt and contamination do not get
into the system.
CAUTION
Contamination can damage internal components. Take precautions to ensure sys-
tem cleanliness when removing and installing system lines.
1. Thoroughly clean all dirt and grime from the outside of the pump.
2. Tag, disconnect, and cap each hydraulic line connected to the pump. As hydraulic lines are disconnected, plug each open port, to
ensure that dirt and contamination do not get into the pump.
3. Remove the pump and its auxiliary pump (if applicable) as a single unit.
Note: Be careful, do not damage solenoids and electrical connections when using straps or chains to support the pump.
5.8.6 Inspection
1. Ensure the work surface and surrounding area are clean and free of contaminants such as dirt and grime.
2. Inspect the system for contamination.
3. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam in the oil, sludge, or metal particles.
5.8.7 Replacement
1. Before replacing the pump, replace all filters and drain the hydraulic system. Flush the system lines and fill the reservoir with the
correct, filtered hydraulic fluid.
2. Fill the pump with clean, filtered hydraulic fluid.
3. Attach the pump to the prime mover. Torque mounting screws according to the manufacturers recommendation.
4. Replace all hydraulic lines. Ensure the charge inlet line is filled with fluid.
5.8.8 Electric Control Module

REMOVAL
Refer to exploded diagram, next page.
1. Using a 5 mm internal hex wrench, remove the six capscrews (D250).
2. Remove the control module and gasket (D150). Discard the gasket.
3. If necessary, remove orifices (F100) using a 3 mm internal hex wrench. Tag and number them for reinstallation.
4. Inspection.
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5. Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches, replace the component.
Note: Remove plug on top of control to ensure the swashplate feedback pin is properly positioned in the center of the control
module when installing control.
REASSEMBLY
Note: Ensure you install dowel pins (D300) in housing before installing control.
1. Install a new gasket (D150).
2. If you removed screen (D084), install a new one. Install with the mesh facing outward.
D084
D084
C orrect s creen Incorrect s creen

orientation orientation
BM110148A
3. If previously removed, install orifices (F100) using a 3 mm internal hex wrench. Torque to 2.5 Nm [1.8 ft. lbs.].
4. Install the control module and six capscrews (D250).
5. Using a 5 mm internal hex wrench, torque the capscrews (D250) to 13.5 Nm [10.ft. lbs.].
Figure 220. Control Module and Solenoid Removal/installation
CONTROL SOLENOIDS REMOVAL

1. Disconnect electrical connection and remove the three capscrews (D050) using a 4.mm internal hex wrench.
2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring.
3. If necessary, remove the coil using a 12 point 26 mm socket.
CONTROL SOLENOIDS INSPECTION

1. Inspect the machined surface on the control. If you find any nicks or scratches, replace the component.
CONTROL SOLENOIDS REASSEMBLY
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1. Lubricate new O-ring (D025A) using petroleum jelly and install.
2. Install solenoid with three capscrews (D050) using a 4 mm internal hex wrench. Torque screws to 5 Nm [4 ft. lbs.].
3. Install coil using a 12 point 26 mm socket. Torque coil nut to 5 Nm [3.7 ft. lbs.].
4. Reconnect electrical connections and test the pump for proper operation.
5.8.9 Shaft, Seal, and Bearing

The front pump input shaft assembly is serviceable without disassembling the pump, the rear shaft is not. Orient the pump on the work
surface so the shaft is pointing to the side.
REMOVAL
1. Unwind the spiral ring (J300) from the housing to release the shaft/seal/bearing subassembly.
2. Pry on the lip of the seal carrier (J275) to remove it from the pump. Remove the seal carrier. Remove and discard O-ring (J260).
Press the seal (J250) out of the carrier and discard.
3. Pull the shaft (J100) with bearing (J150) out of the pump. If necessary, tap lightly on the shaft to dislodge it from the cylinder
block. C
CAUTION
Do not damage the housing bore, shaft or bearing when removing the shaft and
bearing.
4. Remove the retaining ring (J200) using retaining ring pliers. Press the bearing off the shaft.
Figure 221. Shaft Assembly

INSPECTION
1. Inspect the shaft journals for wear, scratching, and pits. Check the splines for fretting; replace if damaged. Rotate the bearing, if it
does not rotate smoothly, replace it.
REASSEMBLY
1. Press the bearing (J150) onto the shaft (J100) and replace the retaining ring (J200). Ensure the retaining ring diameter is less than
38.84 mm [1.53 in.] when installed on the shaft.
2. Install the shaft/bearing assembly into the pump.
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3. Lubricate and install a new O-ring (J260) onto seal carrier (J275). Press a new seal (J250) into the seal carrier. Press the seal until it is
flush within +0.12 mm [0.005 in.] or -0.72 mm [0.0028 in.] of the inside lip of the carrier: see illustration.
4. Cover the shaft with a protective sleeve while installing the seal carrier. Hand press the seal carrier into the housing. Ensure the
seal carrier clears the spiral ring groove in the housing. Remove the protective sleeve.
5. Wind the spiral ring into the housing. Ensure the inside diameter of the spiral ring is greater than 68 mm [2.677 in.] after
installation.
5.8.10 Charge Pump

Position pump with front shaft pointing downward. Attach securely to a proper work stand. If an auxiliary pump is attached, remove
auxiliary pump before servicing charge pump.
REMOVAL
1. Remove screws (K351), and hangers (K975).
2. Remove running cover (K301). Remove and discard seal ring (K250).
3. Using a 10 mm internal hex, remove screws (K400). Remove cover (K101).
4. Remove charge pump assembly with shaft.
Note: Note position of alignment pin (S500) in housing. Alignment pin position will change for clockwise or counterclockwise
rotation.
5. Remove and discard seal (S300).
6. Using a snap ring pliers, remove two clips (K205).
7. Remove geroter cover (S200). Remove geroter assembly (S100).
8. Remove and discard gasket (K151). Remove alignment pins (K450).
9. If it is necessary to remove housing (K300), use a 10 mm internal hex to remove screws (K350).
10. Remove housing (K300).
11. Remove and discard seal (K150).
INSPECTION
1. Inspect all machined surfaces. If you find any nicks or scratches, replace the component.
2. Inspect geroter and cover for wear or damage. If wear or damage is found, replace geroter kit.
3. Inspect shaft for wear or damage. If found, replace shaft.
4. Inspect journal bearings in aux pad and housing. If worn or damaged, replace journal bearings or aux pad or housing assembly.
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Figure 222. Charge Pump

REPLACING CHARGE PUMP JOURNAL BEARINGS
Use a suitable press to remove and replace the journal bearings. Refer to the drawings below for installation dimensions.
ASSEMBLY
1. Lubricate and install new seal (K150).
2. Install housing (K300). Install screws (K350). Using a 10 mm internal hex, torque screws per listing in table.
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3. Install alignment pins (K450). Install new gasket (K151).
4. Lubricate and reassemble charge pump assembly [shaft (K201), pin (S500), geroter (S100), cover (S200), two clips (K205)].
5. Install charge pump assembly into housing in original position.
6. Lubricate and install seal (S300).
7. Install aux pad (K101).
8. Using a 10 mm internal hex, install screws (K400). Torque screws per listing in table.
9. Lubricate and install seal (K250). Install running cover (K301).
10. Install screws (K351) and brackets (K975). Torque screws per listing in the table.
5.8.11 Charge Check / HPRV

The high pressure relief and charge check valve assembly may be removed for cleaning and replacement of the O-rings. These valves are
factory set and are not field adjustable. Refer to the pump model code for the factory setting when ordering replacements.
REMOVAL
1. Using an 8 mm internal hex wrench, remove the valve seat plugs (K007).
2. Carefully lift the valve (H002) and spring (H003) assemblies from the center section using a magnet.
INSPECTION
1. Inspect the valves and mating seats in the valve seat plugs (K007) for damage or foreign material.
REASSEMBLY
1. Lubricate and install new O-rings (K008, K010) and backup ring (K009) on valve seat plug (K007).
2. Verify that the conical springs (H003) are properly retained on the check relief valves (H002). Install the valve assemblies into the
center section. Ensure each valve assembly moves freely in its bore.
3. Install the valve seat plugs into the center section and torque to 80 Nm [59 ft. lbs.].
4. Operate machine through full range of controls to ensure proper operation. Check for leaks.
Figure 223. Charge Check / HPRV
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Figure 224. Charge Check / HPRV
5.8.12 Charge Pressure Relief Valve

Replace the charge pressure relief valve (V10-1) or (V10-2) as a complete unit. Do not attempt to repair the internal components of the
valve.
REMOVAL
1. Using a 27 mm (V10-1) or a 1 in (V10-2) wrench, remove the charge pressure relief valve. Discard the O-rings (V10A).
INSPECTION
1. Inspect the sealing surfaces of the pump and charge pressure relief valve for nicks or scratches, replace components as necessary.
REASSEMBLY
1. Lubricate and install new O-rings (V10A).
2. Install the charge pressure relief valve (V10). Torque to 52 Nm [38 ft. lbs.].
3. Operate vehicle/machine through full range of controls to ensure proper operation.
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Figure 225. Charge Pressure Relief Valve
5.8.13 Control Cutoff Valve

Replace the control cutoff valve as a complete unit. Do not attempt to repair the internal components of the valve.
REMOVAL
1. Disconnect the coil from the vehicle/machine wire harness.
2. Using a 24 mm hex wrench, remove the control cutoff valve coil nut (G30). Remove the coil (G20).
3. Use a 1 1/16 in hex wrench to remove the control cutoff valve (G10). Remove and discard the O-rings and backup rings (G10A).
INSPECTION
1. Inspect the sealing surfaces of the pump and control cutoff valve for nicks or scratches. Replace components as necessary.
REASSEMBLY
1. Lubricate and install new O-rings (G10A) onto the valve.
2. Install the control cutoff valve (G10). Torque to 46 Nm [34 ft. lbs.]. Slide the coil (G20) onto the valve.
3. Install the coil nut (G30). Torque to 9 Nm [7.ft. lbs.]. Do not overtorque.
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4. Operate vehicle/machine through full range of controls to ensure proper operation.
Figure 226. Control Cutoff Valve
Table 68. Fastener Size and Torque Chart
Item Fastener Wrench size Torque

D015 Neutral adjust screw 4 mm internal hex NA
D050 Control coil mounting screw 4 mm internal hex 8 Nm [5.9 ft. lbs.]
D060 Neutral adjust locking nut 13 mm hex 10 Nm [7 ft. lbs.]
D200 Swash plate feedback pin (not shown) 13 mm hex 25 Nm [18.4 ft. lbs.]
D250 Electric control mounting screw 5 mm internal hex 13 Nm [9.5 ft. lbs.]
E350 Servo cylinder locking screw 10 mm hex 14.5 Nm [11 ft. lbs.]
G10 Control cutoff valve 1 1/16 in hex 45 Nm [33 ft. lbs.]

G10B Control cutoff valve coil nut 24 mm hex 9 Nm [7 ft. lbs.]
K007 Charge check / HPRV 8 mm internal hex 80 Nm [60 ft. lbs.]
K350 A pad cover mounting screw 17 mm hex 70 Nm [52 ft. lbs.]
B pad cover mounting screw 8 mm hex 111 Nm [82 ft. lbs.]
V10-1 Charge relief valve 27 mm hex 52 Nm [38 ft. lbs.]
V10-2 Charge relief valve 1 in hex 52 Nm [38 ft. lbs.]
Table 69. Plug Size and Torque Chart
Item O-ring plug Wrench size Torque

B015 7/16 - 20 3/16 internal hex 20 Nm [15 ft. lbs.]
B020 1-1/16 - 12 9/16 internal hex 48 Nm [35 ft. lbs.]
D065 7/16 - 20 3/16 internal hex 12 Nm [9 ft. lbs.]
G250 9/16 - 18 1/4 internal hex (hardened plug) 45 Nm [33 ft. lbs.]
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Figure 227. Fastener and Plug Locations
5.9 FUNCTION PUMP (SAUER)
5.9.1 Disassembly
1. Remove the control from the endcap by removing the 4 control bolts (C300), using a 4 mm internal hex wrench.
2. Remove and discard the 4 O-rings (C200).
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3. Remove the 4 end capscrews (J030) using a 10 mm internal hex wrench.
4. Carefully remove the endcap (J020). Prevent the valve (B090) plate from falling off.
5. Place the endcap and valve plate in a clean area, protecting them from contamination.
6. Remove the bearing cup (B010), bearing cone (B020) and housing O-ring (K060). Discard the O-ring.
7. Tilt the housing on its side to allow fluid to drain.
8. Remove the cylinder block kit while holding onto the front shaft.
9. Set cylinder block on a clean dry surface.
10. Rotate pump back to a position so that the shaft is pointing down.
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11. Pull the shaft (J010) from the shaft seal.
12. Compress the bias spring (B025) and rotate the servo piston assembly (P020) towards the swashplate (B040).
13. Lift the swashplate/servo piston assembly up at an angle and remove it from the housing.
14. Remove the servo piston (P020) and bias spring (B025) from the swashplate by removing the clevis pin (B043) and snap ring
(B044). Discard the snap ring.
15. Pull to remove the front tapered roller bearing cup (B060) and cone (B070).
16. Examine the cradle bearings (B030) to determine if they need replacement.
Note: Removing the pins (B071) will likely damage the cradle bearings, so make sure you have replacement bearings before you
remove them.
17. If cradle bearings need replacing, remove the 2 pins (B071) holding the cradle bearings, and then remove the cradle bearings.
Note the location and orientation of the bearings for re-installation.
18. Orient the housing with the flange facing up.
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19. Using snap-ring pliers, remove the snap ring (K010).
20. Carefully pry out the shaft seal (K020).

If you are unable to pull the shaft seal out, try to push the seal out by going through the inside of the housing.
21. Remove the 4 plugs (C103, C104, C105, C106) and their O-rings (C103A, C104A, C105A, C106A). Discard the O-rings. Remove the 2
set screws (C102). Remove the spools (C112, C132). Note which bore each spool came out of. Also note the orientation of each
spool for reinsertion. There may be differences in reinserting into the same bore.
22. Remove the adjusting screw (C138) and the O-ring (C138A). Discard the O-ring. Remove the springs (C134, C135) and spring guide
(C133).
23. Remove the adjusting screw (C118), O-ring (C116) and 2 backup rings (C117). Discard the O-ring and backup rings. Remove the
springs (C114, C115) and spring guide (C113).
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24. Pull to remove the slipper retainer (K049) with the pistons (K050) from the cylinder kit.
Note: The pistons are not selectively fitted, however units with high hourly usage may develop wear patterns. Number the pistons
and bores for reassembly if they are to be reused.
25. Remove the ball guide (K047).
26. Remove the 3 pins (K046).
Note: Most repairs do not require block spring removal. Perform this procedure only if you suspect problems with the block
spring.
27. Turn the block over. Using a press, apply pressure on the block spring washer (K044) to compress the block spring (K043).
Compress the spring enough to safely remove the spiral retaining ring (K045). While maintaining pressure, unwind the spiral
retaining ring. Carefully release the pressure and remove the outer block spring washer, block spring, and inner block spring
washer (K042) from the cylinder block.
WARNING
Risk of personal injury: Compressing the block spring requires about 350 to 400 N
[80 to 90.lbf]. Use a press sufficient to maintain this force with reasonable effort. En-
sure the spring is secure before attempting to remove. the spiral retaining ring. Re-
lease the pressure slowly after the retaining ring is removed.
5.9.2 Inspection
After disassembly, wash all parts (including the end-cap and housing) thoroughly with clean solvent and allow to air dry. Blow out oil
passages in the housing and endcap with compressed air. Conduct inspection in a clean area and keep all parts free from contamination.
Clean and dry parts again after any rework or resurfacing.
PISTONS AND SLIPPERS
Inspect the pistons for damage and discoloration. Discolored pistons may indicate excessive heat; do not reuse.
Inspect the running surface of the slippers. Replace any piston assemblies with scored or excessively rounded slipper edges. Measure the
slipper foot thickness. Replace any piston assemblies with excessively worn slippers. Check the slipper axial end-play. Replace any piston
assemblies with excessive end-play.
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Minimum slipper foot thickness and maximum axial end-play are given in the table below.
J Frame
Slipperfoot thickness 3.23 mm
[0.127 in]
Piston/slipper end play 0.05 mm
[0.002 in]
BALL GUIDE, SLIPPER RETAINER, AND HOLD-DOWN PINS

The ball guide should be free of nicks and scratches, and should not be excessively scored. Examine for discoloration that may indicate
excessive heat or lack of lubrication. The slipper retainer should be flat, and slippers should fit in the retainer with minimal side play.
Place the hold-down pins on a flat surface and roll them to make sure they are straight. Discard and replace any damaged parts.
BLOCK SPRING, AND WASHERS

If cylinder kit was fully dissembled, visual inspection of the cylinder block, spring, and washers should indicate minimal wear. Replace if
cracks or other damage is present.
CYLINDER BLOCK
Examine the running face of the cylinder block. The surface should be smooth and free of nicks and burrs. Ensure that no scratches or
grooves exist; these may drastically reduce output flow.
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J Frame 45-60 cc 65-75 cc

Minimum cylinder block height (A) 62.25 mm
[2.45 in]
Maximum block bore diameter (B) 19.8 mm 21.57 mm
[0.785 in] [0.85 in]
CONTROL
Carefully examine the plug(s) for signs of wear. Also check the small tip of the plug(s) for heavy wear and replace if necessary. Inspect
each spool’s springs to make sure they are intact. Check the inside and outside surfaces of the springs for wear and replace if necessary.
Check the spool’s outside diameter for scratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating of
hydraulic oil.
INPUT SHAFT
Check to see that the shaft (J010) and its splines are straight and free of damage or heavy wear. Inspect the shaft surface where it meets
the shaft seal. Replace the shaft if a groove exists at the sealing land surface that may let dirt into or hydraulic fluid out of the unit. Clean
the sealing area with a nonabrasive material if necessary. Lubricate the shaft with a light coat of hydraulic fluid.
SWASHPLATE
Carefully inspect each surface of the swashplate for wear. All swashplate surfaces should be smooth. Inspect the swashplate’s slipper
running surface for damage and brass transfer. Excessive brass transfer from slippers may indicate that the slippers should be replaced.
Finally, check the swashplate bearing journal for scratches. Replace swashplate if necessary.
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JOURNAL BEARINGS
Inspect the journal bearings for damage or excessive wear. Replace journal bearings if scratched, warped, or excessively worn. The
polymer wear layer must be smooth and intact.
VALVE PLATE
Inspect the valve plate for scratches and grooves. Check the plate for evidence of any cavitation along the running face of the valve
plate. If pitting from cavitation exists, replace the valve plate. Check for excess wear on the brass running face. If any discoloration or
burn marks are observed, replace the valve plate.
Run a fingernail or pencil tip across the diameter of the sealing land surface (see illustration). No deep or outstanding grooves should be
felt, as these may decrease pump flow. Lap or replace if grooves or nicks are present. Inspect the mating surfaces of the endcap and
valve plate for any possible contamination; even a few thousandths of an inch may affect pump operation.
Measure the thickness of the valve plate. Ensure that valve plate parallelism is equal to or less than 0.025 mm [0.001 in]. Appearance
should be flat and smooth on both the running face and the bottom surface. The valve plate should be flat to 0.005 mm [0.0002. in]
convex. A magnetic particle inspection is recommended to detect cracks. The valve plate must be replaced if any cracks exist.
ENDCAP
Inspect the endcap. Remove the check valve (B092) to expose the spring (B091). Check and record orientation of the timing pin (J050)
The split in the timing pin should be facing into or out of the slot in the valve plate. Inspect the check valve for wear on its sealing face
and replace if necessary. Make sure the spring is undamaged. Replace any components if excess wear is present.
SERVO PISTON
Check the servo piston assembly (P020) for any obvious wear or damage. Check the corresponding endcap bore for galling or excessive
wear. Discard the piston if damaged. Replace the servo piston-rings.
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HOUSING
Inspect the housing to ensure that it is clean and free of foreign material. Inspect the swashplate bearing surfaces, and endcap mating
surfaces.
SHAFT BEARING KITS

The tapered roller bearing kit consists of a cup and cone. Make sure the cup and cone are free of excessive wear or contamination.
Rotate the bearings to check for smoothness. If a contaminated bearing is suspected, clean with a solvent and lubricate with hydraulic
fluid.
Note: Replace the bearing if the problem is not remedied by cleaning.
Inspect for uneven wear. If abnormal wear is found, replace the bearing kit.
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5.9.3 Assembly
1. Coat the journal bearings (B030) with hydraulic fluid and install them into the pump housing. Punch in retaining pins (B071) a
minimum of 0.5 mm [0.002 in.] below the bearing surface.
Note: If journal bearings are reused, reinstall them in their original orientation and position.
2. Reinstall shaft bearing cup (B060) and cone (B070). Before replacing the bias spring (B025), coat the curved surface of the
swashplate with hydraulic fluid.
3. Reinstall the swashplate/servo piston/bias spring assembly in its original orientation in the housing. Rotate the servo piston
perpendicular to the swashplate, and at the same time compress the bias spring to fit into housing pocket. Lubricate all sides of
the servo piston and its respective bore liberally with hydraulic oil. Also, lubricate the flat face of the swashplate to prevent
premature wear during start-up.
4. Insert the input shaft (J010) through the bearing into the housing. You may need to push on the servo piston to rotate the
swashplate in order to put the shaft in properly.
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5. Coat all parts with hydraulic fluid prior to reassembly.
WARNING
Compressing the block spring requires about 350 to 400 N [80 to 90 lbf]. Use a press
sufficient to maintain this force with reasonable effort. Ensure the spring is secure
before attempting to install. the spiral retaining ring. Release the pressure slowly
after the retaining ring is installed.
6. Install the inner block spring washer (K042), block spring (K043), and outer washer (K044) into the cylinder block. Using a press,
compress the block spring enough to expose the retaining ring groove. Wind the spiral retaining ring (K045) into the groove in the
cylinder block.
7. Turn the block over and install the hold-down pins (K046), and ball guide (K047) to the cylinder block.
8. Install the pistons (K050) to the slipper retainer (K049). Install the piston/retainer assembly into the cylinder block. Ensure the
concave surface of the retainer seats on the ball guide. If you’re reusing the pistons, install them to the original block bores.
Lubricate the pistons, slippers, retainer, and ball guide before assembly. Set the cylinder kit aside on a clean surface until needed.
Note: Be sure to install the slipper retainer so it mates correctly with the ball guide (concave side of the slipper retainer against the
convex side of the ball guide).
9. Set the pump on its side. Secure the end of the shaft with one hand and keep it horizontal. Insert the cylinder kit onto the shaft.
While holding the shaft still, slightly rotate the cylinder block kit to help start the shaft splines over the ball guide and align it with
the block splines. When the cylinder block kit slides completely over the shaft splines, reposition the unit with the flange facing
downward.
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10. Clean the valve plate (B090) and endcap. Install the timing pin (J050) in the endcap and verify that it is properly oriented with the
split facing into or out of the slot in the valve plate. The timing pin should be installed to 3.61 ｱ 0.25.mm [0.14.ｱ.0.01 in.] above the
valve plate surface. Apply a liberal amount of assembly grease to the backside of the valve plate surface to hold it in position.
Install the valve plate over the timing pin, check valve (B092), and bearing cup (B010).
Note: To insure proper pump operation, it is extremely important to ensure that there is no contamination between the endcap
and valve plate.
11. Install the bearing cone (B020) onto the shaft. Using assembly grease to hold the seal (K060), install the endcap to the housing.
Ensure that seals remain properly seated and are not pinched during assembly. With a 10 mm internal hex wrench, install and
torque endcapscrews at 127 to 155 Nm [94 to 114 ft. lbs.], using the criss cross pattern. Retorque the first screw to ensure proper
torque retention.
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12. Lubricate the lip of the new shaft seal (K020) with clean hydraulic fluid. Place a protective sleeve over the shaft end to prevent
damage to the seal during installation. Keeping the seal perpendicular to the shaft, press the new seal into the housing just far
enough to clear the retaining ring groove. Install seal with the cupped side toward the shaft bearing. Do not damage the seal
during installation. Using the appropriate snap ring pliers, install the seal retaining ring (K010). Remove the installation sleeve.
13. Clean all control parts and cover with a light coating of hydraulic fluid prior to reassembly.
14. Install the spherical end of the PC spool (C132) into the PC bore (refer to illustration). Install the PC plug (C103) using a new O-ring
(C103A). Torque at 10.8 to 13.5 Nm [8 to 10 ft. lbs.]. Place the two PC springs (C134, C135) onto the PC spring guide (C133) and
install into the PC bore. Place a new O-ring onto the PC plug and install it so that it sits one turn below the surface of the control
housing. Install and tighten set screw (C102) at 7.5 to 10.8 Nm [5.5 to 8.0 ft. lbs.] to retain the adjusting plug.
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15. Hold the control in a horizontal position. Install the spherical end of the LS spool (C112) into the LS bore (see illustration). Using a
new O-ring, install the LS plug (C104), torque at 10.8 to 13.5 Nm [8 to 10 ft. lbs.]. Place the 2 LS springs (C114, C115) onto the LS
spring guide (C113) and install into the LS bore. Place a new O-ring (C116) and Backup rings (C117) onto the LS adjustment screw
(C118). Install the LS plug assembly so that it sits one turn below the surface of the control housing. Install and tighten set screw
(C102) at 7.5 to 10.8 Nm [5.5.to 8.0 ft. lbs.]. Also, install the plugs (C105, C106) with new O-rings. Torque the plugs at 10.8 to 13.5
Nm [8 to 10 ft. lbs.].
Note: PC and LS spools need to be adjusted to proper setting according to tag nomenclature.
16. Using petroleum jelly to retain them, install 4 new seal rings (C200) in the recesses on the control housing. Install the control
assembly onto the endcap using the 4 screws (C300). Torque at 5.4 to 7.5 Nm [4.0 to 5.5 ft. lbs.] using a criss cross pattern and
retorque the first screw to ensure proper torque retention.
5.10 GEAR PUMP (SAUER)
5.10.1 Disassembly
Prior to proceeding it may be necessary to prepare some subassemblies separately.
The details for preparing each subassembly are given in the following section.
Also, some general recommendations are given below.
CLEANLINESS
Cleanliness is a primary factor for reliable pump performance. Wash the outside of the pump thoroughly before disassembly and all
pieces prior to assembly. Cleaning parts with clean shop solvent and air drying is usually adequate.
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LUBRICATION OF MOVING PARTS

During assembly, it is imperative to provide lubrication with clean hydraulic oil to all the running parts of the pump.
It is also necessary to coat the seals with grease. The absence of lubrication during assembly can cause the unit to seize after a few
minutes of running.
CARE OF SURFACE TREATMENT
Be careful when handling all the internal surfaces, especially bearings, gears, and body faces. Do not touch or score them with metal
tools or cutting edges.
MARKING THE PARTS
Mark the parts before completely disassembling a pump. The marks allow components to be reassembled in the same relative position.
This action should be applied to the body, bearings, and gears. Scribing, bluing, or using a felt tip pen to mark the outside of the body
on the inlet side is suggested to indicate the relative position of the front flange and the rear cover to the body. Mark the bearing blocks
also on the inlet side and the gears position relative to each other. DO NOT scribe internal surfaces.
PROCEDURE
Note: Clamping the pump on the body is not recommended because serious damage to the surfaces, on which the ports are located,
may occur.
1. Clamp the unit.

Clamp the unit in a vice from the flange side.
Make sure the vice jaws are clean and have smooth surfaces to prevent damage to the pump.
2. Remove capscrews. (Except Units with 03 Flange.)

Use a 17 mm socket wrench and loosen the four capscrews on the cover. Next completely unscrew the capscrews and remove
them.
Inspect the threads of the capscrews for damage.
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3. Remove socket head capscrews. (03 Flange or Multiple Pump Stages Only).
Using a 4 mm internal hex wrench, loosen and remove the two small socket screws placed in the center of the cover. Repeat the
same operation for the corresponding screws on the rear flange.
4. Remove front flange.

Place the pump on the table and slowly remove the front flange.
Be careful not to damage the shaft seal when removing the flange. Avoid contact of the shaft seal lips with keyway edges (in
tapered and parallel shafts) or splined shaft teeth.
Inspect the front flange and seal area.
Clean with shop solvent, dry, and set aside.
5. Remove rear cover.

Remover rear cover. Clean with shop solvent, dry, and set aside. Visually inspect rear cover and seal area.
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6. Remove bearing blocks and gears.

Place the pump on its side and carefully remove the bearing block and gear set. To accomplish this, hold the pump body and push
with your fingers on the rear bearing block.
Mark the relative positions of the gear mesh (drive gear tooth to idler gear tooth) and the bearing blocks to the body so they can
be reassembled in the same position.
7. Remove pressure seals.

Check the seal quality. Replacement is recommended whenever there are burrs, evidence of extrusion, or marks caused by
overheating. If the seals need to be replaced, carefully remove them from the flange cover, beginning with the backup ring and
then the pressure seal.
Do not use tools with sharp edges to remove the seals, as damage to the cover can result.
After removal, dispose of damaged seals.
8. Remove Outer O-Ring Seal

Check the quality of this seal. If necessary, replace it. Follow the same removal recommendations given in step 7.
After removal, discard the damaged seal.
Do not use tools with sharp edges to remove the seals, as damage to the cover can result.
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9. Remove the snap ring.

Place the flange on the work surface. Using internal snap ring pliers, remove the snap ring.
10. Remove the shaft seal.

Check the shaft seal quality and remove if necessary.
To remove, pry the bottom of the shaft seal and force it out while rotating the flange to lift it out evenly.
Do not use the flange pilot to gain leverage, damage may result. Use a plastic rod or wooden dowel as a fulcrum.
After removal, dispose of damaged seal.
5.10.2 Assembly
1. Prepare the seals.
Have the entire seal kit available.
Lightly coat all seals with seal grease. The grease is needed to adhere the seals to their grooves.
Do not install dry seals.
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2. Install shaft seal into front flange.

Prepare the flange and shaft seal by lightly lubricating with grease.
Seat the seal in the flange by hand. Then, using the shaft seal installation tool, press the seal until the tool stops on the flange. This
will insure the seal is inserted to the proper depth.
3. Install snap ring.

Install the snap ring using internal snap ring pliers. Ensure the snap ring fits securely in its groove. This is necessary to retain the
shaft seal.
4. Install pressure seals.

Prepare the pressure seals by lightly lubricating them with grease.
Install pressure seals into the grooves on the front flange and rear cover. Then install the teflon backup ring.
Ensure that the seals are located in the grooves, as shown.
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5. Prepare the body.

Clean the body.
Inspect the internal and mating surfaces. Ensure the surfaces are free of burrs and scratches. Check both the bearing block mating
surface and the cut-in path. The cut-in path should be no deeper than 0.1 mm (0.004 in.).
6. Install outer seal.

Prepare the outer seal by lightly lubricating with grease.
Install outer seals in the grooves on both sides of the body.
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7. Prepare the gears.
CAUTION
The gear surfaces are super-finished. Residue on hands and fingers may be corro-
sive to this surface. Do not touch.
Carefully clean the two gears. If the gears are new, wash them with shop solvent to remove any anticorrosive grease on the
surfaces.
Inspect the journals and the flat faces on the top and bottom of the gears. Ensure these surfaces are free from burrs or scratches. If
scratches or burrs are found, clean them with a flat stone and/or very fine emery paper. Rewash the gears after this operation.
8. Prepare the bearing blocks.

Clean the two bearing blocks.
Inspect the flat surfaces of the bearing blocks for burrs or scratches on the edges. If necessary, remove burrs with very fine emery
paper. Then rewash the bearings.
Inspect the DU bushings for wear. There should be no bronze showing.
Using clean hydraulic oil, lubricate the internal and external surfaces of the bearing blocks.
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9. Assemble the bearing blocks and gears.

Lubricate the journals and the gear faces.
Assemble the bearing blocks and gears. Ensure that the recessed bearing faces are installed adjacent to the gear faces. Align all
assembly marks made during disassembly. Ensure the front and rear bearing blocks occupy the same location with respect to the
housing as before disassembly. Ensure that the relative position of the gear mesh is maintained as before disassembly.
Misalignment of the gear teeth may increase operating noise.
10. Install the gear block assembly.

Install the bearing block and gear assembly into the body cavity. Align the assembly marks to ensure that the gear block assembly
is installed with the same orientation as before disassembly.
11. Clean the mating surfaces.

Remove any excess lubrication and grease from the mating surfaces of the pump body. Ensure that these surfaces are dry and free
of contamination before moving on to the next step.
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12. Install the dowel pins.

Install four 5 mm dowel pins into the proper cavities on both sides of the body (refer to the illustration). Swab the pins with
assembly grease or petroleum jelly to retain them during assembly.
Do not install dowel pins to the rear cover or flange, as one of them may drop inside the pump during assembly.
13. Clean the mating surfaces.

Remove any excess lubrication and grease from the mating surfaces of the front flange and rear cover. Ensure that these surfaces
are dry and free of contamination before moving on to the next step.
Ensure the pressure seals are seated properly after this operation.
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14. Install Rear Cover.

Mount the cover on the body. Ensure the arrow on the back is oriented properly. The arrow should be In the same direction as the
flow.
Ensure that all the pressure seals stay in place during this operation.
15. Prepare pump for front flange assembly.

Place the pump with the rear cover downwards.
Ensure that the assembly marks on the bearing block / body are properly aligned.
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16. Install the front flange.

Install a protective sleeve over the shaft. The sleeve is used to protect the shaft seal from damage by the shaft splines / keyway
during front flange assembly.
Install the flange onto the body, then remove the protective sleeve.
Ensure that the seals remain seated in their grooves during this operation.
17. Torque sequence.

When assembling units with 01 flange and short coupled tandems, wash the capscrews and apply Medium Strength Threadlocking
Compound or equivalent thread lock compound to the threads before assembly.
Install capscrews. While observing the torque sequence shown, pre tighten the capscrews. Then, using a torque wrench, tighten
them to the proper torque.
Torque 44-54 Nm (32-40 ft. lbs.).
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18. Install socket head capscrews. (03 flange and first stage of multiple).
Using a 4 mm internal hex wrench, install the socket head capscrews to the front flange and rear cover.
Torque 2.5-3.4 Nm (22-30 ft. lbs.).
If used, install new o-ring to flange pilot.
19. Testing
After pump has been disassembled and reassembled, it is suggested that the pump be run in and tested on an appropriate test
stand. This is done to verify the volumetric efficiency and the integrity of the unit.
Test specifications and procedure are given in Testing the Pump.
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20. Prepare the unit for shipment or storage.

Clean the exterior of the pump and install the following:
a. Port Plugs
b. Key (CI and CO shafts)
c. Shaft protective cap (CI and CO shafts)
d. Nut and washer (CO shaft)
Table 70. Troubleshooting
Low or No Flow From Gear Pump

1. Check oil level in reservoir. Description Insufficient oil to supply gear pump. Fill reservoir to proper level.
2. Check input spline condition. Input shaft broken or stripped. Repair or replace gear pump.
3. Check pressure at pump inlet. Recommended inlet Clogged suction filter or inlet screen. Replace filter or clean suction screen.
pressure: 0.8 to 3.0 bar absolute. 0.6 Minimum at cold
start.
4. Check condition of gear faces and bearing blocks. Scored bearing block and gear faces will reduce pump Repair or replace gear pump.
efficiency.
5. Check bushings. Overpressure of gear pump will cause idler gear bushing Repair or replace gear pump.
to fail.
Excessive Noise
1. Check oil level in reservoir. Excessive air will cause cavitation sound. Fill reservoir to proper level .
2. Check inlet line for leaks. Excessive air will cause cavitation sound. Repair inlet line.
3. Check pressure at pump inlet. Recommended inlet Lower than normal inlet pressure causes excessive pump Return inlet pressure to recommended levels.
pressure: 0.8 to 3.0 bar absolute. 0.6 Minimum at cold noise.
start.
External Leakage
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Table 70. Troubleshooting (continued)

Low or No Flow From Gear Pump
1. Check for pinched O-rings or backup ring seal. Pinched seal will allow leakage. Replace pinched seal.
2. Check pressure seals. Damage to pressure seals is typically caused by reduced Inspect condition of bearing blocks. If they are found to
stack-up in the pump assembly. This may be due to be worn, repair or replace the pump .If bearing blocks
under-torqued assembly fasteners, or more commonly is are not worn, replace pressure seals and re-torque pump
attributed to excessive wear on the bearing blocks. assembly fasteners.
Reduced stack-up will affect seal efficiency possibly to
the point of seal extrusion.
5.11 DRIVE & FUNCTION PUMP START UP PROCEDURES
5.11.1 Start-Up Procedure

The 1200/1350 Boom Lift utilizes a Triple Combination Pump coupled to the Deutz diesel engine. The pumps are connected in-line to
each other as follows:
1. The front hydrostatic transmission pump, or drive pump, is coupled directly to the diesel engine and provides oil flow to operate
the machine's right side wheels.
2. The middle hydrostatic transmission pump, or drive pump, is coupled to the back of the front pump and provides oil flow to
operate the machine's left side wheels.
3. The third or rear pump is the function pump. It is coupled to the back of the middle pump and provides oil flow to operate the
boom, axle, steer and platform functions.
The transmission pumps share some common connections. Each pumps charge oil suction ports are connected by steel tubing,
the charge pumps discharge oil flows are connected and flow to a common charge pump inline oil filter, cleaned & filtered oil
flows back to the transmission pumps "G" ports. The pumps case drain ports are connected (T1 & T2), oil flow from the middle
pumps T1 port also provides flows to the oil cooler. The charge pumps oil pressure is regulated by a single boost oil pressure relief
valve installed in the middle pump. The front pump has an orifice cartridge (0.047" diameter) installed in place of a charge oil
pressure relief cartridge. This insures that only one valve controls charge pressure & provides an amount of charge oil flow to the
front pump's case to insure flushing & removal of hot oil.
Each pump has its own separate electrical proportional directional control valve to control oil flow and direction. The signals or
command values to each pump are similar except when steering. During steering and propel of the machine the pump supplying
oil to the "inside turning radius" has a command less than the pump supplying oil flow to the "outside turning radius" pump.
"Posi-Traction" control, front to rear on a given side of the machine, is accomplished by a flow divider/combiner cartridge installed
in the Traction Control Manifold. There is a flow divider/combiner for each side. Each flow divider/combiner also has a "bleed
orifice" to limit the amount of flow splitting or combining.
The middle transmission pump also supplies oil to a hot oil flushing valve cartridge, #120, in the Traction Control Manifold. This
cartridge provides a means to obtain brake release oil pressure. The brake release pressure is controlled by a pressure relief valve
cartridge # 130 and a solenoid operated brake release directional control cartridge, #170, also located in the Traction Control
Manifold. This is important to note as the brake release oil pressure must be set 25 psi (1.7 bar) below the boost oil pressure relief
valve. If the brake release pressure is set too low, brake drag and pump control will be affected. If set too high, damage to the
wheel drive parking brakes could result. Prior to start, connect appropriate pressure gauges to the unit.
FOR THE START-UP OF NEW OR OVERHAULED INSTALLATIONS:
1. Insure all electrical checks have been performed & the machine is set up correctly with the JLG Analyzer.
2. Insure the machine has all four wheels jacked & blocked off the ground per JLG procedures.
3. Insure the triple pump assembly is installed and connected correctly per the hydraulic circuit diagram.
4. Disconnect the electrical connector from the diesel's throttle actuator, to prevent engine start.
5. Crank the engine until charge pressure reaches 50 psi or more.
6. Re-connect throttle actuator electrical connector and start engine. Allow engine to run at idle speed only for at least 5 minutes.
This will allow the hydrostatic system to filled.
7. Listen for any abnormal noises.
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8. Check for oil leaks.
9. Check charge pressure (500 psi +50 psi, - 0 psi [34.4 bar +3.4 bar, - 0 bar]). Pressure can be measured a pump ports Ma & Mb or by
"teeing" into the inlet for the charge oil filter. Charge pressure is checked with the joystick in neutral. A 0-1000 psi (0-70 bar)
pressure gauge must be used. (If pressure gauges were installed in Ma & Mb to check charge pressure, disconnect the gauges
installed in Ma & Mb, as they will be damaged if loop pressure rises above 1000 psi [34.4 bar].)
10. Operate the drive system in the "turtle mode", forward and reverse.
11. De-aerate the system by bleeding fluid from the Ma & Mb ports.
12. Switch the drive mode speed control from "turtle" to "rabbit". Gradually increase drive speed forward & reverse, still with no load -
wheels off the ground.
13. With the joystick in neutral, check for creep in neutral. If evident, most likely dirt is present in the proportional pump control, an
incorrect electrical signal is present on the pump's electrical control(s) or the control was not centered properly when overhauled.
See service manual for centering instructions.
14. Check that the controls are connected so that the transmissions operate in the correct direction related to control input.
15. Continue to monitor all pressure gauges & correct any irregularities.
16. Remove the brake coil (leaving the electrical connection intact)from the brake release solenoid cartridge located on the Traction
Manifold. This disables the machine's ability to release the brakes! Stroke the transmission pumps slightly (less than 20%) and
check the setting of the high pressure cross port relief valves. Setting should be 5000 psi +50 psi, - 0 psi (344.7 bar +3.4 bar, -0 bar).
Install 0-6000 psi (0 - 415 bar) gauges on Pump ports Ma & Mb.
17. Check oil level & temperature.
18. Remove and inspect charge pressure oil filter, replace with new element.
19. Operate the transmission under no load conditions for about 15 minutes to stabilize the temperature and remove any residual air
from the fluid.
20. Set the machine back on the ground. Operate the transmissions under full and normal conditions.
21. Erratic operation may indicate there is still air trapped in the system. By working the pump controls forward and reverse the
remaining air can be eliminated. The system is free of air when all functions can be operated smoothly and when the oil in the
reservoir is no longer aerated. (Usually less than one hour of operation)
Note: If the transmissions do not perform correctly after following the pre-start & start-up procedures, refer to the relevant sections
of the trouble-shooting procedures.
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5.12 HYDRAULIC SCHEMATICS
Figure 228. Hydraulic Schematic - Boom Functions
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Figure 229. Hydraulic Schematic - Axle/Steer Control
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Figure 230. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps
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Figure 231. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps
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560
SECTION 6
JLG CONTROL SYSTEM
6.1 INTRODUCTION
NOTICE
When installing any new module controller on the machine, it will be necessary to
program the controller for the proper machine configuration, including options and
properly calibrate the tilt sensor.
NOTICE
It is a good practice to avoid pressure-washing electrical/electronic 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 minimum distance of 12 inches (30.5 cm) 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.
The JLG designed Control System is a 12 volt based control unit installed on the boom lift.
The JLG Control System has reduced the need for exposed terminal strips, diodes and trimpots and provides simplicity in viewing and
adjusting the various personality settings for smooth control of: acceleration, deceleration, creep, min speed, and max.-speed for all
boom, drive, and steering functions.
The main lift, swing, and drive are controlled by individual joysticks, with steering being controlled by a rocker switch built into the top
the drive joystick. To activate Drive, Lift, and Swing simply pull up on the slide lock location on the joystick and move the handle into the
direction desired.
The control system will control the voltage output to the valves and pump, as programmed for smooth operation and maximum cycle
time. Ground control speeds for all boom functions can also be programmed into the control system.
The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which may be accessed for
troubleshooting. Optional equipment includes a soft touch system, head and tail lights, and ground alarm. These options may be added
later but must be programmed into the control system when installed.
The Control System may be accessed utilizing a custom designed, hand held analyzer (Analyzer Kit, JLG part no. 1001249695) which will
display two lines of information at a time, by scrolling through the program.
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JLG Control System
Figure 232. Hand Held Analyzer
6.2 CANBUS COMMUNICATIONS
CANbus: CAN (Control Area Network) is a two wire differential serial link between the Platform Module, Ground Module, Boom Length
Angle Module and the Chassis Module providing bi-directional communications.
Two-wire: One wire (red) is driven high (5v) and the other low (black) (0v) to send a signal; both wires ”float” (2.5v) when no signal is
being sent.
Differential: Any electrical line noise can affect the high or the low wires but never both, so communications is not corrupted.
Serial Link: Messages are being sent bit by bit along the wires; the high bus speed allow all modules to be constantly updated around 20
times per second. Typical traffic is 300 - 500 messages per second. A complete CANbus circuit is approximately 60 ohms, which can be
verified at the ”T” fitting inside the ground station or below the BLAM. Each individual circuit from the modules is approximately 120
ohms.
The GROUND MODULE is the master system controller. Most functions are dispatched and coordinated from this module, all other
system modules (PLATFORM, BLAM L CHASSIS) handle sub-tasks. All characterized information (values) are stored into the ground
module (i.e., Personalities or Calibrations).
Interlocks: Any device that sends an electrical input. (For an example a limit switch, proximity switch, etc;)
Platform Level: The GROUND MODULE stores the default values and handles interlocks. The PLATFORM MODULE reads the sensors
mounted on the platform assembly and controls the Level Up / Down valves to maintain setpoint sent from the GROUND MODULE.
Steer: The GROUND MODULE stores crack points, sends desired drive direction, sends steering mode and sends axle extend / retract
commands. The PLATFORM MODULE reports the steering switch position to the GROUND MODULE. The CHASSIS MODULE modulates
each steer left / right valve to maintain commanded wheel position.
Drive: The GROUND MODULE stores crack points, sends commands for each drive pump to the BLAM. (Command is computed from
drive joystick input, interlocks, wheel angle, etc). BLAM maintains proper current for the drive pumps by modulating PWM outputs.
Lift, Tele, & Swing:The GROUND MODULE stores default values, handles interlocks and calibration information.Lift, Telescope 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.
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JLG Control System
Figure 233. Control System Block Diagram
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JLG Control System
6.3 CALIBRATION INSTRUCTIONS
This machine incorporates a variety of sensors and a high degree of function interaction. For safety and proper machine functionality,
the calibration procedures must be repeated for any control module replacement, system calibration related fault, or removal or
replacement of any sensors, valves, coils, motors, or pumps. The chart below lists the calibrations required and potential reasons for re-
calibration. All calibration procedures are menu driven through the use of the standard analyzer. With the exception of steering
calibration, no external tools are required to complete the calibration procedures. The user is prompted to exercise the machine in a
specific order to use the machines physical properties to consistently establish sensor response and the interaction of valves, pumps,
and motors. Steering calibration also uses the analyzer and is performed on one side of the machine at a time requiring the use of a
string or other means to determine when the tires are in line with each other. With the exception of the load control calibration, all
calibrations are accessed by connecting the analyzer into the control system inside the main terminal box or on the bottom of the
platform control box.
Table 71. Calibration Instructions

Calibration procedure Reasons for Re-calibration
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 Calibration Ground module replacement

Platform module replacement
Platform level sensor removal or replacement
Platform level sensor calibration fault

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

Lift proportional valve/coil replacement
Erratic controlled arc operation
Erratic controlled boom angle operation
Telescope Crack Point Calibration Ground module replacement
Telescope proportional valve replacement
Erratic controlled arc operation
Erratic controlled boom angle operation
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JLG Control System
Table 71. Calibration Instructions (continued)

Calibration procedure Reasons for Re-calibration
Chassis Tilt Calibration Ground module removal or replacement
Main terminal box removal or replacement
Tilt indication inaccuracy
Boom Sensors Calibration Ground module removal or replacement

BLAM module removal or replacement
Boom angle sensor removal or replacement
Boom length sensor removal or replacement
Moment pin removal or replacement

Boom angle sensor calibration fault
Boom length sensor calibration fault
Moment pin fault

Failed BCS functional check
Boom control system inaccuracies
Installing or removing approved accessories
Changing Platform Size
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JLG Control System
Figure 234. Analyzer Flow Chart - Personalities (Software Version P7.37) - Sheet 1 of 5
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JLG Control System
Figure 235. Analyzer Flow Chart - Calibrations (Software Version P7.37) - Sheet 2 of 5
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JLG Control System
Figure 236. Analyzer Flow Chart - Machine Setup (Software Version P7.37) - Sheet 3 of 5
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JLG Control System
Figure 237. Analyzer Flow Chart - Diagnostics (Software Version P7.37) - Sheet 4 of 5
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JLG Control System
Figure 238. Analyzer Flow Chart - Diagnostics (Software Version P7.37) - Sheet 5 of 5
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JLG Control System
Figure 239. Control Module Location
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JLG Control System
Figure 240. Analyzer Connecting Points
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JLG Control System
Figure 241. Platform Control Module
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JLG Control System
CONNECTOR PIN ASSIGNMENT FUNCTION

1 TOWER LIFT UP HS DIGITAL INPUT
2 TOWER LIFT DOWN HS DIGITAL INPUT
3 TOWER TELESCOPE IN HS DIGITAL INPUT
4 TOWER TELESCOPE OUT HS DIGITAL INPUT
5 MAIN TELESCOPE IN HS DIGITAL INPUT
6 MAIN TELESCOPE OUT HS DIGITAL INPUT
7 PLATFORM ROTATE RIGHT HS DIGITAL INPUT
8 PLATFORM ROTATE LEFT HS DIGITAL INPUT
9 PLATFORM LEVEL UP HS DIGITAL INPUT
10 PLATFORM LEVEL DOWN HS DIGITAL INPUT
11 JIB UP HS DIGITAL INPUT
12 JIB DOWN HS DIGITAL INPUT
13 SPEED PUMP POTENTIOMETER GROUND GROUND
14 ENGINE START HS DIGITAL INPUT
15 AUXILIARY POWER HS DIGITAL INPUT
16 CRAB STEER SELECT HS DIGITAL INPUT
17 COORDINATED STEER SELECT HS DIGITAL INPUT
J1 NATURAL 18 SWITCH POWER BATTERY VOLTAGE
19 JIB 1000LB ENABLE HS DIGITAL INPUT
20 EIM PLATFORM OVERLOAD HS DIGITAL INPUT
21 500/1000LB. CAPACITY SELECT HS DIGITAL INPUT
22 DRIVE ORIENTATION SYSTEM FEATURE ENABLE HS DIGITAL INPUT
23 SPARE PIN HS DIGITAL INPUT
25 LEVEL SENSOR 1 SIGNAL HS DIGITAL INPUT
26 LEVEL SENSOR 2 SIGNAL HS DIGITAL INPUT
27 TWO SPEED VALVE (HIGH ENGINE) HS DIGITAL INPUT
28 TORQUE MODE HS DIGITAL INPUT
29 SOFT TOUCH OVERRIDE HS DIGITAL INPUT
30 HEAD/TAIL LIGHT HS DIGITAL INPUT
31 HORN HS DIGITAL INPUT
32 CREEP MODE HS DIGITAL INPUT
33 DUAL-FUEL SELECT HS DIGITAL INPUT
34 SPEED PUMP POTENTIOMETER REFERENCE VOLTAGE +7REFERENCE VOLTAGE
35 SPEED PUMP POTENTIOMETER ANALOG INPUT

J2 BLUE
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JLG Control System

3 BATTERY VOLTAGE BATTERY VOLTAGE
4 DRIVE ORIENTATION SYSTEM OVERRIDE SWITCH HS DIGITAL INPUT
5 PLATFORM STOWED HS DIGITAL INPUT
6 CHASSIS TILTED INDICATOR LAMP OUTPUT
7 FUNCTION ENABLE INDICATOR LAMP OUTPUT
8 VEHICLE SYSTEM DISTRESS INDICATOR LAMP OUTPUT
9 CREEP SPEED INDICATOR LAMP OUTPUT
10 BROKEN CABLE INDICATOR LAMP OUTPUT
11 PLATFORM OVERLOADED INDICATOR LAMP OUTPUT
12 500LB CAPACITY INDICATOR LAMP OUTPUT
13 1000LB CAPACITY INDICATOR LAMP OUTPUT
14 DRIVE ORIENTATION SYSTEM INDICATOR LAMP OUTPUT
15 GENERATOR ON INDICATOR LAMP OUTPUT
16 SOFT TOUCH TRIGGERED INDICATOR LAMP OUTPUT
17 GLOW PLUG ENGAGED INDICATOR LAMP OUTPUT
18 LAMP RETURN GROUND
19 SPARE PIN LAMP OUTPUT
20 UPRIGHT TILTED INDICATOR LAMP OUTPUT
21 LOW FUEL INDICATOR LAMP OUTPUT
22 1/4 FUEL LEVEL INDICATOR LAMP OUTPUT
25 FUEL LEVEL INDICATORS RETURN GROUND
26 ANALYZER POWER ANALYZER POWER
27 ANALYZER GROUND ANALYZER GROUND
28 ANALYZER RX ANALYZER RX
29 ANALYZER TX ANALYZER TX
30 SPARE PIN LAMP OUTPUT
31 SPARE PIN DIGITAL OUTPUT
34 SWITCH POWER BATTERY VOLTAGE
35 FULL FUEL LEVEL INDICATOR LAMP OUTPUT

1 LIFT/SWING JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE
2 LIFT CENTER TAP ANALOG INPUT
J5 NATURAL
3 LIFT SIGNAL ANALOG INPUT
4 SWING SIGNAL ANALOG INPUT
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JLG Control System

5 SWING CENTER TAP ANALOG INPUT
6 NOT CONNECTED ANALOG INPUT
7 LIFT/SWING JOYSTICK RETURN GROUND
8 SPARE PIN BLANK

1 DRIVE/STEER JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE
2 DRIVE CENTER TAP ANALOG INPUT
3 DRIVE SIGNAL ANALOG INPUT
4 STEER SIGNAL ANALOG INPUT
J6 BLACK
5 STEER LEFT ANALOG INPUT
6 STEER RIGHT ANALOG INPUT
7 DRIVE/STEER JOYSTICK RETURN GROUND
8 SPARE PIN BLANK

1 MODULE GROUND GROUND
J8
2 MODULE POWER BATTERY VOLTAGE

1 GROUND MODE GROUND MODE
2 PLATFORM EMS PLATFORM EMS
3 PLATFORM EMS TO GROUND MODULE PLATFORM MODE
4 FOOT SWITCH (FUNCTION ENABLE SWITCH) POWER BATTERY VOLTAGE
5 PLATFORM ROTATE LEFT ME DIGITAL OUTPUT
6 PLATFORM ROTATE RIGHT ME DIGITAL OUTPUT
7 SOFTTOUCH LIMIT SWITCH POWER BATTERY VOLTAGE
8 FOOT SWITCH SIGNAL DIGITAL INPUT
9 GENERATOR ON SIGNAL DIGITAL INPUT
10 +7 REFERENCE VOLTAGE +7 REFERENCE VOLTAGE
J7 BLACK
11 SPARE PIN +5V REFERENCE VOLTAGE
12 SPARE PIN +5V REFERENCE VOLTAGE
13 SPARE PIN ANALOG INPUT
14 GROUND RETURN GROUND
15 PLATFORM LEVEL UP HS DIGITAL OUTPUT
16 PLATFORM LEVEL DOWN HS DIGITAL OUTPUT
17 JIB BLOCK LIMIT SWITCH HS DIGITAL INPUT
18 SOFT TOUCH LIMIT SWITCH HS DIGITAL INPUT
19 PLATFORM ALARM LAMP OUTPUT
20 ALARM RETURN GROUND
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JLG Control System

21 SPARE PIN GROUND (PTC)0.2 A
22 SPARE PIN GROUND (PTC)0.2 A
24 SPARE PIN DIGITAL OUTPUT
25 JIB UP ME DIGITAL OUTPUT
26 JIB DOWN ME DIGITAL OUTPUT
27 JIB RIGHT ME DIGITAL OUTPUT
28 JIB LEFT ME DIGITAL OUTPUT
29 GROUND RETURN GROUND
30 CAN LOW CAN LOW
31 CAN HIGH CAN HIGH
32 CAN SHIELD CAN SHIELD
33 SPARE PIN GROUND (PTC) 0.2 A
34 SPARE PIN GROUND (PTC) 0.2 A
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JLG Control System
Figure 242. Ground Control Module
Connector Pin Function Type
THROTTLE ACTUATOR (DIESEL

1 DIGITAL OUTPUT
ONLY)
2 SPARE (LP NOT USED) DIGITAL OUTPUT
J1 (Natural) 3 TOWER BOOM LIFT POWER DIGITAL OUTPUT

4 GROUND GROUND INPUT
6 TOWER TELESCOPE ENABLE DIGITAL OUTPUT
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JLG Control System
7 SPARE (LP NOT USED) DIGITAL OUTPUT

10 IGNITION ON RELAY DIGITAL OUTPUT
11 START SOLENOID (DIESEL ONLY) DIGITAL OUTPUT
GLOW PLUG (DIESEL ONLY
12 DIGITAL OUTPUT
OPTION)
13 AUXILIARY POWER DIGITAL OUTPUT
14 COOLANT TEMP (DIESEL ONLY) ANALOG INPUT
15 OIL PRESSURE (DIESEL ONLY) ANALOG INPUT
FLY WHEEL SPEED PICKUP (DIE-
16 FREQUENCY INPUT
SEL ONLY)
18 SPARE GROUND GROUND INPUT
19 SPARE GROUND GROUND INPUT
20 TWO SPEED DIGITAL OUTPUT
MAIN LIFT PILOT PRESSURE
21 DIGITAL INPUT
SWITCH
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-232Rx SERIAL INPUT
30 ANALYZER RS-232Tx SERIAL OUTPUT
31 ANALYZER GROUND GROUND INPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT
33 GROUND SHIELD GROUND INPUT
34 SPARE DIGITAL INPUT
HYDRAULIC OIL TEMPERATURE
35 DIGITAL INPUT
SWITCH

1 SPARE VAVLE RETURN 1 GROUND INPUT
J3 (Black)
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JLG Control System

7 VBAT VBAT OUTPUT
SPARE HS DIGITAL IN (FREQ.
8 DIGITAL INPUT
CAPABLE)
9 ALTERNATOR EXCITATION INPUT DIGITAL INPUT
SPARE HS SWITCH INPUT (MOD-
10 DIGITAL INPUT
EL INPUT FOR 1100S)
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
1 FREQUENCY INPUT 2 FREQUENCY INPUT

2 FREQUENCY INPUT 2 RETURN FREQUENCY INPUT
3 CAN 2 H SERIAL I/O
4 CAN 2 L SERIAL I/O
J12 (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

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
J2 (Gray) 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
NOT CONNECTEDRS232 BACKUP
15 DIGITAL OUTPUT
COMM. ENABLE
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JLG Control System

16 UPPER TELESCOPE OUT DIGITAL OUTPUT
18 SPARE PIN GROUND INPUT
19 LIFT FLOW CONTROL DIGITAL OUTPUT
20 SPARE OUTPUT DIGITAL OUTPUT
MAIN BOOM ANGLE SENSOR#2
21 DIGITAL OUTPUT
POWER
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 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
J4 (Blue)
9 JIB LEFT DIGITAL INPUT
10 TOWER UP DIGITAL INPUT
MAIN TOWER TRANSPORT ANGLE
11 DIGITAL INPUT
OPEN
12 HOUR METER DIGITAL OUTPUT
13 BCS CALIBRATED LAMP DIGITAL OUTPUT
14 OVERLOAD LAMP DIGITAL OUTPUT
15 SPARE DIGITAL OUTPUT
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JLG Control System

16 AUXILIARY POWER DIGITAL INPUT
17 BASKET LEVEL UP DIGITAL INPUT
18 BASKET ROTATE RIGHT DIGITAL INPUT
19 JIB UP DIGITAL INPUT
20 JIB RIGHT DIGITAL INPUT
21 TOWER DOWN DIGITAL INPUT
MAIN BOOM TRANSPORT ANGLE
22 DIGITAL INPUT
CLOSED
23 UPPER LIFT UP DIGITAL INPUT
24 V BAT VBAT OUTPUT
26 NO CHARGE LAMP DIGITAL OUTPUT
27 1000#CAPACITY LAMP DIGITAL OUTPUT
ENGINE HIGH TEMPERATURE
28 DIGITAL OUTPUT
LENGTH
ENGINE LOW OIL PRESSURE
29 DIGITAL OUTPUT
LAMP
30 UPPER TELESCOPE OUT DIGITAL INPUT
33 UPPER LIFT DOWN DIGITAL INPUT
34 SWING LEFT DIGITAL INPUT
35 SWING RIGHT DIGITAL INPUT

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
J7 (Black) 8 SPARE ANALOG INPUT 2 ANALOG INPUT
11 BOOM RETRACTED CLOSED DIGITAL INPUT
12 BROKEN CABLE SWITCH INPUT
13 CAN HI SERIAL I/O
GROUND MODE OUT TO
14 DIGITAL INPUT
PLATFORM
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JLG Control System

15 FOOT SWITCH ENGAGE DIGITAL INPUT
17 CAN TERMINATION TERM I/O
18 CAN SHEILD GROUND INPUT
20 SPARE ANA LOG INPUT 1 ANALOG INPUT
21 PUSH TO TEST DIGITAL INPUT
TOWER BOOM TRANSPORT
22 DIGITAL INPUT
ANGLE
23 GROUND CONTROL ENABLE DIGITAL INPUT
24 CAN LO SERIAL I/O
GROUND (RESERVED FOR CRIB-
28 GROUND INPUT
BING OPTION)
V BAT(RESERVED FOR CRIBBING
33 VBAT OUTPUT
OPTION)
34 CLEARSKY POWER(VBAT) VBAT OUTPUT
35 BOOM RETRACT OPEN DIGITAL INPUT

1 GROUND FROM BATTERY GROUND INPUT
2 GROUND EMS GROUND INPUT
J8 (Black)
3 GROUND TO PLATFORM GROUND OUTPUT
4 GROUND EMS OUT TO PLATFORM GROUND OUTPUT
1 CAN HIGH CH3 SERIAL I/O

2 CAN LOW CH3 SERIAL I/O
3 CAN CH3 TERMINATOR TERM I/O
4 CAN CH3 TERMINATOR TERM I/O
J14 (Gray)
7 LS DIGITAL INPUT 7 DIGITAL INPUT
8 HS DIGITAL INPUT 29 DIGITAL INPUT
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JLG Control System

9 TILT SENSOR #2 POWER DIGITAL OUTPUT
10 ME DIGITAL OUTPUT 20 DIGITAL OUTPUT
CURRENT LIMITED VBAT (200
11 VBAT OUTPUT
mA)
13 CAN HIGH CH1 SERIAL I/O
17 CAN LOW CH1 SERIAL I/O
Figure 243. BLAM Controller
Function
Connector Pin Type
1100/1200/1350 1250 1500
1 PowerFeedThrutoJ2-1 PowerFeedThrutoJ2-1 PowerFeedThrutoJ2-1 Power I/O
J1(Grey)
3 SignalFeedThrutoJ2-4 SignalFeedThrutoJ2-4 SignalFeedThrutoJ2-4 Digital Input
4 Master Ground Connect Master Ground Connect Master Ground Connect Power Input
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JLG Control System
Function
Connector Pin Type
1100/1200/1350 1250 1500
5 Master Ignition Connect Master Ignition Connect Master Ignition Connect Power Input
6 CAN bus High CAN bus High CAN bus High Serial I/O
7 CAN bus Low CAN bus Low CAN bus Low Serial I/O
8 CAN bus Shield CAN bus Shield CAN bus Shield Serial I/O
9 CAN bus Terminator CAN bus Terminator CAN bus Terminator Serial I/O
10 CAN bus Terminator CAN bus Terminator CAN bus Terminator Serial I/O
11 Ignition Ignition Ignition Power Output
12 Ground Ground Ground Power Output

4 Spare Input Load Pin Push toTest Spare Input Digital Input
5 Spare Input Platform Rotate Right Spare Input Digital Input
6 Spare Input Platform Rotate Left Spare Input Digital Input

J2(Black)
7 Spare Input Spare Input Spare Input Digital Input
8 MainBoomAng1(Gravity) TowerBoomAng1(Gravity) MainBoomAng1(Gravity) Digital Input
9 MainBoomAng2(Gravity) TowerBoomAng2(Gravity) MainBoomAng2(Gravity) Digital Input
10 Spare Analog Input Spare Analog Spare Analog Analog Input
11 Right Drive Pump Forward Right Drive Pump Forward Right Drive Pump Forward Digital Output
12 Right Drive Pump Reverse Right Drive Pump Reverse Right Drive Pump Reverse Digital Output
1 +5VAnalogReference +5VAnalogReference +5VAnalogReference Power Output
2 RefVoltagefromJ3-1 RefVoltagefromJ3-1 RefVoltagefromJ3-1 Analog Input
5 Spare Analog Input Tower Boom Cylinder Angle MainCylAngle#1(Absolute) Analog Input

J3(Green)
8 Boom Length Sensor TowerBoomLengthSnsr#1 Boom Length Sensor Analog Input
11 Spare Analog Input TowerBoomLengthSnsr#2 MainCylAngle#2(Absolute) Analog Input
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6.4 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER
1. Connect the cable supplied with the analyzer, to the controller module located in the platform box or at the controller module in
the ground control box 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 key to the platform or ground position and pulling both emergency stop buttons on.
6.5 USING THE ANALYZER
With the machine power on and the analyzer connected properly, the analyzer will display the following:
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you can move between the top level menu items. To select a displayed menu item,
press ENTER.. To cancel a selected menu item, press ESC.; then you will be able to scroll using the right and left arrow keys to select a
different menu item.
The top level menus are as follows:
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)
If you press ENTER, at the HELP: PRESS ENTER display, and a fault is present, the analyzer display will scroll the fault across the screen. If
there was no fault detected, the display will read: HELP: EVERYTHING OK If powered up at the ground station, the display will read:
GROUND OK.
If ENTER is pressed again, the display moves to the following display:
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JLG Control System
LOGGED HELP 1:
POWER CYCLE (0/0)
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 ESC two
times. POWER CYCLE (0/0) indicates a power up.
When a top level menu is selected, a new set of menu items may be offered: for example:
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu. In some cases,
such as DRIVE,, the next level is the parameter or information to be changed. Refer to the flow chart for what menus are available within
the top level menus. You may only view the personality settings for selected menus while in access level 2. Remember, you may always
cancel a selected menu item by pressing the ESC key.
6.6 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:
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JLG Control System
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of the password, 3.
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 second digit of the password which is 33271.
Continue using the arrow keys until all the remaining digits of the password is shown.
Once the correct password is displayed, press . ENTER. The access level should display the following, if the password was entered
correctly:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.
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6.7 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER
Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for
example:
PERSONALITIES:
DRIVE ACCEL 1.0s
There will be a minimum and maximum for the value to ensure efficient operation. The Value will not increase if the arrow is pressed
when at the maximum value nor will the value decrease if the arrow is pressed and the value is at the minimum value for any particular
personality. If the value does not change when pressing the up and down arrows, check the access level to ensure you are at access level
1.
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JLG Control System
6.8 MACHINE SETUP
When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example:
GROUND ALARM:
2 = LIFT DOWN
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 lifting down. 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 Table — Personality Ranges/Defaults, page 602, and in this Service Manual for the recommended factory settings.
Note: Password 33271 will give you access to level 1, which will permit you to change all machine personality settings.
There is a setting that JLG strongly recommends that you do not change. This setting is so noted below:
ELEVATION CUTBACK
NOTICE
Changing this setting may adversely affect the performance of your machine.
Note: Select Market as CE for UKCA specification machine on Analyzer.
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Table 72. Machine Configuration Programming Information - Version P7.37

Configuration Digit Number Description Default Number
Note: The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number
of the machine configuration will cause the personality settings to return to default values.
MODEL NUMBER: 1 1200S 1

1 2 1350S
ENVELOPE HEIGHT: 1 1350S: 135' MAX

2 2 1350S: 125' MAX
3 1350S: 120' MAX
4 1350S: 110' MAX
5 1200S: 120' MAX 5
6 1200S: 110' 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
6 GB
ENGINE: DEUTZ F4 TIER1: Deutz BF4M1011 Diesel

1
(Tier 1)
4 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel
2
(Tier 2)
3 DEUTZ ECM: Engine Control Module 3
4 CAT ECM: Engine Control Module
DEUTZ ECM T4F: Engine Control Module

5
(Tier 4 Final)
DZTCD29 E5 X-55: Engine Control Module
6 (Stage V)
GLOW PLUG: NO GLOW PLUGS: No glow plugs

0
installed.
5* AIR INTAKE: Glow plugs installed in the
1
air intake on the manifold.
IN-CYLINDER: Glow plugs installed in 2
2 each cylinder.
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Table 72. Machine Configuration Programming Information - Version P7.37 (continued)

* Only visible when certain Engine Setup are selected.
STARTER LOCKOUT: DISABLED: Automatic pre-glow time 0

6* determined by ambient air
0 temperature; engine start can be
attempted at any time during pre-
glow.
ENABLED: Automatic pre-glow time

determined by ambient air temperature;
1 engine start is NOT permitted until pre-
glow is finished.
* Only visible when certain Engine Setup and Glow Plug options are selected.
ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown.

7* ENABLED: Shutdown engine when 1
coolant temperature is greater than
1
110 deg. C or the oil pressure is less
than 8 PSI.
* Only visible when Engine Setup is DEUTZ F4 Tier 1 or Tier 2.
FUEL CUTOUT: RESTART: Engine allowed to be 0

8* 0 restarted multiple times when very
low fuel level is reached
ONE RESTART: Engine allowed to be
1 restarted once for 2 minutes when very
low fuel level is reached.
ENGINE STOP: Engine not able to restart
2 when very low fuel level is reached.
* This menu item is only visible if non dual fuel engines are selected.
CHASSIS TILT: 5 DEGREES + DRV CUT: Reduces the 0

9 maximum speed of all boom
0 functions to creep when tilted more
than 5 degrees and above elevation;
also cuts out drive
4 DEGREES + DRV CUT: Reduces the
maximum speed of all boom functions to
1
creep when tilted more than 4 degrees
and above elevation; also cuts out drive
3 DEGREES + DRV CUT: Reduces the
maximum speed of all boom functions to
2
creep when tilted more than 3 degrees
and above elevation; also cuts out drive
5 DEGREES + CUT: Reduces the maximum
speed of all boom functions to creep
3
when tilted more than 5 degrees and
above elevation; also disallows tower lift
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up, tower telescope out, drive, main
telescope out and main lift up.
4 above elevation; also disallows tower lift
5 above elevation; also disallows tower lift
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.

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

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

12 1 4WD drive mode enabled. 1
SOFT TOUCH: 0 NO: Soft touch is disabled. 0

13 1 YES: Soft Touch is enabled.
SKYGUARD OPTION: 0 No SkyGuard is disabled.

14 BAR/SKYLINE: SkyGuard Bar or 1
1 SkyLine installed and enabled
2 SKYEYE - SkyEye installed and enabled
GEN SET/WELDER: 0 NO: No generator installed.

15 1 BELT DRIVE: Belt driven setup. 1
HYDRAULIC DRIVE: Hydraulic driven

2 setup.
GEN SET CUTOUT: MOTION ENABLED: Motion enabled 0

0 when generator is ON.
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16* MOTION CUTOUT: Motion cutout in
1 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

17 1 YES: Head and tail lights installed.
LOAD SYSTEM: CUTOUT PLATFORM: All functions 0

0 cutout, overload lamp lit, platform
alarm beeps (5 sec ON, 2 sec OFF).
18* CUTOUT ALL: All functions cutout, flash
1 overload light, platform alarm beeps (5
sec ON, 2 sec OFF)
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
LOAD TYPE: NON CAN LSS: Non CAN based LSS

0
installed
19 1 CAN LSS: CAN based LSS is installed. 1
FUNCTION CUTOUT: 0 NO: No drive cutout. 0

20* BOOM CUTOUT: Boom function cutout
1 while driving above elevation.
DRIVE CUTOUT: Drive cutout above

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

21* DRIVE: Travel alarm sounds when the
1
drive function is active.
DESCENT: Descent alarm sounds when lift
2
down is active.
MOTION: Motion alarm sounds when 3
3 any function is active.
* Certain market selections will alter default setting.
FLYWHEEL TEETH: 110 TEETH - The engine is configured 0

0 to calculate speed using 110 teeth
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22* 133 TEETH - The engine is configured to
1 calculate speed using 133 teeth
112 TEETH - The engine is configured to

2 calculate speed using 112 teeth.
* Only visible when Engine Setup is DEUTZ F4 Tier 1 or Tier 2.
OSCILLATING AXLE: 0 NO: No oscillating axle system installed.

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

24* 1 METRIC: DEG C, KPA, KGS.
* Certain market selections will alter default setting.
LEVELING MODE: 0 LIFT: Platform leveling during lift only.

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

0
installed.
26 1 YES: ClearSky Telematics system installed
FUEL TANK: 0 31 Gallon Fuel Tank 0

27 1 52 Gallon Fuel Tank
2 45 Gallon Fuel Tank
ALERT BEACON: 0 OFF FOR CREEP 0

28 1 20FPS FOR CREEP
TEMP CUTOUT: 0 NO: Temp Cutout is Disabled 0
29* 1 YES: Temp Cutout is Enabled

PLAT LVL OVR CUT: NO: Platform Level Override will 0

0 always be functional
30 YES: Platform Level Override will only be
1 functional when In Transport
CRIBBING: 0 NO: Cribbing Option is disabled. 0
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31* 1 YES: Cribbing Option is enabled.
WATER IN FUEL SENSOR: NO: The Water In Fuel Sensor option 0

0
is not installed.
32* YES: The Water in Fuel Sensor option is
1
installed.
ALARM/HORN: COMBINED: The horn and alarm is one

0
device installed
33* SEPARATE: The horn and alarm are 1
1 two separate devices installed
TWR/BM STOW IND: NONE: The Tower/Boom Stow 0

0
indicator is not installed
34* PLUG-IN IND: A peripheral indicator has
1
been installed
* Only visible under certain model number selections.
GROUND DISPLAY: 0 NO: No ground display is installed 0
35 1 MDI: The round MDI display is installed
MONO LCD DISP: The square ground

2 display is installed
1001246973-C
Table 73. Machine Configuration Programming Settings 1200SJP - Version P7.37
1200SJP ANSI USA ANSI Export CSA CE Australia Japan GB

Model Number 1 1 1 1 1 1 1
Envelope Height 5 5 5 5 5 5 5
Market 0 1 2 3 4 5 6
Engine 3 3 3 3 3 3 3
Glow Plug 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Starter Lockout 0 0 0 0 0 0 0
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Table 73. Machine Configuration Programming Settings 1200SJP - Version P7.37 (continued)

1 1 1 1 1 1 1
Engine Shutdown 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Fuel Cutout 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Chassis Tilt 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3
4 4 4 4 4 4 4
5 5 5 5 5 5 5
Jib 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
4 Wheel Steer 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Drive Type 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Soft Touch 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Skyguard Option 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Gen Set / Welder 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Gen Set Cutout 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Head & Tail lights 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Load System 0 0 0 X 0 0 X
1 1 1 1 X 1 1
Load Type 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Function Cutout 0 0 0 0 0 0 0
X 1 1 1 1 1 1
X 2 2 X 2 2 X
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X 3 3 X 3 3 X
Ground Alarm 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3
Flywheel Teeth 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Oscillating Axle 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Display Units 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Leveling Mode 0 0 0 0 0 0 0
1 1 1 1 1 1 1
ClearSky 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Fuel Tank 0 0 0 0 0 0 0
1 1 1 1 1 1 1
X X X X X X X
Alert Beacon 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Temperature 0 0 0 0 0 0 0
Cutout
X 1 X 1 X X 1
Platform Level 0 0 0 0 0 0 0
Over Cutout
1 1 1 1 1 1 1
Cribbing 0 0 0 0 0 0 0
1 1 1 X X 1 1
Water In Fuel 0 0 0 0 0 0 0
Sensor
1 1 1 1 1 1 1
Alarm/Horn X X X X X X X
1 1 1 1 1 1 1
TWR/BM Stow Ind 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Ground Display 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Note: BOLD BLUE text indicates the default setting. Plain text indicates another available selection. SHADED CELLS indicate hidden menu or selection.
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1001246973-C
Table 74. Machine Configuration Programming Settings 1350SJP - Version P7.37

Model Number 3 3 3 3 3 3 3
Envelope Height 1 1 1 1 1 1 1
Market 0 1 2 3 4 5 6
Engine 3 3 3 3 3 3 3
Glow Plug 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Starter Lockout 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Engine Shutdown 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Fuel Cutout 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Chassis Tilt 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3
4 4 4 4 4 4 4
5 5 5 5 5 5 5
Jib 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
4 Wheel Steer 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Drive Type 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Soft Touch 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Skyguard Option 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Gen Set / Welder 0 0 0 0 0 0 0
1 1 1 1 1 1 1
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2 2 2 2 2 2 2
Gen Set Cutout 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Head & Taillights 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Load System 0 0 0 X 0 0 X
1 1 1 1 X 1 1
Load Type 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Function Cutout 0 0 0 0 0 0 0
X 1 1 1 1 1 1
X 2 2 X 2 2 X
X 3 3 X 3 3 X
Ground Alarm 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3
Fly Wheel Teeth 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Oscillating Axle 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Display Units 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Leveling Mode 0 0 0 0 0 0 0
1 1 1 1 1 1 1
ClearSky 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Fuel Tank 0 0 0 0 0 0 0
1 1 1 1 1 1 1
X X X X X X X
Alert Beacon 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Temperature 0 0 0 0 0 0 0
Cutout
X 1 X 1 X X 1
Platform Level 0 0 0 0 0 0 0
Over Cutout
1 1 1 1 1 1 1
Cribbing 0 0 0 0 0 0 0
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1 1 1 X X 1 1
Water In Fuel 0 0 0 0 0 0 0
Sensor
1 1 1 1 1 1 1
Alarm/Horn X X X X X X X
1 1 1 1 1 1 1
TWR/BM Stow Ind 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Ground Display 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Note: BOLD BLUE text indicates the default setting. Plain text indicates another available selection. SHADED CELLS indicate hidden menu or selection.
1001246973-C
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JLG Control System
6.9 MACHINE PERSONALITY SETTINGS/FUNCTION SPEEDS
Note: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance.
Table 75. Personality Ranges/Defaults

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

speedNOTE: used when creep switch on pump pot
is active
CREEP DOWN XX% Displays/adjusts maximum main lift down 0 to 75% 45 45
speedNOTE: used when creep switch on pump pot
is active
SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0 2.0
DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5 1.5
MIN LEFT XX% Displays/adjusts minimum swing left speed 0 to 50% 40 40
MAX LEFT XXX% Displays/adjusts maximum swing left speed 0 to 100% 65 65 115-125 115-
125
MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 40 40
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Table 75. Personality Ranges/Defaults (continued)

TIME RANGE (SEC)
(REFER TO SECTION
SPEEDS)
1200 1350 1200S 1350S
MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 100% 65 65 115-125 115-
125
CREEP LEFT XX% Displays/adjusts maximum swing left speedNOTE: 0 to 65% 50 50
used when creep switch on pump pot is active
CREEP RIGHT XX% Displays/adjusts maximum swing right speedNOTE: 0 to 65% 50 50
used when creep switch on pump pot is active
MAIN ACCEL X.Xs Displays/adjusts main telescope acceleration 0.1 to 5.0 sec 1.5 1.5
TELESCOPE:
DECEL X.Xs Displays/adjusts main telescope deceleration 0.1 to 3.0 sec 1.0 1.0
MIN IN XX% Displays/adjusts minimum main telescope in 0 to 65% 15 15

speed. Same as Creep speed
MAX IN XXX% Displays/adjusts maximum main telescope in 0 to 100% 65 65 58-68 65-75
speed
MIN OUT XX% Displays/adjusts minimum main telescope out 0 to 65% 15 15
MAX OUT XXX% Displays/adjusts maximum main telescope out 0 to 100% 60 60 45-55 50-60
speed
BASKET LEVEL: ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts basket level deceleration 0.1 to 3.0 sec 0.5 0.5
MIN UP XX% Displays/adjusts minimum basket level up speed. 0 to 65% 40 40

Same as Creep speed
MAX UP XXX% Displays/adjusts maximum basket level up speed 0 to 100% 70 70
MIN DOWN XX% Displays/adjusts minimum basket level down 0 to 65% 40 40

MAX DOWN XXX% Displays/adjusts maximum basket level down 0 to 100% 70 70
speed
BASKET ROTATE: ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1.0 1.0
DECEL X.Xs Displays/adjusts basket rotate deceleration 0.1 to 3.0 sec 0.5 0.5
MIN LEFT XX% Displays/adjusts minimum basket rotate left 0 to 100% 60 60

MAX LEFT XXX% Displays/adjusts maximum basket rotate left speed 0 to 100% 60 60 24-30 24-30
(180°) (180°)
MIN RIGHT XX% Displays/adjusts minimum basket rotate right 0 to 100% 60 60
MAX RIGHT XXX% Displays/adjusts maximum basket rotate right 0 to 100% 60 60 24-30 24-30
speed (180°) (180°)
JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5 1.5
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Table 75. Personality Ranges/Defaults (continued)

TIME RANGE (SEC)
(REFER TO SECTION
SPEEDS)
1200 1350 1200S 1350S
DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1.0 1.0
MIN UP XX% Displays/adjusts minimum jib up speed. Same as 0 to 65% 40 40

Creep speed
MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 65 65 30-36 30-36
MIN DOWN XX% Displays/adjusts minimum jib down speed. Same 0 to 65% 40 40
as Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 60 60 30-36 30-36
JIB SWING: ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5 0.5
MIN LEFT XX% Displays/adjusts minimum jib left speed. Same as 0 to 65% 40 40
Creep speed
MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 70 60-68 60-68
(180°) (180°)
MIN RIGHT XX% Displays/adjusts minimum jib right speed. Same as 0 to 65% 40 40
Creep speed
MAX RIGHT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 70 60-68 60-68
(180°) (180°)
GROUND MODE: U. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 100% 60 60
U. LIFT DN XXX% Displays/adjusts main lift down speed 0 to 100% 60 60
SWING XXX% Displays/adjusts fixed swing speed 0 to 100% 60 60
BASKET LVL XXX% Displays/adjusts fixed basket level speed 0 to 100% 75 75
BASKET ROT XXX% Displays/adjusts fixed basket rotate speed 0 to 100% 75 75
MAIN TELE XXX% Displays/adjusts fixed main telescope speed 0 to 100% 60 60
TOWER TELE XXX% Displays/adjusts fixed tower telescope speedNot 0 to 100% 100 100
displayed if TOWER TELE=NO
T. LIFT UP XXX% Displays/adjusts fixed tower lift up speedNot 0 to 100% 100 100
displayed if TOWER LIFT=NO
T. LIFT DN XXX% Displays/adjusts fixed tower lift down speedNot 0 to 100% 100 100
displayed if TOWER LIFT=NO
JIB (U/D) XXX% Displays/adjusts jib lift speedNot displayed if JIB = 0 to 100% 60 60
0
JIB (L/R) XXX% Displays/adjusts jib swing speedDisplayed if JIB = 0 to 100% 70 70
2
GEN SET/ ENGINE XXXX RPM Control generator/welder RPM. Not displayed if 1200-2800 1800 1800
WELDER: GEN SET/WELDER = 0
4150453-H
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6.10 MACHINE ORIENTATION WHEN SETTING FUNCTION SPEEDS
Lift Up: From platform control, lowest elevation up to maximum elevation, boom retracted.
Lift Down: From platform control, maximum elevation down to minimum elevation, boom retracted.
Swing Right (Max): 360 Degrees, from platform control, boom approximately 45° elevation, boom retracted.
Swing Left (Max): 360 Degrees, from platform control, boom approximately 45° elevation, boom retracted.
Telescope Out: From platform control, boom horizontal, 500 lb (230 kg) capacity selected.
Telescope In: From platform control, boom horizontal, 500 lb (230 kg) capacity selected.
Drive Forward (Max): Test should be done on a smooth level surface. High Speed - Low Torque setting, drive 200 ft. (61 m) front wheels
to front wheels. Timed after machine has obtained maximum speed.
Drive Reverse (Max): Test should be done on a smooth level surface. High Speed - Low Torque setting, drive 200 ft. (61 m) front wheels
to front wheels. Timed after machine has obtained maximum speed.
Drive Forward (Creep Max): Test should be done on a smooth level surface. High Torque - Low Speed setting, platform speed knob at
full creep.
Drive Reverse (Creep Max): Test should be done on a smooth level surface. High Torque - Low Speed setting, platform speed knob at
full creep.
Drive Forward (Elevated Max - Boom Beyond Transport): Test should be done on a smooth level surface. High speed - Low Torque
setting, platform speed knob out of creep, Lift boom above transport, drive forward 50 ft. (15.2 m).
Drive Reverse (Elevated Max - Boom Beyond Transport): Test should be done on a smooth level surface. High speed - Low Torque
setting, platform speed knob out of creep, Lift boom above transport, drive forward 50 ft. (15.2 m).
6.10.1 Test Notes

1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.
2. Stop watch should be started when the function is activated.
3. Unless noted, all speed tests are run from the platform. These speeds do not reflect the ground control operation.
4. The platform speed knob control must be at full speed (turned clockwise completely).
5. Function speeds may vary due to cold, thick hydraulic oil. Test should be run with the oil temperature above 100°F (38°C).
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6.11 SYSTEM TEST
The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the
following procedures.
6.11.1 Test from the Platform

1. Position the Platform/Ground select switch to the Platform position.
2. Plug the analyzer into the connector at the base of the platform control box.
3. Before proceeding, ensure that the switches on the platform 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.
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4. Pull out the Emergency Stop switch but do not start the engine.
5. The analyzer screen should read:
6. Use the arrow button to reach SYSTEM TEST. Hit Enter. The analyzer will prompt you asking if you want to activate the system test;
hit Enter again to activate.
7. Follow the flow path in Figure , System Test Flow Chart - Platform Tests and go through the component tests. Hit the ESC key
during any part of the test to return to the main menu without completing all tests or wait until all tests are complete. During the
TEST ALL INPUTS sequence, the analyzer allows control switches to be operated and shows if they are closed (CL) or open (OP).
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Figure 244. System Test Flow Chart - Platform Tests
6.11.2 Test from the Ground Station

1. Position the Platform/Ground select switch to the Ground position.
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2. Plug the analyzer into the connector inside the Ground control box.
3. Pull out the Emergency Stop switch but do not start the engine.
5. Use the arrow button to reach SYSTEM TEST. Hit Enter. The analyzer will prompt you asking if you want to activate the system test;
hit Enter again to activate.
6. Follow the flow path in Figure — System Test Flow Chart - Ground Station Tests, page 610 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).
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Figure 245. System Test Flow Chart - Ground Station Tests
Table 76. System Test Messages

Message Displayed
on Analyzer Message Displayed on Analyzer Description
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.
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Table 76. System Test Messages (continued)

Message Displayed
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 wiring.
CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “normal”
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
confirmation 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
confirmation 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.
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=
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Table 76. System Test Messages (continued)

Message Displayed
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 RUNSYSTEMTEST Analyzer menu.
Table 77. Machine Diagnostics Parameters

Diagnostics Sub-
menu(Displayed Parameter (Displayed Parameter Value(Displayed on
Description
on Analyzer 1st on Analyzer 2nd Line) Analyzer 2ndLine)
Line)
DRIVE:
DRIVE FOR/REV XXX% Displays drive joystick direction & demand
STEER RIGHT/LEFT XXX% Displays steer switch direction & demand
4WS NORMAL/COOR/CRAB Displays status of four wheel steer input (Displayed if 4WS = 1)
BRAKES LOCKED/RELEASED Displays brake control system status
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
CRP MODE ACTIVE/NOT ACT Displays creep mode status
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE = 1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE = 1)
TWO SPEED OP/CL Displays status of two speed switch input if selected model has two speed.
2 speed mode ON/OFF Displays status of two speed valve if selected model has two speed
high engine OP/CL Displays status of high engine switch
LT F ANG XX.X Displays status of left front steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT F ANG XX.X Displays status of right front steer angle (Displayed if MODEL NUMBER = 7 or 8)
LT R ANG XX.X Displays status of left rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT R ANG XX.X Displays status of right rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
DOS LIM sw OP/CL Displays status of Drive Orientation System limit switch. (Displayed if MODEL NUMBER
= 7 or 8)
DOS O/R sw OP/CL Displays status of Drive Orientation Limit System override switch. (Displayed if MODEL
NUMBER = 7 or 8)
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Table 77. Machine Diagnostics Parameters (continued)

Diagnostics Sub-
Description
Line)
BOOM:
U LIFT UP/DOWN XXX% Displays main lift joystick direction & demand
SWING RIGHT/LEFT XXX% Displays swing joystick direction & demand
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK TYPE = 1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK TYPE = 1)
LEVEL UP/DOWN XXX% Displays basket level switch direction & demand. NOTE: demand is controlled by the
pump pot
ROT. RIGHT/LEFT XXX% Displays basket rotate switch direction & demand. NOTE: demand is controlled by the
pump pot
U TELE IN/OUT XXX% Displays main telescope switch direction & demand. NOTE: demand is controlled by
the pump pot
T TELE IN/OUT XXX% Displays tower telescope switch direction & demand. NOTE: demand is controlled by
the pump potNot displayed if TOWER TELE=NO (machine digit = 0)
T LIFT UP/DOWN XXX% Displays tower lift switch direction & demand. NOTE: demand is controlled by the
pump potNot displayed if TOWER LIFT=NO (machine digit = 0)
JIB UP/DOWN XXX% Displays jib lift switch direction & demand. NOTE: demand is controlled by the pump
potNot displayed if JIB = NO (machine digit = 0)
JIB RIGHT/LEFT XXX% Displays jib swing switch direction & demand. NOTE: demand is controlled by the
pump potDisplayed if JIB = SIDESWING (machine digit = 2)
JIB INLINE OP/CL Displays status of jib inline limit switch. Displayed on models equipped with the Jib
Stow System
JIB LIMIT OP/CL Displays status of jib right limit switch. Displayed on models equipped with the Jib
Stow System
JIB LIM OVRD OP/CL Displays status of jib limit override switch. Displayed on models equipped with the Jib
Stow System
PCV ON/OFF Displays status of Platform Control Valve. Displayed on models equipped with
Electronic Platform Leveling.
PUMP POT XXX% Displays pump pot demand. Not displayed if MODEL = 601 (machine digit = 4)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
ENGINE:
START ACTIVE/NOT ACTIVE Displays status of the engine start circuit
AIR FILTER OP/CL Displays measured status of air filter by-pass switch. (Not displayed if MODEL NUMBER
= 7 or 8)
BATTERY XX.XV Displays measured battery voltage
COOLANT XXXC Displays measured coolant temperature
OIL PRS LOW / OK or XXPSI Displays measured oil pressure
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Diagnostics Sub-
Description
Line)
FUEL SELECT GAS/LP Displays status of fuel select switch. (Displayed if MODEL NUMBER = 2)
AMB. TEMP XXXC Displays measured ambient air temperature
FUEL LEVEL ¼ / ½ / ¾ / FULL or LOW / OK Displays measured fuel level
XXXx rpm Engine RPM

TIME FROM REGEN XXXHRS XXXMINS Displays amount of time since last successful regeneration (standstillcleaning) reported
by the engine
REMAIN REGEN TMR NOT ACTIVE / XX MINS Displays amount of time remaining in the regeneration (standstill cleaning) cycle
reported by the engine
REGEN STATUS NOT ACTIVE / ACTIVE / REGEN Displays the status of the regeneration process reported by the engine
REQUIRED
REGEN REQUEST NONE / CRYSTALLIZATION Displays the cause of regeneration (standstill cleaning) request the engine is requiring
/MAINTENANCE / HEAT MODE 2 FLT
/HIGH SOOT LOAD
SOOT LOAD XXX% Displays the amount of soot load in the DPF filter reported by the engine
ASH LOAD XXX% Displays the amount of ash load in the DPF filter reported by the engine
SYSTEM:
GM BATTERY XX.XV Ground module battery voltage
PM BATTERY XX.XV Platform module battery voltage
AMB. TEMP XXXC Ambient temperature

FSW1 OP/CL Displays footswitch status. NOTE: FSW1 is wired to the ground module.
FSW2 OP/CL Displays footswitch status. NOTE: FSW2 is wired to the platform module.
ABOVE ELEV. OP/CL/YES/NO Displays above elevation cutout switch status or above angle status
LEN SW 1 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL NUMBER =
7 or 8)
LEN SW 2 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL NUMBER =
7 or 8)
RETRACTED YES/NO Displays status of boom length retracted (Displayed if MODEL NUMBER = 7 or 8)
TRANSPORT YES/NO Displays status of transport position
U LIFT CUTOUT OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL NUMBER =
6)
T LIFT PROX OP/CL Displays status of tower lift proximity switch (Displayed if TOWER PROX SWITCHES =
1)
T TELE PROX OP/CL Displays status of tower telescope proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
BR CABLE CUT. OP/CL Displays status of broken cable switch (Displayed if BROKEN CABLE SWITCH = 1)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status. Not displayed if MODEL = 601 (machine digit
= 4)
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Diagnostics Sub-
Description
Line)
SUPER CREEP ON/OFF Displays super creep mode status (Displayed if MODEL NUMBER = 7 or 8)
TILT XX.X DEG Displays measured vehicle tilt. (Displayed if internal tilt sensor is configured)
LO TILTED - NO/YES Displays status of lo tilt input. (Displayed if external tilt sensor is configured)
HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is configured)
AUX POWER OP/CL Displays the status of the auxiliary power switch input
HORN OP/CL Displays the status of the horn input

R FILTER OP/CL Displays the status of the return hydraulic filter by-pass switch. Displayed ONLY if
MODEL = 600 (Configuration digit = 3)
C FILTER OP/CL Displays measured status of charge pump filter bypass switch. Displayed ONLY if
MODEL = 600 (Configuration digit = 3)
JIB BLOCK OP/CL Displays jib block limit switch status. Not displayed if associated configuration digit =
0
BASKET STOWD YES/NO Displays status of basket stowed mode. (Displayed if MODEL NUMBER = 7 or 8)
SOFT LIMIT OP/CL Displays status of soft touch limit switch. Not displayed if associated configuration
digit = 0
SOFT O/R OP/CL Displays status of soft touch override switch. Not displayed if associated configuration
digit = 0
GEN SET/WELDER OP/CL Displays generator/welder switch input status. Not displayed if associated
configuration digit = 0
LIGHTS OP/CL Displays head and tail light switch input status. Not displayed if associated
configuration digit = 0
BSK TILT1 XX.X Displays indicated platform tilt angle. Displayed on models equipped with Electronic
Platform Leveling.
BSK TILT2 XX.X Displays indicated platform tilt angle. Displayed on models equipped with Electronic
Platform Leveling.
AXLE RET SW OP/CL Displays status of axle extension user switches. (Displayed if MODEL NUMBER = 7 or
8)
AXLE EXT SW OP/CL Displays status of axle retraction user switches. (Displayed if MODEL NUMBER = 7 or
8)
AXLE LIM SW RET/EXT Displays status of axle extension limit switches. (Displayed if MODEL NUMBER = 7 or
8)
DOS LIM SW OP/CL Displays status of Drive Orientation System Limit Switch. (Displayed if MODEL NUMBER
= 7 or 8)
DOS O/R SW OP/CL Displays status of Drive Orientation System Override switch. (Displayed if MODEL
NUMBER = 7 or 8)
CAPACITY SW 500/1000 Displays status of capacity selection switch. (Displayed if MODEL NUMBER = 7 or 8)
OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLATING AXLE =
1)
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Diagnostics Sub-
Description
Line)
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration. (Displayed
if MODEL NUMBER = 7 or 8)
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration. (Displayed if
MODEL NUMBER = 7 or 8)
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration. (Displayed
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration. (Displayed if
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration. (Displayed if
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
(Displayed if MODEL NUMBER = 7 or 8)
REGEN SW CLOSED / OPEN Displays the status of regeneration (standstill cleaning) switch input
LOAD: Not displayed if LOAD=NO, LENGTH=NO, and ANGLE=NO (machine digits = 0)
LENGTH OP /CL Displays measured length, NOTE: Not displayed if MODEL NUMBER = 7 or 8
ANGLE OP / CL Displays measured angle, NOTE: Not displayed if MODEL NUMBER = 7 or 8
WEIGHT XXXX% Percentage of maximum calibrated weight on the platform. An uncalibrated load cell
will read 1000% Displayed if LOAD is not 0 and LOAD TYPE is 0.
OK/OVERLOADED Displayed if LOAD is not 0 and LOAD TYPE is 1.
MOMENT: Displayed if MODEL NUMBER = 7 or 8
(LB-IN) ACTUAL XXXXXXXX Displays current moment value
(LB-IN)OVER XXXXXXXX Displays current over moment setpoint.
(LB-IN)UNDER XXXXXXXX Displays current under moment setpoint.
CAL PTUNDER XXXXXXXX Displays the under moment value recorded during boom sensor calibration.
CAL PTWIT YEL XXXXXXXX Displays the yellow witness mark moment value recorded during boom sensor
calibration.
CAL PTWIT GRN XXXXXXXX Displays the green witness mark moment value recorded during boom sensor
calibration.
CYL PINRATIO X.XXX Displays the current cylinder moment pin ratio of X and Y forces.
PINE FLAGS 0xXXXX Displays the current error flag status of the cylinder moment pin.
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration. (Displayed
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration. (Displayed if
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration. (Displayed
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration. (Displayed if
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Diagnostics Sub-
Description
Line)
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration. (Displayed if
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
(Displayed if MODEL NUMBER = 7 or 8)
ENVELOPE: Displayed if MODEL NUMBER = 7 or 8
LENGTH XXXX.X Displays the current indicated boom length in inches.
ANGLE 1 XX.X Displays the current indicated boom angle 1 in degrees.
ANGLE 2 XX.X Displays the current indicated boom angle 2 in degrees.
A/D LNGTH XXXXX Displays the current indicated boom length in A/D counts.
A/D ANG1 XXXXX Displays the current indicated boom angle 1 in A/D counts or raw angle if calibrated.
A/D ANG2 XXXXX Displays the current indicated boom angle 2 in A/D counts or raw angel if calibrated.
CAN STATISTICS: CAN Statistics as detected by the Ground Module
RX/SEC XXX Displays the number of received messages per second
TX/SEC XXX Displays the number of transmitted messages per second
BUS OFF XX Displays the number of bus off occurrences
PASSIVE XX Displays the number of bus passive occurrences
CALIBRATION
DATA
BASKET UP XXX Displays the basket up calibration point
BASKET DOWN XXX Displays the basket down calibration point

L FWD DRIVE XXX Displays the left forward drive calibration point
R FWD DRIVE XXX Displays the right forward drive calibration point
L REV DRIVE XXX Displays the left reverse drive calibration point
R REV DRIVE XXX Displays the right reverse drive calibration point
F LT STEER XXX Displays the forward left steer calibration point
F RT STEER XXX Displays the forward right steer calibration point
R LT STEER XXX Displays the reverse left steer calibration point
R RT STEER XXX Displays the reverse right steer calibration point
U LIFT UP XXX Displays the main lift up calibration point
U LIFT DOWN XXX Displays the main lift down calibration point
U TELE IN XXX Displays the main telescope in calibration point
U TELE OUT XXX Displays the main telescope out calibration point
BM ANG 1 LO XXX Displays the boom angle 1 low calibration point
BM ANG 1 HI XXX Displays the boom angle 1 high calibration point
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Diagnostics Sub-
Description
Line)
BM ANG 2 LO XXX Displays the boom angle 2 low calibration point
BM ANG 2 HI XXX Displays the boom angle 2 high calibration point
LEN RETRACT XXX Displays the length sensor retracted calibration point
LEN EXTEND XXXXX Displays the length sensor extended calibration point
LEN WIT XXXXX Displays the witness mark calibration point
LEN SWITCH XXXX Displays the length switch calibration point
DATALOG:
ON XXXXhXXm Displays total controller on (EMS) time
ENGINE XXXXhXXm Display engine run time
DRIVE XXXXhXXm Displays total controller drive operation time
LIFT XXXXhXXm Displays total controller lift operation time
SWING XXXXhXXm Displays total controller swing operation time
TELE XXXXhXXm Displays total controller telescope operation time

MAX TEMP XXC Displays maximum measured ambient temp.
MIN TEMP XXC Displays minimum measured ambient temp.
MAX VOLTS XX.XV Displays maximum measured battery voltage

RENTAL XXXXhXXm Displays total controller operation time. NOTE: can be reset
ERASE RENTAL? Not available at Access Level 2.ENTER resets rental data log time to zero.
VERSIONS:
GM SW PX.X Displays ground module software version
GM HW REV XXXX Displays ground module hardware revision
GM SN XXXXXX Displays ground module serial number
PM SW PX.X Displays platform module software version
PM HW REV XXXX Displays platform module hardware revision
PM SN XXXXXX Displays platform module serial number

CM SW PX.X Displays chassis module software version
BM SW PX.X Displays BLAM module software version
C PIN SW Displayed if cylinder moment load pin transmits software version.
C PIN SN Displayed if cylinder moment load pin transmits serial number.

ANALYZER VX.XXXX Displays Analyzer software version
GND LIGHT PLANEL PX.X Displays the Ground Light Panel software version
SOFTWARE:
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Diagnostics Sub-
Description
Line)
PLT LIGHT SOFTWARE: PX.X Displays the Platform Light Panel software version
GROUND DISPLAY PX.X Displays the Ground Display software version

SOFTWARE:
6.12 CALIBRATING STEER
When calibrating steering, each individual wheel must be calibrated in order to make the tire and wheel parallel with the frame. Two
methods to help ensure proper calibration are the use of a carpenter’s square to square the spindle to the axle or aligning the two
wheels on one side using a stretched string.
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3. Pull out the Emergency Stop switch and Start the engine.
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5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter.
8. Use the arrow keys to reach Steer. The screen will read:
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9. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read:
12. Activate the steer control until the tire and wheel are straight in relationship with the chassis, then leave off the control. The
display will read FRT LEFT = and show the numeric calibration value for that wheel.
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14. Repeat steps 10 thru 12 for left rear steer.
15. Left Rear Steer Calibration will be followed by Right Forward Steer Calibration which will be followed by Right Rear Steer
Calibration.
16. After completing all the Steer Calibrations, hit ESC twice to go back to CALIBRATIONS.
6.13 CALIBRATING DRIVE
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8. Use the arrow keys to reach DRIVE.
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12. Activate the Drive Joystick forward full stroke until the machine just begins to move, then leave off the joystick immediately. The
display will read CRK PT = and show the numeric crack point value.
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13. Hit Enter. The number displayed will be the value that the crack point is set to. The screen will show:
15. Repeat steps 10 thru 12 for left reverse drive.
16. Left Reverse Drive Calibration will be followed by Right Forward Drive Calibration which will be followed by Right Reverse
Calibration.
17. After completing all the Drive Calibrations, hit ESC twice to go back to CALIBRATIONS.
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6.14 LOAD SENSING SYSTEM (LSS)
6.14.1 Theory of Operation

The Platform Load Sensing System (LSS) measures platform load from a sensor in the platform support.
If the LSS senses an overload condition (platform load exceeds rated load), the overload alarm will sound and the overload indicator will
flash at both the platform control and the ground control stations.
In the overloaded condition, all normal movement is prevented from the platform control position (As an option, ground control
functions can also be prevented). To regain boom movement, actual platform load must be reduced until it is less than Rated Load (as
indicated on the capacity decal). If unable to resolve an overload condition, authorized personnel may use the emergency override
system (Auxiliary Power) to return the platform to a safe working condition.
Calibration
Calibrate the LSS when one or more of the following conditions occur:
1. Removal or replacement of LSS sensor.
2. Removal or addition of certain platform-mounted accessories. (Refer to Section — Calibration Procedures, page 628)
3. Removal, replacement, or repair of platform.
4. Platform shows evidence of impact.
Note: For detailed LSS calibration instruction refer to Section — Calibration Procedures, page 628.
NOTICE
The LSS requires periodic function verification not to exceed 6 months from pre-
vious verification. Refer to Section — LSS Testing and Evaluation, page 631.
Capacity Zones (Dual Capacity with a Capacity Select Switch)

This machine is equipped with a Dual Capacity System that allows the operator to select operation in unrestricted and restricted capacity
zones by positioning the Capacity Select switch on the platform console. The applicable capacity zone indicator will light in both the
platform control and the ground control stations based on the position of the Capacity Select switch.
When platform load is equal to or less than 500 lb (227 kg), the platform position is unrestricted within the full machine envelope
boundary. When platform load is between 500 lb (227 kg) and 1000 lb (450 kg) the platform position is restricted within a smaller
working envelope boundary.
The machine will stop at the boundary from the restricted to the unrestricted zone unless the Capacity Select switch is in the
unrestricted position. Both capacity lights will flash, and an alarm will sound if the platform is out of the selected capacity range.
Note: Operation in the 1000 lb (454 kg for ANSI markets and 450 kg for CE, UKCA, and Australia markets) envelope requires the jib to
be straight with the boom.
Capacity Limits with Accessories
Accessories mounted to the platform have an impact on the LSS capacity limit.
Accessories like SkyWelder reduce the LSS capacity limit according to their weight, and the load setting must be set to account for their
total weight. Accessories like SkyGlazier or Pipe Racks, which are attached to the platform exterior or extend (or hold materials that
extend) outside of the platform, reduce the LSS capacity limit by more than the weight of equipment. The farther the material or
equipment weight is from the center of the platform, the greater the platform’s capacity is affected and must be reduced. Platform
capacity is based on an evenly distributed load in the platform.
JLG accessories display a decal with their effective contribution (weight) toward rated load. If this decal is missing or if fitting more than
one accessory to a machine, follow the documentation furnished with factory-provided accessories or consult JLG.
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6.14.2 Diagnostic Menu

The Diagnostic Menu is another troubleshooting tool for the Load Sensing System. Sensor and status information is presented in real-
time for the technician. Several sub-menus exist to organize the data.
To access the Diagnostic Menu, use the LEFT and RIGHT Arrow keys to select DIAGNOSTICS from the Top Level Menu. Press the
ENTER key to view the menu.

Press the LEFT and RIGHT Arrow keys to view the displays and select the various sub-menus. To access a sub-menu, press the ENTER key.
Once in a sub-menu, press the LEFT and RIGHT Arrow keys to view the various displays (just like a Top Level menu). To exit a sub-menu,
press the ESC key .
Table — Diagnostic Menu Descriptions, page 628 details the structure of the Diagnostic Menu, and describes the meaning of each piece of
information presented.
Table 78. Diagnostic Menu Descriptions

Diagnostics Menu(Displayed on Ana- Parameter (Displayed on Analyzer Parameter Value(Displayed on Ana-
Description
lyzer 1st Line) 2nd Line) lyzer 2nd Line)
PLATFORM LOAD STATE: OK / OVERLOAD LSS Status.

PLATFORM LOAD ACTUAL: XXX.X KG Calibrated weight of the platform.??? if
Platform Load is Unhealthy**.
PLATFORM LOAD (service*) GROSS: XXX.X KG Gross weight of the platform.??? if both
Cells are Unhealthy**.
PLATFORM LOAD (service*) OFFSET 1: XXX.X KG Stored offset weight of Cell 1.??? if LSS is
not calibrated.
PLATFORM LOAD (service*) OFFSET 2: XXX.X KG Stored offset weight of Cell 1.??? if LSS is
not calibrated.
PLATFORM LOAD (service*) ACCESSORY XXX.X KG Stored accessory weight.??? if LSS is not
calibrated.
PLATFORM LOAD (service*) UNRESTRICT XXX.X KG UGM will set Unrestricted Rated Load as
defined by Machine Configuration.
PLATFORM LOAD (service*) RESTRICT XXX.X KG UGM will set Restricted Rated Load as
defined by Machine Configuration.
PLATFORM LOAD (service*) RAW 1: XXX.X KG Gross value from Cell 1.??? if
Unhealthy**.
PLATFORM LOAD (service*) RAW 2: XXX.X KG Gross value from Cell 2.??? if
Unhealthy**.
* Indicates only visible in service view mode
** Typically indicates a DTC is active
6.14.3 Calibration Procedure

JLG Analyzer
Calibration procedures are performed using the JLG Analyzer. For usage and functions of the JLG Analyzer refer to Section — Using the
Analyzer, page 586.
This machine incorporates a variety of sensors and a high degree of function interaction. To maintain proper machine functionality, the
calibration procedures must be repeated for any control module replacement, system calibration related fault, or removal or
replacement of any sensors, valves, coils, motors, or pumps.
Calibration Preparation
Check and execute the following to prepare for calibration and verification.
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1. Park the machine on a level surface with a slope less than or equal to 0.5 degrees.
2. Fully retract the boom and lower the platform. Ensure the platform is level within ± 5 degrees in both directions.
3. Ensure wind speed is less than or equal to 20 mph (32 kph).
4. Ensure the batteries are fully charged and hydraulic fluid level is acceptable.
5. Resolve any active control system faults.
6. Remove all foreign materials from the platform. This includes all tools, debris, and non-permanent customer-installed devices.
7. Install any JLG Accessories that will be permanently attached (Pipe Racks, SkyGlazier, etc.).
8. If using weights to calibrate, center and evenly distribute known or calibrated weight in the platform.
9. Gently shake or move the platform to settle the platform LSS components. (Generally, the technician stepping into and out of the
platform is sufficient).
Load Sensing System Calibration
Note: All calibration preparation steps must be completed prior to executing calibration procedures.
1. Using the keyswitch, select Ground Mode. LSS Calibration must be performed in Ground Mode.
2. Pull out the Emergency Stop switch and start the machine.
3. Plug the JLG Analyzer into the machine at the Ground Station. The JLG Analyzer enters Operator Access
(Level 2) by default. The Calibration Menu is not available in Operator Access.
4. Go to Service Access (Level 1) by entering password 33271 at the prompt.
5. Use the arrow keys to reach the CALIBRATIONS menu. Press Enter.
Upon entry to the Calibration Menu, the JLG Control System will link to the Analyzer.
6. Use the arrow keys to reach LOAD SENSING menu. The screen will read “CALIBRATION: LOAD SENSING”.
7. Press Enter, the screen will read “LOAD SENSING: CALIBRATE?”.
Note: Calibration will automatically fail if LSS DTC's are active (443, 444, 4479, 4480, 663, 821, 822, 823, 824, 8218, 8222 -> 8238, 991,
992, 993, 994 or 99285).
Pressing the ESC key after starting calibration and before calibration is complete will display the CAL FAILED message. This will not disturb
the prior calibration information.
8. Press Enter, the screen will read “LOAD SENSING: PLATFORM EMPTY?”.
9. Universal Ground Module (UGM) will set the Accessory Weight default value. Press Enter. The screen will read “LOAD SENSING: ACCESSORY
XXX”. (lb or kg)
Calculate the total weight of all installed accessories using the Accessory Weights Table. Use the arrow keys to enter the total additional
accessory weight at the prompt.
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EXAMPLE: The machine has the SkyCutter/SkyWelder Combo, Fire Extinguisher and Work Surface installed. The technician enters 205 lb
(93 kg) at the accessory weight prompt.
SkyCutter/SkyWelder Combo 140 lb (64 kg)

Fire Extinguisher 45 lb (20 kg)
Work Surface 20 lb (9 kg)
Total 205 lb (93 kg)
Note: Accessory weight will reset to 0 lb (0 kg) each time the machine is re-calibrated and will need to be re-entered.
Note: The Accessory weight will be temporarily stored in the Control System until calibration has been completed successfully. Refer to
Table — Accessory Weights, page 630.
Table 79. Accessory Weights

ACCESSORY WEIGHT
SkyWelder (Stick welder) 70 lb (32 kg)
Prep only = 15 lb (7 kg)

SkyWelder Prep
Full install = 70 lb (32 kg)
SkyCutter (Plasma cutter) 70 lb (32 kg)
SkyCutter / SkyWelder Combo 140 lb (64 kg)
Fire Extinguisher 45 lb (20 kg)
Overhead SoftTouch 80 lb (36 kg)
Work Surface 20 lb (9 kg)
Note: Not all Accessories are available on every JLG model. Some Accessory combinations are prohibited due to excessive weight and/or load restriction.
If any installed JLG Accessories are labeled with weight decals but are not listed in the table above, include their weight when entering the ACC WEIGHT value.
10. Press Enter, the screen will read “LOAD SENSING: CALIBRATING”.
11. UGM will set the Glazier default value. Press Enter. The screen will read “LOAD SENSING: SKY GLAZIER? X”.
Use the analyzer keys to select N for no or Y for yes.
12. UGM will set the Pipe Racks default value. Press Enter. The screen will read: “LOAD SENSING: PIPE RACKS? X”.
Use the analyzer keys to select N for no or Y for yes.
Note: If both SkyGlazier and Pipe Racks are configured, capacity will be the lower of the two values.
Table 80. SkyGlazier and Pipe Rack Capacity Reductions

SKYGLAZIER CAPACITY REDUCTIONS PIPE RACK CAPACITY REDUCTIONS
CAPACITY
PLATFORM OVRLD PLATFORM OVRLD RESTRICT PLATFORM OVRLD PLATFORM OVRLD RESTRICT
500 lb (227 kg) 400 lb (181 kg) N/A 400 lb (181 kg) N/A
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Table 80. SkyGlazier and Pipe Rack Capacity Reductions (continued)

SKYGLAZIER CAPACITY REDUCTIONS PIPE RACK CAPACITY REDUCTIONS
CAPACITY
PLATFORM OVRLD PLATFORM OVRLD RESTRICT PLATFORM OVRLD PLATFORM OVRLD RESTRICT
750 lb (340 kg) N/A 590 lb (268 kg) N/A 650 lb (295 kg)
1000 lb (454 kg) N/A 750 lb (340 kg) N/A 900 lb (408 kg)
13. UGM will set the Unrestricted Rated Load. Press Enter. The screen will read “LOAD SENSING UNRSTRICT XXXLBS”.
14. UGM will set the Restricted Rated Load. Press Enter. The screen will read “LOAD SENSING: RSTRICT XXXXLBS”.
15. After a few seconds, the screen will read “LOAD SENSING: CAL COMPLETE”.
16. Press ESC twice to return to CALIBRATIONS menu.
6.14.4 LSS Testing and Evaluation

Preparation
Refer to Section — Troubleshooting, page 633 if the Load Sensing System (LSS) fails to meet these guidelines.
1. Connect the JLG Analyzer.
2. Remove all items from the platform, except permanently fixed JLG Accessories. This includes all tools, debris, and customer-
installed devices.
3. Gently shake or move the platform to settle the platform LSS components. (Generally, the technician stepping into and out of the
platform is sufficient).
4. Level the Platform: The platform should be approximately level for accurate evaluation, or the testing, calibration and other
guidelines will not be applicable.
Level the platform from Ground Control (if necessary) to within ±5 degrees.
5. Observe Empty Platform Weight:

a. Remove all tools, debris, and customer installed devices if not already completed.
b. Proceed to the DIAGNOSTICS, FEATURES, PLATFORM LOAD sub-menu.
c. Observe and record the measured platform load.
Ideally, the PLATFORM LOAD should be zero but can vary ±15lb (± 7kg). The reading should be stable and should not vary by
more than ±2lb (±1kg) (unless there is heavy influence from wind or vibration).
Testing LSS Control System Warnings and Interlocks:
Platform Mode
1. Using the keyswitch, select Platform Mode and power-up.
2. Start the machine and ensure that all controls are functional and the Load Sensing System’s Overload Visual and Audible Warnings
are not active.
3. Simulate an Overload by unplugging the Shear Beam Load Cell. The Overload Visual Warning should flash, and the Audible
Warning (at Platform and Ground) should sound for 5 seconds On, and 2 seconds Off. With the engine running, all control should
be prevented.
4. Cycle the Platform EMS to stop the machine and then power-up again. The Overload Visual and Audible Warnings should
continue.
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5. Verify that platform controls are now responsive when using the Auxiliary Power Unit (for emergency movement).
6. Reconnect the Load Cell. The Overload Visual and Audible Warnings should cease and normal control function should return.
Ground Mode
1. Using the keyswitch, select Ground Mode and power-up.
2. Start the machine and ensure that all controls are functional and the Load Sensing System’s Overload Visual and Audible Warnings
are not active.
3. Simulate an Overload by unplugging the Shear Beam Load Cell. The Overload Visual Warning should flash, and the Audible
Warning (at Platform and Ground) should sound for 5 seconds On, and 2 seconds Off. Controls will remain functional.
Note: The Ground Mode default software settings will allow controls to remain functional when using the engine or the Auxiliary
Power Unit. (2=CUTOUT PLT software setting)
In Ground Mode, to prevent control in an Overload state during engine power:
a. Proceed to the MACHINE SETUP, LOAD SYSTEM sub-menu.
b. Using the arrow keys, set to 3=CUTOUTALL.
4. Reconnect the Load Cell. The Overload Visual and Audible Warnings should cease.
Testing LSS Control System Capacity Indication:
Note: Test only applicable to dual capacity machines equipped with a Capacity Select switch option.
1. Using the keyswitch, select Platform Mode and power-up.
2. If necessary, put the boom in the transport position (fully stowed) and center the jib (if equipped).
3. Place the Capacity Select switch in the unrestricted position and ensure that the unrestricted CAPACITY display indicates ON (but
does not flash) and the restricted CAPACITY indicates OFF.
4. Place the Capacity Select switch in the restricted position and ensure that the restricted CAPACITY display indicates ON (but does
not flash) and the unrestricted CAPACITY indicates OFF.
Testing LSS Platform Load Reading with Calibrated Weights:

This test confirms the LSS is accurately reporting platform load. An accurate empty platform weight must be observed prior to executing
this procedure.
1. From Ground Control, place the boom in the transport position (fully stowed).
2. Plug the JLG Analyzer into the control system connection and proceed to the DIAGNOSTICS, FEATURES, PLATFORM LOAD display.
3. Place calibrated weight ( Example: 500lbs [230kg] ) in the platform and ensure that PLATFORM LOAD is within ±5% of the actual
weight.
For machines with multiple capacities, repeat steps above for each alternate capacity (unrestricted or restricted zones) with weights
corresponding to the zone.
If test is not successful, the LSS should be re-calibrated. Refer to Section — Calibration Procedures, page 628.
Testing LSS Platform Load Reading with a Known Weight:
This test confirms the LSS is accurately reporting platform load when calibrated weights are not available. If other known weights are
also not available, the technician weight may be used to evaluate (as described in the procedure). An accurate empty platform weight
must be observed prior to executing this procedure.
1. From Ground Control, place the boom in the transport position (fully stowed).
2. Plug the JLG Analyzer into the control system connection and proceed to the DIAGNOSTICS, FEATURES, PLATFORM LOAD display.
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3. The technician should enter and stand in the center of the platform and record the PLATFORM LOAD reading. Ensure the
PLATFORM LOAD is within ±5% of the technician’s actual weight.
If test is not successful, the LSS should be re-calibrated. Refer to Section — Calibration Procedures, page 628.
The following tables are furnished to provide possible resolutions for common difficulties. Difficulties are classified as General,
Calibration, Measurement Performance, and Host System Functionality.
Table 81. LSS Troubleshooting Chart

Difficulty Possible Resolution
Empty Platform Weight (DIAGNOSTICS, PLATFORM LOAD) is not within ±15 lb (±7 kg) The LSS System is unable to properly measure the platform weight.
of zero.
or 1. The Load Cell is not properly plugged into the LSS Harness. It is possible poor
electrical contact is made.
Platform Load readings (DIAGNOTICS, PLTLOAD) are unstable by more than ±2 lb (±1 2. Wiring leading to the Load Cell is damaged. Carefully inspect sensor wiring where it
kg) (without the influence of vibration or wind). passes through cable clamps for signs of damage. Inspect wiring where damage to the
channel is apparent.
3. The Load Cell was not assembled properly during installation. Examine the sensor’s
reading using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL, LOAD displays and
or determine if the readings are reasonable. It is often helpful to apply slight downward
pressure above the sensor and observe that its output increases (increasing force
measurement; decreasing means the sensor is mounted upside-down).
There are large variations in Platform Load (DIAGNOSTICS, PLTLOAD) based on the 4. The Load Cell is contaminated by debris or moisture. Examine the sensor’s reading
location of the load. Tolerance to variations is 20 lb for an evaluation using the using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL, LOAD displays and
technician’s weight, and +5% of Rated Load when using calibrated weights. determine if the readings are reasonable and stable (not changing by more than ±2
lb (±1 kg) (without the influence of vibration or wind). Lack of measurement stability
is a key indication of contamination. Unplug the connector and inspect for dirt or
moisture. Look carefully into the female connector on the sensor’s cordset for evidence
of contamination. Debris should be brushed away with a soft bristle brush (do not
introduce any cleaners as they will leave conductive residue). Moisture should be
allowed to evaporate or accelerated with a heat-gun (use low heat and be carefully to
not melt connector materials). Moisture intrusion into the molded portion of the
connector (capillary action into the wire bundle) or the Shear Beam Load Cell itself
will require replacement of the sensor.
5. The Load Cell has been mechanically damaged. If the Load Cell is physically
deformed or has damage to the cover it should be replaced immediately. It is also
possible to have invisible mechanical damage resulting from an extreme overload
(>6000 lb [>2722 kg]).
The Visual and Audible Overload Warnings fail to sound when platform is loaded The Control System is failing to regard the overload signal from the LSS System, or the
beyond Rated Load, or when simulated by unplugging the Load Cell. Controls remain signal is shorted.
functional at Platform and Ground Control positions.
1. The Load Sensing System must be enabled within the Control System. Plug the JLG
Analyzer into the Control System, enter the Access Level 1 password (33271), and
examine the MACHINE SETUP, LOAD sub-menu. The selection “2=CUTOUT PLT” should
be displayed (platform controls prevented during overload, ground controls remain
operational). In country- or customer-specific circumstance, the selection “3=CUTOUT
ALL” is used (platform and ground controls prevented during overload).
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Table 81. LSS Troubleshooting Chart (continued)

Difficulty Possible Resolution
The Ground Audible Warning fails to sound, but the Platform Audible Warning sounds The Ground Alarm is missing or improperly installed. Verify that the device is
properly. mounted. Verify wiring from the Main Terminal Box and Ground Module.
Controls remain functional at the Ground Control position during an overload, or when The JLG Control System is configured to prevent platform controls only in the event of
simulated by unplugging the Load Cell. The Controls at the Platform Control position overload. Alternately, the Host Control System can be configured to prevent ground
are prevented when using the engine, but not when using the Auxiliary Power Unit. and platform controls for country- or customer-specific circumstances.Using the JLG
Analyzer, enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP,
LOAD sub-menu. Set this parameter to “2=CUTOUT PLT” to prevent platform controls
in the event of overload. Set this parameter to “3=CUTOUT ALL” to prevent platform
and ground controls in the event of overload.
6.15 RESETTING THE MSSO SYSTEM
1. Use the following procedure to reset the MSSO system.
2. Position the Platform/Ground select switch to the desired position.
3. Plug the analyzer into the connector coming from the ground control module or from the platform console.
Note: If performing the procedure from the platform console, the Emergency Stop switch on the ground console must also be
pulled out.
4. Pull out the Emergency Stop switch.
6. Use the arrow button to reach OPERATOR ACCESS. Press ENTER .
8. Use the right Arrow key to reach MENU: CALIBRATIONS. Press ENTER .
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9. Use the arrow keys to reach the LOAD SENSING menu. The screen should read:
10. Press ENTER .
11. Use the DOWN arrow to reach MSSO RESET.
12. Press ENTER . The screen will read:
13. Press ENTER . The JLG Control System will reset an active 873 DTC and the MSSO System will be reset. Press Escape to
return to the CALIBRATIONS menu.
6.16 ELECTRONIC PLATFORM LEVELING
6.16.1 Platform Leveling Fault Warning

The JLG Control System takes a snapshot of the two sensor values and records the difference once on each power up. The Control
system allows a ±5 degree difference from those values. For example, if Sensor 1 is at 5 degrees and Sensor 2 is at 11 degrees, the
difference is 6 degrees and the DTC is triggered when the sensors are 1 degree (or less) apart or 11 degrees (or more) apart.
If a fault occurs in the platform leveling system the following will occur:
1. Automatic platform leveling will stop (except when there is a fault in only one sensor automatic leveling will remain active as the
control system will use the other sensor to control leveling)
2. The level fault lamp will flash
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3. The audible alarm will sound
4. All functions will default to creep speed if the platform is out of the transport position (extended more than 12” [51 cm] 1350SJP;
24" [60.9 cm] 1200SJP, or elevated above the horizontal position).
To reset the fault the emergency stop switch should be recycled.
NOTICE
If the fault persists bring the platform to the ground position, switch the machine
off and contact a qualified service representative to investigate the fault.
6.16.2 Fault Response

ERROR RESPONSE
If basket level varies from the current by ± 5.5º for more than 1.5 seconds when the platform is not in the transport position, the
following events will occur:
1. The platform dump valve will be disabled (level, rotate and jib functions disabled).
2. The level system fault lamp will flash (to indicate that the leveling function has been lost).
3. The platform alarm will sound.
4. A system fault will be logged.
5. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the transport
position see below).
When the unit is in the transport position and driving and the current setpoint varies by ± 5.5º for more than 8 seconds the events
1,2,3 & 4 above will occur. (note function speeds will operate normally). Cycling the EMS will clear the fault and allow the operator
to operate the machine as a new level is taken.
VALVE DRIVER ERRORS

In the case of a short to ground or an open circuit, the platform valve cannot be turned on and the following will occur:
1. In the case of a , the platform valve cannot be turned on and the following will occur:
a. All interactions with platform leveling shall cease
b. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost).
c. The platform alarm will sound.
d. A system fault will be logged.
e. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the
transport position).
2. In the case of a short to battery on one of the platform leveling valves, the valve cannot be turned off and the following will
occur:
a. The platform dump valve will be turned off to prevent unintended tilting of the platform.
b. All interactions with platform leveling shall cease.
c. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost).
d. The platform alarm will sound.
e. A system fault will be logged.
f. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the
transport position)
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3. In the case of a short to battery on the platform dump valve , the valve cannot be turned off. The controllability of the platform
leveling function will be impaired and the following will occur:
a. All interactions with platform leveling shall cease.
b. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost).
c. The platform alarm will sound.
d. A system fault will be logged.
e. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the
transport position).
Lift, swing, drive and telescope will continue to operate
In each of the cases above it shall be necessary to re-cycle the EMS to clear the fault. Operable functions shall be in the creep
mode except while below elevation.
TILT SENSOR ERRORS

If the secondary tilt sensor is faulty, the control system will continue to utilize information from the primary sensor.
If the primary sensor is faulty, the control system will switch to the backup sensor for control.
In both cases above the following will occur:
1. The Electronic Leveling System Fault Lamp will flash (to indicate that there is a leveling fault).
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 measurements 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).
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 necessary to re-
cycle the EMS to clear the fault.
6.16.3 CAN Errors

The Ground Module has two direct outputs dedicated to overriding the Platform Module’s control of the leveling valves. The Ground
Module “Platform Level Up/Down” outputs are used to control the platform level up and down valves.
When in ground mode, if the Ground Module reads a platform leveling switch command, the switch command is communicated over
CAN to the Platform Module where it is handled normally.
If Ground Module determines that CAN communication is inoperable, it turns on the platform control valve and the appropriate platform
leveling override outputs while the switch is engaged.
If the Platform Module is still running when CAN is down nothing will operate when in platform mode. When the operator switches to
ground mode, the platform will not control any of its valve outputs and a CAN error message is signaled.
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6.16.4 Additional Platform and Jib Valves

The high side drivers for the platform left and right and the jib up and down valves are be located in the Platform Module and are
proportional. Flow through the valves is individually controllable. The individually controlled duty cycle will be the same as would
otherwise have been commanded to the flow control valve.
Only one platform or jib function is allowed at one time to limit the amount of current draw, minimizing the voltage drop on the supply
to the Platform Module.
The function is enabled first shall remain active until it is released. Any other function commanded while another function is active is
ignored.
6.16.5 Platform Leveling Calibration Procedure

STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
1. Put machine into “Ground Mode”.
2. Start machine and plug in Analyzer.
3. Go to the “Access Level 2” screen.
4. Enter “33271” to get into Access Level 1 mode.
5. Go to the "Personalities" menu and adjust the following personalities. Refer to the Table — Personality Ranges/Defaults, page 602 in
Section 6 - JLG Control System for proper setting values.
Basket Level Up Min
Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
6. Recycle EMS.
STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS

3. Manually level the platform with the switch on the MTB.
6. Go to the “Calibrations” menu and hit ENTER.
7. Use RIGHT ARROW go to “Plat. Leveling” screen.
8. Hit ENTER. “Calibrate?” prompt should appear.
9. Hit ENTER again to calibrate level sensors.
10. When calibration has been successful “Cal. Complete” should appear.
11. Cycle power to the machine.
STEP 3: BLEEDING THE PLATFORM VALVES

5. Go to the "Personalities" menu.
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6. Using the left arrow button, go to the "Ground Mode" menu.
7. Hit ENTER.
8. Using the UP/DOWN arrows, adjust the following personalities to 100%.

Basket Rotate
Basket Level
Jib U/D (if configured)
Start up the machine and exercise each above platform function (from the ground) eight (8) to ten (10) times for 5 seconds in each
direction.
9. Return the personality settings back to the values as shown in Table — Personality Ranges/Defaults, page 602 in Section 6 - JLG
Control System.
10. Recycle EMS.
STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS

5. Go to the “Calibrations” menu and hit ENTER.
6. Go to the “Basket U Crkpt” Screen. Hit ENTER.
7. “Calibrate?” prompt should appear. Hit ENTER again.
8. You will hear engine go to 1800 rpm.
9. Using UP ARROW, increase the value until you see the basket up movement.
10. Hit ENTER again. “Cal. Complete” message should appear
11. Engine should again return to idle.
12. Hit ESC should return to “Basket U Crkpt” screen.
13. Hit RIGHT ARROW to get to the “Basket D Crkpt” screen. Hit ENTER.
14. “Calibrate?” prompt should appear. Hit ENTER again.

Using UP ARROW, decrease the value until you see the basket down movement.
Hit ENTER again. “Cal. Complete” message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
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6.17 CALIBRATING PLATFORM LEVEL
6.17.1 Step 1: Setting the Platform Valve Minimums

3. Pull out the Emergency Stop switch and start the engine.
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7. Use the arrow button to reach PERSONALITIES adjust the following personalities. Refer to Table — Personality Ranges/Defaults,
page 602 for proper setting values.
Basket Level Up Min
Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
8. Recycle EMS.
6.17.2 Step 2: Calibrating the Platform Level Sensors

4. Manually level the platform with the switch on the Main Terminal Box.
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8. Use the arrow button to reach CALIBRATIONS menu and hit ENTER.
9. Use right arrow go to PLAT. LEVELING screen.
10. Hit ENTER. The screen should read:
11. Hit ENTER again to calibrate level sensors.
12. When calibration has been successful CAL. COMPLETE should appear.
13. Cycle power to the machine.
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6.17.3 Step 3: Bleeding the Platform Valves

7. Go to the PERSONALITIES menu.
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8. Using the left arrow button, go to the GROUND MODE menu.
9. Hit ENTER.
10. Using the UP/DOWN arrows, adjust the following personalities to 100%.
Basket Rotate
Basket Level
Jib U/D (if configured)
Start up the machine and exercise each above platform function (from the ground) eight (8) to ten (10) times for 5 seconds in each
direction.
11. Return the personality settings back to the values as shown in the Table — Personality Ranges/Defaults, page 602 in Section 6 - JLG
Control System.
12. Recycle EMS.
6.17.4 Step 4: Calibrating the Platform Level Up and Down Valve Crackpoints
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JLG Control System
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the BASKET U CRKPT Screen. Hit ENTER.
9. CALIBRATE? prompt should appear. Hit ENTER again.
11. Using UP ARROW, increase the value until you see the basket up movement.
12. Hit ENTER again. CAL. COMPLETE message should appear
13. Engine should again return to idle.
14. Hit ESC should return to BASKET U CRKPT screen.
15. Hit RIGHT ARROW to get to the “BASKET D CRKPT” screen. Hit ENTER.
16. CALIBRATE? prompt should appear. Hit ENTER again.

Using UP ARROW, increase the value until you see the basket down movement.
Hit ENTER again. CAL. COMPLETE message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
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6.18 CALIBRATING LIFT CRACK POINT
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JLG Control System
8. Use the arrow keys to reach Upper Lift Crack Point (UPPER LIFT CRKPT). The screen will read:
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JLG Control System
9. Hit enter. The screen will read:
12. Activate the Lift Up function by fully stroking the joystick until the boom starts to move, then leave off immediately. The display
will read CRK PT = and show the numeric crack point value.
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13. Hit enter. The number displayed will be the value that the crack point is set to. The screen will show:
15. Repeat steps 10 thru 12 for the Lift Down function.
16. After completing all the Tele Calibrations, hit ESC twice to go back to CALIBRATIONS.
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6.19 CALIBRATING TELESCOPE CRACK POINT
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JLG Control System
8. Use the arrow keys to reach Upper Telescope Crack Point (UPPER TELE CRKPT). The screen will read:
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JLG Control System
11. Hit enter again. The screen will read:
12. Activate the Tele Out function until the boom starts to move, then leave off immediately. The display will read CRK PT = and show
the numeric crack point value.
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JLG Control System
13. Hit enter. The number displayed will be the value that the crack point is set to. The screen will show:
16. Repeat steps 10 thru 12 for the Tele In function.
17. After completing all the Tele Calibrations, hit ESC twice to go back to CALIBRATIONS.
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6.20 CALIBRATING TILT SENSOR
NOTICE
a new tilt module will act as if it is tilted all of the time until the following procedure
is performed.
WARNING
do not calibrate the level sensor except on a level surface.
1. Use the following procedure to calibrate the tilt sensor.

Before the tilt sensor can be calibrated, the following conditions must be met:
a. Steering previously calibrated.
b. Axles extended.
c. Wheels straight.
d. Turntable centered.
e. Boom fully retracted.
f. Boom angle is less than 45°.
g. Machine on firm, level ground.
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9. Use the arrow keys to reach the TILT SENSOR. The screen should read:
10. Press ENTER.
11. When prompted, swing turntable 180° to opposite end of chassis.
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JLG Control System
12. Press ENTER. The screen should read:
13. Upon completing swing calibration, swing turntable 180° back to the stowed position.
14. Hit ESC twice to go back to CALIBRATIONS.
6.21 DRIVE CUTOUT OVERRIDE SERVICE MODE
WARNING
The service modes in this section should be used with extreme caution as they
override the normal boom envelope control system. Improper use can result in
component interference/damage or machine instability, personnel injury or death.
The Drive Cutout Override Mode provides a qualified service technician a means to move the machine to a safe area for troubleshooting
and repair.
1. Plug the analyzer onto the connector inside the Platform Control Box.
2. Pull out the emergency stop switch.
BM110149A
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4. Use the arrow button to reach ACCESS LEVEL 2. Press the enter key.
5. Enter the Access Code 33271 to get into ACCESS LEVEL 1 mode.
Note: The service mode will only be displayed on the analyzer when in access level 1 and be hidden while in access level 2.
NOTICE
The service mode menu will be selectable at the top level of the analyzer menu
structure. “service mode” will be displayed on the top line of the analyzer with the
current sub-menu selection on the bottom line. The sub-menus will scroll with the
left and right arrow keys.
1. Scroll the analyzer menu until “SERVICE MODE” is displayed. Press the ENTER key.
2. Scroll the menu until “DRIVE CUTOUT” is displayed on the analyzer screen.
3. Enter code 23732, which allows operator to enable drive cutout override.
Note: This mode will be canceled in the event of a power cycle, disconnect of analyzer or pressing ESC on the analyzer.
6.22 CALIBRATING THE BOOM SENSORS
NOTICE
During the boom sensor calibration procedure, it is normal for the rear wheel to lift
from the ground approximately 1 inch (2.5 cm). if the wheel raises appreciably more
than this (i.e. 4 inches [10 cm] or more), check the axle oscillation system for proper
operation or the need for bleeding, then proceed with the boom sensor calibration
procedure.
Use the following step-by-step procedure to calibrate the boom sensors.
1. Before the boom sensors can be calibrated, the following conditions must be met:
a. Steering, telescope crack points, and tilt previously calibrated
b. Axles Extended
c. Wheels Straight
d. Platform Unloaded
e. Jib Horizontal
f. Jib Swing Centered
g. Platform Level
h. Platform Centered
i. Turntable Centered
j. Boom Fully Retracted
k. Level Ground (within 1.5°)
Figure 246. Boom Sensor Calibration Position 1
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JLG Control System
9. Use the arrow keys to reach BOOM SENSORS. The screen should read:
11. After verifying all the conditions listed in step 1 are met, hit Enter. The screen will read:
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JLG Control System
12. After verifying all load (personnel or material) is removed from the platform, hit Enter. The screen will read:
13. After visually verifying that the jib is horizontal, hit Enter. The screen will read:
14. After visually verifying the platform is level, hit Enter. The screen will read:
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JLG Control System
15. After visually verifying the platform is centered, hit Enter. The screen will read:
16. After operating telescope in to verify the boom is fully retracted, hit Enter. The screen will read:
17. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter. The screen will read:
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JLG Control System
22. Use the up/down arrows to select yes if the accessory is installed, no if it is not installed and hit Enter. The screen will read:
23. After making sure the machine is in Calibration Position 1, hit Enter. The screen will read:
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JLG Control System
24. Lift up to stop (full stroke of cylinder) for Calibration Position 2. When the machine is in that position, hit Enter.

The screen will read:
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25. Swing 180 degrees (centered over opposite end of chassis) for Calibration Position 3.

When the machine is in the proper position, hit Enter. The screen will read:
When Position 3 calibrating is complete the screen will read:
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26. Press Enter. The screen will read:
Swing the machine back 180 degrees (centered over original end of chassis) for Calibration Position 4.

When Position 4 calibrating is complete, the screen will read:
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27. Press Enter. The screen will read:
Telescope out to stop (boom must be fully extended) for Calibration Position 5.

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28. Retract to stop (boom must be fully retracted) for Calibration Position 6.

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29. Lift down to stop (boom must be on boom rest) for Calibration Position 7.

When the machine is in the proper position, hit Enter. The screen will read as follows:
When Position 7 Calibrating is complete, the screen will read:
Press Enter. The screen will read:
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30. Lift until the function stops (controller will stop at 5 degrees above horizontal) for Calibration Position 8.

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31. Telescope to the yellow witness mark (controller will be close - operator must position the pointer to center line on decal within
0.25" [6 mm]) for Calibration Position 9.

When the boom is in the proper position, hit Enter. The screen will read:
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32. Telescope in to green witness mark (controller will find the position - operator must visually verify the position).

When the boom is in the proper position, the screen will read:
33. After completing all the Boom Sensors Calibrations, hit ESC twice to go back to Calibrations.
34. Cycle the emergency stop switch.
6.22.1 Boom Control System Check Procedure

Perform the following check with no load (personnel or material) in the platform from the ground control station.
1. With the boom fully retracted, raise the boom off the boom rest to horizontal.
2. Position the jib horizontal, jib straight, and platform level.
3. Extend the boom until it stops.
4. Boom must stop on colored stripe matching the capacity indicator. If the boom does not stop on the correct stripe, the system
must be repaired by JLG authorized Service Personnel before the machine can be used.
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5. Push and hold the gray Boom Control System Test Button on the ground control panel. The lighting of the green Boom Control
System Calibrated indicator indicates the system is functioning properly. No indicator light or the lighting of the red Boom Control
System Warning indicator indicates the system must be repaired by JLG authorized Service Personnel before the machine can be
used.
Figure 256. Fault Code Light Location
Table 82. Diagnostic Trouble Code Chart

Flash Sequence Fault Message Fault Description
DTC Check
Code
001 0 1 EVERYTHING OK The normal help message in Platform
Mode.
002 0 2 GROUND MODE OK The normal help message in Ground
Mode.
0010 0 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED
MAX" while the vehicle is out of
transport position.
000 0 0 <<< HELP COMMENT >>>
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Table 82. Diagnostic Trouble Code Chart (continued)

DTC Check
Code
0011 0 11 FSW OPEN A drive / boom function was selected
with the Footswitch open.
0012 0 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the Creep
Switch is open.
0013 0 13 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All functions at creep while the Platform
is elevated and the Chassis is tilted.
0014 0 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 degrees for - Not reported during
more then 4 seconds. power-up.
0015 0 15 LOAD SENSOR READING UNDER WEIGHT LSS has been calibrated and the UGM Ensure platform is not
has determined that the load sensing resting on the ground
system reading is less than -50lbs for 2 or is not leveled at an
seconds. If the load sensing system extreme negative
determines that the reading is greater angle.Recalibrate the
than -50lbs for 5 seconds this fault will load sensing system if
no longer be annunciated.No control the above items are
system interlocks present when DTC is not a factor.
active.
0016 0 16 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is an envelope violation. - Envelope control
system equipped
vehicle only.
0017 0 17 OVER MOMENT - HYDRAULICS SUSPENDED There is an over moment violation. - Envelope control
system equipped
vehicle only.
0018 0 18 UNDER MOMENT - HYDRAULICS SUSPENDED There is an under moment violation. - Envelope control
system equipped
vehicle only.
0019 0 19 MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is a main envelope violation. - Main envelope
system equipped
vehicle only.
0020 0 20 TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is a tower envelope violation. - Tower envelope
system equipped
vehicle only.
31 0 0 FUEL LEVEL LOW – ENGINE SHUTDOWN "Machine will shutdown the engine, Check Fuel Level
based on configuration machine may
allow restarting of the engine.The fuel
level sensor is reporting empty as the
fuel level."
0039 0 0 SKYGUARD ACTIVE - FUNCTIONS CUTOUT "The SkyGuard sensors have been N/A
activated.Fault cleared when controls
returned to neutral and SkyGuard is no
longer active."
49 0 0 SCR CLEANING REQUIRED "If ignored the ECM will derate the Run Regeneration
engine and machine performance will be (Standstill Cleaning)
derated based on severity.ECM will clear via Regeneration
fault once successful SCR Cleaning has (Standstill Cleaning)
been preformed.The Engine Control Switch on the ground
Module is reporting that the SCR regular panel or JLG Analyzer
maintenance is due."
55 0 0 DPF CLEANING REQUIRED "If ignored the ECM will derate the Run Regeneration
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DTC Check
Code
fault once successful Regeneration (Standstill Cleaning)
(Standstill Cleaning) has been Switch on the ground
preformed.The Engine Control Module is panel or JLG Analyzer
reporting that the DPF regular
maintenance is due."
210 2 1 <<< POWER-UP >>>
211 2 1 POWER CYCLE The normal help message is issued at
each power cycle.
212 2 1 KEYSWITCH FAULTY Both Platform and Ground modes are
selected simultaneously.
213 2 1 FSW FAULTY Both Footswitches are closed for more
then one second.
220 2 2 <<< PLATFORM CONTROLS >>>
227 2 2 STEER SWITCHES FAULTY Both Steer Left and Steer Right inputs
are closed simultaneously.
2211 2 2 FSW INTERLOCK TRIPPED The Footswitch was closed for more then - Can be reported
seven seconds. during power-up.
2212 2 2 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected with - Can be reported
Footswitch open. during power-up.
2213 2 2 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected with
Footswitch open.
2215 2 2 D/S JOY. OUT OF RANGE LOW The D/S Joystick reference voltage is low. - Resistive joysticks,
these faults do not
occur.
2216 2 2 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference voltage is > - Resistive joysticks.- If
8.1V. the reference voltage
is > 7.7V then the
reference voltage is
out of tolerance of a
short to battery has
occurred.
2217 2 2 D/S JOY. CENTER TAP BAD The D/S Joystick center tap voltage is < - Resistive joysticks.-
3.08V or > 3.83V. There is a +/- .1V
range. around these
values due to resistor
tolerances
2218 2 2 L/S JOY. OUT OF RANGE LOW The L/S Joystick reference voltage is low. - Resistive joysticks,
these faults do not
occur.
2219 2 2 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference voltage is > - Resistive joysticks.- If
8.1V. the reference voltage
is > 7.7V then the
reference voltage is
out of tolerance of a
short to battery has
occurred.
2220 2 2 L/S JOY. CENTER TAP BAD The L/S Joystick center tap voltage is < - Resistive joysticks.-
3.08V or > 3.83V. There is a +/- .1V
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DTC Check
Code
range. around these
values due to resistor
tolerances
2221 2 2 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A lift / swing function was selected with
Footswitch open.
2222 2 2 WAITING FOR FSW TO BE OPEN The Footswitch was closed during - Can be reported
Platform selection. during power-up.
2223 2 2 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE A boom function was selected with
Footswitch open.
2224 2 2 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed during engine
start.
2286 2 2 FUNCTION PROBLEM - SOFT TOUCH/SKYGUARD OVERRIDE "The Soft Touch/SkyGuard Override Check wiring and
PERMANENTLY SELECTED swtich is engaged during system power switch
up and Soft Touch or SkyGuard is turned
on in Machine Setup.Fault cleared when
switch is no longer enageged"
230 2 3 <<< GROUND CONTROLS >>>
234 2 3 FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM A boom function has both directions
selected together.
235 2 3 FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER A boom function was selected before
aux power.
236 2 3 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH A boom function was selected before
engine start.
237 2 3 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH The Start Switch was closed during
power-up.
250 2 5 <<< FUNCTION PREVENTED >>>
259 2 5 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been changed.
2513 2 5 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the vehicle
generator is running AND is configured
to prevent drive.
2514 2 5 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while
the vehicle is being driven AND is
configured to not allow simultaneous
drive & boom operation.
2515 2 5 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the vehicle
above elevation AND is configured to
prevent drive while above elevation.
2516 2 5 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while Boom
functions are selected AND is configured
to not allow simultaneous drive & boom
operation.
2517 2 5 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Driving is not possible while the vehicle
is tilted and above elevation AND is
configured to prevent drive while tilted
and above elevation.
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DTC Check
Code
2521 2 5 JIB SWING PREVENTED - IN 1000# MODE JIB Swing is not possible while the
vehicle is in 1000 LB Mode.
2522 2 5 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED CAN Dongle attached. Very limited
restrictions for all hydraulics systems.
2523 2 5 BACKUP BLAM COMMUNICATIONS ACTIVE RS232 serial backup communications link
to the BLAM is active.
2524 2 5 DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RS232 serial backup communications link
RETRIEVAL to the BLAM is needed but an analyzer
is connected.
2549 2 5 DRIVE & BOOM PREVENTED - SOFT TOUCH ACTIVE "The Soft Touch sensor has been
activated.Fault cleared once controls are
returned to neutral and Soft Touch is not
active."
2563 2 5 SKYGUARD SWITCH - DISAGREEMENT "The UGM detects that Skyguard Input 1 Check wiring, verify
and Skyguard Input 2 states do not wiring to relays and
match for more than 160ms.Fault is relays are working
cleared when Skyguard input 1 and correctly.
Skyguard Input 2 must match and
controls are returned to neutral."
2587 2 5 RUNNING AT CREEP - PLATFORM LEVELED UNDER "The UGM has detected the platform is Level Platform
in the leveled under positionFault
cleared when platform is returned to
level"
330 3 3 <<< GROUND OUTPUT DRIVER >>>
331 3 3 BRAKE - SHORT TO BATTERY There is a Short to Battery to the Brake
Valve.
332 3 3 BRAKE - OPEN CIRCUIT There is an Open Circuit to the Brake
Valve.
3311 3 3 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the Ground - Ground Alarm
Alarm. equipped vehicles
only.
3316 3 3 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the Right - Chassis Module
Forward Drive Valve. equipped vehicles
only.
3317 3 3 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the Right - Chassis Module
only.
3318 3 3 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the Right - Chassis Module
only.
3320 3 3 RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the Right - Chassis Module
Reverse Drive Valve. equipped vehicles
only.
3321 3 3 RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the Right - Chassis Module
only.
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DTC Check
Code
3322 3 3 RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the Right - Chassis Module
only.
3324 3 3 LEFT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the Left - Chassis Module
only.
3325 3 3 LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the Left - Chassis Module
only.
3326 3 3 LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the Left - Chassis Module
only.
3328 3 3 LEFT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the Left - Chassis Module
only.
3329 3 3 LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the Left - Chassis Module
only.
3330 3 3 LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the Left - Chassis Module
only.
3336 3 3 ALTERNATOR/ECM POWER - SHORT TO GROUND There is a Short to Ground to the
Alternator/ECM.
3338 3 3 ALTERNATOR POWER - OPEN CIRCUIT There is an Open Circuit to the
Alternator.
3339 3 3 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the
Alternator
3340 3 3 AUX POWER - SHORT TO GROUND There is a Short to Ground to the
Auxiliary Power Pump Relay.
3341 3 3 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the Auxiliary
Power Pump Relay.
3342 3 3 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the
Auxiliary Power Pump Relay.
3343 3 3 COLD START ADVANCE SOLENOID - SHORT TO GROUND There is a Short to Ground to the Cold - CAT engines only.
Start Advance Solenoid.
3344 3 3 COLD START ADVANCE SOLENOID - OPEN CIRCUIT There is an Open Circuit to the Cold Start - CAT engines only.
Advance Solenoid.
3345 3 3 COLD START ADVANCE SOLENOID - SHORT TO BATTERY There is a Short to Battery to the Cold - CAT engines only.
Start Advance Solenoid.
3349 3 3 ELECTRIC PUMP - SHORT TO GROUND There is a Short to Ground to the Pump - CAT engines only.
Relay.
3350 3 3 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the Pump - CAT engines only.
Relay.
3351 3 3 ELECTRIC PUMP - SHORT TO BATTERY There is a Short to Battery to the Pump - CAT engines only.
Relay.
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DTC Check
Code
3358 3 3 MAIN DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the Main
Dump Valve.
3359 3 3 MAIN DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the Main
Dump Valve.
3360 3 3 MAIN DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the Main
Dump Valve.
3361 3 3 BRAKE - SHORT TO GROUND There is a Short to Ground to the Brake
Valve.
3362 3 3 START SOLENOID - SHORT TO GROUND There is a Short to Ground to the Start - Diesel engines only.
Relay.
3363 3 3 START SOLENOID - OPEN CIRCUIT There is an Open Circuit to the Start - Diesel engines only.
Relay.
3364 3 3 START SOLENOID - SHORT TO BATTERY There is a Short to Battery to the Start - Diesel engines only.
Relay.
3368 3 3 TWO SPEED VALVE - SHORT TO GROUND There is a Short to Ground to the Two
Speed Valve.
3369 3 3 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the Two
Speed Valve.
3370 3 3 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the Two
Speed Valve.
3371 3 3 GROUND ALARM - SHORT TO GROUND There is a Short to Ground to the Ground - Ground Alarm
only.
3372 3 3 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the Ground - Ground Alarm
only.
3373 3 3 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the - Generator / Welder
Generator Relay. equipped vehicles
only.
3374 3 3 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the Generator - Generator / Welder
Relay. equipped vehicles
only.
3375 3 3 ECM PULLDOWN RESISTOR - OPEN CIRCUIT "Machine has detected an open circuit Refer to electrical
where there is to be a resistor.Fault schematic and verify
cleared upon correction of issue." wiring.
3376 3 3 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the Head - Head Light equipped
Light Relay. vehicles only.
3377 3 3 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the Head - Head Light equipped
3378 3 3 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the Head - Head Light equipped
3379 3 3 HOUR METER - SHORT TO GROUND There is a Short to Ground to the Hour
Meter.
3380 3 3 HOUR METER - OPEN CIRCUIT There is an Open Circuit to the Hour - Can be reported
Meter. during power-up.
682 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
3381 3 3 HOUR METER - SHORT TO BATTERY There is a Short to Battery to the Hour
Meter.
3385 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling
Platform Level Up Override Valve. system equipped
vehicles only.
3386 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform - Electronic leveling
Level Up Override Valve. system equipped
vehicles only.
3387 3 3 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling
Platform Level Up Override Valve. system equipped
vehicles only.
3391 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling
Platform Level Down Override Valve. system equipped
vehicles only.
3392 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform - Electronic leveling
Level Down Override Valve. system equipped
vehicles only.
3393 3 3 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling
Platform Level Down Override Valve. system equipped
vehicles only.
3394 3 3 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Left Valve.
3395 3 3 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform
Rotate Left Valve.
3396 3 3 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Platform Rotate Left Valve.
3397 3 3 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Right Valve.
3398 3 3 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform
Rotate Right Valve.
3399 3 3 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Platform Rotate Right Valve.
23253 2 3 MACHINE SETUP WIRING - ERROR "An issue with the machine setup wiring Check wiring on UGM
has been detected.Fault cleared once J3-11 and BLAM J2-7
issue resolved." against Electrical
Schematic applicable
to machine
manufacturing date.
Analyzer also provides
status of the inputs
under DIAGNOSTICS
–> SYSTEM –>
SETUP CONFIG 1 and
DIAGNOSTICS –>
SYSTEM –> SETUP
CONFIG 2 (LOW =
Open Circuit, HIGH =
Closed Circuit)
1200SJP , 1350SJP 31220396 683

JLG Control System

DTC Check
Code
33100 3 3 JIB LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Lift
Up Valve.
33101 3 3 JIB LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Lift
Up Valve.
33102 3 3 JIB LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Lift
Up Valve.
33103 3 3 JIB LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Lift
Down Valve.
33104 3 3 JIB LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Lift
Down Valve.
33105 3 3 JIB LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Lift
Down Valve.
33118 3 3 SWING RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Swing
Right Valve.
33119 3 3 SWING RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the Swing
Right Valve.
33120 3 3 MAIN TELESCOPE IN VALVE - SHORT TO BATTERY There is a Short to Battery to the Main
Telescope In Valve.
33121 3 3 SWING RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the Swing
Right Valve.
33122 3 3 SWING LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Swing
Left Valve.
33123 3 3 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the Main
Telescope Out Valve.
33130 3 3 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the
Throttle Actuator.
33131 3 3 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the Throttle
Actuator.
33132 3 3 THROTTLE ACTUATOR - SHORT TO BATTERY There is a Short to Battery to the
Throttle Actuator.
33133 3 3 PLATFORM CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling
Platform Control Valve. system equipped
vehicles only.
33134 3 3 PLATFORM CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform - Electronic leveling
Control Valve. system equipped
vehicles only.
33135 3 3 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling
Platform Control Valve. system equipped
vehicles only.
33136 3 3 MAIN LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the Main - 1250AJP only.
Lift APU Valve.
33137 3 3 MAIN LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Lift - 1250AJP only.
APU Valve.
33138 3 3 MAIN LIFT APU VALVE - SHORT TO BATTERY There is a Short to Battery to the Main - 1250AJP only.
Lift APU Valve.
684 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
33139 3 3 MAIN LIFT PILOT - PRESSURE FAILURE The Main Lift Pilot has a Pressure - 1250AJP only.
Failure.
33140 3 3 MAIN LIFT PILOT - NO PRESSURE The Main Lift Pilot has No Pressure. - 1250AJP only.
33141 3 3 MAIN LIFT PILOT - PRESSURE SWITCH FAILURE The Main Lift Pilot has a Pressure Switch - 1250AJP only.
Failure.
33142 3 3 TOWER LIFT APU VALVE - STUCK OPEN The Tower Lift APU Valve is Stuck Open - 1250AJP only.
33143 3 3 TOWER LIFT ENABLE VALVE - STUCK OPEN The Tower Lift Enable Valve is Stuck - 1250AJP only.
Open
33144 3 3 TOWER LIFT ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the Tower - 1250AJP only.
Lift Enable Valve.
33145 3 3 TOWER LIFT ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the Tower - 1250AJP only.
Lift Enable Valve.
33146 3 3 TOWER LIFT ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the Tower - 1250AJP only.
Lift Enable Valve.
33147 3 3 TOWER TELESCOPE APU VALVE - SHORT TO GROUND There is a Short to Ground to the Tower - 1250AJP only.
Telescope APU Valve.
33148 3 3 TOWER TELESCOPE APU VALVE - OPEN CIRCUIT There is an Open Circuit to the Tower - 1250AJP only.
33149 3 3 TOWER TELESCOPE APU VALVE - SHORT TO BATTERY There is a Short to Battery to the Tower - 1250AJP only.
33150 3 3 LIFT PILOT VALVE - SHORT TO GROUND There is a Short to Ground to the Lift - Gravity Lift Down
Pilot Valve. equipped vehicles
only.
33151 3 3 LIFT PILOT VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Pilot - Gravity Lift Down
Valve. equipped vehicles
only.
33152 3 3 LIFT PILOT VALVE - SHORT TO BATTERY There is a Short to Battery to the Lift - Gravity Lift Down
Pilot Valve. equipped vehicles
only.
33153 3 3 LIFT DOWN AUX VALVE - SHORT TO GROUND There is a Short to Ground to the Lift - Gravity Lift Down
Down Auxiliary Valve. equipped vehicles
only.
33154 3 3 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Down - Gravity Lift Down
Auxiliary Valve. equipped vehicles
only.
33155 3 3 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the Lift - Gravity Lift Down
Down Auxiliary Valve. equipped vehicles
only.
33156 3 3 TOWER LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the Tower - 1250AJP only.
Lift APU Valve.
33157 3 3 TOWER LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the Tower - 1250AJP only.
Lift APU Valve.
33158 3 3 TOWER LIFT APU VALVE - SHORT TO BATTERY There is a Short to Battery to the Tower - 1250AJP only.
Lift APU Valve.
1200SJP , 1350SJP 31220396 685

JLG Control System

DTC Check
Code
33159 3 3 MAIN LIFT ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the Main - 1250AJP only.
Lift Enable Valve.
33160 3 3 MAIN LIFT ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Lift - 1250AJP only.
Enable Valve.
33161 3 3 MAIN LIFT ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the Main - 1250AJP only.
Lift Enable Valve.
33162 3 3 TOWER TELESCOPE APU VALVE - STUCK OPEN The Tower Telescope APU Valve is Stuck - 1250AJP only.
Open
33163 3 3 TOWER TELESCOPE ENABLE VALVE - STUCK OPEN The Tower Telescope Enable Valve is - 1250AJP only.
Stuck Open
33164 3 3 TOWER TELESCOPE ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the Tower - 1250AJP only.
33165 3 3 TOWER TELESCOPE ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the Tower - 1250AJP only.
33166 3 3 TOWER TELESCOPE ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the Tower - 1250AJP only.
33167 3 3 PVG ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the PVG - 1250AJP only.
Valve.
33168 3 3 PVG ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the PVG - 1250AJP only.
Valve.
33169 3 3 PVG ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the PVG - 1250AJP only.
Valve.
33173 3 3 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO There is a Short to Battery or an Open
BATTERY OR OPEN CIRCUIT Circuit to the Axle Lockout Valve.
33174 3 3 RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open
CIRCUIT Circuit to the Brake.
33175 3 3 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Rotate Left Valve.
33176 3 3 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB
Rotate Left Valve.
33177 3 3 JIB ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the JIB
Rotate Left Valve.
33178 3 3 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Rotate Right Valve.
33179 3 3 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB
Rotate Right Valve.
33180 3 3 JIB ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the JIB
Rotate Right Valve.
33181 3 3 MAIN LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Lift
Up Valve.
33183 3 3 MAIN LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the Main
Lift Up Valve.
33184 3 3 MAIN LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Lift
Down Valve.
686 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
33185 3 3 MAIN LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the Main
Lift Down Valve.
33186 3 3 MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT There is an Open Circuit to the Main
33188 3 3 MAIN TELESCOPE OUT VALVE - SHORT TO GROUND There is a Short to Ground to the Main
33189 3 3 MAIN TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the Main
Telescope In Valve.
33190 3 3 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the Main
Telescope In Valve.
33207 3 3 HORN - OPEN CIRCUIT There is an Open Circuit to the Horn.
33208 3 3 HORN - SHORT TO BATTERY There is a Short to Battery to the Horn.
33209 3 3 HORN - SHORT TO GROUND There is a Short to Ground to the Horn.
33279 3 3 GLOWPLUG - OPEN CIRCUIT There is an Open Circuit to the Glow - Glowplugs equipped
Plugs. vehicles only.
33280 3 3 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the Glow - Glowplugs equipped
33281 3 3 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the Glow - Glowplugs equipped
33295 3 3 SWING LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the Swing
Left Valve.
33306 3 3 SWING LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the Swing
Left Valve.
33307 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the Main
Telescope Flow Control Valve.
33308 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the Main
33309 3 3 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the Main
33310 3 3 MAIN LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the Main
Lift Down Valve.
33311 3 3 MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the Main
Lift Flow Control Valve.
33312 3 3 MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Lift
Flow Control Valve.
33313 3 3 MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the Main
Lift Flow Control Valve.
33329 3 3 MAIN LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the Main
Lift Up Valve.
33575 3 3 ECM PULLDOWN RESISTOR - OPEN CIRCUIT "Machine has detected an open circuit Refer to electrical
where there is to be a resistor.Fault schematic and verify
cleared upon correction of issue." wiring.
340 3 4 <<< PLATFORM OUTPUT DRIVER >>>
1200SJP , 1350SJP 31220396 687

JLG Control System

DTC Check
Code
343 3 4 PLATFORM LEVEL UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Up Valve.
344 3 4 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open - Electronic leveling
Circuit to the Platform Level Up Valve. system equipped
vehicles only.
347 3 4 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Down Valve.
348 3 4 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open - Electronic leveling
CIRCUIT Circuit to the Platform Level Down Valve. system equipped
vehicles only.
430 4 3 <<< ENGINE >>>
431 4 3 FUEL SENSOR SHORT TO BATTERY The Fuel Sensor reading is > 4.3V.
432 4 3 FUEL SENSOR SHORT TO GROUND The Fuel Sensor reading is < 0.2V.
433 4 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading is > - Deutz engine only.
6.6V.
434 4 3 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading is < - Deutz engine only.-
0.1V for more then 5 seconds. Not reported during
engine start.
435 4 3 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sensor reading - Deutz engine only.
is < 0.1V.
437 4 3 ENGINE TROUBLE CODE <SPN:FMI> Machine will respond accordingly, if JLG Refer to Engine
DTC number exists machine response will Manufacture's Take
be described there otherwise ECM will Action for Repair
clear fault once issue is no longer procedure in
detected.The UGM received engine Diagnostic Trouble
trouble code from the Engine Control Code list using the
Module. SPN:FMI provided to
diagnose and repair.
438 4 3 HIGH ENGINE TEMP Machine will shutdown the engine and "Refer to Engine
restart prevented.Fault cleared on power Manufacture's Take
cycle but re-evaluated on engine start. Action for Repair
The UGM received high engine procedure in
temperature trouble code from the Diagnostic Trouble
Engine Control Module. The engine has Code list using the
detected an engine temperature greater SPN:FMI provided to
than 130°C. diagnose and repair
(Engine Trouble Code
SPN:FMI = 110:0).
Check coolant system
blockage, fan
malfunction, coolant
level, thermostat
malfunction, etc."
439 4 3 AIR FILTER BYPASSED The Air Filter is clogged.
4310 4 3 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts for more
then 15 seconds after engine start.
4311 4 3 LOW OIL PRESSURE "Machine will shutdown the engine and "Refer to Engine
688 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
The UGM received low oil pressure procedure in
trouble code from the Engine Control Diagnostic Trouble
Module. The engine has detected an oil Code list using the
pressure less than 8 PSI." SPN:FMI provided to
diagnose and repair
SPN:FMI = 100:1).
Check oil level, oil
leak, sensor
malfunction, etc.
4313 4 3 THROTTLE ACTUATOR FAILURE The engine RPM is > XXX for more then
XX seconds.
4314 4 3 WRONG ENGINE SELECTED - ECM DETECTED A ECM was detected with a non-ECM
type engine selected.
4322 4 3 LOSS OF ENGINE SPEED SENSOR The engine RPM sensor indicates 0 RPM - Diesel engine only.
AND the Oil Pressure Sensor indicates >
8 PSI for three seconds.
4323 4 3 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indicates > 4000 - Diesel engine only.
RPM.
4334 4 3 ENGINE COOLANT - LOW LEVEL "Machine will shutdown the engine and "Refer to Engine
The UGM received low coolant level procedure in
trouble code from the Engine Control Diagnostic Trouble
Module. The engine has detected coolant Code list using the
level is too low." SPN:FMI provided to
diagnose and repair
SPN:FMI = 111:1).
Check coolant level,
coolant level sensor
for malfunction, etc."
4364 4 3 CLEANING NOT INITIATED "A regeneration (standstill cleaning) "Verify preconditions
request was sent to the engine but have been met to
regeneration is not required or allowed. start a regeneration.
Fault cleared upon power cycle." Verify there are no
engine trouble codes
relating to the
aftertreatment
system."
4365 4 3 RUNNING AT CREEP – ENGINE POWER REDUCTION "The ECM is derating the engine, Refer to Engine
machine placed in creep.ECM will clear Manufacture's Take
fault once issue is no longer detected. Action for Repair
The Engine Control Module is reporting procedure in
that a SCR system trouble code has been Diagnostic Trouble
ignored too long. Triggered by SPN:FMI Code list using the
524190:14" SPN:FMI provided to
4366 4 3 SCR CLEANING REQUIRED – SOOT DETECTED "If ignored the ECM will derate the Run Regeneration
1200SJP , 1350SJP 31220396 689

JLG Control System

DTC Check
Code
reporting that SCR Crystallization has
been detected."
4368 4 3 ALL FUNCTIONS PREVENTED – ENGINE POWER REDUCTION SEVERE "The ECM is derating the engine, Refer to Engine
machine will lock out engine powered Manufacture's Take
functions but allow APU.ECM will clear Action for Repair
fault once issue is no longer detected. procedure in
The Engine Control Module is reporting Diagnostic Trouble
that a SCR system trouble code has been Code list using the
ignored too long. Triggered by SPN:FMI SPN:FMI provided to
524191:14" diagnose and repair.
4375 4 3 WATER IN FUEL "Machine will shutdown the engine.ECM "Refer to Engine
will clear fault once issue is no longer Manufacture's Take
detected.The UGM received water in fuel Action for Repair
trouble code from the Engine Control procedure in
Module. The engine has detected an Diagnostic Trouble
unacceptable amount of water in the Code list using the
fuel or there is an issue with the water SPN:FMI provided to
in fuel sensor." diagnose and repair
SPN = 97).Check for
Water in fuel filter
separator or water in
fuel sensor for
malfunction."
4376 4 3 FUNCTIONS PREVENTED - ENGINE OIL WARM UP ACTIVE "The engine oil is not warm enough to Let machine run until
run the machine.Fault cleared once fault is cleared
engine oil temperature has reached
temperature"
4379 4 3 SCR CLEANING REQUIRED - CRYSTALLIZATION DETECTED "If ignored the ECM will derate the Run Regeneration
reporting that SCR Crystallization has
been detected."
4380 4 3 DPF CLEANING REQUIRED – SOOT DETECTED "If ignored the ECM will derate the Run Regeneration
reporting that DPF Soot Load too high
has been detected."
4383 4 3 DPF EXCHANGE REQUIRED – HIGH ASH LOAD "If ignored the ECM will derate the Refer to Engine
engine and machine performance will be Manufacture's Take
derated based on severity.ECM will clear Action for Repair
fault once successful DPF filter procedure in
replacement has been preformed.The Diagnostic Trouble
Engine Control Module is reporting that Code list using the
DPF Ash Load too high has been SPN:FMI provided to
detected." diagnose and repair.
4386 4 3 HIGH INTAKE TEMPERATURE – ENGINE SHUTDOWN "Machine will shutdown the engine and Refer to Engine
690 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
The UGM received high intake procedure in
temperature trouble code from the Diagnostic Trouble
Engine Control Module." Code list using the
SPN:FMI provided to
440 4 4 <<< BATTERY SUPPLY >>>
441 4 4 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Battery voltage is < 9V.
442 4 4 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Battery voltage is > 16V.
443 4 4 LSS BATTERY VOLTAGE TOO HIGH The load sensor has determined that its Check for issue with
supply voltage is too high (> 16V).The sensor supply voltage.
machine will assume the platform is
overloaded.
444 4 4 LSS BATTERY VOLTAGE TOO LOW The load sensor has determined that its Check for issue with
supply voltage is too low (> 8V).The sensor supply voltage.
overloaded.
445 4 4 BATTERY VOLTAGE LOW Battery voltage is < 11V for more then 5
seconds.
4479 4 4 LSS BATTERY VOLTAGE - INITIALIZATION ERROR The shear beam is reporting a Sensor Possible sensor
Supply Voltage Initialization ErrorThe hardware issue.
overloaded.This fault, once annunciated
is latched within a given key cycle.
4480 4 4 LSS BATTERY VOLTAGE - NOT CALIBRATED The shear beam is reporting a Sensor Possible sensor
Supply Voltage calibration error.The hardware issue.
450 4 5 <<< CAN CONTROLLED VALVES >>>
451 4 5 MAIN LIFT PVG VALVE - INTERNAL FAULT The Main Lift PVG Valve has an internal - 1250AJP only.
fault.
452 4 5 TOWER LIFT PVG VALVE - INTERNAL FAULT The Tower Lift PVG Valve has an internal - 1250AJP only.
fault.
453 4 5 TOWER TELESCOPE PVG VALVE - INTERNAL FAULT The Tower Telescope PVG Valve has an - 1250AJP only.
internal fault.
454 4 5 MAIN LIFT PVG VALVE - HIGH VOLTAGE The Main Lift PVG Valve supply voltage - 1250AJP only.
is high.
455 4 5 TOWER LIFT PVG VALVE - HIGH VOLTAGE The Tower Lift PVG Valve supply voltage - 1250AJP only.
is high.
456 4 5 TOWER TELESCOPE PVG VALVE - HIGH VOLTAGE The Tower Telescope PVG Valve supply - 1250AJP only.
voltage is high.
457 4 5 MAIN LIFT PVG VALVE - LOW VOLTAGE The Main Lift PVG Valve supply voltage - 1250AJP only.
is low.
458 4 5 TOWER LIFT PVG VALVE - LOW VOLTAGE The Tower Lift PVG Valve supply voltage - 1250AJP only.
is low.
459 4 5 TOWER TELESCOPE PVG VALVE - LOW VOLTAGE The Tower Telescope PVG Valve supply - 1250AJP only.
voltage is low.
1200SJP , 1350SJP 31220396 691

JLG Control System

DTC Check
Code
4510 4 5 MAIN LIFT PVG VALVE - STUCK NEUTRAL The Main Lift PVG Valve is stuck in its - 1250AJP only.
neutral position.
4511 4 5 TOWER LIFT PVG VALVE - STUCK NEUTRAL The Tower Lift PVG Valve is stuck in its - 1250AJP only.
neutral position.
4512 4 5 TOWER TELESCOPE PVG VALVE - STUCK NEUTRAL The Tower Telescope PVG Valve is stuck - 1250AJP only.
in its neutral position.
4513 4 5 MAIN LIFT PVG VALVE - STUCK EXTENDED The Main Lift PVG Valve is stuck in its - 1250AJP only.
extended position.
4514 4 5 TOWER LIFT PVG VALVE - STUCK EXTENDED The Tower Lift PVG Valve is stuck in its - 1250AJP only.
extended position.
4515 4 5 TOWER TELESCOPE PVG VALVE - STUCK EXTENDED The Tower Telescope PVG Valve is stuck - 1250AJP only.
in its extended position.
4516 4 5 MAIN LIFT PVG VALVE - STUCK RETRACTED The Main Lift PVG Valve is stuck in its - 1250AJP only.
retracted position.
4517 4 5 TOWER LIFT PVG VALVE - STUCK RETRACTED The Tower Lift PVG Valve is stuck in its - 1250AJP only.
retracted position.
4518 4 5 TOWER TELESCOPE PVG VALVE - STUCK RETRACTED The Tower Telescope PVG Valve is stuck - 1250AJP only.
in its retracted position.
4519 4 5 MAIN LIFT PVG VALVE - OBSTRUCTED The Main Lift PVG Valve is obstructed - 1250AJP only.
4520 4 5 TOWER LIFT PVG VALVE - OBSTRUCTED The Tower Lift PVG Valve is obstructed - 1250AJP only.
4521 4 5 TOWER TELESCOPE PVG VALVE - OBSTRUCTED The Tower Telescope PVG Valve is - 1250AJP only.
obstructed
4522 4 5 MAIN LIFT PVG VALVE - COMMAND IMPROPER The Main Lift PVG Valve command is - 1250AJP only.
improper.
4523 4 5 TOWER LIFT PVG VALVE - COMMAND IMPROPER The Tower Lift PVG Valve command is - 1250AJP only.
improper.
4524 4 5 TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER The Tower Telescope PVG Valve - 1250AJP only.
command is improper.
4525 4 5 MAIN LIFT PVG VALVE - TIMEOUT The Main Lift PVG Valve has timed out. - 1250AJP only.
4526 4 5 TOWER LIFT PVG VALVE - TIMEOUT The Tower Lift PVG Valve has timed out. - 1250AJP only.
4527 4 5 TOWER TELESCOPE PVG VALVE - TIMEOUT The Tower Telescope PVG Valve has - 1250AJP only.
timed out.
4528 4 5 MAIN LIFT PVG VALVE - SETUP FAULT The Main Lift PVG Valve has a setup - 1250AJP only.
fault.
4529 4 5 TOWER LIFT PVG VALVE - SETUP FAULT The Tower Lift PVG Valve has a setup - 1250AJP only.
fault.
4530 4 5 TOWER TELESCOPE PVG VALVE - SETUP FAULT The Tower Telescope PVG Valve has a - 1250AJP only.
setup fault.
4531 4 5 MAIN LIFT PVG VALVE - SENT UNRECOGNIZED FAULT The Main Lift PVG Valve has an - 1250AJP only.
unrecognized fault.
4532 4 5 TOWER LIFT PVG VALVE - SENT UNRECOGNIZED FAULT The Tower Lift PVG Valve has an - 1250AJP only.
unrecognized fault.
692 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
4533 4 5 TOWER TELESCOPE PVG VALVE - SENT UNRECOGNIZED FAULT The Tower Telescope PVG Valve has an - 1250AJP only.
unrecognized fault.
4534 4 5 MAIN LIFT PVG VALVE - PARAMETERS INCORRECT The Main Lift PVG Valve parameters are - 1250AJP only.
incorrect.
4535 4 5 TOWER LIFT PVG VALVE - PARAMETERS INCORRECT The Tower Lift PVG Valve parameters are - 1250AJP only.
incorrect.
4536 4 5 TOWER TELESCOPE PVG VALVE - PARAMETERS INCORRECT The Tower Telescope PVG Valve - 1250AJP only.
parameters are incorrect.
4537 4 5 MAIN LIFT PVG VALVE - LOCATION IMPROPER The Main Lift PVG Valve is in the wrong - 1250AJP only.
location.
4538 4 5 TOWER LIFT PVG VALVE - LOCATION IMPROPER The Tower Lift PVG Valve is in the wrong - 1250AJP only.
location.
4539 4 5 TOWER TELESCOPE PVG VALVE - LOCATION IMPROPER The Tower Telescope PVG Valve is in the - 1250AJP only.
wrong location.
4540 4 5 MAIN LIFT PVG VALVE - WIRING INCORRECT The Main Lift PVG Valve has incorrect - 1250AJP only.
wiring.
4541 4 5 TOWER LIFT PVG VALVE - WIRING INCORRECT The Tower Lift PVG Valve has incorrect - 1250AJP only.
wiring.
4542 4 5 TOWER TELESCOPE PVG VALVE - WIRING INCORRECT The Tower Telescope PVG Valve has - 1250AJP only.
incorrect wiring.
4543 4 5 MAIN LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
4544 4 5 TOWER LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
4545 4 5 TOWER TELESCOPE PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
660 6 6 <<< COMMUNICATION >>>
662 6 6 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN communication
lost.
663 6 6 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE The control system has lost Check wiring to load
communication with the load sensing sensor.
system load pin.The machine will
assume the platform is overloaded.
666 6 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped
communication lost. engine only.
667 6 6 CANBUS FAILURE - MAIN LIFT PVG Main Lift PVG CAN communication lost. - 1250AJP only.
668 6 6 CANBUS FAILURE - TOWER LIFT PVG Tower Lift PVG CAN communication lost. - 1250AJP only.
669 6 6 CANBUS FAILURE - TOWER TELESCOPE PVG Tower Telescope PVG CAN - 1250AJP only.
communication lost.
6610 6 6 CANBUS FAILURE - BLAM BLAM CAN communication lost. - BLAM equipped
vehicles only.
6611 6 6 CANBUS FAILURE - CHASSIS MODULE Engine Control Module CAN - ECM equipped
communication lost. engine only.
6612 6 6 CANBUS FAILURE - CYLINDER LOAD PIN Cylinder Load Pin CAN communication - Cylinder Load Pin
lost. equipped engine only.
1200SJP , 1350SJP 31220396 693

JLG Control System

DTC Check
Code
6613 6 6 CANBUS FAILURE - EXCESSIVE CANBUS ERRORS There has been > 500 Bus Off errors or
>500 Bus Passive Errors.
6614 6 6 CANBUS FAILURE - MAIN ANGLE SENSOR #1 Angle Sensor #1 CAN communication - 1250AJP only.
lost.
6615 6 6 CANBUS FAILURE - MAIN ANGLE SENSOR #2 Angle Sensor #2 CAN communication - 1250AJP only.
lost.
6622 6 6 CANBUS FAILURE - TCU MODULE Machine Setup/ Telematics=YES, No
device heartbeat for 30 sec
6623 6 6 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telematics=YES, No
device heartbeat for 30 sec
6629 6 6 CANBUS FAILURE - TELEMATICS CANBUS LOADINGTOO HIGH X -Telematics only
6651 6 6 CANBUS FAILURE - GROUND DISPLAY "Fault cleared once the UGM starts "Verify CAN Channel 2
receiving the Heartbeat CAN message. wiringVerify CANbus
The UGM has not received the Heartbeat resistance (60 ohms)
CAN message from the Ground Display" for CAN Channel 2"
6667 6 6 CANBUS FAILURE - PLATFORM DISPLAY "Fault cleared once the UGM starts "Verify CAN Channel 1
receiving the Heartbeat CAN message. wiringVerify CANbus
The UGM has not received the Heartbeat resistance (60 ohms)
CAN message from the Platform Display" for CAN Channel 1"
6682 6 6 CANBUS FAILURE - GROUND LIGHT PANEL "CANbus communications has been lost Verify CANbus wiring
between the UGM and the Ground Light per electrical
Panel.Fault cleared once communications schematic, verify
has been restored." CANbus resistance
6683 6 6 CANBUS FAILURE - PLATFORM LIGHT PANEL "CANbus communications has been lost Verify CANbus wiring
between the UGM and the Ground Light per electrical
Panel.Fault cleared once communications schematic, verify
has been restored." CANbusresistance
680 6 8 <<< TELEMATICS >>>
681 6 8 REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN X -Telematics only
CREEP
810 8 1 <<< TILT SENSOR >>>
813 8 1 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not been
calibrated.
815 8 1 CHASSIS TILT SENSOR DISAGREEMENT X
820 8 2 <<< PLATFORM LOAD SENSE >>>
8211 8 2 LSS READING UNDER WEIGHT LSS has been calibrated and the UGM Ensure platform is not
has determined that the load sensing resting on the ground
system reading is underweight while a or is not leveled at an
period of time while operating drive or extreme negative
boom lift up at speeds greater than angle.Recalibrate the
creep OR the UGM has determined that load sensing system if
the load sensing system reading is less the above items are
than -1.5 x Gross Platform Weight.The not a factor.
8218 8 2 LSS SENSOR DISAGREEMENT The control system has determined that Attempt to re-calibrate
the difference between the calculated the load sensing
694 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
load for sensor 1 and sensor 2 differ by system.Possible sensor
more than 50lbs OR the internal strain hardware issue.
gauge sensor 1 gross platform weight
reading and the internal strain gauge
sensor 2 gross platform weight reading
differ by more than 200lbs.If the
platform is not considered to be
overloaded boom functions will be
restricted to creep.This fault, once
annunciated is latched within a given
key cycle.
822 8 2 LSS CELL #2 ERROR822822
8222 8 2 LSS STRAIN GAUGE 1 - STAGNANT The control system has determined that Possible sensor
the strain gauge 1 reading in the load hardware issue.
sensor is stagnant (not changing).If the
restricted to creep.If DTC 8223 is active
in combination with DTC 8222 the
8223 8 2 LSS STRAIN GAUGE 2 - STAGNANT The control system has determined that Possible sensor
the strain gauge 2 reading in the load hardware issue.
sensor is stagnant (not changing).If the
restricted to creep.If DTC 8222 is active
in combination with DTC 8223 the
8224 8 2 LSS STRAIN GAUGE 1 - OUT OF RANGE LOW The shear beam is reporting an out of Possible sensor
range low issue with the strain gauge 1 hardware issue.
reading. If the platform is not
overloaded the machine will be placed
in to creep.If DTC 8225 is also active the
8225 8 2 LSS STRAIN GAUGE 2 - OUT OF RANGE LOW The shear beam is reporting an out of Possible sensor
range low issue with the strain gauge 2 hardware issue.
8228 8 2 LSS STRAIN GAUGE 1 - INITIALIZATION ERROR The shear beam is reporting an Possible sensor
initialization issue with the strain gauge hardware issue.
1 sensor. If the platform is not
1200SJP , 1350SJP 31220396 695

JLG Control System

DTC Check
Code
8229 8 2 LSS STRAIN GAUGE 2 - INITIALIZATION ERROR The shear beam is reporting an Possible sensor
initialization issue with the strain gauge hardware issue.
2 sensor. If the platform is not
8230 8 2 LSS STRAIN GAUGE 1 - NOT CALIBRATED The shear beam is reporting a calibration Possible sensor
issue with the strain gauge 1 sensor. If hardware issue.
the platform is not overloaded the
machine will be placed in to creep.If DTC
8231 is also active the machine will
assume the platform is overloaded.This
fault, once annunciated is latched within
a given key cycle.
823 8 2 LSS CELL #3 ERROR823823
8231 8 2 LSS STRAIN GAUGE 2 - NOT CALIBRATED The shear beam is reporting a calibration Possible sensor
a given key cycle.
8226 8 2 LSS STRAIN GAUGE 1 - OUT OF RANGE HIGH The shear beam is reporting an out of Possible sensor
range high issue with the strain gauge 1 hardware issue.
8227 8 2 LSS STRAIN GAUGE 2 - OUT OF RANGE HIGH The shear beam is reporting an out of Possible sensor
range high issue with the strain gauge 2 hardware issue.
8232 8 2 LSS STRAIN GAUGE 1 - SENSOR DEFECT The shear beam is reporting a sensor Possible sensor
defect issue with the strain gauge 1 hardware issue.
sensor. If the platform is not overloaded
the machine will be placed in to creep.If
DTC 8233 is also active the machine will
a given key cycle.
8233 8 2 LSS STRAIN GAUGE 2 - SENSOR DEFECT The shear beam is reporting a sensor Possible sensor
defect issue with the strain gauge 2 hardware issue.
696 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
a given key cycle.
8234 8 2 LSS STRAIN GAUGE 1 - NOT INSTALLED The shear beam is reporting a not Possible sensor
installed issue with the strain gauge 1 hardware issue.
assume the platform is overloaded This
a given key cycle.
8235 8 2 LSS STRAIN GAUGE 2 - NOT INSTALLED The shear beam is reporting a not Possible sensor
installed issue with the strain gauge 2 hardware issue.
the machine will be placed in to creep If
assume the platform is overloaded This
a given key cycle.
8236 8 2 LSS NOT DETECTING CHANGE The control system has determined that Possible sensor
the load sensor reading has not deviated hardware issue.
by more than 1lb for 5s while operating
drive or boom functions at greater than
creep speed This fault, once annunciated
8237 8 2 LSS STRAIN GAUGE 1 - A/D DEFECT The shear beam is reporting an internal Possible sensor
a given key cycle.
8238 8 2 LSS STRAIN GAUGE 2 - A/D DEFECT The shear beam is reporting an internal Possible sensor
a given key cycle.
824 8 2 LSS CELL #4 ERROR824824
825 8 2 LSS HAS NOT BEEN CALIBRATED The load sensing system is configured Calibrate the load
but has not been calibrated.The machine sensing system.
will assume the platform is overloaded.
826 8 2 RUNNING AT CREEP - PLATFORM OVERLOADED All functions at creep, the Load Sensing
System indicates the Platform is
overloaded AND is configured to warn
only while the Platform is overloaded.
827 8 2 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are not
possible while the Load Sensing System
1200SJP , 1350SJP 31220396 697

JLG Control System

DTC Check
Code
indicates the Platform is overloaded AND
is configured to prevent drive and boom
functions while the Platform is
overloaded.
828 8 2 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED Lift up and telescope out are not
possible while the Load Sensing System
indicates the Platform is overloaded AND
is configured to prevent Lift up and
telescope out while the Platform is
overloaded.
830 8 3 <<< PLATFORM LEVELING >>>
831 8 3 PLATFORM LEVELING OVERRIDE ON Platform Leveling forced on with Access
Level 0 selection.
832 8 3 PLATFORM LEVELING OVERRIDE OFF Platform Leveling forced off with Access
Level 0 selection.
833 8 3 PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED The Platform Level Up Valve Crackpoint - Electronic leveling
has not been calibrated. system equipped
vehicles only.
834 8 3 PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED The Platform Level Down Valve - Electronic leveling
Crackpoint has not been calibrated. system equipped
vehicles only.
837 8 3 PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling
Platform Level Sensor #1. system equipped
vehicles only.
838 8 3 PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an Open - Electronic leveling
Circuit to the Platform Level Sensor #1. system equipped
vehicles only.
8311 8 3 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling
Platform Level Sensor #2. system equipped
vehicles only.
8312 8 3 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an Open - Electronic leveling
Circuit to the Platform Level Sensor #2. system equipped
vehicles only.
8313 8 3 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #1 reverence - Electronic leveling
voltage is outside acceptable range (4.9 system equipped
to 5.1 volts). vehicles only.
8314 8 3 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #2 reverence - Electronic leveling
voltage is outside acceptable range (4.9 system equipped
to 5.1 volts). vehicles only.
8315 8 3 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads the sensor - Electronic leveling
values at power-up. The fault is system equipped
triggered when there is a ± 5 degree vehicles only.
difference from the initial reading.
8316 8 3 PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST Platform Level Sensor #1 serial - 1200S and 1350S
communication lost. only.
8317 8 3 PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST Platform Level Sensor #2 serial - 1200S and 1350S
communication lost. only.
698 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
8318 8 3 PLATFORM LEVELING SYSTEM TIMEOUT The Platform was unable to maintain
desired level within range for the
allotted time.
840 8 4 <<< ENVELOPE >>>
841 8 4 BOOM ANGLE SENSOR DISAGREEMENT There is a disagreement between the - Envelope Control
Boom Angle Sensors. equipped vehicles
only.
842 8 4 BOOM LENGTH SWITCH FAILED The Boom Length Switches are reporting - Envelope Control
the same state. equipped vehicles
only.
843 8 4 BOOM LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement between the - Envelope Control
Boom Length Switch and the Boom equipped vehicles
Length Sensor. only.
844 8 4 BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE The Boom Length Sensor is not changing - Envelope Control
during a boom telescope command. equipped vehicles
only.
845 8 4 BOOM LENGTH SENSOR - OUT OF RANGE HIGH Boom Length Sensor out of range high. - Envelope Control
equipped vehicles
only.-1200/1350 only
846 8 4 BOOM LENGTH SENSOR - OUT OF RANGE LOW Boom Length Sensor out of range low. - Envelope Control
equipped vehicles
847 8 4 BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH Boom Length out of range high. - Envelope Control
equipped vehicles
848 8 4 BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW Boom Length out of range low. - Envelope Control
equipped vehicles
849 8 4 BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 communications - Envelope Control
lost. equipped vehicles
only.
8410 8 4 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT Boom Angle Sensor #2 communications - Envelope Control
lost. equipped vehicles
only.
8411 8 4 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of range. - Envelope Control
equipped vehicles
only.
8412 8 4 BOOM ANGLE SENSOR #2 - INVALID ANGLE Boom Angle Sensor #2 out of range. - Envelope Control
equipped vehicles
only.
8413 8 4 WRONG TELESCOPE RESPONSE Boom telescope is moving in the - Envelope Control
opposite direction of the command. equipped vehicles
only.
8414 8 4 WRONG LIFT RESPONSE Boom lift is moving in the opposite - Envelope Control
direction of the command. equipped vehicles
only.
1200SJP , 1350SJP 31220396 699

JLG Control System

DTC Check
Code
8415 8 4 TOWER ANGLE SENSOR DISAGREEMENT There is a disagreement between the - Envelope Control
Tower Angle Sensors. equipped vehicles
only.-1250
84151 8 4 TOWER LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) that these Check Hardware,
faults can be set:(a)If the length sensor Wiring
voltage changes more than 0.0168 volts
within 40 milliseconds a counter for the
respective length sensor shall be
incremented to aid service in diagnosing
bad sensor performance. The counter
below shall be incremented anytime the
description above is met. It is cleared/
reset by a power cycleTwrLenSnsr(1/2)
FaultCounter_PowerCycle > 30(b)The
counter below shall be incremented
every time TwrLenSnsr(1/2)
FaultCounter_PowerCycle (described
above) reached its threshold. This value
is stored in EEPROM in order to track the
history of the issue. (A successful Boom
Sensor Calibration will reset this counter
– this is reflected in the boom sensor
calibration document)TwrLenSnsr(1/2)
FaultCounter_EEPROM > 3(c)The fault
every time the trigger condition
described in section (a) is observed
during certain steps during Boom Sensor
Calibration (please see that document
section for further details)TwrLenSnsr(1/
2)FaultCounter_BmSnsrCal > 20If (a) or
(b) or (c) are met (fault triggered) the
machine will be put into Electrical
RetrievalFault, once triggered, is
maintained within a given key-
cycleMachine will be trapped in
transport
84152 8 4 TOWER LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) that these Check Hardware,
faults can be set:(a)If the length sensor Wiring
reset by a power cycleTwrLenSnsr(1/2)
every time TwrLenSnsr(1/2)
FaultCounter_PowerCycle (described
above) reached its threshold. This value
is stored in EEPROM in order to track the
history of the issue. (A successful Boom
Sensor Calibration will reset this counter
– this is reflected in the boom sensor
calibration document)TwrLenSnsr(1/2)
FaultCounter_EEPROM > 3(c)The fault
700 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
every time the trigger condition
described in section (a) is observed
during certain steps during Boom Sensor
Calibration (please see that document
section for further details)TwrLenSnsr(1/
2)FaultCounter_BmSnsrCal > 20If (a) or
(b) or (c) are met (fault triggered) the
machine will be put into Electrical
RetrievalFault, once triggered, is
maintained within a given key-
transport
84153 8 4 BOOM LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) that these Check wiring and
faults can be set:(a)If the length sensor hardware
reset by a power cycleBmLenSnsr(1/2)
every time BmLenSnsr(1/2)FaultCounter_
PowerCycle (described above) reached its
threshold. This value is stored in EEPROM
in order to track the history of the issue.
(A successful Boom Sensor Calibration
will reset this counter – this is reflected
in the boom sensor calibration
document)BmLenSnsr(1/2)FaultCounter_
EEPROM > 3(c)The fault counter below
shall be incremented every time the
trigger condition described in section (a)
is observed during certain steps during
Boom Sensor Calibration (please see that
document section for further details)
BmLenSnsr(1/2)FaultCounter_BmSnsrCal
> 20If (a) or (b) or (c) are met (fault
triggered) the machine will be put into
Electrical RetrievalFault, once triggered,
is maintained within a given key-
transport
84154 8 4 BOOM LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) that these Check wiring and
faults can be set:(a)If the length sensor hardware
reset by a power cycleBmLenSnsr(1/2)
every time BmLenSnsr(1/2)FaultCounter_
1200SJP , 1350SJP 31220396 701

JLG Control System

DTC Check
Code
PowerCycle (described above) reached its
threshold. This value is stored in EEPROM
in order to track the history of the issue.
(A successful Boom Sensor Calibration
will reset this counter – this is reflected
in the boom sensor calibration
document)BmLenSnsr(1/2)FaultCounter_
EEPROM > 3(c)The fault counter below
shall be incremented every time the
trigger condition described in section (a)
is observed during certain steps during
Boom Sensor Calibration (please see that
document section for further details)
BmLenSnsr(1/2)FaultCounter_BmSnsrCal
> 20If (a) or (b) or (c) are met (fault
triggered) the machine will be put into
Electrical RetrievalFault, once triggered,
is maintained within a given key-
transport
8416 8 4 TOWER LENGTH SENSOR DISAGREEMENT There is a disagreement between the - Envelope Control
Tower Length Sensors. equipped vehicles
only.-1250
8417 8 4 MAIN ANGLE SENSOR DISAGREEMENT There is a disagreement between the - Envelope Control
Main Boom Angle Sensors. equipped vehicles
only.-1250
8418 8 4 TOWER LENGTH SENSOR #1 - OUT OF RANGE HIGH Tower Boom Angle Sensor #1 out of - Envelope Control
range high. equipped vehicles
only.-1250
8419 8 4 TOWER LENGTH SENSOR #1 - OUT OF RANGE LOW Tower Boom Angle Sensor #1 out of - Envelope Control
range low. equipped vehicles
only.-1250
only.-1250
only.-1250
8422 8 4 TOWER LENGTH SENSOR - NOT DETECTING LENGTH CHANGE The Tower Length Sensor is not - Envelope Control
changing during a tower telescope equipped vehicles
command. only.-1250
8423 8 4 TOWER LENGTH MOVEMENT WITHOUT COMMAND The Tower Length Sensor is changing - Envelope Control
without a tower telescope command. equipped vehicles
only.-1250
only.-1250
only.-1250
702 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
only.-1250
only.-1250
8428 8 4 TOWER ANGLE SENSOR #1 - INVALID ANGLE Tower Boom Angle Sensor #1 out of - Envelope Control
range. equipped vehicles
only.-1250
8429 8 4 TOWER ANGLE SENSOR #2 - INVALID ANGLE Tower Boom Angle Sensor #2 out of - Envelope Control
only.-1250
8430 8 4 TOWER ANGLE SENSOR #1 - INVALID MODEL Wrong Tower Boom Angle Sensor #1 - Envelope Control
installed. equipped vehicles
only.- 1250AJP Only-
Must be a Rieker
Sensor, not a Spectron
Sensor.
8431 8 4 TOWER ANGLE SENSOR #2 - INVALID MODEL Wrong Tower Boom Angle Sensor #2 - Envelope Control
installed. equipped vehicles
only.- 1250AJP Only-
Must be a Rieker
Sensor, not a Spectron
Sensor.
8432 8 4 MAIN ANGLE SENSOR #1 - INVALID ANGLE Main Boom Angle Sensor #1 out of - Envelope Control
only.-1250
8433 8 4 MAIN ANGLE SENSOR #2 - INVALID ANGLE Main Boom Angle Sensor #2 out of - Envelope Control
only.-1250
8434 8 4 MAIN ANGLE SENSOR - NOT DETECTING ANGLE CHANGE The Main Boom Angle Sensor is not - Envelope Control
changing during a main lift command. equipped vehicles
only.-1250
8435 8 4 MAIN ANGLE MOVEMENT WITHOUT CMD The Main Boom Angle Sensor is - Envelope Control
changing without a main lift command. equipped vehicles
only.-1250
8436 8 4 WRONG TOWER TELESCOPE RESPONSE Tower telescope is moving in the - Envelope Control
opposite direction of the command. equipped vehicles
only.-1250
8437 8 4 WRONG TOWER LIFT RESPONSE Tower lift is moving in the opposite - Envelope Control
only.-1250
8438 8 4 TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE HIGH The Tower Cylinder Angle Sensor is < - Envelope Control
4721 A/D counts. equipped vehicles
only.-1250
8439 8 4 TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE LOW The Tower Cylinder Angle Sensor is > - Envelope Control
29535 A/D counts. equipped vehicles
only.-1250
1200SJP , 1350SJP 31220396 703

JLG Control System

DTC Check
Code
8440 8 4 TOWER CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE The Tower Cylinder Angle Sensor is not - Envelope Control
changing during a tower lift command. equipped vehicles
only.-1250
8441 8 4 TOWER CYLINDER ANGLE MOVEMENT WITHOUT COMMAND The Tower Cylinder Angle Sensor is - Envelope Control
changing without a tower lift command. equipped vehicles
only.-1250
8442 8 4 MAIN TRANSPORT ANGLE SWITCH FAILED The Main Boom Angle Switch is bad. - Envelope Control
equipped vehicles
only.-1250
8443 8 4 TWR TRANSPORT SWITCH DISAGREEMENT There is a disagreement between the - Envelope Control
Tower Boom Length Switch and the equipped vehicles
Tower Length Sensor. only.-1250
8444 8 4 TRANSPORT DUAL CAPACITY SWITCHES BAD Both the Dual Capacity Switch and the - Envelope Control
Transport Switch are bad. equipped vehicles
only.-1250
8445 8 4 TRANSPORT DUAL CAPACITY BAD TRANSITION The Dual Capacity Switch and the - Envelope Control
Transport Switch changed state out of equipped vehicles
order. only.-1250
8446 8 4 MAIN TRANSPORT LENGTH SWITCH DISAGREEMENT There is a disagreement between the - Envelope Control
Main Boom Transport Length Switches. equipped vehicles
only.-1250
8447 8 4 MAIN DUAL CAPACITY LENGTH SWITCH DISAGREEMENT There is a disagreement between the - Envelope Control
Main Boom Dual Capacity Length equipped vehicles
Switches. only.-1250
8448 8 4 MAIN TRANSPORT ANGLE SWITCH/SENSOR DISAGREEMENT There is a disagreement between the - Envelope Control
Main Boom Angle Switch and the Main equipped vehicles
Boom Angle Sensor. only.-1250
8449 8 4 TOWER CYLINDER ANGLE SWITCH/SENSOR DISAGREEMENT There is a disagreement between the - Envelope Control
Tower Boom Angle Switch and the equipped vehicles
Tower Cylinder Angle Sensor. only.-1250
8450 8 4 NEW MAIN ANGLE SENSOR #1 DETECTED A new Main Angle Sensor 1 has been -1250
detected.
8451 8 4 NEW MAIN ANGLE SENSOR #2 DETECTED A new Main Angle Sensor 2 has been -1250
detected.
8452 8 4 TOWER LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement between the - Envelope Control
Tower Length Switch and the Tower equipped vehicles
Length Sensor. only.-1250
8453 8 4 WRONG MAIN TELE RESPONSE Main telescope is moving in the opposite - Envelope Control
only.-1250
8454 8 4 WRONG MAIN LIFT RESPONSE Main lift is moving in the opposite - Envelope Control
only.-1250
8482 8 4 TOWER ENVELOPE MASSIVELY ENCROACHED X
8483 8 4 TOWER ENVELOPE MULTIPLE ENCROACHMENTS X
8484 8 4 BCS VIOLATION - BOOM LOCKED X
704 31220396 1200SJP , 1350SJP

JLG Control System

DTC Check
Code
8485 8 4 BCS - HYDRAULIC RETRIEVAL ACTIVE X
8486 8 4 BCS - ELECTRICAL RETRIEVAL ACTIVE X
8487 8 4 BCS - MULTIPLE FAILURES ACTIVE X
850 8 5 <<< MOMENT / LOAD PINS >>>
851 8 5 MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE The Moment Pin horizontal force is out
of range.
852 8 5 MOMENT PIN - VERTICAL FORCE OUT OF RANGE The Moment Pin vertical force is out of
range.
853 8 5 LOAD PIN - HORIZONTAL FORCE OUT OF RANGE The Load Pin horizontal force is out of -1250
range.
854 8 5 LOAD PIN - VERTICAL FORCE OUT OF RANGE The Load Pin vertical force is out of -1250
range.
855 8 5 MOMENT PIN - SENSOR FAULT The Moment Pin has reported a fault.
856 8 5 LOAD PIN - SENSOR FAULT The Load Pin has reported a fault. -1250
857 8 5 NEW MOMENT PIN DETECTED A new Moment Pin has been detected.
858 8 5 NEW LOAD PIN DETECTED A new Load Pin has been detected. -1250
859 8 5 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT There is a disagreement between the -1250
Load Pin and the Tower Lift cylinder
Angle.
8510 8 5 LOAD PIN - FORCE VALUES NOT CHANGING The Load Pin is not changing. -1250
8511 8 5 LOAD PIN - FORCE TOO LOW OVER TOWER ANGLE CHANGE X -1250
8512 8 5 LOAD PIN - FORCE TOO LOW OVER MAIN ANGLE CHANGE X -1250
8513 8 5 LOAD PIN - FORCE TOO LOW OVER MAIN LENGTH TRANSITION X -1250
860 8 6 <<< STEERING / AXLE >>>
861 8 6 RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH The Oscillating Axle Pressure Switch - Electrically released
DISAGREEMENT indicates pressure while not driving or Oscillated Axles
does not indicate pressure while driving equipped vehicles
and restricted to transport. only.
862 8 6 AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open
Circuit to the Axle Extend Valve.
863 8 6 AXLE EXTEND VALVE - SHORT TO GROUND There is a Short to Ground to the Axle
Extend Valve.
864 8 6 AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open
Circuit to the Axle Retract Valve.
865 8 6 AXLE RETRACT VALVE - SHORT TO GROUND There is a Short to Ground to the Axle
Retract Valve.
866 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open
CIRCUIT Circuit to the Right Front Steer Right
Valve.
867 8 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Right
Front Steer Right Valve.
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DTC Check
Code
868 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open
CIRCUIT Circuit to the Right Front Steer Left
Valve.
869 8 6 RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Right
Front Steer Left Valve.
8610 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open
CIRCUIT Circuit to the Left Front Steer Right
Valve.
8611 8 6 LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Left
Front Steer Right Valve.
8612 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open
CIRCUIT Circuit to the Left Front Steer Left Valve.
8613 8 6 LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Left
Front Steer Left Valve.
8614 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open
CIRCUIT Circuit to the Right Rear Steer Right
Valve.
8615 8 6 RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Right
Rear Steer Right Valve.
8616 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open
CIRCUIT Circuit to the Right Rear Steer Left Valve.
8617 8 6 RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Right
Rear Steer Left Valve.
8618 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open
CIRCUIT Circuit to the Left Rear Steer Right Valve.
8619 8 6 LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Left
Rear Steer Right Valve.
8620 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open
Circuit to the Left Rear Steer Left Valve.
8621 8 6 LEFT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Left
Rear Steer Left Valve.
8622 8 6 FRONT RIGHT STEER SENSOR - DECOUPLED The Front Right Steer Sensor has become
decoupled.
8623 8 6 FRONT LEFT STEER SENSOR - DECOUPLED The Front Left Steer Sensor has become
decoupled.
8624 8 6 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has become
decoupled.
8625 8 6 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has become
decoupled.
8626 8 6 FRONT LEFT STEER SENSOR - NOT RESPONDING The Front Right Steer Sensor is not
responding to steer commands.
8627 8 6 FRONT RIGHT STEER SENSOR - NOT RESPONDING The Front Left Steer Sensor is not
8628 8 6 REAR LEFT STEER SENSOR - NOT RESPONDING The Rear Right Steer Sensor is not
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DTC Check
Code
8629 8 6 REAR RIGHT STEER SENSOR - NOT RESPONDING The Rear Left Steer Sensor is not
8630 8 6 FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an Open
Circuit to the Front Right Steer Sensor.
8631 8 6 FRONT RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the Front
Right Steer Sensor.
8632 8 6 FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an Open
Circuit to the Front Left Steer Sensor.
8633 8 6 FRONT LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the Front
Left Steer Sensor.
8634 8 6 REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an Open
Circuit to the Rear Right Steer Sensor.
8635 8 6 REAR RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the Rear
Right Steer Sensor.
8636 8 6 REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an Open
Circuit to the Rear Left Steer Sensor.
8637 8 6 REAR LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the Rear
Left Steer Sensor.
8651 8 6 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT Engine Start is prevented while there is
an Oscillating Axle fault and vehicle is
out of transport position
876 8 7 WIRE ROPE SERVICE REQUIRED "The Wire Rope Service Proximity sensor "Check wire ropes per
detects slack in wire ropes.Fault cleared torque spec.Check
when proximity switch detects no more sensor wiring."
slack in wire ropes."
990 99 9 <<< HARDWARE >>>
998 9 9 EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has reported an
EEPROM failure.
9910 9 9 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION The Platform Module software version is
IMPROPER not compatible with the rest of the
system.
9914 9 9 PLATFORM MODULE SOFTWARE UPDATE REQUIRED The Platform Module software requires
an updated.
9915 9 9 CHASSIS TILT SENSOR NOT GAIN CALIBRATED The Chassis Tilt Sensor gain calibration
has been lost.
9916 9 9 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain calibration
has become corrupted.
9917 9 9 HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST The Platform Module has reported that
its ADS1213 chip has stopped asserting
its interrupt.
9918 9 9 HIGH RESOLUTION A2D FAILURE - REINIT LIMIT The Platform Module has reported that
its ADS1213 chip had to be reset 3 or
more times.
9919 9 9 GROUND SENSOR REF VOLTAGE OUT OF RANGE The Ground Module has reported that its - Not reported during
sensor reference voltage is outside power-up.
acceptable range.
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DTC Check
Code
9920 9 9 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE The Platform Module has reported that - Not reported during
its sensor reference voltage is outside power-up.
acceptable range.
9921 9 9 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY The Ground Module has reported that its
high side driver cutout failed.
9922 9 9 PLATFORM MODULE FAILURE - HWFS CODE 1 The Platform Module has reported that
the V(Low) FET has failed.
9923 9 9 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has reported that
the V(Low) FET has failed.
9925 9 9 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION The Chassis Module software version is
IMPROPER not compatible with the rest of the
system.
9926 9 9 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION The BLAM software version is not
IMPROPER compatible with the rest of the system.
9927 9 9 GROUND MODULE CONSTANT DATA UPDATE REQUIRED The Ground Module constant data
requires an updated.
9928 9 9 ENVELOPE CONTROL DISABLED Envelope Control has been disabled by - Envelope Control
the user from Access Level 0. equipped vehicles
only.
99282 9 9 GROUND DISPLAY SOFTWARE VERSION IMPROPER "The UGM has detected improper Verify Machine Setup
software version on the ground display. is correct and ground
Fault cleared once software has been display software
updated on the ground display" version is at least P1.5
or greater
99285 9 9 LSS - FACTORY CALIBRATION ERROR The load sensor is reporting a factor Possible sensor
calibration issue (internal error) The hardware issue.
99296 9 9 PLATFORM DISPLAY SOFTWARE VERSION IMPROPER "The UGM has detected improper Verify Machine Setup
software version on the platform display. is correct and platform
Fault cleared once software has been display software
updated on the platform display" version is at least 1.6
or greater
9929 9 9 MOMENT CONTROL DISABLED Moment Control has been disabled by - Envelope Control
the user from Access Level 0. equipped vehicles
only.
9930 9 9 STEER SENSORS NOT CALIBRATED The Steer Sensors have not been - Chassis Module
calibrated. equipped vehicles
only.
9931 9 9 BOOM SENSORS NOT CALIBRATED The Boom Sensors have not been - BLAM equipped
calibrated. vehicles only.
9932 9 9 LIFT CRACKPOINTS NOT CALIBRATED The Lift Valves have not been calibrated. - 1200S and 1350S
only.
9933 9 9 TELESCOPE CRACKPOINTS NOT CALIBRATED The Telescope Valves have not been - 1200S and 1350S
calibrated. only.
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DTC Check
Code
9934 9 9 DRIVE CRACKPOINTS NOT CALIBRATED The Drive Valves have not been - 1200S and 1350S
calibrated. only.
9935 9 9 BLAM SENSOR SUPPLY OUT OF RANGE HIGH The Boom Angle Sensors supply voltage - BLAM equipped
is high. vehicles only.
9936 9 9 BLAM SENSOR SUPPLY OUT OF RANGE LOW The Boom Angle Sensors supply voltage - BLAM equipped
is low. vehicles only.
9937 9 9 LENGTH SENSOR REF VOLTAGE HIGH The Boom Length Sensors supply voltage
is high.
9938 9 9 LENGTH SENSOR REF VOLTAGE LOW The Boom Length Sensors supply voltage
is low.
9939 9 9 BLAM HIGH RES A/D FAILURE The BLAM high resolution analog to - BLAM equipped
digital converter has failed. vehicles only.
9940 9 9 CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH The Chassis Sensors supply voltage is
high.
9941 9 9 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW The Chassis Sensors supply voltage is
low.
9942 9 9 BLAM BACKUP COMMUNICATIONS LINK FAULTY The BLAM backup communications link - BLAM equipped
test was activated at startup, but no vehicles only.-1250
communication connection established/
maintained.
9943 9 9 BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED The BLAM backup communications link - BLAM equipped
was activated, but no communication vehicles only.-1250
connection established/maintained.
9944 9 9 CURRENT FEEDBACK GAINS OUT OF RANGE The factory set current feedback gains
are out of range.
9945 9 9 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT The factory set current feedback
checksum is not correct.
9975 9 9 LOAD PIN NOT CALIBRATED The Load Pin has not been calibrated. -1250
9979 9 9 FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION Temporary fault for the telematics
IMPROPER project. The model needs to be a 600S
or 1350S if not this fault will be
generated and Platform controls will be
prevented. This fault was to insure that
the software will only work for these
two models.
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Figure 257. CANbus Connections Diagram
6.23 CANBUS TROUBLESHOOTING
The PLATFORM MODULE and the CHASSIS MODULE have ”Terminator Resistors” located inside the modules, these resistors squelch high
speed signal reflections in the CANbus transmission lines. The value of the terminators is determined by wire properties, this includes the
type of insulation and geometry, combined to determine the perfect value for bus termination. Improper values or missing terminators
allow bus ringing. A complete CANbus circuit (wired in parallel) is approximately 60 Ohms at the ”T” fitting inside the Ground Station or
at the Boom Length & Angle Module. Each individual circuit from their respective Module should read approximately 120 Ohm. For
CANbus connections, refer to Figure — CANbus Connections Diagram, page 710, Figure — CANbus Connections - Sheet 1 of 5, page 711,
Figure — CANbus Connections - Sheet 2 of 5, page 712, Figure — CANbus Connections - Sheet 3 of 5, page 713 , Figure — CANbus
Connections - Sheet 4 of 5, page 714, and Figure — CANbus Connections - Sheet 5 of 5, page 715.
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JLG Control System
A B
PLATFORM MODULE
CANbus Link
C
BM105904A
Figure 258. CANbus Connections - Sheet 1 of 5
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"BEFORE" Slip Ring

Connection
"AFTER" Slip Ring

Connection
BM105907A
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Chassis Module J1
(Gray) Plug
Chassis Module
CANbus Link
BM105908A
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BM105909A
Figure 263. CANbus Circuit
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JLG Control System
6.23.1 CANbus Communication Failure

If a problem in the CANbus system is suspected, use the following step-by-step procedure to verify which part of the CANbus
communication system has failed.
CANBUS LINK FROM THE PLATFORM MODULE LOST
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5. Press enter twice to reach Logged Help. The screen will read:
BM105910A
6. Hit ESC to get back to the HELP screen and then use the arrow button to reach VERSIONS. Hit Enter.
7. If the CANbus link from the platform module is lost, you will see the Ground Module SW version, Ground Module HW version,
Ground Module SN, BM SW version, Chassis SW version, Platform Module SN, but you will not see the Platform Module SW version
or the Platform Module HW version. The Analyzer screen will read:
BM105911A
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8. Hit the right arrow button once. The screen will read:
BM105912A
TROUBLESHOOTING: PLATFORM CAN COMMUNICATIONS LOST

Note: PLATFORM CAN COMMUNICATIONS LOST (6/6) (Help Fault Code 6-6) basically means all communication linked to the Platform
Module is lost. This does not mean that the Platform Module Link only is affected, this means the communication link between
the Platform Module down to the Chassis Module has been broken, therefore all Canbus links have to be checked. Remember
this link is wired in parallel, so the Ground Module has lost all MSA communication.
Table 83. Troubleshooting: Platform Can Communications Lost

STEP ACTION REQUIRED SPEC YES NO
1 Install the Analyzer at the ground station, scroll to the See Diagnostics / Version Chart See step 2 See step 2
”Diag nostics”sub level menu, press ”enter”then scroll to
the ”Ver sions”menu item press ”enter”and view the
screen, reference the Diagnostics / Version Chart to assist
you in determining which module has lost it’s
communication link. In some cases the module that
shows up with a question may be defective if all other
CANbus links check OK.
2 Disconnect the Ground Module J7 deutsche plug Approximately 60 ohms. CANbus circuit is complete. Reconnect plug and go to step
connection at the "T" fitting inside of the ground control Platform Module suspected 3
station. Perform an ohms check at the ”A”and ”B”pins of defective
the "T" fitting. Inspect the shield wire ”C”for shorts.
3 Make sure the CANbus link wires are installed correctly at See Electrical Schematic in Section 7 Go to step 4 Wire per Electrical Schematic
thePlatform Module.
4 Disconnect the platform cannon plug and ground cannon Continuity Reconnect plug and go to step Repair or replace platform
plug that holds the CANbus link. Red (3) Black (2) and 5 harness.
Shield (1) perform a continuity test.
5 Disconnect the deutsche plug connection from the Approximately 120 ohms. Reconnect plug and go to step Suspected defective
Platform Module at the ”T”fitting inside of the ground 6 PlatformModule.
station. Per- form an ohms check at the ”A”and
”B”sockets of the deut sche plug. Inspect the shield wire
”C”for shorts.
6 Inspect the Platform Module harness connection at the Continuity Reconnect harness and go to Repair or replace harness
ground cannon plug and at the ”T”’fitting inside of the step 7 inside the ground control
ground control station. station.
7 Disconnect the deutsche plug connection from the Boom Approximately 120 ohms Reconnect plug and go to step Verify step 7, inspect the
Length & Angle Module at the ”T’fitting inside of the 8 BLAM to Ground Module
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Table 83. Troubleshooting: Platform Can Communications Lost (continued)

ground station. Perform an ohms check at the ”A”and harness con nection s at both
”B”sockets of the deutsche plug. Inspect the shield wire ”T" fitting connections for
”C”for shorts. proper continuity and correct
wiring per Electrical
schematic.
8 Disconnect all deutsche plug connections at the "T”fitting Continuity (NO OHM VALUES) Reconnect all deutsche plugs Replace defective ”T" fitting
in the ground station and the BLAM, perform a continuity at the "T”fitting and go to plug.
test on all ”A””B”and ”C”pins use the singular end of the step 9
fitting and cross probe the corresponding letters of the
other two connections.
9 Disconnect the Chassis Module deutsche plug at the Approximately 120 ohms Reconnect deutsche plug and Inspect the harness from
”T’fitting below the Boom Length & Angle Module. go to step 10 the”T”fitting at the BLAM to
Perform an ohms check at the ”A”and ”B”sockets of the the Chassis Module plug
deutsche plug. Inspect the shield wire ”C”for shorts. connection at the battery.
Assure proper continuity and
correct wiring per Electrical
Schematic.
10 Disconnect the Chassis Module connection at the right Approximately 120 ohms Reconnect plug and go to Inspect the harness from the
side of the battery at the turntable lock pin. Perform an step11 slip ring connections at the
ohms check at the #1 and #2 connections of the plug. top and bottom plug
Inspect shield wire#3 for possible short. connections of the swivel.
Assure proper continuity and
correct wiring per Electrical
Schematic.
11 Disconnect the Chassis Module connection below the Approximately 120 ohms Reconnect plug and go to Inspect the harness from the
swivel under the machine. Perform an ohms check at the step12 bottom of the swivel into the
#1 and #2 connections of the plug that is routed to the Chassis Module. Assure proper
Chassis Module. Inspect shield wire #3 for possible short. continuity and wiring r sche-
matic 1870149A.
12 Make sure the Chassis Module CANbus link wires are Electrical Schematic Stop Replace the Chassis Module.
installed correctly at the plug near the battery, the plug
below the swivel and 31 plug at the Chassis Module.
CANBUS LINK FROM THE GROUND MODULE LOST

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BM105910A
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7. If the CANbus link from the ground module is lost, you will see the Ground Module SW version, Ground Module HW version,
Ground Module SN, BM SW version, Chassis SW version, Platform Module SN, but you will not see the Platform Module SW version
or the Platform Module HW version. The Analyzer screen will read:
BM105911A
BM105912A
CANBUS LINK FROM THE BOOM LENGTH & ANGLE MODULE (BLAM) LOST
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7. If the CANbus link from the Boom Length & Angle Module is lost, you will see the Platform Module SW version, Platform Module
HW Rev, Platform Module SN, Ground Module SW version, Ground Module HW Revision, Ground Module SN, Chassis SW version,
but you will not see the Boom Length & Angle Module SW revision. The Analyzer screen will read:
TROUBLESHOOTING: BLAM CAN COMMUNICATIONS LOST

Note: BLAM CAN COMMUNICATIONS LOST (6/6) (Help Fault Code 6– 6) basically means all communication linked from the Ground
Module to the Boom Length & Angle Module is lost. This also Indicates the lift cylinder loud moment pin as well.
Table 84. Troubleshooting: BLAM Can Communications Lost

”Diagnostics”sub level menu, press ”enter”then scroll to
the ”Versions”menu item press ”enter”and view the
2 Disconnect the BLAM J 1 deutsche plug connection at the Approximately 60 ohms. CANbus circuit is complete . Reconnect plug and go to step
"T”fitting just above the fuel tank. Perform an ohms BLAM suspected defective. 3
check at the”A”and ”B”pins of the "T”fitting. Inspect the
shield wire ”C”for possible short.
3 Disconnect the Ground Module deutsche plug from ”T”fit- Approximately 120 Ohms Reconnect harness and go to Repair or replace the
ting at the BLAM above the fuel tank. Perform an ohm step 4 GroundModule to BLAM
check at the ”A”and ”B”sockets of the deutsche plug. harness.
Inspect the shield wire ”C ”for possible short.
4 Verify the CANbus link signal wires are installed correctly Electrical Schematic Reconnect plug and go to step Wire per Electrical Schematic
at the ’T”fitting at the Ground Module. 5
5 Verify the lift cylinder load moment harness has good Continuity Reconnect plug and go to step Repair or replace Chassis Mod
continuity and wired correctly at the J4 plug on the 6 ule harness.
BLAM.
6 Disconnect the Chassis Module plug connection at the Approximately l 20 Ohms Reconnect plug and stop Inspect harness and
battery and perform an ohm check at the #1 and #2 connections to the Chassis
socket of the deutsche plug. Inspect the shield wire #3 Module.
for possible short.
CANBUS LINK FROM THE CHASSIS MODULE LOST
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JLG Control System
BM105910A
7. If the CANbus link from the Chassis Module is lost, you will NOT see the Platform Module SW version, Platform Module HW rev,
Platform Module SN, Chassis SW version, Boom Length & Angle Module SW version, but you WILL see the Ground Module SW
version, Ground Module HW rev, and the Ground Module SN. The analyzer screen will read:
BM105911A
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BM105912A
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TROUBLESHOOTING: CHASSIS CAN COMMUNICATIONS LOST

Note: CHASSIS CAN COMMUNICATIONS LOST (6/6) (Help Fault Code 6-6) basically means all communication linked from the Ground
Module to the Chassis Module is lost.
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JLG Control System
Table 85. Troubleshooting: Chassis Can Communications Lost

”Diag- nostics”sub level menu, press ”enter”then scroll to
the ”Ver- sions”menu item press ”enter”and view the
2 Disconnect the BLAM J1 deutsche plug connection at the Approximately 60 ohms. CANbus circuit is complete. Reconnect plug and go to step
"T" fitting just above the fuel tank. Perform an ohms Chassis Module suspected 3
check at the”A”and ”B”pins of the ”T”fitting. Inspect the defective.
shield wire ”C”for possible short.
3 Disconnect the Chassis Module communication harness Continuity Reconnect harness and go to Repair or replace BLAM
from the BLAM ”T”fitting and Chassis Module plug step 4 andChassis Module harness.
connection at the battery. Perform a continuity test.
4 Verify the CANbus link signal wires are installed correctly Electrical Schematic Reconnect plug and go to step Wire per Electrical Schematic
at the Chassis Module plug connection at the battery and 6
at the plug below the swivel.
5 Verify continuity at the Chassis Module harness from the Continuity Reconnect plug and go to step Repair or replace Chassis Mod-
plug connection at the battery down to the plug 6 ule harness.
connection below the swivel.
6 Disconnect the Chassis Module plug connection below the Approximately 120 Ohms Stop Replace Chassis Module
swivel and perform an ohms check at the #1 and #2 of
the plug. Inspect the shield wire #3 plug connection for
possible short.
6.23.2 Load Moment Pin Troubleshooting

The following Troubleshooting Charts outline diagnostic measures to be taken to diagnose problems within the Load Moment Pin
portion of the JLG Control System. If necessary, refer to Section 4 for information concerning replacement of the Load Moment Pin.
Table 86. Load Moment Pin Troubleshooting: Can Communications Lost

STEP FAULT CODE/SYMPTOM REPAIR YES NO
6/6 CYLINDER LOAD PIN CAN COMMUNICATIONS LOST Check for correct and tight wire Go to step 2 Replace harness.
connections at the deutsch and (4922826)
1 phoenix connectors of the Load
Sensing Pin harness and perform
a continuity check.
Check for loose pins in the potting Replace the BLAM & Go to step 3
2 of the Boom Length & Angle Perform the Boom Sensor
Module J4 connection. calibration process.
Inspect the CANbus link ”T” fitting Go to step 4 Replace ”T”

connections at the BLAM & fitting
3 Ground Module. Are the fittings connector.
dry? (4460945)
Inspect the CANbus link ”T” fitting Go to step 5 Replace ”T”

connections at the BLAM & fitting
4 Ground Module. Perform a connector.
continuity check. (4460945)
Check the J1 and J4 plug Go to step 6 Position plug

5 connections on the BLAM, make correctly.
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Table 86. Load Moment Pin Troubleshooting: Can Communications Lost (continued)
sure the notched plugs line up
with the plug sockets correctly.
Use the Analyzer, scroll – + to Go to step 6 Replace the load

the DIAGNOSTICS menu, press moment pin. &
ENTER, then scroll to the MOMENT Perform the
6 menu, and press ENTER, check to Boom Sensor
see i f Actual / Over / Under calibration
moment values are registering on process.
the screen display.
If they are, refer to Figure 5-120., If the problem still exists, Replace the load
Moment Chartfor comparable verify steps 1-7 again moment pin. &
values, if the values are not close, before contacting the JLG Perform the
7 try boom sensor calibration to see Service Dept. Boom Sensor
if the values come within the calibration
chart. process.
Table 87. Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range
8/6 MOMENT PIN HORIZONTAL FORCE OUT OF RANGE Check to see if the platform is Remove excess weight Go tostep 2
The horizontal force is out of allowed range. overloaded in the vertical
1 position. Check the rated capacity
requirement.
Check to see if any additional Perform the Boom Sensor Go to step 3

accessories have been added to calibration process.
2
the platform without proper
calibration.
Perform the BCS daily check Go to step 4 Perform the
procedure to make sure the boom Boom Sensor
3 sections are stopping correctly at calibration
the witness marks matching their process.
capacity selection.
Inspect the job the machine is Go to step 5 Position

performing, making sure that machine
there is no additional force correctly.
4 applied when the boom sections
are in the horizontal position.
Also consider weather conditions
(Wind).
Use the Analyzer, scroll to the Go to step 6 Replace the load
DIAGNOSTICS menu, press ENTER, moment pin. &
then scroll to the MOMENT menu, Perform the
5 and press ENTER, check to see if Boom Sensor
Actual / Over / Under moment calibration
values are registering on the process.
screen display.
chart. process.
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JLG Control System
Table 88. Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range
8/6 MOMENT PIN VERTICAL FORCE OUT OF RANGE Check to see if the platform is Remove excess weight Go tostep 2
The vertical force is out of allowed range. overloaded in the vertical
1 position. Check the rated capacity
requirement.
Check to see if any additional Perform the Boom Sensor Go to step 3

accessories have been added to calibration process.
2
the platform without proper
calibration.
Perform the BCS daily check Go to step 4 Perform the
procedure to make sure the boom Boom Sensor
3 sections are stopping correctly at calibration
the witness marks matching their process.
capacity selection.
Inspect the job the machine is Go to step 5 Position

performing, making sure that machine
there is no additional force correctly.
4 applied when the boom sections
are in the horizontal position.
Also consider weather conditions
(Wind).
Use the Analyzer, scroll to the Go to step 6 Replace the load
DIAGNOSTICS menu, press ENTER, moment pin. &
then scroll to the MOMENT menu, Perform the
5 and press ENTER, check to see if Boom Sensor
Actual / Over / Under moment calibration
values are registering on the process.
screen display.
chart. process.
Table 89. Load Moment Pin Troubleshooting: Moment Pin Sensor Fault
8/6 MOMENT PIN SENSOR FAULT The moment pin Use the Analyzer, scroll to the Replace load moment pin Contact JLG
has reported a fault flag DIAGNOSTICS menu, press ENTER, & Perform the Boom Service Dept.
then scroll to the MOMENT menu, Sensor calibration process
1 and press ENTER, check to see if
PIN E FLAGS has any numbers on
the screen display.
Table 90. Load Moment Pin Troubleshooting: New Moment Pin Detected Fault
8/6 NEW MOMENT PIN DETECTED FAULT A moment Perform the Boom Sensor Verify BCS check and Contact JLG
pin was detected on the system different from the calibration process to accept the review all faults prior to Service Dept.
1 one used to calibrate the machine. new load moment pin. contacting JLG Service
Dept.
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JLG Control System
Figure 264. Moment Chart
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SECTION 7
BASIC ELECTRICAL INFORMATION AND SCHEMATICS
7.1 GENERAL
This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems
which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective
actions, technically qualified guidance should be obtained before proceeding with any maintenance.
7.2 MULTIMETER BASICS
A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. This section shows diagrams
of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary. Please consult the
meter operator’s manual for more information.
7.2.1 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.
7.2.2 Backprobing
To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the back of the
connector. Readings can be done while maintaining circuit continuity this way. If the 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 connector such that the test also checks both
terminals of the connection. 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 gentle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector.
7.2.3 Min/Max
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.
7.2.4 Polarity
Getting a negative Voltage or current reading when expecting a positive reading frequently means the leads are reversed. Check what
reading is expected, the location of the signal and that the leads are connected to the device under test correctly. Also check that the
lead on the "COM" port goes to the Ground or negative side of the signal and the lead on the other port goes to the positive side of the
signal.
7.2.5 Scale
M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
m = milli = (Displayed Number) / 1,000
µ = micro = (Displayed Number) / 1,000,000
Example: 1.2 kW= 1200 W
Example: 50 mA = 0.05 A
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Basic Electrical Information and Schematics
7.2.6 Voltage Measurement
Figure 265. Voltage Measurement (DC)
• If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual)
• Use firm contact with meter leads
7.2.7 Resistance Measurement
Figure 266. Resistance Measurement
• First test meter and leads by touching leads together. Resistance should read a short circuit (very low resistance)
• Circuit power must be turned OFF before testing resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual)
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7.2.8 Continuity Measurement
Figure 267. Continuity Measurement
• Some meters require a separate button press to enable audible continuity testing
• Circuit power must be turned OFF before testing continuity
• Disconnect component from circuit before testing
• First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity
7.2.9 Current Measurement
Figure 268. Current Measurement (DC)
• Set up the meter for the expected current range
• Be sure to connect the meter leads to the correct jacks for the current range you have selected
• If meter is not auto ranging, set it to the correct range (Refer to multi meter’s operation manual)
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7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS
Note: This section is not applicable for battery terminals.
NOTICE
JLG PN 0100048 Dielectric Grease (Novagard G661) is the only material approved
for use as a dielectric grease.
Note: Do NOT apply dielectric grease to the following connections:
• 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 following reasons:
• To prevent oxidation at the mechanical joint between male and female pins.
• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. This procedure applies to all plug
connections not enclosed in a box. Silicone grease should not be applied to connectors with external seals.
1. To prevent oxidation, silicone grease must be packed completely around male and female pins on the inside of the connector
prior to assembly. This is most easily achieved by using a syringe.
Note: Over a period of time, oxidation increases electrical resistance 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 connectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the connector should also be sealed.
Note: This condition is especially common when machines are pressure washed since the washing solution is much more conductive
than water.
3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only.
Note: Curing-type sealants might also be used to prevent shorting 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 conductivity
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).
7.4 DIELECTRIC GREASE APPLICATION
Dielectric grease helps to prevent corrosion of electrical contacts and improper conductivity between contacts from moisture intrusion.
Non-waterproof connectors benefit from the application of dielectric grease.
7.4.1 Installation
The following is general guidance for the installation of dielectric grease in a connector system.
• Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors.
• Apply dielectric grease to plug/male connector housing which typically contains sockets contact/female terminals.
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• Leave a layer of dielectric grease on the mating face of the connector, completely covering each connector terminal hole. Refer the
pictures shown below.
• Assemble the connector system immediately to prevent moisture ingress or dust contamination.
The following connector systems are specifically addressed because of their widespread use at JLG. However, this guidance may be
applied to similar devices.
7.4.2 AMP Mate-N-Lok

This connector system is widely used inside enclosures for general-purpose interconnect. Follow the general guidance for installation.
7.4.3 AMP Faston

This connector system is typically used on operator switches at JLG. Follow the general guidance for installation.
7.4.4 AMP Micro-Fit

This connector system is typically used on control modules at JLG. Follow the general guidance for installation.
7.4.5 AMP Mini Fit Jr

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7.4.6 Mini Fit Sr

7.4.7 DIN Connectors

This connector is typically used on hydraulic valves. Follow the installation instructions.
7.4.8 Exceptions
Some waterproof connector applications do benefit from dielectric grease, and some non waterproof connectors do not benefit from
dielectric grease.
In the exceptions below, we have found dielectric grease is not needed for some applications, and in some cases can interfere with the
intended connection. Dielectric grease shall be used as an exception in other applications.
ENCLOSURES
Application of dielectric grease is not required in properly sealed enclosures. To meet criteria, the enclosure must be rated to at least
IP56 (dust protected; protected from powerful jets of water).
CARLING SWITCH CONNECTORS
Carling switches may experience high impedance, or discontinuity, due to silicone dielectric grease ingress when switching inductive
loads. Therefore, dielectric grease shall not be applied to Carling switch mating connectors unless specifically noted.
7.5 AMP CONNECTOR
7.5.1 Applying Silicone Dielectric Compound to AMP Connectors

Silicone Dielectric Compound must be used on the AMP connections for the following reasons:
• To prevent oxidation at the mechanical joint between male and female pins.
• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and female
pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by using a syringe to fill
the header with silicone dielectric compound, to a point just above the top of the male pins inside the header. When assembling
the housing to the header, it is possible that the housing will become air locked, thus preventing the housing latch from engaging.
2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.
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7.5.2 Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (Refer to Figure — Connector Assembly Figure 1, page 739).
Proceed as follows:
Figure 269. Connector Assembly Figure 1
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (Refer to Figure — Connector Assembly
Figure 2, page 740).
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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 (Refer to Figure —
Connector Assembly Figure 2, page 740).
Figure 270. AMP Connector
3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by
squeezing them inward (Refer to Figure — Connector Assembly Figure 3, page 740).
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4. Slide the wedge lock into the housing until it is flush with the housing (Refer to Figure — Connector Assembly Figure 4, page 741).
Figure 274. Connector Disassembly
7.5.3 Disassembly
1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs.
2. Pry open the wedge lock to the open position.
3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is
removed.
Note: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
7.5.4 Wedge Lock

The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat
probe such as a pocket knife. DO NOT use a sharp point such as an ice pick.
7.5.5 Service - Voltage Reading

DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice
should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in
the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies the effectiveness of the
connector seals and could result in system failure.
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Figure 275. Connector Installation
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7.6 DEUTSCH CONNECTORS
7.6.1 DT/DTP Series Assembly
Figure 276. DT/DTP Contact Installation
1. Grasp crimped contact about 25mm behind the contact barrel.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.
4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedgelock will snap
into place. Rectangular wedges are not oriented. Thy may go in either way.
Note: The receptacle is shown - use the same procedure for plug.
7.6.2 DT/DTP Series Disassembly
Figure 277. DT/DTP Contact Removal
1. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from
the contact with a screwdriver.
3. Hold the rear seal in place, as removing the contact may displace the seal.
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7.6.3 HD30/HDP20 Series Assembly
Figure 278. HD/HDP Contact Installation
1. Grasp contact about 25mm behind the contact crimp barrel.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in
place.
Figure 279. HD/HDP Locking Contacts into Position
Note: For unused wire cavities, insert sealing plugs for full environmental sealing
7.6.4 HD30/HDP20 Series Disassembly
Figure 280. HD/HDP Contact Removal
1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
2. Slide tool along into the insert cavity until it engages contact and resistance is felt.
3. Pull contact-wire assembly out of connector.
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Figure 281. HD/HDP Unlocking Contacts
Note: Do Not twist or insert tool at an angle.
7.7 TELEMATICS GATEWAY
Personnel using machines equipped with an optional telematics gateway will be able to view the following data through their telematics
device:
JLG LABEL DESCRIPTION UNIT

Engine Speed Actual engine speed. RPM
DEF Tank Level (If Indicates the level of DEF (diesel exhaust fluid) within the DEF tank if the machine is equipped with DEF tank.
Equipped)
0% = Empty Percentage (%)
100% = Full
JLG Machine Faults:Active 00 - No Machine Faults
/ Not-Active
01 - Active Machine Fault
Bit
10 - Error
11 - Not available
Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions. Liters
Total Idle Hours Total time of engine operation during idle conditions. Seconds
Total Engine Hours Total time of engine operation. Seconds
Total Fuel Used Total amount of fuel used during vehicle operation. Liters
Fuel Rate Amount of fuel consumed by engine per unit of time. Liters/Hour
Fuel Level Ratio of fuel volume to the total volume of the fuel storage container. When a low fuel limit switch is present,
the fuel level will indicate "full" until the switch opens, which will then indicate 10% fuel remaining.
Percentage (%)
When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents the total fuel in all fuel storage containers. When
Fuel Level 2 is used, Fuel Level 1 represents the fuel level in the primary or left side fuel storage container.
DM1 Engine Faults Shows actual engine fault codes. N/A
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7.7.1 Telematics-Ready (TCU) Plug

The telematics-ready (TCU) plug is a standard 12-pin Deutsch connector. Pin-out locations are shown below:
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Figure 282. Telematics Gateway Harness - Sheet 1 of 3
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Figure 285. Skyguard Harness - Sheet 1 of 2
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Figure 286. Skyguard Harness - Sheet 2 of 2
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Figure 287. Gen 2 Platform Interface - Sheet 1 of 2
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Figure 288. Gen 2 Platform Interface - Sheet 2 of 2
1200SJP , 1350SJP 31220396 753

Figure 289. Chassis Electrical Components - Sheet 1 of 2
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Figure 290. Chassis Electrical Components - Sheet 2 of 2
1200SJP , 1350SJP 31220396 755

Figure 291. Turntable Electrical Components - Sheet 1 of 2
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Figure 292. Turntable Electrical Components - Sheet 2 of 2
1200SJP , 1350SJP 31220396 757

TO WORKLIGHT HARNESS
X564
TO USB OUTLET
TO USB OUTLET
USB-
USB+
1001265163-A
MAF48550A
Figure 293. USB Harness
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USB+ - TO USB OUTLET

CONNPOS WIRECOLOR WIRE LABEL GAUGE JACKET TO
1 RED B+ 16 AWG GXL X564 (2)
USB- - TO USB OUTLET

1 BLK B- 16 AWG GXL X564 (1)
X564 - TO WORKLIGHT HARNESS

1 BLK B- 16 AWG GXL USB- (1)
2 RED B+ 16 AWG GXL USB+ (1)
3
4
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7.8 ELECTRICAL SCHEMATICS
Figure 294. Electrical Schematic - Sheet 1 of 13
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Blank page
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417
Visit our website for JLG Worldwide Locations.

www.jlg.com

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Service & Maintenance Manual

HYDRAULIC SYSTEM SAFETY

1200SJP , 1350SJP 31220396 3

• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

4 31220396 1200SJP , 1350SJP

DATE REVISION DESCRIPTION

1200SJP , 1350SJP 31220396 5

INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS........................................................................ 3

REVISION LOG ............................................................................................................................................... 5

1200SJP , 1350SJP 31220396 7

3.12 Drive Hub .......................................................................................................................... 77

8 31220396 1200SJP , 1350SJP

1200SJP , 1350SJP 31220396 9

7.4 Dielectric Grease Application .............................................................................................. 736

10 31220396 1200SJP , 1350SJP

Hydraulic Tank 55 Gallon (208 L)

Wheel Drive Hub

Reggiana Riduttori 1.59 Quarts (1.5 L)

Load Rating 26,500 lb @ 100 psi (12020 kg @ 6.9 Bar)

Foam Fill Poly urethane HD (55 Durometer) Foam

Max Tire Load

1350SJP 26,250 lb (11,907 kg)

Max Tire Load (Non-Marking Tire)

@6 km/h 33,000 lb (15,000 kg)

@25km/h 25,300 lb (11,500 kg)

1.3 ENGINE DATA

1.3.1 Deutz TD2011L04

Bore 3.7 in. (94 mm)

1200SJP , 1350SJP 31220396 11

Compression Ratio 17.5:1

Firing Order 1-3-4-2

Output 75 hp (56 kW)

Cooling System 5 Quarts (4.5 L)

w/Filter 11 Quarts (10.5 L)

Average Fuel Consumption 1.1 gph (4.1 lph)

Idle Engine RPM 1200

Mid Engine RPM 1800

High Engine RPM 2475

1.3.2 Deutz TCD2.9L4

Min Low Engine RPM 900

High RPM set 2500 ±50 RPM

Low RPM set 1200 ± 50 RPM

Coolant Capacity (Engine Only) 0.79 Gallon (3 L)

Average Fuel Consumption 1.2 gph (4.1 lph)

Acceptable Fuel Grades Ultra Low Sulfur (15 ppm)

(Dependent upon Regulated Area) Up to 5% Biodiesel

1.3.3 Deutz TCD2.9L4 GUOIII

Min Low Engine RPM 900

High RPM set 2500 ±50 RPM

Low RPM set 1200 ± 50 RPM

Coolant Capacity (Engine Only) 0.9 2 Gallon (3.5 L)

12 31220396 1200SJP , 1350SJP

Average Fuel Consumption 1.2 gph (4.1 lph)

Acceptable Fuel Grades Ultra Low Sulfur (15 ppm)

(Dependent upon Regulated Area) Up to 5% Biodiesel

1.3.4 Deutz TCD2.9L4 Stage V

Min Low Engine RPM 1000

High RPM set 2500 ±50 rpm

Low RPM set 1200 ± 50 rpm

Coolant Capacity (Engine Only) 0.92 Gallon (3.5 L)

Average Fuel Consumption 1.3 gph (4.75 lph)