S 1250AJP JLG Service English

Service and Maintenance Manual
Model
1250AJP
PN - 3121171
May 31, 2019 - Rev S
AS/NZS
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A GENERAL C MAINTENANCE
This section contains the general safety precautions which
must be observed during maintenance of the aerial platform.
It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
possible injury to themselves or others, or damage to the SAFETY VIOLATION.
equipment. A maintenance program must be followed to
ensure that the machine is safe to operate.
• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER. • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-
TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
The specific precautions to be observed during maintenance SECURE AT ALL OTHER TIMES.
are inserted at the appropriate point in the manual. These pre-
cautions are, for the most part, those that apply when servic- • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-
ing hydraulic and larger machine component parts. FORMING ANY MAINTENANCE.
Your safety, and that of others, is the first consideration when • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
engaging in the maintenance of equipment. Always be con- TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
scious of weight. Never attempt to move heavy parts without CAUGHT ON OR ENTANGLED IN EQUIPMENT.
the aid of a mechanical device. Do not allow heavy objects to
rest in an unstable position. When raising a portion of the • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
equipment, ensure that adequate support is provided. MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING

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

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

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

VENTS.
3121171 A-1
INTRODUCTION
REVISON LOG
Original Issue A - April 15, 2004

Revised B - June 15, 2004
Revised C - August 14, 2004
Revised D - December 7, 2004
Revised E - January 12, 2006
Revised F - November 29, 2006
Revised G - January 17, 2007
Revised H - November 9, 2007
Revised I - March 20, 2008
Revised J - August 21, 2008
Revised K - March 18, 2010
Revised L - October 26, 2011
Revised M - December 7, 2012
Revised N - June 11, 2013
Revised O - September 9, 2015
Revised P - June 22, 2017
Revised Q - May 30, 2018
Revised R - June 29, 2018
Revised S - May 31, 2019
A-2 3121171
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
C Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - SPECIFICATIONS
1.1 Operating Specifications & Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.5 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Caterpillar 3.4T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Deutz BF4M2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Deutz TD2011L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Deutz TCD2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.9 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.10 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.11 Lubrication & Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Thermal Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
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TABLE OF CONTENTS

2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Do NOT Do the Following When Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Axle Extension System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Axle Limit Switch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.5 Steering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6 Drive/Steering Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.7 Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.8 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.9 Ground Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.10 Oscillating Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.11 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.12 Wheel Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.13 Drive Hub - If Equipped With Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
First Stage Planetary (7) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Second Stage Planet Gears (1) Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
First Stage Planetary (7) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
End Cover Unit (8) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Initial Start-up And After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Oil Change Interval-Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.14 Drive Hub - If Equipped With Bonfiglioli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Installation of the Wheel Drive on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Start Up and Running In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Gearbox Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Disassembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Inspection of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Final Test and Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3.15 Drive Hub - If Equipped With Reggiana Riduttori. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Symbol Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.16 Swing Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Assembly/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
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3.17 Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Roll and Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Hub-Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Hub-Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Motor Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3.18 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
3.19 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Disassembly and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
3.20 Procedure For Setting Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
3.21 Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
3.22 Turntable Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Turntable Bearing Mounting Bolts Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Turntable Bearing Wear Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
Turntable Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
Turntable Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
3.23 Swing Speed Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
3.24 Chassis Tilt Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
3.25 Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
3.26 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
3.27 Cold Weather Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
3.28 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
Replacing Fuel Filter or Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
Cleaning Fuel Strainer (D2011 L03 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
3.29 Deutz EMR 2 (SN 87575 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
3.30 Bio Fuel in Deutz Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
3.31 Deutz Turbocharger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
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3.32 CAT DGC Diagnostic Support And Trouble Code Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193
List of Abbreviations in this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-195
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-196
CAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-196
MIL Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-196
DTC 116- ECT Higher Than Expected Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-197
DTC 117- ECT/CHT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-198
DTC 118- ECT/CHT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-199
DTC 122- TPS1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-201
DTC 123- TPS1 Signal Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-203
DTC 217- ECT Higher Than Expected 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-205
DTC 219- RPM Higher Than Max Allowed Governed Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-206
DTC 336- Crank Signal Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-207
DTC 337- Loss of Crank Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-209
DTC 521- Oil Pressure Sender/Switch High Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-210
DTC 524- Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-211
DTC 562- Battery Voltage (VBat) Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-213
DTC 563- Battery Voltage (VBat) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-215
DTC 601- Microprocessor Failure - FLASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-217
DTC 604- Microprocessor Failure - RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-219
DTC 606- Microprocessor Failure - COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-221
DTC 642- 5 Volt External Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-223
DTC 643- 5 Volt External High Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-224
DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-225
DTC 1615- Microprocessor Failure - A/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-230
DTC 1616- Microprocessor Failure - interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-232
DTC 1625- CAN J1939 Shutdown Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-234
DTC 1626- CAN J1939 Transmit (Tx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-235
DTC 1627- CAN J1939 Receive (Rx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-236
DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-237
DTC 1629- J1939 TSC1 Message Receipt Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-239
DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-240
DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-241
DTC 2112- Unable to Reach Higher TPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-243
DTC 9999- Throttle Actuator Failsafe Spring Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-244
DTC to SPN/FMI Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-244
3.33 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-246
3.34 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-246
SECTION 4 - BOOM & PLATFORM
4.1 Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Transport Position Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 Drive/Steer – Boom Function Interlock System (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.5 Jib Stow System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.6 Envelope Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.7 Tower Path Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.8 Automatic Main Boom Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.9 Electrical Retrieval System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.10 Hydraulic Retrieval System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.11 Controlled Boom Angle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.12 Slow Down System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.13 Dual Capacity System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.14 Hydraulic System Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.15 Reduced Platform Heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.16 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
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4.17 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.18 Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.19 Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.20 Tower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Installation and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Pin Clamp Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.21 Main Boom Transport Angle Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Analyzer Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Possible Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
4.22 Tower Transport Length Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Possible Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.23 Main Boom Transport Length Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Possible Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.24 Dual Capacity Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Possible Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
4.25 Tower Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4.26 Tower Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4.27 Main Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
4.28 Main Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
4.29 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
One Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Two Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
4.30 Hose Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
4.32 Tower Boom Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
4.33 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Greasing Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117
Testing the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117
Bleeding After Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119
4.34 Bolt-on External Fall Arrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
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4.35 Skyguard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123
Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123
Diagnostics & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-124
SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS
5.1 Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tapered Thread Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straight Thread Types, Tube and Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straight Thread Types, Port Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Flange Connection Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Assembly And Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.. . . . . . . . 5-6
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections. . . . . . . . . . . . 5-7
Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Assembly Instructions for 45° SAE Flare Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . . . . . . . . . . . . . . . . . . . 5-16
Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends . . . . . . . . . . . . . . . . . . . . . 5-38
Assembly instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Assembly Instructions for Flange Connections: (FL61 and FL62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
FFWR and TFFT Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5.3 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5.4 Counterbalance Valve Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
5.5 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5.6 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5.7 Enable Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
Air Purge Procedure for Non-Calibrated Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
Air Purge Procedure for Calibrated Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
5.8 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Set Up of the Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Adjustments made at the Main Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
Adjustments Made at the Frame Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-119
Adjustments Made at the Platform Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-123
5.9 Drive Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
Charge Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127
Mechanical Centering of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
Hydraulic Centering of Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
High Pressure Relief Valve Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
Removal and inspection of charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
vi 3121171
TABLE OF CONTENTS

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130
Removal and Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-132
5.10 Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
Sealing the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135
Disassembly and Assembly of the Complete Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-136
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
Pump Control Disassembly For Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-142
5.11 Drive & Function Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-143
Start-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-143
5.12 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
SECTION 6 - JLG CONTROL SYSTEM
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Connect the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Changing Access Level of Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Adjusting Parameters Using Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2 Machine Personality Settings and Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.3 Machine Orientation When Setting Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.4 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Chassis Pin Module Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
BLAM Pin Module Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.6 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
6.7 Calibrating Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
6.8 Calibrating Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
6.9 Calibrating Boom Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
6.10 LSS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
6.11 Resetting The MSSO System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Platform Leveling Fault Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Fault Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
CAN Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Additional Platform and Jib Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
6.13 Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
STEP 2: BLEEDING THE PLATFORM VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS . . . . . . . . . . . . . . 6-75
6.14 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
6.15 Boom Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
General Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Step 1 - Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Step 2 - Position 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Step 3 - Position 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Step 4 - Position 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Step 5 - Position 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Step 6 - Position 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
3121171 vii
TABLE OF CONTENTS

Step 7 - Position 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Step 8 - Position 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Step 9 - Position 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Step 10 - Position 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
Step 11 - Position 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
6.16 Boom Control System (BCS) Violation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
“UNLOCK BOOM” Calibration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
6.17 CANbus Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-140
CANbus Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-146
Load Moment Pin Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-159
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Faston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Micro-Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Mini Fit Jr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Mini Fit Sr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Applying Silicone Dielectric Compound to AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.7 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Telematics-Ready (TCU) Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
viii 3121171
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Lubrication & Operator Maintenance Diagram - Deutz 2011/CAT Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-2. Lubrication & Operator Maintenance Diagram - Deutz 2.9 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3. Hydraulic Return Filter Condition Indicator - Prior to SN 139396 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-4. Hydraulic Return Filter Condition Indicator - SN 139396 to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-5. Torque Chart (SAE Fasteners - Sheet 1 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1-9. Torque Chart (METRIC Fasteners - Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
2-1. Engine Operating Temperature Specifications - Deutz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-2. Hydraulic Oil Operating Temperature Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-3. Engine Operating Temperature Specifications - Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3-1. Axle Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Conventional Two Wheel Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3. Crab Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-4. Coordinated Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-5. Chassis Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-6. Chassis Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-7. Turntable Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-8. Turntable Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-9. Oscillating Axle - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-10. Oscillating Axle - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-11. Axle JLG Threadlocker Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-12. Steering Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-13. Wheel Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-14. Drive Hub - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-15. Drive Hub - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-16. Drive Hub Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-17. Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-18. Gearbox engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-19. Gearbox Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-20. Drive Hub - If Equipped with Bonfiglioli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-21. Drive Hub Special Tools - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3-25. Bearing Track Spacer Mounting C016117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-26. Oil Seal Spacer Mounting C125049 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-27. Bearing Spacer Mounting CO16117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-28. Assembly Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-29. Wrench For Ring Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-30. Anti-rotation Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-31. Anti-rotation Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-32. Anti-rotation Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-33. Assembly Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-34. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3-35. Reggiana Riduttori Hub - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3-36. Reggiana Riduttori Hub - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3-37. Swing System (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-38. Swing System (SN 0300254457 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3-39. Swing Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3-40. Swing Drive - Motor Control Valve Disassembly (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . 3-69
3-41. Swing Drive - Motor and Brake Disassembly (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . . 3-70
3-42. Swing Drive - Main Disassembly (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3-43. Swing Drive - Hub Shaft Disassembly (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3-44. Swing Drive - Carrier Disassembly (SN 0300201017 through 0300254456). . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3-45. Swing Drive - Hub Shaft Sub-Assembly (SN 0300201017 through 0300254456). . . . . . . . . . . . . . . . . . . . . . . 3-74
3121171 ix
LIST OF FIGURES

3-46. Swing Drive - Carrier Sub-Assembly (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3-47. Swing Drive - Main Assembly (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3-48. Swing Drive - Motor and Brake Assembly (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . . . . . 3-79
3-49. Swing Drive - Motor Control Valve Assembly (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . 3-80
3-50. Swing Motor (SN 0300254457 to Present) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
3-51. Swing Motor (SN 0300254457 to Present) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
3-52. Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-53. Swing Brake 8 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3-54. Swing Brake 12 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3-55. Swing Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
3-56. Swing Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
3-57. Swing Drive Ports (SN 0300201017 through 0300254456). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
3-58. Swing Drive Lubrication (SN 0300201017 through 0300254456) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
3-59. Swing Drive Ports (SN 0300254457 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
3-60. Frame Side Bearing Bolt Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
3-61. Frame Side Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
3-62. Turntable Side Bearing Bolt Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
3-63. Turntable Side Bearing Bolt Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
3-64. Dial Indicator General Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3-65. Turntable Bearing Measurement Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3-66. Dial Indicator Measurement Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3-67. Bearing Marking Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3-68. Turntable Bearing Service Boom Placement - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3-71. Turntable Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
3-72. Turntable Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
3-73. Rotary Coupling Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
3-74. Rotary Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3-75. Rotary Coupling Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
3-76. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
3-77. Deutz Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
3-78. Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
3-79. Cold Weather Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3-80. Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
3-81. EMR 2 Engine Side Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
3-82. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3-83. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
3-84. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
3-85. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
3-86. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
3-87. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
3-88. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
3-93. 1st page of Diagnostic Information for a Given Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193
3-94. 2nd Page of Diagnostic Information for a Given Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-194
3-95. Counterweight Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-247
4-1. Tower Path vs. Main Boom Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-2. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-3. Position of Least Backward Stability - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-4. Position of Least Backward Stability - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-5. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-6. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-7. Rotator Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
x 3121171
LIST OF FIGURES

4-8. Main Boom Assembly - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-12. Main Boom Assembly Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-13. Tower Boom Assembly - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-15. Tower Boom Assembly Torque Values - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4-16. Tower Boom Assembly Torque Values - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-17. Boom & Cylinder Installation (Prior to SN 0300144623) - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-18. Boom & Cylinder Installation (SN 0300144623 to Present) - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4-19. Boom & Cylinder Installation - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4-22. Boom and Cylinder Installation Torque Values - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4-25. Boom Wiper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4-26. Pin Clamp Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4-27. Locations for JLG Threadlocker Application - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4-32. Tower Boom Powertrack Installation - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4-35. Boom Sensor Locations Overall View - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4-36. Boom Sensor Locations Overall View - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
4-37. Boom Sensor Locations - Tower Lift Cylinder Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4-38. Boom Sensor Locations - Dual Capacity, Length, & Main Boom Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
4-39. Boom Sensor Locations - Tower Boom Transport Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4-40. Boom Sensor Locations - Level & Jib Position Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4-41. Boom Sensor Locations - Upper Length, Lower Length, & Tower Boom Angle - Sheet 1 of 2. . . . . . . . . . . 4-56
4-42. Boom Sensor Locations - Upper Length, Lower Length, & Tower Boom Angle - Sheet 2 of 2. . . . . . . . . . . 4-57
4-43. Boom Sensor Locations - Rotary Angle & Proximity Sensor - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-44. Boom Sensor Locations - Rotary Angle & Proximity Sensor - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4-45. Main Boom Transport Angle Switch Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4-46. Tower Transport Length Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4-47. Main Boom Transport Length Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4-48. Dual Capacity Switch Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4-49. Tower Telescope Only Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4-50. Tower Lift Only Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-51. Load Sensing Pin Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
4-52. Load Pin Removal Tool, JLG PN 4846765 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4-53. Main Boom Powertrack Installation - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4-55. Tower Boom Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
4-56. Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
4-57. Rotary Actuator - Assembly Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
4-58. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118
4-59. Jib Alignment Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119
4-60. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120
4-61. Bolt-On External Fall Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122
5-1. NPTF Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
3121171 xi
LIST OF FIGURES

5-2. BSPT Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-3. JIC Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-4. SAE Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-5. ORFS Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-6. MTBL-MBTS Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-7. Bulkhead Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-8. ORB-MPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-9. MFF-BSPP Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-10. ORB-MPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-11. Torque Wrench Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-12. Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5-13. FFWR Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5-14. Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5-15. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-16. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-17. Axle Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5-18. Axle Lockout Cylinder (SN 0300201017 through 0300239155). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-19. Axle Lockout Cylinder (SN 0300239156 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5-20. Platform Level Cylinder (Prior to SN 0300080030) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5-21. Platform Level Cylinder (SN 0300080030 through SN 0300201017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5-22. Platform Level Cylinder (SN 0300201017 through 0300238006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-23. Platform Level Cylinder (SN 0300201017 through 0300239155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5-24. Platform Level Cylinder (SN 0300238007 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5-25. Tower Lift Cylinder (Prior to SN 0300144623) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-26. Tower Lift Cylinder (SN 0300211614 through 0300238464). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5-27. Tower Lift Cylinder (SN 0300239465 to Present)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-28. Main Boom Lift Cylinder (SN 0300201017 through SN 0300211613) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-29. Main Boom Lift Cylinder (SN 0300211614 through 0300239976) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-30. Main Boom Lift Cylinder (0300239977 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-31. Jib Cylinder (Prior to 0300239155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-32. Jib Cylinder (SN 0300239156 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-33. Steer Cylinder (Prior to SN 0300201017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
5-34. Steer Cylinder (SN 0300201017 through 0300238558) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5-35. Steer Cylinder (SN 0300238559 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
5-36. Tower Boom Telescope Cylinder (SN 0300201017 through 0300243458) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
5-37. Tower Boom Telescope Cylinder (SN 0300243459 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
5-38. Main Boom Telescope Cylinder (Prior to SN0300144623). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5-39. Main Boom Telescope Cylinder (SN 0300201017 through 0300243463). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5-40. Main Boom Telescope Cylinder (SN 0300243464 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
5-41. Special Tools for Tower Tele Cylinder - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5-42. Special Tools for Tower Tele Cylinder - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5-43. Special Tools for Upper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
5-44. Special Tools for Main Lift Cylinder and Tower Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5-45. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5-46. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5-47. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5-48. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5-49. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5-50. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5-51. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5-52. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5-53. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
5-54. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
5-55. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5-56. Hydraulic Oil Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5-57. Hydraulic Return Filter Condition Indicator - Prior to SN 139396 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5-58. Hydraulic Return Filter Condition Indicator - SN 139396 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
xii 3121171
LIST OF FIGURES

5-59. Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5-60. Chassis Control Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5-61. Platform Valve Identification - JLG P/N 4641266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5-62. Platform Valve Identification - JLG P/N 4641460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5-63. Traction Valve Identification (Prior to SN 0300103907). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5-64. Traction Valve Identification (SN 0300103907 through 0300201017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5-65. Main Valve Identification - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5-66. Main Valve Identification - Front & Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
5-67. Main Valve Identification - Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
5-68. PVG Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
5-69. PVG Section Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5-70. PVP Pump Side Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
5-71. PVP Pump Side Module Torque Values & Tool Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
5-72. PVB Basic Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5-73. PVB Basic Module Torque Values & Tool Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
5-74. Assembly Kit & Torque for PVP Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5-75. Main Valve Ohm Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
5-76. Main Valve Cartridge Torque Values - Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5-77. Main Valve Cartridge Torque Values - Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5-78. Main Valve Cartridge Torque Values - Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5-79. Enable Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5-80. Steer Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-120
5-81. Drive & Function Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133
5-82. Function Pump - Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
5-83. Function Pump, Pressure and Flow Control - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
5-86. Hydraulic Schematic - Sheet 1 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
5-89. Hydraulic Schematic Sheet 4 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-149
6-1. Hand Held Analyzer (Analyzer Controls and Display Similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Control System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3. Analyzer Software P7.24 - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-9. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-10. Chassis and Boom, Length, Angle Modules (BLAM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-11. Ground Control Module (With UGM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-12. Ground Control Module (Without UGM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6-13. Platform Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6-14. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6-15. System Test Flow Chart - Platform Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-16. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6-17. CANbus Connections Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-140
6-18. CANbus Connections - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-141
6-22. CANbus Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-145
3121171 xiii
LIST OF FIGURES

7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-10. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-17. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-18. Telematics Gateway Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-21. Wiring Harness Installation- Sheet 1 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-22. Wiring Harness Installation - Sheet 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7-28. Electrical Schematic - Sheet 1 of 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7-37. Electrical Schematic - Sheet 10 of 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
xiv 3121171
LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications & Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-6 Caterpillar 3.4T (Prior to SN 0300201017). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Deutz BF4M2011 Specifications (Prior to SN 0300127698) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-8 Deutz TD2011L4 Specifications (SN 0300127698 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-9 Deutz TCD2.9L4 Specifications (SN 0300201017 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-10 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-11 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-12 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-13 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-14 Mobil DTE 10 Excel 32 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-15 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-16 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-17 Mobil EAL 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-18 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-19 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-20 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-21 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2-1 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 Steering Assembly Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-2 Brake Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-3 Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade . . . . . . . . . . . . . . . . . . . . . . 3-24
3-4 Drive Hub Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-6 Bearing Model Marking Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3-7 Turntable Bearing Wear by Bearing Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3-8 Coupling Port Information Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
3-9 Engine Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
3-10 J1939 Diagnostic Lamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-196
4-1 Hose/Cable Pull Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4-2 Boom Switch Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
4-3 SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-124
5-1 NPTF Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-2 BSPT Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-3 37° Flare (JIC)Thread - Steel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-4 37° Flare (JIC)Thread - Aluminum/Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5 45° Flare (SAE) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-6 45° Flare (SAE) - Aluminum/Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-7 O-ring Face Seal (ORFS) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-8 O-ring Face Seal (ORFS) - Aluminum/Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-9 DIN 24°Cone (MBTL & MBTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-10 Bulkhead Fittings (BH) - INCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-11 Bulkhead Fittings (BH) - METRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-12 O-ring Boss (ORB) - Table 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
3121171 xv
LIST OF TABLES
TABLE NO. TITLE PAGE NO.

5-18 Metric Flat Face Port (MFF) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-21 Metric Flat Face Port (MFF) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5-22 Metric Flat Face Port (MFF) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-24 Metric Pipe Parallel O-Ring Boss (MPP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-31 Flange Code (FL61 & FL62) -Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5-32 Flange Code (FL61 & FL62) - Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-33 Cylinder Head and Tapered Bushing Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5-34 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5-35 Torque Specs for Relief Valves into Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
5-36 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
6-1 Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-2 Machine Configuration Programming Information - Version P7.24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-3 Machine Personality Settings and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-4 Reasons for Re-Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-5 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
6-6 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6-7 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
6-8 SkyGlazier Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
6-9 Pipe Rack Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
6-10 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
6-11 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
6-12 Analyzer Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
6-13 Troubleshooting: Platform Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-148
6-14 Troubleshooting: BLAM Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-154
6-15 Troubleshooting: Chassis Can Communications Lost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-158
6-16 Load Moment Pin Troubleshooting: Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-159
6-17 Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range. . . . . . . . . . . . . . . . . . . . . . 6-160
6-18 Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range. . . . . . . . . . . . . . . . . . . . . . . . . 6-161
xvi 3121171
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS & PERFORMANCE 1.3 CHASSIS SPECIFICATIONS
DATA Table 1-3. Chassis Specifications
Table 1-1. Operating Specifications & Performance Data Maximum Travel Grade With boom in stowed position 45%
(Gradeability)
Maximum Work Load (Capacity)
Unrestricted 500 lb (230 kg) Maximum Travel Grade With boom in stowed position 5°
Restricted 1000 lb (450 kg) (Side Slope)
Max.Vertical Platform Height (Unrestricted) 125 ft (38.1 m) Turning Radius (Axles Retracted)
Outside 22 ft-6 in (6.8 m)
Max.Vertical Platform Height (Restricted) 125 ft (38.1 m)
Inside 14 ft-5 in (4.4 m)
Max.Horizontal Platform Reach (Unrestricted) 63 ft-2 in (19.3 m)
Turning Radius (Axles Extended)
Max.Horizontal Platform Reach (Restricted) 53 ft-2 in (16.2 m) Inside 8 ft (2.4 m)
Up and Over Height 60 ft-7 in (18.5 m) Outside 19 ft-4 in (5.9 m)
Main Boom Range (At Maximum Up & Over) +75° / -55° Max Tire Load 23700 lb (10750 kg)
Main Boom Range (At Maximum Left & Right) +70° / -55° Max Ground Bearing Pressure 100 psi (7.03 kg/cm2)
Maximum Boom Swing 360° Continuous Maximum Drive Speed
JibPLUS Stowed 3.25 mph (5.2 kph)
Length 8 ft (2.44 m) Elevated 0.75 mph (1.2 kph)
Horizontal Motion 125° working, 210° stowed Gross Machine Weight
Vertical Motion 130° (+75/-55) Platform Empty 44,000 lb (19,958 kg)
Max. Hydraulic System Pressure 4600 psi (317 Bar) Platform Empty w/ Skypower 44,215 lb (20,056 kg)
Maximum Wind Speed 28 mph (12.5 m/s)
Maximum Manual Force 400 N 1.4 TIRES
Electrical System Voltage 12 Volts
Table 1-4. Tire Specifications
Max Tire Load 23,700 lb (10750 kg)
Maximum Platform Rotation ±90° Size 445/50D710
Load Range J
1.2 CAPACITIES Ply Rating 18
Foam Fill Polyurethane HD (55 Durometer) Foam
Table 1-2. Capacities Diameter 46.45 in (117.9 cm)
Hydraulic Tank 53.3 gal (201.7 L) Width 18 in (45.7 cm)
Fuel Tank 31 gal (117 L) Rim Size 15x28
Hydraulic System 65.4 gal (247.5 L) Tire & Wheel Weight 867 lb (393 kg)
Drive Hub Max Tire Load 23,700 lb (10750 kg)
Bonfiglioli 0.53 qt (0.5 L) ± 10% Size 445/65-24
Reggiana Riduttori 1.59 qt (1.5 L) ± 10%
Type Solid
Diameter 45.3 in (115.1 cm)
Width 17.3 in (43.9 cm)
Rim Size 12.00-24
Tire & Wheel Weight 960 lb (435.4 kg)
Max Tire Load 23,700 lb (10750 kg)
3121171 1-1
1.5 DIMENSIONAL DATA Deutz BF4M2011

Table 1-7. Deutz BF4M2011 Specifications
Table 1-5. Dimensional Data (Prior to SN 0300127698)
Overall Width Type Liquid Cooled
Axles Retracted 8 ft-2 in (2.49 m)
Axles Extended 12 ft-6 in (3.8 m) Number of Cylinders 4
Stowed Height 10 ft (3.05 m) Bore 3.7 in (94 mm)
Stowed Length (Transport Mode) 37 ft-7 in (11.46 m) Stroke 4.4 in (112 mm)
Stowed Length (Working Mode) 47 ft-6 in (14.48 m) Total Displacement 190 cu. in (3108 cm³)
Wheelbase 12 ft-6 in (3.81 m) Compression Ratio 17.5
Tailswing Firing Order 1-3-4-2

Tower Up 7 ft (2.13 m) Max Power Output 87 hp (65 kW)
Tower Down 11 ft-3 in (3.43 m) Oil Capacity
Oscillating Axle ±6 in (0.15 m) Cooling System 5 qt (4.5 L)
Ground Clearance (Axle) 12 in (30.4 cm) w/Filter 11 qt (10.5 L)
Total Capacity 16 qt (15 L)
Ground Clearance (Chassis) 25.5 in (64.7 cm)
Average Fuel Consumption 1.1 gph (4.1 Lph)
Low Engine RPM 1000
1.6 ENGINE DATA Mid Engine RPM 1800
High Engine RPM 2800
Caterpillar 3.4T
Deutz TD2011L4
Table 1-6. Caterpillar 3.4T (Prior to SN 0300201017)
Table 1-8. Deutz TD2011L4 Specifications
Type Liquid Cooled, Antifreeze (SN 0300127698 to Present)
Number of Cylinders 4
Type Liquid Cooled
Bore 3.7 in (94 mm)
Number of Cylinders 4
Stroke 4.7 in (120 mm)
Bore 3.7 in (94 mm)
Total Displacement 201 cu. in (3294 cm³)
Stroke 4.4 in (112 mm)
Compression Ratio 19.5:1
Total Displacement 190 cu. in (3108 cm³)
Firing Order 1-3-4-2
Compression Ratio 17.5
Max Power Output 73.7 hp (55 kW) @2500 rpm
Firing Order 1-3-4-2
Max Torque Output 245 Nm @ 1600 rpm
Max Power Output 74.2 hp (55.4 kW) @ 2500 rpm
Oil Capacity 10.5 qt (10 L)
Max Torque Output 260 Nm (192 ft. lbs) @ 1800 rpm
Oil Capacity
Idle Engine RPM 1200 Cooling System 5 qt (4.5 L)
Mid Engine RPM 1800 w/Filter 11 qt (10.5 L)
High Engine RPM 2475 Total Capacity 16 qt (15 L)
Low Engine RPM 1000
Mid Engine RPM 1800
High Engine RPM 2600
1-2 3121171
Deutz TCD2.9L4 1.8 MAJOR COMPONENT WEIGHTS

Table 1-9. Deutz TCD2.9L4 Specifications
(SN 0300201017 to Present) Table 1-11. Component Weights
Type Liquid Cooled Component LBS KG

Number of Cylinders 4 445/50D710, FF 867 393
Tire & Wheel
Bore 3.6 in (92 mm) 445/65-24, Solid 960 435.4
Stroke 4.3 in (110 mm) BONFIGLIOLI 267 121
Drive Hub & Motor
Total Displacement 178 cu. in (2925 cm³) REGGIANA RIDUTTORI 306 138
Firing Order 1-3-4-2 CAT C3.4 551 250
Max Power Output 74.2hp (55.4 kW) @ 2500 rpm Deutz BF4M2011 544 247
Engine Assembly
Max Torque Output 192 ft. lbs. (260 Nm) @ 1800 rpm Deutz TD2011L040
Oil Capacity 2.4 gal (8.9 L) TD 2.9L4 550 249.5
Coolant Capacity (System) 3.2 gal (12.1 L) Main Boom 5196 2357
Average Fuel Consumption 1.2 gph (4.1 Lph) Tower Boom 7147 3242
Low Engine RPM 1200 Tower Telescope Cylinder 915 415
Mid Engine RPM 1800 Axle Oscillation Cylinder 74 34
High Engine RPM 2500 Axle Extend Cylinder 92 42
Level Cylinder 89 40
36 x 96 245 111
Platform
1.7 TORQUE REQUIREMENTS 36 x 72 195 89
Counterweight * 3329 1574
Table 1-10. Torque Requirements * For actual weight, see stamping on counterweight
Description Torque Value (Dry) Interval Hours

1.9 PRESSURE SETTINGS
Wheel Bolts 180 ft-lb (252 Nm) 150
Table 1-12. Pressure Settings
Counterweight Bolts 400 ft-lb (542 Nm) As required
Function PSI Bar
Swing Bearing Bolts 190 ft-lb (260 Nm) 50/600*
Function Pump, High Press. Relief 3200 220.6
Starter or Aux Pump Function Pump Standby Pressure 450 31
Solenoid
Swing 1500 103.4
Contacts 95 in-lb (10.5 Nm) As required
Coil 40 in-lb (4.5 Nm) Main Telescope 2200 151.6
Axle, Extend & Retract 2500 172.3
*Check turntable bearing bolts for security after first 50 hours of operation and
Steer Left 2600 179
every 600 hours thereafter. (See Turntable Bearing in Section 3.)
Steer Right 2000 138
NOTE: When maintenance becomes necessary or a fastener has loosened, Platform Level Up 3000 206.8
refer to the Torque Chart for proper torque value.
Platform Level Down 2500 172.3
Jib, Up & Down 2750 189.6
3121171 1-3
1.10 HYDRAULIC OIL Table 1-15. UCon Hydrolube HP-5046

Table 1-13.Hydraulic Oil Specifications Type Synthetic Biodegradable
Hydraulic System Operating S.A.E. Viscosity Specific Gravity 1.082
Temperature Range Grade Pour Point, Max -58°F (-50°C)
+0° to + 180° F (-18° to +83° C) 10W pH 9.1
Viscosity
+0° to + 210° F (-18° to +99° C) 10W-20, 10W-30
at 0° C (32° F) 340 cSt (1600SUS)
+50° to + 210° F (+10° to +99° C) 20W-20 at 40° C (104° F) 46 cSt (215SUS)
at 65° C (150° F) 22 cSt (106SUS)
NOTE: Hydraulic oils must have anti-wear qualities at least to API Viscosity Index 170
Service Classification GL-3 and sufficient chemical stabil-
ity for mobile hydraulic system service.
Table 1-16. Mobil EAL H 46 Specs
NOTE: Aside from JLG recommendations, it is not advisable to mix Type Synthetic Biodegradable
oils of different brands or types. They may not contain the
ISO Viscosity Grade 46
same required additives or be of comparable viscosities.
Density at 15° C .874
NOTE: If temperatures remain consistently below 20° F (-7° C), JLG Pour Point -49°F (-45°C)
Industries recommends using Mobil DTE10 Excel 32. Flash Point 500°F (260°C)
Operating Temp. -20 to 200°F (-29 to 93°C)
Table 1-14. Mobil DTE 10 Excel 32 Specs
Weight 7.64 lb/gal (0.9 kg/L)
ISO Viscosity Grade #32 Viscosity
Specific Gravity 0.877
at 40° C 48.8 cSt
Pour Point, Max -40°F (-40°C)
at 100° C 7.8 cSt
Flash Point, Min. 330°F (166°C)
Viscosity Viscosity Index 145
at 40° C 33cSt
at 100° C 6.6 cSt Table 1-17. Mobil EAL 46 Specs
at 100° F 169 SUS
Type Synthetic Biodegradable
at 210° F 48 SUS
cp at -20° F 6,200 ISO Viscosity Grade 46
Viscosity Index 140 Density at 15° C .93
Pour Point -27°F (-33°C)
Flash Point 568°F (298°C)
Operating Temp. -20 to 200°F (-29 to 93°C)
Weight 7.64 lb/gal (0.9 kg/L)
Viscosity
at 40° C 43.3 cSt
at 100° C 7.7 cSt
Viscosity Index 149
1-4 3121171
Table 1-18. Quintolubric 888-46

Table 1-20. Exxon Univis HVI 26 Specs
Density 0.92 @ 59°F (15°C)
Pour Point <-22°F (<-30°C) Specific Gravity 32.1
Flash Point 572°F (300°C) Pour Point -76°F (-60°C)
Fire Point 680°F (360°C) Flash Point 217°F (103°C)
Autoignition Temperature >842°F(>450°C) Viscosity
Viscosity at 40° C 25.8 cSt
at 0° C (32° F) 320 cSt at 100° C 9.3 cSt
at 20° C (104° F) 109 cSt Viscosity Index 376
at 40° C (104° F) 47.5 cSt NOTE: Mobil/Exxon recommends that this oil be checked on
a yearly basis for viscosity.
at 100° C (150° F) 9.5 cSt
Viscosity Index 190
Table 1-19. Mobilfluid 424 Specs

SAE Grade 10W30
ISO 55
Gravity, API 29.0
Density, Lb/Gal. 60°F 7.35
Pour Point, Max -46°F (-43°C)
Flash Point, Min. 442°F (228°C)
Viscosity
Brookfield, cP at -18°C 2700
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152
3121171 1-5
4 4
12
19 13,15 10
6 21
7
17,22
2,3
8 9
5 1
4 4
MAE37800
Figure 1-1. Lubrication & Operator Maintenance Diagram - Deutz 2011/CAT Engines

Figure 1-2. Lubrication & Operator Maintenance Diagram - Deutz 2.9 Engine
1-6 3121171
1.11 LUBRICATION & OPERATOR MAINTENANCE 2. Swing Gearbox
NOTE: The following numbers correspond to those in Figure 1-1.,

Lubrication & Operator Maintenance Diagram - Deutz
2011/CAT Engines.
Table 1-21. Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5
or MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.
EO Engine (crankcase). Gas (5W30)- API SN, -Arctic ACEA AI/BI, A5/B5 - API
SM, SL, SJ, EC, CF, CD - ILSAC GF-4. Diesel (15W40, 5W30 Arctic) - API CJ-4.
Lube Point(s) - Fill Plug
Capacity - 79 oz (2.3 L)
Lube - GL-5
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR- Interval - Check level every 150 hours/Change every
MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/ 1200 hours of operation. Fill to cover ring gear.
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
3. Swing Brake
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) - Fill Plug

Lube Point(s) - 2 Grease Fitting Capacity - 2.7 oz (80 ml)
Capacity - A/R Lube - DTE24
Lube - MPG Interval - Check level every 150 hours/Change every
Interval - Every 3 months or 150 hours of operation. 1200 hours of operation.
3121171 1-7
NOTE: After S/N 0300134389 machines may be built with either C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to
Bonfiglioli or Reggiana Riduttori wheel drive hubs. Present)
4. A. Wheel Drive Hub - Rexroth (Prior to S/N 100128)
Lube Point(s) - Level/Fill Plug

Lube Point(s) - Level/Fill Plug Capacity - 0.5 qt (0.5 L) ± 10%
Capacity - 0.5 L (1/2 full) Lube - EPGL
Lube - EPGL Interval - Change after first 150 hours then every 1200
Interval - Change after first 150 hours then every 1200 hours of operation
hours of operation Comments - Place Fill port at 12 o’clock position and
Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position. Pour lubricant into
Check port at 3 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port.
fill port until it just starts to flow out of check port. 5. Hydraulic Return Filter -
B: Wheel Drive Hub - Bonfiglioli (S/N 100128 to Present) (See Figure 1-3. and Figure 1-4.)
Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and every 300
hours thereafter or as indicated by condition indicator.
Lube Point(s) - Level/Fill Plug

Capacity - 2.1 qt (2 L) ± 10%
Lube - EPGL
Interval - Change after first 150 hours then every1200
hours of operation
Comments - Place Fill port at 12 o’clock position and
Check port at 8 o’clock position. Pour lubricant into
fill port until it just starts to flow out of check port.
1-8 3121171
A - Red = Filter Restricted; Filter Bypassed

B - Green = Filter Good; Not Restricted
Figure 1-3. Hydraulic Return Filter Condition Indicator - Prior to SN 139396
Red = Filter Restricted; Filter Bypassed

Green = Filter Good; Not Restricted
Figure 1-4. Hydraulic Return Filter Condition Indicator - SN 139396 to Present
3121171 1-9
6. Hydraulic Charge Filter 7. Main Valve Filter
or Lube Point(s) - Replaceable Element

hours thereafter.
8. Hydraulic Oil
FULL LEVEL (HOT OIL)
FULL LEVEL (COLD OIL)

hours thereafter or as indicated by condition indicator
(if equipped).
Lube Point(s) - Fill Cap
Capacity - 55 gal (208 L) Tank
Lube - HO
Interval - Check level daily. Change every 2 years or 1200
hours of operation.
1-10 3121171
9. Suction Strainers (In Tank) 11. Oil Change w/Filter - Deutz TCD2.9 L4
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
Lube Point(s) - 2 level by mark on dipstick.
Interval - Every 2 years or 1200 hours of operation.
Remove and clean at time of hydraulic oil change. 12. Oil Change w/Filter - CAT
10. Oil Change w/Filter - Deutz D2011
Lube Point(s) - Fill Cap/Spin-on Element (element can be

accessed from below engine tray)
Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10.5 qt (10 L)
Capacity - 11 qt (10.5 L) w/Filter Lube - EO
Lube - EO Interval - Check level daily; change every 150 hours or
Interval - Check level daily; change every 500 hours or three months, whichever comes first. Adjust final oil
six months, whichever comes first. Adjust final oil level by mark on dipstick.
level by mark on dipstick.
3121171 1-11
13. Fuel Filter - Deutz D2011 15. Fuel Strainer - Deutz 2011

Interval - Every year or 600 hours of operation. Lube Point(s) - Replaceable Element
Interval - Every year or 600 hours of operation.
14. Fuel Filter - Deutz TCD2.9
16. Fuel Pre-Filter - Deutz TCD2.9

Interval - Drain water daily; Change every year or 500
hours of operation.
Interval - Every year or 500 hours of operation.
1-12 3121171
17. Fuel Filter/Water Separator - CAT 19. Air Filter - Deutz 2011/CAT
DEUTZ D2011

Interval - Drain water daily; Replace element every
year or 600 hours of operation.
18. Radiator Coolant - Deutz TCD2.9
CAT

Interval - Every 6 months or 300 hours of operation or
as shown by the condition indicator.
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.
3121171 1-13
20. Air Filter - Deutz TCD2.9 21. Platform Filter

Interval - Change after first 50 hours and then every year
or 600 hours of operation thereafter.
22. Optional Fuel Filter/Water Separator

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

Interval - Drain water daily; Change every year or 600
hours of operation.
1-14 3121171
Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
Figure 1-5. Torque Chart (SAE Fasteners - Sheet 1 of 5)
3121171 1-15
To rqu e
Torqu e
Torq ue
Tor que
Torq ue
1-16 3121171
Torq ue
Tor que
Torqu e
Cl amp L oa d
Torq ue
To rqu e
To rque
3121171 1-17
To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
1-18 3121171
To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue
Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 5 of 5)
3121171 1-19
NOTES:
1-20 3121171
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form
and the Inspection and Preventative Maintenance Schedule
MAINTENANCE for items requiring inspection during the performance of
these inspections. Reference the appropriate areas of this
General manual for servicing and maintenance procedures.
This section provides the necessary information needed by Annual Machine Inspection
those personnel that are responsible to place the machine in
operation readiness and maintain its safe operating condition. The Annual Machine Inspection must be performed by a Fac-
For maximum service life and safe operation, ensure that all tory-Certified Service Technician on an annual basis, no later
the necessary inspections and maintenance have been com- than thirteen (13) months from the date of the prior Annual
pleted before placing the machine into service. With proper Machine Inspection. JLG Industries, Inc. recognizes a Factory-
care, maintenance, and inspections performed per JLG's rec- Trained Service Technician as a person who has successfully
ommendations, and with any and all discrepancies corrected, completed the JLG Service Training School for the subject JLG
this product will be fit for continued use. product model. Reference the machine Service and Mainte-
nance Manual and appropriate JLG inspection form for perfor-
mance of this inspection.
Preparation, Inspection, and Maintenance
Reference the JLG Annual Machine Inspection Form and the
It is important to establish and conform to a comprehensive Inspection and Preventative Maintenance Schedule for items
inspection and preventive maintenance program. The follow- requiring inspection during the performance of this inspec-
ing table outlines the periodic machine inspections and main- tion. Reference the appropriate areas of this manual for servic-
tenance recommended by JLG Industries, Inc. Consult your ing and maintenance procedures.
national, regional, or local regulations for further requirements
for aerial work platforms. The frequency of inspections and For the purpose of receiving safety-related bulletins, it is
maintenance must be increased as environment, severity and important that JLG Industries, Inc. has updated ownership
frequency of usage requires. information for each machine. When performing each Annual
Machine Inspection, notify JLG Industries, Inc. of the current
Pre-Start Inspection machine ownership.
It is the User’s or Operator’s primary responsibility to perform a Preventative Maintenance

Pre-Start Inspection of the machine prior to use daily or at In conjunction with the specified inspections, maintenance
each change of operator. Reference the Operator’s and Safety
shall be performed by a qualified JLG equipment mechanic.
Manual for completion procedures for the Pre-Start Inspec-
JLG Industries, Inc. recognizes a qualified JLG equipment
tion. The Operator and Safety Manual must be read in its mechanic as a person who, by possession of a recognized
entirety and understood prior to performing the Pre-Start
degree, certificate, extensive knowledge, training, or experi-
Inspection. ence, has successfully demonstrated the ability and profi-
ciency to service, repair, and maintain the subject JLG product
Pre-Delivery Inspection and Frequent Inspection model.
The Pre-Delivery Inspection and Frequent Inspection shall be Reference the Preventative Maintenance Schedule and the
performed by a qualified JLG equipment mechanic. JLG Indus- appropriate areas of this manual for servicing and mainte-
tries, Inc. recognizes a qualified JLG equipment mechanic as a nance procedures. The frequency of service and maintenance
person who, by possession of a recognized degree, certificate, must be increased as environment, severity and frequency of
extensive knowledge, training, or experience, has successfully usage requires.
demonstrated the ability and proficiency to service, repair, and
maintain the subject JLG product model.
The Pre-Delivery Inspection and Frequent Inspection proce-

dures 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 environ-
ment, severity and frequency of usage requires.
3121171 2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operation and Safety Manual
At each Operator change.
Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
rental delivery. and applicable JLG inspection form.
Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
purchased used.
Annual Machine Inspection Annually, no later than 13 months from the date of Owner, Dealer, or User Factory-Trained Service Service and Maintenance Manual
the prior inspection. Technician and applicable JLG inspection form.
(Recommended)
Preventive At intervals as specified in the Service and Mainte- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance nance Manual.
2.2 SERVICE AND GUIDELINES 3. Clean and inspect all parts during servicing or mainte-
nance, and ensure all passages and openings are unob-
structed. Cover all parts to keep them clean. Be sure all
General parts are clean before they are installed. New parts
should remain in their containers until needed.
The following information is provided to assist you in the use
and application of servicing and maintenance procedures Components Removal and Installation
contained in this book.
1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
Safety and Workmanship cables, etc.) should be parallel to each other and as near
perpendicular as possible to top of part being lifted.
Your safety, and that of others, is the first consideration when
working on or around equipment. Always be conscious of 2. If a component must be removed on an angle, keep in
mind the capacity of an eyebolt or similar bracket less-
weight. Never attempt to move heavy parts without the aid of
ens, as the angle between the supporting structure and
a mechanical device. Do not allow heavy objects to rest in an
the component becomes less than 90 degrees.
unstable position. Always provide adequate support when lift-
ing a portion of the equipment. 3. If a part resists removal, check if all nuts, bolts, cables,
brackets, wiring, etc., have been removed and that no
adjacent parts are interfering.
Cleanliness
1. The most important single item in preserving the long
service life of a machine is to keep dirt and foreign mate-
rials out of 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 to function properly.
2. At any time when air, fuel, or oil lines are disconnected,

clear adjacent areas as well as the openings and fittings
themselves. As soon as a line or component is discon-
nected, cap or cover all openings to prevent entry of for-
eign matter.
2-2 3121171
SECTION 2 - GENERAL
Component Disassembly and Reassembly Bolt Usage and Torque Application

When disassembling or reassembling a component, complete 1. Use bolts of proper length. A bolt which is too long will
steps in sequence. Do not partially disassemble or assemble bottom before the head is tight against its related part. If
one part, then start on another. Always recheck your work to a bolt is too short, there will not be enough thread area
ensure nothing has been overlooked. Do not make any adjust- to engage and hold the part properly. When replacing
ments, other than those recommended, without obtaining bolts, use only those having the same specifications of
proper approval. the original, or one which is equivalent.
2. Unless specific torque requirements are provided in this
Pressure-Fit Parts manual, use standard torque values on heat-treated
When assembling pressure-fit parts, use an anti-seize or bolts, studs, and steel nuts, in accordance with recom-
molybdenum disulfide base compound to lubricate the mat- mended shop practices. (See Torque Chart Section 1.)
ing surface.
Hydraulic Lines and Electrical Wiring
Bearings Clearly mark or tag hydraulic lines and electrical wiring, as well
as their receptacles, when disconnecting or removing them
1. When a bearing is removed, cover it to keep out dirt and from the unit. This will ensure correct reinstallation.
abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used Hydraulic System
but do not spin the bearing.
1. Keep system clean. If evidence of metal or rubber parti-
2. Discard bearings if races and balls (or rollers) are pitted,
cles are found in the hydraulic system, drain and flush
scored, or burned.
the entire system.
3. If bearing is found to be serviceable, apply a light coat of
2. Disassemble and reassemble parts on clean work sur-
oil and wrap it in clean (waxed) paper. Do not unwrap
face. Clean all metal parts with non-flammable cleaning
reusable or new bearings until they are ready to install.
solvent. Lubricate components, as required, to aid
4. Lubricate new or used serviceable bearings before assembly.
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.
Gaskets
Check 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.
3121171 2-3
SECTION 2 - GENERAL
Lubrication Hydraulic Oil

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

15 degrees F (-26 degrees C) is not recommended. If it is
Clean battery, using a non-metallic brush and a solution of necessary to start the system in a sub-zero environment, it
baking soda and water. Rinse with clean water. After cleaning, will be necessary to heat the oil with a low density, 100VAC
thoroughly dry battery and coat terminals with an anti corro- heater to a minimum temperature of -15 degrees F (-26
sion compound. degrees C).
Lubrication and Servicing 3. The only exception to the above is to drain and fill the
system with Mobil DTE 13 oil or its equivalent. This will
Components and assemblies requiring lubrication and servic- allow start up at temperatures down to -20 degrees F (-
ing are shown in the Lubrication Chart in Section 1. 29 degrees C). However, use of this oil will give poor per-
formance at temperatures above 120 degrees F (49
degrees C). Systems using DTE 13 oil should not be oper-
2.3 LUBRICATION AND INFORMATION ated at temperatures above 200 degrees F (94 degrees
C) under any condition.
Hydraulic System
Changing Hydraulic Oil
1. The primary enemy of a hydraulic system is contamina-
tion. Contaminants enter the system by various means,
1. Filter elements must be changed after the first 50 hours
e.g., using inadequate hydraulic oil, allowing moisture,
of operation and every 300 hours (unless specified oth-
grease, filings, sealing components, sand, etc., to enter
erwise) thereafter. If it is necessary to change the oil, use
when performing maintenance, or by permitting the
only those oils meeting or exceeding the specifications
pump to cavitate due to insufficient system warm-up or
appearing in this manual. If unable to obtain the same
leaks in the pump supply (suction) lines.
type of oil supplied with the machine, consult local sup-
plier for assistance in selecting the proper equivalent.
2. Design and manufacturing tolerances of component
Avoid mixing petroleum and synthetic base oils.
working parts are very close, therefore, even the small-
est amount of dirt or foreign matter entering a system
2. Use every precaution to keep the hydraulic oil clean. If
can cause wear or damage to the components and
the oil must be poured from the original container into
cause faulty operation. Every precaution must be taken
another, be sure to clean all possible contaminants from
to keep hydraulic oil clean, including reserve oil in stor-
the service container. Always clean the mesh element of
age. Hydraulic system filters should be checked,
the filter and replace the cartridge any time the system
cleaned, and/or replaced as necessary, at intervals speci-
oil is changed.
fied in the Lubrication Chart in Section 1. Always exam-
ine filters for evidence of metal particles. 3. While the unit is shut down, a good preventive mainte-
nance measure is to make a thorough inspection of all
3. Cloudy oils indicate a high moisture content which per-
hydraulic components, lines, fittings, etc., as well as a
mits organic growth, resulting in oxidation or corrosion.
functional check of each system, before placing the
If this condition occurs, the system must be drained,
machine back in service.
flushed, and refilled with clean oil.
4. It is not advisable to mix oils of different brands or types, Lubrication Specifications

as they may not contain the same required additives or
be of comparable viscosities. Good grade mineral oils, Lubricants specified by component manufacturers are always
with viscosities suited to the ambient temperatures in the best choice. However, multi-purpose greases usually have
which the machine is operating, are recommended for qualities which meet a variety of single purpose grease
use. requirements. Should any question arise, regarding use of
greases in maintenance stock, consult your local supplier for
NOTE: Metal particles may appear in the oil or filters of new evaluation. Refer to Section 1 for an explanation of lubricant
machines due to the wear-in of meshing components. key designations appearing in the Lubrication Chart.
2-4 3121171
SECTION 2 - GENERAL
2.4 CYLINDER DRIFT TEST Cylinder Leakage Test

Cylinder oil must be at stabilized ambient temperature
before beginning this test.
THE TOWER BOOM LIFT CYLINDER HAS A SPECIFIC PROCEDURE FOR TESTING
CYLINDER DRIFT. REFER TO SECTION 4 - BOOM & PLATFORM. Measure drift at cylinder rod with a calibrated dial indicator.
Maximum acceptable cylinder drift is to be measured using In an area free of obstructions, cylinder must have load
the following methods. applied and appropriately positioned to detect drift.
Theory Cylinder leakage is acceptable if it passes this test.
When a hydraulic cylinder is supporting a load, cylinder drift

Table 2-2. Cylinder Drift
may occur as a result of any of the circumstances below:
Max. Acceptable Drift
• Normal leakage of load holding valves or malfunction of Cylinder Bore Diameter
in 10 Minutes
load holding valves. See Cylinder Leakage Test and Table 2-
2, Cylinder Drift below for evaluation. inches mm inches mm
3 76.2 0.026 0.66
• Damaged or worn piston seals.
3.5 89 0.019 0.48
• Normal thermal expansion or contraction of the hydraulic
oil within cylinders (See Cylinder Thermal Drift below). 4 101.6 0.015 0.38
5 127 0.009 0.22
The first two circumstances may result in cylinder movement
due to oil leaking out of the cylinder externally or by leaking 6 152.4 0.006 0.15
back to tank or due to oil leaking internally from one cylinder 7 177.8 0.005 0.13
chamber to the other. 8 203.2 0.004 0.10
9 228.6 0.003 0.08
Thermal expansion or contraction of oil in hydraulic cylinders
is a normal occurrence and does not result in oil leaking out of NOTE: This information is based on 6 drops per minute cylinder
the cylinder or leaking internally from one cylinder chamber leakage.
to the other. Thermal expansion or contraction is the tendency
for materials to change size in response to a change in temper- Cylinder Thermal Drift
ature.
The oil in all hydraulic cylinders will expand or contract due to
thermal effects over time and may result in changes to the
boom and/or platform position while the machine is station-
ary. These effects occur as the cylinder oil changes tempera-
ture, usually from a higher oil temperature as it cools and
approaches the ambient air temperature. Results of these
effects are related to several factors including cylinder length
and change in temperature over the time the cylinder remains
stationary.
3121171 2-5
SECTION 2 - GENERAL
2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT
GUIDELINES NOTE: This instruction applies to repairs, or modifications to the
Filament wound bearings. machine and to welding performed from the machine on
an external structure, or component,
1. Pinned joints should be disassembled and inspected if
the following occurs:
Do the Following When Welding on JLG Equipment
a. Excessive sloppiness in joints.
• Disconnect the battery.
b. Noise originating from the joint during operation.
• Disconnect the moment pin connection (where fitted)
2. Filament wound bearings should be replaced if any of
the following is observed: • Ground only to structure being welded.
a. Frayed or separated fibers on the liner surface. Do NOT Do the Following When Welding on JLG
b. Cracked or damaged liner backing. Equipment
c. Bearings that have moved or spun in their housing.
• Ground on frame and weld on any other area than the
d. Debris embedded in liner surface. chassis.
3. Pins should be replaced if any of the following is • Ground on turntable and weld on any other area than the
observed (pin should be properly cleaned prior to turntable.
inspection):
• Ground on the platform/support and weld on any other
a. Detectable wear in the bearing area. area than the platform/support.
b. Flaking, peeling, scoring, or scratches on the pin sur- • Ground on a specific boom section and weld on any other
face. area than that specific boom section.
c. Rusting of the pin in the bearing area.
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
4. Re-assembly of pinned joints using filament wound valves, electrical wiring, or hoses to be between the
bearings. grounding position and the welded area.
a. Housing should be blown out to remove all dirt and
debris. bearings and bearing housings must be free
of all contamination. FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
b. Bearing / pins should be cleaned with a solvent to PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
remove all grease and oil. filament wound bearing RING, BOOM WIRE ROPES ETC.)
are a dry joint and should not be lubricated unless
otherwise instructed (i.e. sheave pins).
c. Pins should be inspected to ensure it is free of burrs,
nicks, and scratches which would damage the bear-
ing during installation and operation.
2-6 3121171
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Pre-Delivery1or Frequent2 Annual3

(Quarterly) (Yearly)
Inspection Inspection
Boom Assembly
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Platform Assembly
Platform 1,2
Railing 1 1,2
Gate 1 1,5
Floor 1 1,2
Rotator 15 15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly
Swing Bearing 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 16,17,18 16,17,18
Wheel Nuts/Bolts 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Outrigger or Extendable Axle Systems 5,8 5,8
Steer Components 1,2,3,4,15,16,20 1,2,3,4,15,16,20
Drive Motors 1,2,9 1,2,9
Drive Hubs 1,3,9,11,15,23 1,3,9,11,15,23
Functions/Controls
Platform Controls 5,6 5,6
3121171 2-7
SECTION 2 - GENERAL
INTERVAL

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 1,3,5,15,21,22 1,3,5,15,21,22
Drive Brakes 5 5
Swing Brakes 5 5
Boom Synchronization/Sequencing Systems 5
Manual Descent or Auxiliary Power 5 5
Power System
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 9,11 9,11
Air/Fuel Filter 1,7 1,7
Exhaust System 1,9 1,9
Batteries 1,3,9,11,15,19,23 1,3,9,11,15,19,23
Battery Fluid 11 11
Battery Charger 1,3,5,15 1,3,5,15
Fuel Reservoir, Cap, and Breather 1,5, 9,11 1,5, 9,11
Hydraulic/Electric System
Hydraulic Pumps 1,2,9 1,2,9
Hydraulic Cylinders 1,2,7,9 1,2,7,9
Cylinder Attachment Pins and Pin Retainers 1,2,9 1,2,9
Hydraulic Hoses, Lines, and Fittings 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1,2.5, 9,11 1,2.5, 9,11,24
Hydraulic Filter 7 7
Hydraulic Fluid 7,11 7,11
Electrical Connections 1,20 1,20
Instruments, Gauges, Switches, Lights, Horn 5,23
General
Operation and Safety Manuals in Storage Box 21 21
ANSI and EMI Manuals/Handbooks Installed 21
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
Walk-Around Inspection Performed 21 21
2-8 3121171
SECTION 2 - GENERAL
INTERVAL

Annual Machine Inspection Due 21 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21,22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to each sale, lease, or delivery
2 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
3 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or “off” position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
3121171 2-9
SECTION 2 - GENERAL
1001159163-B
Figure 2-1. Engine Operating Temperature Specifications - Deutz
2-10 3121171
SECTION 2 - GENERAL
HYDRAULIC FLUID OPERATION CHART
MACHINE OPERATION USING NON-JLG APPROVED

HYDRAULIC F LUIDS OR OPERAT ION OUTSIDE OF
T HE T EMPERAT URE BOUNDARIES OUT LINED IN
T HE "HYDRAULIC F LUID OPERATION CHART " MAY
RESULT IN PREMAT URE WEAR OR DAMAGE TO
COMPONENT S OF T HE HYDRAULIC SYSTEM.
Fluid Properties Base Classifications

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

Mobil DTE 10 Excel 32 32 164 X X
Univis HVI 26 26 376 X
Mobil EAL Hydraulic Oil 47 176 X X X
Mobil EAL Envirosyn H46 49 145 X X X
Quintolubric 888-46 50 185 X X X X
* Readily biodegradable classification indicates one of the following:
CO2 Conversion > 60% per EPA 560/6-82-003
CO2 Conversion > 80% per CEC-L-33-A-93
** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval
4150740-B
Figure 2-2. Hydraulic Oil Operating Temperature Specifications
3121171 2-11
SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120 F(49 C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
30 F(-1 C)
20 F(-7 C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10 F(-12 C)
FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND
HYDRAULIC OIL TANK HEATER) -30 F(-34 C)
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE
OIL COOLER (CONSULT JLG SERVICE
120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F (38°C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26
70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC
MOBIL DTE 13
40° F (4° C)
SPECIFICATIONS
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) NOTE:
DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS
-30° F (-34° C) AND COLD WEATHERHYDRAULIC OIL BELOW THIS TEMPERATURE 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
-40° F (-40° C) CONSISTENTLY WITHIN SHOWN LIMITS
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
4150548-E
Figure 2-3. Engine Operating Temperature Specifications - Caterpillar
2-12 3121171
SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS Tire Replacement
JLG recommends a replacement tire be the same size, ply and
Tire Inflation brand as originally installed on the machine. Refer to the JLG
Air pressure for pneumatic tires must be equal to air pressure Parts Manual for part number of approved tires for a particular
stenciled on the side of the JLG product or rim decal for safe machine model. If not using a JLG approved replacement tire,
and proper operational characteristics. we recommend replacement tires have the following charac-
teristics:
Tire Damage • Equal or greater ply/load rating and size of original
For pneumatic tires, JLG Industries, Inc. recommends when • Tire tread contact width equal or greater than original
any cut, rip, or tear is discovered that exposes sidewall or tread • Wheel diameter, width, and offset dimensions equal to
area cords in the tire, measures must be taken to remove the original
JLG product from service immediately. Arrangements must be
made for replacement of the tire or tire assembly. • Approved for application by the tire manufacturer (includ-
ing inflation pressure and maximum tire load)
For polyurethane foam filled tires, JLG Industries, Inc. recom-
mends when any of the following are discovered, measures Unless specifically approved by JLG Industries Inc. do not
must be taken to remove the JLG product from service imme- replace a foam filled or ballast filled tire assembly with a pneu-
diately and arrangements must be made for replacement of matic tire. When selecting and installing a replacement tire,
the tire or tire assembly. ensure all tires are inflated to pressure recommended by JLG.
• a smooth, even cut through cord plies which exceeds 3 in Due to size variations between tire brands, both tires on the
(7.5 cm) in total length same axle should be identical.
• any tears or rips (ragged edges) in cord plies which exceeds Wheel and Tire Replacement
1 in (2.5 cm) in any direction
Rims installed on each product model have been designed for
• any punctures which exceed 1 in (2.5 cm) in diameter
stability requirements which consist of track width, tire pres-
• any damage to bead area cords of the tire sure, and load capacity. Size changes such as rim width, center
piece location, larger or smaller diameter, etc., without written
If a tire is damaged but is within the above noted criteria, the
factory recommendations, may result in an unsafe condition
tire must be inspected on a daily basis to ensure damage has
regarding stability.
not exceeded allowable criteria.
3121171 3-1
Wheel Installation 2. Tighten nuts in the following sequence:
It is extremely important to apply and maintain proper wheel

mounting torque.
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE

TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
SEPARATION OF WHEEL FROM AXLE. USE ONLY NUTS MATCHED TO THE CONE
ANGLE OF THE WHEEL.
Tighten lug nuts to 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 fasteners with a lug
wrench, then immediately have a service garage or dealer
tighten lug nuts to the proper torque. Over-tightening will
result in breaking studs or permanently deforming mounting
stud holes in the wheels.
1. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
3. Tighten nuts in stages. Following the recommended

sequence, tighten nuts per wheel torque chart.
Table 3-1. Wheel Torque Chart
TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
45 ft-lb 100 ft-lb 180 ft-lb
(60 Nm) (140 Nm) (252 Nm)
4. Torque wheel nuts before first road use and after each
wheel removal. Check and torque every 3 months or 150
hours of operation.
3-2 3121171
3.2 AXLE EXTENSION SYSTEM automatically reduce the wheel angle to 25 degrees during
axle retraction.
The Axle Extension System allows each of the four axles to be
extended and retracted together while maintaining full steer- NOTE: For more detailed information concerning system adjust-
ing control as the machine is driven. The system allows the ment and operation, refer to Section 6 - JLG Control Sys-
axles to extend or retract only while the boom is in the trans- tem.
port position (see Section 4.2, Transport Position Sensing Sys-
tem) and in order to minimize wheel scrubbing during axle 3.3 AXLE LIMIT SWITCH ADJUSTMENT PROCEDURE
movement, a minimum drive speed must be attained before 1. Fully extend axles.
axle extension/retraction will be permitted.
To extend/retract the axles, the user engages the axle extend/ 2. Initially position the limit switch arm straight.
retract switch on the platform console and the drive control at 3. Select the mounting plate bolt pattern to position the
the same time. The axle set indicator will be off when the axles switch roller within 0.125 inches (mm) from the edge of
are not fully extended and the axle extend/retract switch is the axle cutout. It may be necessary to reposition the
not engaged. It will flash while the axles are extending or switch arm ±10° to accomplish this.
retracting and will be on constantly when the axles are fully
extended. 4. Ensure the arm will clear the axle (without bottoming
out to 70° stroke of the switch) in the retracted position.
The system uses four limit switches (one at each axle) to sense
when the axles are fully extended. If any of the switches are 5. Check for proper operation. Axle set light is to deacti-
not made, the control system considers the axles retracted. vate when the axle is retracted 0.625 inches (16 mm)
With the axles not fully extended, the boom is restricted to maximum from fully extended.
operation within the transport position (see Section 4.2, Trans-
port Position Sensing System). If a signal from any axle extend
sensing switch is lost when the boom is beyond the transport
position, the axle set indicator will flash and drive/steer func-
tions 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
Figure 3-1. Axle Limit Switch Adjustment
3121171 3-3
3.4 DRIVE SYSTEM

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

Each wheel is individually steered by means of a closed circuit
control system utilizing a steer sensor on each wheel, 4 steer
cylinders, and proportional valves.
Figure 3-4. Coordinated Steer Mode
The control system senses the wheel position in relation to the
steering command (direction and steering mode) and auto- Each wheel has its own steer cylinder, wheel angle sensor, and
matically synchronizes the movement of all 4 wheels to the proportional valve, allowing the control system to position
desired position. each wheel to the ideal angle for all steering modes and all
steering commands.
There are three different modes of steering selectable by the
position of the steer select switch on the platform control Changes in steering modes while the footswitch is depressed
panel: conventional two wheel steering, crab and coordinated. causes the wheels to automatically adjust to the appropriate
These are shown below. 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 being depressed or when 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. See the Axle Extension System
(see Section 3.2, Axle Extension System) for interaction with
the axle extension system.
If a wheel cannot achieve its commanded angle within a spec-
ified time, it is considered jammed. When a wheel is consid-
ered 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,
Figure 3-2. Conventional Two Wheel Steer Mode
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
resynchronized by fully steering against the mechanical stops.
NOTE: For more detailed information concerning system adjust-

ment and operation, refer to Section 6 - JLG Control Sys-
tem.
Figure 3-3. Crab Steer Mode
3-4 3121171
3.6 DRIVE/STEERING SPEED CONTROL 3.8 DRIVE ORIENTATION SYSTEM

The Drive/Steering Speed Control system uses the steering The Drive Orientation System (DOS) is intended to indicate to
sensors from the steering control system (see Section 3.5, the operator conditions that could make the direction of
Steering Control System) to increase operator control and movement of the chassis different than the direction of move-
comfort by reducing the effect of turning the chassis and the ment of the drive/steer control handle. The system indicates to
resulting lateral platform speed. The system proportionally the operator the need to match the black and white direc-
varies the drive speed based on the predicted turning radius tional arrows on the platform control panel to the arrows on
of the chassis for both coordinated and conventional two the chassis. The system uses a proximity switch mounted on
wheel steer modes. The tighter the turn the slower the allow- the hydraulic swivel, an indicator light, and a spring return
able drive speed. As crab steer does not steer on a radius, full override switch on the platform display panel. The proximity
drive speed is maintained regardless of steer angle. switch trips when the turntable is swung ± 45 degrees off cen-
ter of the normal driving position. This occurs roughly when
NOTE: For more detailed information concerning system adjust- the main boom is swung past a rear tire. When the turntable is
ment and operation, refer to Section 6 - JLG Control Sys- in the normal drive position with the boom between the rear
tem. tires, no indications or interlocks are made. When the machine
is actively driving when the turntable is swung past the switch
3.7 TRACTION CONTROL SYSTEM point, the system is ignored until drive/steer is released. When
The Traction Control System uses the steering sensors from drive is initiated with the boom swung past the switch point,
the steering control system (see Section 3.5, Steering Control the DOS indicator will flash and the drive/steer functions will
System) to optimize the performance of the drive system. This be disabled. The operator must engage the DOS override
is especially important due to the disparity of wheel speeds switch to enable Drive/steer (high drive will remain disabled).
generated between the inside and outside wheels of the When the DOS is enabled, the DOS indicator will be illumi-
extended axle chassis with large steering angle capability. nated continuously and a 3-second enable timer will be
started and will continue for 3 seconds after the end the last
The steering sensors are used to predict the rolling path and
drive/steer command. If the timer expires, the DOS override
therefore the required wheel speed of each wheel as the steer-
switch must be re-engaged to enable drive/steer.
ing angles change and steering modes change. The control
system can then command the ideal flow from each of the two NOTE: For more detailed information concerning system adjust-
drive pumps, one for the right side of the machine and one for ment and operation, refer to Section 6 - JLG Control Sys-
he left side. Two flow dividers, one for the right side front to tem.
back and one for the left side front to back absorb the varia-
tion in wheel speed front to back. 3.9 GROUND CONTROL ENABLE SYSTEM
NOTE: For more detailed information concerning system adjust- The ground controls include the use of a function enable sys-
ment and operation, refer to Section 6 - JLG Control Sys- tem for the operation of directional functions from the ground
tem. control panel. To operate any directional function, the func-
tion enable switch must be held in combination with the
directional function switch. This switch doubles as the auxil-
iary power switch. When the engine is not running, activating
this switch will operate auxiliary power. When the engine in
running, activating this switch will enable directional func-
tions. Releasing this switch during function commands will
stop the function movement. Unlike the platform enable, no
timer or sequence logic is imposed on the use of the function
enable.
3121171 3-5
0274670 D
Figure 3-5. Chassis Component Location - Sheet 1 of 2
3-6 3121171
1. Axle Limit Switch (Right Front) 9. Axle Limit Switch (Left Rear)
2. Steer Angle Sensor (Right Front) 10. Steer Angle Sensor (Left Rear)
3. Steer Valve (Front) 11. Chassis Module
4. Axle Lockout Valve 12. Swivel/Collector Ring
5. Traction Valve 13. Axle Lockout Pressure Switch
6. Steer Valve (Rear) 14. Steer Angle Sensor (Left Front)
7. Steer Angle Sensor (Right Rear) 15. Axle Limit Switch (Left Front)
8. Axle Limit Switch (Right Rear)
Figure 3-6. Chassis Component Location - Sheet 2 of 2
3121171 3-7
0274670 D
Figure 3-7. Turntable Component Location - Sheet 1 of 2
3-8 3121171
1. Headlight 13. Glow Plug Relay 24. Tower Lift Enable Valve
2. 2500W Generator 14. Drive Pump 25. Tower Tele Enable Valve
3. 2500W Generator Control Box 15. Swivel 26. Main Control Valve
4. Alternator 16. 7500W Generator Control Box 27. Main Lift Enable Valve
5. Throttle Actuator 17. Taillight 28. Alarm
6. Oil Temperature Switch 18. Taillight 29. Horn
7. Oil Pressure Switch 19. Tower Lift Cylinder Load Pin 30. Fuel Level Sensor
8. Glow Plugs 20. Tower Lift Cylinder Angle Sensor 31. Ground Control Box
9. Engine Speed Sensor 21. Auxiliary Power Unit 32. BLAM Module
10. Starter 22. Headlight/Taillight Relay 33. Headlight
11. Drive Pump 23. Auxiliary Power Relay 34. Strobe Light
12. Starter Relay
Figure 3-8. Turntable Component Location - Sheet 2 of 2
3121171 3-9
3
1 DETAIL A
* AXLE STOP SHIMMING PROCEDURE:

6 1. ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL
2 SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME.
2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST
SHIM.
DETAIL B
Figure 3-9. Oscillating Axle - Sheet 1 of 2
3-10 3121171
9
3
11,12,B,G
6
11,12,A,G
8
10
11,12,C,G DETAIL A
11,12,E,G
11,12,F,G
2
4
A - Assemble to Axle Box Mid Plate; Typical 8 Places.
B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 DETAIL B
inches (12.7 ± 1.587 mm) thread engagement.
C - Assemble to Side Plates of Axle Weldments; Typical 16 Places.
D - Assemble to Front and Rear Plates of Axle Boxes; Typical 8 Places.
E - Assemble to Top Plate of Axle Weldment; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5
±0.062 inches (12.7 ± 1.587 mm) thread engagement.
F - Assemble to Bottom Plate of Axle Box Weldment; Typical 8 Places.
G - See Axle Stop Shimming Procedure on Sheet 1
1. Axle Oscillation Cylinder 5. Axle Pivot Pin 9. Hose Clamp

2. Axle 6. Axle Limit Switch 10. Stop Block
3. Axle Powertrack 7. Axle Stop Pin 11. Wear Pad
4. Extension Cylinder 8. Rubber Pad 12. Shim
Figure 3-10. Oscillating Axle - Sheet 2 of 2
3121171 3-11
* *
**
**
*
*** *
*
***
*
*
* * *
*
* *
* *
*
*
* MAE38440
* - JLG Threadlocker PN 0100011

** - JLG Threadlocker PN 0100081
*** - JLG Threadlocker PN 0100019
Figure 3-11. Axle JLG Threadlocker Application
3-12 3121171
Table 3-2. Steering Assembly Notes
A Apply JLG Threadlocker PN 0100011
B Apply JLG Threadlocker PN 0100019
C Apply JLG Threadlocker PN 0100035
D Preload Torque 100-300 ft. lb. (140-420 Nm)

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

2. Angle Sensor Assembly 5. King Pin
3. Steer Cylinder 6. Axle
Figure 3-12. Steering Installation
3121171 3-13
3.10 OSCILLATING AXLE SYSTEM 3.11 OSCILLATING AXLE BLEEDING PROCEDURE AND
The oscillating front axle is attached to the frame by a pivot LOCKOUT TEST
pin, which allows all four wheels to remain on the ground
when traveling on rough terrain. The oscillating axle also Lockout Cylinder Bleeding
incorporates two lockout cylinders connected between the
frame and the axle. The lockout cylinders permit axle oscilla- To start the test, the axle must be fully oscillated in one direc-
tion when the boom is in the transport position (see Section tion. Start with oscillating the axle so that the left lock-out cyl.
4.2, Transport Position Sensing System) and drive is com- is fully retracted (left front tire up), and the right lock-out cyl. Is
manded. fully extended (right front tire down).
Lockout cylinders lock and hold the axle when drive is not
commanded or when the boom is outside the transport posi-
tion. Cylinders unlock when pilot pressure is applied to the ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CENTERED OVER REAR
holding valves mounted on the cylinders and lock when pilot AXLE PRIOR TO BEGINNING BLEEDING PROCEDURE. MAKING SURE MACHINE
pressure is removed. Pilot pressure is available from brake IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED, BRAKE WIRE IS
pressure and is controlled by a solenoid operated lockout DISCONNECTED.
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 1. Making sure machine is on a level surface and rear
is “healthy” when pressure trips the pressure switch when the wheels are blocked, machine is in transport mode.
lockout valve is energized and conversely is healthy when the 2. Disengage drive hubs.
lack of pressure resets the pressure switch when the lockout
valve is de-energized. 3. Use suitable container to catch any residual hydraulic
Failures in the oscillating axle system will cause the control fluid, place container under the lockout cylinder.
system to disallow main boom lift up and telescope out, and 4. With left lockout cylinder retracted, open bleeder on top
tower boom lift up when both booms are within the transport of the cylinder, then have an operator from the platform
position and will disallow drive/steer, lift up and telescope out (on high engine) feather drive. Activate drive fully.
when either boom is beyond the transport position.
5. Close bleeder when there is a steady stream of oil and
NOTE: For more detailed information concerning system adjust- not air.
tem. 6. With axle in the same position, go to right lockout cylin-
der and open bleeder at the rod end. Activate drive in
the same manner and close when all air has been
purged.
7. Close bleeder when there is a steady stream of oil and
not air.
8. Oscillate axle the other direction, left lock-out cyl.
extended (tire down), right lock-out cyl. retracted (tire
up). Use the same procedure for the bleeder in the rod
end of the left lock-out cyl., Then the piston end of the
right lock-out cyl. then close.
9. Repeat process one more time to ensure all air has been
purged from the system.
10. Perform oscillating axle lockout test.
11. If necessary, repeat steps 1 thru 9.
NOTE: Bleeding oscillating axles is an infrequent operation per-

formed after hydraulic line failure or lock-out cylinder
repair.
3-14 3121171
Oscillating Axle Lockout Test 6. Drive machine off of block and ramp back on level sur-
face.
The front axles will oscillate when the boom is in the transport
position. 7. Have an assistant check left front wheel remains locked
in position off ground.
NOTE: The machine is in transport mode until one of the follow- 8. Retract boom back in to transport position. Activate
ing three factors are exceeded: drive and the lockout cylinders should release.
Main boom extended more than 4 ft. (1.2 m)
OR 9. Place the 6 inch (15.2 cm) high block with ascension
Main boom 6° above horizontal (w/tower stowed ramp in front of right front wheel.
OR 10. Place DRIVE control lever to FORWARD and carefully
Tower above horizontal. drive machine up ascension ramp until right front wheel
is on top of block.
11. Telescope the boom out of the transport position.
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS-
12. Drive machine off of block and ramp back onto the level
TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
surface.
SUSPECTED.
13. Have an assistant check to see that right front wheel
NOTE: Ensure booms are fully retracted, lowered, and centered remains locked in position off of ground.
between drive wheels prior to beginning lockout cylinder
14. Retract the boom back in to the transport position. Acti-
test. The axles must also be fully extended.
vate drive and the lockout cylinders should release.
15. If lockout cylinders do not function properly, have quali-
1. Place a 6 inch (15.2 cm) high block with ascension ramp
fied personnel correct the malfunction prior to any fur-
in front of left front wheel.
ther operation.
2. From platform control station, activate machine hydrau-
lic system.
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/
TORQUE SELECT control switches to their respective
LOW positions.
4. Place DRIVE control lever to FORWARD position and
carefully drive machine up ascension ramp until left
front wheel is on top of block.
5. Telescope boom out of transport position.
3121171 3-15
3.12 WHEEL DRIVE ASSEMBLY NOTE: The drive hub and drive motor assembly weighs approxi-
mately 267 lbs. (121 kg).
Removal 4. Use a supporting device capable of handling the weight
NOTE: The drive motors can be removed through the axle flange of the drive hub and drive motor, and unbolt the drive
as part of the wheel drive assembly or they can be removed hub from the frame. Remove the entire assembly from
separately through the bottom of the frame while leaving the machine.
the drive hub bolted to the axle. 5. Remove the capscrews and washers that secure the
drive motor to the drive hub and remove the drive
1. Use a jack to lift the frame enough so the tire and wheel motor. Remove and discard the brake gasket between
assembly is off the ground. Place blocking strong the drive motor and drive hub.
enough to support the weight of the machine under the
frame and remove the jack. Installation
NOTE: The foam-filled tire & wheel assembly weighs approxi- 1. Install a new brake gasket between the drive motor and
mately 867 lbs. (393 kg). The solid tire & wheel assembly drive hub. Apply a coat of JLG Threadlocker PN 0100011
weighs approximately 960 lbs. (435 kg). on capscrews. Install the washers and capscrews to
secure the drive hub and drive motor, and torque to
2. Remove hardware securing wheel and remove tire and 178 ft. lbs. (241 Nm).
wheel assembly. Using suitable lifting device lift the tire
and wheel assembly and place in a suitable area. 2. Place the drive hub flange against the mounting flange
on the axle and fasten it in place with the bolts and
3. Tag and disconnect the hydraulic lines running to the washers. Torque the bolts to 180 ft. lbs. (244 Nm).
drive motor. Cap or plug all openings to ensure no dirt
enters the hydraulic system. 3. Using adequate support, install wheel into wheel
assembly and secure with bolts and washers.
DRIVE MOTOR
BRAKE GASKET
DRIVE HUB
NUT
WASHER
CAPSCREW
WHEEL
Figure 3-13. Wheel Drive Installation
3-16 3121171
3.13 DRIVE HUB - IF EQUIPPED WITH REXROTH 15. Inspect planetary stage assemblies as complete units.
Thoroughly clean and check gearing and the bearings
The final drive consists of two planetary stages with an inte- for damage and apply new oil. If gears or bearings need
grated disconnect mechanism. Each stage incorporates a set replacing, they must be replaced as complete sets.
of matched planetary gears, which provide an equal load dis-
tribution. All torque transmitting components are made of 16. First stage planetary gears (2) must be changed in sets of
forged quenched and tempered high-alloy steels. External three pieces.
gears are carburized. Precision roller bearings support the 17. The first stage planetary gears (2) must be changed as a
sprocket or wheel loads. A shaft seal protects the unit against complete set of three and JLG recommends changing
contamination. the sun gear shaft (43) along with this set of planets.
18. The second stage planetary bearings (11) must be
Disassembly replaced in sets of four pieces.
1. Position drive so that one of the fill holes is at bottom of 19. The second stage planetary gears (1) must be changed
end cover and drain oil. as a complete set of four. JLG recommends changing the
2. Remove all bolts holding the motor. Remove motor from sun gear (3) along with this set of planets.
drive.
Cover Disassembly
3. Compress spring (55) using a simple fixture or other suit-
able device. Loosen and remove hex head bolts (53) to remove cover (51).
4. Remove snap ring (66) and release pressure on spring First Stage Planetary (7) Disassembly
(55) until loose.
5. Remove spring (55). 1. Push sun gear shaft (43) out of first stage.
6. Turn unit so that cover (8) is in the up position. 2. Remove snap rings (14).
7. Remove screw plugs (21) and seal rings (22). 3. Press planet pins (5) out of planet gears (2).
8. Remove O-ring (33). 4. Pull cylindrical roller bearing (10) out of planet gears (2).
9. Remove first stage planetary assembly (7). 5. Remove snap ring (16) from sun gear (3). Remove planet
carrier (7) from sun gear (3).
10. Remove hex bolts (23).
12. Remove ring gear (30) and O-ring (19). Second Stage Planet Gears (1) Disassembly
13. Remove snap rings (15). Press cylindrical roller bearings out of planet gears (1).
14. Pull off planet gears (1) together with cylindrical roller
bearings (11) from spindle (60).
FURTHER DISASSEMBLY OF HUB IS DISCOURAGED. REINSTALLATION OF

SHAFT NUT (4) REQUIRES A SPECIAL TOOL AND A TORQUE OF 626 FT-LB (876
NM) FOR PROPER REASSEMBLY. THESE COMPONENTS WILL FAIL IF NOT PROP-
ERLY REASSEMBLED.
3121171 3-17
First Stage Planetary (7) Assembly 6. Before installation of motor, CHECK THERE IS 1-2 mm OF
CLEARANCE BETWEEN THE MOTOR SPLINE SHAFT
SHOULDER AND THE COUPLER (62).
1. Pre-freeze planet pins (5) and install into planet carrier
(7). 7. Install motor and reconnect hydraulic lines.
2. Install planet carrier (7) together with planet pins (5) on 8. Roll motor so one fill plug is at 12 o’clock position, and
sun gear (3), and install snap ring (16). the other is at 3 o’clock. Fill to bottom of 3 o’ clock plug
with gear oil. reinstall plugs.
3. Put sun gear shaft (43) into sun gear (3).
4. Pre-heat stay rings (17) and install onto planet pins (5). Initial Start-up And After Repairs
5. Pre-heat cylindrical roller bearings (10) and install onto Before operating machine, make sure drive is filled with clean
planet pins (5) and fix bearings with snap rings (14). oil, approximately 0.2 US gal (0.8 L). An accurate oil level is
determined by the oil level plug, which should be removed
End Cover Unit (8) Assembly before oil fill.
1. Install O-ring (54) into groove of cover (8). With gear case filled to their proper levels, start machine and
allow sufficient time for run-in at moderate pressure and
2. Install the cover (51) into cover (8) and fix cover (51) with speed before running at full speed. After 4 hours of operation,
hex bolts (53). Tighten bolts with torque wrench to 6.3 recheck oil level.Maintenance
ft-lb (8.5 Nm).
Daily: - Check for oil leakage
Final Assembly Weekly: - Check oil level
1. Install planet gears (1) onto planet pins which are part of Monthly: - Check mounting bolt torque
spindle (60).
Oil Change Interval-Gear Drive
2. Install snap rings (15) on planet pins of spindle (60) to
retain planet gears (1). 1. Perform first oil change after approximately 150 hours.
3. Insert first stage planetary assembly (7) into drive. 2. Subsequent changes, every 1500 hours or annually,
whichever occurs first.
4. Install O-ring (33) in groove of ring gear (30).
NOTE: Flush drive before filling with new oil.
5. Install seal rings (22) and screw plugs (21).
3-18 3121171
Figure 3-14. Drive Hub - Sheet 1 of 2
3121171 3-19
3-20
1. Planet Gear 14. Snap Ring 28. Washer 52. Thrust Washer 67. Retaining Ring
2. Planet Gear 15. Snap Ring 30. Ring Gear 53. Bolt 68. Retaining Ring
3. Sun Gear 16. Snap Ring 33. O-ring 54. O-ring 69. Bolt
4. Shaft Nut 17. Stay Rings 41. Planet Carrier 55. Spring 72. Brake Disc
5. Planet Pin 19. O-ring 42. Sun Gear 60. Spindle 73. Brake Disc
7. Planet Carrier 20. Shaft Seal 43. Sun Gear 61. Piston 74. Spring
8. Cover 21. Plug 45. Planet Pin 62. Coupler 75. Backup Ring
9. Thrust Button 22. Seal Ring 46. Roller Bearing 63. Ring Locator 76. Seal
10. Roller Bearing 23. Bolt 47. Retaining Ring 64. Backup Plate 77. Backup Ring
11. Roller Bearing 24. Detent Ball 48. Retaining Ring 65. Backup Plate 78. Seal
12. Ball Bearing 27. Bolt 51. Cover 66. Retaining Ring 81. O-ring
13. Hex Bolt
Figure 3-15. Drive Hub - Sheet 2 of 2
3121171
3.14 DRIVE HUB - IF EQUIPPED WITH BONFIGLIOLI 1. Clean the mating surfaces from oils or paint and fit the
wheel drive on the machine frame.
NOTE: After SN 0300134389 machines may be built with either
2. Attach the gearbox to the machine frame with the
Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec-
mounting bolts and torque to 178 ft.lbs. (241 Nm).
tion 3.15, Drive Hub - If Equipped With Reggiana Riduttori.
Do not use different hubs on the same machine.
Start Up and Running In
Product Identification If new hubs are being installed, it is advised to follow the
measures given below:
The identification data of the hub is shown on a name plates on
the hub. Figure 3-16., Drive Hub Identification Plate shows 1. Bleed air from every part of the hydraulic and add oil in
how the information is displayed. the tank if necessary.
The information stamped on the name plates must always be

readable. Use the identification data (at least serial number)
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL BE REC-
for spare part inquiries, information and service, etc.
OGNIZED BY THE PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A
JERKING OF THE MOTOR AS WELL AS EXCESSIVE NOISE COMING FROM THE
Hydraulic Motor Installation MOTOR AND THE VALVES.
The mating areas and the pilot diameter of the gearbox
where the motor is to be mounted must be clean and without 2. Start the gearmotor at a low speed and gradually
burrs. increase it after having verified that it is functioning cor-
Before assembling the hydraulic motor, verify by a depth slide rectly without any noises or vibrations.
gauge the correct assembly of the unit checking the axial dis-
tance as shown in Figure 3-17.
DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN
1. Fit the O-ring seal, supplied with the gearbox, in its seat
FILTERED TO ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.
in the hydraulic motor, and assemble it to the gearbox
being careful not to damage the seal already fitted.
NOTE: During running-in stage follow steps below.
2. Torque bolts to 63.5 ft-lb (86 Nm) torque.
3. Check correct revolution and direction of rotation.
4. Make sure functioning is regular and without any exces-
sive noises and vibrations.
5. Make sure oil temperature does not exceed values
listed previously.
Installation of the Wheel Drive on the Machine
Figure 3-16. Drive Hub Identification Plate
3121171 3-21
After running-in the gearbox, follow steps below. CONNECTING THE BRAKE
6. Check there are no oil leaks. If leaks are present, fix The gearbox is fitted with a negative multi disk safety brake
them before proceeding. with hydraulic control release (parking brake). For information
regarding the characteristics of the brake refer to the installa-
7. Check gearmotor oil level. tion drawing.
8. It possible the presence of air in the system during
Table 3-2. Brake Technical Data
the first start up could cause application of the brake
to be slowed down. It is advised to repeat the Brake Release Pressure (16 bar)
application and release functions of the brake to
Maximum Operating Pressure Brake (50 bar)
purge air from the brake.
Braking Torque (265 ± 10% Nm)
9. Check there are no other problems in general.
General Information FILLING GEARBOX WITH LUBRICATING OIL

The motor and the gearbox have separate lubrication. The
The gearbox is designed and built for wheel drive. gearbox is lubricated by oil splashing. The recommended type
The unit includes planetary gearbox, 3 stages, rotating hous- of oil is SAE 80W/90 or SAE 85W/140 with EP features comply-
ing type. ing with MIL-L-2105 C & API GL5. Refer to Table 3-3, Suggested
The illustrations show the parts and the main functions of the Lubricants According SAE 80W/90 and SAE 85W/140 API GL5
gearbox. Grade.
A strict and consistent compliance with the specifications of NOTE: Oil temperature must not exceed 85-90° C intermittently
this technical manual ensure the minimum operating costs during operation.
and a longer unit life.
Photographic documentation and drawings are supplied for
educational purposes, so as to safely and properly carry out
maintenance operations.
Minor deviations from pictures of this manual may appear on
the actual gearbox. However, these discrepancies are not rele-
vant to the main parameters, or maintenance functions.
3-22 3121171
1= M18x1,5..........................Filling, draining and oil level plugs

2= 7/16” - 20 UNF - 2B..........Brake port
Figure 3-17. Hub Assembly
3121171 3-23
Table 3-3. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade
Ambient temperature -20°C / +30°C +10°C / +45°C

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

below.
1. Check gearbox axis is horizontal. Rotate gearbox hous-
ing until drain plug (A) is on bottom of the vertical axis THE DISENGAGEMENT OPTION MUST BE CONNECTED OR DISCONNECTED ONLY
of the end cover. WHEN GEARBOX IS STOPPED ON FLAT GROUND.
2. Unscrew fill and level oil plug (B).
3. Fill from hole until the lubricant flows out.
3-24 3121171
3. Remove cap nut (5).
MAXIMUM WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25

REV/MIN.
4. Turn cap nut (5) upside down. Pin (3) will be pushed
inside to permit disengagement of the gearbox.
Figure 3-18. Gearbox engaged
1. Remove two socket head screws M8x16 (4) from the end
cover (7) with a male hex head wrench.
5. Rotate cap nut (5).
2. Rotate cap nut (5).
3121171 3-25
6. Tighten two socket head screws M8x16 (4) with a male Maintenance Information
hex head torque wrench to 18.4 ft-lb (25 Nm) torque.
PERIODIC MAINTENANCE
The gearbox only requires the scheduled maintenance proce-
dures set out by the manufacturer (see Table 3-4).
Good maintenance will ensure an ongoing functioning in time
as well as maximum reliability.
Should irregularities in function arise, it will be necessary to
consult the troubleshooting checklist to find the most ade-
quate solution.
If unsuccessful, it may be necessary to partially or completely
disassemble the gearbox.
Table 3-4. Drive Hub Maintenance Schedule
Inspection Frequency Action

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

1. Check gearbox axis is horizontal. Rotate gearbox hous-
ing until drain plug is at bottom of the vertical axis of the
end cover.
Figure 3-19. Gearbox Disengaged
7. Repeat the above steps to engage the gearbox again.
Operation:
a. Engaged gearbox
At this condition the motion is transmitted from the

hydraulic motor to the gearbox. 2. Unscrew both plugs (Fill and Drain) and let the oil flow in
a large enough container. To facilitate draining, the oil
b. Disengaged gearbox must be warm.
3. Wait a few minutes until all the oil is drained and then
proceed to screw on the plugs.
AT THIS CONDITION THE HYDRAULIC MOTOR AND THE BRAKE ARE DISCON-
NECTED TO THE GEARBOX: THE WHEEL IS IDLE. 4. Proceed with the oil fill-up. Refer to Filling-up the Gear-
box with Lubricating Oil.
NOTE: Never mix mineral oils with synthetic oils and vice versa.
DO NOT DISPOSE OF OIL IN THE NATURAL ENVIRONMENT. BE CAREFUL TO

ELIMINATE IT IN COMPLIANCE WITH LOCAL RULES AND REGULATIONS.
3-26 3121171
TROUBLESHOOTING
The following table is provided to help locate problems in the
gearbox.
Table 3-5. Troubleshooting
Symptom Causes Remedies

External oil leakage:
From the lifetime seal a) Lifetime seal damaged a) Replace lifetime seal
From the end cover a) O-ring seal damaged a) Replace O-ring seals
From the plugs a) Plug seal damaged a) Replace plug seal
b) Plugs or screws loose b) Tighten the plugs/screws
Too much noise:
Hydraulic noise (during the slowing down a) Hydraulic circuit malfunctioning a) Verify hydraulic circuit
of the motor speed)
Inside the gearmotor (reductions) a) Internal damage a) Check the gearbox
Other:
Overheating a) Insufficient oil level a) Check the oil level and refill if necessary
b) Hydraulic oil too warm b) Check the hydraulic circuit
c) Brake not fully released c) Check brake release pressure
Parking brake malfunctioning
Insufficient braking torque a) Brake discs worn a) Replace brake disc pack
b) Damaged parts b) Check brake components
Wheel Locked a) Parking brake locked a) Check the complete brake release
b) Mechanical components damaged b) Replace damaged parts
Disassembly Information 4. Provide a work area that meets Work and Health Safety
in the Workplace guidelines.
It is also important this procedure is performed in a workshop
equipped with the proper tools. As well as normal workshop Disassembly
tools, it is necessary to use special tools that can be made (see
special tools attachment) or may be requested from the manu- NOTE: Below are all the steps to follow during Disassembly and
facturer. Assembly. Numbers in brackets in the text correspond to
Special Tools: the references in the exploded view.
Puller...............................................Code/: 6689960240 Initial inspection can be made without disassembling the hub
Tool for lifetime seal assembly........Code/: 6689960300 from the machine. Before wheel drive disassembling, make
sure that the oil is drained from the hub.
Puller for brake disassembly..........Code/: 6689960310
Unscrew and remove the nos. 2 screws M12, grade 8,8, and
Torque multiplier............................Code/: ATZ.09.016.0
remove the hydraulic motor and its O-ring seal (48).
To be able to produce these special tools refer to Figure 3-21.
thru Figure 3-24.
It is important to strictly adhere to all procedures for disassem-
bling and reassembling the gearbox. Proceed with these
instructions using all necessary safety measures, for example:
1. Plug all gearbox hydraulic ports to prevent contaminat-
ing the circuit and gearbox.
2. Do not damage coupling surfaces.
3. Handle with care to ensure personnel safety and guar-
antee reliability of the gearbox.
3121171 3-27
1. Install special tool (6689960310) on the flanged hub 4. Mark position of springs (45) for reassembly.
(31). Turn screw until it compresses springs (45).
5. Remove springs (45) from brake piston seats (44).

2. Remove circlip (47). Remove the special tool.
6. Using pliers, remove circlip (36) from its seat in the brake
3. Remove spring retainer disc (46). shaft (35).
3-28 3121171
1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring
2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring
3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43. Backup Ring
4. Screw 14. Splined Shaft 24. Bearing 34. Spacer 44. Brake Piston
5. Cap Nut 15. Disengagement Shaft 25. Spacer 35. Brake Shaft 45. Springs
6. Oil Plug 16. 1st Reduction Assembly 26. Spacer 36. Circlip 46. Retainer Disc
7. End Cover 17. 2nd Stage Sun Gear 27. O-ring 37. Backup Ring 47. Circlip
8. Pad 18. 2nd Reduction Assembly 28. Spacer 38. O-ring
9. O-ring 19. Circlip 29. Half Seal 39. Spacer
10. 1st Stage Sun Gear 20. 3rd Reduction Assembly 30. Seal Ring 40. Backup Ring
Figure 3-20. Drive Hub - If Equipped with Bonfiglioli
3121171 3-29
7. Using a puller, remove at the same time, the brake pis- 10. Remove external O-Ring seal (38) and backup ring (37)
ton (44), spacer (39) and brake shaft (35). from their seat in the spacer (39).
11. Remove O-ring seal (42) and backup ring (43) from their
seats in the flanged hub (31).
8. Remove spacer (39) from brake piston (44).
12. Remove brake discs pack (32-33).

9. Remove internal O-Ring seal (41) and backup ring (40)
from their seat in the spacer (39).
3-30 3121171
13. Remove disengagement shaft kit (15). 16. Use pliers to remove elastic ring (11) from splined shaft (14).
14. Place the disengagement shaft kit (15) inside the special 17. Remove special tool, spring (13), and washers (12).
tool (6689960240).
18. Turn gearbox upside down. Remove two screws M8x16

15. Tighten two screws M5x16, grade 8.8, in cover with a (4), grade 8.8, from end cover (7).
torque wrench to 18.4 ft-lb (25 Nm).
3121171 3-31
19. Remove cap nut (5). 22. Remove draining-filling-level oil plugs (6) using a male
hex head wrench.
20. Remove pin (3).

23. Remove 10 screws M10X25 (1) from end cover (7).
21. Remove O-ring seal (2) from its seat in the end cover (7).
24. Remove end cover (7).
3-32 3121171
25. Remove O-ring seal (9) from its seat in the end cover (7). 28. Remove 2nd stage sun gear (17).
26. Remove 1st stage sun gear (10). 29. Remove 2nd reduction assembly (18).
27. Remove 1st reduction assembly (16). 30. Using pliers, remove circlips (19) from their seats in the
flanged hub's pins (31).
3121171 3-33
31. Using a puller, remove planet assemblies of the 3rd 34. Using a tackle, place torque multiplier (ATZ.09.016.0) on
reduction (20). ring nut (22).
32. Remove spacer (21) from their seats in the pins of the 35. Using the torque multiplier (ATZ.09.016.0), loosen ring
flanged hub (31). nut (22).
NOTE: To proceed with gearbox disassembly, remove it from 36. Remove ring nut (22).
machine and bring it to a properly equipped workshop.
33. Use a drill remove caulking on the ring nut (22).
3-34 3121171
37. Using a puller and a metal stopper, remove the flanged 40. Using a screwdriver, remove 1st half-seal (29) from the
hub (31) from the gearbox housing (23). flanged hub (31).
38. Using a tackle, remove gearbox housing (23) from 41. Using a screwdriver, remove 2nd half-seal (29) from
flanged hub (31). gearbox housing (23).
39. Remove seal ring (30) from flanged hub (31). NOTE: Gearbox disassembly ends with the above operation. All
items are now available for inspection.
NOTE: In case of oil leaks, it may be necessary to check and

replace the lifetime seal (29), which means metal rings
parts and O-ring seals.
3121171 3-35
Inspection of Parts a. Carefully clean seats (A and B) using, if necessary,

metallic brushes or solvent (surfaces in contact with
Pieces that are subject to general wear and tear are: or (C) must be perfectly clean and dry).
- Gears.
- Bearings.
- All the seals
Replace used or irregular parts using the following steps:
1. Remove dirt and properly clean seals, bearings, and
locking rings seating.
2. Lubricate parts before installing.
3. In case of damaged gears, for example a planetary, do
not replace the individual gear but entire reduction
assembly.
4. When reassembling a part, replace all seals. Apply
grease on the seats and on new seals to make reassem-
bly easier.
5. Replace all damaged parts with original spare parts.
Assembly
Apply grease TECNOLUBE SEAL GS730 on gearbox housing
b. Make sure sealing surfaces (D) of metal rings (E) are
(23).
free from scratches, dings, or foreign substances;
metallic ring surfaces must be perfectly clean and
dry. We suggest to dip the metallic rings in volatile
solvent or industrial degreasing alcohol.
c. Carefully clean lapped surface (D) of metal rings (E)
and remove dust or fingerprints. Lubricate them
with a thin oil film. Do not oil other components.
2. Assemble half seal (29) on tool (6689960300).
1. Follow steps below to prepare the lifetime seal for

assembly:
3-36 3121171
3. Assemble 1st half seal (29) on gearbox housing (23). 6. Insert seal ring (30) in its seat in the flanged hub (31).
4. Using the same tool (6689960300), assemble 2nd half 7. Apply grease TECNOLUBE SEAL GS730 on seal ring (30).
seal (29) on the flanged hub (31).
5. Carefully clean metallic faces of the lifetime seal (29) and

lubricate surfaces with oil. AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL (29)
8. Using a hoist, place gearbox housing (23) on flanged

hub (31).
3121171 3-37
9. Using a press and a metallic stopper, push gearbox 11. Using multiplier (ATZ.09.016.0), tighten ring nut (22),
housing (23) against shoulder on flanged hub (31) until using a torque wrench with an input multiplier torque of
assembling of unit is complete. 71 ± 3 ft-lb (96,5 ± 4, 5 Nm) corresponding to an output
multiplier torque of 3688 ± 184 ft-lb (5000 ± 250 Nm).
12. Stake ring nut (22) near two seats at 180° of flanged hub
SCREW NUT (22) PARTIALLY IN TO PREVENT FLANGED HUB (31) FROM COM- (31) on the right side.
ING OUT OF GEARBOX HOUSING (23) DURING THE FOLLOWING STEPS.
NOTE: Stake Ø 4+5 mm (depth 1+1,5 mm).

10. Use a hoist to place the torque multiplier (ATZ.09.016.0)
on the ring nut (22).
3-38 3121171
13. Install spacers (21) on flanged hub (31)pins. 16. Using pliers, assemble circlips (19) in flanged hub pin
seats (31).
14. Place five planet assemblies of the 3rd reduction (20) on

flanged hub's pins (31). 17. Assemble 2nd reduction assembly (18).
15. Using a rubber hammer and a metal stopper, push 18. Install 2nd stage sun gear (17).
planet assemblies of the 3rd reduction (20) against the
shoulder until assembly is complete.
3121171 3-39
19. Assemble 1st reduction assembly (16). 22. Place end cover (7) on gearbox housing (23).
20. Install 1st stage sun gear (10). 23. Tighten 10 socket head screws M10x25 (1),grade 12,9,
by a torque wrench to 62.7 ft-lb torque (85 Nm).
21. Install O-ring seal (9) into its seat in the end cover (7).
24. Install plugs (6) in oil drain-fill holes of the end cover (7).
Torque plugs to 52 ± 7 ft-lb (70±10 Nm).
3-40 3121171
25. Install O-ring (2) into its seat in the end cover (7). 28. Torque two screws M8x16 (4) to 18.4 ft-lb (25 Nm).
26. Protect seat and pin (3) with grease type MOLYKOTE 29. Install 1st washer (12) on splined shaft (14).
G6000. Wait 15 minutes for it to completely dry. Insert
pin (3) in its seat in the end cover (7).
30. Install spring (13) on splined shaft (14).
27. Install cap nut (5).
3121171 3-41
31. Insert splined shaft (14) in special tool (6689960240). 34. Using pliers, assemble elastic ring (11) into its seat in the
splined shaft (14).
32. Insert 2nd washer (12) correctly in the splined shaft (14).
35. Insert disengagement shaft kit (15) in flanged hub (31).

33. Torque two screws M5x16, grade 8.8, of the cover to 18.4
ft-lb (25 Nm).
3-42 3121171
36. Using pliers, install circlip (36) into its seat in the brake 39. Insert an internally toothed steel disc (32). Repeat opera-
shaft (35). tion until all five sintered bronze discs and four steel
discs are installed.
37. Turn gearbox upside down. Install brake shaft (35) inside
flanged hub (31). 40. Fit internal O-ring seal (41) and backup ring (40) into
their seats in the spacer (39).
38. Assemble brake discs in the following order: first, insert

one sintered bronze disc with external teeth (33). 41. Fit external O-ring seal (38) and backup ring (37) into
their seats in the spacer (39).
3121171 3-43
42. Insert spacer (39) inside flanged hub (31). Do not dam- 44. Lube seal seats into flanged hub (31) and assemble the
age seals already installed. O-ring seal (42) and the backup ring (43).
43. Using a rubber hammer and a metal stopper, push NOTE: O-ring seals (A) and backup rings (B) must be fitted in seats
spacer (39) against flanged hub (31). Do not damage according mutual position shown below.
seals already installed.
3-44 3121171
45. Insert brake piston (44) inside flanged hub (31). Do not 47. Insert springs (45) in previously marked brake piston
damage seals already fitted. (44) holes.
46. Using a rubber hammer and a metal stopper, push brake 48. Install spring retainer disc (46).
piston (44) against flanged hub (31). Do not damage
seals already installed.
3121171 3-45
49. Install special tool (6689960310) on flanged hub (31). Final Test and Reinstallation
Turn screw until it compresses springs (45).
Check product by remounting it to the machine.
Check function of drive hub following all checks shown in
Startup and Running In.
If work on the brake was performed, check for oil leaks. Follow
procedure below:
1. Connect pressure pilot line with manometer (with a
base scale of 100 bars) to the brake release port.
50. Install circlip (47) in its seat and remove special tool.
NOTE: Before assembling hydraulic motor, verify by a depth slide 2. Open flow valve and release brake with pilot pressure of
gauge the correct assembly of the unit checking the axial 50 bar.
distance as shown below.
3. Close flow valve and keep brake released 3 minutes or
longer.
4. Using a manometer, check pressure remains constant.
NOTE: If pressure drops, it may mean brake seals are not tight and
must be replaced, or reassembling was not completed
properly.
5. After reassembling gearbox, install hydraulic motor.

6. Fill gearmotor with lubricant oil.
3-46 3121171
Figure 3-21. Drive Hub Special Tools - Sheet 1 of 4
3121171 3-47
3-48 3121171
3121171 3-49
3-50 3121171
3.15 DRIVE HUB - IF EQUIPPED WITH REGGIANA 8. Wrench for M6, M8, M10 socket head screws and 1/4”G
plug.
RIDUTTORI
9. Socket wrench for M6 hexagonal screw.
NOTE: After SN 0300134389 machines may be built with either
Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec-
tion 3.14, Drive Hub - If Equipped With Bonfiglioli. Do not
use different hubs on the same machine. M- 1326
Symbol Nomenclature Ø240
Ø130
Ø30 5x45°
35
°
= ADHESIVE 15
R5
Ø224
10
5
Ø233
Ø240
60°
= LUBRICANT
60
60
°
A A
= GREASE
N° 6 Hole to 120° Ø30
= TORQUE WRENCH Figure 3-25. Bearing Track Spacer Mounting C016117
M- 1537
= DISPOSAL Ø249
Ø130
Tools Ø30
N° 4 Hole to 90° Ø30
Tools required for assembling and disassembling the wheel
gear RRTD1701TB
29.5
1. Hammer;
2. Clamps for inner retention rings; Ø210
14.5
10
3. Clamps for outer retention rings; Ø219
4. Electric or pneumatic screwdriver;

5. Special spacer mounting; Figure 3-26. Oil Seal Spacer Mounting C125049
6. Torque wrench;
7. Hydraulic press;
3121171 3-51
Ø210
5x45°
Ø130
25
Ø30
M- 1321
LOCTITE 2701
N° 4 Hole to 90° Ø40
110
M- 1320
Ø197.5
Ø210
Figure 3-27. Bearing Spacer Mounting CO16117
Figure 3-28. Assembly Diagram 1
3-52 3121171
M- 1316 M- 1020
30
Ø34 35 35
10
10 10
M- 1317
45°
45°
8 M- 1317
N° 4 R
35
45°
45°
70
A A
35
50
M- 1317
70
50
216.5
Ø
12
10
Ø11
Ø230
20
M- 1316 10x45°
60
Ø16 90
70
Ø17
55
38
11
M- 1317
M- 1317
M- 1317 Figure 3-31. Anti-rotation Block
16 n° 8 Routing to 45°
Ø205
Figure 3-29. Wrench For Ring Nut

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

M6
32
n° 12 Spot-facing to 30° Ø10.5

T.U.15
Figure 3-32. Anti-rotation Pin

6.5
n° 4 Hole to 90° M10

Ø50
Ø275
Ø305
30° 30°
0
°
30
3
°
30°
30°
A A
Figure 3-30. Anti-rotation Flange
3121171 3-53
M- 1126 M- 1126
M- 1125 VTCEI M6X12 n°12
M- 1020
VTCEI M10X60 n°4
Figure 3-33. Assembly Diagram 2
3-54 3121171
Ø105 M- 1546 M- 1548

Ø93.5
+0.1
Ø48
Ø20+0.2 Ø46
5
5
9
80
70
50
8.5
20
Ø8.5
Ø13.5 Ø40.5
5
Ø46
M- 1547
2.5x15°
Ø39.5
t.u. 12
88.5
0
3.5
M8
Ø20 -0.1
VTCEI M8X16 n°1
Figure 3-34. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram
3121171 3-55
Disassembly 3. Release the screws from the release cover and pull the
pin out.
1. Remove plugs and pour lubricant in a container.
4. Remove the BR250 ring and pull cover out. Do not dam-
age O-Ring.
2. Release screws to disassemble the motor flange. Do not

damage O-Ring.
5. Pull reduction gears out.
3-56 3121171
3121171
Figure 3-35. Reggiana Riduttori Hub - Sheet 1 of 2
3-57
3-58
1. Screw 13. Iron Brake Disc 25. Tapered Roller Bearing 37. O-ring
2. Motor Support 14. Plastic Plug 26. Bearing Support 38. Crown Gear
3. O-ring 15. Spindle 27. Ring Nut 39. Crown Gear Screw
4. Inner Retention Ring 16. Planet Wheel 28. Sphere 40. O-ring
5. Brake Spring Spacer 17. Bearing 29. Screw 41. Support Tablet
6. Brake Spring 18. Outer Retention Ring 30. Pinion 42. O-ring
7. Brake Piston 19. Input Shaft 31. Reduction Gears 43. Cover
8. Parbak 20. Input Shaft Bearing 32. Outer Retention Ring 44. Steel Plug
9. O-ring 21. Ring 33. Pinion 45. Cover Retaining Ring
10. O-ring 22. Disengagement Spring 34. Reduction Gears 46. Disengagement Stud
11. Parbak 23. Disengagement Shaft 35. Outer Retention Ring 47. Disengagement Cap
12. Sintered Brake Disc 24. Spindle Oil Seal 36. Pinion 48. Disengagement Screw
Figure 3-36. Reggiana Riduttori Hub - Sheet 2 of 2
3121171
6. Loosen the M10x25 flathead socket screws. Remove 9. Loosen the M6x6 socket headless screws and remove
planetary ring. Do not damage O-Ring. the 3/16” balls.
7. Remove release joint together with the spring. 10. Loosen the ring nut using the special wrench.
8. Disassemble the Ø40 outer snap rings. Using an extrac- 11. Remove hub support with roller bearing inner track.
tor, remove planetary gears from spindle pins.
3121171 3-59
12. Disassemble the Ø160 inner snap ring and pull the Assembly
spring holder spacer out. Remove springs. Using a com-
pressed air jet in the brake control hole, pull piston out 1. Make sure all wheel gear components are devoid of
of the spindle. burrs, machining residues, and are correctly washed.
2. Fit ball bearing in input shaft. Lock with a Ø40 outer
snap ring.
13. Remove brake discs and seals.

3. Install motor shaft in spindle and lock with BR68 ring.
Lubricate bearing.
14. Fit ball bearing into input shaft and lock it with a Ø40
outer snap ring. Install motor shaft in spindle and lock
with a BR68 ring. Lubricate bearing.
3-60 3121171
4. Fit brake sealing rings O-Ring and PARBAK (lubricated 6. Prepare hub support, mounting on it the two roller bear-
with grease) in the respective spindle seats. Place the ing outer tracks. Place first roller bearing inner track.
brake discs making sure to center them on the spindle
and on the input shaft.
7. Install oil seal lubricated with grease on support with

special spacer mounting (see figure A).
5. Insert brake piston and place springs into the piston
holes. Close brake fitting spring holder plate, then lock
with the Ø160 inner snap ring. Check brake leakage, if Fig.A
any, as well as the static torque and minimum opening
pressure.
8. Place hub support already assembled on spindle mak-

ing sure that the first roller bearing inner track goes cor-
rectly against it; then fit the second roller bearing inner
track by means of spacer mounting. Tighten ring nut.
3121171 3-61
9. Check unit roll torque and proceed in the following 11. Using special tool and hammer, make four dents on the
order: spindle thread by the M6 holes of the ring nut.
10. Keeping spindle locked, apply a setting preload by tight-
ening ring nut at 40daNm, turn completely the hub sup-
port twice using the special wrench to recover any
bearing cage misalignments. Release and tighten the
ring nut at the final torque of 30daNm (alternate tight-
ening and some setting turns). Check roll torque with
seal which must be within 1÷1,5 daNm.
12. Fit the 4 3/16” balls and tighten with LOCTITE 243 the 4
M6x6 socket headless screws at the torque of 1daNm.
NOTE: Place ring nut with convex part facing the roller bearing as
shown below.
3-62 3121171
13. Fit bearings on 3rd stage planetary gears and using a 15. Place hub on support making the two holes coincide for
spacer mounting mount everything on the spindle pins. tightening the M10x25 flathead socket screws at the
Lock with an outer snap ring. Lubricate bearings. torque of 5daNm.
16. Fit the reduction gears and the pinion in the unit.
14. Using a marking pen, make a mark between the snap

ring and the bearing. Fit the greased spring and the
release joint. Use grease to fit the O-Ring 2-275 in the
hub support seat.
3121171 3-63
17. Prepare the closing cover fitting the O-ring 5-582 suit- 19. Fit O-Ring 2-163 suitably greased, on motor coupling
ably greased and lock it with the shimming ring. Lubri- flange S-D LC/KC. Mount flange on spindle with 6 M8x25
cate the bearings. socket capscrews at the torque of 2.4daNm with LOC-
TITE 243 Insert pin and perform rotation test according
to PGQ-22 standard.
18. Fit O-Ring 2-177 suitably greased, mount the cover lock-
ing it with the BR250 ring.
20. Mount release cover fastening it with 2 M6x20 hexago-
nal screws at the torque of 1daNm. Mount the 1/4”GAS
plugs on the cover at the torque of 1daNm.
3-64 3121171
1. Swing Drive 4. Outer Race Bearing Bolt

2. Inner Race Bearing Bolt 5. Turntable Lock Pin
3. Swing Bearing 6. Remote Bearing Lubrication Fittings
Figure 3-37. Swing System (SN 0300201017 through 0300254456)
3121171 3-65
6
4
MAE37970
1. Swing Drive 4. Outer Race Bearing Bolt

2. Inner Race Bearing Bolt 5. Turntable Lock Pin
3. Swing Bearing 6. Remote Bearing Lubrication Fittings
Figure 3-38. Swing System (SN 0300254457 to Present)
3-66 3121171
3.16 SWING DRIVE HUB 5. Place swing drive hub in the clean area.
6. Refer to Figure 3-39., Swing Drive Installation, for swing
Removal drive maintenance.
1. Gently loosen the setscrew (1). Do not remove. Assembly/Disassembly
2. Remove the bolt (2).
For detail assembly/disassembly instructions, refer Swing
3. Remove the mounting bolts (8) securing swing drive Drive Hub Manual or contact JLG service for more details.
hub to the turntable.
Installation
4. Using the suitable lifting device, remove the swing drive
hub from mounting plate without damaging the swing Ensure mounting plate and mounting location of the base
gear. plate are clean and painted with a uniform coating of mini-
mum thickness (no runs, drips, etc.).
8
4
5
1001228617-D
MAE38510D
1. Setscrew 4. Shim 7. Sleeve

2. Bolt 5. Washer 8. Mounting Bolt
3. Nut 6. Swing Hub Assembly
Figure 3-39. Swing Drive Installation
3121171 3-67
3.17 SWING DRIVE Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
Roll and Leak Testing should be taken to ensure that the bolts are not tightened
Torque-Hub units should always be roll and leak tested before beyond their specified torque.
disassembly and after assembly to make sure that the unit's The following steps describe how to tighten and torque bolts
gears, bearings and seals are working properly. The following or socket head capscrews in a bolt circle.
information briefly outlines what to look for when performing
these tests.
NOTE: Brake must be released before performing the roll test. This
can be accomplished by pressure testing using the Brake
Leak Test procedure below or tightening the 12 bolts into
the piston through the end plate (See Brake Disassembly
Procedure)
NOTE: Bolts must be removed while performing brake release test
Roll Test
The purpose of the roll test is to determine if the unit's gears
are rotating freely and properly. You should be able to rotate
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con-
cerned if the gears in your unit seem to roll hard as long as
they roll with consistency.
LEAK TEST (MAIN UNIT)
The purpose of a leak test is to make sure the unit is air tight. 1. Tighten (but do not torque) bolt “A" until snug.
You can tell if your unit has a leak if the pressure gauge read- 2. Go to opposite side of bolt circle and tighten bolt “B”
ing on your air checker starts to fall after unit has been pres- until equally snug.
surized and allowed to equalize. Leaks will most likely occur at
pipe plugs, main seal, or wherever O-rings or gaskets are 3. Crisscross around the bolt circle and tighten remaining
located. The exact location of a leak can usually be detected by bolts.
brushing a soap and water solution around the main seal and 4. Use a torque wrench, apply specified torque to bolt “A”.
where the O-rings or gaskets meet on the exterior of the unit,
then checking for air bubbles. If a leak is detected in a seal, O- 5. Using the same sequence, crisscross around the bolt cir-
ring or gasket, the part must be replaced, and the unit cle and apply equal torque to remaining bolts.
rechecked. Leak test at 10 psi (0.7 bar) for 20 minutes.
3-68 3121171
Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36).
Remove fittings from Brake (26) and Motor Control Valve
1. Place unit on bench with motor end up. (32).
2. Remove O-ring Plug (1J). Drain oil from gearbox. 5. Remove O-ring Plugs (21) from Motor Control Valve (32).
3. Remove Hydraulic Tubing Assembly (35) by loosening 6. Remove Motor Control Valve (32) from Motor (10) by
fittings on both ends of tube with a wrench. removing four Bolts (34) and washers (33).
1J. O-Ring Plug 32. Motor Control Valve

10. Hydraulic Motor 33. Lockwasher
21. Plug 34. Hex Bolt
24. ID Plate 35. Hydraulic Tubing
25. Drive Screw 36. Elbow
26. Hydraulic Brake
Figure 3-40. Swing Drive - Motor Control Valve Disassembly (SN 0300201017 through 0300254456)
3121171 3-69
Motor and Brake Disassembly 3. Remove Gasket (31) between Brake (26) and Motor (10).
4. Remove Brake (26) from Main Torque-Hub Assembly
1. With unit resting on bench with Motor (10) end up,
and dump oil out of Brake (26).
loosen Hex Bolts (29) and remove Lift Lugs (28) from
Motor (10). 5. Remove O-ring (27) between Motor (10) and Brake (26).
2. Pull Motor (10) straight up and remove from Brake (26).
10. Hydraulic Motor 28. Lift Lug

26. Hydraulic Brake 29. Bolt
27. O-Ring 31. Gasket
Figure 3-41. Swing Drive - Motor and Brake Disassembly (SN 0300201017 through 0300254456)
3-70 3121171
Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15)
between Input Cover (6) and Carrier (3A) Subassembly.
1. With unit resting on Output Shaft (Pinion) (1A), remove
7. Remove Ring Gear (4) from Housing (1G).
eight Bolts (17), four Shoulder Bolts (18), and four Lock
Washers (19) from Input Cover (6). 8. Remove O-ring (5) between Ring Gear (4) and Housing
(1G).
2. Thread either 1/2-13 UNC eye bolts or motor mounting
Bolts (29) into threaded holes in Input Cover (6) and pull 9. Remove Carrier (3A) Subassembly.
Input Cover (6) off on the main assembly.
10. Remove Thrust Washers (16) and Thrust Bearing (15)
3. Remove O-ring (5) between Input Cover (6) and Ring between Carrier (3A) Subassembly and Internal Gear (2).
Gear (4).
11. Remove Internal Gear (2).
4. Remove Thrust Washer (8) from end of Sun Gear (13).
5. Remove Sun Gear (13).
2. Internal Gear 15. Thrust Bearing

4. Ring Gear 16. Thrust Washer
5. O-Ring 17. Hex Bolt
6. Input Cover 18. Shoulder Bolt
8. Hex Bolt 19. Lockwasher
13. Sun Gear 20. Pipe Plug
Figure 3-42. Swing Drive - Main Disassembly (SN 0300201017 through 0300254456)
3121171 3-71
Hub-Shaft Disassembly 4. Remove Bearing Cone (1F) from Housing (1G).

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

1B. Lip Seal 1G. Housing
1C. Tapered Bearing Cup 1H. Thrust Washer
1D. Tapered Bearing Cone 1I. Retaining Ring
1E. Tapered Bearing Cup 1J. O-Ring Plug
Figure 3-43. Swing Drive - Hub Shaft Disassembly (SN 0300201017 through 0300254456)
3-72 3121171
Carrier Disassembly 3. Slide Planet Gear (3F), two Ball-Indented Thrust Washers
(3H), and two Thrust Washers (3B) out of Carrier (3A).
1. Using a 3/16” (5 mm) punch drive Roll Pin (3G) which
4. Remove both rows of Needle Bearings (3C) and Spacer
holds Planet Shaft (3E) in Carrier (3A) down into the
(3D) from bore of Planet Gear (3F).
Planet Shaft (3E) until it bottoms.
5. Repeat Steps 1 thru 4 for the remaining two Cluster
NOTE: Make sure Roll Pin has bottomed. Otherwise, damage to
Gears (3F).
carrier could occur when Planet Shaft is removed.
2. Remove Planet Shaft (3E) from Carrier (3A). Use a small

punch to remove Roll Pin (3G) from Planet Shaft (3E).
3A. Carrier 3E. Planet Shaft

3B. Tanged Thrust Washer 3F. Cluster Gear
3C. Needle Bearing 3G. Roll Pin
3D. Thrust Washer 3H. Ball Indented Washer
Figure 3-44. Swing Drive - Carrier Disassembly (SN 0300201017 through 0300254456)
3121171 3-73
Hub-Shaft Sub-Assembly 9. Install Bearing Spacer (1H) on Output Shaft (1A) and
against Bearing Cone (1F).
1. Press Bearing Cone (1D) onto Shaft (1A).
10. Install Retaining Ring (1I) in groove of Output Shaft (1A).
2. Press Bearing Cup (1C) into Housing (1G). Ensure cup This Retaining Ring (1I) should never be reused in a
starts square with bore of Hub (1G). repair or rebuild.
3. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing
1G).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
4. Press or tap Seal (1B) into counterbore of Housing (1G)
to the point where it becomes flush with the Housing
11. Tap Retaining Ring (1I) with a soft metal punch to ensure
(1G) face. Ensure Seal (1B) is correctly installed (smooth
Retaining Ring (1I) is completely seated in groove of
face up).
Output Shaft (1A).
5. Invert Hub (1G) and press Bearing Cup (1E) into counter-
bore of Housing (1G).
6. Carefully lower Housing (1G) onto Output Shaft (1A). EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
7. Start Bearing Cone (1F) onto Output Shaft (1A). 12. Install O-ring Plug (1J). Torque to 23 to 24 ft-lb (32 - 33.5
8. Press or tap Bearing Cone (1F) onto Output Shaft (1A) Nm).
until it is seated in Bearing Cup (1E).
1A. Output Shaft 1D. Tapered Bearing Cone 1G. Housing 1I. Retaining Ring
1B. Lip Seal 1E. Tapered Bearing Cup 1H. Thrust Washer 1J. O-Ring Plug
1C. Tapered Bearing Cup 1F. Tapered Bearing Cone
Figure 3-45. Swing Drive - Hub Shaft Sub-Assembly (SN 0300201017 through 0300254456)
3-74 3121171
Carrier Sub-Assembly 8. Slide second Thrust Washer (3E) between Cluster Gear
(3F) and Carrier (3A) with tang of washer located in the
1. Apply a liberal coat of grease to the bore of Cluster Gear cast slot of Carrier (3A). Slide ball-indented Thrust
(3F). This will enable Needle Rollers (3C) to be held in Washer (3H) onto end of the Planet Shaft with indents
place during assembly. against second thrust Washer. Finish sliding the Planet
Shaft (3E) through Thrust Washers (3H) & (3B) and into
2. Install first row of 14 Needle Rollers (3C) into bore of
the Carrier (3A).
Cluster Gear (3F).
9. Position the non-chamfered side on the Planet Shaft (3E)
3. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of
roll pin hole so that it is in line with the hole in the Car-
Needle Rollers (3C).
rier (3A) using a 1/8” (3 mm) diameter punch.
4. Place second row of Needle Rollers (3C) into bore of
10. Use a 3/16” (5 mm) punch to align the two roll pin holes.
Cluster Gear (3F) against Spacer (3D). Remove Planet
Drive Roll Pin (3G) through Carrier (3A) and into the
Shaft (3E).
Planet Shaft (3E) until Roll Pin (3G) is flush with bottom
5. Place Carrier (3A) into tool fixture so one of the roll pin of cast tang slot in the Carrier (3A). Use a 1/4” (6 mm) pin
holes is straight up. punch to make sure Roll Pin (3G) is flush in the slot.
6. Start Planet Shaft (3E) through hole in Carrier (3A). Using 11. Repeat Steps 1 - 10 for remaining two Cluster Gears (3F).
ample grease to hold it in position, slide one Thrust
Washer (3B) over Planet Shaft (3E) with tang resting in
cast slot of the Carrier (3A). Place Ball-Indented Thrust
Washer (3H) on Planet Shaft (3E) with indents against
first washer.
7. With large end of Cluster Gear (3F) facing roll pin hole in
the carrier, place cluster gear into position in Carrier
(3A). Push Planet Shaft (3E) through Cluster Gear (3F)
without going all the way through.
3121171 3-75
3A. Carrier 3E. Planet Shaft

3B. Tanged Thrust Washer 3F. Cluster Gear
3C. Needle Bearing 3G. Roll Pin
3D. Thrust Washer 3H. Ball Indented Washer
Figure 3-46. Swing Drive - Carrier Sub-Assembly (SN 0300201017 through 0300254456)
3-76 3121171
Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
1. With Hub Shaft Sub-Assembly resting on Shaft (1A) with the Internal Gear (2) and Input Gear (13). On the
install Internal Gear (2). Spline of Internal Gear (2) bore Ring Gear (4) locate hole marked “X”, or punch marked,
will mesh with spline of the Output Shaft (1A). over one of the marked counter-bored holes (Step 5) in
Hub (1G). Check timing through slots in the carrier.
2. Inspect location of Internal Gear (2) on Output Shaft
Rotate carrier in assembly to check freedom of rotation.
(1A). The portion of the Output Shaft (1A), which does
not have full spline, should protrude through the Inter- NOTE: NOTE: If gears do not mesh easily or Carrier Assembly does
nal Gear (2) bore. not rotate freely, remove Carrier and Ring Gear and check
Cluster Gear timing
3. Install two Thrust Washers (15) and one Thrust Bearing
(16) on portion of Output Shaft (1A) which protrudes 10. Install Thrust Washer (15)/Thrust Bearing (16) set into
through Internal Gear (2). the counter-bore in the face of the carrier. Use grease to
4. Center Input Gear (13) on end of the Output Shaft (1A) hold in place.
opposite gear with large diameter down. 11. Place O-ring (5) into Cover (6) counter-bore. Use grease
5. Place O-ring (5) into Hub counter-bore. Use grease to to hold O-Ring in place.
hold O-ring in place.
BEWARE OF SHARP EDGES OF THE COUNTER-BORE WHILE SEATING THIS O-

BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE SEATING THIS O- RING.
RING.
12. Using sufficient grease to hold in place, install Thrust
6. Locate and mark the four counter reamed holes in the Washer (8) into the counter-bore of the interface of the
face of the Hub (1G). This is for identification later in Cover (6).
assembly. 13. The Cover (6) is now installed, taking care to correctly
7. Place Carrier (3A) Subassembly on bench with the large align Pipe Plug hole (20) with those in the Hub (1J).
end of Cluster Gears (3F) up with one at the 12 o clock Check timing sheet.
position. Find the punch marked tooth on each gear at 14. Locate the 4 counter-bored holes in Hub (1G) [marked in
the large end and locate at 12 o'clock (straight up) from Step 5] and install 4 Shoulder Bolts (18) with Lockwash-
each planet pin. Marked tooth will be located just under ers (19). Start the shoulder bolts by hand.
the Carrier on upper two gears. Check the timing
through the slots in the carrier. 15. Install Grade 8 Bolts (17) with Lockwashers (19) into
remaining holes.
8. With large shoulder side of Ring Gear (4) facing down,
place Ring Gear (4) over (into mesh with) large end of 16. Torque Shoulder Bolts (18) 43 to 47 ft.-lbs. (60 to 65 Nm)
gears. Be sure that punch marks remain in correct loca- and Grade 8 Bolts (17) to 43 to 47 ft.-lbs. (60 to 65 Nm).
tion during Ring Gear (4) installation. The side of the Roll and leak test the assembly.
Ring Gear (4) with an “X” or punch mark stamped on it 17. With gearbox standing on the pinion end, fill gearbox
should be up. with GEAROIL 80W90 to bottom of plug hole in cover at
Pipe Plug (20).
18. Install Pipe Plug (20) into Cover (6) using thread sealant.
3121171 3-77
2. Internal Gear 15. Thrust Bearing

4. Ring Gear 16. Thrust Washer
5. O-Ring 17. Hex Bolt
6. Input Cover 18. Shoulder Bolt
8. Hex Bolt 19. Lockwasher
13. Sun Gear 20. Pipe Plug
Figure 3-47. Swing Drive - Main Assembly (SN 0300201017 through 0300254456)
3-78 3121171
Motor and Brake Assembly 4. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble
Hex Bolts (29) with Lift Lugs through the Motor (10) and
1. Place O-ring (27) onto end of Brake (26) and locate brake Brake (26) against the motor flange. Torque to 35 ft-lb.
into pilot of cover.
5. Fill Brake (26) with 2.7 oz (80cc) of BRAKOILVG32
2. Place Gasket (31) on brake face and line up holes. (DTE24).
3. Place Motor (10) into Brake pilot against Gasket (31).
10. Hydraulic Motor 28. Lift Lug

26. Hydraulic Brake 29. Bolt
27. O-Ring 31. Gasket
Figure 3-48. Swing Drive - Motor and Brake Assembly (SN 0300201017 through 0300254456)
3121171 3-79
Motor Control Valve Assembly 4. Assemble Tube (35) into Elbow Fittings (36) and torque
13 to 15 ft-lb (18 to 21 Nm).
1. Lay assembly down with motor ports facing up. Remove
5. Install O-ring Plugs (21) into Motor Control Valve (32)
two plastic plugs in motor ports, being careful not to
and torque 30 to 31 ft-lb (42 to 43 Nm).
loose O-ring in each port. Assemble Motor control Valve
(32) to Motor (10) with Bolt (34) and Lock Washers (33). 6. Pressure test brake, tube and control valve connections
Torque Bolts (33) 23 to 27 ft-lb (32 to 38 Nm). by applying 3000 psi (207 bar) pressure to brake bleed
port and holding for 1 minute. Check for leaks at control-
NOTE: Align holes in control valve with motor ports.
valve-motor interface and the tube connections.
2. Install Elbow Fittings (36) into Brake (26) and torque 13 Release pressure.
to 15 ft-lb (18 to 21 Nm). 7. Install I.D. Plate (24) on Housing (1G) with two Drive
3. Install Elbow Fittings (36) into Motor Control Valve (32) Screws (25). Plate must be inline with O-ring Plug (1J).
and torque to 13 to 15 ft-lb (18 to 21 Nm).
1J. O-Ring Plug 25. Drive Screw 34. Hex Bolt

10. Hydraulic Motor 26. Hydraulic Brake 35. Hydraulic Tubing
21. Plug 32. Motor Control Valve 36. Elbow
24. ID Plate 33. Lockwasher
Figure 3-49. Swing Drive - Motor Control Valve Assembly (SN 0300201017 through 0300254456)
3-80 3121171
15
11
9 10
12
13
17
12
14
16
8
5 6
4
4
3
2 7 40
30
6 27
1
26
25
20
18 28
19
29
18
24 7
27
23
22
21 49
20 48
18
19
18 43 47
46
45
44
42
41
31
32
39
38
37
36
35
32
31
34
33 1001228488-B
MAE37600B
Figure 3-50. Swing Motor (SN 0300254457 to Present) - Sheet 1 of 2
3121171 3-81
1. Shaft 11. Spacer 21. Pinion 31. Seal 41. O-ring

2. Ring 12. O-Ring 22. Ring 32. O-Ring 42. Cover
3. Oil Seal 13. Planetory Gear 23. Spacer 33. Steel Disc 43. Screw
4. Bearing 14. Spacer 24. Spacer 34. Disc 44. O-ring
5. Support 15. O-Ring Plug 25. Pinion 35. Disc 45. Motor
6. O-ring Plug 16. Spring 26. Ring 36. Seal 46. Lung Lifting
7. O- ring Plug 17. Capscrew 27. Washer 37. O-ring 47. Capscrew
8. Nut Ring 18. O-ring 28. Brake Housing 38. Piston Brake 48. Brake valve adapter
9. Reduction Gear 19. Planetory Ring 29. Plug 39. Spring Brake 49. Valve
10. Pinion 20. Reduction Gear 30. Capscrew 40. Shaft Input
Figure 3-51. Swing Motor (SN 0300254457 to Present) - Sheet 2 of 2
3-82 3121171
3.18 SWING BRAKE HYDRAULIC/MECHANICAL

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

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

2. Housing 10. Deep Groove Ball Bearing 18. Backing Ring
3. Inner Friction Plate 11. Internal Retaining Ring 19. Dowel Pin
4. Pressure Plate 12. Rotary Shaft Seal 20. Hexagon Plug
5. Gasket 13. Socket Head Capscrew 21. Plastic Plug
6. Outer Plate 14. Shakeproof Washer 21A.Socket Pressure Plug
7. Gasket 15. O-Ring 22. Spring (Natural)
8. Cylinder 16. Backing Ring 23. Spring (Blue)
Figure 3-52. Swing Brake
3121171 3-83
Installation 6. Remove springs (8). Note quantity and orientation of

springs.
Position 1-off gasket (5) over male pilot on brake housing (4).
Locate brake shaft (1) and secure brake in position using 2-off 7. Should it be necessary to replace ball bearing (10) or
1/2” UNC mounting bolts in the through mounting (fixing) shaft seal (12), reverse remainder of brake sub-assembly,
holes provided. supporting on face “c” of housing (2).
8. Remove internal retaining ring (11).
Connect hydraulic pressure supply to brake pressure inlet
port. Ensure hydraulic pressure is set to the required level up 9. Using arbor press or similar to break JLG Threadlocker
to a maximum of 3000 psi (200 bar). Check brake disengages seal, remove brake shaft (1) from housing (2) and lay
and re-engages correctly. aside.
10. Reverse housing (2) and press out ball bearing (10).
Maintenance Shaft seal (12) can also be removed if necessary.
The brake is required to be kept in good working order and
must be included in the planned maintenance program for the Examination
equipment to which the brake is installed. This must include All components can now be examined and inspected, paying
torque testing together with inspection and replacement of particular attention to the following.
working parts such as friction plates (3 & 6) and, springs (22 &
23). Inspection frequency depends on duty demanded of the 1. Inspect friction plates (3 & 6) and friction surface on
brake. pressure plate (4) for wear or damage.
2. Examine friction plates (3) and brake shaft (1) for wear or
Disassembly damage to splines.
To remove brake from its installed position, reverse procedure 3. Examine input and output splines of brake shaft (1) for
previously described in the installation instructions. Place wear or damage.
complete brake assembly on a clean, dry work bench.
4. Examine compression springs (22 & 23) for damage or
fatigue.
NOTE: Remove external gasket (5) as necessary.
5. Check ball bearing (10) for axial float or wear.
NOTE: Refer to Diagrams for the following.
6. Examine O-ring seals (15 & 17) and backing rings (16 &
1. Supporting brake face “A”, remove the six socket head 18) for damage.
capscrews and washers (items 13 & 14) in equal incre-
7. Obtain replacement parts as required.
ments to ensure the spring pressure within the brake is
reduced gradually and evenly.
Alternatively, if press is available, the cylinder housing Assembly
(8) can be restrained on face “B” while removing the six Clean all parts thoroughly.
socket head capscrews and washers (13 & 14). Reverse procedure previously outlined in Dismantling instruc-
The brake assembly can now be fully dismantled and tions taking particular care with.
parts examined.
a. Assembly of shaft seal (12).
2. Remove cylinder housing (8) and piston (9) subassembly
and dismantle if required, removing O-ring seals (15 & b. Assembly of bearing (10).
17) and backing rings (16 & 18) as necessary. c. Quantity and orientation of springs (8).
3. Remove gasket (7) from housing (2). d. Assembly sequence of friction plates (3 & 6).
4. Remove friction plates (3 & 6) and pressure plate (4). 1. Lightly lubricate rotary shaft seal (12) and assemble to
housing (2) taking care not to damage seal lip.
5. Remove 2-off dowel pins (19).
3-84 3121171
2. Apply ring of Loctite 641 or equivalent adhesive to full 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or
circumference of housing (2) bearing recess adjacent to equivalent) silicone grease and assemble together with
shoulder. Apply complete coverage of Loctite 641 to backing rings (16 & 18) to piston (9). To ensure correct
outside diameter of bearing (10) and assemble fully in brake operation, it is important that the backing rings
housing (2), retaining with internal retaining ring (11). are assembled opposite to the pressurized side of piston
Remove excess adhesive with clean cloth. Press shaft (1) (9).
through bearing (10), ensuring bearing inner ring is ade-
5. Correctly orientate piston (9) aligning spaces with the
quately supported.
two dowel pin holes and, assemble into cylinder hous-
3. Assemble correct quantity of springs (8) as shown. Refer ing (2) taking care not to damage seals and carefully lay
to (See Figure 3-53.)and (See Figure 3-54.). aside.
6. Loctite two-off pins (19) in housing (2) followed by pres-
sure plate (4) and friction plates i.e. an inner (3) followed
by an outer (6) in correct sequence.
7. Position gasket (7) in correct orientation.
8. Align two holes in cylinder with dowel pins (19) and
assemble piston & cylinder sub-assembly to remainder
of brake securing with 6-off socket head capscrews and
washers (13 & 14). Torque to 55ft-lb (75 Nm).
NOTE: Use of a suitable press (hydraulic or arbor) pressing down

on cylinder end face “B” will ease assembly of socket head
capscrews (13).
Figure 3-53. Swing Brake 8 Spring Orientation
Figure 3-54. Swing Brake 12 Spring Orientation
3121171 3-85
1. Brake Shaft 8. Cylinder 15. O-Ring

2. Housing 9. Piston 16. Backing Ring
3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring
4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring
5. Gasket 12. Rotary Shaft Seal 19. Dowel Pin
6. Outer Plate 13. Socket Head Capscrew 20. Hexagon Plug
7. Gasket 14. Shakeproof Washer 21. Plastic Plug
21A.Socket Pressure Plug
Figure 3-55. Swing Brake Assembly
3-86 3121171
3.19 SWING MOTOR

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

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

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

exploded view to determine end cover type being serviced.
3121171 3-87
1. Special Bolts 8B. Stator or Stator Vane 16. Seal

2. End Cover 8C. Vane 17. Backup Washer
3. Seal Ring-Commutator 8D. Stator Half 18. Housing
4. Seal Ring 9. Wear Plate 18A. O-Ring
5. Commutator Ring 10. Drive Link 19. Bearing/Bushing, Outer
6. Commutator Ring 12. Coupling Shaft 20. Dirt & Water Seal
7. Manifold 13. Bearing/Bushing, Inner 21. Plug
8. Rotor Set 14. Thrust Washer
8A.Rotor 15. Thrust Bearing
Figure 3-56. Swing Drive Motor
5. If the end cover (2) is equipped with shuttle valve com-

ponents, remove the two previously loosened plugs
(21). BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS
THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE
REMOVED.
NOTE: The insert and if included the orifice plug in the end cover
(2) must not be removed as they are serviced as an integral
part of the end cover.
3-88 3121171
6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal
blow dry. Be sure the end cover valve apertures, includ- ring from commutator, using an air hose to blow air into
ing the internal orifice plug, are free of contamination. ring groove until seal ring is lifted out and discard seal
Inspect end cover for cracks and the bolt head recesses ring. Inspect commutator for cracks or burrs, wear, scor-
for good bolt head sealing surfaces. Replace end cover ing, spalling or brinelling. If any of these conditions exist,
as necessary. replace commutator and commutator ring as a matched
set.
NOTE: A polished pattern (not scratches) on the cover from rota-

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

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

ing, brinelling or spalling. Replace manifold if any of
these conditions exist. A polished pattern on the ground
surface from commutator or rotor rotation is normal.
Remove and discard the seal rings (4) that are on both
sides of the manifold.
3121171 3-89
NOTE: The manifold is constructed of plates bonded together to

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

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

during service procedures. Marking the surface of the rotor
and stator that is facing UP, with etching ink or grease pen-
cil before removal from Torqlink™ will ensure correct reas-
sembly of rotor into stator and rotor set
intoTorqlink™.Marking all rotor components and mating
spline components for exact repositioning at assembly will
ensure maximum wear life and performance of rotor set
andTorqlink™.
NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets
of seven vanes (8C & 8E) as shown in the alternate con-
struction TG rotor set assembly view, check the rotor lobe
to roller vane clearance at both ends of rotor.
3-90 3121171
12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output
not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur-
link for cracks and worn or damaged splines. No percep- faces for spalling, nicks, grooves, severe wear or corro-
tible lash (play) should be noted between mating spline sion and discoloration. Inspect for damaged or worn
parts. Remove and discard seal ring (4) from housing internal and external splines or keyway. Replace cou-
(18). pling shaft if any of these conditions exist.
13. Remove thrust bearing (11) from top of coupling shaft

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

exceeds 0.020 inches (0.51 mm) diametrically, replace cou-
pling shaft.
14. Check exposed portion of coupling shaft (12) to be sure
you have removed all signs of rust and corrosion which
NOTE: A slight “polish” is permissible in the shaft bearing areas.
might prevent its withdrawal through the seal and bear-
Anything more would require coupling shaft replacement.
ing. Crocus cloth or fine emery paper may be used.
16. 16. Remove and discard seal ring (4) from housing (18).
3121171 3-91
17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and
Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is
ment of retained rollers. required.
18. Remove seal (16) and backup washer (17) from Small 20. Inspect housing (18) assembly for cracks, the machined
Frame, housing (18). Discard both. surfaces for nicks, burrs, brinelling or corrosion. Remove
burrs that can be removed without changing dimen-
sional characteristics. Inspect tapped holes for thread
damage. If the housing is defective in these areas, dis-
card the housing assembly.
3-92 3121171
21. If housing (18) assembly has passed inspection to this NOTE: The depth or location of bearing/bushing (13) in relation to
point, inspect housing bearings/bushings (19) and (13) the housing wear plate surface and the depth or location
and if they are captured in the housing cavity, the two of bearing/bushing (19) in relation to the beginning of
thrust washers (14) and thrust bearing (15). Bearing roll- bearing/bushing counter bore should be measured and
ers must be firmly retained in bearing cages, but must noted before removing the bearings/ bushings. This will
rotate and orbit freely. All rollers and thrust washers facilitate the correct reassembly of new bearings/bushings.
must be free of brinelling and corrosion. The bushing
(19) or (13) to coupling shaft diameter clearance must
not exceed 0.010 inch (0.025 mm). A bearing, bushing,
or thrust washer that does not pass inspection must be
replaced. If the housing has passed this inspection the
disassembly of the Torqlink™ is completed.
22. If bearings, bushing, or thrust washers must be replaced

use a suitable size bearing puller to remove bearing/
bushings (19) and (13) from housing (18) without dam-
aging the housing. Remove thrust washers (14) and
thrust bearing (15) if they were previously retained in
the housing by bearing (13).
3121171 3-93
Assembly
Replace all seals and seal rings with new ones each time you
reassemble the Torqlink™ unit. Lubricate all seals and seal rings
with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a complete seal

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

before assembly.
Wash all parts in clean petroleum-based solvents before

assembly. Blow them dry with compressed air. Remove any NOTE: Bearing mandrel must be pressed against lettered end of
paint chips from end cover mating surfaces, commutator set, bearing shell. Take care the housing bore is square with the
manifold rotor set, wear plate and housing, and from port and press base and bearing/bushing is not cocked when press-
sealing areas. ing a bearing/bushing into the housing.
SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY IF BEARING MANDREL SPECIFIED IN “TOOLS AND MATERIALS REQUIRED FOR
SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR SERVICING” SECTION IS NOT AVAILABLE AND ALTERNATE METHODS ARE USED
DEATH. TO PRESS IN BEARING/BUSHING (13) AND (19) THE BEARING/BUSHING
DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADEQUATE BEARING SUP-
PORT AND CORRECT RELATIONSHIP TO ADJACENT COMPONENTS WHEN
ASSEMBLED.
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX-
IMUM AIR PRESSURE REQUIREMENTS.
1. If housing (18) bearing components were removed for BECAUSE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE
replacement, thoroughly coat and pack a new outer HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE
bearing/bushing (19) with clean corrosion resistant REUSED.
grease recommended in the material section. Press the
new bearing/bushing into the counterbore at the
mounting flange end of the housing, using the appro-
priate sized bearing mandrel, which will control the
bearing/ bushing depth.
Torqlink™ housings require the use of bearing mandrel

to press bearing/ bushing (19) into the housing to a
required depth of 0.151/0.161 inches (3.84/4.09 mm)
from the end of the bearing counterbore.
3-94 3121171
2. The Torqlink™ inner housing bearing/bushing (13) can

now be pressed into its counterbore in housing (18)
flush to 0.03 inch (.76 mm) below housing wear plate
contact face. Use opposite end of bearing mandrel used
to press in outer bearing/bushing (19).
3. Press a new dirt and water seal (20) into the housing (18)
outer bearing counterbore.
The Torqlink™ dirt and water seal (20) must be pressed in until
its’ flange is flush against the housing.
3121171 3-95
4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15)
the coupling shaft bore down, clamping against the removed from the Torqlink™.
mounting flange.
NOTE: Torqlinks™ require one thrust washer (14) with thrust bear-
5. On the Torqlinks™ assemble a new backup washer (17) ing (15). Coupling shaft will be seated directly against the
and new seal (16) with the seal lip facing toward the thrust bearing.
inside of Torqlink™, into their respective counterbores in
housing (18) if they were not assembled in procedure 2. 7. Apply masking tape around splines or keyway on shaft
(12) to prevent damage to seal.
8. Ensure a generous amount of clean corrosion resistant

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

BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A
NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).
3-96 3121171
NOTE: One or two alignment studs screwed finger tight into hous-
ing (18) bolt holes, approximately 180 degrees apart, will
OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC facilitate the assembly and alignment of components as
FLUID. BE SURE IT IS THOROUGHLY PACKED WITH RECOMMENDED GREASE, required in the following procedures.The studs can be
PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT #K-70M. made by cutting off the heads of either 3/8-24 UNF 2A or 5/
16-24 UNF 2A bolts as required that are over 0.5 inch (12.7
NOTE: Mobil Mobilith SHC ® 460 mm) longer than the bolts (1) used in the Torqlink™.
NOTE: A 102Tube (PN 406010) is included in each seal kit. 10. Install drive link (10) the long splined end down into the
coupling shaft (12) and engage the drive link splines
NOTE: The coupling shaft (12) will be flush or just below the hous- into mesh with the coupling shaft splines.
ing wear plate surface on Torqlinks™ when properly seated.
The coupling shaft must rotate smoothly on the thrust
bearing package.
NOTE: Use any alignment marks put on the coupling shaft and
drive link before disassembly to assemble the drive link
splines in their original position in the mating coupling
shaft splines.
11. Assemble wear plate (9) over drive link (10) and align-
ment studs onto the housing (18).
9. Apply a small amount of clean grease to a new seal ring

(4) and insert it into the housing (18) seal ring groove.
3121171 3-97
12. Apply a small amount of clean grease to a new seal ring 14. Apply clean grease to a new seal ring (4) and assemble it
(4) and assemble it into the seal ring groove on the wear in the seal ring groove in the rotor set contact side of
plate side of the rotor set stator (8B). manifold (7).
13. Install the assembled rotor set (8) onto wear plate (9) NOTE: The manifold (7) is made up of several plates bonded
with rotor (8A) counterbore and seal ring side down and together permanently to form an integral component.The
the splines into mesh with the drive link splines. manifold surface that must contact the rotor set has it’s
series of irregular shaped cavities on the largest circumfer-
ence or circle around the inside diameter.The polished
impression left on the manifold by the rotor set is another
indication of which surface must contact the rotor set.
15. Assemble manifold (7) over alignment studs and drive

link (10) and onto the rotor set. Ensure correct manifold
surface is against the rotor set.
NOTE: It may be necessary to turn one alignment stud out of the

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

Assembly Procedure.”
NOTE: The rotor set rotor counterbore side must be down against 16. Apply grease to a new seal ring (4) and insert it in the
wear plate for drive link clearance and to maintain original seal ring groove exposed on the manifold.
rotor-drive link spline contact. A rotor set without a coun-
terbore that was not etched before disassembly can be
reinstalled using the drive link spline pattern on the rotor
splines if apparent, to determine which side was down.The
rotor set seal ring groove faces toward the wear plate (9).
3-98 3121171
17. Assemble commutator ring (6) over alignment studs 20. Assemble a new seal ring (4) into end cover (2) and
onto the manifold. assemble end cover over the alignment studs and onto
the commutator set. If end cover has only 5 bolt holes
make sure cover holes are aligned with the 5 threaded
holes in housing (18). The correct 5 bolt end cover bolt
hole relationship to housing port bosses.
18. Assemble a new seal ring (3) flat side up, into commuta-
tor (5) and assemble commutator over the end of drive
link (10) onto manifold (7) with seal ring side up.
19. If shuttle valve components items #21, were removed

from the end cover (2) turn a plug (21), loosely into one
end of the valve cavity in the end cover. A 3/16 inch
Allen wrench is required.
NOTE: If end cover has a valve (24) or has five bolt holes, use the
line you previously scribed on the cover to radially align the
end cover into its original position.
3121171 3-99
21. Assemble the five or seven special bolts (1) and screw in 22. Torque two shuttle valve plug assemblies (21) in end
finger tight. Remove and replace the two alignment cover assembly to 9-12 ft-lb (12-16 N m) if cover is so
studs with bolts after the other bolts are in place. Alter- equipped.
nately and progressively tighten bolts to pull end cover
23. Torque the two relief valve plug assemblies (21) in end
and other components into place with a final torque of
cover assembly to 45-55 ft-lb (61-75 N m) if cover is so
22-26 ft- lb for five bolts or 45-55 ft-lb (61-75 Nm) for the
equipped.
seven 3/8-24 threaded bolts.
One Piece Stator Construction

A disassembled rotor (8A) stator (8B) and vanes (8C) that can-
not be readily assembled by hand can be assembled by the
following procedures.
1. Place stator (8B) onto wear plate (9) with seal ring (4)
side down, after following Torqlink™ assembly proce-
dures 1 through 13. Be sure the seal ring is in place.
2. If assembly alignment studs are not being utilized, align

stator bolt holes with wear plate and housing bolt holes
and turn two bolts (1) finger tight into bolt holes
approximately 180 degrees apart to retain stator and
wear plate stationary.
NOTE: Special bolts required for use with the relief or shuttle valve
(24) end cover assembly (2) are longer than bolts required
with standard and cover assembly. Refer to individual ser-
vice parts lists or parts list charts for correct service part
number if replacement is required.
3-100 3121171
3. Assemble rotor (8A), counterbore down if applicable, 5. Grasp output end of coupling shaft (12) with locking pli-
into stator (8B), and onto wear plate (9) with rotor ers or other appropriate turning device and rotate cou-
splines into mesh with drive link (10) splines. pling shaft, drive link and rotor to seat the rotor and
assembled vanes (8C) into stator (8B), creating the nec-
essary clearance to assemble the seventh or full comple-
ment of seven vanes. Assemble the seven vanes using
minimum force.
NOTE: If the manifold side of rotor was etched during Torqlink

disassembly, this side should be up. If rotor is not etched
and does not have a counterbore, use the drive link spline
contact pattern apparent on the rotor splines to determine
rotor side that must be against the wear plate.
EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD
SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.
4. Assemble six vanes (8C), or as many vanes that will read-

ily assemble into the stator vane pockets.
6. Remove the two assembled bolts (1) if used to retain sta-
tor and wear plate.
3121171 3-101
3.20 PROCEDURE FOR SETTING GEAR BACKLASH 5. Pre-torque capscrews (shown below) to 90 ft-lb (122
Nm) with JLG Threadlocker PN 0100019.
1. Set backlash to 0.010 to 0.015" using the following pro-
cedure.
2. Place shim (JLG PN 4071041) between pinion and bear-
ing on bearing high spot. The bearing high spot should
be stamped with an “X” on the surface below the teeth
and marked with yellow paint in the tooth space.
3. Torque shoulder screw (shown below) to 660 ft-lb (896 6. Tighten setscrew (shown below) until pinion is com-
Nm) with JLG Threadlocker PN 0100019. pletely snug against shim and bearing, then back off the
setscrew.
4. Remove turntable lock pin.

7. Torque setscrew to 50 ft-lb (68 Nm).
3-102 3121171
8. Tighten jam nut (shown below) with JLG Threadlocker The Swing Gearbox is to be filled with 79 ounces (2.3 L) of API
PN 0100019. Service Classification GL-5 Extreme Pressure Gear Lube. Fill to
cover the ring gear..
1.195 IN (30.35 mm) TOP OF HOUSING TO TOP

OF RING GEAR. TO BE FILLED TO COVER RING
GEAR.
9. Torque capscrews shown in step 5 to 660 ft-lb (896 Nm).

10. Remove shim and discard.
3.21 SWING DRIVE LUBRICATION

Figure 3-58. Swing Drive Lubrication (SN 0300201017
through 0300254456)
Swing Brake is to be filled half full, 2.7 ounces (80 ml), with
DTE24 oil.
1 Brake Bleed Port

2 Brake Fill Port
3 Gearbox Fill Port
4 Gearbox Drain Port
Figure 3-57. Swing Drive Ports (SN 0300201017 through

0300254456)
3121171 3-103
MAE37630
1 Swing Gearbox/Brake Fill Port

2 Swing Gearbox/Brake Drain Port
Figure 3-59. Swing Drive Ports (SN 0300254457 to Present)
The brake on swing drive uses same oil cavity as gearbox.

Remove the swing gearbox/brake fill plug and fill the unit with
105 ounces (3.1 L) of ISO VG 150 oil, until oil reaches halfway of
the plug opening. Close the swing gearbox/brake fill port (1)
immediately. Drain oil through the swing gearbox/brake drain
port (2).
3-104 3121171
3.22 TURNTABLE BEARING d. Check a sample of bolts in this 90° quadrant (45° left
and right of indicated position) of the bolt circle.
Turntable Bearing Mounting Bolts Condition Check e. Swing turntable 90 degrees and check selected
bolts at the new position.
f. Continue rotating turntable at 90 degree intervals
until a sampling of bolts have been checked in all
THE TURNTABLE BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AER-
quadrants.
IAL LIFT. IT IS HERE STRESSES OF LIFTING ARE CONCENTRATED AT THE CENTER
OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING 2. Check turntable side bearing bolts as follows:
BEARING BOLTS IS A MUST FOR SAFE OPERATION.
a. Raise main boom to be fully elevated and retracted.
Raise Tower boom 10° or enough to gain access to
NOTE: This check must be performed after first 50 hours of
bearing bolts. Raise jib to be fully elevated and cen-
machine operation and every 600 hours of machine opera-
tered. Center platform and keep it unloaded. (See
tion thereafter. If any bolts are missing or loose, replace
Figure 3-69.)
with new bolts. Apply JLG Threadlocker PN 0100019 to the
bolt threads and torque to 190 ft-lb (260 Nm). Check all
bolts for looseness after replacing or re-torquing any bolt.
NEVER WORK BENEATH BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
1. Check frame side bearing bolts as follows: PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT OR BLOCKING.
a. Raise main boom to be fully elevated and retracted.
Stow tower boom. Raise jib to be fully elevated and b. At position indicated on Figure 3-69., try to insert a
centered. Center platform and keep it unloaded. 0.0015 in (0.038 mm) feeler gauge between turnta-
(See Figure 3-68.) ble side bearing bolt and hardened washer.
b. At position indicated on Figure 3-68., try to insert a
0.0015 in (0.038 mm) feeler gauge between frame

side bearing bolt and hardened washer.

Figure 3-62. Turntable Side Bearing Bolt Location

c. Ensure 0.0015 in (0.038 mm) feeler gauge will not fit
Figure 3-60. Frame Side Bearing Bolt Location under bolt head to bolt shank as shown in Figure 3-63.
c. Ensure 0.0015 in (0.038 mm) feeler gauge will not fit

under bolt head to bolt shank as shown in Figure 3-61.

Figure 3-63. Turntable Side Bearing Bolt Feeler Gauge Check
d. Check a sample of bolts in this 90° quadrant of the

Figure 3-61. Frame Side Bearing Bolt Feeler Gauge Check bolt circle (45° left and right of indicated position).
3121171 3-105
e. Fully raise the tower boom. Lower main boom to be c. Position indicator point to measure turntable base
horizontal and fully extended. Position jib and plat- plate (on doubling plate) 3.5 in (88.9 mm) from gear
form to be horizontal and centered. (See Figure 3-70.) tooth root as shown in Figure 3-65. and Figure 3-66.
f. At position indicated in Figure 3-70., try and insert a
0.0015 in (0.038 mm) feeler gauge between bolt
head and hardened washer.
g. Ensure 0.0015 in (0.038 mm) feeler gauge will not fit
under bolt head to bolt shank as shown in Figure 3-63.
h. Check a sample of bolts in this 90° quadrant of the
bolt circle (45° left and right of indicated position).

Turntable Bearing Wear Measurement
1. Position machine as follows and as shown in Figure 3-68.
a. Rotate turntable 90° so counterweight is over right
side of frame.

b. Stow tower boom.
c. Raise main boom to be fully elevated and retracted Figure 3-65. Turntable Bearing Measurement Point
d. Raise jib to be fully elevated and centered
e. Center platform and keep it unloaded
3.5 in (88.9 mm)
2. Set up dial indicator as follows:
a. Locate dial indicator at rear center of machine, next
to bearing, and opposite counterweight.
b. Position magnetic base of the indicator on vertical
member of frame as shown in Figure 3-64.
Figure 3-66. Dial Indicator Measurement Location

4. Zero dial indicator.
5. Position machine as follows and as shown in Figure 3-70.
a. Do not rotate turntable
b. Fully elevate tower boom
Figure 3-64. Dial Indicator General Location c. Lower main boom until horizontal
d. Fully extend main boom
e. Lower jib to horizontal
f. Keep jib and platform centered and unloaded
g. Verify dial indicator has not shifted. Record bearing
wear value.
3-106 3121171
6. Position machine back to the first position as outlined in Determine turntable bearing wear measurement allowance by
Step 1 and shown in Figure 3-68. The dial indicator bearing model as shown in Figure 3-7.
should return to zero. If dial indicator does not return to
zero, determine corrective action and repeat test. Table 3-7. Turntable Bearing Wear by Bearing Model
7. Determine which model turntable bearing is installed Bearing Model Wear Measurement
by checking location shown in Figure 3-67. and compar-
1 0.179 in (4.54 mm)
ing with markings in Table 3-6.
2 0.205 in (5.214 mm)
NOTE: JLG Boom Lifts may utilize multiple model bearings. 3 0.255 in (6.47 mm)
4 0.197 in (5 mm)
9. Replace turntable bearing if any of the following condi-

tions exist:
a. Bearing wear measurement is greater than allowed
in Table 3-7.
NOTE: If bearing markings are illegible, use 0.179 in (4.54 mm) as

the wear measurement.

b. Increased swing power required.
c. Noise is present when turntable is rotated.
d. Rough operation when turntable is rotated.
Figure 3-67. Bearing Marking Location
Table 3-6. Bearing Model Marking Identification
Model Marking
1 1234567, XXXXX, XXXXX
2 JLG 1234567 A
XX 0001 11 04
3 V 12 3456 789 01 23 4567

SERIAL NR. 08/_ _ _ _ YEAR _ _ _ _
PAG/POS. _ _ _ _ _ _/_ _ _ _ WEIGHT _ _ _ Kg.
JLG PART #1234567
4 D123456
3121171 3-107

Figure 3-68. Turntable Bearing Service Boom Placement - 1
3-108 3121171

3121171 3-109

3-110 3121171
Turntable Bearing Removal Turntable Bearing Installation

1. From Ground Control Station, elevate tower boom to 1. Using suitable lifting equipment, carefully lower turnta-
about 10° or enough to gain access to bearing bolts. Set ble bearing into position on frame. Ensure scribed line of
main boom horizontal and fully retracted. Raise and bearing outer race aligns with scribed line on frame. If a
center jib and platform. (See Figure 3-71.) new turntable bearing is used, ensure spot with mini-
mum gear backlash (stamped with an “X” or marked
with yellow paint) is towards centerline of the swing
drive (as close as bolt pattern allows).
NEVER WORK BENEATH BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT OR BLOCKING.
2. Attach an adequate support sling to the boom. Remove JLG INDUSTRIES RECOMMENDS DISCARDING ALL REMOVED BEARING BOLTS
all slack from sling. Prop or block boom if possible. AND REPLACING WITH NEW BOLTS. SINCE THE TURNTABLE BEARING IS THE
ONLY STRUCTURAL LINK BETWEEN FRAME AND TURNTABLE, IT IS IMPERA-
3. From inside turntable, remove mounting hardware
TIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE
attaching rotary coupling retaining yoke brackets to
OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
turntable.
2. Spray a light coat of Safety Solvent 13 on new bearing
bolts.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-
3. Apply a light coating of JLG Threadlocker PN 0100019 to
CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO THE SYSTEM.
new bearing bolts. Loosely install bolts and washers to
frame and bearing outer race.
4. Tag and disconnect hydraulic lines from fittings on top
of rotary coupling. Use a suitable container to retain any
residual hydraulic fluid. Immediately cap lines and ports.
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED
5. Attach suitable overhead lifting equipment to base of
FOR TIGHTENING BEARING ATTACHMENT BOLTS, CHECK TOOL TORQUE SET-
turntable.
TING ACCURACY BEFORE USE.
6. Scribe a line on the turntable bearing inner race and
underside of turntable. This will aid in aligning the bear- 4. Torque bolts to 190 ft-lb (260 Nm) in sequence shown in
ing during re-installation. Remove bolts and washers Figure 3-72., Turntable Bearing Torque Sequence.
attaching turntable to bearing inner race. Discard bolts.
5. Remove lifting equipment from bearing.
7. Carefully lift complete turntable assembly from bearing.
6. Using suitable lifting equipment, carefully position turn-
Ensure no damage occurs to turntable, bearing, or
table assembly above machine frame.
frame-mounted components. Refer to Figure 3-71.,
Turntable Bearing Removal. 7. Carefully lower turntable onto turntable bearing, ensur-
ing scribed line on bearing inner race aligns with scribed
8. Carefully place turntable on a suitably supported trestle.
line on turntable. If a new turntable bearing is used,
9. Scribe a line on turntable bearing outer race and frame. ensure filler plug fitting is at 90 degrees from fore and
This helps align the bearing during re-installation. aft center line of turntable.
Remove bolts and washers attaching bearing outer race
8. Spray a light coat of Safety Solvent 13 on new bearing
to the frame. Discard bolts.
bolts.
10. Use suitable lifting equipment to remove bearing from
9. Apply a light coating of JLG Threadlocker PN 0100019 to
frame. Move bearing to a clean, suitably supported work
new bearing bolts. Install bolts and washers to turntable
area.
and bearing inner race.
3121171 3-111
3-112
8)4903 3)3
/1/4///4 0!2//4

467
/)3
//1/4,5

!"" #$%&#'
(&#$)&
*+,,$#-+. //
0
12

Figure 3-71. Turntable Bearing Removal
3121171
10. Torque bolts to 190 ft-lb (260 Nm) following sequence 14. At ground control station, use boom lift control to lower
shown in Figure 3-72., Turntable Bearing Torque boom to stowed position.
Sequence.
15. Using all applicable safety precautions, activate hydrau-
11. Remove lifting equipment. lic system and check swing system for proper and safe
operation.
12. Install rotary coupling retaining yoke brackets. Apply a
light coating of JLG Threadlocker PN 0100011 to the
attaching bolts and secure yoke to turntable with
mounting hardware. CHECK FOR MISSING OR LOOSE INNER AND OUTER TURNTABLE BEARING
BOLTS AFTER FIRST 50 HOURS OF OPERATION AND EVERY 600 HOURS THERE-
13. Connect hydraulic lines to rotary coupling as tagged
AFTER.
before removal.
NOTE: Turntable Bearing Torque Sequence is identical for both inner and outer races. Torque all bolts to 190 ft-lb (260 Nm).
Figure 3-72. Turntable Bearing Torque Sequence
3121171 3-113
3.23 SWING SPEED PROPORTIONING 3.24 CHASSIS TILT INDICATOR SYSTEM

Swing Speed Proportioning uses main boom length switches The Chassis Tilt Indicator System measures turntable angle in
and envelope control sensors to improve comfort, speed, and comparison to level ground. The tilt sensor (which is an inte-
control of the turntable swing function. gral part of the ground module) has three settings; 3.0° side
Turntable swing speed is increased as distance of the platform tilt, 5.0° omni directional tilt, and 8.0° omni directional tilt.
to center of rotation is decreased and when the tower boom is The 5.0° omni directional angle setting is used to warn the
lowered in angle. This results in approximately constant plat- operator by using the chassis tilt light in the platform display
form speeds regardless of boom position. panel. When used with the Beyond Transport - Drive Speed
Swing speed proportioning is disabled with any envelope sen- Cutback System (Section 4.3, Beyond Transport - Drive Speed
sors failure. Disabling of swing speed proportioning will Cutback System), the tilt sensor will cause an alarm to sound
default to the slowest swing speed setting. and automatically place all functions in creep speed mode.
With the exception of the speed cutback, this is a warning sys-
NOTE: For detailed information concerning system adjustment tem only indicating to the operator the machine has reached
and operation, refer to Section 6 - JLG Control System. the out of level limit. The machine will continue to function.
The operator is responsible to prevent the machine from
reaching an unstable position.
The 3.0° side tilt setting is used in combination with boom

position and when exceeded, imposes the same functionality
as the 5.0° omni directional setting. The side tilt setting is
ignored when the tower boom is less than 60° regardless of
main boom position, and is proportionally increased in value
up to 5.0° as the main boom is lowered from high angles to
horizontal when the tower is above 60°.
The 8.0° angle is used only for automatically shifting the drive
motors to the maximum displacement position (slow speed).
The control system responds to indicated angle readings 0.5
degree smaller than the required angles to account for calibra-
tion and sensor variation.
NOTE: For detailed information concerning system adjustment

and operation, refer to Section 6 - JLG Control System.
3-114 3121171
3.25 ROTARY COUPLING 6. Reassemble O-ring.
Use the following procedure to for installing the seal kit. 7. Heat cap seals in hydraulic oil for 5 minutes at 300° F
(149° C).
1. Remove snap ring from end.
8. Assemble cap seals over O-rings
2. Remove thrust ring from same end.
9. Reinsert center body into housing (lube with hydraulic
3. Remove center body from housing. oil).
4. Cut off old seals. 10. Replace thrust ring and snap ring.
5. Assemble lip seals in direction shown in Figure 3-73.,
Rotary Coupling Seal Installation.
Figure 3-73. Rotary Coupling Seal Installation
3121171 3-115
1. JLG Threadlocker PN 0100011 5B. Rotary Circuit Contactor

2. Bolt 6. Locknut
3. Bolt 7. Not Used
4. Swivel Bracket 8. Flatwasher
5. Rotary Coupling & Collector Ring Assembly 9. Nut
5A. Rotary Coupling
Figure 3-74. Rotary Coupling Installation
3-116 3121171
Figure 3-75. Rotary Coupling Port Location
3121171 3-117
Every 500 hours

Table 3-8. Coupling Port Information Table
Every 500 hours of operation, service generator brushes and
Operating Proof slip rings. Hostile environments may require more frequent
Port Port service.
Description Pressure Pressure
No. Size
PSI (Bar) PSI (Bar)
1 -12 Return 250 (17) 375 (26)
2 -10 Steer/Axle Extend (Pressure) 3000 (207) 4500 (310)
3 -10 Drive A 5000 (345) 7500 (517)
4 -10 Drive B 5000 (345) 7500 (517)
5 -10 Drive A (Osc. Axle Lock) 5000 (345) 7500 (517)
6 -10 Drive B (Osc. Axle Lock) 5000 (345) 7500 (517)
7 -12 Case Drain 250 (17) 375 (26)
Every 500 hours of service, blow out inside of the generator. If
operating in a hostile environment, clean monthly.
3.26 GENERATOR
Every 250 hours
Every 250 hours of operation, check drive belt for proper ten-
sion.
1/2 in.
(13 mm)
3-118 3121171
Overload Protection Inspecting Brushes, Replacing Brushes, and

Cleaning Slip Rings
Refer to Figure 3-76., Inspecting Generator Brushes, Replacing
STOP ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT BREAKER. Brushes, and Cleaning Slip Rings.
The circuit breaker protects generator windings from over-

INSPECTING BRUSH POSITION
load. If the circuit breaker opens, generator output stops. If the
circuit breaker continues to open, check for faulty equipment Inspect brush alignment with slip rings. View alignment
connected to platform receptacles. 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 brushes from the holders.
Replace the brushes if damaged, or if the brush is at or near

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

belt and turn the shaft by hand for cleaning.
Clean rings with 220 grit emery paper. Remove as little mate-
rial as possible. If rings are deeply pitted and do not clean up,
consult generator factory service.
Reinstall belt, brush holder assembly, and end panel.
3121171 3-119
Brush Position On Slip Rings
2
3
Acceptable Unacceptable
Brushes must ride
completely on slip
rings
1/4 in (6 mm)
Or Less - Replace
7/16 in - 1/2 in
2 (11 - 12 mm) New
1. Brush Holder Assembly

2. Brushes
3. Slip Rings
Figure 3-76. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3-120 3121171
3.27 COLD WEATHER PACKAGE in the engine manufacturer’s operator’s manual. Refer to
Figure 3-77., Deutz Engine Dipstick.
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 Uni-
vis hydraulic oil, and diesel fuel conditioner. See Figure 3-79., MINIMUM OIL
LEVEL
Cold Weather Package.
3.28 ENGINE
NOTE: Refer to the engine manufacturer’s manual for detailed
operating and maintenance instructions. MAXIMUM OIL
LEVEL
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 engine coolant tem-
perature is less than 140° F (60° C). This determination occurs
one second after the Power/Emergency Stop switch has been MINIMUM LEVEL,
OIL HOT
pulled on. The lamp and glow plugs remain energized for the MAXIMUM LEVEL,
period of time specified by the setting in the JLG Control Sys- OIL HOT
tem. Engine start shall be disabled during this period. On
Deutz engines, glow plugs will continue (post glow) after
engine has started for three times the machine digit setting. MINIMUM LEVEL,
OIL COLD
MAXIMUM LEVEL,
Checking Oil Level OIL COLD
NOTE: Hot oil checks should not be made until the engine
1. Switch engine off before checking oil level. has been shut down for a period of 5 minutes.
2. Make sure machine and engine are level.
Figure 3-77. Deutz Engine Dipstick
3. Remove dipstick.
7. Replace dipstick. Make sure it is fully seated in the dip-
4. Wipe dipstick with non-fibrous, clean cloth. stick tube to seal off the crankcase.
5. Insert dipstick to the stop and remove again.
6. Check oil level, and if necessary, top oil level up to MAX

mark with an approved grade and type of oil as outlined
3121171 3-121
Changing Engine Oil 8. Pour in new engine oil. Refer to Section 1 for capacity
and refer to Figure 3-78., Engine Oil Viscosity for the
1. Allow engine to warm up. Engine oil should reach proper grade.
approximately 176° F (80° C).
2. Make sure machine and engine are level.
3. Switch off engine.
4. Place an oil tray under the engine.
5. Open oil drain valve.
Figure 3-78. Engine Oil Viscosity
WHEN DRAINING HOT ENGINE OIL THERE IS A RISK OF SCALDING.
DO NOT LET USED OIL RUN INTO SOIL; COLLECT USED OIL IN A CONTAINER
SUITABLE FOR DISPOSAL OR RECYCLING. DISPOSE OF USED ENGINE OIL IN
ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.
6. Drain oil.
7. Close oil drain valve.
3-122 3121171
Changing Oil Filter 5. Lightly oil rubber gasket on new oil filter.
Most engine oil filters are mounted vertically. Tier 4 engine oil filters
are mounted horizontally. Removal and installation is identical.
6. Manually screw in new filter until gasket is flush.
1. Wipe area around filter to remove dirt and other con-

taminants.
2. Using a suitable oil filter removal tool, loosen the lube oil
filter cartridge and spin off.
7. Tighten filter another half-turn.

8. Check oil level.
9. Check oil pressure.
10. Check oil filter cartridge for leaks.
3. Catch any escaping oil.

4. Clean any dirt from filter carrier sealing surface.
3121171 3-123
Replacing Fuel Filter or Pre-Filter Cleaning Fuel Strainer (D2011 L03 Only)
WHEN WORKING ON FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN FLAMES WHEN WORKING ON FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN FLAMES
OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM. OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
1. Wipe area around filter to clean any dirt from area. 1. Unscrew hexagonal nut (1).
2. Undo 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 rubber gasket of
new filter cartridge.
6. Manually screw in new filter until gasket is flush.
7. Tighten fuel filter cartridge a final half-turn.
8. Open fuel shut-off valve.
9. Check for leaks.
2. Remove fuel strainer cover (2).

3. Clean fuel strainer with diesel fuel, replace if necessary.
4. Place seal (3) in position.
5. Install fuel strainer cover (2) in position and tighten the
hexagonal screw (1).
6. Check for leaks.
3-124 3121171

Figure 3-79. Cold Weather Package
3121171 3-125
Removal NOTE: Hood support weighs approximately 134 lb (61 kg).
1. Disconnect battery.
2. Use a tie strap as shown below to secure hood support
while hood is being removed.
6. When all bolts are removed, lift hood support away from
machine.
3. Remove bolts and clamps that secure engine hood

assembly to hood support.
4. Carefully lift engine hood assembly away from machine.
NOTE: Engine hood assembly weighs approximately 84 lb (38 kg).
7. Remove bolts securing pump assembly.
5. Using an adequate lifting device, support weight of

hood support. Disconnect gas springs and remove bolts
and washers that secure hood support to hinges.
3-126 3121171
1. Hood 5. Washer
2. Hood Support 6. Clamp
3. Gas Spring 7. Hinge
4. Bolt 8. Engine Tray
Figure 3-80. Engine Hood
3121171 3-127
8. Pull pump assembly away from engine. NOTE: Engine assembly weighs approximately 1275 lb (579 kg).
9. Using a ratchet strap, support pump in a position that 13. Carefully lift engine assembly away from machine.
will keep pump from interfering with engine removal.
10. Disconnect all fuel lines from engine. Cap all open hoses
to prevent fuel leakage.
11. Swing engine out to gain access to the back of the
engine, and tag and disconnect all electrical wiring from
relays, switches, etc. Carefully pull disconnected har-
nesses and fuel lines away from engine.
14. If installing a new engine, transfer any necessary compo-

nents from the old engine assembly onto the new
Engine Assembly.
12. Using an adequate lifting device, support weight of the

engine assembly. Remove pivot pin.
3-128 3121171
Installation
1. Using an adequate lifting device, support weight of the
engine assembly and position it in place on the
machine. Install engine pivot pin.
NOTE: Engine assembly weighs approximately 1275 lb (579 kg)
4. Lift hood support back into position. Install bolts and

washers that secure hood support to hinges. Re-con-
nect gas springs to hood support
NOTE: Hood support weighs approximately 134 lb (61 kg)
2. Route all wiring and fuel lines and connect them as

tagged during removal.
3. Unstrap the pump, re-connect it to the engine and bolt
it back into place. Torque the bolts to 75 ft. lbs. (102 Nm).
3121171 3-129
5. Use a tie strap as shown below to secure the hood sup- 3.29 DEUTZ EMR 2 (SN 87575 TO PRESENT)
port when the hood is being installed.
NOTE: SN’s 85693 & 85910 also incorporated EMR2.
The EMR2 consists of the sensors, the control unit and the
actuator. Engine-side controls as well as the JLG Control Sys-
tem are connected by means of separate cable harnesses to
the EMR control unit.
The sensors attached to the engine provide the electronics in
the control unit with all the relevant physical parameters In
accordance with the information of the current condition of
the engine and the preconditions (throttle position etc.), the
EMR2 controls an actuator that operates the control rod of the
injection pump and thus doses the fuel quantity in accordance
with the performance requirements.
6. Carefully lift engine hood assembly onto hood support. The exact position of the regulating rod is reported back and,
if necessary, is corrected, by means of the control rod travel
NOTE: Engine hood assembly weighs approximately 84 lb (38 kg).
sensor, situated together with the rotation magnets in a hous-
ing of the actuator.
The EMR2 is equipped with safety devices and measures in the
hardware and software in order to ensure emergency running
(Limp home) functions.
In order to switch the engine off, the EMR2 is switched in a de-
energized fashion over the ignition switch. A strong spring in
the actuator presses the control rod in the de-energized con-
dition into the zero position. As a redundancy measure, an
additional solenoid serves for switching off and this, indepen-
dently of the actuator, also moves the control rod in the de-
energized condition into the zero position.
After programming, carried out over the ISO9141 interface,
7. Install bolts and clamps that secure engine hood assem-
the EMR2 is possesses a motor-specific data set and this is then
bly to hood support.
fixedly assigned to the engine. Included in this are the various
8. Start engine and check for proper operation and any application cases as well as the customer’s wishes regarding a
leakage. If engine does not start immediately, fuel lines particular scope of function.
may need primed.
Each EMR2 module is matched by serial number to the engine.
NOTE: The delay in starting the engine can be reduced by remov- Modules cannot be swapped between engines.
ing the fuel filter, pre-filling the filter with fuel, and rein-
stalling the filter before attempting to start engine.
3-130 3121171
CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY
COOLANT TEMPERATURE FLYWHEEL SPEED

SENSOR SENSOR
JLG SYSTEM HANDLES ENGINE START/STOP; EMR2

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

OIL PRESSURE TO CONTROL THE ENGINE & FAULT REPORTING.
SENSOR
Figure 3-81. EMR 2 Engine Side Equipment
3121171 3-131
3-132
Figure 3-82. Deutz EMR 2 Troubleshooting Flow Chart
3121171
3121171
Figure 3-83. Deutz EMR 2 Vehicle Side Connection Diagram
3-133
3-134
Figure 3-84. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
3121171
3121171
Figure 3-85. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3-135
Figure 3-86. EMR 2 Engine Plug Pin Identification
3-136 3121171
Figure 3-87. EMR 2 Vehicle Plug Pin Identification
3121171 3-137
3-138
Figure 3-88. EMR2 Fault Codes - Sheet 1 of 5
3121171
3121171
3-139
3-140
3121171
3121171
3-141
3-142
3121171
3.30 BIO FUEL IN DEUTZ ENGINES The use of US bio-diesel based on soy oil methylester is only
permissible in mixtures with diesel fuel with a bio-diesel part of
a max. 20 weight-%. The US bio-diesel used for the mixture must
General
comply with the ASTM D6751-07a (B100) standard.
Use of bio fuels is permitted for the compact engines made by
APPROVED ENGINES
DEUTZ.
The 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and
Distillate fuels with residue oil percentages or mixed fuels may 513 series are approved for bio-diesel from year of manufac-
not be used in DEUTZ compact engines. ture 1993 under compliance with the basic conditions speci-
The DEUTZ vehicle engines are designed for diesel fuels in fied below.
accordance with EN 590 with a cetane number of at least 51. BASIC CONDITIONS TO BE OBSERVED
DEUTZ engines for mobile machinery are designed for a cetane
number of at least 45. When using fuels of a low cetane num- • A power loss of 5-9% in relation to diesel fuel in accordance
ber, disturbing white smoke and ignition misfires are to be with EN 590 is possible due to the lower heating value.
expected under some circumstances. Blocking of the fuel injector is not allowed.
• The lubricating oil quality must correspond to TR 0199-
A cetane number of at least 40 is permissible for the US market,
99-3002. The lubricating oil change interval must be
therefore special engine models have been developed to
halved in relation to operation with diesel fuel in accor-
avoid starting difficulties, extreme white smoke or increased
dance with EN 590.
hydrocarbon emissions (EPA specification - US EPA REGULA-
TIONS FOR LARGE NONROAD COMPRESSION-IGNITION • Standstills of longer than 4 to 6 weeks must be avoided
ENGINES). with bio-diesel. Otherwise the engine must be started and
stopped with diesel fuel.
If the white smoke behavior is unacceptable when using a very
low cetane number, the use of ignition improvers is to be rec- • Bio-diesels can be mixed with normal diesel fuel but the
ommended as a later remedial measure. basic conditions described in this subsection apply for mix-
tures. Mixtures with up to 5% (m/m) bio-diesel (B5) which
The certification measurements for compliance with the legal have recently been on sale at European fuel stations are
emission limits are carried out with the test fuels prescribed by excepted. These fuels must be treated like normal diesel
law. These correspond to the diesel fuels in accordance with fuels because EN 590 expressly permits adding up to 5%
EN 590 and ASTM D 975. No emission values are guaranteed (m/m) bio-diesel in accordance with EN 14214.
with the other fuels described. It is the obligation of the owner
to check the permission for use of the fuels in accordance with • Approx. 30-50 hours after changing over from diesel fuel to
regional regulations. bio-diesel, the fuel filter should be changed as a preventive
measure to avoid a drop in performance due to clogged fuel
Bio Fuel filters. Deposited fuel ageing products are dissolved by bio-
diesel and transported into the fuel filter. They should not
PERMITTED BIO-DIESEL FUELS be changed immediately but after approx. 30 to 50 hours
Originally only rape seed oil methylester (RME) was sold as a because the dissolving of dirt takes a certain amount of
bio-diesel fuel in Europe but fatty acid methylester (FAME) time.
based on other oils have come onto the market increasingly in
recent years. However, with the latter there is a risk that the limit
values of EN 14214 are not kept in the field. Anyone who uses
bio-diesel fuel in DEUTZ engines must therefore choose his
supplier very carefully and have him guarantee compliance
with the EN 14214 limit values. Since experience has shown
that rape seed oil methylester (RME) exceeds the limit values
less often that other esters, it is expressly recommended to use
only rape seed oil methyester. DEUTZ customers in Germany
can additionally ensure the quality by buying bio-diesel fuel
with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Man-
agement Biodiesel e.V.).
3121171 3-143
PLANT OIL PREVENTIVE MEASURES

• Keep storage tank clean, regular cleaning of the tank by
specialist companies
PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS • Installation of fuel pre-filters with water traps, especially in
BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPER- countries with frequently fluctuating fuel qualities and high
ATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH percentage of water.
VISCOSITY, POOR EVAPORATION BEHAVIOR.
If the fuel system and storage tank have already been attacked
Conversion of DEUTZ engines to rape seed oil fuel operation by micro-organisms. The biocide must be dosed according to
with conversion kits and modified tanks systems of various the manufacturer's specifications.
manufacturers is not allowed and leads to loss of warranty • Avoid direct exposure of the storage tank to sunlight
rights.
• Use smaller storage tanks with corresponding low dwell
Biological Contamination In Fuels times of the stored fuel
FUEL ADDITIVES
SYMPTOMS
Use of fuel additives is not permitted. The flow improvers men-
The following symptoms may indicate a fuel tank is contami-
tioned above are an exception. Use of unsuitable additives will
nated by micro-organisms:
result in loss of warranty.
• Internal tank corrosion,
• Filter blockage and the associated loss of power due to gel-
like deposits on the fuel filter (especially after long stand-
stills)
CAUSE
Micro-organisms (bacteria, yeasts, funguses) can form bio-
sludge under unfavorable conditions (favored particularly by
heat and water).
Penetration by water is usually caused by condensation of the
water in the air. Water does not dissolve in fuel so that the pene-
trating water collects at the bottom of the tank. The bacteria and
funguses grow in the watery phase, at the phase boundary to
the fuel phase, from which they draw their nutrition. There is an
increased risk especially with bio-diesel (FAME).
3-144 3121171
3.31 DEUTZ TURBOCHARGER OPERATION LOW AIR TEMPERATURES & INACTIVE OPERATION
If the engine has been inactive for some time or the air tem-
Good engine operating procedures are essential to prolong perature is very low, crank the engine first and then run at idle.
turbocharger life. This allows the oil to circulate throughout the full system
Particular attention to oil system and air system will eliminate before high loads and speeds are applied to engine and turbo-
the two main causes of turbocharger failure. To prevent this charger.
Operators/Owners must ensure that :-
SHUT DOWN
1. Air and oil filters are checked regularly to the manufac- Before shutting the engine down, let the turbocharger cool
turer's specifications. down. When an engine runs at maximum power/high torque,
the turbocharger is operating at very high temperatures and
2. Engine maintenance intervals are adhered to.
speeds. Hot shut down can cause reduced service life which is
3. Engine and equipment are operated in such a way that avoidable by a minute or two of idling. Most mobile equip-
is not harmful to the life of the turbocharger. ment applications include an adequate cooling period during
parking or mooring procedures.
Operating Practices Allow the engine to idle for 1-5 minutes to allow the high tem-
Operators and owners can get maximum service life from their peratures and speed to reduce and thus prolong the life of the
turbochargers if a few good practices are followed: turbocharger.
START UP ENGINE IDLE

When starting the engine use minimum throttle and run in Avoid running the engine for long periods in idle mode
idle mode for approximately one minute. Full working oil pres- (greater than 20-30 minutes). Under idling conditions low
sure builds up within seconds but it is useful to allow the tur- pressures are generated in the turbocharger which can cause
bocharger moving parts to warm up under good lubricating oil mist to leak past seals into the two end housings. Although
conditions. Revving the engine within the first few seconds of no real harm is done to the turbocharger, as load is applied
start up causes the turbocharger to rotate at high speeds with temperatures increase and the oil will start to burn off and
marginal lubrication which can lead to early failure of the tur- cause blue smoke emission problems.
bocharger.
If the engine is allowed to Idle for a period of time, lube oil will
continue to flow cooling the turbine shaft.
AFTER SERVICING
After servicing the engine or turbocharger, ensure the turbo- You can also see spots on the turbo where grooves have been
charger is pre-lubed by adding clean engine oil into the turbo- "worn" in to the turbine shaft at the point where the radial
charger oil inlet until full. After pre-lubing, crank the engine bearing sits. Dirty oil/contaminates in the oil can become
without firing (engine/fuel pump stop out) to allow oil to cir- trapped in between the radial bearing and the surface of the
culate through the full system under pressure. On starting the shaft becoming abrasive and ultimately grinding away the
engine, run at idle for a few minutes to ensure the oil and bear- material.
ing systems are operating satisfactorily.
3121171 3-145
Table 3-9. Engine Fault Codes
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
978 1-2-6 29 2 Diagnostic fault check of synchronism of Plausibility error between sensor and idle Threshold for error detection is an internal ECU
hand throttle and Low idle switch(LIS). switch threshold.
The accelerator pedal must have detected full
load and idle plausibility at least once.
932 1-2-6 29 3 Diagnostic fault check of short circuit to sup- The signal exceeds the applicatable threshold; If the signal is below the applicatable threshold
ply voltage signal range violation APP_uRawSRCHiHTLIS_C, the signal
(signal range check high) of acceleration range violation is reset
pedal signal. after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal is below the threshold
APP_uHTLISCCPHi[1], a signal range violation
is reset
after debouncing.
937 1-2-6 29 4 Diagnostic fault check of short circuit to The signal is below the applicatable threshold; If the signal exceeds the applicatable threshold
ground (signal range check low) of accelera- signal range violation APP_uRawSRCLoHTLIS_C, the signal
tion pedal signal range violation is reset
after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal exceeds the threshold
APP_uHTLISCCPLo[1], a signal range violation
is reset
after debouncing.
935 2-2-6 91 3 Analog accelerator pedal sensor 1 or double Sensor defect. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- Short cut to battery or open loop. and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it.
compared with the position of the second If the signal is below the applicatable threshold
pedal APP_uRaw1SRCHigh_C, the signal
range violation is reset after
the healing debouncing.
940 2-2-6 91 4 Analog accelerator pedal sensor 1 or double Short circuit to ground. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it
compared with the position of the second If the signal exceeds the applicatable threshold
pedal APP_uRaw1SRCLow_C, the signal
range violation is reset after the
healing
976 2-2-6 91 11 Diagnostic fault check of synchronism of sin- Measured voltage of accelerator pedal 1 is out of Threshold for error detection is an internal ECU
gle potentiometer and Low idle switch(LIS). plausible range. threshold.
Check cabling, check accelerator pedal and
pedal sensor and if necessary replace it,
check connection cable and if necessary repair
or replace it.
When the PWM period APP_tiPWMPer is in
between APP_tiSRCLoPWMPer_C and
APP_tiSRCHiPWMPer_C .
3-146 3121171
Deutz Blink
Code Code
474 216 94 1 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Check low fuel pressure system (fuel feed
culated by ECU is underneath the target pump, relay , fuse, wiring, sensor) and if
range; the ECU activates a system reaction necessary repair or replace it.
472 216 94 3 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range Short cut to battery or open loop connection cable and if necessary repair or
replace it
473 216 94 4 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range short cut to ground connection cable and if necessary repair or
replace it
464 228 97 3 Fuel filter water level sensor: the voltage of Sensor not connected or sensor defect. Check of wiring and water in fuel sensor.
sensor measured by ECU is out of the target Check cabling, if charge Water in Fuel sensor is
range not working, check sensor and if
necessary replace it,
or replace it.
465 228 97 4 Fuel filter water level sensor: the voltage of cable break or short circuit, sensor defective, Check sensor and if necessary replace it, check
sensor measured by ECU is out of the target connection cable damaged. connection cable
range. Short cut to ground. and if necessary repair or replace it.
1157 228 97 12 Fuel filter water level sensor: the maximum Water level in fuel pre-filter reservoir over limit Measure Voltage at Water in Fuel Sensor and
level is exceeded (bad fuel quality) renew harness if needed.
736 231 100 1 Oil pressure is below the target range (warn- Oilpressure too low (pressure below warning Threshold for error detection is an internal ECU
ing threshold) threshold) threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value
737 231 100 1 Oil pressure is below the target range (shut Oilpressure too low (pressure below shut off Threshold for error detection is an internal ECU
off threshold) threshold). threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value.
732 224 100 3 Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiring
measured by ECU is out of the target range Check cabling. If sensor not working, check sen-
sor and if necessary replace it,
or replace it.
733 224 100 4 Oil pressure sensor: the voltage of sensor Short circuit to ground The sensed raw voltage value Oil_uRawPSwmp
measured by ECU is out of the target range is above Oil_SRCPSwmp.uMin_C
Check cabling, if sensor not working, check sen-
sor and if necessary replace it, check
connection cable and if necessary repair or
replace it
No detail informationen!
774 223 102 1 charge air pressure below lower limit measured charge air pressure below the thresh- Check complete air system of engine for mas-
old. sive leakage, especially from compressor
to intake air manifold.
Check air filter.
Exchange charge air presure sensor.
3121171 3-147
Deutz Blink
Code Code
88 223 102 2 Charge air pressure messured by sensor is Charged air cooler pressure below threshold. Check waste gate system if necessary replace
above the shut off threshold. TC,
check CAC if all channels are clean,check charge
air piping if nececery.
89 223 102 2 Charge air pressure messured by sensor is Charge air pressure above shut off threshold Check waste gate system if necessary replace
above the warning threshold TC, check CAC if all channels are clean,
check charge air piping if necessery.
772 223 102 2 Deviation between sensed intake manifold deviation between ambient pressure sensor 1) Exchange boost pressure sensor
pressure is not plausible compared to envi- and charge air pressure sensor at not 2) Exchange ECU
ronment pressure. Which sensor is not okay running engine to high
can not be said.
776 223 102 3 Charge air pressure sensor: the measured The Sensor Voltage is above the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and if necessary replace it, check connection
cable and if necessary repair or replace it.
777 223 102 4 Charge air pressure sensor: the measured The Sensor Voltage is below the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and
if necessary replace it, check connection cable
and if necessary repair or replace it
996 233 105 0 Charge air temperature downstream calcu- Charge air temperature (downstream) over Check CAC system and clean it. Check fan func-
lated by ECU is above the target range. warning threshold. tionality.
The ECU activates a system reaction. Check cooling perfomance with temperature
measurement.
997 233 105 0 Charge air temperature downstream calcu- Charge air temperature (downstream) over the Check CAC system and clean it. Check fan func-
lated by ECU is under the shut down thresh- low threshold. tionality. Check cooling perfomance
old. with temperature measurement.
The ECU activates a system reaction.
992 128 105 1 Charged Air cooler down stream tempera- Sensed temperature within intake air manifold actual temperature below -40°C?
ture. < threshold. exchange sensor
Temperature below lower physical thresh-
old.
994 128 105 3 Charge air temperature sensor: the voltage Short circuit to battery. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage > limit age) > Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it.
995 128 105 4 Charge air temperature sensor: the voltage Short circuit to ground or open load. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage < limit. age) is below Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it
752 136 107 0 Air filter differential pressure: the pressure Pressure loss above target range with system Check airfilter and if necessary clean or renew it,
difference of the intake air between the filter reaction, air filter clogged or defective, check cabling, check sensor and if
inlet and outlet calculated by ECU is above sensor not working, connection cable damaged necessary replace it, check connection cable
the target range and the ECU activates a Pressure value above warning threshold and if necessary repair or replace it
system reaction
98 232 110 0 Coolant temperature: the coolant tempera- Cooling temperature too high. Coolant temper- Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target ature above warning threshold level, check cooling system in general,
range; the ECU activates a system reaction check thermostat function, check water pump
3-148 3121171
Deutz Blink
Code Code
99 232 110 0 Coolant temperature: the coolant tempera- Coolant temperature above shut off threshold. Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target level, check cooling system in general,
range. check thermostat function, check water pump
The ECU activates a system reaction
93 225 110 1 Coolant temperature sensor: the voltage of Suspected components:wiring harness, cool- Check wiring harness and connected Coolant
the sensor measured by ECU is out of the tar- ant temperature sensor. Temp Sens.
get range.
96 225 110 3 Coolant temperature sensor: the voltage of Short cut to battery or open load. Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- connection cable and if necessary
get range repair or replace it.
97 225 110 4 Coolant temperature sensor: the voltage of Voltage Surveillance has found shortcut to Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- Ground at Coolant Temperatur Sensor. connection cable and if necessary
get range repair or replace it
Measure Voltage at Coolant Temperature Sen-
sor and renew harness if needed.
101 235 111 1 Coolant level: the coolant level calculated by Coolant level too low, leakage in cooling sys- Check coolant level, inspect cooling system for
ECU is underneath the allowed minimum. tem, sensor defective, wiring damaged. leakage and if necessary repair it,
check sensor and wiring
877 147 157 3 Rail pressure sensor: the voltage of sensor Short cut to battery. Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. Damaged rail pressure sensor. necessary replace it,
or replace it.
878 147 157 4 Rail pressure sensor: the voltage of sensor Check cabling, check rail pressure sensor and if Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. necessary replace it, necessary replace it,
check connection cable and if necessary repair check connection cable and if necessary repair
or replace it. or replace it.
1381 839 164 2 Rail pressure safety function is not executed Rail pressure is still above threshold. Threshold for error detection is an internal ECU
correctly threshold.
Reset the fault and at reappearance check ECU
and injection system
1180 318 168 0 Battery voltage: the voltage measured by Battery voltage over limit Check alternator, regulator of alternator and if
ECU is out of the target range necessary replace it, check wiring and
voltage of alternator
1181 318 168 1 Battery voltage: the voltage measured by Battery voltage below limit Check alternator, cabling, contact resistance,
ECU is out of the target range safety fuses, too high load in energy
system, check battery and if necessary replace it
47 318 168 2 Battery voltage: the voltage measured by If Batteryvoltage (Ubatt_U) > 17V or 31V for Check wiring harness and connected alternator.
ECU is out of the target range, system reac- mor than =0.5sec a warning is generated
tion is initiated Battery voltage above warning threshold
45 318 168 3 Battery voltage: the voltage measured by Battery voltage above warning threshold Check wiring harness and connected alternator.
ECU is out of the target range, system reac- (~38,9Volt), Short cut to battery possible.
tion is initiated
46 318 168 4 Battery voltage: the voltage measured by Battery voltage below warning threshold, Check wiring harness and connected alternator.
ECU is out of the target range, system reac- Short cut to ground
tion is initiated
417 312 171 3 Sensor error SCR-System environment tem- open loop to sensor Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check high and if necessary replace it, check connection
cable and if necessary repair or replace it.
3121171 3-149
Deutz Blink
Code Code
418 312 171 4 Sensor error SCR-System environment tem- short circuit to Ground Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check low and if necessary replace it, check connection
cable and if necessary repair or replace it
1425 226 172 0 sensed intake air temperature at air filter > sensed intake air temperature at air filter > Check outside conditions:
physical high limit physical high limit Temperature > Threshold within the intake air
system of the engine?
E.G: engine sucks in air from hot asphalt out of
paver bucket
Sensor positioned within black air filter housing
above engine lid at hot environmental
conditions and idling or similar?
=> if yes check with application team to adapt
limits
if not check sensor and wiring harness
exchange sensor
1183 226 172 1 sensed air temperature within air intake sensed air temperature within air intake path of Cold start and ambient temperature < thresh-
path of engine below physical low limit engine below physical low limit old
Check wiring harness to AFST-sensor
Exchange AFST-sensor
389 214 190 0 Engine speed: the engine speed calculated Overspeed monitoring during 1 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over Limit.
421 213 190 2 ECU measures a deviation between cam- Offset error between crankshaft and camshaft. Threshold for error detection is an internal ECU
shaft and crankshaft angle to target. threshold, occurs by offset between
crankshaft and camshaft.
Check increment wheel position, clean and
adjust if necessary, check sensor postition.
Check Camshaft and Crankshaft senor or wiring.
419 212 190 8 Camshaft speed sensor: the ECU receives no When disturbed camshaft signal detected. Threshold for error detection is an internal ECU
signal and uses the signal from crankshaft Error in sensor or wiring. threshold, occurs by disturbed
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
Check Camshaft Sensor or wiring.
422 212 190 8 Sensor crankshaft speed; disturbed signal Error in sensor or wiring. Threshold for error detection is an internal ECU
Crankshaft sensor defect. threshold, occurs by disturbed
crankshaft signal.
Check increment wheel position, clean and
Check Crankshaft Sensor or wiring.
390 214 190 11 Engine speed: the engine speed calculated Overspeed monitoring during 2 level of FOC check powertrain0 settings regarding over-
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed speed
activates a system reaction was over limit.
420 212 190 12 Camshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
Threshold: adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
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Code Code
423 212 190 12 Crankshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the Crankshaft signal.
engine speed. Check increment wheel position, clean and
adjust if necessary, check Crankshaft
sensor postition or wiring.
391 214 190 14 Engine speed: the engine speed calculated Overspeed monitoring during ORC (Override check powertrain settings regarding overspeed
by ECU is above the target range; the ECU conditions) if engine speed was over
activates a system reaction 2900rpm
1222 2-1-2 190 14 Camshaft- and Crankshaft speed sensor sig- Sensors for engine speed are defect. Threshold for error detection is an internal ECU
nal not available on CAN or defect. threshold.
Check wiring, check cabels and repair or replace
if necessary.
791 693 411 0 delta pressure across venturi in EGR line sensed value of venturi difference pressure > Threshold for error detection is an internal ECU
above physical high limit high limit threshold.
EGR-Valve blocked open
EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect
792 693 411 1 delta pressure across venturi in EGR line sensed value of venturi difference pressure < Threshold for error detection is an internal ECU
below physical low limit low limit threshold.
Check correct mounting of difference pressure
sensor at venturi tube
Exchange difference pressure sensor broken
795 693 411 3 The sensed raw voltage EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the maxi- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
381 693 411 4 Range check cannot be done or interrupted. EGR or wiring defect Check wiring harness and connected EGR.
796 693 411 4 The sensed raw voltage value EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the mini- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
3121171 3-151
Deutz Blink
Code Code
793 693 411 11 DFC is stored in EEPROM and status kept until deviation between desired O2 concentration in Threshold for error detection is an internal ECU
check is allowed intake air manifold threshold.
to be carried out again and the real O2-concentration within intake air EGR-Valve mechanically blocked open or closed
DFC can be reset by service routine 216 manifold > limit EGR-pipe blocked with metall plate instead
sealing downstream EGR-Valve
EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
1007 682 412 3 EGR downstream temperature sensor: the Short circuit to battery. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage > limit Exchange TEGR-sensor.
the target range.
1008 682 412 4 EGR downstream temperature sensor: the Short circuit to ground or open load. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage < limit Exchange TEGR-sensor.
the target range.
376 281 630 12 Internal hardware monitoring: the ECU finds Section could not be erased Threshold for error detection is an internal ECU
an error during the access to its EEPROM threshold.
memory or works with an alternative value There is no healing possible for the error. In the
every new initialization phase, the
debounce level is set to zero.
If not programmed, EEPROM is defect --> ECU is
defect, reprogramm ECU and if
necessary replace it.
377 281 630 12 Internal hardware monitoring: the ECU finds Minimum 3 blocks could not be readed, There is no healing possible for the error. In the
an error during the access to its EEPROM EEPROM has Checksum Error every new initialization phase, the
memory or works with an alternative value debounce level is set to zero.
If not programmed, EEPROM is defect -->ECU is
necessary replace it
378 281 630 12 Internal hardware monitoring: the ECU finds Block could not be written for minimum 3 times Threshold for error detection is an internal ECU
an error during the access to it's EEPROM threshold.
memory or works with an alternative value If not programmed, EEPROM is defect --> ECU is
necessary replace it.
84 271 639 14 CAN bus 0: the ECU is not allowed to send CAN BusOff error; CAN 0 (Customer CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold.
detected. BusOff bit for CAN A node is set.
Check wiring of CAN bus and if necessary repair
it, check connection cable and if
necessary repair or replace it, check resistance in
CAN lines (120 Ohm)
580 154 651 3 Injector cyl. 1: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 1 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
damaged test for diagnosis.
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Code Code
568 154 651 5 Injector cyl. 1: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 1 threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
repair/replace it.
repair/replace it.
test for diagnosis.
repair/replace it.
test for diagnosis.
repair/replace it.
test for diagnosis.
repair/replace it.
3121171 3-153
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Code Code
543 263 676 11 Cold start aid relay error. Relay defect or wire harness problem Threshold for error detection is an internal ECU
threshold.
check wire harness, replace relay
544 263 676 11 Cold start aid relay open load Relay or wire harness Threshold for error detection is an internal
threshold.
check wire harness, replace relay
956 512 677 3 Start relay (high side power stage): the cur- Short cut HighSide-output to battery. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the tar- threshold.
get range. Check cabling and start relay and if necessary
replace it,
or replace it.
960 512 677 3 Start relay (low side power stage): the cur- Shortcut LowSide-Output to battery. Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- threshold.
replace it,
or replace it.
957 512 677 4 Start relay (high side power stage): Shortcut HighSide-output to ground. Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold.
the target range. Check cabling and start relay and if necessary
replace it,
or replace it.
961 512 677 4 Start relay (low side power stage): the cur- Shortcut LowSide-Output to ground. Threshold for error detection is an internal ECU
replace it,
check connection cable of terminal 50 and if
958 512 677 5 Start relay (low side power stage): the cur- Open circuit/disconnection LowSide-Output. Threshold for error detection is an internal ECU
get range Check cabling and start relay and if necessary
replace it,
or replace it.
959 512 677 12 Start relay (low side power stage): the cur- Temperature over limit. Threshold for error detection is an internal ECU
replace it,
or replace it.
928 928 691 8 Supply module heater: PWM time periode PWM signal for temperature readout from sup- The Time period of the received PWM signal
out of valid range. ply module to the control unit is out of SCR_tiSMPerPwm is within the specified
range. range of150ms to 250ms
Supply modul defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
549 263 729 3 wiring to the intake air heater device is Intake Air Heater Device: overload, short-circuit Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, Check wiring to the intake air
heater device.
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Code Code
551 263 729 4 wiring to the air intake heater is faulty Relay (for cold start aid) cable break or short to Threshold for error detection is an internal ECU
ground: threshold.
Electrical error, check wiring to the air intake
heater.
545 263 729 5 The cold start aid relay is according to wiring Relay defect or wire harness problem Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, check wires
547 263 729 12 The cold start aid relay is overheated, which High temperature around the cold start relay. Check the functionality of relay and replace it if
causes this error needed.
Check the temperature around the cold start
relay during worst case operation.
305 118 898 9 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
- active short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
946 282 1079 13 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of the Pin A19: DEF press / Exh.PressBeforeTurb (P3) / working voltage and if necessary correct
power supply voltage of sensor output 1. Air Pump Press it,
/BrnFuelPressAfterDV2 Pin K19: Fan Speed Sen- check connection cable and if necessary repair
sor or replace it,
Pin A21: LDF6T / OilPress / LowFuelPress Pin if error is not removable, change ECU.
A17: Rail Pressure Sensor
Suspected components EDC17cv54
Pin A21: CAM speed Pin K44: Delta Press Venturi
/ Poti EGR or Inlet Throttle
Pin A24: LDF6T / OilPress / LowFuelPressPin
K43: Reserve 5V Sensor Supply
Pin A09: second footpedal
Pin A21: Cam speed Pin K44: DEF press / Air Fil-
terDiffPress
Pin A24: LDF6T / OilPress / LowFuelPress Pin
K43: second footpedal
Pin A09: Delta Press Venturi
detects a deviation of the target range of the Pin K16: second footpedal working voltage and if necessary correct
power supply voltage of sensor output 2. Pin A20: Exh.PressAfterTurb/DPFDiffPress/ it, check connection cable and if necessary
BrnDV1Press/HCIPressDV1DV2 repair or replace it, if error is not removable,
Suspected components EDC17cv54 change ECU.
Pin K45: DPF Diff Press / Exh. Press After Turb /
Fan Speed Sensor
Pin A46: first footpedal
Pin A22: Fan Speed Sensor
Pin K45: Position EGR or Intake throttle flap
Pin K46: First footpedal
121 341 1109 2 Request of engine shut off: the operator Engine Shut Off demand has been ignored by Depending on error requested a shut off.
ignores the engine shut off request within an the user
allowed period.
1398 681 1136 0 ECU internal temperature; temperature Short-Circuit in ECU, ECU heated by hot air Close warm air circuits, replace ECU
measured by ECU is out of the target range
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Deutz Blink
Code Code
85 271 1231 14 CAN bus 1: the ECU is not allowed to send CAN BusOff error; CAN 1 (Diagnostic CAN) Threshold for error detection is an internal ECU
detected BusOff bit for CAN B node is set.
Warning, no diagnostic with SERDIA2010 Check wiring of CAN bus and if necessary repair
possible it, check connection cable and if
CAN lines (120 Ohm)
86 271 1235 14 CAN bus 2: the ECU is not allowed to send CAN BusOff error; CAN 2 (Engine CAN) Threshold for error detection is an internal ECU
detected. BusOff bit for CAN C node is set.
Warning, depends on engine, EAT. Check wiring of CAN bus and if necessary repair
it, check connection cable and if
CAN lines (120 Ohm)
747 145 1237 2 Override switch switch: the ECU receives a Switch is blocked, taster locked, connection If the Block Button is pressed shorter than the
permanent signal. cable damaged Maximum Plausible pressing Time.
plausbility error "override switch > 250ms Check cabling, if sensor is not working, check
pressed". switch and if necessary replace it, check
replace it.
1593 129 1761 0 The urea tank level sensor detects a value Suspected components: Check level sensor and float gauge
higher than the maximum allowed thresh- Urea Quality Sensor defect
old mechanical defect at the float gauge
1594 129 1761 1 The DEF tank level sensor detects a value Suspected components: Check level sensor and float gauge
lower than the minimum allowed threshold Urea Quality Sensor defect
mechanical defect at the float gauge
1655 138 1761 14 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <5% below applicable threshold 5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
SCRUTnk_rVol_mp must change.
Exchange DEF level sensor, if no change of value
or it's implausible.
1656 138 1761 14 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <2.5% below 2.5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
Exchange DEF level sensor, if no change of value
or it's implausible.
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Code Code
1880 138 1761 14 The DEF tank level is below the threshold. actual DEF tank level SCRUTnk_rVol_mp [%] is Check DEF level => if empty, refill
below the threshold Check DEF level sensor.
If there is urea in the tank loose the sensor and
move it. The floater must be free and
move if you lift the sensor body.
Compare SCRUTnk_rVol_mp to:
1 = SCR_rawUTnkLvl
2 = SCR_rAdapUtnkLvl
3 = SCRUTnk_rActTnkVol
*SCRUTnk_facVolPer_mp
In case of malfunction, exchange DEF level sen-
sor.
1763 415 2791 0 Internal actuator temperature is above Overheating of EGR actuator during operation. Let EGR actuator cool down and check heat
threshold. accumulation during worst case operation.
1753 415 2791 2 corrupted CAN communication with actua- CAN bus error or faulty EGR actuator. Threshold for error detection is an internal ECU
tor. threshold.
Check other CAN bus components. If no mes-
sage is sent, fix the wiring.
If o.k. exchange EGR actuaror.
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.
1757 415 2791 6 Overcurrent to EGR actuator. High voltage from battery. Check battery voltage. Check if EGR is blocked or
EGR actuator is blocked or moving very hard. not running smoothly.
If everything is o.k. change EGR actuator.
1752 415 2791 7 EGR actuator is mechanically blocked. EGR actuator faulty or blocked. Threshold for error detection is an internal ECU
threshold.
Check the EGR actuator and EGR valve to
mechanical blockage / clean.
Check for free movement of the valve. If it'S
blocked, then exchange the EGR valve.
1761 415 2791 7 EGR actuator spring broken. mechanical damage of spring due to overstress. Threshold for error detection is an internal ECU
threshold.
Exchange EGR actuator.
1755 415 2791 12 Internal electrical fault of EGR actuator. Internal damage of EGR actuator due to high Threshold for error detection is an internal ECU
temperature or electrical wiring issue. threshold.
Exchange EGR actuator.
1754 415 2791 13 EGR actuator can not learn stop positions. Error detection during the learning process. Threshold for error detection is an internal ECU
Possibly only second failure if other EGRTV threshold.
failures occure. Start Serdia Usecase to reset EGR actuator.
Check EGR valve and mounting situation. If o.k.
change EGR actuator.
1756 415 2791 13 EGR actuator can not learn stop positions Interruption of learning process due to mechan- Threshold for error detection is an internal ECU
because procedure was interrupted. ical damage. threshold.
Start Serdia Usecase to reset EGR actuator.
1760 415 2791 13 Stop positions of EGR valve not o.k. Mechanical damage of EGR actuator. Threshold for error detection is an internal ECU
EGR valve is blocked or moving very hard. threshold.
Start Serdia Usecase to reset EGR actuator.
1762 415 2791 16 Internal actuator temperature above thresh- overheating of EGR actuator Let EGR actuator cool down, check heat accu-
old. mulation during worst case operation.
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Deutz Blink
Code Code
1337 565 2797 4 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 0 threshold.
Check wiring, component, ECU
Note: affected injector has to be evaluated
according to firing order
1339 565 2797 4 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 0 Note: affected injector has to be evaluated
1338 566 2798 4 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 1 threshold.
Note: affected injector has to be evaluated
1340 566 2798 4 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 1 Note: affected injector has to be evaluated
1135 669 3031 0 The urea tank temperature sensor detects a Sensed urea tank temperature > physical range Case "CANBUS sensor":
value above the maximum allowed thresh- high limit Check urea tank temperature: really hot?
old Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Tank heater permantly on?
Check wiring of DEF-quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really hot?
Check urea tank temperature SCR_tSensUTnkT
Compare urea tank temperature to EnvT_t or to
SCR_tSMT (the urea temperature
inside the supply module) identical?
Tank heater permantly on?
Check wiring of analog DEF T & Level sensor
1136 669 3031 1 The urea tank temperature sensor detects a sensed urea tank temperature < physical range Case "CANBUS sensor":
value lower than the minimum allowed low limit Check ambient temperature EnvT_t => About
threshold. -40 °C? If yes Error could be plausible
Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Check wiring of DEF-quality sensor
Check quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really that cold?
Check ambient temperature EnvT_t =>
About -40 °C? If yes Error could be plausible
Check urea tank temperature SCR_tSensUTnkT
Check wiring of analog DEF T & Level sensor
Check analog DEF T & Level sensor
129 596 3224 2 DLC Error of CAN-Receive-Frame AT1IG1Vol Not Used Threshold for error detection is an internal ECU
NOX Sensor (SCR-system upstream cat; DPF- threshold.
system downstream cat); length of frame Check Nox-Sensor and the wiring from CAN-
incorrect BUS.
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Code Code
130 597 3224 9 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX sensor and sensor connection check
AT1IG1Vol; NOX sensor (SCR-system
upstream cat; DPF-system downstream cat)
138 114 3234 2 DLC Error of CAN-Receive-Frame AT1O1Vol Failure of the CAN Bus message NOX downstream sensor and sensor connection
NOX Sensor (SCR-system downstream cat; check
DPF-system downstream cat); length of
frame incorrect
139 117 3234 9 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX downstream sensor and sensor connection
AT1OG1Vol; NOX sensor (SCR-system down- check
stream cat; DPF-system downstream cat)
1077 677 3361 3 Urea dosing valve (low side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range See substitute function
Check the wiring
1078 677 3361 3 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the target range Check the wiring
1079 677 3361 4 Urea dosing valve (low side power stage): Fault in the wiring Check the wiring
the current drain measured by ECU is above
the target range
1080 677 3361 4 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the target range Check the wiring
1075 677 3361 6 Urea dosing valve: the current measured Fault in the wiriing Check wiring
value by ECU at the end of the injection is too Defect urea dosing injection valve Check the urea dosing injection valve
high
1898 277 3519 3 The integrated diagnostic of the tempera- Wrong diagnostic of the short circuits logic Check the wiring to the suction unit in the DEF
ture sensor of the Urea Quality Sensor recog- inside the temperature sensor of the UQS tank.
nized a short circuit to battery. CAN Communication corrupted Check the CAN bus communication of the suc-
The UQS Sensor is an combined sensor of tion unit. In case the communication is
tank temperature, filling grade and DEF corrupt, exchange the suction unit.
quality and it is also an CAN sensor --> no
PIN
1899 277 3519 4 The integrated diagnostic of the tempera- DEF quality sensor in the suction unit of the DEF Check the wiring to the suction unit of the DEF
ture sensor of the Urea Quality Sensor recog- tank is defect tank.
nized a short circuit to ground CAN Communication corrupted Check the CAN bus communication from the
suction unit. In case the signal is corrupt,
exchange the suction unit in the DEF tank.
3121171 3-159
Deutz Blink
Code Code
1895 277 3519 12 The integrated temperature sensor of the Temperature sensor inside the UQS defect. Check the temperature sensor signal for plausi-
Urea Quality Sensor measures higher tem- CAN Communication corrupted. bility. In case of improper signal,
perature than threshold Overheating of the DEF tank due to malfunction exchange the suction unit in the tank.
of the heating valve. Check CAN bus communication for proper sig-
Flow direction is of coolant is wrong due to nal. In case of improper signal, exchange
mixed up the hoses routed to the heating the suction unit in the tank.
valve. Check the function of heating valve and routing
Overheating of the DEF tank due to heat transfer of the hoses. The coolant flow through
from neighbor parts. the heating valve must be observed according
to the shown arrow.
In case all actions above are OK, check the real
temperature in the DEF tank during
worst case condition and improve the installa-
tion of the DEF tank.
1908 277 3519 13 Temperature at UQS out of range the speci- Suspected Components Check temperature system and/or DEF quality
fied thresholds; invalid quality of the tem- Tank heater sensor
perature DEF sensor
1904 2-7-8 3520 2 Measured DEF Quality from UQS is too low. Suspected components: Check that there is liquid urea of known quality
Quality value received from UQS is < 22 % for Urea quality sensor defect in the tank first
a certain time and a certain number or for Wrong installation (measuring air) Check urea tank level. Add urea until level is at
measuring conditions not observed for a cer- Urea level sensor defect least 10 cm above sensor.
tain time. Non urea filled in tank Ensure that urea is not frozen / sufficient urea is
CANBUS problems liquid
Evaluation conditions for new quality check not Check Sensor: Are urea tank temperature and
fulfilled after one previous mal detection level displayed? Changes the level if you
refill urea?
Check electrical connection
Check CANBus
New quality detection is carried out if urea re-
fill is detected or if an quality evaluation
was triggered and was not finished success-
fully: To provoke a quality measurement: refill
urea, at least 10 % of tank volume
Wait until quality evaluation was carried out,
can take up to 30 minutes => check value.
It should be about 33 %
Exchange quality sensor
1896 278 3520 3 The integrated diagnostic of the Urea Quality wiring harness of UQS corrupted Threshold for error detection is an internal ECU
Sensor recognized a short circuit to battery CAN Communication corrupted threshold.
Check the wiring harness from the ECU to the
suction unit of the DEF tank
Check the CAN bus communication. If the signal
is corrupt, then exchange the suction
unit.
1897 278 3520 4 The integrated diagnostic of the Urea Quality wiring harness to the suction unit in the DEF Threshold for error detection is an internal ECU
Sensor recognized a short circuit to ground. tank is corrupted threshold.
CAN Communication corrupted Check the wiring to the suction unit in the DEF
tank.
Check the CAN bus communication. In case the
communication is corrupt, exchange
the suction unit in the DEF tank.
3-160 3121171
Deutz Blink
Code Code
1907 278 3520 13 Urea quality at UQS out of range the speci- Suspected components Check DEF quality and/or DEF quality sensor
fied thresholds; invalid quality of the urea DEF quality sensor
qualiy DEF
1911 127 3532 3 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or sensor.
greater than the maximum physical range UQS defect
threshold
Comment: tank temperature is measured by
the UQS sensor
1912 127 3532 4 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or Sensor.
lower than the minimum physical range UQS defect
threshold.
1455 711 3711 12 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC
DPF temperature < Threshold 1 temperature, is below or above Exh_tSensOxiCatUs within Stand-still: > 450
Temperature Phy_tPfWgh, the weighted the target temperature towards the end of the °C? If
DPF temperature > Threshold 2 stand-still main phase. not:
towards the end of the stand-still main => Check air path of engine: EGR-Valve,
phase. Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
Check temperature difference across DOC by
Exh_tSensOxiCatDs -
Exh_tSensOxiCatUs within Stand-still: <
100°C? If not:
Check exhaust pipe downstream turbo charger
for oil?
check injectors: is an injector got stuck?
Too many hydrocarbons in exhaust? White
smoke (at hot EAT system, not at cold
start)?
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check exhaust gas temperature sensors within
EAT-system: T upstream DOCC, T
downstream DOC & T upstream SCR catalyst
all three of them can influence Phy_tPfWgh
1917 2-8-6 3936 14 Standstill escalation by time. In case the Stand-still request ignored by the operator. Perform Stand-still. If soot load level of DPF has
standstill request will not be released within Display / stand-still request lamp broken. increased too high already call service
50 h by the driver this fault code will be set. to perform stand-still.
In case the DPF soot load level remove DPF =>
Exchange DPF.
1122 665 4334 0 The absolute pressure value of the urea Suspected Components: Check the urea pump
pump is greater than an applicable maximal Urea pump defect Check the supply module pressur sensor
filtered pressure threshold Supply module pressure sensor defect Clean the urea pump (filter)
Pump contains dirty parts
1123 665 4334 1 Urea supply module pressure sensor: The Check the urea pump Check the urea pump
absolute pressure value of the urea pump is Check the supply module pressur sensor Check the supply module pressur sensor
less than an applicable minimal filtered Clean the urea pump (filter) Clean the urea pump (filter)
pressure threshold
3121171 3-161
Deutz Blink
Code Code
1866 665 4334 2 absolute difference of sensed urea pump absolute difference of sensed urea pump pres- Check environment pressure sensor (EnvP_p)
pressure (SCR_pAbsSensUPmpP) and ambi- sure (SCR_pAbsSensUPmpP) and => plausible value?
ent pressure (EnvP_p) > limit ambient pressure (EnvP_p) > limit Engine shut-off and immediately re-started?
abs(UPmpP_pDiffPmpEnv_mp) > abs(UPmpP_pDiffPmpEnv_mp) > => Shut-off again. Wait until afterun of
UPmpP_pDiffPmpEnv_C (250 hPa) UPmpP_pDiffPmpEnv_C ECU has finished, re-Start engine
Back-flow line free? Does the urea pump pres-
sure show values < 1000 hPa in SCR
state emptying (64)?
Check revision valve => Does the urea pump
pressure show values < 1000 hPa in SCR
state emptying (64)? => exchange supply
module
Supply module pressure sensor defect =>
exchange supply module
1104 675 4341 3 Urea heater supply line: the current drain electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
Check wire harness
Check supply line
Check wire harness
Check supply line
1096 673 4343 3 Urea pressure line heater: the current drain shortcut to battery Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
broken heating element in pressure line Check heating element
1097 673 4343 4 Urea pressure line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
Short cut to ground or broken wiring, broken Check heating element
heating element in pressure line
1094 673 4343 5 Urea pressure line heater: the current drain Open load Threshold for error detection is an internal ECU
Broken wiring, broken heating element in pres- Check heating element
sure line
1092 674 4345 3 Urea backflow line heater: the current drain Shortcut to battery Threshold for error detection is an internal ECU
Short cut to battery or broken wiring, broken Check heating element
heating element in backflow line
1093 674 4345 4 Urea backflow line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
Short cut to ground or broken wiring, broken Check heating element
heating element in backflow line
3-162 3121171
Deutz Blink
Code Code
1090 674 4345 5 Urea backflow line heater: the current drain Open load Threshold for error detection is an internal ECU
Broken wiring, broken heating element in back- Check heating element
flow line
1069 668 4360 0 The filtered urea cat upstream temperature Sensed temperature upstream SCR > physical Check temperature difference across DOC
is greater than an applicable maximum tem- high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at higher
perature threshold engine load => high difference > 100 K?
If yes, the engine emitts too many Hydrocar-
bons => check injectors: is an injector got
stuck?
=> Check EGR Valve
If difference normal the exhaust out of the engie
itself is too hot:
=> Check air path of engine: EGR-Valve,
Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
If that error was set while stand-still operation
the error source could be exothermal
soot burn off in DPF (which should not happen)
=> Dismount DPF and check it visually
exchange temperature sensor upstream SCR
1070 668 4360 1 The filtered temperature before urea cat is Sensed temperature upstream SCR catalyst < Cold start and ambient temperature < Thresh-
less than an applicable minimum tempera- than physical low limit old? Missdetection?
ture threshold Check wiring harness to UCatUsT-sensor
Exchange UCatUsT-sensor
1865 668 4360 2 Error at static plausibility check: Error at static plausibility check: Check whether temperature sensor upstream of
absolut temperature difference of sensed absolut temperature difference of sensed tem- SCR catalyst is physically mounted
temperature upstream SCR catalyst and perature upstream SCR catalyst and within exhaust pipe
ambient temperature > as static plausibility ambient temperature > as static plausibility If cold start condition can be made sure (engine
limit limit was off for at least 8 h) compare
at engine cold start (engine was off for at at engine cold start (engine was off for at least 8 values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
least 8 h), temperature upstream of SCR cat- h), temperature upstream of SCR Exh_tOxiCatDs and
alyst is expected to be identical to ambient catalyst is expected to be identical to ambient SCR_tSensUCatUsT at ignition on, without
temperature => see enable conditions for temperature => see enable conditions for starting the engine. All identical?
details. details. Compare values of Exh_TOxiCatUs,
Error at dynamic plausibility check: Error at dynamic plausibility check: Exh_tOxiCatDs and SCR_tSensUCatUsT after 15
temperature difference of sensed tempera- temperature difference of sensed temperature min in constant operation point: show all simi-
ture upstream SCR catalyst and ambient upstream SCR catalyst and ambient lar values (30 K tolerance width). Are
temperature < as dynamic plausibility limit temperature < as dynamic plausibility limit ambient temperature and (EnvT_t), cooling
dynamic check is blocked if static plausibility dynamic check is blocked if static plausibility water temperature (EngDa_tEng) plausible?
check is already faulty check is already faulty Sensor coated with urea crystalls? Dismount
=> Temperature upstream SCR catalyst => Temperature upstream SCR catalyst must urea injector and inspect temperature
must be by 40°C higher than ambient tem- be by 40°C higher than ambient sensor upstream SCR catalyst visually
perature if engine runs and a certain delay temperature if engine runs and a certain delay Check wiring of sensor
time has expired. time has expired. Replace sensor
1072 668 4361 3 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst > maximum limit Check wiring
of the target range Short circuit to battery Replace UCatUsT-sensor
1073 668 4361 4 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst < minimum limit Check wiring
of the target range Short circuit to ground Replace UCatUsT-sensor
3121171 3-163
Deutz Blink
Code Code
1137 6-6-9 4365 2 Signal error in case of Urea tank temperature CAN message is not send properly. Check sensor connector
trnasmitted via CAN-signal Com_tUTnkT. Check CANbus
1138 6-6-9 4365 3 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The Sensed raw voltage value SCR_uRawUTnkT
is below SCR_SRCUTnkT.uMax_C.
Check wiring.
1914 669 4365 3 Internal error of DEF qualitysensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF qualitysensor
Wiring harness
1139 6-6-9 4365 4 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The sensed raw voltage value SCR_uRawUTnkT
is above SCR_SRCUTnkT.uMin_C.
Check wiring.
1915 6-6-9 4365 4 Internal error of DEF qualitysensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF qualitysensor
Wiring harness
1112 671 4366 3 Urea tank heating valve: the current drain Shortcut to battery Threshold for error detection is an internal ECU
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
1113 671 4366 4 Urea tank heating valve: the current drain Shortcut to ground Threshold for error detection is an internal ECU
1110 671 4366 5 Urea tank heating valve: the current drain Open load Threshold for error detection is an internal ECU
1120 666 4375 3 Urea supply module pump: the current drain Shortcut to battery Threshold for error detection is an internal ECU
a result error: KWP 1089 The hardware detects absence of any short cir-
Broken wiring cuit to battery on the PWM output power
Pump in urea supply module defect stage for the urea pump module actuator
Check wiring
Check pump in the urea supply module
1121 666 4375 4 Urea supply module pump: the current drain Shortcut to ground Threshold for error detection is an internal ECU
a result error: KWP 1089 The hardware detects a short circuit to ground
Broken wiring error on the PWM output power stage
Pump in urea supply module defect for the UreaPump Module Motor Actuator. The
error is updated by setting bit 1 of
measuring point UPmp-
Mot_stPrevTstRslt_mp
Check wiring
3-164 3121171
Deutz Blink
Code Code
1118 666 4375 5 Urea supply module pump: the ECU can not Open load Threshold for error detection is an internal ECU
measure any reaction during pump control Broken wiring threshold
Pump in urea supply module defect The hardware detects the presence of load on
the PWM output power stage for the
urea pump module actuator.
Check wiring
1131 667 4376 3 Urea supply module reversal valve: the cur- Shortcut to battery Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- Fault in the wiring threshold
get range Reversal valve in the urea supply module defect Check wiring
Check urea supply modul
1132 667 4376 4 Urea supply module reversal valve: the cur- Shortcut to ground Threshold for error detection is an internal ECU
1129 667 4376 5 Urea supply module reversal valve: the cur- Open load Threshold for error detection is an internal ECU
1039 683 4765 0 The exhaust temperature value from the sensed temperature upstream DOC > shut-off Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle,
is above an applicable upper shutoff thresh- Check Turbocharger and Piping each for leakage
old and correct function
TOxiCatUs_tShOffThresHiAds_C = Thresh- Check injectors: is an injector got stuck?
old 1 in Normal and Exchange temperature sensor upstream DOC
Heatmodes
(TOxiCatUs_tShOffThresHiRgn_C = Thresh-
old 2
in stand-still)
1040 683 4765 0 The exhaust temperature value from the Sensed temperature upstream DOC > warning Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle, Turbocharger and Piping each
is above an applicable upper warning for leakage and correct function
threshold Check injectors: is an injector got stuck?
TOxiCatUs_tWarnThresHi_C = Threshold Exchange temperature sensor upstream DOC
3121171 3-165
Deutz Blink
Code Code
1036 683 4768 2 Static plausibility check: Static plausibility check: Check ambient temperature => value plausi-
The exhaust temperature value from the The exhaust temperature value from the sensor ble?
sensor before DOC, the exhaust temperature before DOC, the exhaust temperature upstream DOC sensor mounted within exhaust
value from the sensor after DOC, the temper- value from the sensor after DOC, the tempera- line?
ature value from the sensor before ture value from the sensor before T upstream DOC sensor physically mounted in
SCR-Cat, the environment temperature and SCR-Cat, the environment temperature and the correct position upstream DOC? (not
the coolant engine temperature their ratios coolant engine temperature their ratios upstream SCR or downstream DOC?)
to each other exceed their related thresh- to each other exceed their related thresholds. Check T upstream DOC sensor
olds. (difference between temperature after DOC and Check other T-sensors within EAT-system
Dynamic plausibility check with environ- temperature before DOC > Threshold 1 (Exh_tOxiCatDs & UCatUsT_tFlt_mp show
ment temperature sensor value: difference between temperature befor DOC and plausible values? No errors on them?
The exhaust temperature value from the before SCR > Threshold 2
sensor before DOC is lower than an applica- difference between temperature after DOC and
ble environment temperature threshold before SCR < Threshold 3
difference between temperature after DOC and
ambinet temperature < Threshold 4
differnece between temperatur ambient tem-
perature and engine temperature <
Threshold 5)
Dynamic plausibility check with environment
temperature sensor value:
The exhaust temperature value from the sensor
before DOC is lower than an applicable
environment temperature threshold (< envi-
ronmental temperature + Threshold 6)
1881 683 4768 2 At engine cold start conditions the sensed Difference temperature of exhaust gas temper- Check whether all exhaust gas temperature
exhaust gas temperature downstream DOC ature downstream DOC and fixed sensors within the EAT system are
(Exh_tSensTOxiCatDs) ambient temperature at ignition on exceeds a mounted properly: Within the exhaust line and
has exceeded the sum of ambient tempera- certain limit earlier than the difference at correct positions.
ture (EnvT_t) + offset (40°C) earlier than the temperature of exhaust gas temperature Check the position of the sensor upstream SCR
sensed exhaust gas upstream DOC and fixed ambient temperature which might be physically mounted in
temperature upstream of DOC at ignition on. the wrong position.
(Exh_tSensTOxiCatUs). If cold start condition can be made sure (engine
The check is only performed once each igni- was off for at least 8 h) compare
tion cycle and only if the start is judged a cold values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
start. Exh_tOxiCatDs and
Error status is frozen for that ignition cycle. SCR_tSensUCatUsT at ignition on, without
No healing possible. starting the engine. All identical? Then the
sensors itself are okay.
Check exhaust piping for leakage.
Check wiring of sensors
Replace sensors
Check DOC => physicallly intact?
1044 683 4768 3 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is above upstream DOC
ECU is out of the target range Exh_SRCTOxiCatUs.uMax_C Exchange temperature sensor upstream DOC
Shortcut to battery
1045 683 4768 4 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is upstream DOC
ECU is out of the target range below Exh_SRCTOxiCatUs.uMin_C Exchange temperature sensor upstream DOC
Shortcut to ground
3-166 3121171
Deutz Blink
Code Code
1024 594 5763 3 Actuator of the external EGR valve: the ECU Short cut to battery or open loop. Check cabling, actuator defect, check actuator
detects a short circuit to battery or open and if necessary replace it, check
load. connection cable and if necessary repair or
replace it.
1226 594 5763 3 Actuator EGR-valve: short cut to battery is Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
detected threshold.
Check repair with SerDia 2010 use case
1227 594 5763 3 Actuator EGR-valve: short cut to battery on Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
ECU pin is detected threshold.
1025 594 5763 4 Actuator of the external EGR valve: the ECU Short cut to ground Check cabling, actuator defect, check actuator
detects a short circuit to ground. and if necessary replace it, check
replace it.
1228 594 5763 4 Actuator EGR-valve: short cut to ground on Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
1229 594 5763 4 Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal ECU
1232 5-9-4 5763 4 Actuator error EGR-Valve (2.9;3.6) or Throt- Monitoring for CY146 Under Voltage. Threshold for error detection is an internal ECU
tle-Valve (4.1;6.1;7.8); Voltage below threshold.
threshold Check wiring, component
3.6) Drosselklappe (4.1;6.1;7.8); Voltage
below threshold;
1023 5-9-4 5763 5 Actuator error EGR-Valve; signal range check Short circuit to ground. Check wiring, check cabels and repair or replace
low, measured current is below target if necessary, check actuator with
SERDIA 2010 test for EGR and if necessary
replace it.
1014 594 5763 6 Actuator error EGR-Valve. Short cut to batterie. Check wiring and repair or replace if necessary,
Signal range check high. check actuator with SERDIA test for
EGR and if necessary replace it.
1022 5-9-4 5763 6 Actuator error EGR-Valve; signal range check Short circuit to battery or open circuit. Check cabling, actuator defect, check actuator
high, measured current by ECU is over target and if necessary replace it, check
replace it.
1223 594 5763 6 Actuator EGR-Valve: Open load on ECU out- Open circuit on component wiring Threshold for error detection is an internal ECU
put is detected threshold.
1224 594 5763 6 Actuator EGR-valve: too high curent is going Overload on component wiring Threshold for error detection is an internal ECU
into the actuator. Output is switched off threshold.
3121171 3-167
Deutz Blink
Code Code
1230 5-9-4 5763 6 Actuator error EGR-valve; Overload by short- Short Circuit over Load Threshold for error detection is an internal ECU
circuit threshold.
Check wiring, component
1016 594 5763 7 Actuator position for EGR valve is not plausi- Position error of throttle flap (deviation > 7%). Threshold for error detection is an internal ECU
ble, internal error, angular misalignement of threshold.
the flap. Threshold for error detection, deviation from
setpoint > 7%.
Troubleshooting with SERDIA 2010 Use Case
"EGR Diagnostic".
1231 5-9-4 5763 11 Power stage overtemperature due to high Temperature dependent Over Current Threshold for error detection is an internal ECU
current. threshold.
Check wiring, component
1015 594 520521 5 Actuator error EGR-Valve. Short cut to ground. Check wiring and repair or replace if necessary,
Signal range check low. check actuator with SERDIA test for
EGR and if necessary replace it.
825 253 523009 9 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the number of allowed activations. old of the pressure limiting valve. fault with Serdia.
833 2-5-3 523009 10 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the allowed opening time. old of the pressure limiting valve. fault with Serdia.
171 3-3-3 523212 9 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer devices
ComEngPrt; Engine Protection
179 527 523240 9 Timeout CAN-message FunModCtl; Func- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
tion Mode Control short circuit, power interrupt), test
range.
565 151 523350 4 Injector cylinder bank 1: the current drop Short circuit injection bank 1 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
repair/replace it.
566 152 523352 4 Injector cylinder bank 2: the current drop Short circuit injection bank 2 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
repair/replace it.
567 153 523354 12 Internal hardware monitoring: the ECU Defective powerstage in ECU Threshold for error detection is an internal ECU
detects an error of its injector high current threshold.
output. Chip of CY33x defect power stage If error is not removable, change ECU.
components
839 1-4-3 523450 4 Diagnostic fault check for min error of COM The sensed raw value is less than the threshold. Check cabling, check sensor and if necessary
message. replace it,
or replace it.
826 146 523470 2 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
827 146 523470 2 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
3-168 3121171
Deutz Blink
Code Code
876 146 523470 7 Rail pressure is out of the expected average Rail pressure is out of the expected average (A) Check railpressure relief valve and replace if
range. range. necessary.
PRV can not be opened. (B) Check high pressure pumps, pressure relief
valve and metering unit.
(C) Change components if necessary
831 146 523470 11 Rail pressure relief valve can not be opened Railpressure out of tolerance range (PRV can not Threshold for error detection is an internal ECU
due to the railpressure. be opened by a pressure peak in this threshold.
operating point) Check railpressure, check rail pressure sensor for
plausibility, check FCU.
832 146 523470 11 Rail pressure is out of the expected average Averaged rail pressure is outside the expected Threshold for error detection is an internal ECU
range. tolerance range. threshold.
The PRV can not be opened at this operating Check PRV and replace if necessary.
point with a pressure shock.
828 146 523470 12 Rail pressure relief valve: is open. Shut Off after PRV Open Threshold for error detection is an internal ECU
Shutoff conditions. threshold.
Check PRV opening counter and if necessary
replace PRV,
check rail-pressure sensor for plausibility and if
check FCU and if necessary replace it.
829 146 523470 12 Rail pressure relief valve is open. Warning PRV open Threshold for error detection is an internal ECU
Warning conditions. threshold.
replace PRV,
830 146 523470 14 Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal ECU
threshold.
Only after ECU reset.
replace it,
980 515 523550 12 Terminal 50 was operated for more than 2 Startinformation to Starter (T50-switch) Threshold for error detection is an internal ECU
minutes. This may happen due to short to erratic/defect. threshold.
battery or wrong usage of Terminal 50. Check cabling, if sensor not working, check start
Starter control is disabled until this error is switch and if necessary replace it,
healed. check connection cable and if necessary repair
or replace it.
detects a deviation of the target range of the Pin A18: DeltaPressVenturi / Position intake working voltage and if necessary correct
power supply voltage of sensor output 3. throttle flap it,
Pin K20: First footpedal check connection cable and if necessary repair
Pin K21: Air FilterDiffPress or replace it,
Suspected components EDC17cv54 and cv56 if error is not removable, change ECU.
Pin A07: Rail pressure
644 555 523612 3 supply voltage too high not used Threshold for error detection is an internal ECU
threshold.
3121171 3-169
Deutz Blink
Code Code
646 555 523612 4 supply voltage too low not used Threshold for error detection is an internal ECU
threshold.
387 555 523612 12 Internal hardware monitoring: the CPU of Injector shut off demand for the ICO coordinator Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- System responses: threshold.
nally; no item will be created in error mem- not Caution ! Sequence error, check error memory
ory for other errors.
612 555 523612 12 Internal hardware monitoring: the CPU of Plausibility check failed (MoCADC_uNTP_mp is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- higher than MoCADC_uNTPMax_C). threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory.
613 555 523612 12 Internal hardware monitoring: the CPU of Analysis of test voltage (Value is out of the tar- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- get -> ECU internal error) threshold.
nally; no item will be created in error mem- Check wiring, check connected sensors actua-
ory tors.
If error is still present, exchange ECU.
614 555 523612 12 Internal hardware monitoring: the CPU of Analysis of the ratiometric correction (Value is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- out of the target -> ECU internal error) threshold.
nally; Check wiring, check connected sensors actua-
no item will be created in error memory tors.
615 555 523612 12 Internal hardware monitoring: the CPU of Error report due to an error in the plausbility of Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Function Coordination(FC) and threshold.
nally; Monitoring Modul(MM)(ECU internal error) If error is still present, exchange ECU.
no item will be created in error memory
616 555 523612 12 Internal hardware monitoring: the CPU of Error report due to an interrupted SPI communi- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- cation (ECU internal error) threshold.
ory
617 555 523612 12 Internal hardware monitoring: the CPU of multiple error in complete ROM-test during Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- postdrive detected (ECU internal error) threshold.
ory
618 555 523612 12 Internal hardware monitoring: the CPU of Too less bytes received by monitoring memory Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- from CPU as response (ECU internal threshold.
nally; no item will be created in error mem- error). Loss of synchronization sending bytes to If error is still present, exchange ECU.
ory the monitoring memory from CPU
619 555 523612 12 Internal hardware monitoring: the CPU of Suspected components: Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Injector threshold.
nally; no item will be created in error mem- ECU If error is still present, exchange ECU.
ory wiring harness/connector
620 555 523612 12 Internal hardware monitoring: the CPU of Error trying to set MM Response time (ECU Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- internal error) threshold.
ory
621 555 523612 12 Internal hardware monitoring: the CPU of Error detected in the internal ECU communica- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- tion, Too many SPI errors during threshold.
nally; no item will be created in error mem- MoCSOP execution If error is still present, exchange ECU.
ory
3-170 3121171
Deutz Blink
Code Code
623 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- under voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in undervoltage monitoring
624 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- monitoring module (ECU internal error). threshold.
ory
625 555 523612 12 Internal hardware monitoring: the CPU of Time out error trying to set or cancelling the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- alarm task (ECU internal error). Failure threshold.
nally; no item will be created in error mem- setting the alarm task period If error is still present, exchange ECU.
ory
627 555 523612 12 Internal hardware monitoring: the CPU of Error in time monitoring of the shut-off path Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- test (ECU internal error). Diagnostic fault threshold.
nally; no item will be created in error mem- check to report the timeout in the shut If error is still present, exchange ECU.
ory off path test
628 555 523612 12 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- over voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in overvoltage monitoring
629 555 523612 12 The two voltage values (ADC_VAL1, Defect pedal or wiring Threshold for error detection is an internal ECU
ADC_VAL2), detected by threshold.
the accelerator pedal, are not plausible to Check Pedal, repair or exchange the Pedal.
each other. Check wiring.
630 555 523612 12 Impermissible offset between the engine Calculated engine speed in level 1/2 implausi- Threshold for error detection is an internal ECU
speed of level 2 and level 1 ble (-> ECU internal error). threshold.
631 555 523612 12 Diagnostic fault check to report the plausi- Implausible injection energizing time for either Threshold for error detection is an internal ECU
bility error between level 1 energizing time PiIx or MI1 or PoIx. threshold.
and level 2 information If error is still present, exchange ECU.
632 555 523612 12 Error in the plausibility of the start of ener- Implausible start of energising of either PiIx or Threshold for error detection is an internal ECU
gising angles MI1 or PoIx. threshold.
633 555 523612 12 Error in the plausibility of the energising The energising times of the zero fuel quantity Threshold for error detection is an internal ECU
times of the zero fuel quantity calibration calibration ZFC is out of the target. (-> threshold.
ECU internal error) If error is still present, exchange ECU.
634 555 523612 12 Error in the plausibility of PoI2 efficiency. Error in the plausibility of PoI2 efficiency. Threshold for error detection is an internal ECU
threshold.
635 555 523612 12 Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an internal ECU
threshold.
636 555 523612 12 Error in the plausibility of PoI3 efficiency. Error in the plausibility of PoI3 efficiency. Threshold for error detection is an internal ECU
threshold.
3121171 3-171
Deutz Blink
Code Code
637 555 523612 12 Engine speed: the engine speed calculated Error in the plausibility of current energising Threshold for error detection is an internal ECU
by ECU is above the target range; the ECU time with maximum permitted energising threshold.
activates a system reaction time. Diagnostic fault check to report the error If error is still present, exchange ECU.
due to Over
Run
638 555 523612 12 Error in the plausibility of the wave correc- Error in the plausibility of the wave correction Threshold for error detection is an internal ECU
tion parts parts threshold.
639 555 523612 12 Plausibility error of the Rail pressure sensor In case the gradient of rail pressure is larger than Threshold for error detection is an internal ECU
the max threshold or lesser than the threshold.
min threshold. Check metering unit or cable.
Rail metering unit defect. Check Rail pressure. Check the Rail System of
Leakge in the Rail System. leakage.
640 555 523612 12 Error in the torque comparison between per- Error in the torque comparison between the Threshold for error detection is an internal ECU
missible engine torque and current actual permissible inner engine torque and the threshold.
torque current plausible actual torque. If error is still present, exchange ECU.
641 555 523612 12 Diagnosis of curr path limitation forced by The torque comparison is not plausible with the Threshold for error detection is an internal ECU
ECU monitoring level 2 torque monitoring. threshold.
642 555 523612 12 Diagnosis of lead path limitation forced by The setpoint path of the air system is limited by Threshold for error detection is an internal ECU
ECU monitoring level 2 the limitation torque of the functional threshold.
control unit monitoring. If error is still present, exchange ECU.
643 555 523612 12 Diagnosis of set path limitation forced by If the quantity setpoint is exceeds the limit of Threshold for error detection is an internal ECU
ECU monitoring level 2. the torque function. threshold.
714 555 523612 12 Error report "WDA wire is active" due to a Error detection by monitoring module Threshold for error detection is an internal ECU
defect query/response communication threshold.
Software reset.
715 555 523612 12 Error report "ABE wire is active" due to The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
undervoltage detection electrical system voltage (defective threshold.
autobattery) Software reset.
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage
recognition.
716 555 523612 12 Error report "ABE wire is active" due to over- If the ABE/WDA powerstage shut-off is active Threshold for error detection is an internal ECU
voltage detection due to an overvoltage detection. threshold.
software reset.
717 555 523612 12 Error report "ABE/WDA active" due to an The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
unknown reason electrical system voltage (defective threshold.
autobattery) Software reset.
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage
recognition.
1170 555 523612 12 Internal hardware monitoring: the CPU of Error during positive test (ECU internal error). Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Diagnostic fault check to report that the threshold.
nally; no item will be created in error mem- positive test failed Reflash ECU. If error is still activ replace ECU.
ory
3-172 3121171
Deutz Blink
Code Code
1857 555 523612 12 Fault in the monitoring during the engine wiring is not according DEUTZ requirements Threshold for error detection is an internal ECU
start. Start requested in level 1, but not engine start conditions are not observed threshold.
released in level 2 which leads to no fuel low battery voltage during start check other active errors and fix them.
injection. malfunction of starter check all needed engine start conditions, e.g.
neutral switch.
check the engine speed during starting of the
engine. If it's too low, then check the
battery voltage and then check the starter for
malfunction.
973 555 523612 14 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- threshold.
nally;
no item will be created in error memory.
974 555 523612 14 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
nally;
no item will be created in error memory.
975 555 523612 14 Internal hardware monitoring: the CPU of Visibility of SoftwareResets in DSM Threshold for error detection is an internal ECU
nally; If possible the software update has to be done.
no item will be created in error memory Replace the ECU.
856 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Pressure governor deviation exceeds the limit- Threshold for error detection is an internal ECU
lated by ECU is below the target range which ing value based on the engine speed. threshold.
is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
857 134 523613 0 Rail pressure: the fuel pressure in rail calcu- maximum positive deviation of rail pressure Threshold for error detection is an internal ECU
lated by ECU is below the target range which exceeded concerning set flow of fuel. threshold.
is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
858 134 523613 0 Rail pressure: the fuel pressure in rail calcu- leakage is detected based on fuel quantity bal- Threshold for error detection is an internal ECU
lated by ECU is above the target range which ance. threshold.
is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
859 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Maximum negative rail pressure deviation with Threshold for error detection is an internal ECU
lated by ECU is above the target range which metering unit on lower limit is exceeded. threshold.
is dependant on the engine speed. (A) Check backflow pressure
tor) if necessary
862 134 523613 0 Rail pressure: the fuel pressure in rail calcu- Rail pressure exceeds the limiting value. (A) Check backflow pressure
lated by ECU is above the target range. (B) Check pressure relief valve and metering
unit.
3121171 3-173
Deutz Blink
Code Code
861 134 523613 1 Rail pressure: the fuel pressure in rail calcu- Rail pressure falls below the limiting value Threshold for error detection is an internal ECU
lated by ECU is below the target range based on the engine speed. threshold.
which is dependant on the engine speed. (A) Check backflow pressure
tor) if necessary
864 134 523613 2 Rail pressure metering unit, Setpoint of Pressure pump delivery quantity in overrun Threshold for detection is an internal ECU
metering unit in overrun mode not plausi- exceeds the threshold based on the threshold.
ble. pressure. (A) Check backflow pressure
(B) Check pressure relief valve and metering
unit.
594 135 523615 3 Fuel metering unit: the current drain mea- short circuit to battery high side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
596 135 523615 3 Fuel metering unit: the current drain mea- short circuit to battery low side Threshold for error detection is an internal ECU
595 135 523615 4 Fuel metering unit: the current drain mea- short circuit to ground high side Threshold for error detection is an internal ECU
597 135 523615 4 Fuel metering unit: the current drain mea- short circuit to ground low side Threshold for error detection is an internal ECU
592 135 523615 5 Detecting an open load fault in the metering wiring harness defective, cable break Threshold for error detection is an internal ECU
unit threshold.
593 135 523615 12 powerstage of metering unit is overheated over temperature Threshold for error detection is an internal ECU
threshold.
Check functionality of metering unit and
replace it if needed.
Check temperature of metering unit and
improve the installation in case of overheating.
1127 665 523632 3 Urea supply module pressure sensor: the Shortcut to battery Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
1128 665 523632 4 Urea supply module pressure sensor: the Shortcut to ground Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
The sensed raw voltage value
SCR_uRawUPmpP is above
SCR_SRCUPmpP.uMin_C
1117 666 523632 11 Urea supply module pump: the current drain When the pump motor does not switch to pump Threshold for error is an internal ECU threshold
measured by ECU is above the target range actuation mode after temperature
measurement has
been carried out.
3-174 3121171
Deutz Blink
Code Code
122 591 523698 11 Shut off request from supervisory monitor- Engine Shut Off due to supervisory function Threshold for error detection is an internal ECU
ing function threshold.
Check error memory for additional errorcode to
find root cause.
Depending on additional error follow the docu-
mented "Take action for repair".
1100 676 523718 3 Urea heater relay: the current drain mea- Shortcut to battery Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase it threshold
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
1101 676 523718 4 Urea heater relay: the current drain mea- Shortcut to ground Threshold for error detection is an internal ECU
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
1098 676 523718 5 Urea heater relay: the current drain mea- Open load Threshold for error detection is an internal ECU
is a result error: KWP 1089 Test SCR main relay
Broken wiring Check cabling, if necessary replace relay.
broken relay
1109 672 523719 4 Urea supply module heater: the current Shortcut to ground Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply mod-
Heating element in supply module defect ule
1106 672 523719 5 Urea supply module heater: the current Open load Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase is threshold
range a result error: KWP 1089 Check wiring
925 148 523720 8 Supply module heater: Duration of switch on uty cycle for temperature readout from supply When the received supply module heater tem-
is too long. module heater to the control unit is out perature duty cycle SCR_rSMT is out of
of range; Supply modul defect, fault in the wir- the failurerange (SCR_rSMFailMax_C <
ing. SCR_rSMHtrT < SCR_rSMFailMin_C)
Supply module check and replace if necessary.
Check the wiring.
926 148 523720 8 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply When the received supply module heater duty
over error threshold. module heater to the control unit is not cycle SCR_rSMHtrT is in the valid range
valid. (SCR_r-
Check the wiring.
930 689 523721 8 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply Supply module check and replace if necessary.
over error threshold. module to the control unit is out of Check the wiring.
range.
Supply modul defect, fault in the wiring.
3121171 3-175
Deutz Blink
Code Code
931 689 523721 8 Supply module heater: Dutycycle timing out Duty cycle for temperature readout from supply When the received supply module duty cycle
of valid range. module to the control unit is not valid. SCR_rSMT is in the valid range
Supply modul defect, fault in the wiring. (SCR_rSMTVld-Min_C <= SCR_rSMT <=
SCR_rSMTVldMax_C), OR in the failure
range (SCR_rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C)
Check wiring.
927 689 523721 11 Supply module heater: temperature mea- Duty cycle for temperature readout from supply Threshold for detection is an internal ECU
surement not available. module heater to the control unit is not threshold.
available. No erasing in the current driving cycle.
Check the wiring.
929 691 523722 8 Supply module heater: Faulty PWM signal PWM Signal for temperature readout from sup- Threshold for error detection is an internal ECU
from supply module. ply module to the control unit is not valid. threshold.
Supply modul defect, fault in the wiring. When valid Sync followed by temperature
information signal is received AND valid sync
and temperaturesignal for both information is
received one after the other.
Check the wiring.
291 119 523776 9 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Threshold for error detection is an internal ECU
- active threshold.
Check CAN Bus cabling (Bus sheduling, polarity,
short circuit, power interrupt), test
range.
292 119 523777 9 Message TSC1-TE has been missing (passive) Passive timeout Error (Missing CAN Bus mes- Check CAN Bus cabling (Bus scheduling, polar-
sage) ity, short circuit, power interrupt), test
range, check actuator
559 1-5-8 523895 13 Missing or wrong injector adjustment value Missing or wrong injector adjustment value for Threshold for error detection is an internal ECU
programming (IMA) injector 1 (in firing cyl. 1. threshold.
order). Check correct injector adjustment value (IMA).
Use SERDIA UseCase to check it.
programming (IMA) injector 2 (in firing cyl. 2 threshold.
order). check dataset and flash correct injector adjuste-
ment value (IMA). Use SERDIA
UseCase to check it.
561 1-5-8 523897 13 Missing or wrong injector adjustment value Missing or wrong parametrisation of injector Threshold for error detection is an internal ECU
programming (IMA) injector 3 (in firing adjustment cyl. 3. threshold.
3-176 3121171
Deutz Blink
Code Code
73 7-2-2 523912 4 @ engines < 4l: The sensed raw voltage value is below the mini- The sensed raw voltage value
Throttle valve error, Open Load or Short cut mum threshold. DPM_uRawBrnDVDsP is above the minimum
to Battery, blocked valve or wrong control threshold
signal for valve. DPM_SRCBrnDVDsP.uMin_C
@ engines with Burner T4i: @ CRT < 4l: check throttle valve
Pressure Sensor error after valve (DV2), @ engines with Burner T4i: check back-pressure
lower limit reached valve
42 167 523924 4 Overload at Pins O_V_RH2x: A01, K74, K91. Suspected components: Threshold for error detection is an internal ECU
Components on A01, K74, K91 cannot be 1- Pin K91: threshold.
activated. Clutch switch, Brake switch, Engine brake Check wiring harness and connected loads on
Internal ECU power stage switched off. demand, Regeneration activation, Parking pins A01, K74, K91 and/or reflash ECU.
brake, Gearbox N, Fan control 1 If error is still present, exchange ECU.
2- Pin K74:
Boost air cooler bypass or electrical fuel pump
relay, Fan control 2/fuel valve for flame
star
38 731 523925 3 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A88, K57 cannot be 1- Lamps K57: Warn Ash Charge, Diagnostic, pins A88, K57.
activated. Warn Coolant Temp/Level, Warn Oil,
Internal ECU power stage switched off. Warn Boost Air, Warn Air Filter, Warn Water in
Fuel, SCR, Regeneration, Engine
Running.
2- Relay Preheat A88
3- Exhaust Flap A88
43 731 523925 4 Short circuit to ground actuator relais 3 Suspected components: Threshold for error detection is an internal ECU
Overload at Pins O_V_RH3x: A88, K57 1- Pin A88: threshold.
Preheat relay, Exhaust flap Check wiring harness and connected loads on
2- Pin K 57: pinsA88, K57.
- control lamps: If error is still present, exchange ECU.
- OBD, preheat lamp, warning temp., warning
oil, maintenance lamp, regeneration
indicator, alternator management, engine run-
ning, diagnostic
44 732 523926 4 Short circuit to ground aktuator relais 4. Suspected components:Fan, Wiring harness Threshold for error detection is an internal ECU
Overload at Pins O_V_PCV: A90 threshold.
Check wiring harness and connected loads on
pin A90.
40 733 523927 3 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A04, A05 cannot be 1- Urea Pump A04 pins A04, A05.
activated. 2- SCR Heater A05
Internal ECU power stage switched off.
168 763 523935 12 Timeout Error of CAN-Transmit-Frame Fault is detected if a TimeOut of the EEC3VOL1 Check wiring harness and customer nodes
EEC3VOL1; Engine send messages frame has occured.
169 764 523936 12 Timeout Error of CAN-Transmit-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
EEC3VOL2; Engine send messages
3121171 3-177
Deutz Blink
Code Code
133 766 523938 9 Timeout Error (BAM to packet) for CAN- Failure of the CAN Bus message NOX sensor and sensor connection check
Receive-Frame AT1IGCVol1 information;
factors & Sensorcalibration for NOX Sensor
(SCR-system upstream cat; DPF-system
downstream cat)
134 766 523939 9 Broadcast Announce Message of the calibra- Defective Nox sensor, faulty parameterization NOX sensor and sensor connection check
tion message
of the upstream catalytic NOx sensor has
failed.
Timeout Error (BAM to BAM) for CAN-
Receive-Frame AT1IGCVol1 information.
(SCR-system upstream cat, DPF-system
downstream cat).
135 766 523940 9 Timeout Error (PCK2PCK) for CAN-Receive- Failure of the CAN Bus message NOX sensor and sensor connection check
Frame AT1IGCVol1 information; factors &
Sensorcalibration for NOX Sensor (SCR-sys-
tem upstream cat; DPF-system
downstream cat)
140 767 523941 9 Timeout Error (BAM to packet) for CAN- Timeout Error (Missing CAN Bus message) NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information; check
(SCR-system downstream cat; DPF-system
downstream cat)
141 767 523942 9 Timeout Error (BAM to BAM) for CAN- Defective Nox sensor, faulty parameterization. NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information, check.
Calibration message 1 of the after catalyst
NOx sensor has failed.
Factors & Sensorcalibration for NOX Sensor
(SCR-system downstream cat, DPF-system
downstream cat)
142 767 523943 9 Timeout Error (PCK2PCK) for CAN-Receive- The fault is detected when a timeout error in NOX downstream sensor and sensor connection
Frame AT1OGCVol2 information; factors & packet 2 of NOxSenVol2Rx frame occurs. check
Sensorcalibration for NOX Sensor (SCR-sys-
tem downstream cat; DPF-system
downstream cat)
1011 771 523960 0 Physical range check high for EGR cooler Sensed temperature downstream EGR-cooler EGR-Valve blocked open
downstream temperature. > limit. EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
1012 771 523960 1 Physical range check low for EGR cooler sensor voltage > lower limit EGR-Valve blocked open
downstream temperature. EGR-Valve actuator defect
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
3-178 3121171
Deutz Blink
Code Code
360 737 523982 0 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not high. to too high battery voltage. repair or replace if necessary.
361 737 523982 1 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not low. to too low battery voltage. repair or replace if necessary.
1239 788 523984 3 Actuator relay 5: the voltage measured by Short-Circuit to battery to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
1241 176 523986 4 Actuator relay 4: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
1242 791 523987 4 Actuator relay 5: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
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
1505 8-4-3 524057 2 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Threshold for error detection is an internal ECU
culated by ECU is underneath the target threshold.
range; the ECU activates a system reaction Check low fuel pressure system (fuel feed
pump, relay , fuse, wiring, sensor) and if
1558 869 524063 3 SCR heater mainrelay; short circuit to battery Short-Circuit to battery on wiring to component Check wiring, component
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
1559 869 524063 4 Connection between heating valve (Y31) on Faulty wiring, faulty heater relay (K27-K31), Disconnect plug from heating valve (Y31) and
the control unit Pin A:92 and defective heating valve (Y31), reset fault.
Load side SCR heater main relay (K31) is a broken element in heating. If fault is still present you have to look in the wir-
short cut to ground. ing of Y31 to the control unit Pin A:92.
Threshold 1 < If error is no longer present, you have to check
SCRHtr_rUHtrMeasRatio_mp < Threshold the wiring of Y31 via relay K31
2 and possibly the heating cables and relay (K27-
K30).
1555 869 524063 5 Urea backflow line heater: broken wiring Open Load on wiring to component Check wiring, component
detected
Threshold 1 <
2
1556 869 524063 5 Urea main relay: broken wiring detected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
1557 869 524063 5 Urea pressure line heater: broken wiring Open load on wiring to component Check wiring, component
detected
Threshold 1 <
2
1560 869 524063 5 SCR relay for suction line not connected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
3121171 3-179
Deutz Blink
Code Code
1561 869 524063 5 Open load on wiring to component Open load on wiring to component Check wiring, component
Threshold 1 <
2
1562 869 524063 5 SCR heater tank; open load Open load on wiring to component Check wiring, component
1646 869 524063 12 SCR supply module temperature is not Suspected components: Check
reaching a threshold before a calibratable Enviroment temperature sensor defect Environment temperature sensor
time is exceeded. SCR supply module temperature sensor defect SCR supply module temperature sensor
Corresponding to the environmental Tem- SCR supply module electrical heater defect SCR supply module electrical heater
perature a specific defrosting time is given.
After starting the defrosting a clock counter
is starting. Does the counter reach the given
defrosting time limit, an error will be
detected. Is the temperature reached in time
the clock counter will be reset
Example: by using the calibrated tempera-
ture/time curve --> environmental temper-
ature 0°C --> defrosting time limit 6000s --
> if the clock counter reaches 6000s the error
will
be detected
1565 892 524065 0 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check for crystallisation in exhaust line
from the urea cat upstream cal high range limit f(exhaust volume upstream SCR and dwnstream of urea injector
sensor is greater than an applicable maxi- flow) Check correct connection from exhaust line to
mum pressure threshold UCatUsP_pRelFlt_mp > UCatUsP_pMax_mp pressure sensor upstream SCR catalyst:
syphons?, water in tube?, water in sensor?
Check that exhaust pipe outlet is free (down-
stream SCR catalyst)
Check wiring of pressure sensor upstream SCR
catalyst
Check pressure sensor upstream SCR catalyst:
sensor has no connection to vehicle body? =>
Ensure that sensor is free
Does sensor oscillate heavely at engine low idle
/ high idle? => try to supress the
oscillating
Exchange pressure sensor upstream SCR cata-
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
3-180 3121171
Deutz Blink
Code Code
1566 892 524065 1 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check correct connection from exhaust line to
from the urea cat upstream sensor is less cal high range limit f(exhaust volume pressure sensor upstream SCR catalyst:
than an applicable minimum pressure flow) leakage?
threshold UCatUsP_pRelFlt_mp < UCatUsP_pMin_mp Check electric connector: 4h pin open / new
connector type used? pressure exchange
from inside electrical connector with the envi-
ronemt possible
Check exhaust line: any leakages upstream of
SCR catalyst?
catalyst
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
1598 892 524065 2 Comparison of urea cat upstream exhaust absolut value of difference between sensed Check electric connector: 4h pin open / new
gas- and environment pressure, the differ- pressure upstream SCR catalyst and connector type used?
ence should not exceed a certain limit environmental pressure > limit pressure exchange from inside electrical con-
abs(UCatUsP_pDiffEnvCat_mp) > Thresh- abs(UCatUsP_pDiffEnvCat_mp) > Threshold nector with the environemt possible?
old water in sensor?
sensor frozen?
catalyst
lyst
Check intake manifold pressure sensor
(Air_pCACDs)
Check ambient pressure sensor (EnvP_p)
1569 892 524065 3 voltage of pressure sensor upstream SCR > voltage of pressure sensor upstream SCR > volt- Check wiring of pressure sensor upstream SCR
voltage high limit age high limit catalyst
Check pressure sensor upstream SCR catalyst
lyst
1570 892 524065 4 voltage of pressure sensor upstream SCR < voltage of pressure sensor upstream SCR < volt- Check wiring of pressure sensor upstream SCR
voltage low limit age low limit catalyst. Check pressure sensor
upstream SCR catalyst. Exchange pressure sen-
sor upstream SCR catalyst
3121171 3-181
Deutz Blink
Code Code
1581 894 524067 0 Filtered urea supply module heater temper- sensed temperature of supply module heater > Compare SCR_tSMT with SCR_tSMHtrT. Both
ature value is above an applicable maximum physical high range limit show the same value?
heater temperature threshold of the supply Check urea tank temperature
module (SCR_tAdapUTnkT). Very hot (> 70°C), urea
The temperature is read out via the PWM sig- tank heater
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module heater temperature sensor
defect
Supply module heater defect
Supply module defect
1585 894 524067 0 Filtered urea supply module temperature sensed temperature of urea within supply mod- Compare SCR_tSMT with SCR_tSMHtrT. Both
value (SCR_tSMT) is above an applicable ule > physical high range limit show the same value?
maximum temperature threshold of the Check urea tank temperature
supply module (SCR_tAdapUTnkT). Very hot (> 70°C), ure tank
The temperature is read out via the PWM sig- heater
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module temperature sensor defect
Supply module heater defect
Supply module defect
1582 894 524067 1 Filtered urea supply module heater temper- sensed temperature of supply module heater < Check ambient temperature EnvT_t < Thresh-
ature value is below an applicable minimum threshold old?
heater temperature threshold of the supply Compare SCR_tSMT with SCR_tSMHtrT
module Check wiring with regard to supply modul
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module heater temperature sensor
tion was switched on. When that state is defect
left the sensed temperature value is frozen. Supply module defect
1586 894 524067 1 Filtered urea supply module temperature sensed temperature of urea within supply mod- Check ambient temperature EnvT_t < thresh-
(SCR_tSMT) value is below an applicable ule < physical low range limit old?
minimum temperature threshold of the sup- Compare SCR_tSMT with SCR_tSMHtrT
ply module Check wiring with regard to supply modul
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module temperature sensor defect
tion was switched on. When that state is Supply module defect
left the sensed temperature value is frozen.
3-182 3121171
Deutz Blink
Code Code
1867 894 524067 2 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module heater temperature and supply module heater temperature and and CEngTds_t and
ambient temperature ambient temperature SCR_tAdapUTnkT => All identical? If not:
UPmpT_tDiffPmpHtrAmb_mp > threshold UPmpT_tDiffPmpHtrAmb_mp > threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Problem at Supply module unit (broken?) =>
1868 894 524067 2 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module temperature and ambient supply module temperature and ambient and CEngTds_t and
temperature > threshold temperature UPmpT_tDiffPmpAmb_mp > SCR_tAdapUTnkT => All identical? If not:
threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Problem at Supply module unit (broken?) =>
1533 246 524074 9 Open load sensor internally at NOx-sensor Open load sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
dismounting. => If water inside, replace sen-
sor.
Check mounting position of sensor and judge it
regarding condense water formation /
agglomeration.
Check wiring harness
Exchange sensor
1534 247 524075 11 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
sor.
agglomeration? Rearrange if critical and possi-
ble
Exchange sensor
3121171 3-183
Deutz Blink
Code Code
1535 248 524076 9 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
sor.
agglomeration.
Exchange sensor
1536 249 524077 11 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
sor.
agglomeration.
Exchange sensor
1537 255 524078 9 Lambda value of NOx-Sensor downstream sensed lambda value of Nox-sensor down- Check whether NOx-sensor downstream SCR
SCR is out of range. stream SCR catalyst is > physical high limit catalyst is physically mounted within the
When the filtered Lambda concentration ComRxSCR_rCanLamDs_mp > threshold exhaust line
value at the sensor Check Lambda values of NOx-sensor down-
(ComRxSCR_rFltLamDs_mp) is greater than stream SCR catalystat at idle conditions,
the physical range check max. lambda ComRxSCR_rCanLamDs_mp > threshold?
threshold Compare to ComRxSCR_rCanLamUs_mp. Val-
ues must be almost identical
Check CANBus of NOx-sensor downstream SCR
catalyst
Check NOx-sensor downstream SCR catalyst
wiring
itself
Replace NOx-sensor downstream SCR catalyst
3-184 3121171
Deutz Blink
Code Code
1538 256 524079 9 sensed lambda value of NOx-sensor down- sensed lambda value of NOx-sensor down- Compare to ComRxSCR_rCanLamUs_mp.
stream SCR catalyst is < physical low limit stream SCR catalyst is < physical low limit ComRxSCR_rCanLamDs_mp must be
ComRxSCR_rCanLamDs_mp < threshold ComRxSCR_rCanLamDs_mp < threshold almost identical!
If almost identical,
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check injection system of engine. Injector
stuck?
if sensed lambda upstream SCR higher
(ComRxSCR_rCanLamUs_mp) : Diesel in
Urea-tank?
Check CANBus of NOx-sensor downstream SCR
catalyst
wiring
itself
1539 257 524080 9 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check whether NOx-sensor upstream SCR cata-
upstream SCR catalyst is > physical high SCR catalyst is > physical high limit lyst is physically mounted within the
limit ComRxSCR_rCanLamUs_mp > Threshold exhaust line
ComRxSCR_rCanLamUs_mp > Threshold Check Lambda values of NOx-sensor upstream
SCR catalystat at idle conditions,
ComRxSCR_rCanLamUs_mp < Threshold?
Compare to ComRxSCR_rCanLamDs_mp. Must
be almost identical
Check CANBus of NOx-sensor upstream SCR cat-
alyst
Check NOx-sensor upstream SCR catalyst wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
1540 258 524081 9 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check air path of engine: EGR-Valve, Intake-
upstream SCR catalyst is < physical low limit SCR catalyst is < physical low limit Throttle, Turbocharger and Piping each
ComRxSCR_rCanLamUs_mp < Threshold ComRxSCR_rCanLamUs_mp < Threshold for leakage and correct function
Check injection system of engine. Injector
stuck?
Check CANBus of NOx-sensor upstream SCR cat-
alyst
1542 261 524083 9 sensed NOx-value of NOx-sensor down- sensed Nox-value of Nox-sensor downstream Check CANBus of NOx-sensor downstream SCR
stream SCR catalyst < Threshold SCR catalyst < physical low limit catalyst
wiring
itself
3121171 3-185
Deutz Blink
Code Code
1544 912 524085 9 sensed Nox-value of Nox-sensor upstream sensed Nox-value of Nox-sensor upstream SCR Check CANBus of NOx-sensor upstream SCR cat-
SCR catalyst < Threshold catalyst < physical low limit alyst
1666 924 524100 9 Timeout error of CAN-Transmit-Frame Com- Open load on CANBUS wiring. Check wiring, component.
DPFHisDat.
1676 928 524104 9 Timeout error of CAN-Receive-Frame Com- Time out of Check CANBUS EAT Control Receive Threshold for error detection is an internal ECU
RxDPFCtl. CM1 Module Customer Recieve Message, PGN65348. threshold.
Message. The message is not received. Check CANBUS EAT Control Receive Message,
PGN65348.
CM1 Module Customer Recieve Message.
1672 9-4-2 524118 9 Timeout error of CAN-Receive-Frame If the frame CM1 message is not transmitted Check CAN Bus cabling (Bus sheduling, polarity,
ComRxCM1 successfully short circuit, power interrupt), test
range.
1683 9-4-5 524121 9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
RxTrbChActr short circuit, power interrupt), test
range.
1687 9-4-9 524125 9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
TxTrbChActr short circuit, power interrupt), test
range.
1827 192 524141 7 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
1858 192 524141 7 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
3-186 3121171
Deutz Blink
Code Code
1639 966 524147 13 No proper urea pressure level could be build This error shows up, if no proper urea pressure Make sure that frozen lines, pump or tank can be
up within the SCR system state "Fill Lines" level could be build up within the SCR excluded!
=> SCRCo_stStatus_mp = 1 within some system state "Fill Lines" => Check whether there is urea in the urea tank
miuntes SCRCo_stStatus_mp = 1 within some minutes Check urea lines:
Once the urea pump pressure has exceeded the All lines connected? The right lines connected to
threshold the error is declared as the correct places?
okay. Suction line blocked?
Suspected components: No leakage? Not also urea to the outside but also
Suction line blocked air into the lines, especially in the
PWM Powerstage has a defect and a default suction line!
value which leads not to a rising pressure Perform service routine "pressure test":
Pump Pressure sensor defect Does the urea pump work? => check wiring
pump filter contains dirty parts harness & PWM signal for pump
reverting valve continously open Does the urea pressure rise?
DFC already healed?
If all unsuccessful so far:
Check urea pressure sensor: At ignition on and
SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
Check reverting valve => see
DFC_SCRCoRevVlvBlk
Check pump filter: dirt inside?
Suspected components:
Urea pump broken
Reverting valve continously open
Urea suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
Pump Pressure sensor broken
1874 971 524152 2 CAN message is not received fora definite CAN message is not received for a definite time Check eletrical connection oif urea quality sen-
time => error is set. As soon as the message => error is set. As soon as the sor
is received the error heals. message is received the error heals. Check engine CAN bus
Check urea quality sensor itself
Exchange urea quality sensor
1875 997 524153 2 CAN message is not reseived for a definite CAN message is not reseived for a definite time Check eletrical connection of suction unit sen-
time => error is set. As soon as the message => error is set. As soon as the sor (combined sensor with tank level and
is received the error heals. message is received the error heals. tank temperature)
Check engine CAN bus
Check level sensor itself
Exchange suction unit
1705 972 524156 9 Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
ComRxEBC2 from wheel speed sensor. Defect on wheel speed sensor. short circuit, power interrupt), test
range.
Replace the wheel speed sensor.
3121171 3-187
Deutz Blink
Code Code
1863 995 524177 7 The error shows up, if no proper urea presure This error shows up, if no proper urea presure Make sure that DEF lines, pump and tank are not
could be build up within the SCR system could be build up within the SCR system frozen.
state "Fill Lines" => SCRCo_stStatus_mp = state "Fill Lines" => SCRCo_stStatus_mp = 1. Check for DEF level in the tank.
1. 3 cases can lead to the error: Check DEF lines:
Case A: increasing pressure is detected within Are all DEF lines connected?
15s the check has passed => no error Is the suction line blocked?
Case B: The pressure threshold was not reached Is ther any leakage? Not only urea to the outside
within the 60s but case A was not but also air into the lines, especially in
positiv. the suction line!
Case C: The minimum pressure of 3000 hPa was Perform SERDIA usecase "pressure test":
not reached within the 60s. Does the DEF pump work? => check wiring har-
ness & PWM signal for pump.
Does the urea pressure increase?
All errors are already healed?
If still unsuccessful so far:
Check urea pressure sensor: At ignition on and
Check DEF pump filter: Is any dirt inside?
Suction line
PWM Powerstage has a defect and a default
value which leads not to a rising pressure
DEF pump pressure sensor defect
DEF pump filter contains dirty parts
3-188 3121171
Deutz Blink
Code Code
1864 996 524178 7 The urea pump is not able to control the urea The urea pump controller is not able to control Make sure that DEF lines, pump and tank are not
pressure between 9bar and 11 bar. the urea pressure between 9bar and 11 frozen.
bar due to malfunction in the SCR system. Check for DEF level in the tank
Suspected components: Check DEF lines:
- DEF pump broken All lines connected? The right lines connected to
- Reverting valve continously open the correct places?
- Urea suction line, backflow line broken or con- Suction line blocked?
nection swapped Is there any leakage? Not also urea to the out-
- PWM Powerstage has a defect side but also air into the lines, especially
- Pump Pressure sensor broken in the suction line!
Perform SERDIA usecase "pressure test":
Does the DEF pump work properly? => check
wiring harness & PWM signal for pump
Does the DEF pressure rise?
Is the error healed?
If still unsuccessful so far:
- Check DEF pressure sensor: At ignition on and
- Check reverting valve
- Check DEF pump filter: dirt inside?
DEF pump broken
Reverting valve continously open
DEF suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
DEF pump pressure sensor broken
1891 272 524190 14 Not enough urea in tank or low urea quality Low DEF tank level Check DEF level in tank. If there is no DEF, refill
or hardware tampering failure is detected or Low DEF quality up to volume above the warning
hardware failure is detected Hardware Tampering is active threshold.
Hardware Failure is active Check the DEF quality in the tank. If wrong fluid
is filled, refill with proper DEF.
Check other errors based on hardware malfunc-
tions.
1892 273 524191 14 A low DEF tank level or a low DEF quality is Low DEF tank level Threshold for error detection is an internal ECU
detected or hardware tampering(system Low DEF quality threshold.
components are pinched off) or hardware Hardware Tampering is active Check the DEF level in tank. If there is no DEF,
failures as shortcut to battery, shortcut to Hardware Failure is active refill up above the warning level.
ground Check DEF quality filled in the tank.
etc. are detected. Check other errors based on hardware tamper-
ing or failure.
3121171 3-189
Deutz Blink
Code Code
1893 275 524193 8 The total time in standstill-regeneration Stand-still mode is very often aborted by the Read out stand-still statistics => see service
mode exceeds the long-limit threshold operator. manual:
within last 500h total engine run time. Stand-still mode does not reach required tem- Stand-still operation finished or often inter-
The error is activated if the engine runs to perature level and regeneration level is rupted by driver / engine shut-off? => Run
many times in Standstill regeneartion. therefore reached after a short time again stand-still and instruct operator
Stand-still operation required often by soot
load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPf allow it:
Perform Stand-still and check reached temper-
ature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min
stand-still main phase 590°C are reached?
Temerature traces are steady and even?
Temperature downstream DOC higher than
upstream DOC but difference does not
exceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C downstream
DOC are not reached) => exchange DOC
Very big difference (>100 K after 25 min stand-
still main phase, 590 °C downstream
DOC exceeded) => check injection system of
engine & engine air path
3-190 3121171
Deutz Blink
Code Code
1894 276 524194 8 The total time in standstill-regeneration Stand-still mode is aborted / interrupted too Read out stand-still statistics => see service
mode exceeds the long-limit threshold: 2,5h often by the operator manual:
stand-still operation within 50h total motor Stand-still is required too often due to miscalcu- Stand-still operation finished or often inter-
run time. lation in the soot model rupted by driver / engine shut-off? => Run
The error is activated if the engine runs to Stand-still mode does not reache temperature stand-still and instruct operator
much time in short Standstill regeneartion. level and regeneration level is therefore Stand-still operation required often by soot
reached after a short time again. load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPF allows it:
Perform Stand-still and check reached temper-
ature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min
stand-still main phase 590°C are reached?
Temerature traces are steady and even?
Temperature downstream DOC higher than
upstream DOC but difference does not
exceed 100 K?
Very small difference (< 10 K after 25 min
stand-still main phase, 590 °C downstream
DOC are not reached) => exchange DOC
Very big difference (>100 K after 25 min stand-
still main phase, 590 °C downstream
DOC exceeded) => check injection system of
engine & engine air path
3121171 3-191
Deutz Blink
Code Code
1900 279 524195 14 The standstill request of detected crystalli- Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line and
zation is ignored for more than reached a level which indicates inspect visually the injector and the
5h(>300min) crystallisation inside of exhaust line. exhaust line for urea crystallisation upstream of
This will be activated if there is a standstill The error detection depends on the sensed pres- SCR catalyst:
request activated by Crystalisation Monitor- sure upstream of the SCR catalyst and If crystallisation can be clearly seen, then stand-
ing. the calculated exhaust volume flow through still must be processed.
the mixer pipe. Has the engine been operated in low load for
In case of error is set, but no crystallisation can longer time? If yes, then it could be the
be found in the mixing pipe, a possible reaoson for crystallisation.
reason can be the defect sensors: Does the NOx-Sensors work properly? Compare
- exhaust pressure & temperature upstream of ComRxSCR_rNOxUs to
the SCR catalyst, ComRxSCR_rNOxDs, when
- the ambient pressure ComRxSCR_stNOxRdyUs = 1 &
- the exhaust mass flow => Check air path sys- ComRxSCR_stNOxRdyDs = 1 (Warm engine
tem at the engine. and EAT-system,
SCRT_tCatAvrgExhGs_mp > 250°C,
SCR_stStatus = "Dosing" = 8): sensed NOx
upstream of SCR catalyst must be higher than
downstream of SCR catalyst.
Go to idle and wait until SCR system enters sta-
tus "stand-by" (no dosing),
SCRT_tCatAvrgExhGs_mp < 225°C:
ComRxSCR_rNOxUs = ComRxSCR_rNOxDs
Clean urea injector: rinse it thourougly under
water
Check EGR-Path: difference pressure sensor at
venturi tube, EGR cooler, EGR-Valve,
Reed-Valve, Intake throttle regarding function
and leakage. Does the EGR-cooler leak
water in the exhaust?
Check air path for leakage
Check turbocharger
No crystallisation can be seen in the mixing
pipe:
Check exhaust pressure sensor upstream of SCR
catalyst (SCR_pSensUCatUsP):
tube, water in sensor?
Check environmental pressure sensor
(EnvP_p): plausible?
Check exhaust temperature sensor upstream of
SCR-catalyst (SCR_tSensUCatUsT):
plausible compared to Exh_tOxiCatUs &
Exh_tOxiCatDs e.g. when engine has idled for
20 minutes?
=> Run stand-still to remove crystallisation
and to reset the DFC
1108 672 5232719 3 Urea supply module heater: the current Short circuit to battery Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error:KWP 1089 Check wiring
3-192 3121171
3.32 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE This section is organized in the following manner:
CODE DEFINITIONS 1st page of Diagnostic Information for a Given Fault (See Fig-
ure 3-93.) then:
This section defines the diagnostics and recommended trou-
bleshooting procedures associated with the engine control 2nd Page of Diagnostic Information for a Given Fault (See Fig-
module (ECM) on the CAT 3.4 engine. ure 3-94.)
DTC XXXX- Diagnostic Condition
Block Diagram of Circuit
External Hardware Input/Output- This identifies the hardware that either sends an input
to the ECM or is driven by and ECM output.
Check Condition- This defines what condition to troubleshoot the fault condition.
Fault Condition(s)- This identifies the condition(s) that set the fault.
Corrective Action(s)- This identifies the RECOMMENED corrective action(s) that the
ECM is generally programmed to perform. In some instances, the calibration
engineer(s) may choose to perform a different action.
Emissions or Non-emissions related fault
Text to identify the circuit of interest and its use for control.
Text to describe t he conditions that cause the fault to set.
Figure 3-93. 1st page of Diagnostic Information for a Given Fault
3121171 3-193
DTC XXXX- Diagnostic Condition
Note: Helpful tips used to aid troubleshooting
Yes
Troubleshooting flow
chart
No
Figure 3-94. 2nd Page of Diagnostic Information for a Given Fault
3-194 3121171
List of Abbreviations in this Section ABBREVIATION MEANING
ABBREVIATION MEANING PWM Pulse Width Modulated
AL Adaptive Learn RAM Random Access Memory
BP Barometric Pressure RPM Revolutions Per Minute
CAN Controller Area Network Rx Receive
CCP CAN Calibration Protocol SAE Society of Automotive Engineering
CHT Cylinder Head Temperature SA Source Address
CL Closed Loop SPFI Sequential Port Fuel Injection
CNG Compressed Natural Gas SPN Suspect Parameter Number
DBW Drive-By-Wire Tach Tachometer
DGC Diesel Governor Control TBI Throttle Body Injection
DM Diagnostic Message TDC Top Dead Center
DMM Digital Multi-Meter (high impedance) TIP Throttle Inlet Pressure
DST Diagnostic Scan Tool TPS Throttle Position Sensor
DTC Diagnostic Trouble Code TSC Torque/Speed Control
DVOM Digital Voltage and Ohm Meter (high impedance) Tx Transmit
ECI EControls Inc. FP Fuel Pressure
ECIPP EControls Inc. Proprietary Protocol FPP Foot Pedal Position
ECM Engine Control Module FRP Fuel Rail Pressure
ECT Engine Coolant Temperature FRT Fuel Rail Temperature
ECU Engine Control Unit FSS Fault Snapshot
EDIS EControls Display and Interface Software FT Fuel Temperature
EGO Exhaust Gas Oxygen Sensor, typically heated GCP Global Control Platform
EMWT Exhaust Manifold Water Temperature HDGCP Heavy-Duty Global Control Platform
(On-Road Heavy-Duty)
EPR Electronic Pressure Regulator
HEGO Heated Exhaust Gas Oxygen Sensor (same as HO2S)
ERWT Exhaust Manifold Riser Temperature
HO2S Heated Oxygen Sensor (same as HEGO)
ETB Electronic Throttle Body
IAC Idle Air Control
ETC Electronic Throttle Control
IAT Intake Air Temperature
FDR Flight Data Recorder
ICAV Instant Crank Angle Velocity
FMI Failure Mode Indicator
IVS Idle Validation Switch
FO Firing Order
LDGCP Light-Duty Global Control Platform (Industrial, Smart/
LED Light Emitting Diode Logic Coil)
LPG Liquefied Propane Gas UEGO Universal Exhaust Gas Oxygen Sensor
MAP Manifold Absolute Pressure (also called wide-range EGO)
MGCP Marine Global Control Platform VDC Voltage, Direct Current
μP Microprocessor VR Variable Reluctance
Mfg Manufacture Vsw Switched, Ignition Voltage
MIL Malfunction Indicator Lamp WGP Waste-Gate Pressure
NG Natural Gas
OBD On-Board Diagnostics
OEM Original Equipment Manufacture
PC Personal Computer
PCU Powertrain Control Unit
PFI Port Fuel Injection
PGN Parameter Group Number
3121171 3-195
Diagnostic Trouble Codes Resetting active and previously active DTCs is handled
through DM11 and DM3, respectively DM1 and DM2 lamp
The numeric diagnostic trouble codes assigned to the faults in
indicators are assigned to each fault based on the fault.s diag-
this section are cross-referenced to SAE’s “Recommended
nostic action as defined in the calibration. The lamps are
Practice for Diagnostic Trouble Code Definitions” (SAE J2012).
assigned based on the configuration outlined in Table 3-10.
While these codes are recommended, the manufacturer may
define their own codes by assigning a new number to the flash
code in the diagnostic calibration. This will assign both the Table 3-10. J1939 Diagnostic Lamp Configuration
DTC as displayed in EDIS as well as the flash code output on
the MIL output pin. EDIS may be used to connect to the DGC ECI DIAGNOSTIC ACTION J1939 LAMP
ECM via CAN.
MIL MIL
CAN
Soft Warning Amber
The DGC supports SAE J1939 CAN based diagnostic support.
This includes: Hard Warning, Low Rev Limit, Shutdown Red Stop
• DM1: Active Diagnostic Trouble Codes
Power Derate 1 & 2 Protect
• DM2: Previously Active Diagnostic Trouble Codes
• DM3: Diagnostic Data Clear/Reset of Previously Active None (use in combination with other
Forced Idle
DTCs action)
• DM4: Freeze Frame Parameters

• DM5: Diagnostic Readiness (bytes 1, 2, and 3 are sup-
MIL Output
ported) The MIL output is used to convey fault information to the
equipment operator. The MIL is always on (grounded) when
• DM11: Diagnostic Data Clear/Reset For Active DTCs the system is in a key-on (Vsw), engine-off state. This provides
• DM12: Emissions-Related Active Diagnostic Trouble Codes assurance that the output is functional. If a DTC is logged as
previously-active (historic), the MIL will send a single flash for
• DM19: Calibration Information the “Blink on-time” every “Blink off-time.”
All diagnostic trouble codes broadcast over CAN will be SAE
J1939 DM1 and DM2 formatted messages. DGC ECMs are com-
pliant with J1939 OBD-M, supporting the Diagnostic Messages
above as well as user indicators and CAN data defined in the
OBD-M protocol. Faults available for broadcast and their
respective SPN/FMI numbers are dependent on the applica-
tion and engine calibration. There are 4 CAN SPN/FMI lists
available in the DGC software set, contact EControls Inc. for a
list of CAN SPN/FMIs.
The data capture at the occurrence of a fault, known in the
ECM as fault snapshot (FSS), is available upon DM4 request.
The following bytes are supported for DM4 if configured in the
ECM software:
• Byte 1: Freeze Frame Length
• Byte 2-6: SPN, FMI, SPN Conversion Method, and Occur-
rence
• Byte 7: Manifold Absolute Pressure
• Byte 8-9: Engine Speed
• Byte 10: Engine Load (MAP based estimate)
• Byte 11: Engine Coolant Temperature
• Byte 14: # of starts since fault was last active
• Byte 15: Index into FSS_storage table for Fault Snap Shot
retrieval
3-196 3121171
DTC 116- ECT Higher Than Expected Stage 1
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor Diagnostic Aids

• Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the trou-
• Fault Condition-Engine Coolant Temperature reading or bleshooting procedures for that fault as it may have caused
estimate greater than the stage 1 limit when operating at a "ECT Higher Than Expected 1."
speed greater than defined in the diagnostic calibration If the cooling system utilizes an air-to-water heat exchanger
• Corrective Action(s): Sound audible warning or illuminate (radiator) and fan:
secondary warning lamp, disable adaptive learn fueling
• Check that the radiator has a proper amount of ethylene
correction during active fault. Recommend a power derate
glycol/water and that the radiator is not leaking
1/2 and/or a low rev limit to protect engine from possible
damage. • Ensure that there is no trapped air in the cooling path
• Non-emissions related fault • Inspect the cooling system (radiator and hoses) for cracks
and ensure connections are leak free
The Engine Coolant Temperature sensor is a thermistor (tem-
perature sensitive resistor) located in the engine coolant. • Check that the fan is operating properly
Some engines use a CHT sensor that is located in the coolant • Check that the thermostat is not stuck closed
in the cylinder head. Some engines use an ECT (Engine Cool-
ant Temperature) sensor that is located in the coolant near the If the cooling system utilizes a water-to-water heat exchanger:
thermostat. If the engine is equipped with a CHT sensor then • Check that the heat exchanger has a proper amount of eth-
the ECT value is estimated. If equipped with an ECT sensor ylene glycol/water and that the heat exchanger is not leak-
then the CHT value is estimated. They are used for engine air- ing
flow calculation, ignition timing control, to enable certain fea-
tures, and for engine protection. The ECM provides a voltage • Ensure that there is no trapped air in the cooling path
divider circuit so when the sensor reading is cool the sensor • Inspect the cooling system (radiator and hoses) for cracks
reads higher voltage, and lower when warm. and ensure connections are leak free
This fault will help protect the engine in the event of over tem- • Check that the raw water pickup is not blocked/restricted
perature. When the coolant exceeds x deg. F and engine RPM by debris and that the hose is tightly connected
exceeds y RPM for the latch time this fault will set.
• Check that the thermostat is not stuck closed
• Check that the raw water pump/impeller is tact and that it
is not restricted
3121171 3-197
DTC 117- ECT/CHT Low Voltage
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor The Engine Coolant Temperature sensor is a thermistor (tem-
perature sensitive resistor) located in the engine coolant.
• Check Condition-Engine Running
Some engines use an ECT sensor that is located in the coolant
• Fault Condition-CHT/ECT sensor voltage less than the limit near the thermostat. Some engines use a CHT (Cylinder Head
defined in the diagnostic calibration Temperature) sensor that is located in the coolant in the cylin-
• Corrective Action(s)- Sound audible warning or illuminate der head. If the engine is equipped with an ECT sensor then
secondary warning lamp, disable adaptive learn fueling the CHT value is estimated. If equipped with a CHT sensor then
correction during active fault, or any combination thereof the ECT value is estimated. The ECM provides a voltage divider
as defined in calibration. Recommend a power derate 1/2 circuit so that when the coolant is cool, the signal reads higher
to reduce the possibility of engine damage due to the voltage, and lower when warm.
inability to sense temperature. This fault will set if the signal voltage is less than the limit
• Non-emissions related fault defined in the diagnostic calibration anytime the engine is
running. The limit is generally set to 0.10 VDC. The ECM will
use a default value for the CHT/ECT sensor in the event of this
fault.
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3-198 3121171
DTC 118- ECT/CHT High Voltage
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor This fault will set if the signal voltage is higher than the high
voltage limit as defined in the diagnostic calibration anytime
the engine is running. The limit is generally set to 4.90 VDC. In
• Fault Condition-CHT/ECT sensor voltage higher than the many cases, this condition is caused by the CHT/ECT sensor
limit defined in the diagnostic calibration being disconnected from the engine harness, an open-circuit
• Corrective Action(s)- Sound audible warning or illuminate or short-to-power of the CHT/ECT circuit in the wire harness,
secondary warning lamp, disable adaptive learn fueling or a failure of the sensor. The ECM will use a default value for
correction during active fault, or any combination thereof the CHT/ECT sensor in the event of this fault.
as defined in calibration. Recommend a power derate 1/2
to reduce the possibility of engine damage due to the
inability to sense temperature.
• Non-emissions related fault
The Engine Coolant Temperature sensor is a thermistor (tem-
perature sensitive resistor) located in the engine coolant.
Some engines use an ECT sensor that is located in the coolant
near the thermostat. Some engines use a CHT (Cylinder Head
Temperature) sensor that is located in the coolant in the cylin-
der head. If the engine is equipped with an ECT sensor then
the CHT value is estimated. If equipped with a CHT sensor then
the ECT value is estimated. The ECM provides a voltage divider
circuit so that when the coolant is cool, the signal reads higher
voltage, and lower when warm.
3121171 3-199
3-200 3121171
DTC 122- TPS1 Signal Voltage Low
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor 1 condition while the engine is cranking or running. The limit is
generally set to 4.90 VDC. In many cases, this condition is
• Check Condition-Key On, Engine Off
caused by the TPS sensor being disconnected from the engine
• Fault Condition-TPS1 sensor voltage lower than the limit harness, an open-circuit or short-to-ground of the TPS circuit
defined in the diagnostic calibration in the wire harness, or a failure of the sensor. This fault should
• Corrective Action(s): Sound audible warning or illuminate be configured to trigger an engine shutdown and the engine
secondary warning lamp, shutdown engine will not start with this fault active.

In the case of a diesel engine, an actuator controls a fuel injec-
tion pump, directly affecting the fueling level into the cylin-
ders. This may be by direct manipulation of the fuel injection
pump rack or by manipulation of the mechanical governor
control level or “throttle arm.” In the DGC ECM and EDIS, refer-
ences to the throttle and throttle position sensor refer to these
fuel injection pump control actuators and their position feed-
back sensors. When the fuel injection pump is electronically
controlled it can be used to control the idle stability and limit
engine speed based on operating conditions.
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit or
2) a non-contact hall-effect sensor to determine throttle actu-
ator position, and is located within the throttle actuator.
There are two types of throttle actuators;
1) actuator with analog position feedback and
2) actuator with digital position feedback
The first type, with analog position feedback, provides an ana-
log return signal between 0 and 5 volts that is proportional to
the throttle actuator position. The second type, with digital
position feedback, provides a serial data signal to the ECM
with the throttle actuator position voltage level encoded in
the data stream.
This fault will set if TPS1 voltage is lower than the low voltage
limit as defined in the diagnostic calibration at any operating
3121171 3-201
3-202 3121171
DTC 123- TPS1 Signal Voltage High
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor 1 There are two types of throttle actuators, 1) actuator with ana-
log position feedback and 2) actuator with digital position
• Check Condition-Key On, Engine Off
feedback. The first type, with analog position feedback, pro-
• Fault Condition-TPS1 sensor voltage higher than the limit vides an analog return signal between 0 and 5 volts that is pro-
defined in the diagnostic calibration portional to the throttle actuator position. The second type,
• Corrective Action(s): Sound audible warning or illuminate with digital position feedback, provides a serial data signal to
secondary warning lamp, shutdown engine the ECM with the throttle actuator position voltage level
encoded in the data stream.
This fault will set if TPS1 voltage is higher than the limit set in
In the case of a diesel engine, an actuator controls a fuel injec- the diagnostic calibration at any operating condition while the
tion pump, directly affecting the fueling level into the cylin- engine is cranking or running. The limit is generally set to 4.90
ders. This may be by direct manipulation of the fuel injection VDC. In many cases, this condition is caused by a short-to-
pump rack or by manipulation of the mechanical governor power of the TPS circuit in the wire harness or a failure of the
control level or “throttle arm.” In the DGC ECM and EDIS, refer- sensor. This fault should be configured to trigger an engine
ences to the throttle and throttle position sensor refer to these shutdown and the engine will not start with this fault active.
fuel injection pump control actuators and their position feed-
back sensors. When the fuel injection pump is electronically
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit or
2) a non-contact hall-effect sensor to determine throttle actu-
ator position, and is located within the throttle actuator.
3121171 3-203
3-204 3121171
DTC 217- ECT Higher Than Expected 2
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor Diagnostic Aids

If the "ECT High Voltage” fault is also present, follow the trou-
• Fault Condition-Engine Coolant Temperature reading or bleshooting procedures for that fault as it may have caused
estimate greater than the stage 2 limit when operating at a “ECT Higher Than Expected 2."
speed greater than defined in the diagnostic calibration
If the cooling system utilizes an air-to-water heat exchanger
• Corrective Action(s)- Sound audible warning or illuminate
(radiator) and fan:
secondary warning lamp, disable adaptive learn fueling
correction during active fault. Recommend a power derate • Check that the radiator has a proper amount of ethylene
2 and/or a forced idle or engine shutdown to protect glycol/water and that the radiator is not leaking
engine from possible damage. • Ensure that there is no trapped air in the cooling path
• Non-emissions related fault • Inspect the cooling system (radiator and hoses) for cracks
The Engine Coolant Temperature sensor is a thermistor (tem- and ensure connections are leak free
perature sensitive resistor) located in the engine coolant. • Check that the fan is operating properly
Some engines use a CHT sensor that is located in the coolant
in the cylinder head. Some engines use an ECT (Engine Cool-
ant Temperature) sensor that is located in the coolant near the If the cooling system utilizes a water-to-water heat exchanger:
thermostat. If the engine is equipped with a CHT sensor then • Check that the heat exchanger has a proper amount of eth-
the ECT value is estimated. If equipped with an ECT sensor ylene glycol/water and that the heat exchanger is not leak-
then the CHT value is estimated. The ECM provides a voltage ing
divider circuit so when the sensor reading is cool the sensor
reads higher voltage, and lower when warm. • Ensure that there is no trapped air in the cooling path
• Inspect the cooling system (radiator and hoses) for cracks
This fault will help protect the engine in the event of over tem- and ensure connections are leak free
perature. When the coolant exceeds x deg. F and engine RPM
exceeds y RPM for the latch time this fault will set. • Check that the raw water pickup is not blocked/restricted
by debris and that the hose is tightly connected
• Check that the raw water pump/impeller is tact and that it
is not restricted
3121171 3-205
DTC 219- RPM Higher Than Max Allowed Governed

Speed
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Max Govern Speed Override- Crankshaft Position Sensor Diagnostic Aids

• Check Condition-Engine Running NOTE: If any other DTCs are present, diagnose those first.
• Fault Condition-Engine speed greater than the max gover-
• Ensure that no programmed governor speeds exceed the
nor override speed as defined in the diagnostic calibration
limit set in the diagnostic calibration for Max Gov Override
• Corrective Action(s): Sound audible warning or illuminate Speed
secondary warning lamp, reduce throttle to limit speed.
• Check mechanical operation of the throttle actuator
Recommend closed loop and adaptive learn fueling correc-
tion remains active during fault.
This fault will set anytime the engine RPM exceeds the limit set
in the diagnostic calibration for the latch time or more. This
speed overrides any higher max governor speeds pro-
grammed by the user. This fault is designed to help prevent
engine or equipment damage.
The throttle will be lowered in order to govern the engine to
the speed set in the diagnostic calibration.
DTC 219- RPM Higher Than Max Allowed Governed Speed
(continued)
3-206 3121171
DTC 336- Crank Signal Input Noise
2 WHITE/PURPLE PURPLE/WHITE
WHITE/PURPLE
1 PURPLE/WHITE
• Crankshaft Position sensor The ECM must see a valid crankshaft position signal while run-
ning. If no signal is present, the signal amplitude is too high
• Check Condition- Key On, Engine On
(due to improper air gap with respect to trigger wheel), or an
• Fault Condition- Electrical noise or irregular crank pattern irregular crank pattern is detected causing the ECM to resyn-
detected causing x number of crank resynchronization chronize x times for y ms or longer as defined in the diagnostic
events as defined in the diagnostic calibration calibration, this fault will set. Irregular crank patterns can be
• Corrective Action(s)- Illuminate MIL and/or sound audible detected by the ECM due to electrical noise, poor machining
warning or illuminate secondary warning lamp and disable of trigger wheel, or trigger wheel runout and/or gear lash.
adaptive fueling correction for remainder of key-cycle. Ensure crank circuit used with VR/magnetic pick-up sensors
• Emissions related fault are properly twisted.
The crankshaft position sensor is a magnetic sensor (variable

reluctant/magnetic pick-up or hall effect) installed in the
engine block adjacent to a “coded” trigger wheel located on
the crankshaft. The sensor-trigger wheel combination is used
to determine crankshaft position (with respect to TDC cylinder
#1 compression) and the rotational engine speed. Determina-
tion of the crankshaft position and speed is necessary to prop-
erly activate the ignition, fuel injection, and throttle governing
systems for precise engine control.
3121171 3-207
• Key On, Engine Running

• System Mode= “Running”
Operate engine at condition

that set fault based on fault
snapshot
Yes Is crank sensor a VR/ No Check wiring and electrical connections

Does DTC 336 reset ?
magnetic pick-up? between crankshaft position sensor and ECM
No Yes
No
Is the wiring OK? Repair wireharness
Intermittent fault
Yes
Faulty wireharness No Is wiring between sensor
(twist circuit) and ECM properly twisted?
• Poor system ground
• Bad crankshaft position sensor
• Bad ECM
Yes
Yes
Increase the air gap between Does fault only occur at
sensor and trigger wheel high operating speeds?
No
Check wiring and electrical connections

between crankshaft position sensor and ECM
No
Repair wireharness Is the wiring OK?
Yes
• Poor system ground

• Bad crankshaft position sensor
• Bad ECM
3-208 3121171
DTC 337- Loss of Crank Input Signal
2 WHITE/PURPLE PURPLE/WHITE
WHITE/PURPLE
1 PURPLE/WHITE
• Crankshaft Position sensor The ECM must see a valid crankshaft position signal while run-
ning. If no signal is present while x cam pulses continue the
• Check Condition- Key On, Engine On
fault will set. The engine typically stalls or dies as a result of
• Fault Condition- Loss of crankshaft position signal while this fault condition due to the lack of crankshaft speed input
valid camshaft position signals continue for x number of resulting in the inability to control ignition timing.
cam pulses as defined in the diagnostic calibration
DTC 337- Loss of Crank Input Signal (continued)
• Corrective Action(s)- Illuminate MIL and/or sound audible
warning or illuminate secondary warning lamp Diagnostic Aids
• Emissions related fault • Check that crankshaft position sensor is securely con-
nected to harness
The crankshaft position sensor is a magnetic sensor (variable
reluctant/magnetic pick-up or hall effect) installed in the • Check that crankshaft position sensor is securely installed
engine block adjacent to a “coded trigger wheel located on into engine block
the crankshaft. The sensor-trigger wheel combination is used • Check crankshaft position sensor circuit wiring for open cir-
to determine crankshaft position (with respect to TDC cylinder cuit
#1 compression) and the rotational engine speed. Determina-
tion of the crankshaft position and speed is necessary to prop-
erly activate the ignition, fuel injection, and throttle governing
systems for precise engine control.
3121171 3-209
DTC 521- Oil Pressure Sender/Switch High The ECM can be configured to monitor oil pressure through a
proportional transducer or through a switch. Oil pressure
Pressure monitoring is important to prevent engine damage due to low
oil pressure resulting in higher friction and lack of lubrication.
19 In addition, high oil pressure can be undesirable because it
BLACK/GREEN can cause oil to leak past seals and rings, can be a result of a
2 1 BLUE restriction in the oil flow path, or can be a sign of a malfunc-
tioning oiling system.
Additionally for normally-open type oil pressure switches, a
high pressure indication while the engine is off is a symptom
of a failed oil pressure switch. The ECM can monitor oil pres-
• Engine Oil Pressure sure indication when the engine is stopped for this failure
mode.
• Check Condition- Key on, Engine on (or Engine off )
• Fault Condition- For sender types, oil pressure higher than For sender types, this fault sets if the engine oil pressure is
x psia while engine speed is greater that y RPM. For switch higher than x psia and engine speed greater than y RPM as
types, oil pressure is indicating high when the engine has defined in the diagnostic calibration. For switch types, this
been stopped for more than n seconds. fault sets if the engine oil pressure is indicating high when the
engine is stopped for more than n seconds. Recommend a
• Corrective Action(s)- Illuminate MIL and/or sound audible power derate and/or low rev limit to help prevent possible
warning or illuminate secondary warning lamp, possibly engine damage and reduce oil pressure.
configure for power derate 1 or low rev limit
• Key-On, Engine Off

• System Mode= “Stopped”
• Key Off
No • Disconnect harness from Oil Pressure switch
Does DTC 524 • Check continuity through switch to ground.
reset ?
Yes
Intermittent Problem
No • Oil Pressure circuit shorted-to-ground in harness

Is switch open?
• Faulty ECM
Yes
• Faulty Oil Pressure Switch (short circuit)

• Faulty engine oiling system (verify with
mechanical gauge)
3-210 3121171
DTC 524- Oil Pressure Low For systems that use a transducer, this fault sets if the engine
oil pressure is less than x psia and engine speed is greater than
y RPM after the engine has been running for z seconds as
19
defined in the diagnostic calibration. For systems that use a
BLACK/GREEN
2 1 BLUE switch this fault can be configured two different ways. It may
use a normally closed switch or a normally open switch. If the
switch is normally open, the fault will set if the circuit becomes
grounded. If the switch is normally closed, the fault will set if
the circuit becomes open. Go to the Faults page in EDIS to
determine how the input is configured. (“Open=OK” is nor-
mally open and “Ground=OK” is normally closed). The engine
• Engine Oil Pressure
will should be configured to derate or force idle and/or shut
• Check Condition- Key on, Engine on down in the event of this fault to help prevent possible dam-
• Fault Condition- Engine oil pressure lower than expected age.
while engine has been running for a minimum amount of
time while engine speed is above some limit as defined in
the diagnostic calibration
warning or illuminate secondary warning lamp, generally
configured to derate the engine and trigger an engine
shutdown
The ECM can be configured to monitor oil pressure through a
proportional transducer or through a switch. Oil pressure
monitoring is important to prevent engine damage due to low
oil pressure resulting in higher friction and lack of lubrication.
In addition, high oil pressure can be undesirable because it
can cause oil to leak past seals and rings, can be a result of a
restriction in the oil flow path, or can be a sign of a malfunc-
tioning oiling system.
3121171 3-211
Normally Closed Switch
• Key-On, Engine On
• System Mode= “Running”
• Key Off
• Disconnect harness from Oil Pressure switch
• Jumper Oil Pressure signal wire to ground
• Warm engine at idle to normal • Clear DTC 524
operating temperature • Key On, Engine On
• Increase RPM above limit set • System Mode= “Running”
in diagnostic calibration • Operate engine et idle for at least one minute
• Increase RPM above limit set in diagnostic calibration
• Disconnect wireharness header from ECM

• Carefully remove yellow lock from header
Yes at device output terminal
Does DTC 524 • CAREFULLY check resistance between
reset ? Oil Pressure signal at ECM header and
Does DTC 524 Yes signal at sensor. NOTE: DO NOT
reset? INSERT probe or object into terminals
No as this will cause the terminal to
spread and may no longer make
No contact with ECM pin. Spread pins will
void warranty! Probe on the side of
Intermittent Problem terminal.
• Faulty Oil Pressure Switch (open circuit)
• Faulty engine oiling system (verify with
mechanical gauge)
• Faulty connection at sensor Yes Does DMM indicate a

• Faulty ECM resistance < 5.0 ohms?
No
• Faulty harness
(open circuit)
3-212 3121171
DTC 562- Battery Voltage (VBat) Low
BLACK
RED/TAN
• System voltage to ECM The battery voltage powers the ECM and must be within limits
to correctly operate throttle actuator, power supplies, and
• Check Condition- Key on, Engine on
other powered devices that the ECM controls.
• Fault Condition- Battery voltage to ECM less than x volts This fault will set if the ECM detects system voltage less than x
while the engine is operating at y RPM or greater as volts while the engine is operating at y RPM as defined in the
defined in the diagnostic calibration diagnostic calibration as the alternator should be charging the
• Corrective Action(s)- Illuminate MIL and/or sound audible system.
warning or illuminate secondary warning lamp, disable
adaptive fueling correction for remainder of key cycle
• Non-emissions related fault.
3121171 3-213
3-214 3121171
DTC 563- Battery Voltage (VBat) High
BLACK
RED/TAN
• System voltage to ECM The battery voltage powers the ECM and must be within limits
to correctly operate throttle actuator, power supplies, and
• Check Condition- Key on, Engine Cranking or Running
other powered devices that the ECM controls.
• Fault Condition- Battery voltage to ECM greater than x
volts while the engine is running as defined in the diagnos- This fault will set if the ECM detects system voltage greater
tic calibration than x volts while the engine is running or cranking as defined
in the diagnostic calibration.
warning or illuminate secondary warning lamp, disable
adaptive fueling correction for remainder of key cycle
• Non-emissions related fault.
3121171 3-215
3-216 3121171
DTC 601- Microprocessor Failure - FLASH
ECM
Microprocessor
RAM
• Engine Control Module- Flash Memory The ECM has checks that must be satisfied each time an
instruction is executed. Several different things can happen
• Check Condition- Key on
within the microprocessor that will cause this fault.
• Fault Condition- Internal microprocessor error
If this fault sets, the ECM will reset itself and log the code. The
• Corrective Action(s)- Illuminate MIL and/or sound audible fault should be configured to never forget and will not self-
warning or illuminate secondary warning lamp, disable erase and will not clear until a technician performs diagnostics
adaptive fueling correction for remainder of key cycle, rec- and manually clears the code. This fault should be configured
ommend power derate 2 and low rev limit to reduce possi- to set a power derate 2 and low rev limit to reduce possible
ble engine damage and/or overspeed condition engine damage and reduce possibility of an overspeed condi-
• Non-emissions related fault tion. A fault of flash memory can occur for any calibration vari-
able set and thus could cause undesirable operation.
3121171 3-217
3-218 3121171
DTC 604- Microprocessor Failure - RAM
ECM
Microprocessor
RAM
• Engine Control Module- Random Access Memory This fault will set if the ECM detects a problem accessing or
writing information to RAM and should be configured to set a
power derate 2 and low rev limit to reduce possible engine
• Fault Condition- Internal ECM microprocessor memory damage and reduce possibility of an overspeed condition. If
access failure this fault sets, the ECM will reset itself and log the code. This
• Corrective Action(s)- Illuminate MIL and/or sound audible fault should be erased by a technician after diagnostics are
warning or illuminate secondary warning lamp, disable performed. The fault should be configured to never forget and
adaptive fueling correction for remainder of key cycle, rec- will not self-erase.
ommend power derate 2 and low rev limit to reduce possi-
ble engine damage and/or overspeed condition
Random Access Memory is located within the microprocessor
and can be read from or written to at any time. Data stored in
RAM include DTCs (when fault configuration is set to “Battery
Power Retained”), adaptive fuel learn tables, octane adapta-
tion table, misfire adaption tables, and closed loop fuel multi-
pliers. The ECM has checks that must be satisfied each time an
instruction is executed.
3121171 3-219
3-220 3121171
DTC 606- Microprocessor Failure - COP
ECM
Microprocessor
RAM
• Engine Control Module The ECM has checks that must be satisfied each time an
within the microprocessor that will cause this fault.
• Fault Condition- Internal microprocessor error
If this fault sets, the ECM will reset itself and log the code. The
• Corrective Action(s) - Illuminate MIL and/or sound audible fault should be configured to never forget and will not self-
warning or illuminate secondary warning lamp, disable erase and will not clear until a technician performs diagnostics
adaptive fueling correction for remainder of key cycle, rec- and manually clears the code. This fault should be configured
ommend power derate 2 and low rev limit to reduce possi- to set a power derate 2 and low rev limit to reduce possible
ble engine damage and/or overspeed condition engine damage and reduce possibility of an overspeed condi-
• Non-emissions related fault tion.
3121171 3-221
3-222 3121171
DTC 642- 5 Volt External Low Voltage
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Engine Control Module Diagnostic Aids

• Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the key
• Fault Condition- ECM 5-volt output is below the acceptable on and the engine stopped. Verify that the output is lower
limit than the fault thresholds configured in the diagnostic cali-
bration.
warning or illuminate secondary warning lamp • Inspect the 5-Volt output circuit in the wire harness and
look for shorts to ground or other harness circuits.
• Disconnect each device powered by the 5-volt output of
The ECM supplies 5-volt power to sensors, switches, and actu- the ECM one-at-a-time. Powered devices may include the
ators external to the ECM. By supplying the power to these throttle actuator, smart sensors, smart actuators, etc. After
devices, the ECM can accurately measure their output relative disconnecting device, observe the system fault and deter-
to its own ground reference. The ECM can also control when mine if the fault has cleared. If the fault clears, troubleshoot
the devices are active and put the devices in a low or no power the disconnected device for failures.
state based on the current operating condition of the engine
or vehicle. • With all 5-volt powered devices disconnected, look for a
change in the fault state and measure the 5-volt output of
If this fault sets, something other than the ECM is drawing the the ECM and verify it is within acceptable limits.
5-volt power output of the ECM below an acceptable thresh-
old. This may be due to a short in the wire harness, malfunc-
tioning device, or failure of the ECM power output circuitry.
3121171 3-223
DTC 643- 5 Volt External High Voltage
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Engine Control Module Diagnostic Aids

• Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the key
• Fault Condition- ECM 5-volt output is above the acceptable on and the engine stopped. Verify that the output is lower
limit than the fault thresholds configured in the diagnostic cali-
bration.
warning or illuminate secondary warning lamp • Inspect the 5-Volt output circuit in the wire harness and
look for shorts to ground or other harness circuits.
• Disconnect each device powered by the 5-volt output of
The ECM supplies 5-volt power to sensors, switches, and actu- the ECM one-at-a-time. Powered devices may include the
ators external to the ECM. By supplying the power to these throttle actuator, smart sensors, smart actuators, etc. After
devices, the ECM can accurately measure their output relative disconnecting device, observe the system fault and deter-
to its own ground reference. The ECM can also control when mine if the fault has cleared. If the fault clears, troubleshoot
the devices are active and put the devices in a low or no power the disconnected device for failures.
state based on the current operating condition of the engine
or vehicle. • With all 5-volt powered devices disconnected, look for a
change in the fault state and measure the 5-volt output of
If this fault sets, something other than the ECM is drawing the the ECM and verify it is within acceptable limits.
5-volt power output of the ECM above an acceptable thresh-
old. This may be due to a short in the wire harness, malfunc-
tioning device, or failure of the ECM power output circuitry.
3-224 3121171
DTC 1612- Microprocessor Failure - RTI 1
ECM
Microprocessor
RAM
within the microprocessor that will cause this fault. The ECM
• Fault Condition- Internal microprocessor error will reset itself in the event this fault is set, and the MIL will be
• MIL- On until code is cleared by technician on until the code is cleared. This fault should be erased after
diagnosis by removing battery power. It will not self-erase.
• Adaptive- Disabled for the remainder of the key-on cycle
During this active fault, Power Derate (level 2) will be enforced.
• Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%.
• Power Derate (level 2 until fault is cleared manually) This is enforced until the fault is manually cleared.
3121171 3-225
ECM
Microprocessor
RAM
3-226 3121171
SFC 555- RTI 2 Loss
Key On - Engine Running

System Data Mode
Check all power and

Clear System Fault
ground circuits to ECM
Does SFC 555 reset Yes

with engine idling?
Yes Replace ECM with known
Are all circuits ok?
good part and retest
No
No
Fault is intermittent
Repair wiring to
ECM and retest
3121171 3-227
ECM
Microprocessor
RAM
3-228 3121171
SFC 556- RTI 3 Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 556 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
3121171 3-229
DTC 1615- Microprocessor Failure - A/D
ECM
Microprocessor
RAM
3-230 3121171
SFC 513- A/D Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 513 reset

with engine idling?
Yes
Replace ECM with known
No
No
Repair wiring to
ECM and retest
3121171 3-231
DTC 1616- Microprocessor Failure - interrupt
ECM
Microprocessor
RAM
3-232 3121171
SFC 512- Invalid Interrupt

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 512 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
3121171 3-233
DTC 1625- CAN J1939 Shutdown Request
BLUE/RED or PINK
BLUE/WHITE
• Controller Area Network Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running • The ECM has shutdown the engine upon command by a
• Fault Condition- ECM has received shutdown message external controller. This is the requested and expected
from another CAN device and is shutdown on request. behavior.
• Corrective Action(s)- Illuminate MIL, sound audible warn-
ing or illuminate secondary warning lamp
In some situations, external controllers may send a request to
the ECM to shutdown engine operation and stop the engine.
This request may be sent in response to a safety related condi-
tion in the vehicle.
This fault will set if the ECM receives the J1939 shutdown
request via the CAN interface. This is the expected behavior.
3-234 3121171
DTC 1626- CAN J1939 Transmit (Tx) Fault
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are properly
• Fault Condition- ECM CAN transceiver transmit error grounded
counts greater than the limit defined in the diagnostic cali- • Verify that the CAN network is properly terminated
bration (must be < 125 failures)
• Check CAN wire routing with respect to noise sources (igni-
• Corrective Action(s)- Illuminate MIL, sound audible warn- tion coils, spark plug coil wires, etc.) and shield if necessary
• Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communication
network used to transmit and receive data between intelligent
devices. Systems that utilize CAN communication include
smart actuators, smart sensors, dash panels and gauges, and
other microcomputers. Each smart sensor, actuator, or control-
ler incorporates a CAN transceiver that interprets logic level
signals on the network and translates the information into dig-
ital data.
This fault will set if CAN communication is enabled and the
ECM transceiver broadcasts a number of packets (as defined in
the diagnostic calibration, must be set to less than 125 fail-
ures) to the network that are not received.
3121171 3-235
DTC 1627- CAN J1939 Receive (Rx) Fault
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are properly
• Fault Condition- ECM CAN transceiver receive error counts grounded
greater than the limit defined in the diagnostic calibration • Verify that the CAN network is properly terminated
(must be < 125 failures)
• Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communication
network used to transmit and receive data between intelligent
devices. Systems that utilize CAN communication include
smart actuators, smart sensors, dash panels and gauges, and
other microcomputers. Each smart sensor, actuator, or control-
ler incorporates a CAN transceiver that interprets logic level
signals on the network and translates the information into dig-
ital data.
This fault will set if CAN communication is enabled and the
ECM transceiver is expecting to see network traffic and either
does not see traffic (as defined in the diagnostic calibration,
must be set to less than 125 failures).
3-236 3121171
DTC 1628- CAN Address Conflict Failure
BLUE/RED or PINK
BLUE/WHITE
• CAN device(s) The Controller Area Network serves as a communication portal

between intelligent devices. These devices may be but are not
• Check Condition- Key On, Engine on
limited to other engine ECMs (slave), diagnostic tools, “smart”
• Fault Condition- two or more devices on the network that gauges, “smart” sensors, powertrain control units, vehicle con-
contain the same SA trollers, actuators, etc. The network permits several devices to
• Corrective Action(s)- Sound audible warning or illuminate communicate with each other receiving and broadcasting
secondary warning lamp commands as programmed. This type of network allows
devices to be added to an entire system through only two con-
• Non-emissions related fault ductors and permits all other devices to broadcast and receive
commands to and from the device when properly com-
manded.
This fault indicates that there are two (2) or more devices on
the network that use the same source address.
3121171 3-237
3-238 3121171
DTC 1629- J1939 TSC1 Message Receipt Loss
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Running • Verify that the CAN device generating the TSC1 message is
• Fault Condition- ECM is expecting to receive J1939 TSC1 powered and properly grounded
messages and has not received a message for more than n • Verify that the CAN network is properly terminated
seconds (as defined in the diagnostic calibration).
ing or illuminate secondary warning lamp. Govern engine
speed at a forced idle. • Check CAN (+) and (-) wires for short circuits

J1939 TSC1 may be used to send a commanded (or desired)
engine speed to the ECM. If configured, the ECM will govern
the engine speed to this commanded speed if possible. When
operating in this mode, the ECM expects to receive TSC1 mes-
sages on a regular interval. When this message is not received,
the ECM must operate the engine at a default idle speed until
commanded to do otherwise.
This fault will set if CAN communication is enabled, the engine
is running, and no TSC1 messages are received over the CAN
bus for more than n seconds (as determined by the diagnostic
calibration).
3121171 3-239
DTC 1652- TPS1 Loss of Communications
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Actuator (with serial/digital position feedback) Diagnostic Aids

• Check Condition- Key On, Engine Running and/or Stopped • Verify that the throttle actuator 5V supply voltage is pres-
• Fault Condition- ECM is expecting to receive throttle posi- ent at the actuator.
tion information from the throttle actuator and is not. • Check for a all four TPS feedback wires for short circuits.
• Corrective Action(s)- Illuminate MIL, sound audible warn- • Check TPS SER+ and TPS SER- wire routing with respect to
ing or illuminate secondary warning lamp. Shutdown noise sources (ignition coils, spark plug coil wires, etc.) and
engine. shield if necessary.
In the case of a throttle actuator with serial/digital position
feedback, the ECM receives a constant data stream from the
throttle actuator. If the communication is absent or inter-
rupted, the ECM can no longer control the position of the
throttle.
This fault will set if the key is on, the throttle actuator is receiv-
ing power, and the ECM is not receiving digital information
from the actuator.
3-240 3121171
DTC 2111- Unable to Reach Lower TPS
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable resistor
and voltage divider circuit or 2) a non-contact hall-effect sen-
• Check Condition-Cranking or Running
sor to determine throttle actuator position, and is located
• Fault Condition-Throttle command is 20% less than throttle within the throttle actuator.
position for 200ms or longer
There are two types of throttle actuators, 1) actuator with ana-
• MIL-On during active fault log position feedback and 2) actuator with digital position
• Engine Shut Down feedback. The first type, with analog position feedback, pro-
vides an analog return signal between 0 and 5 volts that is pro-
In the case of a diesel engine, an actuator controls a fuel injec- portional to the throttle actuator position. The second type,
tion pump, directly affecting the fueling level into the cylin- with digital position feedback, provides a serial data signal to
ders. This may be by direct manipulation of the fuel injection the ECM with the throttle actuator position voltage level
pump rack or by manipulation of the mechanical governor encoded in the data stream.
ences to the throttle and throttle position sensor refer to these This fault will set if the throttle command is 20% less than the
fuel injection pump control actuators and their position feed- actual throttle position. During this active fault the MIL light
back sensors. When the fuel injection pump is electronically will be on and the engine will shut down.
3121171 3-241
3-242 3121171
DTC 2112- Unable to Reach Higher TPS
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable resistor
and voltage divider circuit or 2) a non-contact hall-effect sen-
• Check Condition-Cranking or Running
sor to determine throttle actuator position, and is located
• Fault Condition-Throttle command is 20% more than within the throttle actuator.
actual throttle position
There are two types of throttle actuators, 1) actuator with ana-
• MIL-On during active fault log position feedback and 2) actuator with digital position
• Engine Shut Down feedback. The first type, with analog position feedback, pro-
vides an analog return signal between 0 and 5 volts that is pro-
In the case of a diesel engine, an actuator controls a fuel injec- portional to the throttle actuator position. The second type,
tion pump, directly affecting the fueling level into the cylin- with digital position feedback, provides a serial data signal to
ders. This may be by direct manipulation of the fuel injection the ECM with the throttle actuator position voltage level
pump rack or by manipulation of the mechanical governor encoded in the data stream.
ences to the throttle and throttle position sensor refer to these This fault will set if the throttle command is 20% or more than
fuel injection pump control actuators and their position feed- the actual throttle position. During this active fault the MIL
back sensors. When the fuel injection pump is electronically light will be on and the engine will shut down.
3121171 3-243
DTC 9999- Throttle Actuator Failsafe Spring

Failure
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Actuator Diagnostic Aids

• Check Condition- Key Off, Engine Stopped • Disconnect the throttle actuator from the wire harness.
• Fault Condition- When the key is off (or the actuator is Remove the throttle actuator from the engine and manu-
unpowered), the ECM is expecting the failsafe spring in the ally move it. Verify that the internal spring forces the throt-
actuator to return the throttle position to near 0%. If the tle back to near 0% position.
throttle does not reach this position when the actuator is • Inspect the throttle arm or fuel rack on the fuel pump. Ver-
powered, a fault is generated. ify that it is not stuck.
• Corrective Action(s)- Illuminate MIL, sound audible warn-
ing or illuminate secondary warning lamp. Govern the
engine speed to a forced idle speed.
The throttle actuator has a return spring that causes the throt-
tle to move to a near 0% position when powered off. This
causes the engine to shutdown following a key off. If the ECM
detects the throttle position to be above x volts when the key
is off (as determined by the diagnostic calibration), it will
power up the actuator and attempt to drive it to a zero posi-
tion. This should ensure that the engine is stopped.
This fault will set if the throttle does not return to a near 0%
position with the key is off.
DTC to SPN/FMI Table
3-244 3121171
FAULT DTC SET

DESCRIPTION
INDEX SPN FMI
2 DTC 118: ECT voltage high 110 3
3 DTC 117: ECT voltage low 110 4
4 DTC 116: ECT higher than expected stage 1 110 15
9 DTC 563: Vbat voltage high 168 15
10 DTC 562: Vbat voltage low 168 17
11 DTC 643: Sensor supply voltage 1 high 1079 3
12 DTC 642: Sensor supply voltage 1 low 1079 4
13 DTC 123: TPS1 voltage high 51 3
14 DTC 122: TPS1 voltage low 51 4
29 DTC 524: Oil pressure low 100 1
86 DTC 217: ECT higher than expected stage 2 110 0
89 DTC 2112: Unable to reach higher TPS 51 7
90 DTC 2111: Unable to reach lower TPS 51 7
96 DTC 336: CRANK input signal noise 636 2
98 DTC 606: Microprocessor failure - COP 629 31
99 DTC 1612: Microprocessor failure - RTI 1 629 31
102 DTC 1615: Microprocessor failure - A/D 629 31
103 DTC 1616: Microprocessor failure - Interrupt 629 31
104 DTC 601: Microprocessor failure - FLASH 628 13
105 DTC 604: Microprocessor failure - RAM 630 12
106 DTC 219: RPM higher than max allowed govern speed 515 15
144 DTC 337: Crank signal loss 636 4
145 DTC 1625: J1939 shutdown request 1384 31
146 DTC 1626: CAN-J1939 Tx fault 639 12
147 DTC 1627: CAN-J1939 Rx fault 639 12
175 DTC 1628: J1939 CAN address / engine-number conflict 639 13
188 DTC 521: Oil pressure high 100 0
189 DTC 1652: TPS1 loss of communications 51 9
190 DTC 1629: CAN-J1939 TSC1 Parameter Rx Fault 695 9
191 DTC 1113: Unable to achieve lower RPM 515 31
192 DTC 9999: TPS1 failsafe spring failure 51 7
3121171 3-245
3.33 AUXILIARY POWER SYSTEM 3.34 COUNTERWEIGHT

The Auxiliary Power System is intended as a secondary means If counterweight has been removed, ensure retaining bolts are
of moving the boom in the event of primary power loss. This torqued to the proper value as shown in Figure 3-95., Counter-
system uses an electric motor/pump unit powered by a 12V weight Bolt Torque.
battery capable of operating all functions except drive and
controlled boom angle (see Section 4.11, Controlled Boom
Angle System). 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 functional-
ity. When commanded, the control system will attempt to use
the force of gravity to operate main lift down, tower lift down,
and tower telescope in by supplying pilot pressure to the
respective cylinders. If appropriate movement is not detected
by the boom sensors, the auxiliary power system will supply
the hydraulic flow to power the movement conventionally.
The envelope control system (see Section 4.6, Envelope Con-
trol System) remains active during auxiliary power operation,
however, functionality of tower lift or main lift only approxi-
mates the normal tower path control (see Section 4.7, Tower
Path Control System) or main boom control (see Section 4.8,
Automatic Main Boom Control System) functionality. Rather
than the normal combined movements of tower lift, tower
telescope, and main lift, these movements will automatically
alternate during commands for tower lift or main lift to
approximate the movements made under normal engine
power.
3-246 3121171
A. Part Number\Actual Weight Stamping
B. Apply JLG Threadlocker PN 0100019 to Bolt Threads and to Threads in Counterweight. Torque to 400 ft. lbs. (542 Nm). Typical Four Places.
Figure 3-95. Counterweight Bolt Torque
3121171 3-247
NOTES:
3-248 3121171
SECTION 4. BOOM & PLATFORM

4.1 PLATFORM CONTROL ENABLE SYSTEM This system is used in the control of the following systems:
Platform controls use a time dependent enable circuit to limit • Beyond Transport - Drive Speed Cutback System.
the time availability of “live” or enabled controls. To operate • Drive/Steer - Boom Function Interlock System - CE Only
any directional function, the footswitch must be depressed
• Jib Stow System
before activation of the function. When the footswitch is
depressed, the controls are enabled and the operator has 7 • Electrical Retrieval System
seconds to operate any function. The controls will remain
• Swing Speed Proportioning System
enabled as long as the operator continues to use any function
and will remain enabled 7 seconds after the last function has • Axle Extension System
been used. While the controls are “live”, the enable light will be • Oscillating Axle System
illuminated in the platform display panel. When the time limit
has been reached, the enable light will turn off and the con- NOTE: For more detailed information concerning system adjust-
trols will be “dead” or disabled. To continue use of the machine ment and operation, refer to Section 6 - JLG Control Sys-
the controls must be re-enabled to start the timer system over tem.
again. This is done by releasing all functions, then releasing
and re-depressing the footswitch. 4.3 BEYOND TRANSPORT - DRIVE SPEED CUTBACK
NOTE: For more detailed information concerning system adjust- SYSTEM
ment and operation, refer to Section 6 - JLG Control Sys- When boom is positioned beyond the transport position as
tem. described in Section 4.2, Transport Position Sensing System,
the drive motors are automatically restricted to their maxi-
4.2 TRANSPORT POSITION SENSING SYSTEM mum displacement position (slow speed). See Section 3.24,
The Transport Position Sensing System uses the following sen- Chassis Tilt Indicator System for interaction with the tilt sensor.
sors to sense when the boom is in the position associated with
high speed travel.
• Main boom angle sensors (mounted at the tower to main tem.
boom pivot pin).
4.4 DRIVE/STEER – BOOM FUNCTION INTERLOCK
• The main boom angle limit switch will be used in the event
of a main boom angle sensor fault. SYSTEM (CE ONLY)
• Four main boom length limit switches (mounted on the The Drive/Steer – Boom Function Interlock System uses the
main base boom). Transport Position Sensing System to sense when the boom is
out of the transport position. All controls are simultaneously
• Tower lift cylinder angle sensor (mounted at the tower lift
functional when the booms are within the transport position
cylinder pivot to the turntable).
as on the standard machine. When the boom is beyond the
• The tower angle sensors in conjunction with the chassis tilt transport position, the control functions are interlocked to
sensor will be used in the event of a tower lift cylinder prevent simultaneous operation of any boom function with
angle sensor fault. drive/steer. The first function set to be operated while in this
• Tower boom length sensors (mounted in the pivot end of mode, becomes the master function set. In other words, while
the tower base boom). operating drive/steer functions the boom functions are inop-
erable. Likewise, while operating boom functions drive/steer
• The tower length switch will be used in the event of a functions are inoperable.
tower length sensor fault.
• The position of the articulated jib is not considered. ment and operation, refer to Section 6 - JLG Control Sys-
tem.
3121171 4-1
4.5 JIB STOW SYSTEM This system uses two gravitationally based angle sensors and
two length sensors to continuously measure the position of
This machine is equipped with a full function side swing rota- the tower boom in addition to two rotary angle sensors to
tor that is mechanically limited to 55 degree rotation to the continuously measure the position of the main boom. Each
left and electrically limited to 70 degrees to the right through pair of sensors are continuously monitored for mutual agree-
the use of a positive action limit switch mounted on the rota- ment, proper response to command, and for correlation to a
tor assembly. The machines stowed length can be reduced to main boom angle limit switch, a tower boom length limit
facilitate transportation on standard trailers by swinging the switch, and a tower rotary angle sensor. Recognized faults
jib further to the right using the hydraulic power of the side within this system will result in control by the Electrical
swing rotator. The control system will prevent swinging the jib Retrieval System (Section 4.9, Electrical Retrieval System),
past the 70 degree position unless the axles are retracted, the reduced function speeds, and BCS warning light illumination.
boom is in the transport position (see Section 4.2, Transport After retrieval the boom will be restricted from leaving the
Position Sensing System), and the jib stow override button on transport position (see Section 4.2, Transport Position Sensing
the platform control panel is held in combination with the jib System) until the fault is resolved.
swing function switch. When the jib is stowed, automatic plat-
form leveling is disabled, the boom is restricted to the trans- Boom position violations outside of the allowable envelope
port position, and axle extension is disabled. This system is will result in reduced function speeds, BCS warning light illu-
functional only in the 500# (230 kg) mode of the Dual Capacity mination, restriction of functions, and sounding of the plat-
System (see Section 4.13, Dual Capacity System). form alarm and the flashing of the BCS light with attempts to
operate restricted functions.
Normally, the tower lift function switch on the ground and
platform control panels automatically activates both tower lift
tem.
and tower telescope as described in the tower path control
4.6 ENVELOPE CONTROL SYSTEM system (see Section 4.7, Tower Path Control System). Violations
of the tower envelope will result in the suspension of this
The Envelope Control System is the primary means of control- automatic feature. In an otherwise healthy control system, vio-
ling the working positions of the tower and main boom within lations of the tower envelope can be corrected by actuating
the stability and structural requirements of the machine. either of the tower lift up or tower lift down directions of the
Although the machine includes a load pin capable of measur- tower lift switch regardless of the direction of the violation.
ing the changing forces on the boom, it is used exclusively for The control system will telescope or lift the tower in a singular
boom retrieval as described in the electrical retrieval system manner to correct the tower position.
(see Section 4.9, Electrical Retrieval System) and is not used for
The restricted functions due to backward tower envelope vio-
controlling the stability of the machine until a fault is detected
lations are disallowing automatic tower lift down with tower
within the primary envelope control system. The control sys-
lift down commands, automatic tower telescope out with
tem is therefore not considering the load on the machine but
tower lift up commands, main lift up and down, main tele-
rather the measured position of the boom within the enve-
scope in, jib, swing, drive and steer.
lope.
The restricted functions due to forward tower envelope viola-
The main boom must be controlled in maximum angle and
tions are disallowing automatic tower lift up with tower lift up
minimum angle to avoid entering a position that could com-
commands, automatic tower telescope in with tower lift down
promise backward stability and avoid main boom to tower
commands, main lift up and down, main telescope out, jib,
boom interference. The tower boom must be controlled by
swing, drive and steer.
permitting only specific combinations of tower length and
tower angle to avoid entering a position that could compro- The restricted functions due to maximum main boom enve-
mise forward and backward stability (see Section 4.7, Tower lope violations are disallowing tower lift up and down, main
Path Control System). lift up, main telescope in, jib, swing and drive.
The restricted functions due to minimum main boom enve-
lope violations are disallowing main lift down, swing and
drive.

tem.
4-2 3121171
4.7 TOWER PATH CONTROL SYSTEM 4.8 AUTOMATIC MAIN BOOM CONTROL SYSTEM
(see Figure 4-1., Tower Path vs. Main Boom Angle) The Automatic Main Boom Control System uses the envelope
control sensors to enhance the control of the main boom dur-
The Tower Path Control System uses the envelope control sen- ing tower lift functions. Due to the mechanical joining of the
sors to enhance the control of the tower boom for increased main and tower booms, changes in tower boom angle would
user efficiency and is used as an integral part of the envelope normally have an opposite effect on the main boom angle. To
control system (see Section 4.6, Envelope Control System). compensate for this, when the tower is raised the control sys-
Both the ground and platform control panels use one function tem automatically introduces main lift up. Similarly, when the
switch to control the tower. User commands for tower lift up or tower is lowered the control system automatically introduces
tower lift down causes the control system to automatically main lift down. This is done to keep the platform moving in
introduce the correct combination of tower telescope and the same direction as the user command and to increase user
tower lift for the tower boom to follow a pre-described path or efficiency during tower lift functions.
trajectory of the tower nose.
The tower path is a fixed relationship of tower length and The interaction of the main boom and the tower boom is
tower angle (relative to gravity) and is variable only by the slightly different when the main boom is above or below 60°
angle of the main boom. With main boom angles below +15°, relative to gravity.
the tower boom will reach maximum angles of 68° (at full During tower lift up or tower lift down movements with the
tower boom extension) and with main boom angles above main boom below 60°, the control system will maintain the
+65° the tower boom will reach maximum angles of 72° (at full angle of the main boom (relative to gravity) read at the start of
tower boom extension). the tower lift command or as read at the conclusion of main
Movement of the main boom will cause the control system to lift during combined tower and main lift commands.
adjust the tower path accordingly. A fully raised tower boom
During tower lift down movements with the main boom ini-
will automatically vary in angle from 72° to 68° as the main
tially above 60°, the control system will lower the main boom
boom is lowered from its maximum angle to the ground and
to approximately 60° before initiating tower movement. The
conversely be raised from 68° to 72° as the main boom is
control system will then control the main boom to 60° for the
raised from the ground to maximum angle. The amount of
remainder of the tower lift down command.
tower angle variation during main boom movements dimin-
ishes as the tower is lowered. During tower lift up movements with the main boom initially
above 60°, the control system will delay automatic compensa-
NOTE: For more detailed information concerning system adjust- tion of the main boom angle during the tower lift movement
ment and operation, refer to Section 6 - JLG Control Sys- until the main boom reaches approximately 60°. The control
tem. system will then control the main boom to 60° until the tower
boom has reached its maximum height. Continuing to operate
the tower lift up function when the tower reaches its maxi-
mum height, will cause the control system to automatically
raise the main boom to its original angle.

tem.
3121171 4-3
TOWER PATH FOR MAIN

BOOM ANGLES BELOW 15
DEGREES
TOWER PATH FOR MAIN

BOOM ANGLES ABOVE 55
DEGREES
Figure 4-1. Tower Path vs. Main Boom Angle
4-4 3121171
MAIN BOOM
FULLY EXTENDED
MACHINE WILL TIP OVER IN

DIRECTION OF ARROWS IF OVERLOADED
OR OPERATED
ON AN OUT-OF-LEVEL SURFACE
TOWER BOOM
FULLY LOWERED TO
FULLY RAISED
TURNTABLE ROTATED
90 DEGREES FROM
STOWED POSITION
Figure 4-2. Position of Least Forward Stability
3121171 4-5
JIB ELEVATED

DIRECTION OF ARROW IF OVERLOADED
OR OPERATED
MAIN BOOM
FULLY ELEVATED
TOWER BOOM
FULLY LOWERED
TO FULLY RAISED
TURNTABLE ROTATED
90 DEGREES FROM
STOWED POSITION
Figure 4-3. Position of Least Backward Stability - Sheet 1 of 2
4-6 3121171
JIB ELEVATED

DIRECTION OF ARROW IF OVERLOADED
OR OPERATED
MAIN BOOM
FULLY ELEVATED
TOWER BOOM
FULLY LOWERED TO
FULLY RAISED
TURNTABLE ROTATED
90 DEGREES FROM
STOWED POSITION
Figure 4-4. Position of Least Backward Stability - Sheet 2 of 2
3121171 4-7
4.9 ELECTRICAL RETRIEVAL SYSTEM Although the envelope control system (see Section 4.6, Enve-
lope Control System) remains active during the hydraulic
The Electrical Retrieval System provides a backup means of retrieval, the tower lift functionality will follow the tower path
retrieving an elevated boom in the event of a failure of any (see Section 4.7, Tower Path Control System) in an approxi-
sensor used in the envelope control system (see Section 4.6, mated fashion. Rather than the normal combined movements
Envelope Control System). Although the system is continu- of tower lift, tower telescope, and main lift, the tower lift
ously monitored for its viability, it is not active until a failure of movements will move in an alternating sequence between
the envelope control system is detected. tower lift and tower telescope with the automatic main lift sys-
The system uses a load cell pin to attach the tower lift cylinder tem (see Section 4.8, Automatic Main Boom Control System)
to the turntable. This pin is instrumented with gauges allow- disabled.
ing the forces in the pin to be monitored. The control system Operating in this mode will result in reduced function speeds,
uses these force readings to select one of two sequences of and restriction of functions. Attempts to operate restricted
retrieving the boom in a manner necessary to maintain the functions will flash the BCS light and sound the platform
stability and structural integrity of the machine. alarm.
The two sequences of boom retrieval are determined based
on the boom being closest to a position of forward stability
concern or closest to a position of backward stability concern
tem.
(See Figure 4-2., Figure 4-3., and Figure 4-4.). Regardless of the
sequence selected by the control system, the control system 4.11 CONTROLLED BOOM ANGLE SYSTEM
must recognize successive positions of the main and tower
booms before continuing with the sequence. The Controlled Boom Angle System uses the envelope control
While operating in this mode, the positions of the booms are sensors to enhance the control of the boom by minimizing the
determined by sensors not used by the primary envelope con- interaction of swing and drive functions with the envelope
trol system. These include the tower length switch, tower cyl- edges. This interaction is due to two factors. First, the envelope
inder angle sensor, main boom angle switch, and main boom is controlled relative to gravity regardless of ground slope and
length switches. second, the turntable/boom mounting is effected by swing
and drive functions when the ground slope varies. This can
Operating in this mode will result in reduced function speeds,
cause the boom position to vary within the envelope or even
BCS warning light illumination, and restriction of functions.
violate the envelope edges when swinging or driving without
Attempts to operate restricted functions will flash the BCS
intentionally moving the boom. The controlled boom angle
light and sound the platform alarm.
system minimizes this effect by automatically introducing
NOTE: For more detailed information concerning system adjust- either the tower or main boom lift up or down during swing
ment and operation, refer to Section 6 - JLG Control Sys- and drive commands to maintain a constant boom angle rela-
tem. tive to gravity.
When the tower is below the tower transport angle and the
4.10 HYDRAULIC RETRIEVAL SYSTEM main boom is 25 degrees above the tower boom, the angle of
the main boom is controlled. When the tower is above the
The Hydraulic Retrieval System provides a backup means of
tower transport angle, the angle of the tower is controlled
retrieving an elevated boom in the event of a recognized fail-
regardless of main boom position.
ure within the primary hydraulic control system related to the
main lift, tower lift, and tower telescope functions. The control Just as the booms are controlled during swing and drive func-
system monitors the primary hydraulic control system for tions, the tower angle is also controlled during main boom lift
short and open circuits, unexpected boom sensor response to and main boom telescope functions.
command, control valve spool position faults, internal valve Controlled boom angle is disabled with any envelope violation
control module faults, and CAN BUS communication faults. or failure.
When a fault is detected, the control system automatically
bypasses the appropriate hydraulic components and using
alternative valves and control logic allows the operator to
tem.
return the boom to the ground. In some cases the boom will
be allowed to move only to the extent gravity is capable of
assisting and in other cases the boom will be powered to allow
complete retrieval to the transport position.
4-8 3121171
4.12 SLOW DOWN SYSTEM NOTE: For more detailed information concerning system adjust-
To reduce the machine dynamics and improve operator con- tem.
trol, the control system uses the envelope control sensors to
automatically slow down the tower lift up, main lift up, and 4.14 HYDRAULIC SYSTEM WARM UP
main lift down function speeds as the minimum and maxi-
mum angles of the working envelope are approached. The For optimal life and performance of the hydraulic system in
control system indicates to the operator this automatic intro- extremely cold temperatures, the control system monitors the
duction of slow down by flashing the creep light on the plat- hydraulic system temperature and automatically limits the
form display panel. This feature applies to both platform and function speeds of the high demand functions.
ground controls, however, no indication is made on the While the system is cold and in the warm up mode, the tower
ground control panel. lift, main lift, and main telescope functions are limited to creep
speeds and is indicated to the operator by flashing the creep
NOTE: For more detailed information concerning system adjust- light on the platform control panel.
Operating the machine while in the warm up mode will gener-
tem.
ate sufficient heat to bring the hydraulic temperature up to
4.13 DUAL CAPACITY SYSTEM allowable temperatures and the warm up mode will be auto-
matically turned off. Although operating any function will
The Dual Capacity System is a multiple envelope control sys- generate heat, the tower lift function will warm the hydraulic
tem as opposed to a capacity indication system. The control system temperature the fastest as this function will operate
system changes the allowable working envelope to match the tower lift, tower telescope, and main lift function automati-
capacity select mode to either the 500# (230 kg) mode or the cally.
1000# (450 kg) mode. It then displays the capacity mode on Functions being operated when the warm up mode turns off
the platform and ground display panel and controls the posi- will remain in the creep speed until the function is re-initiated.
tions of the main boom within the allowable envelope for that
mode. This mode is selectable by the operator with the dual NOTE: For more detailed information concerning system adjust-
capacity select switch on the platform control panel. ment and operation, refer to Section 6 - JLG Control Sys-
The 500# (230 kg) mode has the largest envelope and allows tem.
the use of the side swing jib. The 1000# (450 kg) mode has a
smaller envelope and requires the jib to be fixed in the cen-
4.15 REDUCED PLATFORM HEIGHTS
tered position. The control system allows the maximum platform height of
The control system uses the envelope control sensors (item16) the machine to be restricted to a selectable reduced height to
in addition to the 4 limit switches and cams mounted on the allow increased versatility in the rental market. The selection
main base and fly booms to restrict the main boom length of 125, 100, and 80 ft maximum platform heights are available
between the main boom angles of +55° and –45° for the 1000# in the dealer mode - machine set up menu on the analyzer.
envelope. The reduced platform heights are implemented by restricting
To select the 1000# (450 kg) mode the boom must already be the travel of the tower boom up the tower path (see Section
in the smaller 1000# (450 kg) envelope and the jib must be 4.7, Tower Path Control System) while maintaining all other
centered (+/-10 degrees) verified to the control system by the aspects of the envelope control system (see Section 4.6, Enve-
jib centered limit switch mounted on the side swing rotator. lope Control System). The limits and functionality of the main
boom are unaffected by the selection.
When the operator selects the 1000# (450 kg) mode and these
conditions are met, the capacity light changes from 500# (230
kg) to 1000# (450 kg), jib swing is disallowed, and the enve-
lope is changed accordingly.
When the operator selects the 1000# mode and these condi-
tions are not met, both capacity lights will flash, the platform
alarm will sound, and all functions except jib swing will be dis-
abled until the capacity select switch is put back into the 500#
(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.
When in the 1000# (450 kg) mode, attempts to telescope, lift
or lower the main boom into the restricted area will cause that
function to be prevented.
3121171 4-9
4.16 ELECTRONIC PLATFORM LEVELING 4.17 PLATFORM

The Electronic Platform Leveling System uses two tilt sensors
(mounted on either side of the pivot weldment), a control
Support Removal
valve (mounted to the platform support), a level cylinder, and 1. Disconnect electrical cables from control console.
the platform control module (mounted in the platform control
box) to automatically measure and control the incline of the 2. Tag and disconnect the hydraulic lines from the rotator.
platform with respect to gravity. This system is active while Use suitable container to retain any residual hydraulic
operating drive, telescope, lift or swing. It is not active while fluid. Cap hydraulic lines and ports.
operating any other function (e.g. rotate, jib, or steer). The sys- 3. Remove the bolts securing the platform to the platform
tem controls the platform angle relative to gravity using a set support, then remove the platform.
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 opera-
tor 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 (see Section
4.2, Transport Position Sensing System)
To reset a platform leveling fault, the emergency stop switch
should be recycled.
MAE17160

ment and operation, refer to Section 6 - JLG Control Sys- 4. Using a suitable lifting device, support the platform sup-
tem. port.
NOTE: The platform support weighs approximately 125 lbs.

(56.8 kg).
4-10 3121171
5. Remove the bolts and washers securing the support to Support Installation
the rotator.
1. Using a suitable lifting device, support the platform sup-
port and position it on the rotator.
NOTE: The platform support weighs approximately 125 lbs.

(56.7 kg).
2. Install the rotator center bolt.
MAE17170
6. Using a suitable brass drift and hammer, remove the

rotator center bolt, then remove the support from the
rotator.
MAE17180
3. Apply JLG Threadlocker PN 0100011 to the bolts and

washers securing the support to the rotator and install
the bolts and washers.
MAE17180
MAE17170
4. Torque the nut on the rotator center bolt to 586 ft. lbs.
(795 Nm). Torque the retaining bolts to 40 ft. lbs.
(55 Nm).
3121171 4-11
5. Position the platform on the platform support and 6. Remove tag and reconnect the hydraulic lines to the
install the bolts securing the platform to the platform rotator.
support.
7. Connect the electrical cables to the platform control
console.
MAE17160
A, B, D
C, D
NOTE: If any rotator bolts are replaced, replace all
bolts on the rotator and torque them
A Torque to 40 ft.lbs. (55 Nm)

B JLG Threadlocker PN 0100011
C Torque 586ft. lbs. (795 Nm)
D Check torque every 150 hours of operation
E Torque 105 ft. lbs. (145 Nm)
Figure 4-5. Platform Support Torque Values
4-12 3121171
A,B,D NOTE: If any rotator bolts are replaced, all bolts on the
rotator should be retorqued.
C,D
A Torque to 50 ft.lbs. (68 Nm)

B JLG Threadlocker PN 0100011
C Torque to 586ft. lbs. (795 Nm)
D Check torque every 150 hours of operation
E Torque to 75 ft. lbs. (102 Nm)
Figure 4-6. Platform Support Torque Values
3121171 4-13
4.18 ROTATOR 4. Remove the hardware from pin #2. Using a suitable
brass drift and hammer, remove pin #2 and remove the
rotator.
Removal
1. Remove the Platform and Platform Support. Refer to Installation
Section 4.17, Platform.
NOTE: The rotator approximately weighs 60 lbs. (27 kg).
2. Tag and disconnect hydraulic lines to rotator. Use suit-
able container to retain any residual hydraulic fluid. Cap 1. Supporting the rotator and jib assembly, align rotator
or plug all openings of hydraulic lines and ports. with jib assembly mounting point and jib. Using a soft
head mallet, install pin #1 to the jib assembly. Install
NOTE: The rotator approximately weighs 60 lbs. (27 kg).
hardware securing pin #1.
3. Supporting the rotator and jib assembly, remove hard- 2. Using a soft head mallet install pin #2 to jib assembly
ware from pin #1. Using a suitable brass drift and ham- and install the rotator. Install hardware securing pin #2.
mer remove pin #1.
JIB ASSEMBLY
JIB LIFT CYLINDER
ROTATOR
2
MAE37980
Figure 4-7. Rotator Removal/Installation
4-14 3121171
4.19 MAIN BOOM 8. Remove the cover from the top of the main boom to
gain access to the telescope cylinder attaching hard-
ware.
Disassembly
NOTE: The following procedure allows the boom base section to
remain attached to the machine.
1. Make sure the machine is on a firm, level surface.
NOTE: The jib and platform assembly weighs approximately

1000 lbs. (454 kg).
2. Support the jib sand platform assembly.

3. Tag and disconnect all electrical lines running to the jib
and platform.
4. Tag and disconnect all hydraulic lines running to the jib
and platform.
5. Remove the bolts, keeper pins, and pivot pins that
secure the jib rotator support to the nose of the fly sec-
tion.
9. Remove the bolt, keeper pin, and retaining pin securing

the barrel end of the telescope cylinder to the main
boom base section.
6. Remove the jib/platform assembly from the boom.

7. Extend the fly section enough to attach an adequate lift- 10. Using an adequate lifting device, pull the main fly sec-
ing device for removing the fly section. tion and telescope cylinder out of the main boom base
section.
NOTE: The main boom fly section including telescope cylinder

and level cylinder weighs approximately 2000 lbs. (907 kg).
3121171 4-15
11. If necessary, remove the shoulder screws, retaining 13. If necessary, remove the shoulder screws, retaining ring,
rings, and pin that secures the rod end of the telescope and pin that secures the barrel end of the level cylinder
cylinder to the main boom fly section and remove the to the main boom fly section and remove the level cylin-
telescope cylinder from the fly section. der from the fly section.
12. If necessary, remove the bolt, keeper pin, and pivot pin Assembly
securing the upper link to the boom nose and remove
1. If removed during assembly, install the level cylinder
the upper and lower links as an assembly. If necessary,
into the fly section. Install the shoulder screws, retaining
remove the bolt (screw prior to S/N 80869), pin retainer
ring, and pin that secures the barrel end of the level cyl-
sleeve, and nut securing the lower link to the upper link.
inder to the main boom fly section.
2. If removed during assembly, install the pin retainer

sleeve, bolt (screw prior to S/N 80869), and nut securing
the lower link to the upper link. On machines using the
bolt and nut, torque to 190 ft. lbs. (260 Nm). Position the
4-16 3121171
upper link to the boom nose and secure in place with 4. Install the bolt, keeper pin, and retaining pin that
the pivot pin, keeper pin, and bolt. secures the barrel end of the telescope cylinder to the
main boom base section.
5. Install the cover to the top of the main boom.
3. If removed during assembly, install the telescope cylin-

der into the fly section. Install the shoulder screws,
retaining rings, and pin that secures the rod end of the
telescope cylinder to the main boom fly section.
4. Using an adequate lifting device, slide the main fly sec-

tion and telescope cylinder into the main boom base
section.
NOTE: The main boom fly section including telescope cylinder

and level cylinder weighs approximately 2000 lbs. (907 kg)
3121171 4-17
6. Install the jib/platform assembly onto the boom.

7. Extend the fly section enough to attach an adequate lift-
ing device for removing the fly section.
8. Install the bolts, keeper pins, and pivot pins that secure
the jib rotator support to the nose of the fly section.
9. Connect all hydraulic lines running to the jib and plat-

form as tagged during disassembly.
10. Connect all electrical lines running to the jib and plat-
form as tagged during removal.
4-18 3121171
3121171
See Figure 4-9., Main Boom Assembly - Sheet 2 of 4 See Figure 4-9., Main Boom Assembly - Sheet 2 of 4
Figure 4-8. Main Boom Assembly - Sheet 1 of 4
4-19
4-20
1. JLG Threadlocker PN 0100011

2. Washer
3. Bolt
4. Shim
5. Wear Pad
6. Screw
7. Main Tele Cyl.
8. Bolt
9. Shoulder Screw
10. Pin
11. Tele Exhaust Hose
12. Tele Extend Hose
13. Tele Retract Hose
3121171
3121171
ALIGN ENDS OF ALL FIBERGLASS BARS
TO BE FLUSH WITH HOLES IN SIDE
OF FLY BOOM AS SHOWN HERE
CENTER FIBERGLASS BARS VERTICALLY
OVER HOLES IN SIDE OF FLY BOOM
AS SHOWN HERE
4-21
4-22
1. Pivot Assembly 5. Bolt 9. Shoulder Screw 13. Bolt 17. Upper Jib Link 21. Fly Boom Section 25. Pin
2. Upper Front Wear Pad 6. Level Cylinder Pin 10. Level Cylinder 14. Jib Rotator 18. Platform Rotator 22. Base Boom Section
3. Shim 7. Tele Cylinder Pin 11. Side Wear Pad 15. Lower Jib Link 19. Level Link Pin 23. Bolt
4. Bolt 8. Retaining Ring 12. Shim 16. Jib Cylinder 20. Retaining Ring 24. Keeper
3121171
NOTE: If any rotator bolts are replaced, all bolts on the rota-
tor should be retorqued. Check torque on the bolts
every 150 hours of operation.
Ft-Lbs. Nm
A 85 115
B 300 410
C 480 650
D 85 115
E 190 260
Figure 4-12. Main Boom Assembly Torque Values
3121171 4-23
4.20 TOWER BOOM

Installation and Assembly
NOTE: To ease assembly of the tower base boom to the machine,
have the base section slightly tilted downward towards the
pivot pin bushings.
1. Use an overhead crane or other suitable lifting device,

and maneuver the tower boom base section in place.
Install the pivot pin. Install the keeper pin and apply JLG
Threadlocker PN 0100019 to the retaining bolt. Torque
the bolt to 285 ft. lbs. (386 Nm).
4. Lift the tower base section up and extend the lift cylin-
der to align it with the attachment lugs. Refer to the Ser-
vice Mode procedure in Section 4.26, Tower Lift Cylinder.
NOTE: The tower lift cylinder weighs approximately 643 pounds

(292 kg).
2. Use a ratchet strap to carefully raise the lift cylinder up

into position under the boom.
5. When the lift cylinder and tower base pivot holes are
aligned, install the pivot pin. Install the keeper pin and
apply JLG Threadlocker PN 0100019 to the retaining
bolt. Torque the bolt to 285 ft. lbs. (386 Nm).
3. Place blocking under the front of the tower base and

move the lifting strap out to the end of the tower base
section.
4-24 3121171
FLY TO MID
FLY TO BASE
VIEW A - A FLY TO BASE
SOME ITEMS REMOVED FOR CLARITY VIEW B - B

SOME ITEMS REMOVED FOR CLARITY FLY TO MID
305.375" (775.65 cm) RET - 669.375" (1700.21 cm) EXT

180.500" (458.47 cm) FLY TELE STROKE
183.500" (466.09 cm) MID TELE STROKE
364.000" (924.56 cm) TOTAL STROKE
0801370-E
MAE38700E
Figure 4-13. Tower Boom Assembly - Sheet 1 of 3
3121171 4-25
18
0801370-E
MAE38710E
1. Tower Fly 6. Bolt 10. Screw 14. Front Lower Wear Pad
2. Tower Mid 7. Washer 11. Shoulder Bolt 15. Wear Pad Shim
3. Tower Base 8. Front Side Wear Pad 12. Snap Ring 16. Bolt
4. Front Upper Wear Pad 9. Wear Pad Shim 13. Retaining Pin 17. Washer
5. Wear Pad Shim 18. Cover (Prior to SN 0300120859)
4-26 3121171
17
0801370-E
MAE38720E
1. Upper Rear Wear Pad 5. Rear Side Wear Pad 9. Keeper Shim 13. Wear Pad Shim
2. Wear Pad Shim 6. Wear Pad Shim 10. Bolt 14. Bolt
3. Bolt 7. Screw 11. Tower Tele Cylinder
15. Washer
4. Washer 8. Trunnion Keeper Block 12. Bottom Rear Wear Pad
16. Hose Loop
17. Cover (Prior to SN 0300120859)
3121171 4-27
Ft-Lbs. Nm
A 85 115
B 35 47.5
Figure 4-15. Tower Boom Assembly Torque Values - Sheet 1 of 2
4-28 3121171
Ft-Lbs. Nm
A 85 115
B 35 47.5
Figure 4-16. Tower Boom Assembly Torque Values - Sheet 2 of 2
3121171 4-29
BOLT, KEEPER PIN
DETAIL A
PIVOT PIN
DETAIL E
DETAIL A
DETAIL D
See Figure 4-21., Boom & Cylinder

Installation - Sheet 5 of 5 DETAIL C DETAIL B
0272979-M
Figure 4-17. Boom & Cylinder Installation (Prior to SN 0300144623) - Sheet 1 of 5
4-30 3121171
LOCK NUT
DRIVE HUB
SECTION A-A
A A
1001138811-G
1001120653-H
MAE37830
Figure 4-18. Boom & Cylinder Installation (SN 0300144623 to Present) - Sheet 2 of 5
3121171 4-31
LOAD SENSING PIN
TOWER LIFT CYLINDER

BOLT, KEEPER PIN
SCREW
PIVOT PIN
BOLT, KEEPER PIN
PIVOT PIN
MAIN LIFT CYLINDER

0272979-M
1001120653-H
1001138811-G
Figure 4-19. Boom & Cylinder Installation - Sheet 3 of 5
4-32 3121171
See Figure 4-26., Pin

Clamp Detail
0272979-M
1001120653-H
1001138811-G
1. Upper Link 7. Pin

2. Retaining Ring 8. Keeper
3. Bolt 9. Bolt
4. Keeper 10. Pin
5. Pin 11. Bolt
6. Lower Link 12. Keeper
3121171 4-33
NOTE: If space is available install one thrust washer on each side of the boom assembly between the
tower fly boom section and the main base boom section. If space only allows for the use of
one thrust washer, install it on the same side as the proximity sensor. (Same as the left side or
powertrack side of the machine.)
THRUSTWASHER THRUSTWASHER
0272979-M
1001120653-H
1001138811-G
4-34 3121171
Bolt # Ft-Lbs. Nm
1 675 915
2 285 386
3 190 260
4 600 813
5 200 271
0272979-M
1001120653-H
1001138811-G
Figure 4-22. Boom and Cylinder Installation Torque Values - Sheet 1 of 3
3121171 4-35
0272979-M
1001120653-H
1001138811-G
4-36 3121171
Bolt # Ft-Lbs. Nm
1 675 915
2 285 386
3 190 260
4 600 813
5 200 271
0272979-M
1001120653-H
1001138811-G
3121171 4-37
0273513 E
1. Bar
2. Blade
3. Plate
A Apply JLG Threadlocker PN 0100011 & torque to 85 ft.lbs. (115 Nm)
B Apply JLG Threadlocker PN 0100011 & torque to 35 ft.lbs. (47 Nm)
C Adjust all blades 0.000 to 0.063" (0 to 1.6 mm) from side boom plate
Figure 4-25. Boom Wiper Installation
4-38 3121171
4. Align the telescope cylinder trunnions. Install the keep-

ers and shims. Secure them in place with the retaining
bolts.
5. Install the upper and lower length sensors.
1. Install the tower mid section into the tower base sec-
tion. Install the wear pads in the tower base section.
NOTE: Keep the tower fly section out of the tower mid section
enough to allow for installation of the telescope cylinder
retaining pin.
2. Install the tower fly section into the tower mid section. 6. Connect all hoses and electrical lines as tagged during
Install the wear pads in the tower mid section. disassembly.
3. Extend the telescope cylinder so the rod will be 7. Install the power track to the side of the tower boom.
extended enough to install the retaining pin holes in the Connect all hoses as tagged during disassembly.
tower fly section. It may be necessary to secure one end
to make sure the desired rod end extends. Install the
telescope cylinder into the tower boom. Refer to the Ser-
vice Mode procedure in Section 4.25, Tower Telescope
Cylinder.
3121171 4-39
9. Install the pivot pin. Install the keeper pin and apply JLG
the bolt to 285 ft.lbs. (386Nm).
NOTE: The lower link weighs approximately 659 lbs. (299 kg).
8. Insert a pin through the hole in the lower link so that a

lifting strap can be used to position the link in the tower
fly section. NOTE: The main lift cylinder weighs approximately 785 lbs. (356
kg). The upper link weighs approximately 412 lbs. (187 kg).
10. Lift the main lift cylinder into position with the lower
link. Install the pivot pin in part way. Lift the upper link
to align the pivot pin bushings in the lower link, lift cyl-
inder, and upper link.
4-40 3121171
11. Install the pivot pin. Install the keeper pin and apply JLG Pin Clamp Installation Procedure
the bolt to 675 ft. lbs. (915 Nm). 1. Install the main boom pivot pin and loosely install the
cross bolt and nut.
2. Install the pin clamp bar. Clamp the bolts and washers.
Tighten the clamp bolts enough to hold the pin clamp in
position for the following steps (5 ft. lbs. [7 Nm] maxi-
mum).
3. Install the jack screws and jam nuts. Torque the jack
screws to 600 ft. lbs. (813 Nm). Torque the jam nuts to
200 ft. lbs. (271 Nm).
4. Torque the clamp bolts to 190 ft. lbs. (260 Nm).
5. Torque the cross bolt and nut to 190 ft. lbs. (260 Nm).
NOTE: The main boom assembly weighs approximately 5,186 lbs.

(2357 kg).
12. Lift the main boom in position to align the pivot pin
bushings in the main boom and tower boom. Install the
main boom pivot pin as described in the Pin Clamp
Installation Procedure below.
13. Lift the upper link into position to align the pivot pin
holes in the main boom with the pivot pin bushings in
the upper link. Install the keeper pin and apply JLG
the bolt to 285 ft.lbs. (386Nm).
1. Pivot Pin
2. Cross Bolt
3. Nut
4. Pin Clamp Bar
5. Clamp Bolt
6. Jack Screw
7. Jam Nut
Figure 4-26. Pin Clamp Detail
3121171 4-41
*
*
*
*
**
**
*
*
* JLG Threadlocker PN 0100011
** JLG Threadlocker PN 0100019
MAE38250
Figure 4-27. Locations for JLG Threadlocker Application - Sheet 1 of 5
4-42 3121171
*
*
*
*
*
*
MAE38460
3121171 4-43
*
*
*
*
*
*

*
MAE38470
4-44 3121171

MAE38480
3121171 4-45
*
MAE38490
4-46 3121171
DIA "X" Table 4-1. Hose/Cable Pull Chart

Dim. X
A Letter Description
In. Cm.
B A Platform Supply Hose 60 152
C B Platform Return Hose 7 18
D C Main Tele Extend Hose 7 18
D Main Tele Retract Hose 7 18
E
E Main Lift Extend Hose 60 152
F
F Main Lift Retract Hose 60 152
G G Main Lift Pilot Hose 60 152
H H Tower Boom Control Cable 8 20
I I Tower Boom Sensor Harness 8 20

J AC Cable 62 157
J
K Weld Lead 62 157
K L 7500W Generator (Optional) 62 157
L M Air Line (Optional) 62 157
M NOTE: All X Dimensions are ± 1 in. (2.5 cm)
SEE DETAIL A
SEE DETAIL B
5.0 ± 1.0 in (127 ± 25 mm)
DETAIL A
DETAIL B
4.0 ± 0.5 in (100 ± 12 mm)

MAINTAIN HOSE/CABLE LOOP
AT THIS DIMENSION 4.0 ± 1.0 in (100 ± 25 mm)
6.0 ± 0.5 in (152 ± 12 mm)
MAINTAIN HOSE/CABLE LOOP
AT THIS DIMENSION
0273360-F
MAE37840F
Figure 4-32. Tower Boom Powertrack Installation - Sheet 1 of 3
3121171 4-47
USING CINCH STRAPS, MAKE

THREE SEPERATE BUNDLES AS FOLLOWS: ADJUST PUSHTUBE POSITION SO THAT THERE IS
1. MAIN TELESCOPE EXTEND, RETRACT & PLATFORM RETURN 0.25 ± 0.12 (6 ± 3 mm) CLEARANCE BETWEEN
HOSES. DETAIL E PUSHTUBE AND POWERTRACK ROLLER AT THIS
2. PLATFORM SUPPLY & (3) MAIN LIFT CYLINDER HOSES. LOCATION
3. ALL OTHER CABLES & AIRLINE THAT ARE ROUTED THROUGH
MAIN BOOM BAR CLAMP.
STRAPS ARE TO BE LOCATED AT 6.0 ± 1.0 in (152 ± 25 mm) AND
16.0 ± 1.0 in (406 ± 25 mm) FROM TOWER FLY BOOM HOSE LOOP
ROUTE HOSE/CABLE BUNDLE THROUGH HOSE

LOOP ON TOWER FLY BOOM AS SHOWN
PLATFORM
GENERATOR CABLE CONTROL
OR WELD LEAD CABLE
BOOM
MAIN LIFT CYL SENSOR
CABLE
AIRLINE
PLATFORM DETAIL C
SUPPLY
MAIN LIFT CYL

ROUTE HOSES THROUGH PUSHTUBE
PLATFORM TUBES AS SHOWN ABOVE
RETURN
MAIN LIFT CYL

MAIN TELE CYL
MAIN TELE CYL
DETAIL E
PLATFORM RETURN
MAIN TELESCOPE CYL

MAIN LIFT CYL
PLATFORM SUPPLY
MAIN TELE CYL

MAIN LIFT CYL
MAIN LIFT CYL
AIRLINE ROUTE HOSES THROUGH POWER TRACK

SEPERATOR BARS AS SHOWN BELOW
ELECTRICAL CABLES
GENERATOR CABLE
OR WELD LEAD
DETAIL C
0273360-F
MAE37850F
4-48 3121171
SEE DETAIL D
ROUTE HOSES THROUGH CARRIER

TUBES AS SHOWN ABOVE
PLATFORM SUPPLY MAIN LIFT CYL

MAIN TELE CYL
AIRLINE
PLATFORM RETURN
GENERATOR CABLE
OR WELD LEAD
MAIN LIFT CYL
MAIN TELE CYL

ELECTRICAL CABLES
CABLE
MAIN LIFT CYL
DETAIL D
0273360-F
MAE37860F
3121171 4-49
1. Tower Lift Cylinder Angle Sensor (1) 7. Main Boom Transport Length Switch (2)
2. Load Pin(1) 8. Dual Capacity Length Switch (2)
3. Tower Angle Sensors (2) 9. Main Boom Transport Angle Switch (1)
4. Tower Length Sensors (2) 10. Jib Stow Switch (1)
5. Tower Transport Length Switch (1) 11. Dual Capacity Jib Position Switch (1)
6. Main Boom Angle Sensor (2)
Figure 4-35. Boom Sensor Locations Overall View - Sheet 1 of 2
4-50 3121171
SEE DUAL CAPACITY LENGTH SWITCH &

MAIN BOOM TRANSPORT LENGTH SWITCH DETAILS SEE LEVEL SENSOR &
Figure 4-38. JIB SWITCH DETAILS
Figure 4-40.
IMPORTANT: THE CONTROL SYSTEM MUST BE RECALIBRATED AT THE CON-

CLUSION OF ASSEMBLY OR REPLACEMENT OF ANY SENSOR.
SEE TOWER BOOM LENGTH SENSOR &

TOWER BOOM ANGLE SENSOR DETAILS
Figure 4-41.
SEE ROTARY ANGLE SENSOR DETAILS

& ANGLE SWITCH DETAIL
Figure 4-43. SEE TOWER LIFT CYLINDER
ANGLE SENSOR DETAIL
Figure 4-37.
SEE TOWER BOOM TRANSPORT

LENGTH SWITCH DETAIL
Figure 4-38.
0273121-P
Figure 4-36. Boom Sensor Locations Overall View - Sheet 2 of 2
3121171 4-51
1. Sensor Cover
2. Washer
3. Ring
4. Bolt
5. Sensor Arm
6. Sensor Switch
7. Lift Cylinder
TOWER LIFT CYLINDER

ANGLE SENSOR DETAIL
SENSOR COVER REMOVED
FOR CLARITY
SECTION A-A
SEE TOWER LIFT CYLINDER

ANGLE SENSOR DETAIL
0273121-P
Figure 4-37. Boom Sensor Locations - Tower Lift Cylinder Angle Sensor
4-52 3121171
MAIN BOOM TRANSPORT

ENSURE THAT MAIN BOOM TRANSPORT

2X 90° LENGTH SWITCH LEVERS AND HEADS
ARE ORIENTED AS SHOWN
ROUTE SWITCH HARNESS AROUND COVER MOUNT TO AVOID DAMAGE: SWITCH LEVER TRAVEL LIMIT MUST BE
AS SHOWN EQUAL IN BOTH DIRECTIONS. ORIENT SWITCH LEVER AT
SPLINE INDEX LOCATION CLOSEST TO 90°
DUAL CAPACITY
ENSURE THAT DUAL CAPACITY
LENGTH SWITCH LEVERS AND HEADS
ARE ORIENTED AS SHOWN 2X 90°
TO AVOID DAMAGE: SWITCH LEVER TRAVEL LIMIT MUST BE

EQUAL IN BOTH DIRECTIONS. ORIENT SWITCH LEVER AT
0273121-P
Figure 4-38. Boom Sensor Locations - Dual Capacity, Length, & Main Boom Transport
3121171 4-53
TOWER BOOM TRANSPORT

LEVER FULLY
EXTENDED
90°
TO AVOID DAMAGE: SWITCH LEVER TRAVEL LIMIT MUST BE

EQUAL IN BOTH DIRECTIONS. ORIENT SWITCH LEVER AT
0273121-P
Figure 4-39. Boom Sensor Locations - Tower Boom Transport Length
4-54 3121171
SEE PUSH NUT DETAIL
PUSH NUT
PUSH NUT DETAIL
LEVEL SENSOR DETAIL

SENSOR SENSOR COVER
MOUNT TYPICAL ON LEFT & RIGHT
SIDE OF BOOM
MOUNTING
BOLT
JIB STOW SWITCH TO ACTIVATE WHEN JIB ROTATES 70°

TOWARDS RIGHT SIDE OF MACHINE FROM CENTER
POSITION THE JIB SWITCH MOUNT TO ACHIEVE

0.000" - 0.030" (0.00mm - 0.79mm)
CLEARANCE BETWEEN SWITCH ROLLERS
AND ROTATOR CAM
JIB SWITCH DETAIL
JIB CENTER SWITCH TO ACTIVATE

WHEN JIB IS ROTATED 10° ± 1° BOTH
DIRECTIONS FROM CENTER
0273121-P
Figure 4-40. Boom Sensor Locations - Level & Jib Position Switches
3121171 4-55
LOWER SENSOR DETAIL
NOTE: LENGTH SENSOR COVER NOT SHOWN FOR

CLARITY
UPPER SENSOR DETAIL
ATTACH LATCH HOOK TO RING

ON FLY BOOM AS SHOWN
TYPICAL ON UPPER & LOWER SENSORS
SEE UPPER SENSOR DETAIL
TOWER BOOM ANGLE

SENSOR DETAIL
TOWER BOOM LENGTH

SENSOR DETAIL
SEE LOWER SENSOR DETAIL
0273121-P
Figure 4-41. Boom Sensor Locations - Upper Length, Lower Length, & Tower Boom Angle - Sheet 1 of 2
4-56 3121171
HOSE LOOP
NOTE: ROUTE 3/4" TELE CYL EXTEND HOSE

THROUGH HOSE LOOP
ROUTE ALL SENSOR HARNESSES WITH

3/4" TELE CYL EXTEND HOSE BUT DO NOT
ROUTE THE SENSOR HARNESSES
THROUGH THE HOSE LOOP
ROUTE REMAINING TELE CYL HOSES WITH

3/4" TELE CYL EXTEND HOSE, BUT DO
NOT ROUTE THE REMAING HOSES
THROUGH THE HOSE LOOP.
USE TIE STRAPS TO FASTEN HARNESSES TO

TELE CYL HOSES AT LOCATIONS SHOWN
MAINTAIN 58" (147 cm) OF HARNESS

LENGTH FROM TURNTABLE HOSE LOOP
TO ALLOW FOR BOOM MOVEMENT
TYPICAL ON LEFT & RIGHT

SIDES OF BOOM
ATTACH SENSOR HARNESS
TERMINAL HERE
TYPICAL ON LEFT & RIGHT

SIDES OF BOOM
36" (91 cm)

STRAP LOCATION
27" (69 cm) 32" (81 cm) NOTE: DO NOT STRAP LEFT & RIGHT
22" (56 cm)
TURNTABLE HOSE LOOP STRAP LOCATION STRAP LOCATION TOWER BOOM ANGLE SENSOR HARNESSES
STRAP LOCATION
(ALL STRAP LOCATION IN THIS TIE STRAP
MEASUREMENTS ARE
TAKEN FROM THIS LOOP)
0273121-P
Figure 4-42. Boom Sensor Locations - Upper Length, Lower Length, & Tower Boom Angle - Sheet 2 of 2
3121171 4-57
REPOSITION SWITCH HEAD AND

LEVER AS SHOWN ON LIMIT SWITCH
LEVER IN-LINE
WITH SWITCH BODY
TYPICAL
LEFT & RIGHT SIDES OF BOOM
ALIGN TIMING MARKS ON SHAFT WITH LABELED

LETTERS (L or R)
EACH SENSOR MUST CORRESPOND WITH
SIDE OF BOOM ON WHICH IT IS MOUNTED
ROTARY SENSOR DETAIL

TYPICAL
LEFT & RIGHT SIDES OF BOOM
SEE ROTARY SENSOR DETAIL (LEFT SIDE OF BOOM SHOWN) 0273121-P
Figure 4-43. Boom Sensor Locations - Rotary Angle & Proximity Sensor - Sheet 1 of 2
4-58 3121171
ADJUST PROXIMITY SENSOR TO BE FLUSH ±0.015 (0.396 mm)

WITH BOTTOM OF COUNTERBORE IN SENSOR MOUNT
DETAIL C
MAIN BASE BOOM

PIVOT DOUBLER
PROXIMITY SENSOR
PROXIMITY SENSOR MOUNT

0.138 (3.5mm)
ADJUST SENSOR MOUNT TO HAVE 0.138 ± 0.030 (3.5 ± 0.76 mm)

CLEARANCE TO PIVOT DOUBLER WHEN BOOMS ARE IN STOWED POSITION
PROXIMITY SENSOR
PROXIMITY SENSOR MOUNT
SLIDE COUPLING ONTO SWITCH

UNTIL IT BOTTOMS OUT
TORQUE CLAMP SCREW
TO 8 in.lbs. (0.9 Nm)
SLIDE COUPLING ONTO COUPLING
MOUNT UNTIL IT BOTTOMS OUT INITIAL ADJUSTMENT: USE TRUNNION KEEPER SHIMS TO ADJUST SEN-
TORQUE CLAMP SCREW SOR MOUNT BAR TO BE FLUSH
TO 8 in.lbs. (0.9 Nm) ±0.060 (1.52mm) WITH MAIN BOOM
PIVOT PIN AS SHOWN BELOW
MEASUREMENT SURFACE
NOTE: BOOM OPERATION CAN CAUSE BOOM TO MOVE SIDE-TO-SIDE ON

ITS PIVOT PIN. PROPER ADJUSTMENT OF MOUNTING BLOCK CAN BE VAR-
IED FROM THE FLUSH CONDITION IF THE MEASUREMENT SURFACE ON
ONE SIDE OF THE BOOM IS UNDER HEIGHT BY AN EQUAL VALUE AS TEH
OPPOSITE SIDE IS OVER HEIGHT.
SEE DETAIL C
SECTION B-B
FROM Figure 4-36.
0273121-P
Figure 4-44. Boom Sensor Locations - Rotary Angle & Proximity Sensor - Sheet 2 of 2
3121171 4-59
4.21 MAIN BOOM TRANSPORT ANGLE SWITCH and
See Figure 4-38., Boom Sensor Locations - Dual Capacity, Length,

& Main Boom Transport and Figure 4-45., Main Boom Transport
Angle Switch Wiring
The Main Boom Transport Angle Switch is located on the left

side of the tower fly boom underneath the cover. This switch is
used as a backup for the rotary angle sensors and trips (acti-
vates) when the main boom is approximately 15° above the
tower boom. It is used to find the transport position in the
event of a rotary angle sensor failure and also used during
Electrical Retrieval (see Section 4.9, Electrical Retrieval System)
to assist in determining the angle of the main boom when a
fault is detected to any sensor in the Envelope Control System
(see Section 4.6, Envelope Control System).
While conducting boom sensor calibration (see Section 6.15,

Boom Sensor Calibration), “position 2” states to lift up the
main boom to stop. The control system will stop the main
boom lift up function at the main boom angle limit switch trip
point (approx 15°).
Analyzer Readings
The analyzer reading for these switches can be found in the In the OUT of transport position, the screen should read
Diagnostics menu under Transport Data.
In the Transport position, the screen should read:
4-60 3121171
and 4.22 TOWER TRANSPORT LENGTH SWITCH

& Main Boom Transport and Figure 4-46., Tower Transport Length
Switch Wiring
The Tower Transport Length Switch is located on the left side

of the tower base boom underneath the cover. This switch is
used as a backup for the tower boom string pot length sensors
and trips (activates) when the tower boom is extended
approximately 7” (18 cm). It is used to find the transport posi-
tion in the event of a tower length sensor failure and during
Electrical Retrieval (see Section 4.9, Electrical Retrieval System)
to assist in determining the length of the tower boom when a
fault is detected to any sensor in the Envelope Control System
(see Section 4.6, Envelope Control System).
Analyzer Readings
The analyzer reading for these switches can be found in the
In the Transport position, the screen should read:
Possible Faults
1. Stuck Switch
• 8/4 Fault Code
• MAIN BOOM TRN AGL SW/SENSOR DISAGREEMENT
Analyzer message.
2. Wire Broken/Disconnected
• 8/4 Code Fault Code
• MAIN BOOM TRN AGL SW FAILED Analyzer message
3121171 4-61
and In the OUT of Transport position, the screen should read:
and and
4-62 3121171
Possible Faults In Transport - Switch #2 on cam:
1. Stuck Switch
• 8/4 Fault Code
• TWR LEN SW/SENSOR DISAGREEMENT Analyzer
message.
• TWR LEN SW DISAGREEMENT Analyzer message
4.23 MAIN BOOM TRANSPORT LENGTH SWITCHES

& Main Boom Transport and Figure 4-47., Main Boom Transport
Length Switch Wiring
The Transport Length Switches are located on the right side of

the Main Base boom underneath the cover. These switches run
on cams mounted to the upper fly boom to determine if the
main boom is telescoped within or beyond the transport posi-
tion. They also work with the Dual Capacity Switches to deter-
mine the length of the main boom to restrict the main boom
length between the main boom angles of +55° and -45° for the Out of Transport - Switch #1 on cam:
1000 lb (450 kg) envelope.
Analyzer Readings
In Transport - Switch #1 off cam:
3121171 4-63
Out of Transport - Switch #2 off cam: 4.24 DUAL CAPACITY SWITCHES

& Main Boom Transport and Figure 4-48., Dual Capacity Switch
Wiring
The Dual Capacity Switches are located on the left side of the
Main Base boom underneath the cover. The Dual Capacity
Switches along with the Main Boom Transport Length
Switches run on a series of cams mounted on the fly boom to
determine the length of the main boom. These switches
restricts the main boom length between the main boom
angles of +55° and -45° for the 1000 lb (450 kg) envelope.
Analyzer Readings
Switch #1 off cam:
Possible Faults
1. Stuck Switch
• 8/4 Fault Code
• TRANS SW SW DISAGREEMENT* Analyzer message
*This fault will not show up until telescope is activated.
• TRANS SW SW DISAGREEMENT Analyzer message
4-64 3121171
Switch #2 on cam: Switch #2 off cam:
Switch #1 on cam:
Possible Faults
1. Stuck Switch
• 8/4 Fault Code
• CAP LEN SW DISAGREEMENT* Analyzer message
*This fault will not show up until telescope is activated.
• CAP LEN SW DISAGREEMENT Analyzer message
3121171 4-65
IN TRANSPORT: OUT OF TRANSPORT:

12 volts on red (2-70-6) 12 volts on red (2-70-6)
12 volts on white (49-122) 9 volts on white (49-122)
9 volts on black (49-123) 12 volts on black (49-123)
Figure 4-45. Main Boom Transport Angle Switch Wiring

9 volts on red 12 volts on red
12 volts on white 12 volts on white
12 volts on black 9 volts on black
Figure 4-46. Tower Transport Length Switch Wiring
4-66 3121171
#1 MAIN BOOM TRANSPORT LIMIT SWITCH, MOUNTED ON THE RIGHT #2 MAIN BOOM TRANSPORT LIMIT SWITCH, MOUNTED ON THE RIGHT
SIDE OF THE MAIN BOOM (TOP SWITCH). THIS SWITCH IS IN THE N.C. SIDE OF MAIN BOOM (BOTTOM SWITCH). THIS SWITCH IS OPEN
POSITION WHEN THE MAIN BOOM IS FULLY RETRACTED. WHEN THE MAIN BOOM IS FULLY RETRACTED.

When Switch #1 (top switch) is off cam: When Switch #1 (top switch) is on cam:
When Switch #2 (bottom switch) is on cam: When Switch #2 (bottom switch) is off cam:
Figure 4-47. Main Boom Transport Length Switch Wiring
#1 DUAL CAPACITY LIMIT SWITCH, MOUNTED ON LEFT SIDE OF #2 DUAL CAPACITY LIMIT SWITCH, MOUNTED ON LEFT SIDE OF
BOOM (TOP SWITCH). THIS SWITCH IS IN THE N.C. POSITION BOOM (BOTTOM SWITCH). THIS SWITCH IS OPEN
WHEN THE MAIN BOOM IS FULLY RETRACTED. WHEN THE MAIN BOOM IS FULLY RETRACTED.
When Switch #1 (top switch) is off cam: When Switch #1 (top switch) is on cam:
When Switch #2 (bottom switch) is on cam: When Switch #2 (bottom switch) is off cam:
Figure 4-48. Dual Capacity Switch Wiring
3121171 4-67
4.25 TOWER TELESCOPE CYLINDER 5. Position the Platform/Ground select switch to the
Ground position.
Removal
1. Place the machine on a firm, level surface with the axles
fully extended or the turntable centered between the
rear wheels.
2. Select lift up and raise the tower boom until it is in a hor-
izontal position.
NOTE: The main boom must be elevated approximately 12 inches

(30 cm) above the boom rest but no more than 15° above
the tower to prevent damage to the machine. Refer to Fig-
ure 4-49., Tower Telescope Only Restrictions.
3. Support the main boom and tower boom in position

using boom props or an adequate lifting device.
4. Chain the tower mid section to the tower base section
to ensure that only the tower fly section will extend.
Figure 4-49. Tower Telescope Only Restrictions
4-68 3121171
6. Plug the analyzer into the connector inside the Ground

control box.
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.
11. Scroll through the analyzer menu until "SERVICE MODE"

is displayed. Press the ENTER key.
12. Scroll through the menu until "TWR TELE ONLY?” is dis-
played as shown below.
7. Pull out the Emergency Stop switch and start the

engine.
8. The analyzer screen should read:
9. Use the arrow button to reach ACCESS LEVEL 2. Press the

ENTER key.
10. 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 in the ground mode and be hidden
while in access level 2.
3121171 4-69
13. Press ENTER. The analyzer will read: If the main boom angle sensors are calibrated and
working properly the control system will verify the
main boom angle readings are between +0.0 and
+15.0 (ref tower boom). If they are calibrated and
working properly and outside the angle limits, the
analyzer will read:

ure 4-49., Tower Telescope Only Restrictions.
14. Press the ENTER key, the control system will perform the
following checks: 15. After the successful completion of the checks, the ana-
lyzer will read:
The axles must be extended or the DOS (Direction of
Steering) switch must indicate the turntable is between
the rear tires, otherwise the analyzer will read:
4-70 3121171
16. Enter code 95268. The analyzer will read:
BEFORE CONTINUING WITH THIS PROCEDURE, DOUBLE CHECK ALL SUPPORT-

ING DEVICES AND MID BOOM RESTRAINING CHAIN.
19. Extend the tower fly section no more than necessary to

gain access to the telescope cylinder retaining pin
(about 5.5 ft. [1.7 m]). When access is gained to the tele-
scope cylinder retaining pin, remove the four shoulder
bolts and two snap rings that hold it in place and
remove the telescope cylinder retaining pin.
WHEN THE STABILITY CONTROL IS OFF THE MACHINE WILL TIP IF USED 20. At the rear of the tower boom, tag and disconnect the
INCORRECTLY. wires going to the angle sensors. Remove the bolts and
washers that fasten the angle sensors to the boom sec-
17. Press the ENTER key to acknowledge the stability control tion and remove the angle sensors.
is turned off. The analyzer should read:
18. The control system will now allow only tower telescope
using the tower lift switch on the ground console.
3121171 4-71
21. Disconnect the length sensor cables from the tower

boom fly section.
26. Place blocking under the tower telescope cylinder to

prevent it from dropping suddenly and begin pulling
the cylinder out of the boom using an adequate lifting
device. Reposition the blocks and lifting straps as
needed to prevent the cylinder from dropping suddenly
22. Tag and disconnect the electrical lines going to the and to keep it balanced.
upper and lower tower boom length sensors. NOTE: The tower telescope cylinder weighs approximately 915
lbs. (415 kg).
Installation
1. Place blocking for support under the tower telescope
cylinder and begin pushing the cylinder into the boom
using an adequate lifting device. Reposition the blocks
and lifting straps as needed to prevent the cylinder from
dropping and to keep it balanced.
NOTE: The tower telescope cylinder weighs approximately 915

lbs. (415 kg).
2. Position the telescope cylinder trunnions into place and

install the shims and trunnion keeper blocks. Apply JLG
23. Remove the bolts and washers securing the length sen- Threadlocker PN 0100011 to the retaining bolts and
sor mounting brackets and remove the sensors and torque to 35 ft.lbs. (47.5 Nm).
brackets as an assembly.
24. Tag and disconnect all the hydraulic hoses running to
the tower telescope cylinder. Cap or plug all openings.
25. Remove the bolts securing the trunnion keeper blocks
and shims and remove the blocks and shims.
3. Connect all the hydraulic hoses running to the tower

telescope cylinder as tagged during removal.
4-72 3121171
4. Connect the length sensor cables to the tower boom fly 7. Secure the angle sensors to the boom section with the
section. retaining bolts and washers. At the rear of the tower
boom, connect the wires going to the angle sensors as
tagged during removal.
8. If necessary, refer to Removal and use the analyzer Ser-

5. Install the length sensors and mounting brackets. vice Mode to cycle the cylinder in and out several times
Secure them in place with the retaining bolts and wash- to purge air from the cylinder.
ers.
9. Install the telescope cylinder retaining pin. It may be
necessary to use the analyzer Service Mode procedure
to align the pin. Secure it in place with the four shoulder
bolts and two snap rings.
6. Connect the electrical lines going to the upper and

lower tower boom length sensors as tagged during
removal.
10. If necessary, use the analyzer Service Mode procedure to

telescope the boom in.
11. Place the machine in the stowed position.
3121171 4-73
4.26 TOWER LIFT CYLINDER 4. If the Boom Control System allows tower telescope, skip
to step 18. If not, continue with step 6.
Removal 5. Plug the analyzer into the connector inside the Ground
control box.
rear wheels.
2. Select lift up and raise the tower boom until it is in a hor-
izontal position.

ure 4-50., Tower Lift Only Restrictions.
3. Position the Platform/Ground select switch to the

Ground position.

engine.
Figure 4-50. Tower Lift Only Restrictions
4-74 3121171
7. The analyzer screen should read: 11. Scroll through the menu until "TWR LIFT ONLY?" is dis-
12. Press ENTER. The analyzer will read:

ENTER key.
9. Enter Code 33271 to get into Access Level 1 mode.

when in access level 1 in the ground mode and be hidden
while in access level 2.
ARROW KEYS.
10. Scroll through the analyzer menu until "SERVICE MODE"

is displayed. Press the ENTER key.

ure 4-50., Tower Lift Only Restrictions.
3121171 4-75
13. Press the ENTER key. The control system will perform the 15. After the successful completion of the checks, the ana-
following checks: lyzer will read:
The axles must be extended or the DOS (Direction of

Steering) switch must indicate the turntable is between
the rear tires, otherwise the analyzer will read:
16. Enter code 74466. The analyzer will read:
14. If the main boom angle sensors are calibrated and work-
ing properly the control system will verify the main
boom angle readings are between +0.0 and +15.0 (ref
tower boom). If they are calibrated and working prop-
erly and outside the angle limits, the analyzer will read:
WHEN THE STABILITY CONTROL IS OFF THE MACHINE WILL TIP IF USED
INCORRECTLY.
4-76 3121171
17. Press the ENTER key to acknowledge the stability control 22. At the rod end of the cylinder, remove the retaining bolt
is turned off. The analyzer should read: and pivot pin that secures that end of the cylinder to the
tower boom.
23. At the barrel end of the cylinder, remove the sensor

cover to gain access to the sensor. Remove the angle
sensor, sensor arm, and sensor pin.
18. The control system will allow only tower lift (without
auto tower telescope) using the tower lift switch on the
ground console.
19. Activate tower lift enough to gain access to the tower lift
cylinder.
24. Loosen and remove the bolt that secures the retaining
20. Use a crane or other suitable supporting device to sup- pin and remove the retaining pin.
port the weight of the tower and main boom assem-
blies.
NOTE: The tower and main boom assemblies weigh approxi-

mately 14000 lbs. (6350 kg).
21. Put a nylon strap capable of supporting the weight of

the lift cylinder around the cylinder.
NOTE: The tower lift cylinder weighs approximately 644 lbs. (292
kg).
3121171 4-77
25. Disconnect the wiring harness from the strain relief con- 2. When installing a new load sensing pin, make sure all of
nector at the opposite side of the load sensing pin. 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
26. Use the Load Pin Removal Tool (JLG PN 4846765) to pre-
way in by hand, remove the pin and align the holes bet-
vent the pin from being damaged, and use a hammer to
ter. Also make sure the pin is installed with the strain
remove the pin. To make the tool refer to Figure 4-52.,
relief connector opposing the pin orientation bar as
Load Pin Removal Tool, JLG PN 4846765. If the Load Pin
shown.
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 cylin-
der weight from the load sensing pin.
27. After both retaining pins have been removed, carefully

remove the lift cylinder, repositioning the lifting strap as
necessary.
3. Using a wooden block, carefully tap the pin until it is
Installation fully installed. Secure the pin in place with the retaining
pin and retaining pin bolt.
NOTE: The tower lift cylinder weighs approximately 644 lbs. (292
kg).
1. Put a nylon strap capable of supporting the weight of DO NOT TAP ON THE CENTER OF THE PIVOT PIN.
the lift cylinder around the cylinder. Carefully position
the lift cylinder in place, repositioning the lifting strap as 4. Connect the wiring harness to the strain relief connector
necessary. as shown in Figure 4-51., Load Sensing Pin Harness
Installation and re-calibrate the boom sensors.
4-78 3121171
Pin Harness
PN 4922826
Cross harness ends

and cable tie to filter
box as shown
Orient harness with

Deutsch connector
routed over filter box
Position harness with filter

box supported by turntable
access hole as shown
Figure 4-51. Load Sensing Pin Harness Installation
3121171 4-79
5. Secure the pin in place with the retaining pin and retain- 7. Cycle the cylinder in and out several times to purge air
ing pin bolt on the other end. Torque the bolt to 285 from the cylinder. If necessary, refer to Removal and use
ft.lbs. (386 Nm). the analyzer Service Mode.
8. At the rod end of the cylinder, install the retaining bolt
and pivot pin that secures that end of the cylinder to the
tower boom. It may be necessary to use the analyzer
Service Mode to align the pin. Torque the bolt to 285
ft.lbs. (386 Nm).
6. Install the sensor pin, sensor arm, and angle sensor. Con-
nect the wiring harness to the sensor and install the sen-
sor cover.
9. If necessary, use the analyzer Service Mode procedure to

lower the tower boom.
10. Re-calibrate the boom sensors. Refer to Section 6.15,
Boom Sensor Calibration.
4-80 3121171
Figure 4-52. Load Pin Removal Tool, JLG PN 4846765
3121171 4-81
4.27 MAIN LIFT CYLINDER 7. The analyzer screen should read:
Removal
rear wheels. The tower boom must also be fully lowered
and retracted.
2. Connect the JLG Control System Analyzer to the connec-
tor at the ground control box.
3. Start the engine.
Ground position.

ENTER key.
mode.

5. Plug the analyzer into the connector inside the Ground when in access level 1 in the ground mode and be hidden
control box. while in access level 2.
ARROW KEYS.

engine.
4-82 3121171
10. Scroll through the analyzer menu until SERVICE MODE is 12. Press the ENTER key. The control system will perform
displayed. Press the ENTER key. several tests to make sure the machine is in the proper
position. If the axles are not extended or the turntable is
not centered between the rear wheels, the screen will
read:
11. Scroll through the menu until the "MAIN LIFT?" is dis-
If the tower boom angle sensors are calibrated and
operating properly, the control system will verify the
tower boom angle readings are less than +5°. If the
tower boom angle is outside the limit, the screen will
read:
3121171 4-83
If the tower boom length sensors are calibrated and 14. Enter code 55050. The analyzer will read:
tower boom length readings are less than 6 in. (15.2 cm).
If the tower boom length is not within the limits, the
screen will read:
INCORRECTLY.
13. When the machine passes all the configuration checks,
the screen will read:
15. Press the ENTER key to acknowledge the stability control
4-84 3121171
16. If the main boom angle sensors are calibrated and oper- Installation
ating properly, the control system will now allow main
lift up/down below main boom angles of +65°. 1. Using an adequate lifting device, position the main lift
cylinder in place on the machine.
17. Activate main lift and elevate the boom enough to gain
access to remove the main lift cylinder. NOTE: The main lift cylinder weighs approximately 785 lbs. (356
kg).
18. Use a crane or other suitable supporting device to sup-
port the weight of the main boom assembly. 2. Install the retaining bolt, keeper pin, and pivot pin
securing the barrel end of the lift cylinder to the lower
NOTE: The main boom assembly weighs approximately 6500 lbs.
link.
(2950 kg).
19. Put a nylon strap capable of supporting the weight of

the lift cylinder around the cylinder.
NOTE: The main lift cylinder weighs approximately 785 lbs. (356
kg).
20. At the barrel end of the cylinder, place blocking under

the lower link and between the upper and lower links so
they do not drop when the pivot pin is removed.
21. Remove the retaining bolt, keeper pin, and pivot pin
securing the barrel end of the lift cylinder to the lower
link.

vice Mode to cycle the cylinder in and out several times
to purge air from the cylinder.
4. At the rod end of the cylinder, install the retaining bolt,
keeper pin, and pivot pin securing the rod end of the lift
cylinder to the boom. It may be necessary to use the
analyzer Service Mode to align the pin.
22. At the rod end of the cylinder, remove the retaining bolt,
keeper pin, and pivot pin securing the rod end of the lift
cylinder to the boom.
5. Remove the blocking placed under the lower link and

between the upper and lower links during removal.
6. Refer to Removal, and use the analyzer Service Mode
procedure to lower the boom.
23. Remove the cylinder from the machine.
3121171 4-85
4.28 MAIN BOOM TELESCOPE CYLINDER 8. The analyzer screen should read:
Removal
rear wheels. The tower boom must also be fully lowered
and retracted.
2. Connect the JLG Control System Analyzer to the connec-
tor at the ground control box.
3. Start the engine.
Ground position.

ENTER key.
mode.

5. If the Boom Control System allows tower telescope, skip when in access level 1 in the ground mode and be hidden
to step 18. If not, continue with step 6. while in access level 2.
control box.
ARROW KEYS.

engine.
4-86 3121171
11. Scroll through the analyzer menu until SERVICE MODE is 13. Press ENTER. The control system will perform several
displayed. Press the ENTER key. tests to make sure the machine is in the proper position.
If the axles are not extended or the turntable is not cen-
tered between the rear wheels, the screen will read:
12. Scroll through the menu until the screen reads:
If the tower boom angle sensors are calibrated and

working properly, the control system will verify the
tower boom angle is less than +5°. If the tower boom is
outside the limit, the analyzer screen will read:
3121171 4-87
If the tower boom length sensors are calibrated and 15. Enter code 69286. The analyzer will read:
tower boom length is less than 6 in. (15.2 cm). If the
tower boom is outside the length limit, the screen will
read:
INCORRECTLY.
14. When the machine passes all the configuration checks,
the screen will read:
16. Press the ENTER key to acknowledge the stability control
17. The control system will now allow main telescope using
the telescope control switch on the ground console.
4-88 3121171
18. Telescope the main boom out until the retaining pin at 23. Remove the bolts securing the rear boom cover and
the end of the telescope cylinder rod can be accessed. remove the cover.
19. Place blocking or boom supports under the main boom

to support it.
24. Place blocking under the telescope cylinder to prevent it
20. Place blocking under the main lift cylinder to support it. from falling when the retaining pin is removed.
21. Place blocking under the lower link to support it. 25. Remove the bolt and keeper pin securing the retaining
22. Remove the shoulder screws, retaining rings, and pin pin in place. Remove the retaining pin.
securing the end of the telescope cylinder.
26. Tag and disconnect the hydraulic lines running to the

telescope cylinder. Cap or plug all openings.
3121171 4-89
27. Support the upper link using a nylon strap or blocking. Installation
Remove the bolt, keeper, and pin securing the upper
link to the base boom. Carefully lower the upper link NOTE: The telescope cylinder weighs approximately 663 lbs. (300
enough to allow the telescope cylinder to be removed. kg).
1. Carefully install the telescope cylinder into the rear of

the main boom. Place blocking under the cylinder to
support it inside the boom and reposition the lifting
straps balance the load.
2. Connect the hydraulic lines running to the telescope cyl-
inder as tagged during removal.
3. Install the bolt and keeper pin securing the cylinder
retaining pin in place. Remove the retaining pin.
NOTE: The telescope cylinder weighs approximately 663 lbs. (300

kg).
28. Carefully remove the telescope cylinder from the rear of

the main boom, repositioning the blocking and lifting
straps to prevent the cylinder from falling.

vice Mode to cycle the cylinder in and out several times
to purge air from the cylinder.
4-90 3121171
5. Install the shoulder screws, retaining rings, and pin 7. Install the rear boom cover and secure it in place with
securing the end of the telescope cylinder. It may be the retaining bolts.
necessary to use the analyzer Service Mode to align the
pin.
6. Carefully raise the upper link into position. Install the

bolt, keeper, and pin securing the upper link to the base
8. Remove all blocking used during the Removal proce-
boom.
dure.
9. If necessary, refer to Removal, and use the analyzer Ser-
vice Mode procedure to retract the boom.
3121171 4-91
4.29 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of
the powertrack.
One Piece Bracket Maintenance

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

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

powertrack on the first link.
4-92 3121171
5. Slide the poly roller off of the round bar. 7. Slide the flat bar out.
6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket.
9. Remove the snap ring from the other side of the bracket.
3121171 4-93
10. Push down with slight pressure on the link and slide the Two Piece Bracket Maintenance
bracket side up and over the extrusion on the link.
1. Loosen the screw.
11. Repeat the previous step on the other side.
2. Slide the roller off the bar.
12. Slide the bracket off of the powertrack.
3. Hold the bar tightly and remove the other screw.
4-94 3121171
4. Hold the flat bar and remove the screws. 7. Slide the link out.
5. Remove the snap rings and pins. Snap Rings and Screws
WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO

DISCARD AND REPLACE ALL OLD SCREWS.
Make sure screws are tight and installed properly.
6. Remove the screws from the bar. Remove the snap ring
and pin. LOOSE SCREW TIGHT SCREW
3121171 4-95
Make sure that all snap rings are closed and seated. A seated and closed snap ring is shown below.
CLOSED
OPEN
10-24 x 0.812 button torx socket head with blue locking patch:
An open snap ring is shown below. • Tighten to 45-50 in.lbs. (5-5.6 Nm).
• Use T-25 torx bit.
• Do not reuse this screw. After removing replace with a new
one.
A snap ring that is not seated is shown below.
4-96 3121171
3121171
0273361-G
Figure 4-53. Main Boom Powertrack Installation - Sheet 1 of 3
4-97
LOCATE (2) TIES 1.0 ± 0.25” FROM EACH END
4-98
DO NOT ROUTE LEVEL CYLINDER EQUALLY DISTRIBUTE REMAINING (2) TIES
HOSES OR RIGHT LEVEL SENSOR LOCATE END 1.0 ± 0.5
HARNESS THROUGH HOSE GUIDE PAST HOSE LOOP AS SHOWN ROUTE LEVEL CYLINDER HOSES
ROD ON TOP OF PIVOT WELDMENT THROUGH TWO HOSE LOOPS INSIDE
(1.000)
FLY BOOM, THROUGH THE PLASTIC
JOIN RIGHT LEVEL SENSOR HARNESS INSERT, THROUGH THE HOSE LOOP
WITH LEVEL CYLINDER HOSES HERE ON THE OUTSIDE OF THE FLY NOSE,
AND UP TO THE JIB ROTATOR PIVOT
HOSES MUST BE ROUTED THROUGH

THE PLASTIC INSERT BEFORE
CONNECTING BOTH ENDS OF
THE HOSES
JOIN LEFT LEVEL SENSOR

HARNESS WITH HOSE BUNDLE HERE
ROUTE TWO HOSES TO INSIDE

OF POWERTRACK AS SHOWN AND ROUTE ROUTE HOSE/CABLE BUNDLE
CABLES, AIRLINES, AND WELD LEADS UNDER VALVE MOUNTING
TO OPPOSITE (AWAY FROM BOOM) SIDE BRACKET
AS SHOWN
PLATFORM RETURN
PLATFORM SUPPLY
AC CABLE
CONTROL CABLE
OPTIONAL AIRLINE/WELD LEAD/

7500W GENERATOR CABLE
0273361-G
3121171
3121171
Table 4-1. Hose/Cable Pull Chart
LETTER DESCRIPTION DIM "Z"
J LEVEL UP HOSE (PORT L1) 64" 162.5 cm
K LEVEL DOWN HOSE (PORT L2) 64" 162.5 cm
Table 4-1. Hose/Cable Pull Chart L SWING RIGHT HOSE (PORT S1) 62" 157.5 cm
M SWING LEFT HOSE (PORT S2) 62" 157.5 cm
LETTER DESCRIPTION DIM "X"
N JIB LIFT UP HOSE (PORT J1) 60" 152.5 cm
A BOOM CONTROL CABLE 12" 30.5 cm
O JIB LIFT DOWN HOSE (PORT J2) 60" 152.5 cm
B AC CABLE (10/3) 12" 30.5 cm
P PLATFORM SUPPLY (PORT P) 58" 147.5 cm
C HARNESS, DUAL CAPACITY SWITCHES (18/3) 72" 183 cm
Q TANK (PORT T) 55" 140.0 cm
D HARNESS, TRANSPORT POS. SWITCHES (18/3) 72" 183 cm
NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm)
E WELD LEAD (3/0 CABLE)(OPTIONAL) 12" 30.5 cm
F 7500W GENERATOR (8/5 CABLE)(OPTIONAL) 12" 30.5 cm
G AIRLINE (8LOLA)(OPTIONAL) 12" 30.5 cm
NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm)
0273361-G
4-99
Switch States / Boom Length Regions

Dual Cap. Switch #1 Off Cam Off Cam Off Cam Disagree On Cam On Cam On Cam Disagree Disagree
Dual Cap. Switch #2 On Cam On Cam On Cam Disagree Off Cam Off Cam Off Cam Disagree Disagree
Control System Conclusion of Dual Cap. Switches B/A B/A B/A Disagree C/D C/D C/D Disagree Disagree
Main Transport Switch #1 Off Cam Disagree On Cam On Cam On Cam Disagree Off Cam Off Cam Disagree
Main Transport Switch #2 On Cam Disagree Off Cam Off Cam Off Cam Disagree On Cam On Cam Disagree
Control System Conclusion of Main Transport Switches A/D Disagree B/C B/C B/C Disagree A/D A/D Disagree
Control System Conclusion of Main Boom Length A A/B B B/C C C/D D Switch Fault Switch Fault
Table 4-2. Boom Switch Logic
4-100 3121171
4.30 HOSE ROUTING PROCEDURE PLATFORM VALVES
For proper hose routing and cable wrap placement and The platform specific valves are located in a manifold at the
clamping, refer to Figure 4-32., Figure 4-33., Figure 4-34., Fig- platform.
ure 4-53., Figure 4-54., and Figure 4-55. It is important to peri- There are individual proportional control valves that control
odically inspect hoses, wraps and clamps for proper slack each of the four platform functions; Platform Level, Platform
adjustments and clamping integrity (pull check). Any Rotate, Jib Lift, and Jib Swing.
changes as a result of inspection should be verified by per-
forming full strokes of boom functions especially lift, tele- There is also a Platform Dump Valve, located in the platform
scope, jib, and platform rotate. valve manifold, which is used to hydraulically isolate the con-
trol valves and to improve hydraulic response.
4.31 ELECTRONIC PLATFORM LEVELING The Ground Module controls this valve to provide manual
platform leveling in the event that the Platform Module is
inoperable.
tem. In ground mode, the platform dump valve is turned on when-
ever any platform or jib valve output is turned on. Whenever
Description all platform and jib valves are turned off, the platform dump
valve is turned off.
Electronic platform leveling replaces the conventional hydrau-
lic method of platform leveling. In platform mode, the platform dump valve is turned on
whenever the footswitch is depressed.
To control electronic platform leveling the platform is
equipped with a pair of tilt sensors, one primary and one sec- Normal Operation
ondary, mounted to the non-rotating portion of the platform
rotator. The tilt sensors are monitored regularly and the plat- AUTOMATIC LEVELING
form level up and down valves are automatically controlled to Two tilt sensors, mounted on either side of the platform sup-
maintain set point as the machine is operated. port, are used to measure the incline of the platform with
PRIMARY AND SECONDARY TILT SENSOR INTERACTION respect to gravity and control the automatic leveling function,
one is used as the primary sensor and one as a secondary
The secondary tilt sensor is used as a backup to the primary tilt backup sensor.
sensor. Any time a tilt set point is reset, a value from each sen-
sor shall be set. The level system shall assume a new fixed set point (fixed
incline of the platform with respect to gravity) each time the
If a fault occurs with the primary sensor, control will revert to control system is powered up (cycling of the EMS).
the secondary sensor. (This is discussed in more detail in the
error response section.) Automatic platform leveling only functions while operating
drive, telescope, lift or swing. It does not operate while operat-
Because of the mounting orientation of the tilt sensors, the ing any other function (e.g. rotate, jib, or steer).
primary tilt sensor will output ascending voltage values with
increases in positive platform tilt angle. The backup or second- The proportional control for these valves varies. This is depen-
ary tilt sensor will output descending voltage values with dant on the tilt variance from target as well as on the impact
increases in positive platform angle. 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, auto-
matic 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.
3121171 4-101
In order to obtain acceptable performance while performing During the power-up procedure, function enable, in both Plat-
all hydraulic functions, five sets of parameters are used. These form and Ground Mode, is delayed during the 1.5 second
“zones” allow compensation for differences in how the basket startup lamp test. During this 1.5 second startup period, the
level changes when doing different functions. These zones are basket level up valve will be energized at 100% duty cycle for
as follows: 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
1. Lift up
valves from sticking.
2. Lift down
PLATFORM LEVEL MANUAL OVERRIDE
3. Other boom functions
In addition to automatic leveling the operator is able to manu-
4. Drive ally adjust the platform level position by means of the level
override switches located at the platform and ground control
5. Auxiliary positions (similar to a Master/Slave hydraulic system).
The other boom functions zone includes Swing, Telescope, Jib The level system assumes a new set point after a level over-
swing (It is not necessary to level with jib lift, since the ride switch is operated. In other words the operator can chose
mechanical linkage keeps the basket level). a platform level incline other than level with gravity and the
These zones are prioritized when multiple functions are active. system will maintain this set point during automatic leveling.
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
4-102 3121171
4.32 TOWER BOOM DRIFT TEST 5. While still in the DIAGNOSTICS/BOOM SENSORS menu
using the left arrow record the displayed value of

the TOWER ANGLE 1 and TOWER ANGLE 2. Press the
NEVER DIAGNOSE A SUSPECTED TOWER BOOM LIFT CYLINDER DRIFT BY FULLY
ELEVATING THE BOOMS. MACHINE TIPOVER COULD OCCUR.
escape button one time, press the left arrow
to SYSTEM and press enter . Record the

DO NOT LEAVE THE MACHINE UNATTENDED AT ANY TIME DURING THE TEST.
CHASSIS TILT angle. NOTE: The displayed value for Tower
Angle #1 and Tower Angle #2 should be between 10.0°
1. Place the machine on a firm, level surface with an empty
and 12.5° (see Figure 4-55., Tower Boom Drift Test).
platform, axles completely extended, tires to be ori-
ented straight and both upper and tower booms 6. Visually monitor the tower boom and analyzer display
retracted and in the transport position. The booms are for drift.
to be parallel to the wheels.
a. After residual boom movement has stopped and all
NOTE: The machine’s hydraulic oil must be at ambient tempera- angle readings listed above have been recorded,
ture prior to starting step 2. recheck each of the angles on the analyzer to ensure
the values are not currently changing. If immediate
2. Connect the hand held analyzer inside the ground box. tower boom drift is evident, return the upper boom
Place the key switch to the ground position. Pull out the to the transport position and then return the tower
emergency stop switch and start the engine. Using the boom to the transport position. Discontinue use,
tag the unit out of service and remove key. Contact
analyzer, right arrow to DIAGNOSTICS and press JLG service or JLG service provider for diagnosis and
repair information.
b. If tower boom drift is not immediately evident,
ENTER . Press the right arrow to get to
record the time at the start of test. Turn key switch
to the off position and depress the emergency stop
BOOM SENSORS and press ENTER . Press the right switch. Tag unit out of service and remove key.
7. After the unit has remained in this position for 60 min-
arrow until TOWER CYLINDER ANGLE is visible. utes, pull out the emergency stop switch. Using the ana-
3. Using the control operations position the upper and jib
booms at the maximum angle. The telescope cylinder lyzer, right arrow to DIAGNOSTICS and press enter
must be completely retracted. Refer to Figure 4-55.,
Tower Boom Drift Test.
. Press the right arrow to get to BOOM SEN-
4. Using the ground controls and analyzer display, position
the tower lift cylinder to an angle position between
SORS and press enter . Record the TOWER ANGLE1,
17.0° and 18.0°. Record tower lift cylinder angle as dis-
TOWER ANGLE 2 and TOWER CYLINDER ANGLE readings.
played on the analyzer.
8. If the angular drift of any of the recorded values exceeds
0.3°, discontinue use, tag the machine out of service and
remove the key. Contact JLG service for diagnosis and
repair information. If the boom drift is less than 0.3°, the
tower lift cylinder is fit for continued service.
3121171 4-103
JIB BOOM
NOTE: UPPER BOOM AND JIB BOOM ARE FULLY

ELEVATED, UPPER TELESCOPE BOOM IS FULLY RETRACTED.
LOWER BOOM IS ELEVATED TO 10°.
UPPER (MAIN) BOOM
10.0° TOWER BOOM
Figure 4-55. Tower Boom Drift Test
4-104 3121171
4.33 ROTARY ACTUATOR Required Tools

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

failure and overall condition.
2. Felt Marker - match mark the timing marks and outline
troubled areas.
3. Allen wrench - removal of port plugs and set screws.
4. Box knife - removal of seals.
5. Seal tool - assembly and disassembly of seals and wear
guides.
6. Pry bar - removal of end cap and manual rotation of
shaft.
7. Rubber mallet- removal and installation of shaft and pis-
ton sleeve assembly.
8. Nylon drift - installation of piston sleeve
9. End cap dowel pins - removal and installation of end cap
(sold with Helac seal kit).
Bars indicate starting positions As fluid pressure is applied, the

The seal tool is merely a customized standard flat head screw-
of piston and shaft. Arrows indi- piston is displaced axially while driver. To make this tool you will need to heat the flat end with
cate direction they will rotate. the helical gearing causes the a torch. Secure the heated end of the screwdriver in a vice and
The housing with integral ring piston and shaft to rotate simul- physically bend the heated end to a slight radius. Once the
gear remains stationary. taneously. The double helix radius is achieved round off all sharp edges of the heated end
design compounds rotation: by using a grinder. There may be some slight modifications for
shaft rotation is about twice that your own personal preference.
of the piston.
The shaft is supported radially by the large upper radial bear-

ing and the lower radial bearing. Axially, the shaft is separated
from the housing by the upper and lower thrust washers. The
end cap is adjusted for axial clearance and locked in position
by set screws or pins.
3121171 4-105
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-56. Rotary Actuator - Exploded View
4-106 3121171
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-57. Rotary Actuator - Assembly Drawing
3121171 4-107
Disassembly 6” drill bit to a depth of 1/2” (12.7mm) to drill out the

entire pin.
1. Remove the capscrews (113) over end cap lock pins
4. Install the end cap (4) removal tools provided with the
(109).
Helac seal kit.
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” 5. Using a metal bar, or something similar, unscrew the end
(4.76mm). cap (4) by turning it counter clockwise.
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 5/1
4-108 3121171
6. Remove the end cap (4) and set aside for later inspec- 8. Every actuator has timing marks for proper engage-
tion. ment.
7. Remove the stop tube if included. The stop tube is an

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

clearly indicate the timing marks between shaft and pis-
ton. This will greatly simplify timing during assembly.
3121171 4-109
10. Remove the shaft (2). It may be necessary to strike the 13. At the point when the piston gear teeth come out of
threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the pis-
ton and housing with a marker as shown.
11. Before removing the piston (3), mark the housing (1)
ring gear in relation to the piston O.D. gear. There should 14. Remove the o-ring (204) and backup ring (207) from end
now be timing marks on the housing (1) ring gear, the cap (4) and set aside for inspection.
piston (3) and the shaft (2).
15. Remove the wear guides (302) from the end cap (4) and
12. To remove the piston (3) use a rubber mallet and a plas- shaft (2).
tic mandrel so the piston is not damaged.
4-110 3121171
16. To remove the main pressure seals (205), it is easiest to 19. Remove the piston O.D. seal (202).
cut them using a sharp razor blade being careful not to
damage the seal groove.
20. Remove the piston I.D. seal (200). You may now proceed
to the inspection process.
17. Remove the thrust washers (304), from the end cap (4)
and shaft (2).
18. Remove the wiper seal (304.1) from its groove in the end
cap (4) and shaft (2).
3121171 4-111
Inspection 3. Inspect the wear guide condition and measure thick-

ness (not less than 0.123” or 3.12 mm).
1. Clean all parts in a solvent tank and dry with com-
pressed air prior to inspecting. Carefully inspect all criti-
cal areas for any surface finish abnormalities: Seal
grooves, bearing grooves, thrust surfaces, rod surface,
housing bore and gear teeth.
Assembly
1. Gather all the components and tools into one location
prior to re-assembly. Use the cut away drawing to refer-
ence the seal orientations.
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).
4-112 3121171
2. Install the thrust washer (304) onto shaft (2) and end cap 4. Using a seal tool install the main pressure seal (205) onto
(4). shaft (2) and end cap (4). Use the seal tool in a circular
motion.
3. Install the wiper seal (304.1/green 0-ring) into it’s groove 5. Install the wear guide (302) on the end cap (4) and shaft
on the shaft (2) and end cap (4) around the outside edge (2).
of the thrust washer (304).
6. Install the inner T-seal (200) into the piston (3) using a
circular motion.
Install the outer T-seal (202) by stretching it around the

groove in a circular motion.
3121171 4-113
Each T-seal has 2 backup rings (see drawing for orienta- 7. Insert the piston (3) into the housing (1) as shown, until
tion). the outer piston seal (202) is touching inside the hous-
ing bore.
Beginning with the inner seal (200) insert one end of b/u
ring in the lower groove and feed the rest in using a cir- 8. Looking from the angle shown, rotate the piston (3) until
cular motion. Make sure the wedged ends overlap cor- the marks you put on the piston and the housing (1)
rectly. during disassembly line up as shown. Using a rubber
Repeat this step for the outer seal (202). mallet, tap the piston into the housing up to the point
where the gear teeth meet.
4-114 3121171
9. Looking from the opposite end of the housing (1) you 11. Looking from the view shown, use the existing timing
can see if your timing marks are lining up. When they do, marks to line up the gear teeth on the shaft (2) with the
tap the piston (3) in until the gear teeth mesh together. gear teeth on the inside of the piston (3). Now tap the
Tap the piston into the housing the rest of the way until flange end of the shaft with a rubber mallet until the
it bottoms out. gear teeth engage.
10. Install the shaft (2) into the piston (3). Be careful not to 12. Install 2 bolts in the threaded holes in the flange. Using a
damage the seals. Do not engage the piston gear teeth bar, rotate the shaft in a clockwise direction until the
yet. wear guides are seated inside the housing bore.
13. Install the stop tube onto the shaft end. Stop tube is an
available option to limit the rotation of an actuator.
3121171 4-115
14. Coat the threads on the end of the shaft with anti-seize 17. Tighten the end cap (4). In most cases the original holes
grease to prevent galling. for the lock pins will line up.
18. Place the lock pins (109) provided in the Helac seal kit in
15. Install the 0-ring (204) and backup ring (207) into the
the holes with the dimple side up. Then, using a punch,
inner seal groove on the end cap (4).
tap the lock pins to the bottom of the hole.
16. Thread the end cap (4) onto the shaft (2) end. Make sure
the wear guide stays in place on the end cap as it is 19. Insert the set screws (113) over the lock pins. Tighten
threaded into the housing (1). them to 25 in. lbs. (2.825 Nm).
4-116 3121171
Greasing Thrust Washers Installing Counterbalance Valve

Refer to Figure 4-58., Rotator Counterbalance Valve.
1. After the actuator is assembled but before it is put into
service, the thrust washer area must be packed with 1. Make sure the surface of the actuator is clean, free of any
Lithium grease. contamination and foreign debris including old JLG
Threadlocker.
There are two grease ports located on both the shaft
2. Make sure the new valve has the O-rings in the counter-
flange and the end cap. They are plugged with cap-
bores of the valve to seal it to the actuator housing.
screws (113) or set screws. Remove the grease port
screws from the shaft flange and end cap. (See exploded 3. The bolts that come with the valve are grade 8 bolts.
view) New bolts should be installed with a new valve. JLG
Threadlocker PN 0100011 should be applied to the
shank of the three bolts at the time of installation.
4. Torque the 1/4-inch bolts 110 to 120 inch pounds (12.4
to 13.5 Nm). Do not torque over 125 inch pounds (14.1
Nm). Torque the 5/16-inch bolts 140 inch pounds (15.8
Nm). Do not torque over 145 inch pounds (16.3 Nm).
Testing the Actuator

If the equipment is available, the actuator should be tested on
a hydraulic test bench. The breakaway pressure — the pres-
sure at which the shaft begins to rotate — should be approxi-
mately 400 psi (28 bar). Cycle the actuator at least 25 times at
3000 psi (210 bar) pressure. After the 25 rotations, increase the
pressure to 4500 psi (315 bar) to check for leaks and cracks.
Perform the test again at the end of the rotation in the oppo-
site direction.
IF A HYDRAULIC TEST BENCH IS NOT AVAILABLE, THE ACTUATOR CAN BE
ROTATED BY HAND, OPEN THE PRESSURE PORTS AND USE A PRY BAR WITH TESTING THE ACTUATOR FOR INTERNAL LEAKAGE
CAPSCREWS INSERTED INTO THE SHAFT FLANGE TO TURN THE SHAFT IN THE If the actuator is equipped with a counterbalance valve, plug
DESIRED DIRECTION. the valve ports. Connect the hydraulic lines to the housing
ports. Bleed all air from the actuator (see Installation and
Insert the tip of a grease gun into one port and apply Bleeding) Rotate the shaft to the end of rotation at 3000 psi
grease to the shaft flange. Continue applying until (210 bar) and maintain pressure. Remove the hydraulic line
grease flows from the opposite port. Cycle the actuator from the non-pressurized side.
five times and apply grease again. Repeat this process
on the end cap. Insert the capscrews into the grease Continuous oil flow from the open housing port indicates
ports and tighten to 25 in-lbs. (2.8 Nm). 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.
3121171 4-117
Figure 4-58. Rotator Counterbalance Valve
4-118 3121171
Bleeding After Installation 1. Connect a 5 foot (1.5 m) long 3/16" inside diameter, 5/
16" outside diameter clear vinyl drain tube to each of
NOTE: Bleeding will be necessary if excessive backlash is displayed the two bleeder valves. Secure the tubes in place with
after the actuator is installed. To do this, bleeder valves hose clamps.
must be installed in the actuator at the locations shown
2. Place the end of the tubes in a clean 5 gallon (19 L) con-
below. The following steps are recommended when a mini-
tainer to collect the purged oil. The oil can be returned
mum of two gallons (8 liters) is purged.
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.
ALIGN TIMING MARKS IN ROTATOR WITH

TIMING MARKS IN PIVOT AS SHOWN
JIB WILL BE 35 DEGREES OUT OF LINE

WITH THE BOOM WITH ROTATOR CENTERED
REALIGN THE JIB WITH THE BOOM AFTER

ALL HARDWARE IS ASSEMBLED
Figure 4-59. Jib Alignment Timing Marks
3121171 4-119
4.34 BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands,
kinks, or any signs of corrosion.
The bolt-on external fall arrest system is designed to provide a
lanyard attach point while allowing the operator to access GAP
GAPSHOWING:
SHOWING:
areas outside the platform. Exit/Enter the platform through INCORRECT
INCORRECT
the gate area only. The system is designed for use by one per-
son.
Personnel must use fall protection at all times. A full body har-
ness is required with lanyard not to exceed 6 ft. (1.8 M) in
length, that limits the maximum arrest force to 900 lbs. (408
kg). NO GAP:
NO GAP: CORRECT
CORRECT
Bolt-on external fall arrest system capacity is 310 lb (140 kg) -
one (1) person maximum.
Do not move the platform during use of the bolt-on external

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

BE CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION. Figure 4-60. Bolt-On External Fall Arrest Cable Tension
• Fittings & Brackets: Ensure all fittings are tight and there are
no signs of fractures. Inspect brackets for any damage.
IF THE BOLT-ON EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL • Attachment Ring: No cracks or signs of wear are accept-
OR IS OTHERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND able. Any signs of corrosion requires replacement.
THE PLATFORM FULLY INSPECTED BEFORE RETURNING TO SERVICE. REFER TO
• Attaching Hardware: Inspect all attaching hardware to
THE SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES.
ensure there are no missing components and hardware is
THE BOLT-ON EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPEC- properly tightened.
TION AND CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICATION
• Platform Rails: No visible damage is acceptable.
MUST BE PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER.
Inspection Before Use

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

components:
4-120 3121171
Installation nuts onto the cable finger tight so the mark on the cable
does not move.
1. Install the retaining hardware (bolts, nuts, and washers)
and secure the brackets to the platform rail. Tighten the WASHER
nuts but do not torque them yet. BELLEVILLE
NUT WASHER
BOLT
WASHER
JAM NUT
5. Use the two jam nuts to prevent the cable from rotating
while the nut is tightened. Tighten the nut until the bel-
leville washers are fully compressed and no gap is pres-
ent at the outside diameter of the washers. Ensure the
WASHER cable has not rotated during tightening.
NUT
2. Attach the fall arrest cable to the right hand bracket

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

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

4. Without twisting the fall arrest cable, pull it thru the left
hand bracket and mark the top of the swaged cable end.
Install the fall arrest cable through the left hand bracket
and secure it using the belleville washers, washer, retain-
ing nut, and jam nuts. Orient the hardware as shown
below and with the belleville washers so the gap is pres-
ent at the outside diameter of the washers. install the
3121171 4-121
7
1,2,3,4
1. Belleville Washer
2. Washer
3. Hex Nut
4. Jam Nut
5. LH Bracket
6. Attachment Ring 8
7. Cable
8. RH Bracket
9. Decal
MAE38500
Figure 4-61. Bolt-On External Fall Arrest System
4-122 3121171
4.35 SKYGUARD Function Test

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

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

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

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

TO ENSURE PROPER OPERATION OF THE SKYGUARD SYSTEM.
3121171 4-123
SOFT TOUCH ONLY Engage the SkyGuard sensor and observe the Analyzer to
If Soft Touch only is selected in machine setup determine if the switch/relay closes.
(refer to Table 6-2), machine will treat the Soft Touch/SkyGuard
If the status of the switch/relay remains OPEN while the Sky-
override switch as if it is a Soft Touch switch.
Guard sensor is actively engaged, it is possible the sensor has
failed and should be replaced immediately.
SKYGUARD NOT SELECTED IN MACHINE SETUP
If the SkyGuard system is installed on the machine, but no If the status of the switch/relay remains CLOSED while the Sky-
option is selected in the machine setup (refer to Table 6-2), Guard sensor is actively engaged, a power or ground wire may
SkyGuard sensor status will be ignored. No function cutout or not be making good contact or may be loose or broken. Addi-
reversal will be implemented. tionally, there is a low probability that both relays may have
failed.
Diagnostics & Troubleshooting
If the switch/relay status is in disagreement, then one may
If SkyGuard does not function when the sensor is engaged, have failed or is not installed correctly. In this case, the
first verify the configuration under the machine will be inoperable.
MACHINE SETUP: SKYGUARD OPTION menu using the hand-
held Analyzer. Ensure the selected configuration matches the FAULT CODES
actual system installed on the machine. If not, select the cor- Refer to Table 6-11 for more fault code information
rect configuration, then verify operation.
• 0039 - SkyGuard switch activation fault
Additionally, use the handheld analyzer to navigate to the • 2563 - switch disagreement fault
DIAGNOSTICS: FEATURES  SKYGUARD INPUTS menu to
determine additional SkyGuard fault information.
Table 4-3. SkyGuard Function Table
Tower Tower Tower Boom

Drive Drive Tower Boom Boom Boom Jib Basket Basket
Steer Swing Lift Tele Lift Lift Jib Lift
Forward Reverse Tele In Lift Up Tele Out Tele In Swing Level Rotate
Up Out Down Down
R*/C** R C R C C C C R R R C C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* DOS (Drive Orientation System) Enabled
* * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active
Note: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing
4-124 3121171
SECTION 5. HYDRAULICS AND HYDRAULIC SCHEMATICS

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

prior to assembly.
Cup and Brush

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

• Small paint brush 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring is
coated with hydraulic oil.
1. Hold the fitting in one hand while using the brush with
the other hand to dip into the container. Remove excess
hydraulic oil from the brush so an even film of oil is
applied on the o-ring.
3121171 5-1
Dip Method Spray Method

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

2. Using slight pressure to the body of the spray bottle,
invert the bottle so the brush end is in the downward
position.
3. Brush hydraulic oil on the entire o-ring, applying an
3. O-ring Boss type fittings will require more pressure in even coat of oil.
able to immerse more of the fitting into the saturated
sponge. This will also cause more oil to be dispersed
from the sponge.
5-2 3121171
5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512
TORQUE SPECIFICATION
Tapered Thread Types
NPTF = national tapered fuel (Dry Seal) per SAE J476/J512
60°
30° Figure 5-4. SAE Thread
ORFS = o-ring face seal per SAE J1453
Figure 5-1. NPTF Thread

BSPT = British standard pipe tapered per ISO7-1
55°
Figure 5-5. ORFS Thread
MBTL = metric flareless bite type fitting, pressure rating L
(medium) per ISO 8434, DIN 2353
MBTS = metric flareless bite type fitting, pressure rating S
(high) per ISO 8434, DIN 2353
Thread
O.D.
Figure 5-2. BSPT Thread Figure 5-6. MTBL-MBTS Thread
Straight Thread Types, Tube and Hose Connections BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
JIC = 37° flare per SAE J514
Figure 5-3. JIC Thread

Figure 5-7. Bulkhead Thread
3121171 5-3
Straight Thread Types, Port Connections Flange Connection Types

ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162
MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162
6149, DIN 3852
Figure 5-10. ORB-MPP Thread
Tightening Methods
Torque = Application of a twisting force to the applicable con-
Figure 5-8. ORB-MPP Thread nection by use of a precise measurement instrument (i.e.
torque wrench).
MFF = metric flat face port per ISO 9974-1
Finger Tight = The point where the connector will no longer
BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852- thread onto the mating part when tightened by hand or fin-
2 gers. Finger Tight is relative to user strength and will have
some variance. The average torque applied by this method is 3
ft-lbs [4 N-m] Also referred to as ‘Hand Tight.’
TFFT = Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by hand (fin-
gers) and applying an additional rotation counted by a
defined number of turns by use of a tool.
FFWR = Flats from Wrench Resistance; Application of a pre-
load to a connection by tightening to the point of initial
wrench resistance and turning the nut a described number of
‘flats’. A ‘flat’ is one side of the hexagonal tube nut and
equates to 1/6 of a turn. Also referred to as the ‘Flats Method.’
Figure 5-9. MFF-BSPP Thread
5-4 3121171
Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the
correct torque values.
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the con- a. Verify the material designation in the table head-
nector being installed. Refer to the Figures and Tables in this ings.
section. b. If specifications are given only for steel fittings and
components, the values for alternate materials shall
GENERAL TUBE TYPE FITTING ASSEMBLY be as follows: Aluminum and Brass- reduce steel val-
INSTRUCTIONS ues by 35%; Stainless Steel- Use the upper limit for
steel.
1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling 5. To achieve the specified torque, the torque wrench is to
or assembly. Nicks and scratches in sealing surfaces can be held perpendicular to the axis of rotation.
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting attach-
ment to ensure that the tube has not been damaged.
3. The assembly process is one of the leading causes for
contamination in air and hydraulic systems. Contamina-
tion can prevent proper tightening of fittings and adapt-
ers from occurring.
a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as nec-
essary before re-installing.
c. Sealing compounds should be applied where speci- Figure 5-11. Torque Wrench Angle
fied; however, care should be taken not to introduce
sealant into the system. 6. Refer to the appropriate section in this manual for more
d. Avoid applying sealant to the area of the threads specific instructions and procedures for each type of fit-
where the sealant will be forced into the system. ting connection
This is generally the first two threads of a fitting.
e. Sealant should only be applied to the male threads.
f. Straight thread fittings do not require sealants. O-
rings or washers are provided for sealing.
g. When replacing or installing an O-ring, care is to be
taken while transferring the O-ring over the threads
as it may become nicked or torn. When replacing an
O-ring on a fitting, the use of a thread protector is
recommended.
h. When installing fittings with O-rings, lubrication
shall be used to prevent scuffing or tearing of the O-
ring. See O-ring Installation (Replacement) in this
section.
3121171 5-5
Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN-
MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR
Thread Tapered (NPTF) Connections. ALIGNMENT.
1. Inspect components to ensure male and female port
5. Rotate male fitting the number of turns per Table 5-1,
threads are free of rust, splits, dirt, foreign matter, or
NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT
burrs.
procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to
the male pipe threads if not already applied. Ensure the NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
first 1 to 2 threads are uncovered to prevent system con- applicable for the following material configurations:
tamination. • STEEL fittings with STEEL mating components
3. Assemble connection hand tight. • STEEL fittings with ALUMINUM or BRASS mating com-
4. Mark fittings, male and female. ponents
• ALUMINUM or BRASS fittings with STEEL mating com-
ponents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND • ALUMINUM or BRASS fittings with ALUMINUM or
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR. BRASS mating components.
Table 5-1. NPTF Pipe Thread
60° ØA dimension is measured

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

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

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

** See FFWR and TFFT Methods subsection for TFFT procedure requirements.
5-6 3121171
Assembly Instructions for British Standard Pipe 5. Rotate male fitting the number of turns per Table 5-2,
BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT
Thread Tapered (BSPT) Connections procedure requirements.
1. Inspect components to ensure male and female port NOTE: TFFT values provided in Table 5-2, BSPT Pipe Thread are
threads are free of rust, splits, dirt, foreign matter, or applicable for the following material configurations:
burrs.
• STEEL fittings with STEEL mating components
2. Apply a suitable thread sealant, such as Loctite 567, to
the male pipe threads if not already applied. Ensure the • STEEL fittings with ALUMINUM or BRASS mating com-
first 1 to 2 threads are uncovered to prevent system con- ponents
tamination. • ALUMINUM or BRASS fittings with STEEL mating com-
3. Assemble connection hand tight. ponents
• ALUMINUM or BRASS fittings with ALUMINUM or
4. Mark fittings, male and female.
BRASS mating components.
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND

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

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

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

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

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

** See Appendix B for TFFT procedure requirements.
3121171 5-7
Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table Table 5-3, 37°
Flare (JIC)Thread - Steel or Table 5-4, 37° Flare
1. Inspect the flare for obvious visual squareness and con- (JIC)Thread - Aluminum/Brass while using the Double
centricity issues with the tube OD. Ensure surface is Wrench Method per Double Wrench Method. Refer to
smooth, free of rust, weld and brazing splatter, splits, FFWR and TFFT Methods for procedure requirements if
dirt, foreign matter, or burrs. If necessary replace fitting using the FFWR method.
or adapter.
NOTE: Torque values provided in Table Table 5-3, 37° Flare
(JIC)Thread - Steel and Table 5-4, 37° Flare (JIC)Thread -
Aluminum/Brass are segregated based on the material
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT configuration of the connection.
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO LEAK-
AGE. ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
COMPONENTS’ indicate either the following material configu-
2. Align tube to fitting and start threads by hand. rations:
• STEEL fittings with ALUMINUM or BRASS mating com-
ponents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT- • ALUMINUM or BRASS fittings with STEEL mating com-
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION ponents
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
5-8 3121171
Table 5-3. 37° Flare (JIC)Thread - Steel
Thread OD
A
B
37°
Type/Fitting Identification Torque

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

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

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

8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
* ØA and ØB thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121171 5-9
Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass
Thread OD
A
B
37°
TYPE/FITTING IDENTIFICATION Torque

Flats from
Thread Wrench
MATERIAL

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

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

6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1
** See FFWR and TFFT Methodsfor FFWR procedure requirements.
5-10 3121171
This page left blank intentionally
3121171 5-11
Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using
1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section. Refer to
centricity issues with the tube OD. Ensure surface is FFWR and TFFT Methods for procedure requirements if using
smooth, free of rust, weld and brazing splatter, splits, the TFFT method.
dirt, foreign matter, or burrs. If necessary replace fitting
or adapter. NOTE: Torque values provided in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass are segre-
gated based on the material configuration of the connec-
tion.
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO LEAK- ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
AGE. COMPONENTS’ indicate either the following material configu-
rations:
2. Align tube to fitting. • STEEL fittings with ALUMINUM or BRASS mating com-
3. Tighten fitting by hand until hand tight. ponents
ponents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT- • ALUMINUM or BRASS fittings with ALUMINUM or
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION BRASS
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
mating components.
5-12 3121171
Table 5-5. 45° Flare (SAE) - Steel

Thread
MATERIAL

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

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

Thread
MATERIAL

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

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

10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83
** See FFWR and TFFT Methods for TFFT procedure requirements.
3121171 5-13
Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal
(ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu-
Fittings minum/Brass while using the Double Wrench Method.
Refer to FFWR and TFFT Methods for procedure require-
1. Ensure proper O-ring is installed. If O-ring is missing
ments if using the FFWR method.
install per O-ring Installation (Replacement).
2. Ensure surface is smooth, free of rust, weld and brazing NOTE: Torque values provided in Table 5-7, O-ring Face Seal
splatter, splits, dirt, foreign matter, or burrs. If necessary (ORFS) - Steel and Table 5-8, O-ring Face Seal (ORFS) - Alu-
replace fitting or adapter. minum/Brass are segregated based on the material config-
uration of the connection.

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

TYPE/FITTING IDENTIFICATION Torque Resistance
(F.F.W.R)**
Thread Size ØA* ØB* [Ft-Lb] [N-m] Swivel &
MATERIAL
Tube
Dash Size Hose
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Nuts
Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
STEEL MATING COMPONENTS;
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4

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

12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
5-14 3121171
Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass
Flats from Wrench

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

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

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

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

12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
** See FFWR and TFFT Methods for FFWR procedure requirements.
3121171 5-15
Assembly Instructions for DIN 24° Flare Bite Type

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

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

tion, external damage, rust, splits, dirt, foreign matter, or
burrs. Ensure tube end is visibly square. If necessary
replace fitting or tube.
2. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
3. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
4. Push the tube end into the coupling body.
5. Slide collet into position and tighten until finger tight.
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed in Table Table 5-9, DIN
24°Cone (MBTL & MBTS) while using the Double Wrench
Method. The tube must not turn with the nut.
5-16 3121171
Table 5-9. DIN 24°Cone (MBTL & MBTS)
DIN 24° CONE FLARELESS BITE FITTING

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

MATERIAL
ØA* ØB* C* ØD* Wrench

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

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

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

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

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

FFWR is the recommended
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
method of fitting assembly.
12 M20 x 1.5 18.50 20.00 7.50 12.20 1.5 to 1.75
14 M22 x 1.5 20.50 22.00 8.00 14.20 Torque values are application 1.5 to 1.75
16 M24 x 1.5 22.50 24.00 8.50 16.20 specific due to variability in the 1.5 to 1.75
fitting supplier, coating,
20 M30 x 2 27.90 30.00 10.50 20.20 lubrication, and other physical 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 characteristics of the connection. 1.5 to 1.75
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
Refer to the specific procedure
38 M52 x 2 49.90 52.00 16.00 38.30 in the 1.5 to 1.75
* ØA, ØB, C, & ØD thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121171 5-17
Assembly Instructions for Bulkhead (BH) Fittings

1. Ensure threads and surface are free of rust, weld and
brazing splatter, splits, burrs or other foreign material. If
necessary replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
5. Torque nut onto fitting per Table 5-10 and Table 5-11
while using the Double Wrench Method.
5-18 3121171
Table 5-10. Bulkhead Fittings (BH) - INCH
FASTENING JAM NUT

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

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

(UNF) Min Nom Max Min Nom Max
3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
37° FLARE (JIC) BULKHEAD FITTING
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
10 7/8-14 85 90 94 115 122 127
12 1 1/16-12 135 142 149 183 193 202
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
3121171 5-19
Table 5-11. Bulkhead Fittings (BH) - METRIC
FASTENING JAM NUT

for Bulkhead Connectors
Connecting Torque
Thread M Size
MATERIAL TYPE Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
DIN 24° CONE FLARELESS BITE
(MBTL) BULKHEAD FITTING
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
STEEL FITTINGS
Connecting Torque
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING
Thread M Size
Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
14 M22 x 1.5 44 47 50 60 64 68
16 M24 x 1.5 70 75 80 95 102 108
20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
5-20 3121171
3121171 5-21
Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru
Table 5-17 while using the Double Wrench Method.
Fittings
a. The table headings identify the straight thread O-
1. Inspect components to ensure that male and female ring port and the type on the other side of the fit-
port threads are free of rust, splits, dirt, foreign matter, or ting. The torque will be applied to the straight
burrs. thread O-ring port.
2. Ensure proper O-ring is installed. If O-ring is missing b. Torque values provided in Table 5-12 thru Table 5-17
install per O-ring Installation (Replacement). are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE
ponents
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
3. Pre-lubricate the O-ring with Hydraulic Oil. ponents
4. For Non-Adjustable and Plugs, thread the fitting by • ALUMINUM or BRASS fittings with ALUMINUM or
hand until contact. BRASS mating components.
5. For Adjustable fittings, refer to Adjustable Stud End 7. Inspect to ensure the O-ring is not pinched and the
Assembly for proper assembly. washer is seated flat on the counter bore of the port.
5-22 3121171
Table 5-12. O-ring Boss (ORB) - Table 1 of 6
HEX TYPE PLUGS & STUD ENDS

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

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

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

5 1/2-20 0.50 12.70 15 16 17 20 22 23
6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
3121171 5-23
STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end
MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 26 27 28 35 37 38
5 1/2-20 0.50 12.70 30 32 33 40 43 45

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

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

5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
5-24 3121171
ADJUSTABLE STUD END

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

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

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

5 1/2-20 0.50 12.70 14 15 15 19 20 20
6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
3121171 5-25
ADJUSTABLE STUD END

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

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

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

5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
5-26 3121171
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

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

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

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

5 1/2-20 0.50 12.70 9 10 10 12 14 14
6 9/16-18 0.56 14.28 22 24 25 30 33 34
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
3121171 5-27
ZERO LEAK GOLD®

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

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

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

5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
20 1 5/8-12 1.63 41.30 Fitting size greater than -12 not typically specified on
24 1 7/8-12 1.87 47.60 JLG applications. Consult specific service procedure if encountered.
32 2 1/2-12 2.50 63.50

5-28 3121171
3121171 5-29
Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18,
Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5-
Metric (MFF) Fittings 23 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the Metric port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the Metric port.
2. If O-ring is not pre-installed, install proper size, taking b. Torque values provided in Table 5-18, Table 5-19,
care not to damage it. See O-ring Installation (Replace- Table 5-20, Table 5-21, Table 5-22, and Table 5-23
ment) for instructions. are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ponents
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or
by hand until contact. BRASS mating components.
5-30 3121171
Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3
FORM A (SEALING WASHER) FORM B (CUTTING FACE)

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

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

M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
3121171 5-31


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

M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
5-32 3121171
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
Thread Connecting Torque Torque Torque

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

M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
3121171 5-33
Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3

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

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

M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
5-34 3121171
Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3
FORM E (EOLASTIC SEALING RING)

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

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

M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
3121171 5-35
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS

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

M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
5-36 3121171
3121171 5-37
Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24
while using the Double Wrench Method.
Port Assembly Stud Ends
a. The table headings identify the Metric port and the
1. Inspect components to ensure that male and female type on the other side of the fitting. The torque will
threads and surfaces are free of rust, splits, dirt, foreign be applied to the Metric port.
matter, or burrs. b. Torque values provided in Table 5-24 are segregated
2. If O-ring is not preinstalled, install proper size, taking based on the material configuration of the connec-
care not to damage it. See O-ring Installation (Replace- tion. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/
ment) for instructions. BRASS MATING COMPONENTS’ indicate either the
following material configurations:
ponents
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE • ALUMINUM or BRASS fittings with STEEL mating com-
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. ponents
4. For Non-Adjustable Fittings and Plugs, thread the fitting
7. Inspect to ensure the O-ring is not pinched and the
by hand until contact.
washer is seated flat on the counter bore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
Assembly for proper assembly.
5-38 3121171
Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
Note: Metric O-ring

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

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

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

M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
3121171 5-39
Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25,
Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5-
(BSPP) Fittings 30 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the BSPP port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the BSPP port.
2. If O-ring is not preinstalled, install proper size, taking b. Torque values provided in Table 5-25, Table 5-26,
care not to damage it. See O-ring Installation (Replace- Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are
ment) for instructions. segregated based on the material configuration of
the connection. ‘ALUMINUM/BRASS FITTINGS OR
ponents
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or
by hand until contact. BRASS mating components.
5-40 3121171
Table 5-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

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

** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
3121171 5-41
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
BSPP Torque Torque
Connecting
Thread G
Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Torque Torque
Connecting
Thread G
Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 42 259 272 285 351 369 386 259 272 285 351 369 386

5-42 3121171
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
Connecting
Thread G
Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321

3121171 5-43
Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
Bonded Washer
Seal
Bonded
Washer
Bonded Washer
(e.g. Dowty) Seal
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

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

5-44 3121171
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS
BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386

3121171 5-45
Note: BSPP O-ring only

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

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

5-46 3121171
3121171 5-47
Assembly Instructions for Flange Connections:

(FL61 and FL62)
1. Make sure sealing surfaces are free of rust, splits,
scratches, dirt, foreign matter, or burrs.
2. See Figure for O-ring installation instructions.
4. Position flange and clamp halves.
5. Place lock washers on bolt and bolt through clamp
halves.
6. Tighten all bolts by hand.
7. Torque bolts in diagonal sequence in two or more incre-
ments to the torque listed on Table Table 5-31and Table
5-32.
5-48 3121171
Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners
STEEL 4-BOLT FLANGE SAE J518

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

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

16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
* A dimension for reference only.
3121171 5-49
Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners
STEEL 4-BOLT FLANGE SAE J518

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

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

16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
* A dimension for reference only.
5-50 3121171
Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper
hose installation. A twisted lay-line usually indicates the hose
To prevent undesired hose or connector rotation, two is twisted. See Figure 5-12. for double wrench method require-
wrenches must be used; one torque wrench and one backup ments.
wrench. If two wrenches are not used, inadvertent component
rotation may occur which absorbs torque and causes
improper joint load and leads to leaks. For hose connections,
Figure 5-12. Double Wrench Method
3121171 5-51
FFWR and TFFT Methods Adjustable Stud End Assembly

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

1. Tighten the swivel nut to the mating fitting until no lat-
eral movement of the swivel nut can be detected; finger
tight condition.
2. Mark a dot on one of the swivel hex nut flats and
another dot in line on the connecting tube adapter.
3. Use the double wrench method per Appendix A, turn
the swivel nut to tighten. The nut is to be rotated clock-
wise the number of turns as defined by the applicable
Table in Section 5.0.
4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering
the dots, to indicate the connection has been properly
tightened.
5-52 3121171
Position #1 Position #2 Position #4

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

straight threads, ensure O-ring is seated all the way past
Care must be taken when installing O-rings over threads dur- the threads prior to installation.
ing replacement or installation. O-rings could become nicked
or torn. A damaged O-ring could lead to leakage problems. 5. Inspect O-ring for any visible nicks or tears. Replace if
found.
1. Inspect O-ring for tears or nicks. If any are found replace
O-ring.
2. Ensure proper O-ring to be installed. Many O-rings look
the same but are of different material, different hard-
ness, or are slightly different diameters or widths.
3. Use a thread protector when replacing O-rings on fit-
tings.
3121171 5-53
5.3 CYLINDER REPAIR 4. Place the cylinder barrel into a suitable holding fixture.
NOTE: The following are general procedures that apply to all of
the cylinders on this machine. Procedures that apply to a
specific cylinder will be so noted.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK

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

the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER

SLIGHTLY TO AVOID TRAPPING PRESSURE. Figure 5-15. Cylinder Barrel Support
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source. NOTE: Step 5 only applies to the steer cylinder.
Adequately support the cylinder rod, if applicable. 5. Using a spanner wrench, unscrew the cylinder head
3. If applicable, remove the cartridge-type holding valve from the barrel.
and fittings from the cylinder port block. Discard o- 6. Mark cylinder head and barrel with a center punch for
rings. easy realignment. Using an allen wrench, loosen the
eight (8) cylinder head retainer capscrews, and remove
capscrews from cylinder barrel.
Figure 5-16. Capscrew Removal
7. Attach a suitable pulling device to the cylinder rod port

block end or cylinder rod end, as applicable.
5-54 3121171
1
18**
19
17*
16
3
18
9 19
17
10
14 11
15
14
13
12
4 5
6
7
8
* Torque to 9 ft. lbs. (12 Nm)

** Torque to 50 - 55 ft. lbs. (68 - 75)
1684102-E
1001228020-A
MAE35980E
1. Barrel 6. Rod Wiper 11. Wear Ring 16. Tapered Bushing

2. Rod 7. Washer Ring 12. Backup Ring 17. Capscrew
3. Piston 8. Capscrew 13. O-Ring 18. Holding Valves
4. Head 9. O-Ring 14. Wear Ring 19. O-Ring Plug
5. Seal 10. Backup Ring 15. T-Seal
Figure 5-17. Axle Extension Cylinder
3121171 5-55
8
6
20*
20*
8
1
7
4
3
7 15
16
12
5
14
13 11
19
18
13 17
10
21 2
8
* Torque to 12 - 15 ft. lbs. (16 - 20 Nm)

1684081-F
MAE35990F
1. Barrel 5. Head 9. O-Ring Plug 13. Lock Ring 17. Wiper

2. Rod 6. Counterbalance Valve 10. Capscrew 14. Backup Ring 18. Seal
3. Piston 7. Capscrew 11. Wear Ring 15. O-Ring 19. Rod Seal
4. Tapered Bushing 8. Bushing 12. Backup Ring 16. O-Ring 20. Bleeder Valve
21. Ring Washer
Figure 5-18. Axle Lockout Cylinder (SN 0300201017 through 0300239155)
5-56 3121171
11
6****
19 19***
11 1
4
18** 12
3
14
15
14
17
13
16
17 10
9
5
8
7
20*
2
11
11
** Torque to 9.5 ft. lbs. (13 Nm)
*** Torque to 12.5 - 15 ft. lbs. (17 - 20 Nm) 1001228019-A
MAE35830A
**** Torque to 30 - 35 ft. lbs. (41 - 47 Nm)
1. Barrel 5. Head 9. Backup Ring 13. Wear Ring 17. Lock Ring
2. Rod 6. Counterbalance Valve 10. O-Ring 14. Backup Ring 18. Capscrew
3. Piston 7. Wiper 11. Bushing 15. O-Ring 19. Bleeder Valve
4. Tapered Bushing 8. Rod Seal 12. O-Ring Plug 16. Seal 20. Capscrew
Figure 5-19. Axle Lockout Cylinder (SN 0300239156 to Present)
3121171 5-57
10
28
13
12
5
6
19
29
27
16
27
19
20
20 22
23
18
17
17
9
25 11
26
21
24
15
1684343-D
1. JLG Threadlocker PN 0100011 (Not Shown) 7. Bearing 13. O-Ring Plug 19. Lock Ring 25. Rod Seal
2. JLG Threadlocker PN 0100019 (Not Shown) 8. Bushing 14. Not Used 20. Backup Ring 26. Rod Wiper
3. Locking Primer (Not Shown) 9. Head 15. Roll Pin 21. Washer Ring 27. Guide Ring
4. Rod Link 10. Barrel 16. Piston 22. O-Ring 28. Holding Valve
5. Capscrew 11. Rod 17. Wear Ring 23. O-Ring 29. Holding Valve
6. Tapered Bushing 12. O-Ring Plug 18. Backup Ring 24. Capscrew
Figure 5-20. Platform Level Cylinder (Prior to SN 0300080030)
5-58 3121171
7
30
12
5
28 6
29 19
13 27
16
27
19
20
20 22 24
23
18 25
17 26
17
9
21
11
15
4
1684430-B
1. JLG Threadlocker PN 0100011 (Not Shown) 7. Bearing 13. O-Ring Plug 19. Guidelock 25. Polyseal
2. JLG Threadlocker PN 0100019 (Not Shown) 8. Bushing 14. Not Used 20. Backup Ring 26. Wiper Seal
3. Primer #7471 9. Head 15. Roll Pin 21. Washer Ring 27. Hydrolock
4. Rod End Block 10. Barrel 16. Piston 22. O-Ring 28. Counterbalance Valve
5. Capscrew 11. Rod 17. Wear Ring 23. O-Ring 29. Orifice
6. Tapered Bushing 12. O-Ring Plug 18. Backup Ring 24. Capscrew 30. Counterbalance Valve
Figure 5-21. Platform Level Cylinder (SN 0300080030 through SN 0300201017)
3121171 5-59
22
19**
1
22
23
15
18* 14
20** 11
24 10
10
11
13 16
12
13
7
8
5
6 4
3 2 17
26
21 ** Torque to 20 - 25 ft. lbs. (27 - 34 Nm)
1684430-E
25 MAE38540E
1. Barrel 7. O-ring 13. Backup Ring 19. Counterbalance Valve 25. Link
2. Rod 8. Backup Ring 14. Tapered Ring 20. Orifice Valve 26. Roll Pin
3. Head 9. Piston 15. Capscrew 21. Bushing
4. Wiper Seal 10. Hydrolock Seal 16. Capscrew 22. Bushing
5. Rod Seal 11. Guidelock Seal 17. Washer Ring 23. Plug
6. Wear Ring 12. O-ring 18. Counterbalance Valve 24. Plug
Figure 5-22. Platform Level Cylinder (SN 0300201017 through 0300238006)
5-60 3121171
26**
7
4
2
24* 3
25**
15
10
23
12
23
15
16
18 20
16
19
14
21
13 22
17
6 8
11
5
** Torque to 20 - 25 ft. lbs. (27 - 34 Nm)
1001138813-C
MAE38600C
1. Rod End Block 7. Barrel 13. Wear Ring 19. O-ring 25. Orifice
2. Capscrew 8. Rod 14. Backup Ring 20. Capscrew 26. Counterbalance Valve
3. Tapered Bushing 9. O-ring Plug 15. Guide Lock 21. Rod Seal
4. Bearing 10. O-ring Plug 16. Backup Ring 22. Wiper Seal
5. Bushing 11. Roll Pin 17. Washer Ring 23. Hydro Lock
6. Head 12. Piston 18. O-ring 24. Counterbalance Valve
Figure 5-23. Platform Level Cylinder (SN 0300201017 through 0300239155)
3121171 5-61
22
19*
23
15***
18* 14
20**
11
24 10
9
10
11
13
12
13 16****
7
8
5
6 4
6
3 17
2
26
21 * Torque to 30 - 35 ft. lbs. (41 - 47 Nm)

*** Torque to 10 ft. lbs. (13 Nm)
**** Torque to 85 ft. lbs. (115 Nm)
1001228034-B
25 MAE33950B
1. Barrel 7. O-ring 13. Backup Ring 19. Counterbalance Valve 25. Link Rod
2. Rod 8. Backup Ring 14. Tapered Ring 20. Orifice Valve 26. Rollpin
4. Wiper Seal 10. Hydrolock Seal 16. Capscrew 22. Bushing
5. Rod Seal 11. Guidelock Ring 17. Washer Ring 23. Plug
Figure 5-24. Platform Level Cylinder (SN 0300238007 to Present)
5-62 3121171
10
16*
11
6
17* 10
18** 7
10 10
11
12
13 102
105
102
3
101
108
104
109
109 103
104 106
107
15
5
8
* Torque 30-35 ft.lbs. (40.5-47.5 Nm) Max

** Torque 45-50 ft.lbs. (61-68 Nm) Max 5
1684292-E
1. JLG Threadlocker PN 0100011 7. Barrel 13. Piston 100. Not Used 105. O-ring
2. Locking Primer 8. Rod 14. Not Used 101. Wear Ring 106. O-ring
3. Capscrew 9. Head 15. Capscrew 102. Backup Ring 107. Wiper Seal
4. Tapered Bushing 10. O-ring Plug 16. Counterbalance Valve 103. Backup Ring 108. Rod Seal
5. Bushing 11. O-ring Plug 17. Shuttle Valve 104. Guidelock Ring 109. Hydrolock
6. Bushing 12. O-ring Plug 18. Counterbalance Valve
Figure 5-25. Tower Lift Cylinder (Prior to SN 0300144623)
3121171 5-63
23
18** 17** 24
20
23
23 19*
1
23***
24***
22
14
9 13
12
13
15
5
11
10
10 8
7
11
4
16
* Torque to 45 - 50 ft. lbs. (61 - 67.5 Nm) 21

*** Torque to 12 - 14 ft. lbs. (16.5 - 19 Nm)
1001165507-C
MAE37450C
21
1. Barrel 7. O-ring 13. Backup Ring 19. Counterbalance Valve

2. Rod 8. Backup Ring 14. Tapered Ring 20. Bushing
4. Wiper Ring 10. Hydrolock Ring 16. Capscrew 22. Plug
5. Rod Seal 11. Lock Ring 17. Counterbalance Valve 23. Plug
Figure 5-26. Tower Lift Cylinder (SN 0300211614 through 0300238464)
5-64 3121171
18**** 23
20 17**** 24
23
23
19***
1
24 22
23
14
11
10
15*
9
10
11
13
12
13
8
7
6
5
4
16**
21
2

** Torque to 302 ft. lbs. (410 Nm) 21
*** Torque to 45 - 50 ft. lbs. (61 - 68 Nm)
1001228077-C
MAE37460C
1. Barrel 7. O-ring 13. Backup Ring 19. Counterbalance Valve

2. Rod 8. Backup Ring 14. Tapered Ring 20. Bushing
4. Wiper Ring 10. Hydrolock Ring 16. Capscrew 22. Plug
5. Rod Seal 11. Lock Ring 17. Counterbalance Valve 23. Plug
Figure 5-27. Tower Lift Cylinder (SN 0300239465 to Present))
3121171 5-65
1. JLG Threadlocker PN 0100011 6. Rod 9. Not Used 13. Capscrew 103. Backup Ring 107. O-Ring
2. Capscrew 6A. Bushing 10. Piston 14. Valve Block 104. Wear Ring 108. Hydrolock
3. Tapered Bushing 7. O-Ring Plug 11. Washer Ring 101. Lock Ring 105. Backup Ring 109. Wiper Ring
4. Barrel 8. O-Ring Plug 12. Capscrew 102. Wear Ring 106. O-Ring 110. Rod Seal
5. Head
Figure 5-28. Main Boom Lift Cylinder (SN 0300201017 through SN 0300211613)
5-66 3121171
11
13
7
1
14
21 8
15
21
14
17
20 9
18
16
23 19
18
22
10
12
1001165510-D
6 MAE37470D
1. Capscrew 7. O-ring Plug 13. Valve Block 19. O-ring

2. Tapered Bushing 8. O-ring Plug 14. Lock Ring 20. O-ring
3. Barrel 9. Piston 15. Wear Ring 21. Hydrolock
4. Head 10. Washer Ring 16. Backup Ring 22. Wiper Ring
5. Rod 11. Capscrew 17. Wear Ring 23. Rod Seal
6. Bushing 12. Capscrew 18. Backup Ring
Figure 5-29. Main Boom Lift Cylinder (SN 0300211614 through 0300239976)
3121171 5-67
11
7 13
14
21
1** 15
21 8
14
18
19
18
17
20
16
4
10
23
12 * 22
* Torque to 302 ft. lbs. (410 Nm) 6

** Torque to 135 ft. lbs. (183 Nm)
1001228078-D
6 MAE37480D
1. Capscrew 7. O-ring Plug 13. Valve Block 19. O-ring

2. Tapered Bushing 8. O-ring Plug 14. Lock Ring 20. O-ring
3. Barrel 9. Piston 15. Wear Ring 21. Hydrolock
4. Head 10. Washer Ring 16. Backup Ring 22. Wiper Ring
5. Rod 11. Capscrew 17. Wear Ring 23. Rod Seal
6. Bushing 12. Capscrew 18. Backup Ring
Figure 5-30. Main Boom Lift Cylinder (0300239977 to Present)
5-68 3121171
9 14
14
9
4
4
1
14
14 10
15
13
5
19
13
8 20
21
24
17
16
25 18 6
16
7
22
23
11
2
12
1684173-H
1001138803-B
3 MAE38520
1. Barrel 7. Spacer 13. Capscrew 19. Seal 25. Seal

2. Rod 8. Tapered Bushing 14. O-ring Plug 20. O-ring
3. Bushing 9. Counterbalance Valve 15. O-ring Plug 21. O-ring
4. Bushing 10. Check Vlave 16. Wear Ring 22. Seal
5. Piston 11. Washer Ring 17. Wear Ring 23. Rod Wiper
6. Head 12. Capscrew 18. Backup Ring 24. Backup Ring
Figure 5-31. Jib Cylinder (Prior to 0300239155)
3121171 5-69
9****
14*** 4
14***
9**** 14***
14***
10
14
8 15
16
25
16
13**
5
19
18
20
18
20 7
21
24
17
6
22
23 11
12*

3
*** Torque to 18 - 20 ft. lbs. (24 - 27 Nm)
1001228025-E
3 MAE37490E
1. Barrel 7. Spacer 13. Capscrew 19. Seal 25. Seal

2. Rod 8. Tapered Bushing 14. O-ring Plug 20. O-ring
3. Bushing 9. Counterbalance Valve 15. O-ring Plug 21. O-ring
4. Bushing 10. Check Vlave 16. Wear Ring 22. Seal
5. Piston 11. Washer Ring 17. Wear Ring 23. Rod Wiper
6. Head 12. Capscrew 18. Backup Ring 24. Backup Ring
Figure 5-32. Jib Cylinder (SN 0300239156 to Present)
5-70 3121171
1. Barrel 7. Not Used 13. Wear Ring

2. Rod 8. Rod End Bushing 14. Piston Seal
3. Head 9. Barrel End Bushing 15. Wear Ring
4. Piston 10. Not Used 16. O-ring
5. Nut 11. Wiper 17. backup Ring
6. Loctite #222 (not shown) 12. Rod Seal 18. O-ring
Figure 5-33. Steer Cylinder (Prior to SN 0300201017)
3121171 5-71
7
1
10
4
5* 10
9
3
16
11 15
12
13
14
8
1684314-F
MAE38530F
6
1. Barrel 7. Bushing 13. O-ring

2. Rod 8. Wiper 14. Backup Ring
3. Head 9. Rod Seal 15. O-ring
4. Piston 10. Wear Ring 16. Cap Cylinder
5. Nut 11. Piston Seal
6. Bushing 12. Wear Ring
Figure 5-34. Steer Cylinder (SN 0300201017 through 0300238558)
5-72 3121171
7
7 1
17
5** 11
17
4
8
10
16*
12 15
13
14
9
2 6

** Torque to 402 ft. lbs. (545 Nm) 1001228031-B
MAE37510B
1. Barrel 7. Bushing 13. O-ring

2. Rod 8. Wiper 14. Backup Ring
3. Head 9. Rod Seal 15. O-ring
4. Piston 10. Wear Ring 16. Cap Cylinder
5. Nut 11. Piston Seal 17. Plug
6. Bushing 12. Wear Ring
Figure 5-35. Steer Cylinder (SN 0300238559 to Present)
3121171 5-73
8
9
15
17 8
32
31
19 7 27
35 28 16 29
2 21 27
14
3 35 15 1
26 33 13
30 35 3 34 4
5 33
15
33
4 34
33 28 30
13 26 31
1
16 20
3 27 14
19
35 29 27
7
15 6
32
10 11
24 25
6 23
37
36 18
12
22
1684320-H
MAE38610H
1. JLG Threadlocker PN 0100011 7. Barrel 12. Fitting 18. Bracket 23A. Valve 104. O-Ring
2. Locking Primer 8. Rod 13. Fitting 19. Capscrew 23B. Valve 105. O-Ring
3. Capscrew 9. Head 14. Plug 20. Capscrew 23C. Valve 106. Seal
4. Screw 10. Rod 15. Plug 21. Spacer 101. Backup Ring 107. Rod Wiper
5. Screw 10A. Bushing 16. Wear Pad 22. Spacer 102. Backup Ring 108. Wear Ring
6. Tapered Bushing 11. Fitting 17. Piston 23. Valve 103. Wear Ring 109. Seal
* Torque to 30 ft. lbs. (40.6 Nm)
Figure 5-36. Tower Boom Telescope Cylinder (SN 0300201017 through 0300243458)
5-74 3121171
9
6
9
19 15
6
32 21
31 27
7
17 26 34
30 16
28 14 29 4
2
33 1
13 15 33
3
3 5
15
3
15
5 13
4
28
1 33 26
33 32
29 14 7
19
16 20
34 30
31
27 10 11
8
24
25
23
36
35
8
12 22
18
1001228032-A
MAE37540A
1. Barrel 8. Rod 15. Wear Pad 22. Valve 29. O-ring 36. O-ring
2. Screw 9. Bushing 16. Piston 23. Valve 30. O-ring
3. Screw 10. Fitting 17. Bracket 24. Valve 31. Seal Rod
4. Tapered Bushing 11. Fitting 18. Capscrew 25. Valve 32. Rod Wiper
5. Barrel 12. Fitting 19. Capscrew 26. Backup Ring 33. Wear Ring
6. Rod 13. Plug 20. Spacer 27. Backup Ring 34. Seal
7. Head 14. Plug 21. Spacer 28. Wear Ring 35. O-ring
Figure 5-37. Tower Boom Telescope Cylinder (SN 0300243459 to Present)
3121171 5-75
1. JLG Threadlocker PN 0100011 6. Head 9. O-Ring Plug 14. Foot Plate 101. Wear Ring 106. O-Ring
2. Capscrew 7. Barrel 10. O-Ring Plug 15. Capscrew 102. Backup Ring 107. Seal
3. Bolt 7A. Bushing 11. Wear Pad 16. Capscrew 103. Backup Ring 108. Rod Wiper
4. Bolt 8. Rod 12. Piston 17. Spacer 104. Wear Ring 109. Seal
5. Tapered Bushing 8A. Bushing 13. Bracket 18. Valve 105. O-Ring
Figure 5-38. Main Boom Telescope Cylinder (Prior to SN0300144623)
5-76 3121171
30
16
29 34
34
33
31
19
32
10 34
7 7
6
15
11
6
12
23
26
2
14
22 17
24 25 5
13 22
21
1 27
24 2
4
18
20 12
24
28
20
18
24
8
8
9
1001175888-D
MAE37520D
1. Capscrew 7. Bushing 13. Piston 19. Valve Assembly 25. O-ring 31. Valve
2. Bolt 8. Rod 14. Bracket 20. Wear Ring 26. Seal 32. Valve
3. Bolt 9. Bushing 15. Foot Plate 21. Backup Ring 27. Rod Wiper 33. Valve
4. Tapered Bushing 10. O-ring Plug 16. Capscrew 22. Backup Ring 28. Seal 34. Valve
5. Head 11. O-ring Plug 17. Capscrew 23. Wear Ring 29. Fitting
6. Barrel 12. Wear Pad 18. Spacer 24. O-ring 30. Fitting
Figure 5-39. Main Boom Telescope Cylinder (SN 0300201017 through 0300243463)
3121171 5-77
33
32
31 26
30 30
29 27****
30 28****
24
28
1
19
22
18
25
13
13 1
11
10
9** 14
11
20***
12
12 15
12
14
8 12
7
3
2
6
6 16
5
4
17 23*
* Torque to 55 ft. lbs. (75 Nm) 19

2
*** Torque to 9.5 ft. lbs. (13 Nm)
**** Torque to 45 - 50 ft. lbs. (61 - 68 Nm) 19 1001228080-B
MAE37530B
1. Barrel 7. O-ring 13. Backup Ring 19. Bushing 25. O-ring Plug 31. Fitting
2. Rod 8. Backup Ring 14. Spacer 20. Capscrew 26. Valve Assembly 32. Fitting
3. Head 9. Piston 15. Tapered Bushing 21. Bolt 27. Valve 33. Capscrew
4. Wiper 10. Seal 16. Wear Pad Plate 22. Bolt 28. Valve
5. Rod Seal 11. Wear Ring 17. Wear Pad 23. Capscrew 29. Valve
6. Wear Ring 12. O-ring 18. Telefoot Plate 24. O-ring Plug 30. Valve
Figure 5-40. Main Boom Telescope Cylinder (SN 0300243464 to Present)
5-78 3121171
R.010 MIN
R.010 MIN
7X
R.020 .010
SECTION A-A
32 MAX SURFACE FINISH

(2 SURFACES)
2.740 .010 2.995 .010

2.020 .010
2.593 .060
2.905 .010
A A
1.125 .030 2X
15 2
8.000 .030 HEAD INSTALLATION SLEEVE
9.000 .060
JLG P/N 1001107143
4.500 .060
2X
.005/.015 X 45
2.130 .010 2.015 .010
2X
R.010 .005
PISTON INSTALL SLEEVE

JLG P/N 1001107145
Figure 5-41. Special Tools for Tower Tele Cylinder - Sheet 1 of 2
3121171 5-79
2.250 .125
1.755 .010
R.030 MAX
2.020 .010
1.250 .250 3.000
STK
3X
.030/.100 X 45
GO (PISTON) GAUGE
JLG P/N 1001107146
3.875 .125
3.357 .010
R.030 MAX
2.020 .010
1.250 .250 3.000
STK
.030/.100 X 45
GO (PISTON) GAUGE
JLG P/N 1001107147
Figure 5-42. Special Tools for Tower Tele Cylinder - Sheet 2 of 2
5-80 3121171

(3 SURFACES)
4.965 .010
2X
4.770 .010
4.874 .020
2X
15 2
6X R.020 MIN
3.000 .060
HEAD INSTALL SLEEVE
JLG P/N 1001107000
5.000 .060
2X
.005/.015 X 45
4.650 .010 4.515 .010
2X
R.010 .005
JLG P/N 1001107001
3.000 .125
2.438 .010
R.030 MAX
4.520 .010
1.250 .250 5.000

STK
.030/.100 X 45
GO (PISTON) GAUGE
JLG P/N 1001107002
Figure 5-43. Special Tools for Upper Lift Cylinder
3121171 5-81

(3 SURFACES)
3.965 .010
3.770 .010 3.874 .020
2X
15 2
6X R.020 MIN
3.000 .060
HEAD INSTALL SLEEVE

JLG P/N 1001106846
3.500 .060
2X
.060/.100 X 45
3.625 .010 3.015 .010
2X
R.125 .030

JLG P/N 1001106847
2.000 .125
1.688 .010
R.030 MAX
3.020 .010
1.250 .250 4.500

STK
GO (PISTON) GAUGE
(Tower Lift Cylinder Only)
.030/.100 X 45
JLG P/N 1001106848
Figure 5-44. Special Tools for Main Lift Cylinder and Tower Lift Cylinder
5-82 3121171
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,

HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
8. With the barrel clamped securely, apply pressure to the

rod pulling device and carefully withdraw the complete
rod assembly from the cylinder barrel.

Figure 5-46. Tapered Bushing Removal
14. Screw the piston CCW, by hand, and remove the piston
from cylinder rod.
15. Remove and discard the piston o-rings, seal rings, and
backup rings.
16. Remove piston spacer, if applicable, from the rod.
17. Remove the rod from the holding fixture. Remove the
cylinder head gland and retainer plate, if applicable. Dis-
Figure 5-45. Cylinder Rod Support card the o-rings, backup rings, rod seals, and wiper seals.
9. Using suitable protection, clamp the cylinder rod in a Cleaning and Inspection
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
NOTE: Step 10 applies only to the steer cylinder.
2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
10. Loosen and remove nut which attaches the piston to the
or equivalent. Replace rod if necessary.
rod, and remove the piston.
3. Inspect threaded portion of rod for excessive damage.
11. Loosen and remove the capscrew(s), if applicable, which
Dress threads as necessary.
attach the tapered bushing to the piston.
12. 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.
13. Remove the bushing from the piston.
3121171 5-83
4. Inspect inner surface of cylinder barrel tube for scoring 13. If applicable, inspect rod and barrel bearings for signs of
or other damage. Check inside diameter for tapering or correct excessive wear or damage. Replace as necessary.
ovality. Replace if necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
5. Inspect threaded portion of barrel for damage. Dress etc. to facilitate bearing installation.
threads as necessary. b. Inspect steel bushing for wear or other damage. If
6. Inspect piston surface for damage and scoring and for steel bushing is worn or damaged, rod/barrel must
distortion. Dress piston surface or replace piston as nec- be replaced.
essary. c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
7. Inspect threaded portion of piston for damage. Dress
threads as necessary. d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary. NOTE: Install pin into the composite bearing dry. Lubrication is
not required with nickel plated pins and bearings.
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 nec-
essary.
Figure 5-47. 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.
5-84 3121171
Assembly 2. Use a soft mallet to tap a new wiper seal into the appli-
cable cylinder head gland groove. Install a new wear
NOTE: Prior to cylinder assembly, ensure that the proper cylinder ring into the applicable cylinder head gland groove.
seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components prior to

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

applicable cylinder head gland groove.
Figure 5-49. Poly-Pak Piston Seal Installation
Figure 5-48. Rod Seal Installation
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS ARE INSTALLED Figure 5-50. Wiper Seal Installation
PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
TATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAK-
AGE AND IMPROPER CYLINDER OPERATION.
3121171 5-85
3. Place a new “o”ring and backup seal in the applicable NOTE: The backup rings for the solid seal have a radius on one
outside diameter groove of the cylinder head. side. This side faces the solid seal.(See magnified insert in
Figure 5-52.)The split of seals and backup rings are to be
positioned so as not to be in alignment with each other.
Figure 5-51. 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.
5. Carefully slide the piston spacer (if applicable) on the
rod.
NOTE: Main boom telescope cylinder piston has an o-ring

installed inside the spacer.
6. If applicable, correctly place new o-ring in the inner pis-

ton diameter groove. (The backup ring side facing the
O-ring is grooved.) Figure 5-52. Piston Seal Kit Installation
7. If applicable, correctly place new seals and guide lock
rings in the outer piston diameter groove. (A tube, with 8. Using suitable protection, clamp the cylinder rod in a
I.D. slightly larger than the O.D.of the piston is recom- vise or similar holding fixture as close to piston as possi-
mended to install the solid seal.) ble.
9. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and backup rings are not
damaged or dislodged.
5-86 3121171
10. Thread piston onto rod until it abuts the spacer end and b. Tap each space once; this means the tapered bush-
install the tapered bushing. ing is tapped 3 times as there are 3 spaces between
the capscrews.
NOTE: When installing the tapered bushing, piston and mating
end of rod must be free of oil.
WHEN REBUILDING THE TELESCOPE, LIFT, JIB, LEVEL, AXLE LOCKOUT OR AXLE
EXTENSION CYLINDERS, TIGHTEN SECURELY. (SEE TABLE 5-33)
11. Assemble the tapered bushing loosely into the piston

and insert JLG capscrews (not vendor capscrews)
through the drilled holes in the bushing and into the
tapped holes in the piston.
Figure 5-54. Seating the Tapered Bearing
14. Re-torque capscrews evenly and progressively in rota-

tion to specified torque value. (See Table 5-33, Cylinder
Head and Tapered Bushing Torque Specifications).
15. Remove the cylinder rod from the holding fixture.
16. Place new guide locks and seals in the applicable out-
side diameter grooves of the cylinder piston. (See Figure
5-52., Piston Seal Kit Installation)
17. Position the cylinder barrel in a suitable holding fixture.
Figure 5-53. Tapered Bushing Installation

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
12. Tighten the capscrews evenly and progressively in rota-
HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
tion to the specified torque value. (See Table 5-33, Cylin-
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
der Head and Tapered Bushing Torque Specifications).
13. After the screws have been torqued, tap the tapered 18. With barrel clamped securely, and while adequately sup-
bushing with a hammer (16 to 24 oz.) and brass shaft porting the rod, insert the piston end into the barrel cyl-
(approximately 3/4" in diameter) as follows; inder. Ensure that the piston loading o-ring and seal ring
are not damaged or dislodged.
a. Place the shaft against the cylinder rod and in con-
tact with the bushing in the spaces between the 19. Continue pushing the rod into the barrel until the cylin-
capscrews. der head gland can be inserted into the barrel cylinder.
3121171 5-87
20. Secure the cylinder head gland using the washer ring Table 5-33. Cylinder Head and Tapered Bushing Torque
and socket head bolts. (See Table 5-33, Cylinder Head Specifications
and Tapered Bushing Torque Specifications and Table 5-
34, Holding Valve Torque Specifications) Tapered
Head Torque Value
Description Bushing Torque
(Wet)
Value (Wet)
Tower Tele Cylinder 80 ft. lbs. 9 ft. lb.s

(108 Nm) (12.6 Nm)
Main Boom Tele 80 ft. lbs. 9 ft. lb.s

Cylinder (108 Nm) (12.6 Nm)
Level Cylinder 120 ft. lbs. 9 ft. lb.s

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

(41 Nm) (9 Nm)
Figure 5-55. Rod Assembly Installation
Tower Lift Cylinder 300 ft. lbs. 60 ft. lbs.
(410Nm) (81 Nm)
21. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the Main Boom Lift Cylinder 300 ft. lbs. 135 ft. lbs.
reinstallation of any holding valve or valves. (410 Nm) (183 Nm)
22. If applicable, install the cartridge-type holding valve and
Axle Oscillation 120 ft. lbs. 9 ft. lb.s
fittings in the rod port block, using new o-rings as appli-
cable. (See Table 5-34, Holding Valve Torque Specifica-
tions) Axle Extend 50 ft. lbs. 9 ft. lb.s
Table 5-34. 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)
50-55 ft. lbs.

RACINE - 1 1/8 HEX 1 1/16 - 12 THDS.
(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)
5-88 3121171
5.4 COUNTERBALANCE VALVE CHECK 7. After applying the torque to the valve, examine the
valve for hydraulic oil leaks. If the valve leaks, replace the
1. Position the machine on a firm level surface. counterbalance valve, see Step #10. If the valve does not
leak, proceed to Step #13.
2. Ensure the tower boom and main booms are on their
respective boom rests. 8. To replace the counterbalance valve:
3. Swing the turntable to the side about 35-45° to gain a. Remove the valve cartridge.
access to the counterbalance valve. b. Examine the removed cartridge for completeness of
4. Access the Tower Lift Cylinder Counterbalance Valve the valve, the o-rings and seals.
through the access hole in the bottom plate of the turn- c. If the valve, seals and o-rings are complete and
table. accounted for, proceed to the next step.
d. If any portion of the valve, o-rings or seals are miss-
ing, quarantine the machine. Do NOT allow the
tower boom to be raised. Contact a certified service
technician and make sure the missing parts are
accounted for.
IF THE CARTRIDGE REQUIRES REPLACEMENT, THE PORT IN THE VALVE BLOCK

MUST BE FREE OF RESIDUAL HYDRAULIC OIL BEFORE INSTALLING THE NEW
CARTRIDGE OR THE CARTRIDGE SEALS MAY BE DAMAGED DURING INSTALLA-
TION.
9. Inspect the new counterbalance valve for completeness

of the valves, o-rings and seals.
10. Carefully install the new counterbalance valve into the
valve block and torque 45 to 50 foot pounds (61 to 68
5. Torque the counterbalance valve 45 to 50 foot pounds Nm).
(61 to 68 Nm) and take note of how much the counter-
balance valve moves. 11. Return the machine to the stowed position.
6. If the valve moves less than 0.125" (3 mm) radially (see

example below), proceed to the next step. If the valve
moves more than 0.125" (3 mm) radially (see sketch
below), replace the counterbalance valve, proceed to
Step #8.
1/8”
(3 mm)
3121171 5-89
5.5 HYDRAULIC TANK

The hydraulic tank has a capacity of 53.3 gallons (201.7 liters)
and includes the hydraulic return filter and two suction strain-
ers. 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 5-56., Hydraulic Oil FULL LEVEL (HOT OIL)
Level Gauge. 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
FULL LEVEL (COLD OIL)
of the hydraulic tank during emergency lowering operations.
Figure 5-56. Hydraulic Oil Level Gauge
5-90 3121171
5.6 HYDRAULIC RETURN FILTER Replace the filter element before the indicator reaches the red
filter restricted area or every 300 hours, whichever comes first.
Check the hydraulic return filter indicator with the hydraulic oil
at normal operating temperature and the engine running.
A - Red = Filter Restricted; Filter Bypassed

B - Green = Filter Good; Not Restricted
Figure 5-57. Hydraulic Return Filter Condition Indicator - Prior to SN 139396
Red = Filter Restricted; Filter Bypassed

Green = Filter Good; Not Restricted
Figure 5-58. Hydraulic Return Filter Condition Indicator - SN 139396 to Present
3121171 5-91
2
4
1. Return Filter
2. Vented Fill Cap
3. Sight/Temperature Gauge
4. Filter Mounting Bracket
5. Magnetic Drain Plug
Figure 5-59. Hydraulic Tank
5-92 3121171
A. Front Steer Valve/Axle Extend

B. Traction Valve
C. Rear Steer Valve/Axle Extend
D. Chassis Module Controller
E. Junction Manifold Valve
Figure 5-60. Chassis Control Valve Locations
3121171 5-93
1. Level Up 5. Jib Down 9. Platform Dump 13. Main Pressure Check Port
2. Rotate Right 6. Jib Swing Left 10. Level Up Relief 14. Level Up Test Port
3. Level Down 7. Jib Up 11. Jib Up/Down Relief 15. Level Down Test Port
4. Rotate Left 8. Jib Swing Right 12. Level Down Relief 16. Jib Up/Down Test Port
Figure 5-61. Platform Valve Identification - JLG P/N 4641266
5-94 3121171
1. Level Up 5. Jib Down 9. Platform Dump 13. Main Pressure Check Port
2. Rotate Right 6. Jib Swing Left 10. Level Up Relief 14. Level Up Test Port
3. Level Down 7. Jib Up 11. Jib Up/Down Relief 15. Level Down Test Port
4. Rotate Left 8. Jib Swing Right 12. Level Down Relief 16. Jib Up/Down Test Port
Figure 5-62. Platform Valve Identification - JLG P/N 4641460
3121171 5-95
10
6
6
5
15 5
11
9
16
7
11
4
1
14 9
1 6
5
2
7 11 8
3
12
11
11
MAE38690
11
13
7
1. Flow Divider Valve 5. Brake and lockout Valve 9. Fitting 13. Orifices Fitting
2. Shuttle Valve 6. Coil 10. Fitting 14. Pressure Check
3. Relief Valve 7. Shuttle Valve 11. Fitting 15. Plug
4. Orifice 8. Check Valve 12. Fitting 16. Pressure Switch
Figure 5-63. Traction Valve Identification (Prior to SN 0300103907)
5-96 3121171
12
11
10
6
11
10 8
2
10 3
8
1
9
14
6 7
11
10
10 MAE38680
1. Brake and Axle Lockout Valve 5. Shuttle Valve 9. Fitting 13. Plug
2. Relief Valve 6. Flow Divider Valve 10. Fitting 14. Coil
3. Pilot Valve 7. Check Valve 11. Fitting
4. Pressure Switch 8. Fitting 12. Pressure Check
Figure 5-64. Traction Valve Identification (SN 0300103907 through 0300201017)
3121171 5-97
1. Tower Lift 6. Swing Right Relief 11. Main Tele Extend Port 16. Temperature Switch
2. Tower Tele 7. Main Tele Extend Relief 12. Main Tele Retract Port 17. Port to Platform Valve
3. Main Lift 8. Main Tele Extend Check 13. Main Tele Differential Sensing
4. Main Tele Exhaust Port 9. Main Tele Retract Check 14. Main Tele Retract Relief
5. Main Tele Exhaust Check 10. Swing Differential Sensing 15. Aux Port to Main Lift
Figure 5-65. Main Valve Identification - Top
5-98 3121171
1. Main Tele Exhaust Check 6. Main Lift Solenoid 11. Main Pressure Port 16. Swing Left Test Port
2. Swing Right Test Port 7. Pressure from Aux Pump 12. Tower Lift Solenoid 17. Swing Left Relief
3. Main Tele Extend Test Port 8. Return (Swivel) 13. Main Dump Solenoid
4. Main Tele Retract Test Port 9. Pressure from Function Pump 14. Swing Check Valve
5. Pressure Switch 10. Tower Tele Solenoid 15. Proportional Swing Valve
Figure 5-66. Main Valve Identification - Front & Side
3121171 5-99
1. Load Sense Port 6. Main Tele Proportional Valve

2. PVG Enable Solenoid Valve 7. Main Tele Retract Solenoid
3. Swing Left Port 8. Aux Port to Tower Lift
4. Swing Right Port 9. Main Pressure Check
5. Main Tele Extend Solenoid 10. Swing Check
Figure 5-67. Main Valve Identification - Bottom
5-100 3121171
1. Pressure Adjustment 6. Tower Telescope Section

2. Main Lift Extend Shock Valve 7. Tower Telescope Retract Shock Valve
3. Main Lift Section 8. Tower Telescope Extend Shock Valve
4. Tower Lift Retract Shock Valve 9. Tower Lift Extend Shock Valve
5. Tower Lift Section 10. Main Lift Retract Shock Valve
Figure 5-68. PVG Section
3121171 5-101
1. Pressure Port 5. Tower Telescope B Port

2. LS Port 6. Tower Telescope A Port
3. Main Lift B Port 7. Tower Lift A Port
4. Tower Lift B Port 8. Main Lift A Port
Figure 5-69. PVG Section Ports
5-102 3121171
1. Inlet Compensator 7. Orifice 12. Spool 17. Thrust Pad 22. Plug 27. Relief Valve
2. Plug 8. Plug 13. O-ring 18. Spring 23. Seal 28. Conversion Kit
4. Plug 9. Plug 14. Plug 19. O-ring 24. Screw
5. Washer 10. Spring 15. Filter 20. Adjusting Screw 25. Plug
6. Housing 11. Cone 16. Seat 21. Plug 26. Pilot Supply
Figure 5-70. PVP Pump Side Module
3121171 5-103
6
25 ± 3 Nm
(221 ± 27 in.lb.)
6
20 ± 3 Nm
(177 ± 27 in.lb.) 6
8 ± 1 Nm
(71 ± 9 in.lb.)
24
45 ± 5 Nm
(398 ± 44 in.lb.)
4 ± 1 Nm
(35 ± 9 in.lb.)
8 ± 1 Nm
2.5
(71 ± 9 in.lb.)
4 4 ± 1 Nm
35 ± 3 Nm
(35 ± 9 in.lb.)
(308 ± 27 in.lb.)
2.5
6
6
35 ± 3 Nm
(308 ± 27 in.lb.)
3
4 ± 1 Nm
(35 ± 9 in.lb.)
Figure 5-71. PVP Pump Side Module Torque Values & Tool Size
5-104 3121171
1. Compensator Valve 6. O-ring 10. Check Valve 14. O-ring 18. PVLP 22. Relief Valve
2. Housing 7. Adjusting Screw 11. Shuttle 15. Screw 19. O-Ring
4. Thrust Pad 8. Plug 12. Shuttle 16. Washer 20. PVLA valve
5. Spring 9. Plug 13. Pipe 17. Plug 21. PVLA Plug
Figure 5-72. PVB Basic Module
3121171 5-105
6 40 ± 3 Nm
(354 ± 27 in.lb.)
40 ± 3 Nm 13
(354 ± 27 in.lb.)
10 ± 1 Nm
(88.5 ± 9 in.lb.)
10
35 ± 3 Nm
(308 ± 27 in.lb.)
6
Figure 5-73. PVB Basic Module Torque Values & Tool Size
5-106 3121171
22 + 3,-0 Nm
(195 + 44, -0 in.lb.)
13
1. Nut
2. Washer
3. Stay Bolt
4. O-ring
5. O-ring
6. O-ring
7. O-ring
Figure 5-74. Assembly Kit & Torque for PVP Section
3121171 5-107
A. 5.2 Ohm ± 5%
B. 7.2 Ohm
C. 8.7 Ohm ± 5%
D. 4.7 Ohm ± 5%
Figure 5-75. Main Valve Ohm Values
5-108 3121171
Ft-Lbs. Nm
A 14 19
B 20-25 27-34
C 8-10 10-15
D 30-35 41-47
E 90-100 122-136
Coil Nuts 4-6 5-8
Figure 5-76. Main Valve Cartridge Torque Values - Top
3121171 5-109
Ft-Lbs. Nm
A 354 in.lbs. 40
B 20-25 27-34
C 35-40 47-54
D 50 68
E 90-100 122-136
Coil Nuts 4-6 5-8
Figure 5-77. Main Valve Cartridge Torque Values - Front
5-110 3121171
Ft-Lbs. Nm
A 195 in.lbs. 22
B 50 68
C 50-55 68-75
D 8-10 10-15
E 90-100 122-136
Coil Nuts 4-6 5-8
Figure 5-78. Main Valve Cartridge Torque Values - Bottom
3121171 5-111
5.7 ENABLE VALVES 7. Tag and disconnect the electrical harness from each
enable valve solenoid.
Removal 8. Remove the existing hardware securing the enable
valves to the turntable and remove the three enable
1. Make sure the machine is on a firm level surface. valves.
2. Extend the axles until the axle locked light is illumi-
nated. Installation
3. Position the machine with the booms on suitable boom 1. Install the enable valves onto the turntable using the
rests. mounting hardware.
4. Shut off the engine; remove the key and tag out the 2. Connect all hoses and electrical lines as tagged during
machine. removal.
5. Locate and identify the three enable valves on the left 3. If coils were removed, reinstall and torque to 5 foot
side of the machine. Mark the function that the valve pounds (6.8 Nm) maximum.
controls on the valve, i.e. tower lift, tower tele, main lift.
4. Check the hydraulic oil level in the tank and replenish as
6. Position a drain pan to catch any hydraulic spills and tag necessary.
and disconnect the hydraulic hoses going to the three
5. Remove the tag out from the machine.
enable valves. Cap or plug all hoses to prevent contami-
nation of the hydraulic system and loss of hydraulic oil. 6. Proceed to next test procedure.
MAIN LIFT ENABLE TOWER LIFT ENABLE
TOWER TELE ENABLE
Figure 5-79. Enable Valves
5-112 3121171
Air Purge Procedure for Non-Calibrated Machines Air Purge Procedure for Calibrated Machines
1. Loosen the hoses on Port #2 (side) of Tower Lift and 1. Loosen the hoses on Port #2 (side) of Tower Lift and
Tower Telescope enable valves. This is not necessary on Tower Telescope enable valves. It is not necessary on
Main Lift Enable Valve because the orientation of the Main Lift Enable Valve because the orientation of the
valve allows the air to escape. valve allows the air to escape.
2. Operate the Main Telescope in until oil appears at Port 2. Operate the Main Telescope in until oil appears at Port
#2 of both valves. #2 of both valves.
3. Tighten both hoses. 3. Tighten both hoses.
4. Raise the Main Boom to approximately 10° above hori- 4. Operate Tower Lift up until Tower Booms begins to Tele-
zontal. scope.
5. Operate the Tower Lift for 25 of the following cycles: 5. If an ENABLE VALVE STUCK OPEN fault occurs;
a. Raise the Tower Boom approximately 18” a. Cycle power.
b. Pause for approximately 2 seconds. b. Use Auxiliary Power to raise the Tower Boom until
c. Lower the Tower Boom to the boom rest. the Tower Telescope starts to move.
d. Pause for approximately 2 seconds. 6. Under engine power, operate the Tower Lift for 25 of the
following cycles:
6. Operate the Tower Telescope for 25 of the following
cycles: a. Raise the Tower Boom approximately 18”.
a. Extend the Tower Booms approximately 2’ b. Pause for approximately 2 seconds.
b. Pause for approximately 2 seconds c. Lower the Tower Boom 18”.
c. Fully retract the Tower Booms. NOTE: Do not pause at this reversal. Quickly switch from Tower
d. Pause for approximately 2 seconds. down to Tower up.
7. Raise the Tower Boom 18”, then lower it and stop before
the boom is on the boom rest.
8. Command Tower Boom up until boom moves.
9. Check for faults.
10. If there are faults, continue cycling as in Step #6 until
there are no faults after completing Steps #7 and #8.
11. If there are no faults, position the machine in the stowed
position.
3121171 5-113
5.8 PRESSURE SETTING PROCEDURE stand by adjustment is the outside adjustment, closest
to the turntable.
Cold temperatures have a significant impact on pressure read-
ings. JLG Industries Inc. recommends operating the machine
until the hydraulic system has warmed to normal operating
temperatures prior to checking pressures. JLG Industries Inc.
also recommends the use of a calibrated gauge. Pressure read-
ings are acceptable if they are within ± 5% of specified pres-
sures.
To ensure all pressures are set correctly, the following proce-

dures must be followed in order.
1. All applicable steps in Section 5.11, Drive & Function
Pump Start Up must be followed. REXROTH PUMP
2. Set up of the function pump.
3. Adjustments made at the main valve bank.
4. Adjustments made at the platform valve.
Set Up of the Function Pump

STAND BY PRESSURE OR LOW PRESSURE RELIEF - 450 PSI
(31 BAR)
1. Install a low pressure gauge at port MP1 of the main
valve block capable of reading 450 psi (31 bar).
SAUER PUMP
4. To make an adjustment to this pressure on a Rexroth

pump, go to the engine compartment and locate the
function pump which is the back pump. The high pres-
sure 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. 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 pressure.
To make an adjustment to this pressure on a Sauer

pump, loosen the 4 mm setscrew towards the engine.
2. Start the engine from the ground control. The gauge Using a 6 mm allen wrench, turn clockwise to increase
should read 425-475 psi (29.3-32.75 bar). pressure and counterclockwise to decrease pressure.
3. To make an adjustment to this pressure, go to the 5. After adjusting the pressure, tighten the jam nut and the
engine compartment, locate the function pump. The cover nut if applicable.
6. Start the engine and verify the gauge reads 425-475 psi
(29.3-32.75 bar).
5-114 3121171
HIGH PRESSURE RELIEF - 3200 PSI (220.6 BAR)

1. Install a high pressure gauge at the MP1 port of the
main valve block.
SAUER PUMP
5. After adjusting the pressure, tighten the jam nut and the
cover nut if applicable. This is the maximum relief pres-
sure for all the functions governed by this pump.
Adjustments made at the Main Valve Bank

2. Using a screwdriver, remove the Din connector from the
telescope proportional flow coil. SWING 1500 PSI (103.4 BAR)
3. Activate telescope in. The gauge should read 3200 psi 1. Install turntable lock pin.
(220.6 bar).
2. Install high pressure gauge at port "M13".
4. To make an adjustment to this pressure on a Rexroth
pump, go to the engine compartment and locate the
function pump which is the back pump. The high pres-
sure 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. 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 pressure.
To make an adjustment to this pressure on a Sauer

pump, loosen the 4 mm setscrew towards the engine.
Using a 6 mm allen wrench, turn clockwise to increase
pressure and counterclockwise to decrease pressure.
3. Activate swing right.

4. Swing right relief valve is located on top surface of valve
directly behind “M13”. The adjustment is below the
outer plug. Turn CW to increase pressure.
REXROTH PUMP
3121171 5-115
5. Install high pressure gauge at "M14". 5. Install high pressure relief at "M2".
6. Activate swing left. 6. Activate main telescope retract.
7. Swing left relief is located to the left of "M14". The 7. Main telescope retract is on top surface of valve directly
adjustment is below the outer cap. Turn CW to increase behind "M2". The adjustment is below the outer plug.
pressure. Turn CW to increase pressure.
8. Remove turntable lock pin. 8. Reconnect hoses.
MAIN TELESCOPE 2200 PSI (151.6 BAR) PVG VALVE (MAIN LIFT, TOWER LIFT, AND TOWER TELE)
1. Cap ports 1 and 2. Because of an internal shuttle network in the PVG valve, all
port pressures can be measured at the "LS" quick connect on
2. Install high pressure gauge at "M1". the top surface of the valve to the extreme left.
NOTE: Pressures are not adjustable and can only be monitored.

Should the setting be outside of the pressure tolerance the
respective shock valve must be replaced.
1. To check port pressure on PVG, install analyzer and go to

access level 1 as follows.
a. Plug the analyzer into the connector inside the
Ground control box.
3. Activate main telescope extend.

4. Main telescope extend relief is located on the top sur-
face of the valve directly behind "M1". The adjustment is
below the outer cap. Turn CW to increase pressure.
b. Pull out the Emergency Stop switch and start the

engine.
5-116 3121171
c. The analyzer screen should read: 2. In this level, enter the "service mode" menu then scroll
left or right to "set pressure" submenu as shown below.
3. Set Pressures - allows function of selected submenu

d. Use the arrow button to reach ACCESS LEVEL 2. with enable valve closed (to set pressure settings of
Press the ENTER key. functions that should not/cannot not be independently
e. Enter the Access Code, 33271 to get into Access operated)
Level 1 mode. 4. When the operator presses the ENTER key, the controller
NOTE: The service mode will only be displayed on the analyzer will display “SET PRESSURES” on the top line and “CODE
when in access level 1 or 0 in the ground mode and be hid- 00000" on the bottom line of the analyzer.
den while in access level 2.
ARROW KEYS.
3121171 5-117
5. When the operator enters access code 146005, "SET play "SERVICE FAILED" on the top line and "VALVE FAULT"
PRESSURES" will be displayed on the top line and cur- on the bottom line as shown below.
rent sub-menu on the bottom line. The sub-menus will
scroll with the left and right arrow keys.
6. Pressure setting sub-menus will include the following:
• "MAIN LIFT?"
• "TWR LIFT?"
• "TWR TELE?"
7. When the operator presses the ENTER key, "SET PRES-
SURES" will be displayed on the top line of the analyzer
and the bottom line will display the following: "WARN-
ING" flashed on a 0.5 hertz rate for 3 cycles followed by
the scrolling of "MOVEMENT POSSIBLE". This flashing
and scrolling will repeat until the ENTER key is pressed.
9. Pressing the ESCAPE or the ENTER key once will revert

back to the pressure setting sub-menus ("MAIN LIFT",
"TWR LIFT", "TWR TELE").
10. Select the PVG function then use the toggle switches at
ground control to energize function. Pressure should be:
• Main Lift UP - 2755 to 3088 psi (190 to 213 Bar)
• Main Lift DN - 2755 to 3088 psi (190 to 213 Bar)
• Tower lift UP - 2755 to 3088 psi (190 to 213 Bar)
• Tower Lift DN - 2755 to 3088 psi (190 to 213 Bar)
• Tower Tele OUT - 2537 to 2871 psi (175 to 198 Bar)
• Tower Tele IN - 2537 to 2871 psi (175 to 198 Bar)
8. When the operator pressed the ENTER key, the control-
ler will display "SET PRESSURE" on the top line, "MAIN
LIFT" or "TWR LIFT" or "TWR TELE" on the bottom line
and will allow operation of the selected submenu func-
tion with the enable valve closed. If movement of any of
the three functions is detected, the controller will dis-
5-118 3121171
Adjustments Made at the Frame Valve Bank 1. Position machine with front and rear axles fully
extended.
AXLE EXTEND AND RETRACT, FRONT AND REAR - 2500 PSI
(172.3 BAR)
2. Install the Analyzer in the platform control box and scroll
1. To extend axles, drive machine back and forth until menu’s to Access Level 2 and insert password (33271) to
extended. A machine that cannot be driven must be get into Access Level 1.
jacked up.
2. On both the front and rear frame valve banks, install a
high pressure gauge on ports MA1 for extend and MA2
for retract. The gauge should read 2500 psi (172.3 Bar) in
both directions.
3. The axle extend/retract cylinders are connected hydrau-
lically 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 3. Scroll to the calibration mode. Once in the calibration
is needed for verifying / adjusting pressure readings and mode, press “ENTER” and scroll to steer. Once in the
wheel spindle alignment the other for operating the steer steer calibration mode, the Analyzer is going to ask to
functions and using the Analyzer from the platform. calibrate the steer sensors, this is going to allow extend-
ing and retracting each steer cylinder individually dur-
The Analyzer is required to perform the pressure check proce- ing this process. The JLG control system will ask to
dure through access of the calibration menu. The calibration calibrate the left front sensor, the left rear sensor, the
menu will allow for extending and retracting the steer cylin- right front sensor and finally the right rear sensor in that
ders individually, verifying pressures, and proper steer sensor order. During this calibration mode each individual steer
calibration. Verification of the steer sensor calibration will cylinder will be extended and retracted to verify correct
require one of two types of measuring methods; using a pressures with the marked MS (Measure Steer) ports on
square and ruler or using string as explained in Section 6 - JLG the steer / axle valve that pertains to that steer cylinder.
Control System. The purpose of these measuring tools is to Refer to the Hydraulic Schematic in Section 7 - Schemat-
assure that the wheel spindle is aligned “straight” with the ics.
extended axle weldment.
3121171 5-119
Figure 5-80. Steer Pressure Adjustments
5-120 3121171
4. Remove the circular covers at the side or square cover at 6. Remove the pressure gauge from MS2 port and install
the top to gain access to the axle/steer valves. 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.
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.
7. This step involves aligning the left front wheel spindle

with the axle weldment. Position the left front wheel
spindle “straight” using a square and rule or string for
proper alignment (Refer to Section 6 - JLG Control Sys-
tem). Once the left front wheel spindle has been prop-
erly measured, press “ENTER” on the Analyzer. This is
calibrating data to the JLG Control System that the left
front steer sensor is centered.
3121171 5-121
8. Checking the left rear steer cylinder is identical to the mounted next to MS2 port CW to increase or CCW to
procedure for left front steer cylinder, except now we are decrease.
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.
10. The next step is identical to the left front step men-
tioned above. Make sure the left rear wheel spindle is
straight and press “ENTER” to accept the new calibration
settings, now press “ESC” (escape) and scroll to the right
front steer calibration step.
11. Checking the right front steer cylinder is identical to the
procedure laid out for the left front steer cylinder, except
the pressures are now checked at MS3 port of the front
9. Remove the gauge from MS1 port and install on MS2
axle/steer valve. This should be at the right side of the
port, which is on the right side of the rear axle/steer
valve closest to the right front wheel spindle. Install the
valve, closest to the right rear wheel spindle. Position
gauge at MS3 port. Position the steer switch to activate
the steer switch to activate the left rear steer cylinder
the right front steer cylinder until the rod is in the fully
until the rod is in the fully extended position and hold
retracted position and hold the steer switch for a few
the steer switch for a few seconds after the rod has been
seconds after the rod has been fully retracted. If the
fully extended. The MS2 port should read 2000 psi (179
pressure is not 2600 psi (179 Bar), adjust the relief valve
Bar). If the pressure is not correct, adjust the relief valve
mounted next to the MS3 port CW to increase or CCW to
decrease.
5-122 3121171
12. Remove the gauge from MS3 port and install on MS4 16. The next step is identical to the left front step men-
port, which is on the left side of the front axle/steer tioned above, make sure the right rear wheel spindle is
valve, closest to the left front wheel spindle. Position the straight and press “ENTER” to accept the new calibration
steer switch to activate the right front steer cylinder settings, now escape out of the calibration menu and
until the rod is in the fully extended position and hold remove the Analyzer and pressure gauge.
the steer switch for a few seconds after the rod has
stopped extending. The MS4 port should read 2000 psi Adjustments Made at the Platform Valve Bank
(138 Bar). If the pressure is not correct, adjust relief valve
mounted next to the MS4 port CW to increase or CCW to PLATFORM LEVEL UP - 3000 PSI (206.8 BAR)
decrease. 1. Install a high pressure gauge at the gauge port M1.
13. The next step is identical to the left front step men- 2. Activate level up to the end of stroke, it should read
tioned above. Make sure the right front wheel spindle is 3000 psi (206.8 Bar).
straight and press “ENTER” to accept the new calibration
settings. Scroll over to right rear steer calibration step. 3. All the relief valves are located on the same face. The
level up relief valve is located closest to the M1 gauge
14. Checking the right rear steer cylinder is identical to the port. Turn clockwise to increase, counterclockwise to
procedure laid out for the left rear steer cylinder. Install decrease.
gauge at MS4 port of the rear axle/steer valve. This
should be at the right side of the valve closest to the PLATFORM LEVEL DOWN - 2500 PSI (172.3 BAR)
right rear wheel spindle. Position the steer switch to acti- 1. Install a high pressure gauge at gauge port M2.
vate the right rear steer cylinder until the rod is in the
fully extended position and hold the steer switch for a 2. Activate level down to the end of stroke, it should read
few seconds after the rod has stopped extending. The 2500 psi (172.3 Bar).
MS4 port should read 2000 psi (138 Bar. If the pressure is 3. The level down relief valve is located to the left of the
not correct, adjust relief valve next to the MS4 port CCW level up relief valve. Turn clockwise to increase, counter-
to increase or CCW to decrease. clockwise to decrease.
15. Remove gauge from MS4 port and install on MS3 port, ARTICULATING JIB UP AND DOWN - 2750 PSI (189.6 BAR)
which is on the left side of the rear axle/steer valve, clos-
est to the left rear wheel spindle. Position the steer 1. Install a high pressure gauge on gauge port M3. The jib
switch to activate the right rear steer cylinder until the relief valve is located below the level down relief valve.
rod is in the fully retracted position and hold the steer Activate jib up or down, it should read 2750 psi (189.6
switch for a few seconds after the rod stops retracting. If Bar). Turn clockwise to increase, counterclockwise to
the pressure is not 2600 psi (179 Bar), adjust the relief decrease.
valve mounted next to the MS3 port CW to increase or
CCW to decrease.
3121171 5-123
5.9 DRIVE PUMPS 2. Transmission does not propel the machine, diesel
engine running properly - Charge Pump/Relief Valve
Troubleshooting Procedure a. Is there any charge pressure at port G or indicated
by measuring pressure at Ma and Mb?
To aid in troubleshooting, refer also to the pressure measuring
No - Proceed to step 2.d
port connections for test gauge installation information as
Yes - Proceed to step 2.b
shown on the hydraulic circuit diagram. Procedure assumes
proper gauges are installed. (Minimum gauges required: (2) 0- b. Is the charge pressure at least 500 psi while running
6000 psi, (1) 0-3000 psi & (1) 0-1000 psi [{2} 0-415 bar, {1} 0-210 at high engine speed?
bar & {1} 0-70 bar]). This procedure was written to aid the trou- No - Proceed to step 2.c
bleshooter in following a logical approach to a hydraulic sys- Yes - Proceed to step 3.a
tem fault. c. Can the charge pressure be raised by removing dirt/
debris from charge relief poppet or by adding or
1. Transmission does not propel the machine, diesel
removing shims from the charge pressure relief
engine running properly
valve mounted in the second pump of the triple?
a. Is there oil in the reservoir? No - Proceed to step 2.d
No - Fill reservoir Yes - Adjust pressure to 500 psi +50 psi, -0 psi (34.4
Yes - If yes, proceed to step 1.b bar +3.4 bar, -0 bar)
b. Is the pump input shaft connected to the engine NOTE: The propulsion circuit uses a hot oil flushing valve to
flex plate or rear of forward pump? obtain brake release pressure. The hot oil flushing valve
No - Connect pump input shaft cartridge (#120) is mounted in the Traction Control Mani-
Yes - If yes, proceed to step 1.c fold. The flushing valve receives its oil from the "left side"
c. Are the hydraulic hoses and tubing connected in wheel drive pump; the middle pump of the triple. With the
accordance with the hydraulic circuit diagram? engine running and propelling the machine forward or
reverse, the "hot oil flushing valve" and the brake release
No - Correct the hoses/tubing pressure must be adjusted to 475 psi, +25 psi, -0 psi (32.7
Yes - If yes, proceed to step 1.d bar, +1.7 bar, -0 bar), as set by adjusting pressure relief car-
d. Is the pump direction of rotation correct? (clockwise tridge (#130). The brake release pressure must be 25 psi
as looking at the shaft) less than the charge pump pressure. Measure pressure at
port "MP" using a 0-1000 psi (0 - 70 bar) pressure gauge.
No - Fit pump having the correct direction of rota- d. Is the transmission pumps suction hose pinched
tion shut?
Yes - If yes, proceed to step 1.e No - Proceed to step 2e
e. Are there "O"-rings missing from fittings (as exam- Yes - Repair damaged hose
ple - suction leak), pinched hoses, broken tubing, e. Is the charge pump suction pressure/vacuum within
etc? recommended limits? (0.8 bar absolute or 6.3 inches
of mercury)
No - Proceed to step 1.f No - Proceed to step 2.f
Yes - Repair damage or fault Yes - Proceed to step 2.g
f. Are the electrical connectors/wiring intact and f. Is the suction strainer inside the reservoir blocked,
secure to the pump control solenoids? clogged, restricted?
No - Repair damage or fault No - Proceed to step 2.g
Yes - If yes, proceed to step 1.g Yes - Repair/replace with a clean suction strainer
g. Does the engine "labor" when attempting drive, are g. Is the reservoir air breather blocked or restricted?
the brakes released? No - Proceed to step 2.h
No - Proceed to step 1.h Yes - Clean or replace air breather
Yes - Check brake release circuit, measure pressure
at port "MP" on Traction Control manifold
h. Are all four wheel drive planetary reduction gear-
boxes engaged?
No - Engage wheel drive(s)
Yes - If yes, proceed to step 2.a
5-124 3121171
h. Remove charge pressure relief valve from the mid- pressure to increase above charge pressure. Pro-
dle pump and inspect. Is it damaged? ceed to step 3.a
No - Refit cartridge and proceed to step 2.i Yes - Proceed to step 3.g
Yes - Clean & inspect cartridge, poppet, springs, g. Is it possible to adjust high pressure relief valves
seals to determine cause of damage. Repair or fit a using 0-6000 psi (0 - 415 bar) gauges to monitor
new cartridge and return to step 2.a pressure at Ma & Mb? (Refer to relief valve adjust-
i. Remove and inspect charge pump assemblies. Are ment)
they damaged? No - Replace high pressure relief valve and return to
No - Proceed to step 2.j step 3.c
Yes - Repair and/or replace damaged components Yes - Adjust high pressure relief valves to 5000 psi
and return to step 2.a +50 psi, -0 psi (344.7 bar +3.4 bar, -0 bar)
j. Is the charge pump installed for the clockwise rota- h. Actuate control in both directions. Does transmis-
tion? sion operate?
No - Refit charge pump. Return to step 2.a No - Check that minimum displacement stops on
Yes - With proper charge pressure and transmission the wheel drive motors are adjusted properly, check
still does not operate, proceed to step 3.a that the motors stroke between maximum to mini-
mum.
3. Transmission does not propel the machine, diesel
Yes - Operate the transmission
engine running properly - Pump Control: (Insure Gener-
ator Drive option is not turned "on") 4. Transmission Drive is Sluggish or Erratic
a. Are the electrical connectors & wiring connected a. Does the "EP" proportional pump control current
properly to the pump control solenoids? vary with joystick movement?
No - Connect a ammeter in series with solenoid wir- No - Rectify the problem - broken wires, electrical
ing. Is a current of 400 mA to 1060 mA being connector, open solenoid coil, etc.
applied. (Current signal varies with joystick position) Yes - Proceed to step 4.b
b. Are all four (4) brakes fully released?
b. Are all four of the two-speed motors, mounted in No - Check brake release pressure and insure each
the wheel drive planetary reduction gearboxes, wheel receives correct release pressure.
shifted to maximum displacement (high torque - Yes - Proceed to step 4.c
low speed)?
c. Are the pumps stroking time orifices installed tight
No - Select maximum displacement
and clean?
Yes - Proceed to step 3.c
No - Remove the Plugs in ports X1 and X2. Remove
c. Actuate the pump control in both directions. Do
orifices with a 3mm allen wrench. Check that ori-
the pumps stroke? Do they go to full stroke?
fices are clean & re-install.
No - Refer to the pump service manual and then
Yes - Proceed to step 4.d
proceed to step 3.d
Yes - Operate the transmission d. Is an motor displacement stroking time orifice
plugged or is the two-speed shift hose pinched?
d. Remove stroking orifices in X1 and X2. Install pres-
Yes - Inspect and clean stroking orifice, check two-
sure gauges in X 1 and X 2 (0-500 psi [0 - 35 bar]). speed hose routing
Stroke the pump in both directions. Do the pres- e. Is a flow divider/combiner cartridge stuck in the
sures at X1 and X2 alternate between 30 & 250 psi (2 Traction Control Manifold? Flow divider/combiner
& 17 bar)? cartridge # 111 controls the right side wheels, # 112
No - Remove the EP control module & replace it with controls the left side wheels. Also check to insure
a new unit. Repeat step 3.c bypass orifices #151 (right side) and # 152 (left side
Yes - Proceed to step 3.e. are not plugged.
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
3121171 5-125
5. Transmission Drives in one direction only 7. Transmission Does Not Find or Hold Neutral
a. Are electrical connections to pump control propor- a. Does pump remain in neutral with electrical con-
tional solenoids correct, intact and without defects? nectors removed?
Yes - Proceed to step 5.b No - proceed to step 7.b
No - Rectify the problem Yes - Check electrical system for signal problem
b. Check hot oil flushing valve cartridge #120 located b. With electrical connectors removed and machines
in the Traction Control Manifold. wheels jacked off the ground and engine running,
Remove and inspect flushing valve cartridge for momentarily apply 12 volt DC signal (battery volt-
stuck spool or damaged cartridge "O"-ring seals & age) to a pump control solenoid. Does the pump
backup rings. return to neutral after the 12 volt signal is removed?
c. Inspect "Make-Up" check valve cartridges, #190.1- No - Apply 12 volts to opposite solenoid & recheck.
190.4, installed in the Traction Control Manifold. Is a No - Replace pump control module, repeat step 7.a
cartridge "stuck" open with debris or is an "O"-ring Yes - Possibly dirt was dislodged from control mod-
failed? ule, re-check thoroughly to determine problem has
No - Proceed to step 5.d definitely been resolved.
Yes - Clean/repair or replace Make-Up check car- c. Check mechanical centering of the pumps
tridge.
8. Transmission Drives at a High Noise Level
d. Swap high pressure relief valves in the transmission.
Does the transmission drive in the other direction? a. Are the wheel drive planetary reduction gearboxes
No - Proceed to step 5.e filled to the correct level and do they have the
Yes - Repair/clean/adjust or replace high pressure proper lubricant?
relief valve on the non-driving side No - Fill gearbox with correct grade of oil to the pre-
scribed level.
e. Replace "EP" control module. Does pump operate
properly?
No - Replace or repair pump b. Is the engine flex plate and drive coupling correctly
Yes - Operate the transmission installed and aligned with the transmission pump?
No - Install flex plate and bell housing per manufac-
6. Transmission Drives in Wrong Direction turer's instructions
Yes - proceed to step 8.c
a. Check to see if electrical connectors or wiring have
been swapped on the pump. c. Is a rigid item or object contacting the resilient
mounted engine/pump assembly?
b. Check to determine want end of the machine the No - Proceed to step 8.d
boom is swung over. Yes - Insure no item is contacting the unit, transmit-
ting air borne noise.
d. Is the suction pressure/vacuum at the charge
pumps inlets within recommended limits?
No - Return to step 1.h
Yes - Proceed to step 8.e
e. Is there air in the hydraulic fluid? This may be indi-
cated by foaming or milky colored oil.
No - Proceed to step 8.f
Yes - De-aerate the oil and inspect system for cause
of air induction. Check for loose or missing O-rings
on face seal connections.
5-126 3121171
f. Is a wheel drive hydraulic motor operating at exces- 11. Transmission Pump(s) Do Not Develop Maximum Horse-
sive speed? power (Flow & Pressure)
Yes - Check minimum displacement stop screw
adjustments on the motors. Should be 0.433" or a. Does the charge pump pressure meet specification?
11mm above the stop screw lock nut. Is one or No - Return to step 2.a
more motors "stuck" at minimum displacement, Yes - Proceed to step 11.b
check for plugged/blocked two-speed stroking ori- b. Does the pump case pressure exceed 15 psi gauge
fice(s). pressure?
No - Proceed to step 11.c
9. Transmission Operates at a Higher than Normal Temper-
Yes - Check case drain hoses, oil cooler, etc. for
ature
pinched or restricted oil flow
a. Is the reservoir temperature above 195oF (90.5° C)? c. Are the pump(s) high pressure cross port relief
No - 195oF (90.5° C) is the upper limit. If tempera- valves adjusted to the required pressure (5000 psi)
ture is over 195oF (90.5° C), the oil cooler may need so they do not bypass prematurely?
to be cleaned. No - Inspect/clean/adjust and or replace valve car-
Yes - Proceed to step 9.c tridge
Yes - Replace the pump, after blocking the "A" & "B"
b. Are the hydraulic motor(s) stalling (wheels not turn- ports, running the pump and measuring pressure
ing) intermittently? developed at "A" & "B". This must be done to insure
No - Proceed to step 9.c that flow & pressure loss in not elsewhere in the sys-
Yes - Hydraulic fluid is being heated through system tem. (motors, swivel coupling, etc)
pressure relief valves. Shut down system and rectify
the cause of motor stall. d. Is the diesel engine capable of developing horse-
power at design rpm?
c. Does oil temperature remain above 195oF (90.5° C), Follow recommended troubleshooting procedures
after cleaning the oil cooler? to insure the engine is developing full power at
No - Operate transmission. Check oil cooler more specified rpms.
often.
Yes - Proceed to step 8.a Charge Pressure Relief Valve Adjustment
10. Transmission Operates at a Higher than Normal Temper-
ature
a. Check for differential temperature across the oil
cooler. Is there a temperature difference?
No - Check to determine if the bypass check valve
(10 psi [0.7 bar] crack pressure) is stuck open. Check
to determine if the oil cooler is restricted internally,
causing oil flow to pass across the bypass check
valve.
NOTE: Oil cooler flow is received from the transmission pumps

cases, max. continuous pump case pressure is 15 psi gauge CHARGE RELIEF
pressure. Higher pressure will prematurely damage pump
shaft seals With a low pressure (0 – 1000 psi [0 - 70 bar]) pressure gauge
b. Disconnect pump case drain from oil cooler & check tee’d into the ”G” port or two (2) low pressure gauges installed
flow rate from charge pumps. Is the flow rate 3.8 into ”Ma” and ”Mb”, run pump at engine idle speed. Do not
GPM (14.4 LPM) with diesel idle speed of 1200 rpm? place the pump on stroke – low pressure gauges installed in
No - Refer to charge pump removal & inspection ”Ma” & ”Mb” will be damaged! Prior to adjusting pressure,
procedure insure charge pressure relief valve is clean of any dirt or debris.
The charge pressure relief valve does not wear appreciably
over time. If charge pressure was normal and then has
decayed, check for other causes of low charge pressure. If pres-
sure is low, remove relief valve and add shim(s). If pressure is
high, remove relief valve and take out shim(s).
3121171 5-127
NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are avail- Hydraulic Centering of Control Modules
able in 0.3, 0.5, and 1.0 mm thickness.
PREPARATION FOR ADJUSTMENT
When control modules are exchanged or replaced, it is gener-
ally necessary to center the new module. This is done by run-
ning the pump with gauges installed at ports X1, X2, MA, and
MB Release the jam nut and turn the adjustment screw on top
of the control module valve body.
Mechanical Centering of Pump

PREPARATION FOR ADJUSTMENT
The control piston has strong centering springs to ensure that
once the pump is adjusted for the neutral position it will
always return to neutral. If an adjustment is necessary follow
the steps listed below.
To ensure there is equal pressure on both sides of the control
module during the centering operation, it is necessary to con-
nect the X1 and X2 ports together by means of hose or tubing.
(No less than a 1/4 inch ID) The port sizes are:
Pump Size Allen Wrench Wrench
28 5 mm 17 mm
With pressure gages installed at MA, and MB, and with A and B
ports blocked (or motor stalled), and with the pump running, The adjustment screw is an eccentric, therefore, turning more
loosen the jam nut. Turn the mechanical centering adjusting than 90’ in either direction will have no further centering
screw until 1000 psi is read on MA, or MB then turn screw effect, and could cause damage to the eccentric pin.
opposite direction until 1000 psi is read on other pressure Pump Size Tool Required Wrench
port. Turn the screw back, splitting the distance between the
previous two positions. This should be the neutral position. 28 Screwdriver 10 mm
Pressure on MA, and MB should be equal.
CENTERING THE EP CONTROL MODULE
With no electrical signal to solenoids A and B, (remove both
plug-in connectors), the EP control module is correctly
adjusted when any or all of the following conditions exist:
1. Approximately, when equal control pressures are
obtained at control pressure ports X1 and X2.
2. The hydraulic motor does not turn when the brake is

released.
3. Charge pressure is registered equally at ports MA and
MB, when the flow output of the pump is deadheaded
against a locked motor or a valve.
If difficulties are encountered in obtaining neutral position of
the HD or EP control modules, check that the ends of the con-
Tighten jam nut, stop the pump drive, remove the hose con-
necting ports X1 and X2.
5-128 3121171
trol spring are correctly located in the grooves near the end of Removal and inspection of charge pump
the feedback lever arms.
Before removing capscrews, mark the position of the charge
pump housing and separator plate in relation to the port
block.
High Pressure Relief Valve Adjustments

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

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

3. Holding spring loading nut (ref. item 4) rotate valve
spindle (ref. item 3). For high range relief valve, one turn
equals approximately 630 psi (44 bar). For low range
relief valve, one turn equals approximately 377 psi (26
bar).
4. After adjustment is completed torque jam screw (ref.
item 4) to 5 ft.lb. (7 Nm). Remove charge pump housing and inspect for wear or dam-
age to gear set and 0-ring seals. Grease 0-rings prior to reas-
5. Install relief valve assembly into pump, reinstall cover
(ref. item 1) to proper torque.
Table 5-35. Torque Specs for Relief Valves into Port Block
Pump Size Wrench Size Torque

28 32 mm 66 ft.lb. (90 Nm)
3121171 5-129
sembly. Make sure 0-rings are completely seated in their Routine Maintenance
grooves.
The Variable Displacement Hydrostatic Transmission Pumps
are relatively maintenance free. Maintenance work is confined
to the system, by way of maintaining hydraulic fluid condition,
the "life blood" of the machine. Oil monitoring, changes and
filter renewal promote system cleanliness. This will prevent
premature breakdown and repairs. Under normal application
conditions, the following maintenance intervals are sug-
gested:
1. Renewal of Filter Elements
a. After commissioning or re-build.
b. At every 500 operating hours or when filter indica-
tor shows a dirty element.
c. With the suction strainer, the strainer should be
renewed as soon as charge pump inlet pressure is
less than -3.2 psi, 6.3"Hg or 0.8 bar absolute.
d. Only JLG recommended filter elements are to be
used. Paper elements cannot be cleaned; use
Withdraw pinion shaft and inspect gear teeth and bearing sur- throwaway cartridges.
faces for abnormal wear.
2. Hydraulic Fluid Change
When reassembling, make sure chamfer (on outer edge of
driven gear and drive gear) is installed into housing per illus- a. After 2000 operating hours (1st oil change)
tration. b. Thereafter, every 2000 operating hours or annually,
irrespective of operating hours achieved.
c. Oil change should be performed with the system in
warm running condition. Before re-filling, the reser-
voir interior should be inspected and cleaned to
remove any sludge.
d. Rags or threaded material must not be used.
e. This machine has been designed & manufactured to
operate on an Exxon-Mobil Oil Co. hydraulic fluid,
Mobilfluid #424, Product #52233-4. Consult JLG
Industries prior to introducing any other type of
fluid to prevent interaction or possible contamina-
tion.
f. The recommended interval between oil changes is
Torque value for bolts when replacing charge pump. based on various factors and should be carried out
according to the degree of aging, contamination
Pump Size Torque and water content.
28 18 ft.lb. (24 Nm)
NOTE: If serious wear or damage has occurred to one component,

the complete charge pump assembly must be replaced
because they are matched components.
5-130 3121171
g. Under application conditions with a heavy occur- 5. Oil Level Inspection

rence of dust or severe temperature fluctuations,
a. Inspect oil level in the reservoir daily.
the intervals between fluid maintenance should be
shortened accordingly. b. If "topping off" is required, use only the same Mobil-
fluid #424, Product #52233-4.
c. Do Not Mix Fluids.
PRACTICAL EXPERIENCE SHOWS THAT MOST FLUID MAINTENANCE ERRORS 6. Hydraulic Fluid - The "Life Blood" of the Machine
OCCUR DURING AN OIL CHANGE DUE TO:
a. The type of hydraulic fluid supplied in the machine
• Use of an unsuitable hydraulic fluid from the factory was selected after extensive testing
and development. The fluid was selected to per-
• Use of oil contaminated due to poor storage practices form under "most" applications and conditions.
• Failure to clean the reservoir Should this machine be in service for extended time
periods at the extremes (hot or cold), JLG should be
• Inadequate cleanliness when filling the reservoir (dirty drums, con- consulted for assistance in selection of the most
tainers, water, etc) suitable fluid type and grade for your application.
3. Leakage Inspection b. When operating at temperatures below 0oF, allow a
a. After commissioning warm-up period, if at all possible, to a temperature
b. The complete transmission drive system (pumps, of 40oF.
motors, hosing, filters, valves, etc) should be c. When beginning motion of a "cold" machine, oper-
checked for leakage at regular intervals. ate all functions at reduced speeds until the "cold"
c. Leaking joints & connections must only be tight- oil has circulated out of the drive loop.
ened when pressureless.
4. Cleanliness Inspection
a. The oil tank breather should be regularly cleaned of
dirt and dust to prevent clogging. With each cylin-
der movement, gallons of oil pumped, an equal
amount of air exchange occurs across the reservoir
breather. A dirty or clogged breather will affect all
machine functions!
b. The air/oil cooler surfaces and engine radiator
should be cleaned at the same time.
c. If hose connections are disassembled, it is impera-
tive that the utmost care be taken that no foreign
bodies infiltrate the oil circuit. Catastrophic compo-
nent failure may occur.
3121171 5-131
Removal and Installation of Shaft Seal Press in shaft seal with bushing to the stop. Then replace snap
ring.
Remove the retaining ring with snap ring pliers.
Screw in sheet metal screw into the holes fitted with rubber.
Pull out shaft seal with pliers.
5-132 3121171
1. Torque 50 ft lbs (222 Nm) w/JLG Threadlocker PN 0100011

2. Torque 35 ft lbs (156 Nm) w/JLG Threadlocker PN 0100011
3. Function Pump
4. Left Side Drive Forward
5. Right Side Drive Forward
6. Right Side Drive Pump
7. Right Side Drive Reverse
8. Left Side Drive Pump
9. Left Side Drive Reverse
NOTE: Drive Coils are approximately 5.5 ohms.
Figure 5-81. Drive & Function Pumps
3121171 5-133
5.10 FUNCTION PUMP
Figure 5-82. Function Pump - Sectional View
Spare Parts 2. Drive Shaft
1. Sealing kit, existing spare parts: shaft sealing ring, o-

rings, and a circlip.
3. Bearing set, miscellaneous parts.
5-134 3121171
4. Rotary Group complete: 9 pistons, cylinder subassem- Sealing the Drive Shaft
bly, valve plate, retaining plate, and retaining ball.
BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED DURING THE

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

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

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

tape to prevent the shaft splines from damaging the
seal.
7. DFR pilot valve.
3121171 5-135
4. Assemble the sealing ring, fitting tool holds the correct 2. Mark the position of the port plate and remove the
position of the sealing ring in the pump housing. socket screw of the port plate.
5. Assemble the snap ring. 3. Remove the port plate together with the valve plate
(hold the valve plate so the plate can’t fall down).
6. Assemble the snap ring in the correct position.

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

5. Disassemble the taper roller bearing (nearby port plate).
1. Disassemble the pilot valve.
5-136 3121171
6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position.
7. Unscrew the cap nut and remove it. 11. Disassemble the stopper max flow.
8. Loosen the fixing nut of the stopper max flow and disas- 12. Remove the threaded pin.
semble it.
13. Disassemble the plug.

9. Turn in the stopper max flow to get swivel angle zero.
3121171 5-137
14. Disassemble the control piston while moving the swash 18. Remove both bearing shells.
plate.
19. Remove the drive shaft.

15. The swash plate must be lifted a little bit to disassemble
the piston rod.
20. Disassemble the snap ring.
16. Remove the swash plate.
21. Disassemble the sealing ring.
17. Remove the spring.
5-138 3121171
22. The external front bearing ring is pulled out of the pump 25. The spring has additional pretension while you disas-
housing. semble the three pressure pins inside the cylinder.
23. Remove the o-ring. Lifting of the valve plate isn’t shown. Assembly
1. Measurement of the taper roller bearing pretention.
24. A bearing puller is used to disassemble the external

bearing ring of the taper roller bearing inside the port
plate. Take care of the surface of the port plate. 2. Ensure there is a correct connection of the piston rod
and the swash plate.
3121171 5-139
3. Pumps clockwise driven must have a position of the Adjustments

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

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

Differential volume if you are rotating the threaded pin - each
rotation is approximately 3.1 cm3.
5. Note the correct position of the drilling that connects
high pressure to the control valve. Check control valve Tightening Torques
drilling position at the pump housing and fit together.
For break-off plugs, use Loctite #601.
For all other parts, use Loctite #242.
Table 5-36. Tightening Torques
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8.8 2.3 5.0 8.5 21 41 72 115 176 240 350 600 1220
10.9 3.2 7.2 12 29 58 100 165 250 350 490 840 1670
12.9 4.1 8.5 14.5 35 70 121 195 300 410 590 990 2000
5-140 3121171
Figure 5-83. Function Pump, Pressure and Flow Control - Sheet 1
3121171 5-141
Pump Control Disassembly For Cleaning 5. Remove three (3) 0-rings (Parker # 2-011, Viton 90 shore)
or the sealing plate.
NOTE: If the Function Pump does not perform correctly after
following pre-start procedures, it is possible that a contami- 6. Remove both the adjustment hex caps and bonded seal
nate particle has lodged in the pump control preventing rings. (17 mm wrench)
proper operation. The pump control’s internal parts are not 7. Remove both the adjustment lock nuts and bonded seal
provided as spare parts due to the close tolerances required rings. (17 mm wrench)
between the mating parts. However, the control can be disas-
sembled, cleaned and placed back in service should the only 8. Remove both the adjusting screws. (3-mm Allen
problem prove to be contamination. Disassembly, inspection, wrench)
cleaning and reassembly MUST BE done in a clean well-illumi- 9. Remove spring cover hex cap for the ”outer” flow regula-
nated area. tion adjustment this requires a 19-mm wrench.
Pump Control removal: 10. Remove the spring disc.
1. Disconnect plug the hose attached to the pump control 11. Remove the adjusting springs (two springs, one
Port ”X”. ”nested” inside the other) and spring follower.
2. Remove the four (4) socket head capscrews that attach 12. The flow regulation spool should slide from the control
the control to the pump. Insure that the three (3) ”0”- housing, (a magnet should aid in removal). If it does not,
rings are also removed with the control. remove the hollow hex head plug at the rear of the flow
3. Hydraulic fluid may drip from the pump. Wiping the sur- regulation spool and carefully push the spool from the
face clean and installing some adhesive tape should pre- housing - do not scratch/mar the spool’s bore.
vent oil from seeping from the pump control. 13. Remove the spring cover hex cap for the ”inner” pres-
4. Work on a clean, lint free area. sure compensation adjustment – this requires a 30-mm
wrench.
NOTE: The pump control can be equipped with either O-rings or a
sealing plate. These components are NOT interchangeable. 14. Remove the spring disc.
5-142 3121171
15. Remove adjusting springs (two springs, one ”nested” 5.11 DRIVE & FUNCTION PUMP START UP
inside the other).
16. Remove spring follower. Pressure compensation spool Start-Up Procedure
should slide from control housing, (a magnet should aid
The machine utilizes a Triple Combination Pump coupled to
in removal). If it does not, remove the hollow hex head
the Deutz diesel engine. Pumps are connected in-line to each
plug at rear of flow regulation spool. Carefully push
other as follows:
spool from housing. Do not scratch/mar spool bore.
1. The front hydrostatic transmission pump, or drive pump,
NOTE: Spools are identical. is coupled directly to the diesel engine and provides oil
17. Wash housing and all parts in a clean JLG approved sol- flow to operate the machine's right side wheels.
vent such as non-chlorinated brake cleaner, Stoddard 2. The middle hydrostatic transmission pump, or drive
solvent, etc. pump, is coupled to the back of the front pump and pro-
18. Blow off all parts with clean, dry compressed air. vides oil flow to operate the machine's left side wheels.
19. Blow out housing with clean compressed air. Inspect 3. The third or rear pump is the function pump. It is cou-
housing for contamination or plugged orifices. Clean pled to the back of the middle pump and provides oil
orifices carefully with a soft steel wire to ensure they are flow to operate the boom, axle, steer and platform func-
open. Inspect parts for burrs, scoring, debris, etc. tions.
Transmission pumps share some common connections. Each
pumps’ charge oil suction ports are connected by steel tubing.
ON CONTROL HOUSING MOUNTING SURFACE, BETWEEN OIL PORTS, IS WHAT Discharge oil flows are connected and flow to a common
APPEARS TO BE A SLOTTED HEAD SCREW. IT IS NOT A SCREW. THIS IS A BLEED charge pump inline oil filter. Cleaned & filtered oil flows back
ORIFICE, WHICH MUST BE ORIENTATED TO ALLOW PROPER CONTROL OPERA- to the transmission pumps "G" ports. Case drain ports are con-
TION. THE SLOT IN THE HEAD SHOULD BE ORIENTED TO FALL IN-LINE WITH nected (T1 & T2), oil flow from the middle pumps T1 port also
THE OIL PORTS, NOT PERPENDICULAR TO THE OIL PORTS. IF SLOT IS ORI- provides flows to the oil cooler.
ENTED PERPENDICULAR TO THE THREE PORTS, PUMP PRESSURE WILL NOT The charge pumps oil pressure is regulated by a single boost
RETURN FROM LOAD PRESSURE TO STAND-BY PRESSURE AT THE END OF oil pressure relief valve installed in the middle pump. The front
OPERATING A FUNCTION! PUMP PRESSURE WILL REMAIN AT THE LAST HIGH- pump has an orifice cartridge (0.047" diameter) installed in
EST PRESSURE GENERATED.) place of a charge oil pressure relief cartridge. This insures that
only one valve controls charge pressure & provides an amount
20. After all parts are clean and dry, lightly oil a control of charge oil flow to the front pump's case to insure flushing &
spool and install in its bore. The spool must slide removal of hot oil.
smoothly and easily within the housing. If it does not, Each pump has its own separate electrical proportional direc-
check for contamination. If contamination cannot be tional control valve to control oil flow and direction. The sig-
found check for ”scoring” or ”burring” of the control nals or command values to each pump are similar except
housing. If spool does not slide smoothly & freely, the when steering. During steering and propel of the machine the
control must be replaced with a new unit. pump supplying oil to the "inside turning radius" has a com-
21. Lightly oil and check operation of the second spool. The mand less than the pump supplying oil flow to the “outside
spools are installed correctly when there ”pointed” end turning radius” pump.
faces the spring followers “Posi-Traction” control, front to rear on a given side of the
machine, is accomplished by a flow divider/combiner car-
22. Re-assemble in reverse order.
tridge installed in the Traction Control Manifold. There is a flow
23. Bench set the pressure adjustments as described in ”C. divider/combiner for each side. Each flow divider/combiner
4” of the Operating Instructions. also has a “bleed orifice” to limit the amount of flow splitting
or combining.
NOTE: The pump control can be equipped with either O-rings or a
The middle transmission pump also supplies oil to a hot oil
sealing plate. These components are NOT interchangeable.
flushing valve cartridge, #120, in the Traction Control Mani-
24. Re-install Function Pump. Ensure 0-rings or sealing plate fold. This cartridge provides a means to obtain brake release
are installed properly. Tighten four (4) M6 socket head oil pressure. The brake release pressure is controlled by a pres-
capscrews to 105 in-lb. sure relief valve cartridge # 130 and a solenoid operated brake
release directional control cartridge, #170, also located in the
Traction Control Manifold.
3121171 5-143
13. With joystick in neutral, check for creep in neutral. If evi-

dent, most likely dirt is present in the proportional
BRAKE RELEASE OIL PRESSURE MUST BE SET 25 PSI (1.7 BAR) BELOW THE pump control, an incorrect electrical signal is present on
BOOST OIL PRESSURE RELIEF VALVE. IF BRAKE RELEASE PRESSURE IS SET TOO the pump's electrical control(s), or the control was not
LOW, BRAKE DRAG AND PUMP CONTROL WILL BE AFFECTED. IF SET TOO HIGH, centered properly when overhauled. See service manual
DAMAGE TO THE WHEEL DRIVE PARKING BRAKES COULD RESULT. PRIOR TO for centering instructions.
START, CONNECT APPROPRIATE PRESSURE GAUGES TO THE UNIT.
14. Check controls are connected so transmissions operate
FOR START-UP OF NEW OR OVERHAULED INSTALLATIONS: in correct direction related to control input.
1. Insure all electrical checks have been performed & the 15. Continue to monitor all pressure gauges & correct any
machine is set up correctly with the JLG Analyzer. irregularities.
2. Insure the machine has all four wheels jacked & blocked 16. Remove brake coil (leaving electrical connection intact)
off the ground per JLG procedures. from brake release solenoid cartridge located on the
Traction Manifold.
3. Ensure the triple pump assembly is installed and con-
nected correctly per the hydraulic circuit diagram. NOTE: This disables machine's ability to release brakes.
4. Disconnect the electrical connector from the diesel's 17. Stroke transmission pumps slightly (less than 20%) and
throttle actuator, to prevent engine start. check the setting of the high pressure cross port relief
valves. Setting should be 5000 psi +50 psi, - 0 psi (344.7
5. Crank the engine until charge pressure reaches 50 psi or
bar +3.4 bar, -0 bar). Install 0-6000 psi (0 - 415 bar)
more.
gauges on Pump ports Ma & Mb.
6. Re-connect throttle actuator electrical connector and
18. Check oil level & temperature.
start engine. Allow engine to run at idle speed only for
at least 5 minutes. This will allow the hydrostatic system 19. Remove and inspect charge pressure oil filter. Replace
to filled. with new element.
7. Listen for any abnormal noises. 20. Operate transmission under no load conditions for
about 15 minutes to stabilize temperature and remove
8. Check for oil leaks.
any residual air from the fluid.
9. Check charge pressure (500 psi +50psi, - 0 psi [34.4 bar
21. Set machine back on the ground. Operate transmissions
+3.4 bar, - 0 bar]). Pressure can be measured at pump
under full and normal conditions.
ports Ma & Mb or by “teeing” into the inlet for the
charge oil filter. Charge pressure is checked with the joy- 22. Erratic operation may indicate there is still air trapped in
stick in neutral. A 0-1000 psi (0-70 bar) pressure gauge the system. By working the pump controls forward and
must be used. (If pressure gauges were installed in Ma & reverse the remaining air can be eliminated. The system
Mb to check charge pressure, disconnect the gauges is free of air when all functions can be operated
installed in Ma & Mb, as they will be damaged if loop smoothly and when the oil in the reservoir is no longer
pressure rises above 1000 psi [34.4 bar].) aerated. (Usually less than one hour of operation)
10. Operate drive system in “turtle mode”, forward and NOTE: If transmissions do not perform correctly after following
reverse. pre-start & start-up procedures, refer to relevant sections of
the trouble-shooting procedures.
11. De-aerate system by bleeding fluid from Ma & Mb ports.
12. Switch drive mode speed control from “turtle” to “rab-
bit”. Gradually increase drive speed forward & reverse,
still with no load - wheels off the ground.
5-144 3121171
3121171 5-145
5.12 HYDRAULIC SCHEMATICS
Figure 5-86. Hydraulic Schematic - Sheet 1 of 8
5-146 3121171
1001110761 C
3121171 5-147
5-148 3121171
1001110761 C
Figure 5-89. Hydraulic Schematic Sheet 4 of 8
3121171 5-149
5-150 3121171
1001110761 C
3121171 5-151
5-152 3121171
1001110761 C
3121171 5-153
NOTES:
5-154 3121171
SECTION 6. JLG CONTROL SYSTEM

6.1 INTRODUCTION The main lift, swing, and drive are controlled by individual joy-
sticks, with steering being controlled by a rocker switch built
into the top the drive joystick. To activate Drive, Lift, and Swing
simply pull up on the slide lock location on the joystick and
WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE MACHINE, IT IS move the handle into the direction desired.
NECESSARY TO PROGRAM THE CONTROLLER FORPROPER MACHINE CONFIGU-
The control system will control the voltage output to the
RATION, INCLUDING OPTIONS, AND PROPERLY CALIBRATE THE TILT SENSOR.
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.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- The JLG Control System controller has a built in LED to indicate
TRONIC COMPONENTS. IF PRESSURE-WASHING IS USED TO WASH AREAS CON- any faults. The system stores recent faults which may be
TAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. accessed for troubleshooting.
RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM
DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELEC- Optional equipment includes head and tail lights, and ground
TRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE alarm. These options may be added later but must be pro-
DIRECT FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION. grammed into the control system when installed.
The Control System may be accessed with a custom designed,
The JLG designed Control System is a 12 volt based control direct connect hand held analyzer or wireless adapter using an
unit installed on the boom lift. app on your Android or iPhone/iPad device. The analyzer or
The JLG Control System reduces the need for exposed terminal wireless output displays two lines of information at a time, by
strips, diodes, and trimpots. It provides simplicity in viewing scrolling through the program.
and adjusting the various personality settings for smooth con- Each module has a label with JLG part number and a serial num-
trol of: acceleration, deceleration, creep, min speed, and max.- ber containing a date code.
speed for all boom, drive, and steering functions.
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub Level,
To return home or access previ-
and item menus
ous menu
Left & Right Arrow Keys

Up & Down Arrow Keys Used to move between Top Level, Sub
Value Selector
Level, and item menus
Figure 6-1. Hand Held Analyzer (Analyzer Controls and Display Similar)
3121171 6-1
Connect the JLG Control System Analyzer If you press ENTER, at the HELP: PRESS ENTER display, and a
fault is present, the analyzer display will scroll the fault across
1. Connect the cable supplied with the analyzer, to the the screen. If there was no fault detected, the display will read:
controller module located in the platform box or at the HELP: EVERYTHING OK. If powered up at the ground station,
controller module in the ground control box and con- the display will read: GROUND OK.
nect the remaining end of the cable to the analyzer.
If ENTER is pressed again, the display moves to the following
NOTE: The cable has a four pin connector at each end of the cable; display:
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 emer-
gency stop buttons on.
Using the Analyzer

With the machine power on and the analyzer connected prop-
erly, the analyzer will display the following:
LOGGED HELP
1: POWER CYCLE (2/1)
At this point, the analyzer will display the last fault the system
has seen, if any are present. You may scroll through the fault
logs to view what the last 25 faults were. Use the right and left
arrow keys to scroll through the fault logs. To return to the
beginning, press ESC. two times. POWER CYCLE (2/1) indi-
cates a power up.
When a top level menu is selected, a new set of menu items
HELP: may be offered: for example:
PRESS ENTER
DRIVE
At this point, using the RIGHT and LEFT arrow keys, you can BOOM
move between the top level menu items. To select a displayed SYSTEM
menu item, press ENTER. To cancel a selected menu item, DATALOG
press ESC.; then you will be able to scroll using the right and VERSIONS
left arrow keys to select a different menu item.
Pressing ENTER with any of the above displayed menus, will
The top level menus are as follows: display additional sub-menus within the selected menu. In
HELP some cases, such as DRIVE, the next level is the parameter or
DIAGNOSTICS information to be changed. Refer to the flow chart for what
SYSTEM TEST menus are available within the top level menus. You may only
ACCESS LEVEL view the personality settings for selected menus while in
PERSONALITIES access level 2. Remember, you may always cancel a selected
MACHINE SETUP menu item by pressing the ESC. key.
CALIBRATIONS (view only)
6-2 3121171
Changing Access Level of Hand Held Analyzer Once the correct password is displayed, press ENTER. The
access level should display the following, if the password was
When the analyzer is first connected, you will be in access level entered correctly:
2 which enables you to only view most settings which cannot
be changed until you enter a password to advance to a lower
level. This ensures that a setting cannot be accidentally
altered. To change the access level, the correct password must
be entered. To enter the password, scroll to the ACCESS LEVEL
menu. For example:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not dis-
played or you can not adjust the personality settings.
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.
3121171 6-3
Adjusting Parameters Using Hand Held Analyzer Machine Setup

Once you have gained access to level 1, and a personality item When a machine digit item is selected, press the UP or DOWN
is selected, press the UP or DOWN arrow keys to adjust its arrow keys to adjust its value, for example:
value, for example:
GROUND ALARM:
PERSONALITIES: 2 = LIFT DOWN
DRIVE ACCEL 1.0s
The effect of the machine digit value is displayed along with
There will be a minimum and maximum for the value to its value. The above display would be selected if the machine
ensure efficient operation. The Value will not increase if the UP was equipped with a ground alarm and you wanted it to
arrow is pressed when at the maximum value nor will the sound when lifting down. There are certain settings allowed to
value decrease if the DOWN arrow is pressed and the value is install optional features or select the machine model.
at the minimum value for any particular personality. If the
When selection the machine model to match the size of the
value does not change when pressing the up and down
machine, the personality settings will all default to the factory
arrows, check the access level to ensure you are at access level
recommended setting.
1.
NOTE: Refer to Table 6.2, Machine Personality Settings and Func-
tion Speeds in this Service Manual for the recommended
factory settings.
NOTE: Password 33271 will give you access to level 1, which will
permit you to change all machine personality settings.
There is a setting that JLG strongly recommends that you do

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

MACHINE.
6-4 3121171
Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations
ABBREVIATION MEANING ABBREVIATION MEANING
ACCEL ACCELERATE LEN LENGTH
ACT ACTIVE LIM LIMIT
A/D ANALOG DIGITAL CONVERTER COUNT LVL LEVEL

AMB. AMBIENT m MINUTES
ANG ANGLE MIN MINIMUM
AUX AUXILIARY MAX MAXIMUM
BCS BOOM CONTROL SYSTEM MN MAIN

BM or BLAM BOOM LENGTH ANGLE MODULE NO NORMALLY OPEN or NO
BR BROKEN NC NORMALLY CLOSED
BSK BASKET OP OPEN
CAL CALIBRATION O/R OVERRIDE or OUTRIGGER
CL CLOSED OSC OSCILLATING

CM CHASSIS MODULE OVRD OVERRIDE
CNTL or CNTRL CONTROL P or PRS PRESSURE
COOR COORDINATED PCV PROPORTIONAL CONTROL VALVE
CRK PT CRACK POINT PLAT PLATFORM

CRP CREEP PM PLATFORM MODULE
CUT CUTOUT POT POTENTIOMETER

CYL CYLINDER PT POINT
DECEL DECELERATE R REAR or RIGHT

D or DN DOWN REV REVERSE or REVISION
DEG. DEGREE RET RETRACT
DOS DRIVE ORIENTATION SYSTEM ROT. ROTATE
DRV DRIVE RT RIGHT
E ERROR SEL SELECTOR
E&T ELEVATED & TILTED SN SERIAL NUMBER
ELEV ELEVATION SPD SPEED
ENG ENGINE STOW or STOWD STOWED
EXT EXTEND SW SWITCH or SOFTWARE
F or FNT FRONT TELE TELESCOPE

FL FLOW TEMP TEMPERATURE
FOR or FWD FORWARD TORQ. TORQUE

FSW FOOT SWITCH TRN TRANSPORT
GRN GREEN T/T or TURNTBL TURNTABLE
GM GROUND MODULE TWR TOWER

h HOURS U UPPER or UP
HW HARDWARE VER VERSION

L or LT LEFT VLV VALVE
LB POUND WIT WITNESS
YEL YELLOW
3121171 6-5
Figure 6-2. Control System Block Diagram
6-6 3121171
Table 6-2. Machine Configuration Programming Information - Version P7.24
Default
Configuration Digit Number Description
Number
NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal-
ity settings first and then changing the model number of the machine configuration will cause the personality settings
to return to default
MODEL NUMBER: 1 1 1200S 1

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

2 1350S: 125' MAX
3 1350S: 120' MAX
4 1350S: 110' MAX
5 1200S: 120' MAX
6 1200S: 110' MAX
7 1250A: 125' MAX
8 1250A: 100' MAX
9 1250A: 80' MAX
10 1100S: 110’ MAX
Note: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial default setting.
MARKET: 3 0 ANSI USA 0

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

2 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)
3 DEUTZ ECM: Engine Control Module
4 CAT ECM: Engine Control Module
5 DEUTZ ECM T4F: Engine Control Module (Tier 4 Final)
3121171 6-7
Default
Number
GLOW PLUG: 5 0 NO GLOW PLUGS: No glow plugs installed. 2

1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2 IN-CYLINDER: Glow plugs installed in each cylinder.
STARTER LOCKOUT: 6 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start 0
can be attempted at any time during pre-glow.
1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permit-
ted until pre-glow is finished.
ENGINE SHUTDOWN: 7 0 DISABLED: No engine shutdown. 1
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or oil pres-
sure is less than 8 PSI.
FUEL CUTOUT: 8 0 RESTART: Engine allowed to be restarted multiple times when very low fuel is reached. 0
1 ONE RESTART: Engine allowed to be restarted once for 2 minutes when very low fuel is reached.
2 ENGINE STOP: Engine not able to restart when very low fuel is reached.
* This menu item is only visible if non dual fuel engines are selected.
CHASSIS TILT: 9 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more 1
than 5 degrees and above elevation; also reduces drive speed to creep.
2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees
and above elevation; also reduces drive speed to creep.
3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees
and above elevation; also reduces drive speed to creep.
4 5 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 5
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out,
and main lift up.
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the machine is also above elevation.
6-8 3121171
Default
Number
JIB: 10 0 NO: No jib installed. 2

1 YES: Jib installed.
2 SIDESWING:Jib with sideswing installed.
4WS: 11 0 NO: 2WS mode enabled. 1

1 YES: 4WD drive mode enabled.
DRIVE: 12 0 2WD drive mode enabled. 1

1 4WD mode enabled.
STOUCH/SKYGUARD: 13 0 NONE: No Soft Touch or SkyGuard system installed. 0

1 SOFT TOUCH: Soft Touch only installed.
2 SKYGUARD: Skyguard only installed.
3 BOTH (CUTOUT): Soft Touch and SkyGuard installed.
GEN SET/WELDER: 14 0 NO: No generator installed. 1

1 BELT DRIVE: Belt driven setup.
2 HYDRAULIC DRIVE: Hydraulic driven setup.
GEN SET CUTOUT: 15* 0 MOTION ENABLED: Motion enabled when generator is ON. 0
1 MOTION CUTOUT: Motion cutout in platform mode only.
* Only visible if Gen Set / Welder Menu selection is not 0.
H & T LIGHTS: 16 0 NO: No head and tail lights installed. 0

1 YES: Head and tail lights installed.
3121171 6-9
Default
Number
LOAD SYSTEM: 17* 0 NO: No load sensor installed. 0

1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps
(5 sec ON, 2 sec OFF).
4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform
alarm beeps (5 sec ON, 2 sec OFF).
* Only visible under certain market selections.

* Certain market selections will limit load system options or alter default setting.
LOAD TYPE: 18 0 NON CAN LSS: Non CAN based LSS is installed. 1
1 CAN LSS: CAN based LSS is installed.
FUNCTION CUTOUT: 19* 0 NO: No drive cutout. 0

1 BOOM CUTOUT: Boom function cutout while driving above elevation.
2 DRIVE CUTOUT: Drive cutout above elevation.
3 DRIVE CUT E&T: Drive cutout above elevation and tilted.

* Certain market selections will limit function cutout options or alter default setting.
GROUND ALARM: 20* 0 NO: No ground alarm installed. 0

1 DRIVE: Travel alarm sounds when the drive function is active (Option).
2 DESCENT: Descent alarm sounds when lift down is active (Option).
3 MOTION: Motion alarm sounds when any function is active (Option).
* Certain market selections will alter default setting.
OSCILLATING AXLE: 21 0 NO: No oscillating axle system installed. 1

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

1 METRIC: DEG C, KPA, KGS.
* Certain market selections will alter default setting.
6-10 3121171
Default
Number
LEVELING MODE: 23 0 LIFT: Platform leveling during lift only. 1

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

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

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

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

1 YES: Temp Cutout is Enabled.
PLAT LVL OVR CUT: 28 0 NO: Platform Level Override will always be functional. 0
1 YES: Platform Level Override will only be functional when in Transport.
HV CONTROL: 29 0 NO: Machine is not configured with HV Control. 0

1 YES: Machine is configured for HV Control.
CRIBBING OPTION: 30 0 NO: Cribbing Option is disabled. 0

1 YES: Cribbing Option is enabled.
WATER IN FUELSENSOR: 31 0 NO: The Water In Fuel Sensor option is not installed. 0
1 YES: The Water in Fuel Sensor option is installed.
4150364-U
3121171 6-11
ANSI Export
ANSI Export
Australia
ANSI USA
ANSI USA
Australia
Japan
CSA
Japan
1250AJP
CE
CSA
1250AJP
CE
Model Number 2 2 2 2 2 2 Function Cutout 0 0 0 0 0 0
Envelope Height 7 7 7 7 7 7 X 1 1 1 1 1
Market 0 1 2 3 4 5 X 2 2 X 2 2
Engine 3 3 3 3 3 3 X 3 3 X 3 3
Glow Plug 0 0 0 0 0 0 Ground Alarm 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2
Starter Lockout 0 0 0 0 0 0 3 3 3 3 3 3
1 1 1 1 1 1 Oscillating Axle 0 0 0 0 0 0
Engine Shutdown 0 0 0 0 0 0 1 1 1 1 1 1
1 1 1 1 1 1 Display Units 0 0 0 0 0 0
Fuel Cutout 0 0 0 0 0 0 1 1 1 1 1 1
1 1 1 1 1 1 Leveling Mode 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
Tilt 1 1 1 1 1 1 Clearsky 0 0 0 0 0 0
2 2 2 2 2 2 1 1 1 1 1 1
3 3 3 3 3 3 Fuel Tank 0 0 0 0 0 0
4 4 4 4 4 4 1 1 1 1 1 1
5 5 5 5 5 5 2 2 2 2 2 2
6 6 6 6 6 6 Alert Beacon 0 0 0 0 0 0
Jib 0 0 0 0 0 0 1 1 1 1 1 1
1 1 1 1 1 1 Temp Cutout X 0 X 0 X X
2 2 2 2 2 2 X 1 X 1 X X
4 Wheel Steer 0 0 0 0 0 0 Plat Lvl Ovr Cut 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Drive Type 0 0 0 0 0 0 HV Control 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Soft Touch\Skyguard 0 0 0 0 0 0 Cribbing Option 0 X X X X X
1 1 1 1 1 1 1 X X X X X
2 2 2 2 2 2 Water In Fuel Sensor 0 0 0 0 0 0
3 3 3 3 3 3 1 1 1 1 1 1
Gen Set / Welder 0 0 0 0 0 0 BOLD TEXT indicates the default setting. Plain text indicates another available selec-
tion. ITALIC TEXT indicates the default when option is factory installed. SHADED CELLS
1 1 1 1 1 1
indicates hidden menu or selection.
2 2 2 2 2 2 4150364-U
Gen Set Cutout 0 0 0 0 0 0
1 1 1 1 1 1
Head & Tail lights 0 0 0 0 0 0
1 1 1 1 1 1
Load System 0 0 0 0 0 0
X 1 X X X 1
X 2 X 2 2 2
X 3 X 3 X 3
X 4 X X X 4
Load Type 0 0 0 0 0 0
1 1 1 1 1 1
6-12 3121171
6.2 MACHINE PERSONALITY SETTINGS AND

FUNCTION SPEEDS
NOTE: Personality settings can be adjusted within the allowed
range in order to achieve optimum machine performance.
Table 6-3. Machine Personality Settings and Speeds
TIME RANGE (SEC)

(SEE Section FOR
Submenu Parameter DEFAULT MACHINE
(Displayed on Description Range
Analyzer 1st Line) (Displayed on Analyzer 2nd Line) VALUES ORIENTATION
WHENSETTING
SPEEDS)
DRIVE:
ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2.0
DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.3
MIN forward XX% Displays/adjusts minimum forward drive speed 0 to 35% 1
40-48 (see
MAX forward XXX% Displays/adjusts maximum forward drive speed 0 to 100% 100
orientation)
MIN reverse XX% Displays/adjusts minimum reverse drive speed 0 to 35% 1
MAX reverse XXX% Displays/adjusts maximum reverse drive speed 0 to 100% 100
Displays/adjusts maximum drive speed
93-104 (see
ELEV. MAX XX% NOTE: used when elevation cutout switches are lim- 0 to 50% 25
orientation)
iting maximum speed
Displays/adjusts maximum drive speed 79-87 (see
CREEP MAX XX% 0 to 50% 35
NOTE: used when creep switch on pump pot is active orientation)
STEER:
max SPEED XXX% Displays/adjusts maximum steer speed. 0 to 100% 100
MAIN LIFT:
ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1.0
DECEL X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1.0
MIN Up XX% Displays/adjusts minimum main lift up speed 0 to 60% 1
57-69 (see
MAX UP XX% Displays/adjusts maximum main lift up speed 0 to 60% 60
orientation)
Displays/adjusts maximum main lift up speed
CREEP UP XX% 0 to 65% 35
NOTE: used when creep switch on pump pot is active
MIN DOWN XX% Displays/adjusts minimum main lift down speed 0 to 60% 1
59-70 (see
MAX DOWN XXX% Displays/adjusts maximum main lift down speed 0 to 60% 60
orientation)
Displays/adjusts maximum main lift down speed
CREEP DOWN XX% 0 to 75% 35
3121171 6-13

SWING:
ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0
DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5
MIN LEFT XX% Displays/adjusts minimum swing left speed 0 to 50% 20
102-146 (see orien-
MAX LEFT XXX% Displays/adjusts maximum swing left speed 0 to 65% 73
tation)
Displays/adjusts maximum swing left speed
CREEP LEFT XX% 0 to 65% 45
MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 20
102-146 (see orien-
MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 65% 65
tation)
Displays/adjusts maximum swing right speed
CREEP RIGHT XX% 0 to 65% 45
TOWER LIFT:
ACCEL X.Xs Displays/adjusts tower lift acceleration 1.0 to 1.0 sec 1.0
DECEL SLOW-FAST Displays/adjusts tower lift deceleration Slow, Medium, Fast 0.5
MIN Up XX% Displays/adjusts minimum tower lift up speed 1 to 1% 1
105-119 (see
MAX UP XX% Displays/adjusts maximum tower lift up speed 60 to 60% 60
orientation)
MIN DOWN XX% Displays/adjusts minimum tower lift down speed 1 to 1% 1
108-122 (see
MAX DOWN XXX% Displays/adjusts maximum tower lift down speed 60 to 60% 60
orientation)
MAIN TELESCOPE:
ACCEL X.Xs Displays/adjusts main telescope acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts main telescope deceleration 0.1 to 3.0 sec 0.5
Displays/adjusts minimum main telescope in
MIN IN XX% 0 to 65% 40
speed. Same as Creep speed
35-54 (see
MAX IN XXX% Displays/adjusts maximum main telescope in speed 0 to 100% 85
orientation)
Displays/adjusts minimum main telescope out
MIN OUT XX% 0 to 65% 40
Displays/adjusts maximum main telescope out 29-49 (see
MAX OUT XXX% 0 to 100% 85
speed orientation)
TOWER TELESCOPE:
ACCEL X.Xs Displays/adjusts tower telescope acceleration 1.0 to 1.0 sec 1.0
DECEL X.Xs Displays/adjusts tower telescope deceleration 0.5 to 0.5 sec 0.5
Displays/adjusts minimum tower telescope in
MIN IN XX% 1 to 1% 1
Displays/adjusts maximum tower telescope in
MAX IN XXX% 60 to 60% 60
speed
Displays/adjusts minimum tower telescope out
MIN OUT XX% 1 to 1% 1
Displays/adjusts maximum tower telescope out
MAX OUT XXX% 60 to 60% 60
speed
6-14 3121171

BASKET LEVEL:
ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts basket level deceleration 0.1 to 3.0 sec 0.5
Displays/adjusts minimum basket level up speed.
MIN UP XX% 0 to 65% 40
Same as Creep speed
MAX UP XXX% Displays/adjusts maximum basket level up speed 0 to 100% 70
Displays/adjusts minimum basket level down
MIN DOWN XX% 0 to 65% 40
Displays/adjusts maximum basket level down
MAX DOWN XXX% 0 to 100% 70
speed
BASKET ROTATE:
ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1.0
DECEL X.Xs Displays/adjusts basket rotate deceleration 0.1 to 3.0 sec 0.5
Displays/adjusts minimum basket rotate left speed.
MIN LEFT XX% 0 to 100% 60
Same as Creep speed
MAX LEFT XXX% Displays/adjusts maximum basket rotate left speed 0 to 100% 60 24-30 (180)
Displays/adjusts minimum basket rotate right
MIN RIGHT XX% 0 to 100% 60
Displays/adjusts maximum basket rotate right
MAX RIGHT XXX% 0 to 100% 60 24-30 (180)
speed
JIB LIFT:
ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1.0
Displays/adjusts minimum jib up speed. Same as
MIN UP XX% 0 to 65% 40
Creep speed
MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 65 30-36
Displays/adjusts minimum jib down speed. Same as
MIN DOWN XX% 0 to 65% 40
Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 60 30-36
JIB SWING:
ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5
Displays/adjusts minimum jib left speed. Same as
MIN LEFT XX% 0 to 65% 40
Creep speed
MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 42-47 (125)
Displays/adjusts minimum jib right speed. Same as
MIN RIGHT XX% 0 to 65% 40
Creep speed
MAX RIGHT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 42-47 (125)
3121171 6-15
GROUND MODE:
m. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 100% 60
m. lift DN XXX% Displays/adjusts main lift down speed 0 to 100% 60
SWING XXX% Displays/adjusts fixed swing speed 0 to 65% 45
BASKET LVL XXX% Displays/adjusts fixed basket level speed 0 to 100% 75
BASKET ROT XXX% Displays/adjusts fixed basket rotate speed 0 to 100% 75
MAIN TELE XXX% Displays/adjusts fixed main telescope speed 0 to 100% 65
Displays/adjusts fixed tower telescope speed

TOWER TELE XXX% 40 to 40% 40
Not displayed if TOWER TELE=NO
Displays/adjusts fixed tower lift up speed

T. LIFT UP XXX% 40 to 40% 40
Not displayed if TOWER LIFT=NO
Displays/adjusts fixed tower lift down speed
T. LIFT DN XXX% 40 to 40% 40
Not displayed if TOWER LIFT=NO
Displays/adjusts jib lift speed
JIB (U/D) XXX% 0 to 100% 60
Not displayed if JIB = 0
Displays/adjusts jib swing speed
JIB (L/R) XXX% 0 to 100% 70
Displayed if JIB = 2
GEN SET/WELDER:
Control generator/welder RPM. Not displayed if GEN
Engine XXXX RPM 1200-2800 1800
SET/WELDER = 0
NOTE: Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.
Stop watch should start when the function is activated.Not with the controller or switch.
Unless noted, function speeds should be measured from platform.
Platform speed knob must be at full speed (fully clockwise).
All test should be done with the oil temp above 100° F (38° C).
4150517-C
6-16 3121171
6.3 MACHINE ORIENTATION WHEN SETTING Test Notes

SPEEDS 1. Personality settings can be adjusted anywhere within
the adjustment range in order to achieve optimum
MAIN BOOM LIFT UP: From platform control, lowest elevation
machine performance
up to maximum elevation, main boom retracted, tower boom
on boom rest. 2. Stop watch should start when the function is acti-
vated.Not with the controller or switch.
MAIN BOOM LIFT DOWN: From platform control, maximum
elevation down to minimum elevation, main boom retracted, 3. Unless noted, function speeds should be measured from
tower boom on boom rest. platform.
TOWER BOOM LIFT UP: From platform control, lowest eleva- 4. Platform speed knob must be at full speed (fully clock-
tion up to maximum elevation, main boom retracted and hori- wise). All test should be done with the oil temp above
zontal. 100° F (38° C).
TOWER BOOM LIFT DOWN: From platform control, maximum
elevation down to minimum elevation, main boom retracted
and horizontal.
SWING RIGHT (Max): 360 Degrees, from platform control,
main boom retracted, tower boom on boom rest.
SWING LEFT (Max): 360 Degrees, from platform control, main
boom retracted, tower boom on boom rest.
MAIN BOOM TELESCOPE OUT: from platform control, main

boom horizontal, tower boom on boom rest, 500 lb. capacity
selected, jib swing centered.
MAIN BOOM TELESCOPE IN: from platform control, boom

horizontal, tower boom on boom rest, 500 lb. capacity
selected, jib swing centered.
DRIVE FORWARD (Max): high speed - low torque setting,

drive 200 ft. front wheels to front wheels. Timed after machine
has obtained maximum speed.
DRIVE REVERSE (Max): high speed - low torque setting, drive
200 ft. front wheels to front wheels. Timed after machine has
obtained maximum speed.
DRIVE FORWARD (Creep Max): high torque - low speed set-
ting, platform speed knob at full creep
DRIVE REVERSE (Creep Max): high torque - low speed set-
ting, platform speed knob at full creep
DRIVE FORWARD (Elevated Max - Boom Beyond Trans-

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

high speed - low torque setting, platform speed knob out of
creep, Lift boom above transport, drive backward 50 ft.
3121171 6-17
6.4 CANBUS COMMUNICATIONS Interlocks: Any device that sends an electrical input. (For an
example a limit switch, proximity switch, etc;)
CANbus: CAN (Control Area Network) is a two wire differential
Platform Level: The GROUND MODULE stores the default val-
serial link between the Platform Module, Ground Module,
ues and handles interlocks. The PLATFORM MODULE reads the
Boom Length Angle Module and the Chassis Module provid-
sensors mounted on the platform assembly and controls the
ing bi-directional communications.
Level Up / Down valves to maintain setpoint sent from the
Two-wire: One wire (red) is driven high (5v) and the other low GROUND MODULE.
(black) (0v) to send a signal; both wires ”float” (2.5v) when no
Steer: The GROUND MODULE stores crack points, sends
signal is being sent.
desired drive direction, sends steering mode and sends axle
extend / retract commands. The PLATFORM MODULE reports
Differential: Any electrical line noise can affect the high or the
the steering switch position to the GROUND MODULE. The
low wires but never both, so communications is not corrupted.
CHASSIS MODULE modulates each steer left / right valve to
maintain commanded wheel position.
Serial Link: Messages are being sent bit by bit along the wires;
the high bus speed allow all modules to be constantly Drive: The GROUND MODULE stores crack points, sends com-
updated around 20 times per second. Typical traffic is 300 - mands for each drive pump to the BLAM. (Command is com-
500 messages per second. puted from drive joystick input, interlocks, wheel angle, etc).
BLAM maintains proper current for the drive pumps by modu-
A complete CANbus circuit is approximately 60 ohms, which lating PWM outputs.
can be verified at the ”T” fitting inside the ground station or
below the BLAM. Each individual circuit from the modules is Lift, Tele, & Swing: The GROUND MODULE stores default val-
approximately 120 ohms. ues, handles interlocks and calibration information. Lift, Tele-
scope and Swing commands are dependent upon interlocks
The GROUND MODULE is the master system controller. Most through out the machine. Boom angle, length and swing are
functions are dispatched and coordinated from this module, controlled by the GROUND MODULE. The BLAM monitors and
all other system modules (PLATFORM, BLAM L CHASSIS) han- communicates (CANbus) to the GROUND MODULE boom
dle sub-tasks. All characterized information (values) are stored angle and boom length via two angle sensors, a length sensor
into the ground module (i.e., Personalities or Calibrations). and a load moment pin.
6-18 3121171
6.5 CALIBRATION INSTRUCTIONS Table 6-4. Reasons for Re-Calibration

This machine incorporates a variety of sensors and a high Calibration Procedure Reasons for Re-calibration
degree of function interaction. For safety and proper machine
Steering Calibration Ground module replacement
functionality, the calibration procedures must be repeated for
Chassis module replacement
any control module replacement, system calibration related
Steer sensor removal or replacement
fault, or removal or replacement of any sensors, valves, coils,
Persistent wheel misalignment
motors, or pumps. The chart below lists the calibrations
required and potential reasons for re-calibration. Drive Calibration Ground module replacement
BLAM module replacement
All calibration procedures are menu driven through the use of
Drive pump/coil replacement
the standard JLG analyzer. With the exception of steering cali-
Drive pulls to one side
bration, no external tools are required to complete the calibra-
Drive lugs engine
tion procedures. The user is prompted to exercise the machine
Poor slow speed control
in a specific order to use the machines physical properties to
consistently establish sensor response and the interaction of Boom Valve Calibration Main lift valve/control module replacement
valves, pumps, and motors. Steering calibration also uses the Tower lift valve/control module replacement
analyzer and is performed on one side of the machine at a Tower telescope valve/control module replacement
time requiring the use of a string or other means to determine Platform Level Crack Point Cali- Platform module replacement
when the tires are in line with each other. With the exception bration Ground module replacement
of the load control calibration, all calibrations are accessed by Platform level valve/coil replacement
connecting the analyzer into the control system inside the Erratic platform leveling
main terminal box or on the bottom of the platform control Chassis Tilt Calibration Ground module removal or replacement
box. Calibration of the platform load sensing system is Main terminal box removal or replacement
accessed by connecting the analyzer directly into the EIM Tilt indication inaccuracy
module.
Boom Sensors Calibration Ground module removal or replacement
BLAM module removal or replacement
Tower boom angle sensor removal or replacement
Tower boom length sensor removal or replacement
Tower lift cylinder angle sensor removal or replace-
ment
Load pin removal or replacement
Main boom angle sensor removal or replacement
Any boom sensor calibration faults
Boom control system inaccuracies
Platform Load Sensing System EIM module replacement
Calibration Load cell removal or replacement
Load control inaccuracy
3121171 6-19
6-20
ACCESS LEVEL:
CODE 33271
MENU : ACCESS LEVEL :

ACCESS LEVEL 1 CODE 00000
MENU : PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PERSONALITIES DRIVE STEER MAIN LIFT SWING TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE PLATFORM LEVEL PLATFORM ROTATE JIB LIFT
DRIVE: STEER: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE: PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT:
ACCEL X.XS MAX SPEED X% ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS
DRIVE: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE: PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT:
DECEL X.XS DECEL X.XS DECEL X.XS DECEL MEDIUM DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS
MIN UP X% MIN LEFT X% MIN LEFT X% MIN UP X%
MIN FORWARD X% MIN UP X% MIN IN X% MIN IN X% MIN UP X%

MAX FORWARD X% MAX UP X% MAN LEFT X% MAX UP X% MAX IN X% MAX IN X% MAX UP X% MAX LEFT X% MAX UP X%
MIN REVERSE X% CREEP UP X% CREEP LEFT X% MIN UP X% MIN OUT X% MIN OUT X% MIN DOWN X% MIN RIGHT X% MIN UP X%
MAX REVERSE X% MIN DOWN X% MIN RIGHT X% MAX DOWN X% MAX OUT X% MAX OUT X% MAX DOWN X% MAX RIGHT X% MAX UP X%
DRIVE: MAIN LIFT: SWING:

ELEV. MAX X% MAX DOWN X% MAX RIGHT X%
DRIVE: MAIN LIFT: SWING:
CREEP MAX X% CREEP DOWN X% CREEP RIGHT X%
TO
MENU:
MACHINE SETUP PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
JIB SWING GROUND MODE GEN SET/WELDER TEMPERATURE CUT
JIB LIFT: GROUND MODE: GEN SET WELDER: LOW TEMPERATURE:
ACCEL X.XS MAIN UP: XXX% ENGINE 1800 RPM CUTOUT SET: XXXC
JIB LIFT: GROUND MODE:
DECEL X.XS MAIN DOWN: XXX%
MIN LEFT X% SWING: XXX%
MAX LEFT X% PLT LEVEL: XXX%
MIN RIGHT X% PLT ROTATE: XXX%
MAX RIGHT X% MAIN TELE: XXX%
GROUND MODE:
TOWER TELE: XXX%
GROUND MODE:
TOWER UP: XXX%
GROUND MODE:
TOWER DOWN: XXX%
GROUND MODE:
JIB (U/D): XXX%
GROUND MODE:
JIB (L/R): XXX%
MAE38550L
1001119510-L
Figure 6-3. Analyzer Software P7.24 - Sheet 1 of 6
3121171
FROM
MENU:
PERSONALITIES
3121171
MENU: MODEL NUMBER: ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN: FUEL CUTOUT: CHASSIS TILT:
MACHINE SETUP 1250A 1250A: 125" MAX ANSI USA DEUTZ F4 TIER1 NO GLOW PLUGS DISABLED ENABLED RESTART 5 DEG + DRV CUT
MODEL NUMBER: ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN: FUEL CUTOUT: CHASSIS TILT:
NO MODEL 1250A: 100" MAX ANSI EXPORT DEUTZ F4 TIER2 AIR INTAKE ENABLED DISABLED ONE RESTART 4 DEG + DRV CUT
ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG: FUEL CUTOUT: CHASSIS TILT:
1250A: 80" MAX CSA CAT ECM T4I IN-CYLINDER* ENGINE STOP 3 DEG + DRV CUT
MARKET: ENGINE: CHASSIS TILT:

CE DEUTZ ECM* 5 DEG + CUT
MARKET: ENGINE: CHASSIS TILT:

AUSTRALIA DEUTZ ECM T4F 4 DEG + CUT
MARKET: CHASSIS TILT:

JAPAN 3 DEG + CUT
STOUCH/SKYGUARD: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: LOAD SYSTEM: LOAD TYPE: FUNCTION CUTOUT: GROUND ALARM: OSCILLATING
NONE NO MOTION ENABLED NO NO CAN LSS NO NO AXLE: YES
STOUCH/SKYGUARD: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: LOAD SYSTEM: LOAD TYPE: FUNCTION CUTOUT: GROUND ALARM: OSCILLATING
SOFT TOUCH BELT DRIVE MOTION CUTOUT YES WARN ONLY NON CAN LSS BOOM CUTOUT DRIVE AXLE: NO
STOUCH/SKYGUARD: GEN SET/WELDER: LOAD SYSTEM: FUNCTION CUTOUT: GROUND ALARM:

SKYGUARD HYDRAULIC DRIVE CUTOUT PLATFORM DRIVE CUTOUT DESCENT
STOUCH/SKYGUARD: LOAD SYSTEM: FUNCTION CUTOUT: GROUND ALARM:

BOTH (CUTOUT) CUTOUT ALL DRIVE CUT E & T MOTION
LOAD SYSTEM:
SPECIAL 1
DISPLAY UNITS: LEVELING MODE: CLEARSKY: FUEL TANK SIZE: ALERT BEACON: TEMP CUTOUT: PLAT LVL OVR CUT CRIBBING OPTION: WATER IN FUEL
IMPERIAL LEVEL ALL NO 31 GALLON OFF FOR CREEP NO NO NO SENSOR: NO
DISPLAY UNITS: LEVELING MODE: CLEARSKY: FUEL TANK SIZE: ALERT BEACON: TEMP CUTOUT: PLAT LVL OVR CUT CRIBBING OPTION: WATER IN FUEL
METRIC LEVEL LEFT YES 52 GALLON 20FPM FOR CREEP YES YES YES SENSOR: YES
TO
MENU:
CALIBRATION
MAE38560L
1001119510-L
6-21
6-22
FROM
MENU:
MACHINE SETUP
MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:
CALIBRATIONS STEER DRIVE BOOM VALVES LEVEL UP CRKPT LEVEL DOWN CRKPT MAIN LIFT CRKPT MAIN TELE CRKPT TILT SENSOR BOOM SENSORS UNLOCK BOOM
CALIBRATE CALIBRATE CALIBRATE CALIBRATE LEVEL CALIBRATE LEVEL CALIBRATE MAIN CALIBRATE MAIN POSITION 1: POSITION 1: UNLOCK BOOM:
STEER? DRIVE? BOOM VALVES? UP CRACKPOINT? DOWN CRACKPOINT? LIFT CRACKPOINT? TELE CRACKPOINT? CHECK SYSTEM? CHECK SYSTEM? CHECK SYSTEM?
CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

DEUTZ SETUP: PLT LVL CUTOUT MSSO NONE AVAILABLE
DEUTZ SETUP: TILT SENSOR: MSSO RESET
SETUP 1 CALIBRATE? CONFIRM?
DEUTZ SETUP:
SETUP 2
DEUTZ SETUP:
SETUP 3
DEUTZ SETUP:
SETUP 4
MENU: SERVICE MODE: SERVICE MODE: SERVICE MODE: SERVICE MODE: SERVICE MODE: SERVICE MODE:
SERVICE MODE TWR TELE ONLY? TWR LIFT ONLY? MAIN LIFT? MAIN TELE? SET PRESSURES? PRODUCTION TEST?
MENU: HELP:
HELP: PRESS ENTER GROUND MODE OK
TO
MENU:
DIAGNOSTICS
MAE38570L
1001119510-L
3121171
FROM
MENU:
HELP: PRESS ENTER
3121171
MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
TO
ENGINE
DIAGNOSTICS:
DIAGNOSTICS DRIVE BOOM FUNCTIONS SYSTEM TRANSPORT BCS ENVELOPE BOOM SWITCHES
JOYSTICK DRIVE: JOYSTICK LIFT: START SEQUENCE: GROUND MODULE DIAGNOSTICS MODE: BCS STATUS: MAIN BOOM
FORWARD XXX% MAIN UP XXX% NOT ACTIVE BATTERY: XX.XV OUT OF TRANSPORT NORMAL LENGTH: XXX.X
JOYSTICK STEER: JOYSTICK SWING: BATTERY VOLTAGE: PLATFORM MODULE ST/SG INPUTS: TOWER LIFT ELEC. RETRIEVAL: MAIN BOOM
LEFT XXX% LEFT XXX% XX.XV BATTERY: XX.XV OPEN STATUS: STOWED NOT ACTIVE ANGLE1: XX.X DEG
DRIVE OUTPUT: LIFT OUTPUT: COOLANT UGM ST/SG INPUT 1 TOWER TELESCOPE HYD. RETRIEVAL: MAIN BOOM
FORWARD XXX% MAIN UP XXX% TEMPERATURE: XXXC TEMPERATURE: XXXC OPEN STATUS: RETRACTED NOT ACTIVE ANGLE2: XX.X DEG
STEER OUTPUT: SWING OUTPUT: ENGINE OIL PLATFORM SELECT ST/SG INPUT 2 MAIN LIFT MAIN ENVELOPE MAIN BOOM A/D
LEFT XXX% LEFT XXX% PRESSURE: XXXXPSI KEYSWITCH: CLOSED OPEN STATUS: ELEVATED STATUS: NOMINAL LENGTH: XXXXX
STEER TYPE: PLATFORM LEVEL: AMBIENT GROUND SELECT ST OVERRIDE SW: MAIN TELESCOPE MAIN ENVELOPE MAIN BOOM A/D
NORMAL UP XXX% TEMPERATURE: XXXC KEYSWITCH: OPEN OPEN STATUS: RETRACTED LOW: NOMINAL ANGLE1: XXX.X
SG OVERRIDE SW:
BRAKES STATUS: PLATFORM ROTATE: FUEL LEVEL STATION CONTROL: MAIN IN LIMIT TOWER ENVELOPE MAIN BOOM A/D
OPEN
LOCKED LEFT XXX% SENSOR: OK GROUND SWITCH 1: OPEN STATUS: NOMINAL ANGLE2: XXX.X
SG/ST OVERRIDE SW:
CREEP SWITCH: MAIN TELESCOPE: STARTER FOOTSWITCH INPUT MAIN IN LIMIT MAIN BOOM ANGLE BOOM CONTROL:
OPEN
CLOSED IN XXX% CRANK TIME: XX S GROUND: OPEN SWITCH 2: OPEN ZONE: 4 AUTOMATIC
GENSET/WELDER
CREEP MODE: TOWER TELESCOPE: ENGINE SPEED FOOTSWITCH INPUT PLATFORM MAIN BOOM LENGTH BOOM CONTROL:
SWITCH: OPEN
OFF IN XXX% ACTUAL: XXXX RPM PLATFORM: CLOSED STOWED: NO ZONE: A MODE SW: OPEN
LIGHTS
2-SPEED SWITCH: TOWER LIFT: ENGINE SPEED TRANSPORT MODE: AXLE STATUS:
SWITCH: OPEN
CLOSED UP XXX% TARGET: XXXX RPM OUT OF TRANSPORT EXTENDED
PLATFORM TILT1
2-SPEED VALVE JIB LIFT: CABLE BREAK FRONT AXLE
ANGLE: XX.X DEG
OUTPUT: OFF UP XXX% SWITCH: CLOSED SWITCH: CLOSED
PLATFORM TILT2
HIGH ENGINE JIB SWING: CREEP REAR AXLE
ANGLE: XX.X DEG
SWITCH: OPEN LEFT XXX% SWITCH: CLOSED SWITCH: CLOSED
PLATFORM TILT1
DRIVE MODE: PLATFORM CONTROL CREEP MODE: JIB STOWED LIMIT
RAW: XXXX
MID ENGINE VALVE: OFF OFF SWITCH: CLOSED
PLATFORM TILT2
L FRONT WHEEL FUNCTION SPEED: CREEP TILT: JIB STOWED LIMIT
RAW: XXXX
ANGLE: XX.X PUMP POT XXX% XX.X DEGREES OVERRIDE: OPEN
OSCILLATING AXLE
R FRONT WHEEL CREEP SWITCH: CHASIS TILT: AXLE INPUT SW.:
PRES. SW.: OPEN
ANGLE: XX.X CLOSED X-AXIS: X.X EXTENDED CLOSED
HYDRAULIC OIL
L REAR WHEEL CREEP MODE: CHASIS TILT:
TEMP. SW.: OPEN
ANGLE: XX.X OFF Y-AXIS: X.X
HYDRAULIC OIL:
R REAR WHEEL AUXILLARY POWER WARM UP NOT DONE
ANGLE: XX.X SWITCH: OPEN
MAIN LIFT PILOT
DRV. ORIENTATION HORN PRES. SW.: OPEN
SWITCH: CLOSED SWITCH: OPEN
DRV. ORIENTATION SOFT TOUCH LIMIT MODEL ID

OVERRIDE: OPEN SWITCH: OPEN INPUT: OPEN
AMBIENT TEMP
DRV. ORIENTATION SKYGUARD INPUTS:
XXXC
STATUS: REQUIRED OPEN
SKYGUARD INPUT 1 LOW TEMPERATURE

CRIBBING OPTION: CUTOUT: INACTIVE
OPEN
ENABLED
SKYGUARD INPUT 2
CRIBBING OPTION: OPEN
DISABLED
MENU: SYSTEM TEST:

SYSTEM TEST ACTIVATE?
MAE38580L
1001119510-L
6-23
6-24
4- CELL 1- CELL
TO
FROM DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS: LOAD PIN MOMENT LOAD LOAD
ENVELOPE BOOM SWITCHES BOOM SENSORS CAN STATSTICS
LOAD PIN MOMENT ACTUAL MOMENT PLATFORM PLATFORM
MAIN BOOM LENGTH TOWER LENGTH 1 VALUE: XXXX XXXXXXXX LB*IN CAPACITY: 1000 LB CAPACITY: 1000 LB
SWITCH NC: OPEN SENSOR: X.X
LOAD PIN RATIO OVER MOMENT DUAL CAPACITY DUAL CAPACITY
MAIN BOOM LENGTH TOWER LENGTH 2 TOWER EXTENDED VALUE: XX.XXX XXXXXXXX LB*IN SWITCH NC: OPEN SWITCH NC: OPEN
SWITCH NO: CLOSED SENSOR: X.X LENGTH 2: XXXXXX
LOAD PIN ANGLE UNDER MOMENT DUAL CAPACITY DUAL CAPACITY
TOWER ANGLE 1 TOWER TRIP POINT VALUE: XXX.X XXXXXXXX LB*IN SWITCH NO: CLOSED SWITCH NO: CLOSED
MAIN BOOM LENGTH
ZONE: A/D SENSOR: XX.X LENGTH: XXXX.X
LOAD PIN VECTOR UNDER MOMENT DUAL CAPACITY DUAL CAPACITY
FORCE: XXXXXX CAL POINT: X LENGTH ZONE: A/B LENGTH ZONE: A/B
DUAL CAPACITY TOWER ANGLE 2 TOWER ANGLE 1
SWITCH NC: OPEN SENSOR: XX.X LOW CAL: XXX.X LOAD PIN MOMENT YELLOW WITNESS JIB IN-LINE
JIB IN-LINE
RAW: XXXXX CAL: XXXXXXXX SWITH: OPEN SWITCH: OPEN
TOWER CYLINDER TOWER ANGLE 2
DUAL CAPACITY
ANGLE: XX.X LOW CAL: XXX.X LOAD PIN RATIO GREEN WITNESS PLATFORM LOAD PLATFORM LOAD
SWITCH NO: CLOSED
RAW: XX.XXX CAL: XXXXXXXX STATE: OK STATE: OK
TOWER ANGLE 1
DUAL CAPACITY MAIN ANGLE 1 TO
HIGH CAL: XXX.X LOAD PIN ANGLE LOAD PIN RATIO PLATFORM LOAD
LENGTH ZONE: A/B TOWER: XX.X
RAW: XXX.X VALUE: XX.XXX ACTUAL: XXXLBS
TOWER ANGLE 2
TOWER TELESCOPE MAIN ANGLE 2 TO LOAD PIN V-FORCE LOAD PIN ERROR PLATFORM LOAD
HIGH CAL: XXX.X
SWITCH NC: OPEN TOWER: XX.X RAW: XXXXXXXX FLAGS: 0X000 GROSS: XXXLBS
TOWER CYLINDER LOAD PIN ANGLE
TOWER TELESCOPE MAIN ANGLE L TO SKY WELDER PLATFORM LOAD
LOW CAL: XXXXXX CAL POINT: XXX.X
SWITCH NO: CLOSED GRAVITY: XXX.X INSTALLED: NO OFFSET 1: XXXLBS
TOWER CYLINDER LOAD PIN V-FORCE SKY CUTTER PLATFORM LOAD

TOWER TELESCOPE MAIN ANGLE H TO
HIGH CAL: XXXXXX CAL: XXXXX INSTALLED: NO OFFSET 2: XXXLBS
STATUS: RETRACTED GRAVITY: XXX.X
MAIN ANGLE 1 LOAD PIN MOMENT SKY GLAZIER PLATFORM LOAD
TOWER LIFT ANGLE TOWER LENGTH 1 CAL POINT: XXXXX INSTALLED: NO ACCY: XXXLBS
LOW CAL: XXXXXX
SWITCH: OPEN A/D: XXXXX
LOAD PIN ERROR SKY BRIGHT PLATFORM LOAD
MAIN ANGLE 2
MAIN LIFT ANGLE TOWER LENGTH 2 FLAGS: 0X0000 INSTALLED: NO RAW 1: XXXLBS
LOW CAL: XXXXXX
SWITCH NC: OPEN A/D: XXXXX
LOAD PIN X-AXIS PIPE RACKS PLATFORM LOAD
MAIN ANGLE 1 VALUE: XXX INSTALLED: NO RAW 2: XXXLBS
MAIN LIFT ANGLE TOWER ANGLE 1
HIGH CAL: XXXXXX
SWITCH NO: CLOSED A/D: XX.X
LOAD PIN Y-AXIS CAMERA MOUNT
MAIN ANGLE 2 VALUE: XXX INSTALLED: NO
MAIN LIFT ANGLE TOWER ANGLE 2 HIGH CAL: XXXXXX
STATUS: TRANSPORT A/D: XX.X LOAD PIN X-AXIS
MAIN TRIP POINT RAW VALUE: XXX
TOWER CYLINDER ANGLE: XXX.X
ANGLE A/D: XXXXX LOAD PIN Y-AXIS
RAW VALUE: XXX
MAIN LIFT 1
ANGLE A/D: XXXXX
MAIN LIFT 2
ANGLE A/D: XXXXX
MAIN LIFT 1 RAW

ANGLE: XXX.X
MAIN LIFT 2 RAW

ANGLE: XXX.X
TOWER RETRACTED
LENGTH 1: XXXXXX
MAE38590L
1001119510-L
TOWER RETRACTED
LENGTH 2: XXXXXX
TOWER EXTENDED
LENGTH 1: XXXXXX
3121171
3121171
FROM DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS: DIAGNOSTICS:
LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
CAN STATISTICS PLATFORM UP DATLOG: GROUND MODULE
RX/SEC: X CAL: X ON XXH XXM SOFTWARE: PX.X
CAN STATISTICS PLATFORM DOWN DATLOG: GROUND MODULE
TX/SEC: X CAL: X ENGINE XH XM CNST DATA : PX.X
CAN STATISTICS LEFT FORWARD DATLOG: GROUND MODULE
BUS OFF X DRIVE CAL: XXXX DRIVE XH XM HARDWARE: REV X
CAN STATISTICS RIGHT FORWARD DATLOG: GROUND MODULE
PASSIVE XXXXX DRIVE CAL: XXXX LIFT XH XM S/N: XXXXXX
CAN STATISTICS LEFT REVERSE DATLOG: PLATFORM MODULE
MSG ERROR: XXXX DRIVE CAL: XXXX SWING XH XM SOFTWARE: PX.X
RIGHT REVERSE DATLOG: PLATFORM MODULE
DRIVE CAL: XXXX TELE XH XM HARDWARE: REV X
L FRONT STEER DATLOG: PLATFORM MODULE
CAL: XXXXX MAX TEMP XXC S/N: XXXXXX
R FRONT STEER DATLOG: CHASSIS MODULE
CAL: XXXXX MIN TEMP XXC SOFTWARE: PX.X
L REAR STEER DATLOG: B.L.A. MODULE

CAL: XXXXX MAX VOLTS XX.XV SOFTWARE: PX.X
R REAR STEER DATLOG: CYLINDER PIN
CAL: XXXXX RENTAL XH XM SOFTWARE: RX.XX
MAIN LIFT UP DATLOG: CYLINDER PIN
CAL: XXXXX ERASE RENTAL? S/N: XXXXXX
MAIN LIFT DOWN MAIN ANGLE 1
CAL: XXXXX S/N: XXXXXX
MAIN TELESCOPE MAIN ANGLE 1
IN CAL: XXXXX REV X.X
MAIN TELESCOPE MAIN ANGLE 2
OUT CAL: XXXXX S/N: XXXXXX
MAIN ANGLE 1 MAIN ANGLE 2
LO CAL: X REV X.X
MAIN ANGLE 1 CRIB MODULE
HI CAL: X SOFTWARE: PX.X
MAIN ANGLE 2 CRIB MODULE
LO CAL: X HARDWARE: REV X
MAIN ANGLE 2 VERSIONS:
HI CAL: X ANALYZER V6.3
LENGTH RETRACTED
CAL: XXXXX
LENGTH EXTENDED
CAL: XXXXX
YELLOW WITNESS
MARK CAL: X
LENGTH SWITCH
CAL: XXXXX
MAE38670L
1001119510-L
6-25
Figure 6-9. Control Module Location
6-26 3121171
3121171 6-27
J4
J1 GREY PIN 1
GREY 8 PIN J2
12 PIN
BLACK
12 PIN
PIN 1
J3
GREEN PIN 1
12 PIN
J5
PIN 1 BROWN
12 PIN
Figure 6-10. Chassis and Boom, Length, Angle Modules (BLAM)
6-28 3121171
Chassis Pin Module Function

CONNECTOR PIN FUNCTION TYPE
1 IGNITION POWER OUTPUT
CONNECTOR PIN FUNCTION TYPE 2 GROUND POWER OUTPUT
1 POWER FEED THROUGH TO J2-1 POWER I/O 3 CANBUS HIGH SERIAL I/O
2 POWER FEED THROUGH TO J2-2 POWER I/O J4 4 CANBUS LOW SERIAL I/O
3 SIGNAL FEED THROUGH TO J2-4 DIGITAL INPUT (GREY) 5 CANBUS SHIELD ANALOG INPUT
4 MASTER GROUND CONNECT POWER INPUT 6 BOOTSTRAP MODE DIGITAL INPUT
5 MASTER IGNIITION CONNECT POWER INPUT 7 IGNITION POWER OUTPUT
J1 6 CANBUS HIGH SERIAL I/O 8 GROUND POWER OUTPUT
(GREY) 7 CANBUS LOW SERIAL I/O
8 CANBUS SHIELD SERIAL I/O
9 CANBUS TERMINATOR SERIAL I/O CONNECTOR PIN FUNCTION TYPE
10 CANBUS TERMINATOR SERIAL I/O 1 RIGHT FRONT STEER RIGHT DIGITAL OUTPUT
11 IGNIITION POWER OUTPUT 2 RIGHT FRONT STEER LEFT DIGITAL OUTPUT
12 GROUND POWER OUTPUT 3 LEFT FRONT STEER RIGHT DIGITAL OUTPUT
4 LEFT FRONT STEER LEFT DIGITAL OUTPUT
5 RIGHT REAR STEER RIGHT DIGITAL OUTPUT
CONNECTOR PIN FUNCTION TYPE J5 6 RIGHT REAR STEER LEFT DIGITAL OUTPUT
1 POWER FEED THROUGH TO J1-1 POWER I/O
(BROWN) 7 LEFT REAR STEER RIGHT DIGITAL OUTPUT
2 POWER FEED THROUGH TO J1-2 POWER I/O
8 LEFT REAR STEER LEFT DIGITAL OUTPUT
3 GROUND POWER OUTPUT
4 FRONT AXLES LIMIT SWITCH DIGITAL INPUT
10 RS232 RECEIVE SERIAL INPUT
5 REAR AXLES LIMIT SWITCH DIGITAL INPUT
11 RS232 TRANSMIT SERIAL OUTPUT
6 DRIVE ORIENTATION SWITCH DIGITAL INPUT
J2 12 GROUND POWER OUTPUT
OSCILLATING AXLE PRESSURE
(BLACK) 7 DIGITAL INPUT
SWITCH
8 SPARE INPUT DIGITAL INPUT
9 SPARE INPUT DIGITAL INPUT
10 SPARE ANALOG INPUT ANALOG INPUT
11 FRONT/REAR AXLE EXTEND DIGITAL OUTPUT
12 FRONT/REAR AXLE RETRACT DIGITAL OUTPUT

1 +5V ANALOG REFERENCE POWER OUTPUT
2 FRONT RIGHT STEER ANGLE ANALOG INPUT
5 FRONT LEFT STEER ANGLE ANALOG INPUT
(GREEN) 7 +5V ANALOG REFERENCE POWER OUTPUT
8 REAR RIGHT STEER ANGLE ANALOG INPUT
11 REAR LEFT STEER ANGLE ANALOG INPUT
3121171 6-29
BLAM Pin Module Function

CONNECTOR PIN FUNCTION TYPE 2 GROUND POWER OUTPUT
1 POWER FEED THROUGH TO J2-1 POWER I/O 3 CANBUS HIGH SERIAL I/O
2 POWER FEED THROUGH TO J2-2 POWER I/O J4 4 CANBUS LOW SERIAL I/O
3 SIGNAL FEED THROUGH TO J2-4 DIGITAL INPUT (GREY) 5 CANBUS SHIELD POWER INPUT
4 MASTER GROUND CONNECT POWER INPUT 6 BOOTSTRAP MODE DIGITAL INPUT
5 MASTER IGNIITION CONNECT POWER INPUT 7 IGNITION POWER OUTPUT
J1 6 CANBUS HIGH SERIAL I/O 8 GROUND POWER OUTPUT
(GREY) 7 CANBUS LOW SERIAL I/O
8 CANBUS SHIELD SERIAL I/O
9 CANBUS TERMINATOR SERIAL I/O CONNECTOR PIN FUNCTION TYPE
10 CANBUS TERMINATOR SERIAL I/O 1 LEFT DRIVE PUMP FORWARD DIGITAL OUTPUT
11 IGNIITION POWER OUTPUT 2 LEFT DRIVE PUMP FORWARD DIGITAL OUTPUT
12 GROUND POWER OUTPUT 3 OSCILLATING AXLES DIGITAL OUTPUT
4 TOWER BOOM TRANSPORT ANGLE DIGITAL OUTPUT
5 SPARE OUPUT -D006 DIGITAL OUTPUT
CONNECTOR PIN FUNCTION TYPE J5 6 SPARE OUPUT -D007 DIGITAL OUTPUT
1 POWER FEED THROUGH TO J1-1 POWER I/O (BROWN) 7 SPARE OUPUT -D008 DIGITAL OUTPUT
2 POWER FEED THROUGH TO J1-2 POWER I/O 8 SPARE OUPUT -D009 DIGITAL OUTPUT
3 GROUND POWER OUTPUT 9 IGNITION POWER OUTPUT
4 LOAD PIN PUSH TO TEST DIGITAL INPUT 10 RS232 RECEIVE SERIAL INPUT
5 PLATFORM ROTATE RIGHT DIGITAL INPUT 11 RS232 TRANSMIT SERIAL OUTPUT
J2 6 PLATFORM ROTATE LEFT DIGITAL INPUT 12 GROUND POWER OUTPUT
(BLACK) 7 SPARE INPUT DIGITAL INPUT
8 TOWER BOOM ANG 1 (GRAVITY) DIGITAL INPUT
9 TOWER BOOM ANG 2 (GRAVITY) DIGITAL INPUT
10 SPARE ANALOG ANALOG INPUT
11 RIGHT DRIVE PUMP FORWARD DIGITAL OUTPUT
12 RIGHT DRIVE PUMP REVERESE DIGITAL OUTPUT

2 REFERENCE VOLTAGE FROM J3-1 ANALOG INPUT
5 TOWER BOOM CYLINDER ANGLE ANALOG INPUT
(GREEN) 7 +5V ANALOG REFERENCE POWER OUTPUT
8 TOWER BOOM LENGTH SENSOR #1 ANALOG INPUT
11 TOWER BOOM LENGTH SENSOR #2 ANALOG INPUT
6-30 3121171
3121171 6-31
J8
J1
J7
J12
J2
J3 J4
1001119508-P
MAE37420P
Figure 6-11. Ground Control Module (With UGM)
6-32 3121171
Connector Pin Function Type Connector Pin Function Type

THROTTLE ACTUATOR 1 MAIN LIFT PILOT DIGITAL OUTPUT
1 DIGITAL OUTPUT
(DIESEL ONLY) 2 HORN DIGITAL OUTPUT
2 SPARE (LP NOT USED) DIGITAL OUTPUT 3 PLATFORM CONTROL VALVE DIGITAL OUTPUT
3 TOWER BOOM LIFT POWER DIGITAL OUTPUT 4 UPPER TELESCOPE IN DIGITAL OUTPUT
4 PRESSURE TRANSDUCER GROUND GROUND INPUT 5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT
5 GROUND GROUND INPUT 6 GROUND GROUND INPUT
6 TOWER TELESCOPE ENABLE DIGITAL OUTPUT 7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT
7 SPARE (LP NOT USED) DIGITAL OUTPUT 8 TOWER TELESCOPE POWER DIGITAL OUTPUT
8 GROUND GROUND INPUT 9 TELESCOPE FLOW CONTROL DIGITAL OUTPUT
9 GROUND GROUND INPUT 10 LIFT PILOT DIGITAL OUTPUT
10 IGNITION ON RELAY DIGITAL OUTPUT 11 UPPER LIFT UP DIGITAL OUTPUT
11 START SOLENOID (DIESEL ONLY) DIGITAL OUTPUT 12 LIFT DOWN AUXILIARY DIGITAL OUTPUT
GLOW PLUG 13 MAIN DUMP DIGITAL OUTPUT
12 DIGITAL OUTPUT
(DIESEL ONLY OPTION)
14 GROUND GROUND INPUT
13 AUXILIARY POWER DIGITAL OUTPUT
NOT CONNECTEDRS232 BACKUP
14 COOLANT TEMP (DIESEL ONLY) ANALOG INPUT 15 DIGITAL OUTPUT
COMM. ENABLE
15 OIL PRESSURE (DIESEL ONLY) ANALOG INPUT 16 UPPER TELESCOPE OUT DIGITAL OUTPUT
FLYWHEEL SPEED PICKUP 17 GROUND GROUND INPUT
16 FREQUENCY INPUT
(DIESEL ONLY) J2
18 SPARE PIN GROUND INPUT
17 GROUND GROUND INPUT (Gray)
J1 19 LIFT FLOW CONTROL DIGITAL OUTPUT
(Natural) 18 SPARE GROUND GROUND INPUT
20 SPARE OUTPUT DIGITAL OUTPUT
19 SPARE GROUND GROUND INPUT
MAIN BOOM ANGLE SENSOR #2
20 TWO SPEED DIGITAL OUTPUT 21 DIGITAL OUTPUT
POWER
MAIN LIFT PILOT PRESSURE 22 UPPER LIFT DOWN DIGITAL OUTPUT
21 DIGITAL INPUT
SWITCH
23 MAIN BOOM LIFT ENABLE DIGITAL OUTPUT
22 GENERATOR/WELDER(OPTION) DIGITAL OUTPUT
24 TOWER CYLINDER TYPE DIGITAL INPUT
23 PARKING BRAKE DIGITAL OUTPUT
25 FUEL SENSOR ANALOG INPUT
24 CONSTANT BATTERY N/C N/C
26 HEAD/TAIL LIGHT DIGITAL OUTPUT
25 RS-485 HI SERIAL I/O
27 ALARM DIGITAL OUTPUT
26 RS-485 LO SERIAL I/O
28 ANALYZER POWER VOLTAGE OUTPUT
29 ANALYZER RS-232 Rx SERIAL INPUT
31 PVG ENABLE DIGITAL OUTPUT
30 ANALYZER RS-232 Tx SERIAL OUTPUT
32 TOWER BOOM TELESCOPE PILOT DIGITAL OUTPUT
31 ANALYZER GROUND GROUND INPUT
33 TOWER BOOM LIFT ENABLE DIGITAL OUTPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT
34 SWING LEFT DIGITAL OUTPUT
33 GROUND SHIELD GROUND INPUT
35 SWING RIGHT DIGITAL OUTPUT
34 SPARE DIGITAL INPUT
HYDRAULIC OIL TEMPERATURE
35 DIGITAL INPUT
SWITCH
3121171 6-33
Connector Pin Function Type Connector Pin Function Type

1 SPARE VAVLE RETURN 1 GROUND INPUT 1 AXLES SET LAMP DIGITAL OUTPUT
2 SPARE VAVLE RETURN 2 GROUND INPUT 2 500# CAPACITY LAMP DIGITAL OUTPUT
3 GROUND GROUND INPUT 3 BOOM CONTROL SYSTEM LAMP DIGITAL OUTPUT
4 SPARE VAVLE RETURN 4 GROUND INPUT 4 START SWITCH DIGITAL INPUT
5 SPARE VAVLE RETURN 5 GROUND INPUT 5 BASKET LEVEL DOWN DIGITAL INPUT
6 SPARE VAVLE RETURN 6 GROUND INPUT 6 BASKET LEVEL DOWN DIGITAL INPUT
7 VBAT VBAT OUTPUT 7 UPPER TELESCOPE IN DIGITAL INPUT
J3 SPARE HS DIGITAL IN 8 JIB DOWN DIGITAL INPUT
(Black) 8 DIGITAL INPUT
(FREQ. CAPABLE) 9 JIB LEFT DIGITAL INPUT
9 ALTERNATOR EXCITATION INPUT DIGITAL INPUT 10 TOWER UP DIGITAL INPUT
SPARE HS SWITCH INPUT MAIN TOWER TRANSPORT
10 DIGITAL INPUT 11 DIGITAL INPUT
(MODEL INPUT FOR 1100S) ANGLE OPEN
11 SPARE LS DIGITAL INPUT DIGITAL INPUT 12 HOUR METER DIGITAL OUTPUT
12 ANALOG REF. VOLTAGE VOLTAGE OUTPUT 13 BCS CALIBRATED LAMP DIGITAL OUTPUT
13 SPARE ANALOG INPUT 8 ANALOG INPUT 14 OVERLOAD LAMP DIGITAL OUTPUT
14 SPARE VALVE RETURN 3 GROUND INPUT 15 SPARE DIGITAL OUTPUT
16 AUXILIARY POWER DIGITAL INPUT
Connector Pin Function Type 17 BASKET LEVEL UP DIGITAL INPUT
1 GROUND FROM BATTERY GROUND INPUT 18 BASKET ROTATE RIGHT DIGITAL INPUT
J4
J8 2 GROUND EMS GROUND INPUT (Blue) 19 JIB UP DIGITAL INPUT
(Black) 3 GROUND TO PLATFORM GROUND OUTPUT 20 JIB RIGHT DIGITAL INPUT
4 GROUND EMS OUT TO PLATFORM GROUND OUTPUT 21 TOWER DOWN DIGITAL INPUT
MAIN BOOM TRANSPORT ANGLE
22 DIGITAL INPUT
CLOSED
Connector Pin Function Type
23 UPPER LIFT UP DIGITAL INPUT
1 FREQUENCY INPUT 2 FREQUENCY INPUT
24 VBAT VBAT OUTPUT
2 FREQUENCY INPUT 2 RETURN FREQUENCY INPUT
25 VBAT VBAT OUTPUT
3 CAN 2 H SERIAL I/O
26 NO CHARGE LAMP DIGITAL OUTPUT
J12 4 CAN 2 L SERIAL I/O
27 1000# CAPACITY LAMP DIGITAL OUTPUT
(Black) 5 CAN 2 SHIELD GROUND INPUT
ENGINE HIGH TEMPERATURE
6 CAN 2 TERMINATOR TERM I/O 28 DIGITAL OUTPUT
LENGTH
7 CAN 2 TERMINATOR TERM I/O
ENGINE LOW OIL PRESSURE
8 SPARE LS DIGITAL INPUT DIGITAL INPUT 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
6-34 3121171
Connector Pin Function Type

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
8 SPARE ANALOG INPUT 2 ANALOG INPUT
11 BOOM RETRACTED CLOSED DIGITAL INPUT
12 BROKEN CABLE SWITCH INPUT
13 CAN HI SERIAL I/O
14 GROUND MODE OUT TO PLATFORM DIGITAL INPUT
15 FOOTSWITCH ENGAGE DIGITAL INPUT
16 PRESSURE TRANSDUCER EXCITATION VOLTAGE OUTPUT
17 CAN TERMINATION TERM I/O
18 CAN SHEILD GROUND INPUT
J7
(Black) 19 SPARE PIN GROUND INPUT
20 SPARE ANALOG INPUT 1 ANALOG INPUT
21 PUSH TO TEST DIGITAL INPUT
22 TOWER BOOM TRANSPORT ANGLE DIGITAL INPUT
23 GROUND CONTROL ENABLE DIGITAL INPUT
24 CAN LO SERIAL I/O
GROUND
28 GROUND INPUT
(RESERVED FOR CRIBBING OPTION)
29 VBAT VBAT OUTPUT
30 VBAT VBAT OUTPUT
31 VBAT VBAT OUTPUT
32 VBAT VBAT OUTPUT
VBAT
33 VBAT OUTPUT
(RESERVED FOR CRIBBING OPTION)
34 CLEARSKY POWER (VBAT) VBAT OUTPUT
35 BOOM RETRACT OPEN DIGITAL INPUT
3121171 6-35
J8
J7
J1
J2
J3
J4
1600333-N
MAE37410N
Figure 6-12. Ground Control Module (Without UGM)
6-36 3121171
CONNECTOR PIN FUNCTION TYPE CONNECTOR PIN FUNCTION TYPE

1 PLATFORM EMS DIGITAL INPUT 1 GROUND FROM BATTERY GROUND INPUT
2 PLATFORM MODE DIGITAL INPUT 2 GROUND EMS GROUND INPUT
3 GROUND MODE DIGITAL INPUT J8 (BLACK) 3 GROUND TO PLATFORM GROUND OUTPUT
SPARE (SJP) / TOWER CYLINDER GROUND EMS OUT TO
4 ANALOG INPUT 4 GROUND OUTPUT
PRESSURE (AJP) PLATFORM
6 CAN TERMINATION TERM I/O CONNECTOR PIN FUNCTION TYPE
7 SPARE ANALOG INPUT 1 SPARE VALVE RETURN GROUND INPUT
8 SPARE ANALOG INPUT 2 SPARE VALVE RETURN GROUND INPUT
9 SPARE GROUND INPUT 3 SPARE GROUND INPUT
10 SPARE GROUND INPUT 4 SPARE VALVE RETURN GROUND INPUT
BOOM TRANSPORT LENGTH SWITCH 5 SPARE VALVE RETURN GROUND INPUT
11 CLOSED (SJP) / TOWER TRANSPORT DIGITAL INPUT
6 SPARE VALVE RETURN GROUND INPUT
LENGT CLOSED (AJP)
7 VBAT VBAT OUTPUT
BROKEN CABLE SWITCH (SJP) /
12 BOOM TRANSPORT LENGTH #1 INPUT J3 (BLACK) SPARE HS DIGITAL IN (FREQ
8 DIGITAL INPUT
CLOSED (AJP) CAPABLE)
13 CAN 1 HI SERIAL I/O 9 SPARE DIGITAL INPUT
14 GROUND MODE OUT TO PLATFORM DIGITAL INPUT 10 SPARE HS SWITCH INPUT DIGITAL INPUT
15 FOOTSWITCH ENGAGE DIGITAL INPUT 11 SPARE LS DIGITAL INPUT DIGITAL INPUT
SPARE (SJP) / PRESSURE 12 SPARE ANALOG REF. VOLTAGE VOLTAGE OUTPUT
16 VOLTAGE OUTPUT
TRANSDUCER EXCITATION (AJP) 13 SPARE ANALOG ANALOG INPUT
17 CAN TERMINATION TERM I/O 14 SPARE VALVE RETURN GROUND INPUT
J7 (BLACK)
18 CAN 1 SHIELD GROUND INPUT
BROKEN CABLE SWITCH GROUND
19 GROUND INPUT
(SJP) / SPARE (AJP)
20 SPARE ANALOG INPUT
BCS TEST SWITCH (SJP) / BOOM
21 DIGITAL INPUT
TRANSPORT LENGTH #2 OPEN (AJP)
SPARE (SJP) / TOWER TRANSPORT
22 DIGITAL INPUT
ANGLE BLAM J5-4 (AJP)
23 GROUND CONTROL ENABLE DIGITAL INPUT
24 CAN 1 LO SERIAL I/O
25 SPARE GROUND INPUT
26 SPARE REFERENCE VOLTAGE VOLTAGE OUTPUT
27 SPARE REFERENCE VOLTAGE VOLTAGE OUTPUT
29 VBAT VBAT OUTPUT
30 VBAT VBAT OUTPUT
31 VBAT VBAT OUTPUT
32 VBAT VBAT OUTPUT
33 VBAT VBAT OUTPUT
34 CLEARSKY POWER VBAT OUTPUT
BOOM TRANSPORT LENGTH SWITCH
35 OPEN (SJP) / TOWER TRANSPORT DIGITAL INPUT
LENGTH SWITCH OPEN (AJP)
3121171 6-37
CONNECTOR PIN FUNCTION TYPE CONNECTOR PIN FUNCTION TYPE

1 AXLES SET LAMP DIGITAL OUTPUT 1 BOOM LIFT PILOT VALVE DIGITAL OUTPUT
2 500# CAPACITY LAMP DIGITAL OUTPUT 2 HORN DIGITAL OUTPUT
3 BOOM CONTROL SYSTEM LAMP DIGITAL OUTPUT 3 PLATFORM DUMP VALVE DIGITAL OUTPUT
4 START SWITCH DIGITAL INPUT 4 BOOM TELE IN VALVE DIGITAL OUTPUT
5 BASKET LEVEL DOWN SWITCH DIGITAL INPUT 5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT
BASKET ROTATE LEFT SWITCH 6 FUEL SENSOR GROUND GROUND INPUT
6 (SJP) / DUAL CAPCITY SWITCH DIGITAL INPUT 7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT
#2 SIGNAL (AJP)
8 TOWER TELESCOPE PVG POWER DIGITAL OUTPUT
7 BOOM TELESCOPE IN SWITCH DIGITAL INPUT
BOOM TELESCOPE FLOW CONTROL
8 JIB LIFT DOWN SWITCH DIGITAL INPUT 9 DIGITAL OUTPUT
VALVE
9 JIB SWING LEFT SWITCH DIGITAL INPUT BOOM LIFT DOWN AUX SELECT (SJP)
SPARE (SJP) / TOWER LIFT UP 10 / BOOM ANGLE SENSOR #1 POWER DIGITAL OUTPUT
10 DIGITAL INPUT
SWITCH (AJP) (AJP)
SPARE (SJP) / BOOM TRANSPORT BOOM LIFT UP (SJP) / BOOM LIFT
11 DIGITAL INPUT 11 DIGITAL OUTPUT
ANGLE OPEN (AJP) PVG POWER (AJP)
12 HOUR METER DIGITAL OUTPUT BOOM LIFT DOWN AUX (SJP) /
12 DIGITAL OUTPUT
13 BCS CALIBRATED LAMP DIGITAL OUTPUT TOWER LIFT PILOT VALVE (AJP)
14 OVERLOAD LAMP DIGITAL OUTPUT 13 MAIN DUMP DIGITAL OUTPUT
SPARE (SJP) / GLOW PLUG 14 SPARE GROUND INPUT
15 DIGITAL OUTPUT
LAMP (AJP) 15 NC RS232 BACKUP COMM. ENABLE DIGITAL OUTPUT
16 AUXILIARY POWER SWITCH DIGITAL INPUT 16 BOOM TELESCOPE OUT VALVE DIGITAL OUTPUT
17 BASKET LEVEL UP SWITCH DIGITAL INPUT 17 SPARE GROUND INPUT
J4 (BLUE) BASKET ROTATE RIGHT SWITCH 18 SPARE GROUND INPUT
J2 (GRAY)
18 (SJP) / DUAL CAPACITY SWITCH DIGITAL INPUT 19 BOOM LIFT FLOW CONTROL VALVE DIGITAL OUTPUT
#1 SIGNAL (AJP)
20 SPARE DIGITAL OUTPUT
19 JIB LIFT UP SWITCH DIGITAL INPUT
BOOM ANGLE SENSOR #2 POWER
20 JIB SWING RIGHT SWITCH DIGITAL INPUT 21 DIGITAL OUTPUT
(AJP)
21 TOWER LIFT DOWN SWITCH DIGITAL INPUT MAIN LIFT DOWN (SJP) / SPARE
22 DIGITAL OUTPUT
SPARE (SJP) / BOOM TRANSPORT (AJP)
22 DIGITAL INPUT
ANGLE CLOSED (AJP) SPARE (SJP) / BOOM LIFT ENABLE
23 DIGITAL OUTPUT
23 BOOM LIFT UP SWITCH DIGITAL INPUT VALVE (AJP)
24 SPARE VBAT OUTPUT SPARE (SJP) / TOWER CYLINDER
24 DIGITAL INPUT
25 SWITCHES POWER VBAT OUTPUT TYPE (AJP)
26 NO CHARGE LAMP DIGITAL OUTPUT 25 FUEL SENSOR ANALOG INPUT
27 1000# CAPACITY LAMP DIGITAL OUTPUT 26 HEAD/TAIL LIGHT DIGITAL OUTPUT
ENGINE HIGH TEMPERATURE 27 ALARM DIGITAL OUTPUT
28 DIGITAL OUTPUT
LAMP 28 SPARE GROUND INPUT
ENGINE LOW OIL PRESSURE 29 GROUND GROUND INPUT
29 DIGITAL OUTPUT
LAMP 30 SPARE GROUND INPUT
30 BOOM TELESCOPE OUT SWITCH DIGITAL INPUT 31 SPARE (SJP) / PVG ENABLE (AJP) DIGITAL OUTPUT
31 INDICATORS GROUND GROUND INPUT SPARE (SJP) / TOWER TELESCOPE
32 DIGITAL OUTPUT
32 SPARE GROUND INPUT PILOT (AJP)
33 BOOM LIFT DOWN SWITCH DIGITAL INPUT SPARE (SJP) / TOWER LIFT ENABLE
33 DIGITAL OUTPUT
34 SWING LEFT SWITCH DIGITAL INPUT (AJP)
35 SWING RIGHT SWITCH DIGITAL INPUT 34 SWING LEFT DIGITAL OUTPUT
35 SWING RIGHT DIGITAL OUTPUT
6-38 3121171

1 THROTTLE ACTUATOR (DIESEL ONLY) DIGITAL OUTPUT
2 SPARE (LP NOT USED) DIGITAL OUTPUT
3 TOWER LIFT POWER DIGITAL OUTPUT
TOWER CYLINDER PRESSURE
4 GROUND INPUT
TRANSDUCER GROUND
6 TOWER TELESCOPE ENABLE DIGITAL OUTPUT
7 SPARE (LP NOT USED) DIGITAL OUTPUT
10 IGNITION ON RELAY DIGITAL OUTPUT
11 START SOLENOID (DIESEL ONLY) DIGITAL OUTPUT
12 GLOW PLUG (DIESEL ONLY OPTION) DIGITAL OUTPUT
13 AUXILIARY POWER DIGITAL OUTPUT
14 COOLANT TEMP (DIESEL ONLY) ANALOG INPUT
15 OIL PRESSURE (DIESEL ONLY) ANALOG INPUT
FLYWHEEL SPEED PICKUP (DIESEL FREQUEN
16 INPUT
ONLY) CY
J1 (NATURAL)
19 IGNITION RELAY COIL GROUND GROUND INPUT
20 TWO SPEED DIGITAL OUTPUT
BOOM 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-232 RX SERIAL INPUT
30 ANALYZER RS-232 TX SERIAL OUTPUT
31 ANALYZER GROUND GROUND INPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT
33 SPARE GROUND SHIELD GROUND INPUT
34 SPARE DIGITAL INPUT
35 HYDRAULIC OIL TEMP SWITCH DIGITAL INPUT
3121171 6-39
J5 J2
J6
J8
J7
J1
1600343-Q
MAE37430Q
Figure 6-13. Platform Control Module
6-40 3121171
CONNECTOR PIN ASSIGNMENT FUNCTION CONNECTOR PIN ASSIGNMENT FUNCTION

1 TOWER LIFT UP HS DIGITAL INPUT LIFT / SWING JOYSTICK SUPPLY
1 SUPPLY VOLTAGE
2 TOWER LIFT DOWN HS DIGITAL INPUT VOLTAGE
3 TOWER TELESCOPE IN HS DIGITAL INPUT 2 LIFT CENTER TAP ANALOG INPUT
4 TOWER TELESCOPE OUT HS DIGITAL INPUT 3 LIFT SIGNAL ANALOG INPUT
5 MAIN TELESCOPE IN HS DIGITAL INPUT J5 NATURAL 4 SWING SIGNAL ANALOG INPUT
6 MAIN TELESCOPE OUT HS DIGITAL INPUT 5 SWING CENTER TAP ANALOG INPUT
7 PLATFORM ROTATE RIGHT HS DIGITAL INPUT 6 NOT CONNECTED ANALOG INPUT
8 PLATFORM ROTATE LEFT HS DIGITAL INPUT 7 LIFT / SWING JOYSTICK RETURN GROUND
9 PLATFORM LEVEL UP HS DIGITAL INPUT 8 SPARE PIN BLANK
10 PLATFORM LEVEL DOWN HS DIGITAL INPUT
11 JIB UP HS DIGITAL INPUT CONNECTOR PIN ASSIGNMENT FUNCTION
12 JIB DOWN HS DIGITAL INPUT DRIVE / STEER JOYSTICK SUPPLY
1 SUPPLY VOLTAGE
SPEED PUMP POTENTIOMETER VOLTAGE
13 GROUND
GROUND 2 DRIVE CENTER TAP ANALOG INPUT
14 ENGINE START HS DIGITAL INPUT 3 DRIVE SIGNAL ANALOG INPUT
15 AUXILIARY POWER HS DIGITAL INPUT J6 BLACK 4 STEER SIGNAL ANALOG INPUT
16 CRAB STEER SELECT HS DIGITAL INPUT 5 STEER LEFT ANALOG INPUT
17 COORDINATED STEER SELECT HS DIGITAL INPUT 6 STEER RIGHT ANALOG INPUT
18 SWITCH POWER BATTERY VOLTAGE 7 DRIVE / STEER JOYSTICK RETURN GROUND
J1 NATURAL
19 JIB 1000LB ENABLE HS DIGITAL INPUT 8 SPARE PIN BLANK
20 EIM PLATFORM OVERLOAD HS DIGITAL INPUT
21 500/1000 LB. CAPACITY SELECT HS DIGITAL INPUT CONNECTOR PIN ASSIGNMENT FUNCTION
DRIVE ORIENTATION SYSTEM FEATURE 1 MODULE GROUND GROUND
22 HS DIGITAL INPUT
ENABLE J8
2 MODULE POWER BATTERY VOLTAGE
23 SPARE PIN HS DIGITAL INPUT
24 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-FUELSELECT HS DIGITAL INPUT
SPEED PUMP POTENTIOMETER +7 REFERENCE
34
REFERENCE VOLTAGE VOLTAGE
35 SPEED PUMP POTENTIOMETER ANALOG INPUT
3121171 6-41
CONNECTOR PIN ASSIGNMENT FUNCTION CONNECTOR PIN ASSIGNMENT FUNCTION

1 SPARE PIN HS DIGITAL INPUT 1 GROUND MODE GROUND MODE
2 SPARE PIN HS DIGITAL INPUT 2 PLATFORM EMS PLATFORM EMS
3 BATTERY VOLTAGE BATTERY VOLTAGE PLATFORM EMS TO GROUND
3 PLATFORM MODE
DRIVE ORIENTATION SYSTEM MODULE
4 HS DIGITAL INPUT
OVERRIDE SWITCH FOOTSWITCH (FUNCTION
4 BATTERY VOLTAGE
5 PLATFORM STOWED HS DIGITAL INPUT ENABLE SWITCH) POWER
6 CHASSIS TILTED INDICATOR LAMP OUTPUT 5 PLATFORM ROTATE LEFT ME DIGITAL OUTPUT
7 FUNCTION ENABLE INDICATOR LAMP OUTPUT 6 PLATFORM ROTATE RIGHT ME DIGITAL OUTPUT
VEHICLE SYSTEM DISTRESS SOFT TOUCH LIMIT SWITCH
8 LAMP OUTPUT 7 BATTERY VOLTAGE
INDICATOR POWER
9 CREEP SPEED INDICATOR LAMP OUTPUT 8 FOOTSWITCH SIGNAL DIGITAL INPUT
10 BROKEN CABLE INDICATOR LAMP OUTPUT 9 GENERATOR ON SIGNAL DIGITAL INPUT
PLATFORM OVERLOADED 10 +7 REFERENCE VOLTAGE +7 REFERENCE VOLTAGE
11 LAMP OUTPUT
INDICATOR 11 SPARE PIN +5V REFERENCE VOLTAGE
12 500 LB CAPACITY INDICATOR LAMP OUTPUT 12 SPARE PIN +5V REFERENCE VOLTAGE
13 1000 LB CAPACITY INDICATOR LAMP OUTPUT 13 SPARE PIN ANALOG INPUT
DRIVE ORIENTATION SYSTEM 14 GROUND RETURN GROUND
14 LAMP OUTPUT
INDICATOR 15 PLATFORM LEVEL UP HS DIGITAL OUTPUT
15 GENERATOR ON INDICATOR LAMP OUTPUT 16 PLATFORM LEVEL DOWN HS DIGITAL OUTPUT
SOFT TOUCH TRIGGERED J7 BLACK 17 JIB BLOCK LIMIT SWITCH HS DIGITAL INPUT
16 LAMP OUTPUT
INDICATOR
J2 BLUE 18 SOFT TOUCH LIMIT SWITCH HS DIGITAL INPUT
GLOW PLUG ENGAGED
17 LAMP OUTPUT 19 PLATFORMALARM LAMP OUTPUT
INDICATOR
20 ALARM RETURN GROUND
18 LAMP RETURN GROUND
21 SPARE PIN GROUND
19 SPARE PIN LAMP OUTPUT
22 SPARE PIN GROUND
20 UPRIGHT TILTED INDICATOR LAMP OUTPUT
23 SPARE PIN ANALOG INPUT
21 LOW FUEL INDICATOR LAMP OUTPUT
24 SPARE PIN DIGITAL OUTPUT
22 1/4 FUEL LEVEL INDICATOR LAMP OUTPUT
25 JIB UP ME DIGITAL OUTPUT
26 JIB DOWN ME DIGITAL OUTPUT
27 JIB RIGHT ME DIGITAL OUTPUT
25 FUEL LEVEL INDICATORS RETURN GROUND
28 JIB LEFT ME DIGITAL OUTPUT
26 ANALYZER POWER ANALYZER POWER
29 GROUND RETURN GROUND
27 ANALYZER GROUND ANALYZER GROUND
30 CAN LOW CAN LOW
28 ANALYZER RX ANALYZER RX
31 CAN HIGH CAN HIGH
29 ANALYZER TX ANALYZER TX
32 CAN SHIELD CAN SHIELD
30 SPARE PIN LAMP OUTPUT
33 SPARE PIN GROUND
31 SPARE PIN DIGITAL OUTPUT
34 SPARE PIN GROUND
32 BATTERY VOLTAGE BATTERY VOLTAGE
35 SPARE PIN ANALOG INPUT
33 BATTERY VOLTAGE BATTERY VOLTAGE
34 SWITCH POWER BATTERY VOLTAGE
35 FULL FUEL LEVEL INDICATOR LAMP OUTPUT
6-42 3121171
PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 6-14. Analyzer Connecting Points
3121171 6-43
6.6 SYSTEM TEST 3. Before proceeding, ensure that the switches on the plat-
form console are in the following positions:
The Control System Incorporates a built-in system test to
a. Drive speed switch is in the Middle position. (Turtle
check the system components and functions. To use this func-
Icon)
tion, use the following procedures.
b. 4WS switch is in the Middle position. (2WS mode)
Test from the Platform c. Capacity select switch in the 1000 lb. (450 kg) mode.
1. Position the Platform/Ground select switch to the Plat- d. Function speed potentiometer out of creep mode
form position. switch.
e. Generator (if equipped) switched to the off position.
f. Head and Tail lights (if equipped) switched to the off
position.
2. Plug the analyzer into the connector at the base of the

platform control box.
6-44 3121171
4. Pull out the Emergency Stop switch and Start the 6. Use the arrow button to reach SYSTEM TEST. Hit Enter.
engine. The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
7. Follow the flow path in Figure 6-15., System Test Flow
Chart - Platform Tests and go through the component
tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
3121171 6-45
6-46
Figure 6-15. System Test Flow Chart - Platform Tests
3121171
Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the
engine.
Ground position.

control box.
5. Use the arrow button to reach SYSTEM TEST. Hit Enter.

The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
6. Follow the flow path in Figure 6-16., System Test Flow
Chart - Ground Station Tests and go through the compo-
nent tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
3121171 6-47
6-48
Figure 6-16. System Test Flow Chart - Ground Station Tests
3121171
Table 6-5. System Test Messages
Message Displayed on Message Displayed on

Description
Analyzer Analyzer
RUNNING Initial display when system test is run; certain “critical” checks are made. Problems that can be
reported include below messages.
ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16 V).
CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from the platform and
ground modules. The system test cannot run in ground mode unless data is being received from
the platform module.
CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check speed encoder.
BAD GROUND MODULE An internal problem was detected in the ground module.
HIGH TILT ANGLE The vehicle is very tilted (19.3°), or the tilt sensor has been damaged. Check tilt sensor.
HOT ENGINE The engine temperature exceeds 100C. This is only a warning.
BAD I/O PORTS The controller detected a problem with its internal circuits at switch on. If other problems are also
detected, the controller may need replacing.
SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings at switch on.
Check and, if necessary correct, all personality settings.
OPEN FSW In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW In platform mode, the footswitch must be closed when this message is displayed; the footswitch
MUST BE KEPT CLOSED during the valve & contactor tests.
BAD FSW The two footswitch signals are not changing together, probably because one is open-circuit. One
footswitch signal (“FSW1”) is routed to the power module, the other (“FSW2”) is routed to the
platform module. Check footswitch and wiring.
TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized;
checks are made for open- and short- circuit valve coils.
NOTE: In platform mode, the footswitch must be closed.
NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if
TOWER TELE=NO. Jib valves are not tested if JIB = NO. Extendable axle valves are not tested if EXT
AXLES=NO. Four wheel steer valves are not tested if 4WS=NO.
NOTE: Left/right jib valves are not tested unless JIB = SIDESWING.
Problems that can be reported include below messages.
CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning correctly. Check valve
wiring. Check ground alarm & hour meter wiring.
XXXXXXX S/C The named valve is drawing too much current so is presumed to be short-circuited. Check valve
wiring.
XXXXXXX O/C The named valve is drawing too little current so is presumed to be open-circuit. Check valve wir-
ing.
3121171 6-49

Description
Analyzer Analyzer
CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “nor-
mal” position; function switches should be open, cutout switches should be closed, joysticks
should be in neutral.
In platform mode any non-neutral platform switch or joystick is reported; any active cutouts are
reported.
In ground mode any non-neutral ground switches is reported; any active cutouts are reported.
NOTE: Switches, which are not in use (due to the settings of machine digits), are not checked.
NOTE: The pump pot is checked only for a wire-off condition; it can be at any demand from creep
to maximum.
Problems that can be reported include below messages.
CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring.
CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick.
TESTING LAMPS Indicates that the lamps test is beginning. Each lamp is energized in turn; a prompt asks for con-
firmation that the lamp is lit.
ENTER must be pressed or clicked to continue the test.
NOTE: Lamps, which are not in use (due to the settings of machine digits), are not checked.
NOTE: Platform Lamps are only tested in platform mode.
NOTE: The GM overload lamp and 500# capacity lamp are not tested.
NOTE: Head and tail lamps are tested in both platform and ground mode if enabled by a machine
digit.
TESTING ALARMS Indicates that the alarms test is beginning. Each alarm is energized in turn; a prompt asks for con-
firmation that the alarm is sounding.
ENTER must be pressed or clicked to continue the test.
NOTE: The platform alarm and the horn are only tested in platform mode.
NOTE: The ground alarm is not tested if GROUND ALARM = NO.
6-50 3121171

Description
Analyzer Analyzer
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends.
If ENTER is pressed or clicked, each operator input is prompted for in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope switches are not
tested if TOWER TELE=NO. Jib switches are not tested if JIB = NO. Extendable axle switches are
not tested if EXT AXLES=NO. Four wheel steer switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX The named switch should be closed.
OPEN XXXXXXX The named switch should be opened.
XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction.
XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX The pump pot should be turned to maximum.
PUMP POT TO MIN The pump pot should be turned to minimum.
MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could be a short
between two inputs.
TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and
should now be rectified. Press ESC/CANCEL to return to the RUN SYSTEM TEST Analyzer menu.
3121171 6-51
6.7 CALIBRATING STEER 1. Position the Platform/Ground select switch to the Plat-
form position.
When calibrating steering, each individual wheel must be cali-
brated in order to make the tire and wheel parallel with the
frame. Two methods to help ensure proper calibration are the
use of a carpenter’s square to square the spindle to the axle or
aligning the two wheels on one side using a stretched string.

6-52 3121171
3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Steer. The screen will read:
engine.
9. Hit Enter. The screen will read:
5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.

6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
3121171 6-53
10. Hit Enter. The screen will read: 13. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer.
15. Left Rear Steer Calibration will be followed by Right For-
ward Steer Calibration which will be followed by Right
Rear Steer Calibration.
16. After completing all the Steer Calibrations, hit ESC twice
to go back to CALIBRATIONS.
12. Activate the steer control until the tire and wheel are
straight in relationship with the chassis, then leave off
the control. The display will read FRT LEFT = and show
the numeric calibration value for that wheel.
6-54 3121171
6.8 CALIBRATING DRIVE 3. Pull out the Emergency Stop switch and Start the
engine.
1. Position the Platform/Ground select switch to the Plat-
form position.


Enter.
3121171 6-55
8. Use the arrow keys to reach DRIVE. 10. Hit Enter again. The screen will read:
9. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read:
12. Activate the Drive Joystick forward full stroke until the
machine just begins to move, then leave off the joystick
immediately. The display will read CRK PT = and show
the numeric crack point value.
6-56 3121171
13. Hit Enter. The number displayed will be the value that 14. Hit Enter. The screen will read:
the crack point is set to. The screen will show:
15. Repeat steps 10 thru 12 for left reverse drive.

16. Left Reverse Drive Calibration will be followed by Right
Forward Drive Calibration which will be followed by
Right Reverse Calibration.
17. After completing all the Drive Calibrations, hit ESC twice
3121171 6-57
6.9 CALIBRATING BOOM VALVES 4. The analyzer screen should read:

Ground position.

control box.

7. Use the arrow keys to reach CALIBRATIONS. Hit Enter.
3. Pull out the Emergency Stop switch.
6-58 3121171
8. Use the arrow keys to reach Boom Valves. The screen will 10. Hit Enter. The screen will read:
read:
11. If the main lift wiring and hosing is properly installed

9. Hit Enter. The screen will read: and not damaged, hit enter. The screen will read:
3121171 6-59
12. If the tower lift wiring and hosing is properly installed 14. The control system will next calibrate the LIFT, TWR LIFT,
and not damaged, hit enter. The screen will read: and TWR TELE valves. This can be confirmed by watch-
ing the LED’s on the respective valves as they are being
calibrated. When the valves are calibrated, the screen
will read:
13. If the tower telescope wiring and hosing is properly

installed and not damaged, hit enter. The screen will
read:
NOTE: It may take several minutes per valve section for the cali-
bration procedure.
15. After completing Boom Valve Calibration, hit ESC twice

6-60 3121171
6.10 LSS SYSTEM

The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF
form load via a sensor mounted in the platform support struc- THE FOLLOWING CONDITIONS OCCUR:
ture. If the actual platform load exceeds the selected Rated
Load, the following will occur: d. LSS Sensor removal or replacement
1. The Overload Visual Warning Indicator will e. Addition or removal of certain platform mounted
flash at the selected control position (plat- accessories. (Refer to Calibration)
form or ground). f. Platform is removed, replaced, repaired or shows
evidence of impact.
2. The Platform and Ground Alarms will sound 5 seconds

On, and 2 seconds Off.
THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION VERIFICATION
3. All normal movement will be prevented from the plat- NOT TO EXCEED 6 MONTHS FROM PREVIOUS VERIFICATION. REFER TO TEST-
form control position (optional - ground control func- ING & EVALUATION.
tions may be prevented).
4. Further movement is permitted by: All calibration procedures are menu driven through the use of
a JLG Analyzer.
a. Removing the excess platform load until actual plat-
form load is less than Rated Load.
b. Operation of the overriding emergency system
(Auxiliary Power Unit).
c. By an authorized person at the ground control posi-
tion (optional - ground control functions may be
prevented).
3121171 6-61
Diagnostic Menu Press the LEFT and RIGHT Arrow keys to view the displays and
select the various sub-menus. To access a sub-menu, press the
The Diagnostic Menu is another troubleshooting tool for the ENTER key. Once in a sub-menu, press the LEFT and RIGHT
Load Sensing System. Sensor and status information is pre- Arrow keys to view the various displays (just like a Top Level
sented in real-time for the technician. Several sub-menus exist
to organize the data.
menu). To exit a sub-menu, press the ESC key .
Table 6-6, Diagnostic Menu Descriptions details the structure
To access the Diagnostic Menu, use the LEFT and RIGHT of the Diagnostic Menu, and describes the meaning of each
piece of information presented.
Arrow keys to select DIAGNOSTICS from the Top Level
Menu. Press the ENTER key to view the menu.
Table 6-6. Diagnostic Menu Descriptions
Diagnostics Menu Parameter (Displayed on Parameter Value

Description
(Displayed on Analyzer 1st Line) Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
PLATFORM LOAD STATE: OK / OVERLOAD LSS Status.
PLATFORM LOAD ACTUAL: XXX.X KG Calibrated weight of the platform.
??? if Platform Load is Unhealthy**.
PLATFORM LOAD (service*) GROSS: XXX.X KG Gross weight of the platform.
??? if both Cells are Unhealthy**.
PLATFORM LOAD (service*) OFFSET 1: XXX.X KG Stored offset weight of Cell 1.
??? if LSS is not calibrated.
PLATFORM LOAD (service*) OFFSET 2: XXX.X KG Stored offset weight of Cell 1.
PLATFORM LOAD (service*) ACCESSORY XXX.X KG Stored accessory weight.
PLATFORM LOAD (service*) UNRESTRICT XXX.X KG UGM will set Unrestricted Rated Load as defined by Machine Con-
figuration.
PLATFORM LOAD (service*) RESTRICT XXX.X KG UGM will set Restricted Rated Load as defined by Machine Config-
uration.
PLATFORM LOAD (service*) RAW 1: XXX.X KG Gross value from Cell 1.
??? if Unhealthy**.
PLATFORM LOAD (service*) RAW 2: XXX.X KG Gross value from Cell 2.
??? if Unhealthy**.
* Indicates only visible in service view mode
** Typically indicates a DTC is active
6-62 3121171
Calibration Procedure
5. Press the ENTER key to view the menu. Upon entry
1. Remove everything from the platform, except perma- to the Calibration Menu, the JLG Control System will link
nently fixed JLG Accessories, to allow the Load Sensing to the Analyzer and the screen will read:
System to record its’ weight during calibration. This
includes all tools, debris, and customer-installed devices.
2. Plug the JLG Analyzer into the Machine at the Ground
Station and enter Service Access Password 33271.
3. The platform should be approximately level for calibra-
tion. Level the platform from ground control (if neces-
sary) to within +/- 5°.
4. To access the Calibration Menu, use the LEFT and RIGHT
Arrow keys to select CALIBRATION from the Top Level
Menu. The screen will read:
6. Press Enter . The Screen will read:
NOTE: The Calibration Menu is not available in OPERATOR

ACCESS.
NOTE: Calibration will auto fail if LSS DTC's are active (443, 444,
4479, 4480, 663, 821, 822, 823, 824, 8218, 8222 -> 8238,
991, 992, 993, 994 or 99285).
3121171 6-63
NOTE: Accessory weight will reset to 0 lbs. each time the machine
Pressing the ESC key after starting calibration and is re-calibrated and will need to be re-entered.
before calibration is complete will display the CAL FAILED
message. This will not disturb the prior calibration infor- NOTE: The Accessory weight will be temporarily stored in the Con-
mation. trol System until calibration has been completed success-
fully.
Refer to Table 6-7, Accessory Weights. Use the up and

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

will read:
Table 6-7. Accessory Weights
Accessory Weight
LOAD SENSING: SkyWelder (stick welder) 70 lb (32 kg)
accessory xxxlbs: SkyWelder Prep Prep only = 15 lb (7 kg)
Full install = 70 lb (32 kg)
SkyCutter (plasma cutter) 70 lb (32 kg)
SkCutter / SkyWelder Combo 140 lb (64 kg)
Fire Extinguisher 45 lb (20 kg)
Overhead SoftTouch 80 lb (36 kg)
Work Surface 20 lb (9 kg)
NOTE: Not all Accessories are available on every JLG model.
Some Accessory combinations are prohibited due to
excessive weight and/or load restriction. If any installed
JLG Accessories are labeled with weight decals but are
not listed in the table above, include their weight when
entering the ACC WEIGHT value.
6-64 3121171
9. The control system will calculate the load cell readings 11. Use the analyzer keys to select N for no or Y for yes. Press
and ensure it is greater than 130 lbs. (59 kg), but less
than 575 lbs.(261 kg). ENTER . The screen will read:
If the platform weight is not within the allowed range,
the calibration attempt will be unsuccessful and the
Analyzer will show the following:
10. Press ENTER . The control system will ask for

installed accessories. The screen will show the following:
3121171 6-65
12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-9. Pipe Rack Capacity Reductions
ENTER . The control system will default to an esti- PLATFORM OVRLD

Capacity PLATFORM OVRLD
mate of unrestricted capacity, which can be adjusted if RESTRICT
necessary. Refer to Table 6-8, SkyGlazier Capacity Reduc- 500 lb (227 kg) 400 lb (181 kg) n/a
tions and Table 6-9, Pipe Rack Capacity Reductions. 550 lb (250 kg) 450 lb (204 kg) n/a
The screen will read: 600 lb (272 kg) 500 lb (227 kg) n/a
750 lb (340 kg) n/a 650 lb (295 kg)
1000 lb (454 kg) n/a 900 lb (408 kg)
Note: If both SkyGlazier and Pipe Racks are configured, capacity will be the lower of the
two values.
13. Press ENTER . The following screen will be dis-

played for restricted capacity, which can be adjusted if
necessary. Refer to Table 6-8, SkyGlazier Capacity Reduc-
tions and Table 6-9, Pipe Rack Capacity Reductions.
Table 6-8. SkyGlazier Capacity Reductions
PLATFORM OVRLD
Capacity PLATFORM OVRLD
RESTRICT
500 lb (227 kg) 400 lb (181 kg) n/a
550 lb (250 kg) 400 lb (181 kg) n/a
600 lb (272 kg) 400 lb (181 kg) n/a
750 lb (340 kg) n/a 590 lb (268 kg)
1000 lb (454 kg) n/a 750 lb (340 kg)
Note: If both SkyGlazier and Pipe Racks are configured, capacity will be the lower of the
two values.
6-66 3121171
14. Press ENTER . If calibration is successful, the screen

will read:
3121171 6-67
Testing & Evaluation 6. Confirm Control System Capacity Indication (optional

for vehicles with Dual Capacity Ratings). For vehicles
Refer to Troubleshooting if the Load Sensing System fails to equipped with a Capacity Select switch on the Platform
meet these guidelines. Console Box, it is necessary to examine an additional
interface between the Load Sensing System and the
1. Connect the JLG Analyzer.
Control System. Using the keyswitch, select Platform
2. Level the Platform. The platform should be approxi- Mode and power-up. If necessary, put the boom in the
mately level for analysis, or the guidelines below will not transport position (completely stowed) and center the
be applicable. Level the platform from Ground Control Jib Plus (if equipped). Place the Capacity Select switch in
(if necessary) to within ±5 degrees. the unrestricted position and ensure that the proper
indicator illuminates on the Platform Console Box. Plug
3. Observe the Empty Platform Weight. Proceed to the
the JLG Analyzer into the Analyzer connection and pro-
DIAGNOSTICS, PLTLOAD sub-menu and observe the
ceed to the DIAGNOSTICS, SYSTEM submenu. Ensure
measured platform load. All tools, debris, and customer-
that the CAPACITY displays indicate OFF. Place the
installed devices shall be removed during evaluation.
Capacity Select switch in the unrestricted position (if so
Ideally, the PLTLOAD should be zero but can vary ±15lbs
equipped) and ensure that the proper indicator illumi-
(± 7kg). Further, the reading should be stable and
nates on the Platform Console Box (but does not flash).
should not vary by more than ±2lbs (±1kg) (unless there
For vehicles with unrestricted capacity, ensure that the
is heavy influence from wind or vibration).
unrestricted CAPACITY display indicates ON but the
4. Use the Technician’s Weight to Evaluate. The technician restricted CAPACITY indicates OFF. For vehicles with
should enter the platform and record the PLTLOAD read- restricted capacity, ensure that the unrestricted CAPAC-
ing while standing in the center of the platform. ITY display indicates OFF but the restricted CAPACITY
indicates ON.
5. Confirm Control System Warnings and Interlocks. Using
the keyswitch, select Platform Mode and power-up. 7. Confirm Load Sensing System Performance with Cali-
Start the vehicle’s engine and ensure that all controls are brated Weights. Operate the vehicle from Ground Con-
functional and the Load Sensing System’s Overload trol and place the boom in the transport position (fully
Visual and Audible Warnings are not active. Simulate an stowed) for safety. Plug the JLG Analyzer into the control
Overload by unplugging the Shear Beam Load Cell. The system connection and proceed to the DIAGNOSTICS,
Overload Visual Warning should flash, and the Audible PLTLOAD display. Place 500lbs (230kg) in the platform
Warning (at Platform and Ground) should sound for 5 and ensure that PLTLOAD is with ±5% of the actual
seconds On, and 2 seconds Off. With the engine run- weight. For Dual Capacity vehicles, do the same for the
ning, all control should be prevented. Cycle the Platform alternate capacity (unrestricted or restricted).
EMS to stop the engine and then power-up again. The
Overload Visual and Audible Warning should continue.
Confirm that controls are responsive when using the
Auxiliary Power Unit for emergency movement. Recon-
nect the Load Cell. The Overload Visual and Audible
Warnings should cease and normal control function
should return. Switch the vehicle’s keyswitch to Ground
Mode and repeat the above procedure. The Overload
Visual Warning at the Ground Controls should flash, and
the Audible Warning (at Platform and Ground) should
sound for 5 seconds On, 2 seconds Off. However, the
controls should remain functional when using the
engine and the Auxiliary Power Unit (if the Control Sys-
tem’s MACHINE SETUP, LOAD is set to “2=CUTOUT PLT”. If
set to “3=CUTOUT ALL”, then Ground Controls will be
prevented when using the engine as in the platform).
6-68 3121171
Troubleshooting
The following tables are furnished to provide possible resolu-
tions for common difficulties. Difficulties are classified as Gen-
eral, Calibration, Measurement Performance, and Host System
Functionality.
Table 6-10. LSS Troubleshooting Chart
Difficulty Possible Resolution

Empty Platform Weight (DIAGNOSTICS, PLAT- The LSS System is unable to properly measure the platform weight.
FORM LOAD) is not within ±15lbs (±7kg) of
zero. 1. The Load Cell is not properly plugged into the LSS Harness. It is possible poor electrical contact is made.
or
Platform Load readings (DIAGNOTICS, PLTLOAD) 2. Wiring leading to the Load Cell is damaged. Carefully inspect sensor wiring where it passes through cable clamps for signs of damage.
are unstable by more than ±2lbs (±1kg) (with- Inspect wiring where damage to the channel is apparent.
out the influence of vibration or wind).
or 3. The Load Cell was not assembled properly during installation. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAG-
There are large variations in Platform Load NOSTICS, CELL, LOAD displays and determine if the readings are reasonable. It is often helpful to apply slight downward pressure above the
(DIAGNOSTICS, PLTLOAD) based on the location sensor and observe that its output increases (increasing force measurement; decreasing means the sensor is mounted upside-down).
of the load. Tolerance to variations is 20lbs for
an evaluation using the technician’s weight, 4. The Load Cell is contaminated by debris or moisture. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS,
and +5% of Rated Load when using calibrated CELL, LOAD displays and determine if the readings are reasonable and stable (not changing by more than ±2lbs (±1kg) (without the influ-
weights. ence of vibration or wind). Lack of measurement stability is a key indication of contamination. Unplug the connector and inspect for dirt or
moisture. Look carefully into the female connector on the sensor’s cordset for evidence of contamination. Debris should be brushed away
with a soft bristle brush (do not introduce any cleaners as they will leave conductive residue). Moisture should be allowed to evaporate or
accelerated with a heat-gun (use low heat and be carefully to not melt connector materials). Moisture intrusion into the molded portion of
the connector (capillary action into the wire bundle) or the Shear Beam Load Cell itself will require replacement of the sensor.
5. The Load Cell has been mechanically damaged. If the Load Cell is physically deformed or has damage to the cover it should be replaced
immediately. It is also possible to have invisible mechanical damage resulting from an extreme overload (>6000lbs [>2722kg]).
The Visual and Audible Overload Warnings fail The Control System is failing to regard the overload signal from the LSS System, or the signal is shorted.
to sound when platform is loaded beyond Rated
Load, or when simulated by unplugging the 1. The Load Sensing System must be enabled within the Control System. Plug the JLG Analyzer into the Control System, enter the Access
Load Cell. Controls remain functional at Plat- Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu. The selection “2=CUTOUT PLT” should be displayed (plat-
form and Ground Control positions. form controls prevented during overload, ground controls remain operational). In country- or customer-specific circumstance, the selec-
tion “3=CUTOUT ALL” is used (platform and ground controls prevented during overload).
The Ground Audible Warning fails to sound, but The Ground Alarm is missing or improperly installed. Verify that the device is mounted. Verify wiring from the Main Terminal Box and
the Platform Audible Warning sounds properly. Ground Module.
Controls remain functional at the Ground Con- The JLG Control System is configured to prevent platform controls only in the event of overload. Alternately, the Host Control System can be
trol position during an overload, or when simu- configured to prevent ground and platform controls for country- or customer-specific circumstances.
lated by unplugging the Load Cell. The Controls Using the JLG Analyzer, enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter to
at the Platform Control position are prevented “2=CUTOUT PLT” to prevent platform controls in the event of overload. Set this parameter to “3=CUTOUT ALL” to prevent platform and
when using the engine, but not when using the ground controls in the event of overload.
Auxiliary Power Unit.
3121171 6-69
6.11 RESETTING THE MSSO SYSTEM 9. Use the arrow keys to reach the LOAD SENSING menu.
The screen should read:
1. Use the following procedure to reset the MSSO system.
desired position.
3. Plug the analyzer into the connector coming from the
ground control module or from the platform console.
NOTE: If performing the procedure from the platform console, the

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

10. Press ENTER .
11. Use the Down arrow to reach MSSO RESET.
6. Use the arrow button to reach OPERATOR ACCESS. Press
Enter .
8. Use the right Arrow key to reach MENU: CALIBRATIONS.
Press Enter .
6-70 3121171
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.
3121171 6-71
6.12 ELECTRONIC PLATFORM LEVELING VALVE DRIVER ERRORS

There are three possible level valve driver errors, short to bat-
Platform Leveling Fault Warning tery, short to ground, and open circuit.
The JLG Control System takes a snapshot of the two sensor val- 1. In the case of a short to ground or an open circuit, the
ues and records the difference once on each power up. The platform valve cannot be turned on and the following
Control system allows a ±5 degree difference from those val- will occur:
ues. For example, if Sensor 1 is at 5 degrees and Sensor 2 is at
a. All interactions with platform leveling shall cease
11 degrees, the difference is 6 degrees and the DTC is trig-
gered when the sensors are 1 degree (or less) apart or 11 b. The Electronic Leveling System Fault Lamp shall
degrees (or more) apart. flash (to indicate that the leveling function has been
lost).
If a fault occurs in the platform leveling system the following
c. The platform alarm will sound.
will occur:
d. A system fault will be logged.
1. Automatic platform leveling will stop (except when
e. All function speeds (lift, swing, telescope and drive)
there is a fault in only one sensor automatic leveling will
will be placed in creep mode (except when the plat-
remain active as the control system will use the other
form is in the transport position).
sensor to control leveling)
2. In the case of a short to battery on one of the platform
2. The level fault lamp will flash
leveling valves, the valve cannot be turned off and the
3. The audible alarm will sound following will occur:
4. All functions will default to creep speed if the platform is a. The platform dump valve will be turned off to pre-
out of the transport position. vent unintended tilting of the platform.
To reset the fault the emergency stop switch should be recy- b. All interactions with platform leveling shall cease.
cled. c. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has been
lost).
IF THE FAULT PERSISTS BRING THE PLATFORM TO THE GROUND POSITION, d. The platform alarm will sound.
SWITCH THE MACHINE OFF AND CONTACT A QUALIFIED SERVICE REPRESEN- e. A system fault will be logged.
TATIVE TO INVESTIGATE THE FAULT. f. All function speeds (lift, swing, telescope and drive)
Fault Response form is in the transport position)
ERROR RESPONSE 3. In the case of a short to battery on the platform dump
valve, the valve cannot be turned off. The controllability
If basket level varies from the current setpoint by ± 5.5° for of the platform leveling function will be impaired and
more than 1.5 seconds when the platform is not in the trans- the following will occur:
port position, the following events will occur:
a. All interactions with platform leveling shall cease.
1. The platform dump valve will be disabled (level, rotate
and jib functions disabled). b. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has been
2. The level system fault lamp will flash (to indicate that lost).
the leveling function has been lost). c. The platform alarm will sound.
3. The platform alarm will sound. d. A system fault will be logged.
4. A system fault will be logged. e. All function speeds (lift, swing, telescope and drive)
5. All function speeds (lift, swing, telescope and drive) will form is in the transport position).
be placed in creep mode (except when the platform is in
Lift, swing, drive and telescope will continue to operate
the transport position see below).
In each of the cases above it shall be necessary to re-cycle the
When the unit is in the transport position and driving and the
EMS to clear the fault. Operable functions shall be in the creep
current setpoint varies by ± 5.5° for more than 8 seconds the
mode except while below elevation.
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 set-
point is taken.
6-72 3121171
TILT SENSOR ERRORS CAN Errors

If the secondary tilt sensor is faulty, the control system will The Ground Module has two direct outputs dedicated to over-
continue to utilize information from the primary sensor. riding the Platform Module’s control of the leveling valves. The
If the primary sensor is faulty, the control system will switch to Ground Module “Platform Level Up/Down” outputs are used
the backup sensor for control. to control the platform level up and down valves.
In both cases above the following will occur: When in ground mode, if the Ground Module reads a platform
leveling switch command, the switch command is communi-
1. The Electronic Leveling System Fault Lamp will flash (to cated over CAN to the Platform Module where it is handled
indicate that there is a leveling fault). normally.
2. The platform alarm will sound. If Ground Module determines that CAN communication is
3. A system fault will be logged. inoperable, it turns on the platform control valve and the
appropriate platform leveling override outputs while the
4. All function speeds (lift, swing, telescope, jib and drive) switch is engaged.
will be placed in creep mode (except when the platform
is in the transport position). If the Platform Module is still running when CAN is down noth-
ing will operate when in platform mode. When the operator
5. Automatic leveling remains active. switches to ground mode, the platform will not control any of
Lift, swing, drive and telescope will continue to operate. its valve outputs and a CAN error message is signaled.
In each of the cases above it will be necessary to re-cycle the Additional Platform and Jib Valves
EMS to clear the fault. Operable functions shall be in the creep
mode except while below elevation. 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
When both sensors appear to be working but have measure- are proportional. Flow through the valves is individually con-
ments that disagree by ±5.5° The following will occur: trollable. The individually controlled duty cycle will be the
1. All interactions with platform leveling shall cease. same as would otherwise have been commanded to the flow
control valve.
2. The Electronic Leveling System Fault Lamp shall flash (to
indicate that the leveling function has been lost). Only one platform or jib function is allowed at one time to
limit the amount of current draw, minimizing the voltage drop
3. The platform alarm will sound. on the supply to the Platform Module.
4. A system fault will be logged. The function is enabled first shall remain active until it is
released. Any other function commanded while another func-
5. All function speeds (lift, swing, telescope and drive) will
tion is active is ignored.
be placed in creep mode (except when the platform is in
the transport position)
At this point, the operator must use the level up and down
toggle switch to manually level during descent. It shall be nec-
essary to re-cycle the EMS to clear the fault.
3121171 6-73
6.13 CALIBRATING PLATFORM LEVEL 4. The analyzer screen should read:
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS

Ground position.

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

Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
8. Recycle EMS.

engine.
6-74 3121171
STEP 2: BLEEDING THE PLATFORM VALVES 8. Using the left arrow button, go to the GROUND MODE
menu.
9. Hit ENTER.
Ground position.
10. Using the UP/DOWN arrows, adjust the following per-
sonalities to 100%.
control box.
Basket Rotate
Basket Level
Jib U/D (if configured)
Start up the machine and exercise each above platform

function (from the ground) eight (8) to ten (10) times for
5 seconds in each direction.
11. Return the personality settings back to the values as
shown in the Personality Ranges/Defaults table in Sec-
tion 6 - JLG Control System.
12. Recycle EMS.
STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND

DOWN VALVE CRACKPOINTS
3. Pull out the Emergency Stop switch and start the Ground position.
engine.

7. Go to the PERSONALITIES menu.
3121171 6-75
2. Plug the analyzer into the connector inside the Ground 11. Using UP ARROW, increase the value until you see the
control box. basket up movement.
12. Hit ENTER again. CAL. COMPLETE message should
appear
13. Engine should again return to idle.
14. Hit ESC should return to BASKET U CRKPT screen.
15. Hit RIGHT ARROW to get to the “BASKET D CRKPT”
screen. Hit ENTER.
16. CALIBRATE? prompt should appear. Hit ENTER again.
17. You will hear engine go to 1800 rpm.
Using UP ARROW, increase the value until you see the basket
down movement.
Hit ENTER again. CAL. COMPLETE message should appear
Engine should again return to idle.
3. Pull out the Emergency Stop switch and start the Hit ESC to exit.
engine.
Cycle power to the machine.

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.
10. You will hear engine go to 1800 rpm.
6-76 3121171
6.14 CALIBRATING TILT SENSOR 3. Plug the analyzer into the connector inside the Ground
control box.
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE
FOLLOWING PROCEDURE IS PERFORMED.
DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE.
1. Use the following procedure to calibrate the tilt sensor.
Before the tilt sensor can be calibrated, the following

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

Enter.
3121171 6-77
9. Use the arrow keys to reach the TILT SENSOR. The screen 6.15 BOOM SENSOR CALIBRATION
should read:
To begin calibration of the boom sensors, the following condi-
tions must be met:
• Successful completion of the steering sensor and tilt
sensor calibrations
• The axles are completely extended
• The wheels are straight
• The platform is unloaded and booms are clean
• The jib is fully raised
• The jib swing is centered
• The platform is level
• The platform is not rotated
• The turntable is centered between the rear tires
• The tower boom is fully retracted
• The tower boom is fully lowered
• The main boom is fully retracted
• The main boom is fully lowered
10. Press ENTER.
• The machine indicates that it is on a level surface
11. When prompted, swing turntable 180° to opposite end (within ±1.5
of chassis. • Ground Mode is selected
12. Press ENTER. The screen should read:
General Notes:
• During all Control System lag times the analyzer
should display “CALIBRATING…”
• After each “ENTER” input and before the Control

System records sensor values, the Control System will
wait 10 seconds for the boom activity to settle down
before readings are taken.
• During calibration, if the ESC key is pressed after

the calibration procedure is started, the calibration will
be aborted and “CAL FAILED” will be displayed on the
bottom line of the analyzer and the previous calibra-
tion values will be used for the boom sensors. The ana-
lyzer will continue to display “CAL FAILED” and follow
the electrical retrieval system sequence for positions of
backward stability concern until all transport positions
are met or the power is cycled. Refer to Section 4.9,
Electrical Retrieval System.
13. Upon completing swing calibration, swing turntable

180° back to the stowed position.
14. Hit ESC twice to go back to CALIBRATIONS.
6-78 3121171
• During calibration if the main boom becomes

extended the Control System will abort the calibration
After pressing the ENTER key , the Control System
sequence and the analyzer will display “CAL FAILED”
will verify the load pin, main boom angle, tower boom
and “MAIN EXTENDED”. Continue to display “CAL
angle, tower lift cylinder rotary angle, and tower boom
FAILED” and follow the electrical retrieval system
length sensors are reporting valid data, the axles are
sequence for positions of backward stability concern
completely extended, the wheels are straight within 10,
until all transport positions are met or the power is
the tower length sensors are reading less than 8.41
cycled. Refer to Section 4.9, Electrical Retrieval System.
inches plus 6.39 inches (21.36 cm plus 16.23 cm) of toler-
ance for the upper length and 12.47 inches plus 6.39
Step 1 - Position 1 inches (31.67 cm plus 16.23 cm) of tolerance for the
1. After the machine is in Position 1, using the analyzer, put lower length, tower boom transport length, main boom
the machine into Access Level 1 and enter the “BOOM transport length, and main boom dual capacity length,
limit switches are all in the retracted positions, the main
SENSORS” calibration.
boom transport angle switch is in the transport position,
the tower lift cylinder rotary angle sensor reads less than
21.5 +15 of tolerance, the drive orientation switch is
indicating the turntable is between the rear tires, the jib
aligned switch is on, the chassis tilt sensor reads less
than 1.5 out of level, the steering and tilt sensor calibra-
tions have been successfully completed, and the
machine is in Ground Mode.
If these conditions are not met, the analyzer will prompt
the operator with any of the following analyzer mes-
The analyzer will read: sages necessary to satisfy the initial conditions.
• “BLAM CAN LOST”
• “AXLE VALVE FAULT”
• “OSC AXL SW FAULT”
• “PARK BRAKE FAULT”
• “LOAD PIN FAULT”
• “MAIN ANGL1 FAULT”
• “MAIN ANGL2 FAULT”
• “TWR ANGL1 FAULT”
• “TWR ANGL2 FAULT”
• “CYL ANGL FAULT”
• “TWR LEN1 FAULT”,
• “TWR LEN2 FAULT”
• “EXTEND AXLES”
• “CENTER WHEELS”
• “TOWER IN”
• “MAIN DOWN”
• “TOWER DOWN”
• “RETRACT MAIN”
• “ALIGN TURNTABLE”
• “CENTER JIB SWING”
• “LEVEL MACHINE”
3121171 6-79
• “CAL STEERING” If there is a fault in the configuration process “CAL

FAILED” and “MAIN ANGL1 FAULT” or “MAIN ANGL2
• “CAL TILT SENSOR”
FAULT” will be displayed. The Control System will then
• “SELECT GRND MODE” record right main boom min angle, left main boom min
angle, retracted tower length 1 (upper), retracted tower
The analyzer will then prompt with “UNLOAD PLAT-
length 2 (lower) and low cylinder angle. The main boom
FORM?”, “LEVEL PLATFORM?”, “CENTER PLATFORM?”, “JIB
min angle will be set at –4.2 (ref tower). The low cylin-
UP TO MAX?”, “MAIN DWN TO MIN?”, “TWR DWN TO
der angle will be set to 1.0. The tower retracted length
MIN?”(control system energizes tower lift down and
will be set at 305.4” (775.7 cm). The right main boom
tower tele in with tower lift down commands), “TWR IN
angle sensor reading must be within 5 and 25 and the
TO MIN?”(control system energizes tower lift down and
left main boom angle sensor reading must be within
tower tele in with tower lift down commands) to ensure
155 and 175 or “CAL FAILED” and “MAIN ANGL1
the machine is set up in the proper position for Calibra-
FAULT” or “MAIN ANGL2 FAULT” will be displayed. The
tion Step 1.
length 1 sensor and the length 2 sensor must be within
2. Once the initial conditions are verified, the analyzer will range or “CAL FAILED” and “TWR LEN1 FAULT” or “TWR
display “SKY WELDER YES”. If a sky welder is not installed, LEN2 FAULT” will be displayed. The cylinder angle read-
press an ARROW key to switch to “SKY WELDER NO. A ing must be within range or “CAL FAILED” and “CYL
similar set of menus will prompt selection of Sky Cutter, ANGL FAULT” will be displayed.
Sky Glazier, Sky Bright, Pipe Racks and Camera Mount. If
Sky Bright is selected, the analyzer will display “CAL Step 2 - Position 2
FAILED” and “REMOVE SKYBRIGHT”. If more then one
accessories is selected except for the combination of Sky 1. After completing the previous step, the analyzer will
Welder/Sky Cutter the analyzer will display “CAL FAILED” read:
and “# OF ACCESSORIES”. If a valid accessory option has
been selected after the camera mount selection and the
operator presses the ENTER key , the analyzer will

display “CALIBRATE?” on the bottom line.
3. After pressing the ENTER key , the analyzer will

read:
The Control System will disable all functions except auto

platform level and main lift up. The Control System will
energize main lift up, tower lift down and tower tele in
with the main lift up command until the main boom
transport angle limit switch is tripped. The analyzer will
display “CAL FAILED” and “TWR NOT IN” if movement of
either tower length sensors is detected or “TWR NOT
DWN” if movement of the cylinder angle sensor is
detected. The Control System will monitor and record
the main boom angle reading at which the main boom
transport angle limit switch is tripped (see position 6 for
6-80 3121171
use of this value). The analyzer will display “CAL FAILED” Step 3 - Position 3
and “MAIN ANGL FAULT” if the uncalibrated main boom
angle sensors read more than 30 (ref tower) before the 1. After completing the previous step, the analyzer will
main boom transport angle limit switch is tripped. read:
2. After the operator presses the ENTER key , the

Control System will verify the main boom transport
angle limit switch has changed state, otherwise, the ana-
lyzer will display “CAL FAILED” on the top line and “MAIN
UP TO STOP” on the bottom line each time the ENTER
key is pressed and the switch has not changed platform level and swing.
state. The analyzer will display “CALIBRATING…”on the Swing turntable 180° - The turntable MUST be centered
bottom line and the Control System will record left over opposite end of chassis
tower angle 2, right tower angle 2 and chassis tilt sensor
values
3121171 6-81

platform level and tower lift up.
2. After the pressing the ENTER key , the analyzer will
display “CALIBRATING…”on the bottom line and Control Operate the Lift tower function.
System will record left tower angle 3, right tower angle
3, and chassis tilt sensor values. The Control System
must see a change in the drive orientation switch or
“CAL FAILED” and “DRIVE ORNT SW” will be displayed. If
the change in right sensor readings is more than 1.0
from the change in left sensor readings, “CAL FAILED”
and “TWR ANGL FAILED” will be displayed. The control
system establishes the ground slope in relation to the
boom using the 4 tower boom angle sensor readings
before and after rotation. Ground Slope Left angle sen-
sor = (left 2-left 3)/2; Ground Slope Right angle sensor =
(right 2-right 3)/2. The Control system establishes the
low tower angle calibration point per sensor by taking
the difference between the angle 3 and the ground
slope in the direction of the boom. Low Tower Angle
Calibration value = -3.8 +/- Ground Slope. The chassis tilt
calibration is calculated as in the chassis tilt calibration
procedure. The chassis tilt calibration will be established
here and in the separate chassis tilt procedure. If the 2. Once the Tower Boom lifts such that the Tower Boom
chassis tilt reads more than 1.75 the Control System will Angle reads greater then 25 degrees, Tower Lift Up will
keep the chassis tilt calibration data and the analyzer be suspended and the analyzer will display “CHECKING
will display “CAL FAILED” and “TILT CAL FAULT”. BOOM…”
3. Once “CHECKING BOOM…” is started the control system
Step 4 - Position 4 will wait 2 seconds and then capture the position of the
1. After completing the previous step, the analyzer will Main Boom to Tower, Tower Cylinder Angle and Tower
read: Length. The control system will then command the Main
Lift, Tower Lift and Tower Telescope PVG valves to 40%,
engage the Main Control and PVG enable valves and
command the Engine to 1800 RPM for 20 seconds. The
control system will monitor for the Main Lift angle
increasing by more then 0.2 deg, Tower Lift angle
increasing by more than 0.2 deg and the Tower Tele-
scope length increasing by more than 0.5" (1.3 cm). If
one of these conditions occur the test will abort and dis-
play on the top line “CHECK FAILED:” and “MN LIFT
ENABLE”, “TWR LIFT ENABLE” or “TWR TELE ENABLE” on
the bottom line depending on which section moved.
After the 20 seconds has elapsed the control system will
command the engine back to idle, shut off the com-
mands to the PVG valves, disengage the Main Control
and PVG enable valves and Turn On the Main Lift, Tower
Lift and Tower Telescope Enable valves and monitor the
Main Lift angle for decreasing movement of more than
0.2 deg, Tower Lift angle for decreasing movement of
more than 0.2 deg and Tower Telescope length decreas-
ing movement of more than 0.5" (1.27 cm) for 60 sec-
onds. If one of these conditions occur the test will abort
and display on the top line “CHECK FAILED:” and “MAIN
LIFT HOLD”, “TOWER LIFT HOLD” or “TOWER TELE HOLD”
on the bottom line depending on which section moved.
After the 60 seconds has elapsed the control system will
leave the enable valves on and turn on the Main Control
Valve and turn on the Tower Lift PVG valve at a 20%
down command and monitor the Main Lift angle for
6-82 3121171
decreasing movement of more than 0.2 deg, Tower Lift Step 5 - Position 5
angle for decreasing movement of more than 0.2 deg
and Tower Telescope length decreasing movement of 1. After completing the previous step, the analyzer will
more than 0.5" (1.27 cm) for 60 seconds. If one of these read:
conditions occur the test will abort and display on the
top line “CHECK FAILED:” and “MAIN LIFT APU”, “TOWER
LIFT APU” or “TOWER TELE APU” on the bottom line
depending on which section moved.
4. If the “CHECKING BOOM…” test passes then Tower Lift
Up will be enabled and the analyzer will read:

platform level and tower tele out. The Control System
will energize tower lift up with the tower tele out com-
mand. The analyzer will display “CAL FAILED” and “TWR
NOT UP” if movement of the cylinder angle sensor is
the tower length sensor reading at which the tower
The Control System will disable all functions except auto transport length switch changes state. The analyzer will
platform level and tower lift up. display “CAL FAILED” and “TWR LEN FAULT” if the switch
does not change state by 4”+/-3”.
5. After the pressing the ENTER key , the analyzer will

display “CALIBRATING…”on the bottom line and Control
System will record left tower angle 4, right tower angle
4, and high cylinder angle. The Control system estab-
lishes the high tower angle calibration point per sensor
by taking the difference between the angle 4 and the
ground slope in the direction of the boom. High Tower
Angle Calibration value = 80.0 (77.0 on old cylinder
stroke towers) +/- Ground Slope. The high cylinder angle
will be set to 81.7. The cylinder angle reading must be
within the proper range or “CAL FAILED” and “CYL ANGL
FAULT” will be displayed.
3121171 6-83
Telescope tower out to max length 3. If the “CHECK BOOM…” test passes the analyzer will dis-
play “CALIBRATING…”on the bottom line and record
tower extended length 1 (upper) and tower extended
length 2 (lower). The tower extended length will be set
at 669.4”. The length 1 sensor and the length 2 sensor
must be in the proper range or “CAL FAILED” and “TWR
LEN1 FAULT” or “TWR LEN2 FAULT” will be displayed. The
precise tower transport length switch trip point will be
verified to be 4.0”+3.5”/-1.5”, otherwise the analyzer will
display “CAL FAILED” and “TWR L SW FAULT”.
Step 6 - Position 6
1. After completing the previous step, the analyzer will
read:

display “CHECKING BOOM…” and capture the position
of the Tower Length. The control system will then, Keep
the PVG command at zero leave the Main Control and
PVG enable valves off and Turn On the Tower Telescope
Enable valve and monitor the Tower Telescope length
for decreasing movement of more than 0.5" (1.27 cm) for
60 seconds. If this occurs the test will abort and display
on the top line “CHECK FAILED:” and “TOWER TELE
HOLD” on the bottom line. After the 60 seconds has
elapsed the control system will leave the Enable valve
on and turn on the Main Control Valve and monitor the
Tower Telescope length for decreasing movement of
more than 0.5" (1.27 cm) for 60 seconds. If this occurs
the test will abort and display on the top line “CHECK
FAILED:” and “TOWER TELE APU” on the bottom line.
6-84 3121171
Step 7 - Position 7
read:

platform level and tower tele in. The Control System will
energize main lift up with the tower tele in command.
The analyzer will display “CAL FAILED” and “MAIN NOT
UP” if movement of either main angle sensors is
the tower tele in crack point at which the control system
detects movement of the tower length sensors (if
The Control System will disable all functions except auto required).
platform level and main lift up. The Control System will
energize tower tele out with the main lift up command.
The analyzer will display “CAL FAILED” and “TWR NOT
OUT” if movement of either tower length sensors is
detected.
2. After pressing the ENTER key , the analyzer will dis-

play “CALIBRATING…”on the bottom line and record
right main boom max angle, left main boom max angle.
The main boom max angle will be set at 145.0 (ref
tower). The right main boom angle sensor reading must
be within 155 and 175 and the left main boom angle
sensor reading must be within 5 and 25 or “CAL
FAILED” and “MAIN ANGL1 FAULT” or “MAIN ANGL2
FAULT” will be displayed. The Control System will calcu-
late and verify the precise main boom angle reading at
main boom transport angle switch trip (from position 2)
to be 15.8+6.0/-3.0, otherwise the analyzer will dis-
play “CAL FAILED” and “MAIN A SW FAULT”
3121171 6-85
Step 8 - Position 8
read:

platform level and tower lift up and down. The Control
System will monitor and record the tower lift down crack
point at which the control system detects movement of
the cylinder angle sensor (if required). When tower lift is
commanded, the tower cylinder angle will be controlled
2. After pressing the ENTER key , the Control System to target angle of 74.6 +/-0.5 (relative to the turntable).
will verify the measured length of the tower boom When the target angle is reached the Control System
matches the expected length of 305.4” +/- 0.5”, other- will disable tower lift up and down. If the tower angle
wise, the analyzer will display “CAL FAILED” on the top (ref. To gravity) gets below 66 disable tower lift down
line and “TWR IN TO MIN” on the bottom line each time and display “CAL FAILED” and “TOWER TOO LOW” on the
analyzer.
the ENTER key is pressed and the measured

length does not match the expected length.
6-86 3121171
Step 9 - Position 9
read:
The Control System will disallow all functions except

auto platform level and swing.
Swing turntable 180° - The turntable must be centered
over the original end of chassis
2. After pressing the ENTER key , the Control System

will verify the measured angle of the tower cylinder
matches the target angle of 74.6 +/-0.5 (relative to the
turntable), otherwise, the analyzer will display “CAL
FAILED” on the top line and “TWR UP TO STOP” or
“TOWER DWN TO STOP” on the bottom line each time
the ENTER key is pressed and the measured angle does
not match the expected angle. If the target is reached,
the analyzer will display “CAL POSITION 8” on the top
line and “CALIBRATING…”on the bottom line and calcu-
late the load pin cal resultant force 8, load pin cal force
vector angle (ref t/t base plate), and the calculated cylin-
der angle at load pin cal point. The Control System will
calculate the required rotation correction angle of the
load pin cal force vector angle to match the cylinder
angle at the load pin cal point. The control system will
modify the load pin x and y values into x’ and y’ values
for use in determining moments by rotating the forces
by the rotation correction angle and redistributing the
forces onto the new axis. The control system shall calcu-
late the corrected load pin cal moment 8. The Control
System will also verify the calculated rotational correc-
tion angle is +/- 10 degrees. If it falls outside of this toler-
ance, the Control System will fail calibration and the
analyzer will display “PIN ANGLE FAULT”.
3121171 6-87
Step 10 - Position 10
read:
Lift main down to stop

display “CALIBRATING…”on the bottom line and Control
System will calculate load pin cal resultant force 9. The
Control System must see a change in the drive orienta-
tion switch or “CAL FAILED” and “DRIVE ORNT SW” will
be displayed. The Control System will calculate and
record the load pin cal resultant force by averaging the
load pin cal angle resultant forces 8 and 9. If the load pin
cal resultant force is not within 31,140lb +/-13000lb, the
analyzer will display “CAL FAILED” and “LOAD PIN
FAULT”, otherwise the control system shall calculate the
corrected load pin cal moment 9 and calculate and
record the corrected load pin cal moment by averaging
the corrected load pin cal moments 8 and 9. If the load
pin cal moment is not within 1,011,000 +/-566000, the
analyzer will display “CAL FAILED” and “LOAD PIN
FAULT”. The Control System will disable all functions except auto
platform level and main lift down. When main lift down
is commanded, the main boom angle will be controlled
to the target angle of 15.0 +/- 3.0 (relative to tower).
When the angle is reached, the Control System will dis-
able main lift down. The Control System will monitor
and record the main lift down crack point at which the
6-88 3121171
control system detects movement of the main boom

angle sensors (if required).

will verify the angle of the main boom matches the tar-
get angle of 15.0 +/- 3.0 (relative to tower), otherwise,
the analyzer will display “CAL FAILED” on the top line
and “MAIN UP TO STOP” or “MAIN DWN TO STOP” on the
bottom line each time the ENTER key is pressed

and the measured angle does not match the expected
angle.
Step 11 - Position 11
1. If the target is reached in the previous step, the analyzer
will read:
will verify the cylinder angle reading is less than 5.9,
otherwise, the analyzer will display “CAL FAILED” on the
top line and “TWR NOT DWN” on the bottom line each
time the ENTER key is pressed and the measured

angle not less than the expected angle. If the angle is
less than the expected angle, the analyzer will read:
The Control System will disallow all functions except

auto platform level and tower lift down.
Lift tower down to min angle
After Boom Sensor Calibration is complete, the BCS will

light. DTCs 6614 and 6615 will also be set. This is a nor-
mal condition and the codes will be reset when power is
cycled.
3. Cycle the emergency stop switch.
3121171 6-89
6.16 BOOM CONTROL SYSTEM (BCS) VIOLATION • the turntable is centered between the rear tires
• Ground Mode is selected
The Boom Control System (BCS) will generate a fault (“BCS VIO-
LATION – BOOM LOCKED”) when one of the following faults
become active;
NOTE: During the calibration procedure, if the ESC key is
• “TOWER LENGTH MOVEMENT WITHOUT COMMAND” pressed after the procedure is started, the calibration will
be terminated and exit back to the “UNLOCK BOOM”
• “MAIN ANGLE MOVEMENT WITHOUT COMMAND”
prompt.
• “TOWER CYLINDER ANGLE MOVEMENT WITHOUT
COMMAND” NOTE: In the BCS state, Main envelope and Tower envelope will
continuously be monitored after the initial conditions are
• “TOWER ENVELOPE MASSIVELY ENCROACHED” satisfied. If at any time during the test the BCS state is not
• “TOWER ENVELOPE MULTIPLE ENCROACHMENTS”. Normal or the Main envelope or Tower envelope indicated
encroachment the Calibration will terminate and the ana-
This fault will be stored in BCS memory and prevent Main Tele- lyzer will display “BCS VIOLATION”.
scope Out and Main Lift Up functions when that section is out
of Transport position and Lock the Boom into Transport posi- 1. Using the analyzer, put the vehicle into Access Level 1
tion once a section reaches transport position. The fault will and enter the “UNLOCK BOOM” calibration. The analyzer
also cause the Ground and Platform alarms to sound and illu- will display the following:
minate the BCS Lamp.
To clear the “BCS VIOLATION – BOOM LOCKED” fault a
“UNLOCK BOOM” calibration procedure shall be used.
“UNLOCK BOOM” Calibration Procedure

To perform the Unlock Boom Calibration Procedure, these ini-
tial conditions must be met:
• successful completion of Boom Sensors and Tilt Sensor
calibrations
• The Boom must be operating in the BCS Normal Mode
• The “AXLE LOCKOUT VALVE – SHORT TO BATTERY OR
OPEN CIRCUIT FAULT” fault must not be active
• The “OSCILLATING AXLE PRESSURE SWITCH DISAGREE-
MENT” fault must not be active
• The “BRAKE – SHORT TO BATTERY” fault must not be
active
• the main boom must be fully retracted
• the main boom must be fully lowered
• the tower boom must be fully retracted
• the tower boom must be fully lowered
• the axles must be completely extended
• the machine indicates that it is not tilted
6-90 3121171
3. The Control System will then prompt with the following:

2. After the operator presses the ENTER key , the
Control System will verify that the BCS is in the Normal
state:
• The “AXLE LOCKOUT VALVE – SHORT TO BATTERY
OPEN CIRCUIT FAULT”, “OSCILLATING AXLE PRESSURE
SWITCH DISAGREEMENT” and “BRAKE – SHORT TO
BATTERY” faults are not active
• the axles are completely extended
• the tower is retracted the boom transport length
• main boom dual capacity length and limit switches are
all in the retracted positions
• the main boom transport angle switch is in the trans-
port position
• the tower lift is below elevation
• the drive orientation switch is indicating the turntable
is between the rear tires
• the chassis is not tilted
• the Boom Sensors and tilt sensor calibrations have
been successfully completed
• the machine is in Ground Mode. The control system will then suppress the “BCS VIOLA-
TION – BOOM LOCKED” fault to allow the boom to be
If the initial conditions are not met, the Control System taken out of transport position and disable all hydraulic
will prompt the operator with analyzer messages to sat- functions except Tower Lift Up and Down.
isfy the initial conditions.
4. Once the Tower boom lifts such that the Tower Cylinder
• “CHECK FAULTS” Angle sensor reads greater then 20 degrees, Tower Lift
• “AXLE VALVE FAULT” up will be suspended and Main Lift up and down will be
enabled. The screen will read:
• "OSC AXL SW FAULT”
• “PARK BRAKE FAULT”
• “EXTEND AXLES”
• “TOWER IN”
• “MAIN DOWN”
• “TOWER DOWN”
• “RETRACT MAIN”
• “ALIGN TURNTABLE”
• “LEVEL MACHINE”
• “CAL. BOOM”
• “SELECT GRND MODE”
3121171 6-91
5. Once the Main boom lifts such that the Main Boom to 6. Once “CHECKING BOOM…” is started, the control system
Gravity Angle reads greater then 50 degrees, Main Lift will wait 2 seconds and then capture the position of the
Up control will be suspended and once the Main Lift up Main Boom to Tower, Tower Cylinder Angle and Tower
control is released, the analyzer will read: Length. The control system then will command the Main
Lift, Tower Lift and Tower Telescope PVG valves to 40%,
engage the Main Control and PVG enable valves and
command the Engine to 1800 RPM for 20 seconds. The
control system will monitor for the Main Lift and Tower
Lift angles increasing by more then 0.2 deg and the
Tower Telescope length increasing by more then 0.5”. If
one of these conditions occur the test will abort and dis-
play on the top line “CHECK FAILED:” and “MN LIFT
ENABLE”, “TWR LIFT ENABLE” or “TWR TELE ENABLE” on
During the “CHECKING BOOM…” test if Tower Lift or

Main Lift is selected, the test will abort and the screen
will read:
6-92 3121171
or 7. After the 20 seconds has elapsed the control system will

command the engine back to idle, shut off the com-
mands to the PVG valves, disengage the Main Control
and PVG enable valves and turn on the Main Lift, Tower
Lift and Tower Telescope Enable valves and monitor the
Main Lift and Tower Lift angles for decreasing move-
ment of more then 0.2 deg and Tower Telescope length
decreasing movement of more then 0.5” for 60 seconds.
If one of these conditions occur the test will abort and
display on the top line “CHECK FAILED:” and “MAIN LIFT
HOLD”, “TOWER LIFT HOLD” or “TOWER TELE HOLD” on
or
3121171 6-93
or 8. After the 60 seconds has elapsed the control system will

Leave the Enable valves on and turn on the Main Control
Valve and turn on the Tower Lift PVG valve at a 20%
down command and monitor the Main Lift and Tower
Lift angles for decreasing movement of more then 0.2
deg and Tower Telescope length decreasing movement
of more then 0.5” for 60 seconds. If one of these condi-
tions occur the test will abort and display on the top line
“CHECK FAILED:” and “MAIN LIFT APU”, “TOWER LIFT
APU” or “TOWER TELE APU” on the bottom line depend-
ing on which section moved.
or
6-94 3121171
or 9. Once the “CHECKING BOOM…” testing is complete and

the test passes the control system will clear the Tower
Event log and clear the “BCS VIOLATION – BOOM
LOCKED” fault flag. The screen will read:
or
10. Once “ENTER” is pressed on either one of the

“CHECK FAILED” or “CHECK PASSED” states the control
system will Prompt for “MAIN DWN TO STOP” and
enable all hydraulic functions.
3121171 6-95
11. Once the Main boom transport angle switch indicates it 12. Once the Tower Boom is below elevation the Analyzer
is below elevation the Analyzer will display “TWR DWN will display “TEST COMPLETE”.
TO STOP”.
6-96 3121171
Table 6-11. Diagnostic Trouble Code Chart
Flash
DTC Sequence Fault Message Fault Description Check
Code
001 00 1 EVERYTHING OK The normal help message in Plat-
form Mode.
002 00 2 GROUND MODE OK The normal help message in
Ground Mode.
0010 00 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELE-
VATED MAX" while the vehicle is
out of transport position.
000 00 0 <<< HELP COMMENT >>>
0011 00 11 FSW OPEN A drive / boom function was
selected with the Footswitch
open.
0012 00 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the
Creep Switch is open.
0013 00 13 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All functions at creep while the
Platform is elevated and the Chas-
sis is tilted.
0014 00 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 degrees - Not reported during power-up.
for more then 4 seconds.
0015 0 15 LOAD SENSOR READING UNDER WEIGHT LSS has been calibrated and the Ensure platform is not resting on
UGM has determined that the the ground or is not leveled at an
load sensing system reading is extreme negative angle.
less than -50lbs for 2 seconds. If
the load sensing system deter- Re-calibrate the load sensing sys-
mines that the reading is greater tem if the above items are not a
than -50lbs for 5 seconds this fault factor.
will no longer be annunciated.
No control system interlocks pres-

ent when DTC is active.
0016 00 16 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is an envelope violation. - Envelope control system
equipped vehicle only.
0017 00 17 OVER MOMENT - HYDRAULICS SUSPENDED There is an over moment viola- - Envelope control system
tion. equipped vehicle only.
0018 00 18 UNDER MOMENT - HYDRAULICS SUSPENDED There is an under moment viola- - Envelope control system
0019 00 19 MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is a main envelope viola- - Main envelope system equipped
tion. vehicle only.
0020 00 20 TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is a tower envelope viola- - Tower envelope system
0021 00 ADS1213 REINITIALIZED
0030 00 RUNNING AT CREEP - PLATFORM STOWED
0031 00 FUEL LEVEL LOW - ENGINE SHUTDOWN
0035 00 APU ACTIVE
3121171 6-97
Flash
Code
210 21 0 <<< POWER-UP >>>
211 21 1 POWER CYCLE The normal help message is
issued at each power cycle.
212 21 2 KEYSWITCH FAULTY Both Platform and Ground modes
are selected simultaneously.
213 21 3 FSW FAULTY Both Footswitches are closed for
more then one second.
220 22 0 <<< PLATFORM CONTROLS >>>
227 22 7 STEER SWITCHES FAULTY Both Steer Left and Steer Right
inputs are closed simultaneously.
2211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed for - Can be reported during power-
more then seven seconds. up.
2212 22 12 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected with - Can be reported during power-
Footswitch open. up.
2213 22 13 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected with
Footswitch open.
2215 22 15 D/S JOY. OUT OF RANGE LOW The D/S Joystick reference voltage - Resistive joysticks, these faults
is low. do not occur.
2216 22 16 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference voltage - Resistive joysticks.
is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2217 22 17 D/S JOY. CENTER TAP BAD The D/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2218 22 18 L/S JOY. OUT OF RANGE LOW The L/S Joystick reference voltage - Resistive joysticks, these faults
is low. do not occur.
2219 22 19 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference voltage - Resistive joysticks.
is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2220 22 20 L/S JOY. CENTER TAP BAD The L/S Joystick center tap voltage - Resistive joysticks.
is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2221 22 21 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A lift / swing function was
selected with Footswitch open.
2222 22 22 WAITING FOR FSW TO BE OPEN The Footswitch was closed during - Can be reported during power-
Platform selection. up.
2223 22 23 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE A boom function was selected
with Footswitch open.
2224 22 24 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed during
engine start.
6-98 3121171
Flash
Code
230 23 0 <<< GROUND CONTROLS >>>
234 23 4 FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM A boom function has both direc-
tions selected together.
235 23 5 FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER A boom function was selected
before aux power.
236 23 6 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH A boom function was selected
before engine start.
237 23 7 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH The Start Switch was closed dur-
ing power-up.
23100 23 TOWER LIFT PRESSURE SENSOR - OUT OF RANGE HIGH Pressure transducer output more Out of range high
than 4.6 VDC.
23101 23 TOWER LIFT PRESSURE SENSOR - OUT OF RANGE LOW Pressure transducer output less Out of range low
than 0.4 VDC.
23102 23 TOWER LIFT PRESSURE SENSOR - NOT DETECTING CHANGE Pressure does not change by at Not detecting change
least 20 psi when tower lift is com-
manded
23103 23 TOWER LIFT CYLINDER - OVER PRESSURE At the conclusion of a tower lift Tower lift cylinder over pressure
command that was held for at
least three seconds with the boom
not on the rest and the pressure is
greater than 2200 psi for three
seconds
250 25 0 <<< FUNCTION PREVENTED >>>
259 25 9 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been
changed.
2513 25 13 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the
vehicle generator is running AND
is configured to prevent drive.
2514 25 14 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible
while the vehicle is being driven
AND is configured to not allow
simultaneous drive & boom oper-
ation.
2515 25 15 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the
vehicle above elevation AND is
configured to prevent drive while
above elevation.
2516 25 16 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while Boom
functions are selected AND is con-
figured to not allow simultaneous
drive & boom operation.
2517 25 17 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Driving is not possible while the
vehicle is tilted and above eleva-
tion AND is configured to prevent
drive while tilted and above ele-
vation.
2521 25 21 JIB SWING PREVENTED - IN 1000# MODE JIB Swing is not possible while the
vehicle is in 1000 LB Mode.
3121171 6-99
Flash
Code
2522 25 22 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED CAN Dongle attached. Very lim-
ited restrictions for all hydraulics
systems.
2523 25 23 BACKUP BLAM COMMUNICATIONS ACTIVE RS232 serial backup communica-
tions link to the BLAM is active.
2524 25 24 DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RS232 serial backup communica-
RETRIEVAL tions link to the BLAM is needed
but an analyzer is connected.
2546 25 MACHINE SETUP FAULT - JIB SWING
2547 25 MACHINE SETUP FAULT - MODEL
2587 2 5 RUNNING AT CREEP - PLATFORM LEVELED UNDER The control system has deter-
mined that the platform is leveled
under and is being considered to
be in a loading/unloading posi-
tion. Boom, Tower, and Level
Override functions will operate at
creep speed.
330 33 0 <<< GROUND OUTPUT DRIVER >>>
331 33 1 BRAKE - SHORT TO BATTERY There is a Short to Battery to the
Brake Valve.
332 33 2 BRAKE - OPEN CIRCUIT There is an Open Circuit to the
Brake Valve.
3311 33 11 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3316 33 16 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Forward Drive Valve. cles only.
3317 33 17 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3318 33 18 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3320 33 20 RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Reverse Drive Valve. cles only.
3321 33 21 RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3322 33 22 RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3324 33 24 LEFT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Forward Drive Valve. cles only.
3325 33 25 LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the Left - Chassis Module equipped vehi-
Forward Drive Valve. cles only.
3326 33 26 LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
Left Forward Drive Valve. cles only.
3328 33 28 LEFT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Reverse Drive Valve. cles only.
6-100 3121171
Flash
Code
3329 33 29 LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the Left - Chassis Module equipped vehi-
Reverse Drive Valve. cles only.
3330 33 30 LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
Left Reverse Drive Valve. cles only.
3336 33 36 ALTERNATOR/ECM POWER - SHORT TO GROUND There is a Short to Ground to the
Alternator/ECM.
3338 33 38 ALTERNATOR POWER - OPEN CIRCUIT There is an Open Circuit to the
Alternator.
3339 33 39 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the
Alternator
3340 33 40 AUX POWER - SHORT TO GROUND There is a Short to Ground to the
Auxiliary Power Pump Relay.
3341 33 41 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the Aux-
iliary Power Pump Relay.
3342 33 42 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the
Auxiliary Power Pump Relay.
3343 33 43 COLD START ADVANCE SOLENOID - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Cold Start Advance Solenoid.
3344 33 44 COLD START ADVANCE SOLENOID - OPEN CIRCUIT There is an Open Circuit to the Cold - CAT engines only.
Start Advance Solenoid.
3345 33 45 COLD START ADVANCE SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
Cold Start Advance Solenoid.
3349 33 49 ELECTRIC PUMP - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Pump Relay.
3350 33 50 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
Pump Relay.
3351 33 51 ELECTRIC PUMP - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
Pump Relay.
3358 33 58 MAIN DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Dump Valve.
3359 33 59 MAIN DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Dump Valve.
3360 33 60 MAIN DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Dump Valve.
3361 33 61 BRAKE - SHORT TO GROUND There is a Short to Ground to the
Brake Valve.
3362 33 62 START SOLENOID - SHORT TO GROUND There is a Short to Ground to the - Diesel engines only.
Start Relay.
3363 33 63 START SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - Diesel engines only.
Start Relay.
3364 33 64 START SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - Diesel engines only.
Start Relay.
3121171 6-101
Flash
Code
3368 33 68 TWO SPEED VALVE - SHORT TO GROUND There is a Short to Ground to the
Two Speed Valve.
3369 33 69 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the Two
Speed Valve.
3370 33 70 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the
Two Speed Valve.
3371 33 71 GROUND ALARM - SHORT TO GROUND There is a Short to Ground to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3372 33 72 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3373 33 73 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the - Generator / Welder equipped
Generator Relay. vehicles only.
3374 33 74 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the - Generator / Welder equipped
3375 33 75 GEN SET/WELDER - SHORT TO BATTERY There is a Short to Battery to the - Generator / Welder equipped
3376 33 76 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the - Head Light equipped vehicles
Head Light Relay. only.
3377 33 77 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the - Head Light equipped vehicles
3378 33 78 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the - Head Light equipped vehicles
3379 33 79 HOUR METER - SHORT TO GROUND There is a Short to Ground to the
Hour Meter.
3380 33 80 HOUR METER - OPEN CIRCUIT There is an Open Circuit to the - Can be reported during power-
Hour Meter. up.
3381 33 81 HOUR METER - SHORT TO BATTERY There is a Short to Battery to the
Hour Meter.
3385 33 85 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Up Override Valve. equipped vehicles only.
3386 33 86 PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
3387 33 87 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
3391 33 91 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Down Override equipped vehicles only.
Valve.
3392 33 92 PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3393 33 93 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
6-102 3121171
Flash
Code
3394 33 94 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Left Valve.
3395 33 95 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3396 33 96 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
3397 33 97 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Right Valve.
3398 33 98 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3399 33 99 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
33100 33 100 JIB LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Lift Up Valve.
33101 33 101 JIB LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Lift Up Valve.
33102 33 102 JIB LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Lift Up Valve.
33103 33 103 JIB LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Lift Down Valve.
33104 33 104 JIB LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Lift Down Valve.
33105 33 105 JIB LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Lift Down Valve.
33118 33 118 SWING RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Swing Right Valve.
33119 33 119 SWING RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the
Swing Right Valve.
33120 33 120 MAIN TELESCOPE IN VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope In Valve.
33121 33 121 SWING RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Swing Right Valve.
33122 33 122 SWING LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Swing Left Valve.
33123 33 123 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope Out Valve.
33130 33 130 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the
Throttle Actuator.
33131 33 131 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the
Throttle Actuator.
33132 33 132 THROTTLE ACTUATOR - SHORT TO BATTERY There is a Short to Battery to the
Throttle Actuator.
33133 33 133 PLATFORM CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Control Valve. equipped vehicles only.
33134 33 134 PLATFORM CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
3121171 6-103
Flash
Code
33135 33 135 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
33136 33 136 MAIN LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Main Lift APU Valve.
33137 33 137 MAIN LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33138 33 138 MAIN LIFT APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33139 33 139 MAIN LIFT PILOT - PRESSURE FAILURE The Main Lift Pilot has a Pressure - 1250AJP only.
Failure.
33140 33 140 MAIN LIFT PILOT - NO PRESSURE The Main Lift Pilot has No Pres- - 1250AJP only.
sure.
33141 33 141 MAIN LIFT PILOT - PRESSURE SWITCH FAILURE The Main Lift Pilot has a Pressure - 1250AJP only.
Switch Failure.
33142 33 142 TOWER LIFT APU VALVE - STUCK OPEN The Tower Lift APU Valve is Stuck - 1250AJP only.
Open
33143 33 143 TOWER LIFT ENABLE VALVE - STUCK OPEN The Tower Lift Enable Valve is - 1250AJP only.
Stuck Open
33144 33 144 TOWER LIFT ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Lift Enable Valve.
33145 33 145 TOWER LIFT ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33146 33 146 TOWER LIFT ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33147 33 147 TOWER TELESCOPE APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Telescope APU Valve.
33148 33 148 TOWER TELESCOPE APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33149 33 149 TOWER TELESCOPE APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33150 33 150 LIFT PILOT VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Pilot Valve. cles only.
33151 33 151 LIFT PILOT VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift - Gravity Lift Down equipped vehi-
Pilot Valve. cles only.
33152 33 152 LIFT PILOT VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
Lift Pilot Valve. cles only.
33153 33 153 LIFT DOWN AUX VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Down Auxiliary Valve. cles only.
6-104 3121171
Flash
Code
33154 33 154 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift - Gravity Lift Down equipped vehi-
Down Auxiliary Valve. cles only.
33155 33 155 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
Lift Down Auxiliary Valve. cles only.
33156 33 156 TOWER LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Lift APU Valve.
33157 33 157 TOWER LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33158 33 158 TOWER LIFT APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33159 33 159 MAIN LIFT ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Main Lift Enable Valve.
33160 33 160 MAIN LIFT ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33161 33 161 MAIN LIFT ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33162 33 162 TOWER TELESCOPE APU VALVE - STUCK OPEN The Tower Telescope APU Valve is - 1250AJP only.
Stuck Open
33163 33 163 TOWER TELESCOPE ENABLE VALVE - STUCK OPEN The Tower Telescope Enable Valve - 1250AJP only.
is Stuck Open
33164 33 164 TOWER TELESCOPE ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
33165 33 165 TOWER TELESCOPE ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33166 33 166 TOWER TELESCOPE ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33167 33 167 PVG ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
PVG Valve.
33168 33 168 PVG ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the PVG - 1250AJP only.
Valve.
33169 33 169 PVG ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
PVG Valve.
33173 33 173 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BAT- There is a Short to Battery or an
TERY OR OPEN CIRCUIT Open Circuit to the Axle Lockout
Valve.
33174 33 174 RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an
CIRCUIT Open Circuit to the Brake.
33175 33 175 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Rotate Left Valve.
3121171 6-105
Flash
Code
33176 33 176 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Rotate Left Valve.
33177 33 177 JIB ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Rotate Left Valve.
33178 33 178 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Rotate Right Valve.
33179 33 179 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Rotate Right Valve.
33180 33 180 JIB ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Rotate Right Valve.
33181 33 181 MAIN LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Lift Up Valve.
33183 33 183 MAIN LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Lift Up Valve.
33184 33 184 MAIN LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Lift Down Valve.
33185 33 185 MAIN LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
33186 33 186 MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT There is an Open Circuit to the
33188 33 188 MAIN TELESCOPE OUT VALVE - SHORT TO GROUND There is a Short to Ground to the
33189 33 189 MAIN TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the
33190 33 190 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the
33207 33 207 HORN - OPEN CIRCUIT There is an Open Circuit to the
Horn.
33208 33 208 HORN - SHORT TO BATTERY There is a Short to Battery to the
Horn.
33209 33 209 HORN - SHORT TO GROUND There is a Short to Ground to the
Horn.
33279 33 279 GLOWPLUG - OPEN CIRCUIT There is an Open Circuit to the - Glowplugs equipped vehicles
Glow Plugs. only.
33280 33 280 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the - Glowplugs equipped vehicles
Glow Plugs. only.
33281 33 281 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the - Glowplugs equipped vehicles
Glow Plugs. only.
33285 33 ALTERNATOR EXCITATION LINE - SHORT TO BATTERY
33295 33 295 SWING LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the
Swing Left Valve.
6-106 3121171
Flash
Code
33306 33 306 SWING LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Swing Left Valve.
33307 33 307 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Telescope Flow Control
Valve.
33308 33 308 MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
Valve.
33309 33 309 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
Valve.
33310 33 310 MAIN LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the
33311 33 311 MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Lift Flow Control Valve.
33312 33 312 MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
33313 33 313 MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
33329 33 329 MAIN LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Lift Up Valve.
340 34 0 <<< PLATFORM OUTPUT DRIVER >>>
343 34 3 PLATFORM LEVEL UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Up Valve.
344 34 4 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Open Circuit to the Platform Level equipped vehicles only.
Up Valve.
347 34 7 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Down Valve.
348 34 8 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Down Valve.
430 43 0 <<< ENGINE >>>
431 43 1 FUEL SENSOR SHORT TO BATTERY The Fuel Sensor reading is > 4.3V.
432 43 2 FUEL SENSOR SHORT TO GROUND The Fuel Sensor reading is < 0.2V.
433 43 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading is - Deutz engine only.
> 6.6V.
434 43 4 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 43 5 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sensor - Deutz engine only.
reading is < 0.1V.
437 43 7 ENGINE TROUBLE CODE Displays engine SPN FMI code.
438 43 8 HIGH ENGINE TEMP (Ford engine only) The engine - Ford / Deutz engine only.
temperature is > 117 C.
(Deutz engine only) The engine
temperature is > 130 C.
3121171 6-107
Flash
Code
439 43 9 AIR FILTER BYPASSED The Air Filter is clogged.
4310 43 10 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts for
more then 15 seconds after
engine start.
4311 43 11 LOW OIL PRESSURE (Ford engine only) The ECM has - Ford / Deutz engine only.
reported a low oil pressure fault.
(Deutz engine only) Oil pressure is
< 8 PSI for more then 10 seconds
after engine start.
4313 43 13 THROTTLE ACTUATOR FAILURE The engine RPM is > XXX for more
then XX seconds.
4314 43 14 WRONG ENGINE SELECTED - ECM DETECTED A ECM was detected with a non-
ECM type engine selected.
4322 43 22 LOSS OF ENGINE SPEED SENSOR The engine RPM sensor indicates 0 - Diesel engine only.
RPM AND the Oil Pressure Sensor
indicates > 8 PSI for three sec-
onds.
4323 43 23 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indicates - Diesel engine only.
> 4000 RPM.
4331 43 SOOT LOAD WARNING - LOW
4332 43 SOOT LOAD WARNING - HIGH
4333 43 SOOT LOAD WARNING - SEVERE
4375 4 3 WATER IN FUEL The engine has shut down Water in fuel filter for water or in
because an unacceptable amount fuel or water in fuel sensor.
of water has been detected in the
fuel or there is an issue with the
water in fuel sensor.
If operating in platform mode,

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

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

vented until Engine Oil Warm Up is
complete.
6-108 3121171
Flash
Code
440 44 0 <<< BATTERY SUPPLY >>>
441 44 1 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Battery voltage is < 9V.
442 44 2 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Battery voltage is > 16V.
443 4 4 LSS BATTERY VOLTAGE TOO HIGH The load sensor has determined Check for issue with sensor supply
that its supply voltage is too high voltage.
(> 16V).
The machine will assume the plat-

form is overloaded.
4430 4 4 BATTERY VOLTAGE TOO LOW The control system has detected Check the control system battery
that the system battery voltage is as the control system has indi-
less than 11 volts for 5s and the cated that its voltage is low.
engine is not cranking and auxil-
iary mode is not active.
444 4 4 LSS BATTERY VOLTAGE TOO LOW The load sensor has determined Check for issue with sensor supply
that its supply voltage is too low voltage.
(> 8V).

form is overloaded.
445 44 5 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 Sen- Possible sensor hardware issue.
sor Supply Voltage Initialization
Error

form is 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 Sen- Possible sensor hardware issue.
sor Supply Voltage calibration
error.

form is overloaded.

450 45 0 <<< CAN CONTROLLED VALVES >>>
451 45 1 MAIN LIFT PVG VALVE - INTERNAL FAULT The Main Lift PVG Valve has an - 1250AJP only.
internal fault.
452 45 2 TOWER LIFT PVG VALVE - INTERNAL FAULT The Tower Lift PVG Valve has an - 1250AJP only.
internal fault.
453 45 3 TOWER TELESCOPE PVG VALVE - INTERNAL FAULT The Tower Telescope PVG Valve - 1250AJP only.
has an internal fault.
454 45 4 MAIN LIFT PVG VALVE - HIGH VOLTAGE The Main Lift PVG Valve supply - 1250AJP only.
voltage is high.
3121171 6-109
Flash
Code
455 45 5 TOWER LIFT PVG VALVE - HIGH VOLTAGE The Tower Lift PVG Valve supply - 1250AJP only.
voltage is high.
456 45 6 TOWER TELESCOPE PVG VALVE - HIGH VOLTAGE The Tower Telescope PVG Valve - 1250AJP only.
supply voltage is high.
457 45 7 MAIN LIFT PVG VALVE - LOW VOLTAGE The Main Lift PVG Valve supply - 1250AJP only.
voltage is low.
458 45 8 TOWER LIFT PVG VALVE - LOW VOLTAGE The Tower Lift PVG Valve supply - 1250AJP only.
voltage is low.
459 45 9 TOWER TELESCOPE PVG VALVE - LOW VOLTAGE The Tower Telescope PVG Valve - 1250AJP only.
supply voltage is low.
4510 45 10 MAIN LIFT PVG VALVE - STUCK NEUTRAL The Main Lift PVG Valve is stuck in - 1250AJP only.
its neutral position.
4511 45 11 TOWER LIFT PVG VALVE - STUCK NEUTRAL The Tower Lift PVG Valve is stuck in - 1250AJP only.
its neutral position.
4512 45 12 TOWER TELESCOPE PVG VALVE - STUCK NEUTRAL The Tower Telescope PVG Valve is - 1250AJP only.
stuck in its neutral position.
4513 45 13 MAIN LIFT PVG VALVE - STUCK EXTENDED The Main Lift PVG Valve is stuck in - 1250AJP only.
its extended position.
4514 45 14 TOWER LIFT PVG VALVE - STUCK EXTENDED The Tower Lift PVG Valve is stuck in - 1250AJP only.
its extended position.
4515 45 15 TOWER TELESCOPE PVG VALVE - STUCK EXTENDED The Tower Telescope PVG Valve is - 1250AJP only.
stuck in its extended position.
4516 45 16 MAIN LIFT PVG VALVE - STUCK RETRACTED The Main Lift PVG Valve is stuck in - 1250AJP only.
its retracted position.
4517 45 17 TOWER LIFT PVG VALVE - STUCK RETRACTED The Tower Lift PVG Valve is stuck in - 1250AJP only.
its retracted position.
4518 45 18 TOWER TELESCOPE PVG VALVE - STUCK RETRACTED The Tower Telescope PVG Valve is - 1250AJP only.
stuck in its retracted position.
4519 45 19 MAIN LIFT PVG VALVE - OBSTRUCTED The Main Lift PVG Valve is - 1250AJP only.
obstructed
4520 45 20 TOWER LIFT PVG VALVE - OBSTRUCTED The Tower Lift PVG Valve is - 1250AJP only.
obstructed
4521 45 21 TOWER TELESCOPE PVG VALVE - OBSTRUCTED The Tower Telescope PVG Valve is - 1250AJP only.
obstructed
4522 45 22 MAIN LIFT PVG VALVE - COMMAND IMPROPER The Main Lift PVG Valve command - 1250AJP only.
is improper.
4523 45 23 TOWER LIFT PVG VALVE - COMMAND IMPROPER The Tower Lift PVG Valve com- - 1250AJP only.
mand is improper.
4524 45 24 TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER The Tower Telescope PVG Valve - 1250AJP only.
command is improper.
4525 45 25 MAIN LIFT PVG VALVE - TIMEOUT The Main Lift PVG Valve has timed - 1250AJP only.
out.
4526 45 26 TOWER LIFT PVG VALVE - TIMEOUT The Tower Lift PVG Valve has - 1250AJP only.
timed out.
4527 45 27 TOWER TELESCOPE PVG VALVE - TIMEOUT The Tower Telescope PVG Valve - 1250AJP only.
has timed out.
6-110 3121171
Flash
Code
4528 45 28 MAIN LIFT PVG VALVE - SETUP FAULT The Main Lift PVG Valve has a - 1250AJP only.
setup fault.
4529 45 29 TOWER LIFT PVG VALVE - SETUP FAULT The Tower Lift PVG Valve has a - 1250AJP only.
setup fault.
4530 45 30 TOWER TELESCOPE PVG VALVE - SETUP FAULT The Tower Telescope PVG Valve - 1250AJP only.
has a setup fault.
4531 45 31 MAIN LIFT PVG VALVE - SENT UNRECOGNIZED FAULT The Main Lift PVG Valve has an - 1250AJP only.
unrecognized fault.
4532 45 32 TOWER LIFT PVG VALVE - SENT UNRECOGNIZED FAULT The Tower Lift PVG Valve has an - 1250AJP only.
unrecognized fault.
4533 45 33 TOWER TELESCOPE PVG VALVE - SENT UNRECOGNIZED FAULT The Tower Telescope PVG Valve - 1250AJP only.
has an unrecognized fault.
4534 45 34 MAIN LIFT PVG VALVE - PARAMETERS INCORRECT The Main Lift PVG Valve parame- - 1250AJP only.
ters are incorrect.
4535 45 35 TOWER LIFT PVG VALVE - PARAMETERS INCORRECT The Tower Lift PVG Valve parame- - 1250AJP only.
ters are incorrect.
4536 45 36 TOWER TELESCOPE PVG VALVE - PARAMETERS INCORRECT The Tower Telescope PVG Valve - 1250AJP only.
parameters are incorrect.
4537 45 37 MAIN LIFT PVG VALVE - LOCATION IMPROPER The Main Lift PVG Valve is in the - 1250AJP only.
wrong location.
4538 45 38 TOWER LIFT PVG VALVE - LOCATION IMPROPER The Tower Lift PVG Valve is in the - 1250AJP only.
wrong location.
4539 45 39 TOWER TELESCOPE PVG VALVE - LOCATION IMPROPER The Tower Telescope PVG Valve is - 1250AJP only.
in the wrong location.
4540 45 40 MAIN LIFT PVG VALVE - WIRING INCORRECT The Main Lift PVG Valve has incor- - 1250AJP only.
rect wiring.
4541 45 41 TOWER LIFT PVG VALVE - WIRING INCORRECT The Tower Lift PVG Valve has - 1250AJP only.
incorrect wiring.
4542 45 42 TOWER TELESCOPE PVG VALVE - WIRING INCORRECT The Tower Telescope PVG Valve - 1250AJP only.
has incorrect wiring.
4543 45 43 MAIN LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
4544 45 44 TOWER LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
4545 45 45 TOWER TELESCOPE PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
3121171 6-111
Flash
Code
660 66 0 <<< COMMUNICATION >>>
662 66 2 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN communi-
cation lost.
663 66 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE
666 66 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN com- - ECM equipped engine only.
munication lost.
667 66 7 CANBUS FAILURE - MAIN LIFT PVG Main Lift PVG CAN communica- - 1250AJP only.
tion lost.
668 66 8 CANBUS FAILURE - TOWER LIFT PVG Tower Lift PVG CAN communica- - 1250AJP only.
tion lost.
669 66 9 CANBUS FAILURE - TOWER TELESCOPE PVG Tower Telescope PVG CAN com- - 1250AJP only.
munication lost.
6610 66 10 CANBUS FAILURE - BLAM BLAM CAN communication lost. - BLAM equipped vehicles only.
6611 66 11 CANBUS FAILURE - CHASSIS MODULE Engine Control Module CAN com- - ECM equipped engine only.
munication lost.
6612 66 12 CANBUS FAILURE - CYLINDER LOAD PIN Cylinder Load Pin CAN communi- - Cylinder Load Pin equipped
cation lost. engine only.
6613 66 13 CANBUS FAILURE - EXCESSIVE CANBUS ERRORS There has been > 500 Bus Off
errors or >500 Bus Passive Errors.
6614 66 14 CANBUS FAILURE - MAIN ANGLE SENSOR #1 Angle Sensor #1 CAN communica- - 1250AJP only.
tion lost.
6615 66 15 CANBUS FAILURE - MAIN ANGLE SENSOR #2 Angle Sensor #2 CAN communica- - 1250AJP only.
tion lost.
6622 66 22 CANBUS FAILURE - TCU MODULE Machine Setup/ Telematics=YES,
No device heartbeat for 30 sec
6623 66 23 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telematics=YES,
No device heartbeat for 30 sec
6629 66 29 CANBUS FAILURE - TELEMATICS CANBUS LOADING X -Telematics only
TOO HIGH
663 6 6 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE The control system has lost com- Check wiring to load sensor.
munication with the load sensing
system load pin.

form is overloaded.
680 68 0 <<< TELEMATICS >>>
681 68 1 REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN X -Telematics only
CREEP
810 81 0 <<< TILT SENSOR >>>
813 81 3 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not
been calibrated.
815 81 5 CHASSIS TILT SENSOR DISAGREEMENT X
6-112 3121171
Flash
Code
820 82 0 <<< PLATFORM LOAD SENSE >>>
821 82 LSS CELL #1 ERROR
8211 8 2 LSS READING UNDER WEIGHT LSS has been calibrated and the Ensure platform is not resting on
UGM has determined that the the ground or is not leveled at an
load sensing system reading is extreme negative angle.
underweight while a period of
time while operating drive or Re-calibrate the load sensing sys-
boom lift up at speeds greater tem if the above items are not a
than creep OR the UGM has deter- factor.
mined that the load sensing sys-
tem reading is less than -1.5 x
Gross Platform Weight.

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

be overloaded boom functions
will be restricted to creep.

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

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

tion with DTC 8222 the machine
will assume the platform is over-
loaded.

3121171 6-113
Flash
Code
8223 8 2 LSS STRAIN GAUGE 2 - STAGNANT The control system has deter- Possible sensor hardware issue.
mined that the strain gauge 2
reading in the load sensor is stag-
nant (not changing).

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

tion with DTC 8223 the machine
will assume the platform is over-
loaded.

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

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

machine will assume the platform
is overloaded.

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

creep.

is overloaded.

6-114 3121171
Flash
Code
8226 8 2 LSS STRAIN GAUGE 1 - OUT OF RANGE HIGH The shear beam is reporting an Possible sensor hardware issue.
out of range high issue with the

creep.

is overloaded.

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

creep.

is overloaded.

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

creep.

is overloaded.

3121171 6-115
Flash
Code
8229 8 2 LSS STRAIN GAUGE 2 - INITIALIZATION ERROR The shear beam is reporting an Possible sensor hardware issue.
initialization issue with the strain
gauge 2 sensor.

creep.

is overloaded.

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

creep.

is overloaded.

8231 8 2 LSS STRAIN GAUGE 2 - NOT CALIBRATED The shear beam is reporting a cali- Possible sensor hardware issue.
bration issue with the strain
gauge 2 sensor.

creep.

is overloaded.

6-116 3121171
Flash
Code
8232 8 2 LSS STRAIN GAUGE 1 - SENSOR DEFECT The shear beam is reporting a sen- Possible sensor hardware issue.
sor defect issue with the strain
gauge 1 sensor.

creep.

is overloaded.

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

creep.

is overloaded.

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

creep.

is overloaded.

3121171 6-117
Flash
Code
8235 8 2 LSS STRAIN GAUGE 2 - NOT INSTALLED The shear beam is reporting a not Possible sensor hardware issue.
installed issue with the strain
gauge 2 sensor.

creep.

is overloaded.

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

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

creep.

is overloaded.

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

creep.

is overloaded.

6-118 3121171
Flash
Code
825 8 2 LSS HAS NOT BEEN CALIBRATED The load sensing system is config- Calibrate the load sensing system.
ured but has not been calibrated.

form is overloaded.
826 82 6 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 82 7 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are
not possible while the Load Sens-
ing System indicates the Platform
is overloaded AND is configured to
prevent drive and boom functions
while the Platform is overloaded.
828 82 8 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 83 0 <<< PLATFORM LEVELING >>>
831 83 1 PLATFORM LEVELING OVERRIDE ON Platform Leveling forced on with
Access Level 0 selection.
832 83 2 PLATFORM LEVELING OVERRIDE OFF Platform Leveling forced off with
Access Level 0 selection.
833 83 3 PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED The Platform Level Up Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
834 83 4 PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED The Platform Level Down Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
837 83 7 PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #1. equipped vehicles only.
838 83 8 PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Sensor #1.
8311 83 11 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #2. equipped vehicles only.
8312 83 12 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Sensor #2.
3121171 6-119
Flash
Code
8313 83 13 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #1 rever- - Electronic leveling system
ence voltage is outside acceptable equipped vehicles only.
range (4.9 to 5.1 volts).
8314 83 14 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #2 rever- - Electronic leveling system
ence voltage is outside acceptable equipped vehicles only.
range (4.9 to 5.1 volts).
8315 83 15 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads the sen- - Electronic leveling system
sor values at power-up. The fault is equipped vehicles only.
triggered when there is a ± 5
degree difference from the initial
reading.
8316 83 16 PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST Platform Level Sensor #1 serial - 1200S and 1350S only.
communication lost.
8317 83 17 PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST Platform Level Sensor #2 serial - 1200S and 1350S only.
communication lost.
8318 83 18 PLATFORM LEVELING SYSTEM TIMEOUT The Platform was unable to main-
tain desired level within range for
the allotted time.
840 84 0 <<< ENVELOPE >>>
841 84 1 BOOM ANGLE SENSOR DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Boom Angle Sensors. cles only.
842 84 2 BOOM LENGTH SWITCH FAILED The Boom Length Switches are - Envelope Control equipped vehi-
reporting the same state. cles only.
843 84 3 BOOM LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Boom Length Switch and the cles only.
Boom Length Sensor.
844 84 4 BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE The Boom Length Sensor is not - Envelope Control equipped vehi-
changing during a boom tele- cles only.
scope command.
845 84 5 BOOM LENGTH SENSOR - OUT OF RANGE HIGH Boom Length Sensor out of range - Envelope Control equipped vehi-
high. cles only.
-1200/1350 only
846 84 6 BOOM LENGTH SENSOR - OUT OF RANGE LOW Boom Length Sensor out of range - Envelope Control equipped vehi-
low. cles only.
-1200/1350 only
847 84 7 BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH Boom Length out of range high. - Envelope Control equipped vehi-
cles only.
-1200/1350 only
848 84 8 BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW Boom Length out of range low. - Envelope Control equipped vehi-
cles only.
-1200/1350 only
6-120 3121171
Flash
Code
849 84 9 BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 communi- - Envelope Control equipped vehi-
cations lost. cles only.
8410 84 10 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT Boom Angle Sensor #2 communi- - Envelope Control equipped vehi-
cations lost. cles only.
8411 84 11 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of - Envelope Control equipped vehi-
range. cles only.
8412 84 12 BOOM ANGLE SENSOR #2 - INVALID ANGLE Boom Angle Sensor #2 out of - Envelope Control equipped vehi-
range. cles only.
8413 84 13 WRONG TELESCOPE RESPONSE Boom telescope is moving in the - Envelope Control equipped vehi-
opposite direction of the com- cles only.
mand.
8414 84 14 WRONG LIFT RESPONSE Boom lift is moving in the oppo- - Envelope Control equipped vehi-
site direction of the command. cles only.
8415 84 15 TOWER ANGLE SENSOR DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Tower Angle Sensors. cles only.
-1250
3121171 6-121
Flash
Code
84151 8 4 TOWER LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) that Check Hardware, Wiring
these faults can be set:
(a)
If the length sensor voltage
changes more than 0.0168 volts
within 40 milliseconds a counter
for the respective length sensor
shall be incremented to aid ser-
vice in diagnosing bad sensor per-
formance. The counter below
shall be incremented anytime the
description above is met. It is
cleared/reset by a power cycle
TwrLenSnsr(1/
2)FaultCounter_PowerCycle > 30
(b)
The counter below shall be incre-
mented every time TwrLen-
Snsr(1/
2)FaultCounter_PowerCycle
(described above) reached its
threshold. This value is stored in
EEPROM in order to track the his-
tory of the issue. (A successful
Boom Sensor Calibration will reset
this counter – this is reflected in
the boom sensor calibration docu-
ment)
TwrLenSnsr(1/
2)FaultCounter_EEPROM > 3
(c)
The fault counter below shall be
incremented every time the trig-
ger condition described in section
(a) is observed during certain
steps during Boom Sensor Cali-
bration (please see that docu-
ment section for further details)
TwrLenSnsr(1/
2)FaultCounter_BmSnsrCal > 20
If (a) or (b) or (c) are met (fault

triggered) the machine will be put
into Electrical Retrieval
Fault, once triggered, is main-
tained within a given key-cycle
Machine will be trapped in trans-
port
6-122 3121171
Flash
Code
84152 8 4 TOWER LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) that Check Hardware, Wiring
(a)
TwrLenSnsr(1/
(b)
mented every time TwrLen-
Snsr(1/
ment)
TwrLenSnsr(1/
(c)
TwrLenSnsr(1/

port
3121171 6-123
Flash
Code
84153 8 4 BOOM LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) that Check wiring and hardware
(a)
BmLenSnsr(1/
(b)
mented every time BmLenSnsr(1/
ment)
BmLenSnsr(1/
(c)
BmLenSnsr(1/

port
6-124 3121171
Flash
Code
84154 8 4 BOOM LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) that Check wiring and hardware
(a)
BmLenSnsr(1/
(b)
mented every time BmLenSnsr(1/
ment)
BmLenSnsr(1/
(c)
BmLenSnsr(1/

port
3121171 6-125
Flash
Code
8416 84 16 TOWER LENGTH SENSOR DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Tower Length Sensors. cles only.
-1250
8417 84 17 MAIN ANGLE SENSOR DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Main Boom Angle Sensors. cles only.
-1250
8418 84 18 TOWER LENGTH SENSOR #1 - OUT OF RANGE HIGH Tower Boom Angle Sensor #1 out - Envelope Control equipped vehi-
of range high. cles only.
-1250
8419 84 19 TOWER LENGTH SENSOR #1 - OUT OF RANGE LOW Tower Boom Angle Sensor #1 out - Envelope Control equipped vehi-
of range low. cles only.
-1250
-1250
-1250
8422 84 22 TOWER LENGTH SENSOR - NOT DETECTING LENGTH CHANGE The Tower Length Sensor is not - Envelope Control equipped vehi-
changing during a tower tele- cles only.
scope command. -1250
8423 84 23 TOWER LENGTH MOVEMENT WITHOUT COMMAND The Tower Length Sensor is - Envelope Control equipped vehi-
changing without a tower tele- cles only.
scope command. -1250
-1250
-1250
6-126 3121171
Flash
Code
-1250
-1250
8428 84 28 TOWER ANGLE SENSOR #1 - INVALID ANGLE Tower Boom Angle Sensor #1 out - Envelope Control equipped vehi-
of range. cles only.
-1250
8429 84 29 TOWER ANGLE SENSOR #2 - INVALID ANGLE Tower Boom Angle Sensor #2 out - Envelope Control equipped vehi-
of range. cles only.
-1250
8430 84 30 TOWER ANGLE SENSOR #1 - INVALID MODEL Wrong Tower Boom Angle Sensor - Envelope Control equipped vehi-
#1 installed. cles only.
- 1250AJP Only
- Must be a Rieker Sensor, not a
Spectron Sensor.
8431 84 31 TOWER ANGLE SENSOR #2 - INVALID MODEL Wrong Tower Boom Angle Sensor - Envelope Control equipped vehi-
#2 installed. cles only.
- 1250AJP Only
- Must be a Rieker Sensor, not a
Spectron Sensor.
8432 84 32 MAIN ANGLE SENSOR #1 - INVALID ANGLE Main Boom Angle Sensor #1 out of - Envelope Control equipped vehi-
range. cles only.
-1250
8433 84 33 MAIN ANGLE SENSOR #2 - INVALID ANGLE Main Boom Angle Sensor #2 out of - Envelope Control equipped vehi-
range. cles only.
-1250
8434 84 34 MAIN ANGLE SENSOR - NOT DETECTING ANGLE CHANGE The Main Boom Angle Sensor is - Envelope Control equipped vehi-
not changing during a main lift cles only.
command. -1250
8435 84 35 MAIN ANGLE MOVEMENT WITHOUT CMD The Main Boom Angle Sensor is - Envelope Control equipped vehi-
changing without a main lift com- cles only.
mand. -1250
8436 84 36 WRONG TOWER TELESCOPE RESPONSE Tower telescope is moving in the - Envelope Control equipped vehi-
mand. -1250
8437 84 37 WRONG TOWER LIFT RESPONSE Tower lift is moving in the oppo- - Envelope Control equipped vehi-
site direction of the command. cles only.
-1250
8438 84 38 TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE HIGH The Tower Cylinder Angle Sensor is - Envelope Control equipped vehi-
< 4721 A/D counts. cles only.
-1250
3121171 6-127
Flash
Code
8439 84 39 TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE LOW The Tower Cylinder Angle Sensor is - Envelope Control equipped vehi-
> 29535 A/D counts. cles only.
-1250
8440 84 40 TOWER CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE The Tower Cylinder Angle Sensor is - Envelope Control equipped vehi-
not changing during a tower lift cles only.
command. -1250
8441 84 41 TOWER CYLINDER ANGLE MOVEMENT WITHOUT COMMAND The Tower Cylinder Angle Sensor is - Envelope Control equipped vehi-
changing without a tower lift cles only.
command. -1250
8442 84 42 MAIN TRANSPORT ANGLE SWITCH FAILED The Main Boom Angle Switch is - Envelope Control equipped vehi-
bad. cles only.
-1250
8443 84 43 TWR TRANSPORT SWITCH DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Tower Boom Length Switch cles only.
and the Tower Length Sensor. -1250
8444 84 44 TRANSPORT DUAL CAPACITY SWITCHES BAD Both the Dual Capacity Switch and - Envelope Control equipped vehi-
the Transport Switch are bad. cles only.
-1250
8445 84 45 TRANSPORT DUAL CAPACITY BAD TRANSITION The Dual Capacity Switch and the - Envelope Control equipped vehi-
Transport Switch changed state cles only.
out of order. -1250
8446 84 46 MAIN TRANSPORT LENGTH SWITCH DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Main Boom Transport Length cles only.
Switches. -1250
8447 84 47 MAIN DUAL CAPACITY LENGTH SWITCH DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Main Boom Dual Capacity cles only.
Length Switches. -1250
8448 84 48 MAIN TRANSPORT ANGLE SWITCH/SENSOR DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Main Boom Angle Switch and cles only.
the Main Boom Angle Sensor. -1250
8449 84 49 TOWER CYLINDER ANGLE SWITCH/SENSOR DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Tower Boom Angle Switch and cles only.
the Tower Cylinder Angle Sensor. -1250
8450 84 50 NEW MAIN ANGLE SENSOR #1 DETECTED A new Main Angle Sensor 1 has -1250
been detected.
8451 84 51 NEW MAIN ANGLE SENSOR #2 DETECTED A new Main Angle Sensor 2 has -1250
been detected.
8452 84 52 TOWER LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement between - Envelope Control equipped vehi-
the Tower Length Switch and the cles only.
Tower Length Sensor. -1250
8453 84 53 WRONG MAIN TELE RESPONSE Main telescope is moving in the - Envelope Control equipped vehi-
mand. -1250
8454 84 54 WRONG MAIN LIFT RESPONSE Main lift is moving in the opposite - Envelope Control equipped vehi-
direction of the command. cles only.
-1250
6-128 3121171
Flash
Code
8482 84 82 TOWER ENVELOPE MASSIVELY ENCROACHED 8482 TOWER ENVELOPE MAS- 8482 TOWER ENVELOPE MAS-
SIVELY ENCROACHED - Tower has SIVELY ENCROACHED - Tower has
exceeded the maximum tower exceeded the maximum tower
path stop line.1250 Only path stop line.1250 Only
8483 84 83 TOWER ENVELOPE MULTIPLE ENCROACHMENTS The tower has encroached the -1250
envelope twice in a 15 minute
period.
8484 84 84 BCS VIOLATION - BOOM LOCKED Control system has detected one -1250
of the following faults 8423, 8435,
8441, 8482, 8483. Main lift will be
disallowed and boom will be
locked in transport until a boom
unlock procedure has been per-
formed. This fault is maintained
through a power cycle.
8485 84 85 BCS - HYDRAULIC RETRIEVAL ACTIVE Alerts operator when control sys- -1250
tem is in hydraulic retrieval mode.
8486 84 86 BCS - ELECTRICAL RETRIEVAL ACTIVE Alerts operator when control sys- -1250
tem is in electrical retrieval mode.
8487 84 87 BCS - MULTIPLE FAILURES ACTIVE Control system has detected a -1250
main and a tower envelope
encroachment at the same time.
850 85 0 <<< MOMENT / LOAD PINS >>>
851 85 1 MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE The Moment Pin horizontal force
is out of range.
852 85 2 MOMENT PIN - VERTICAL FORCE OUT OF RANGE The Moment Pin vertical force is
out of range.
853 85 3 LOAD PIN - HORIZONTAL FORCE OUT OF RANGE The Load Pin horizontal force is -1250
out of range.
854 85 4 LOAD PIN - VERTICAL FORCE OUT OF RANGE The Load Pin vertical force is out of -1250
range.
855 85 5 MOMENT PIN - SENSOR FAULT The Moment Pin has reported a
fault.
856 85 6 LOAD PIN - SENSOR FAULT The Load Pin has reported a fault. -1250
857 85 7 NEW MOMENT PIN DETECTED A new Moment Pin has been
detected.
858 85 8 NEW LOAD PIN DETECTED A new Load Pin has been -1250
detected.
3121171 6-129
Flash
Code
859 85 9 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT There is a disagreement between -1250
the Load Pin and the Tower Lift
cylinder Angle.
8510 85 10 LOAD PIN - FORCE VALUES NOT CHANGING The Load Pin is not changing. -1250
8511 85 11 LOAD PIN - FORCE TOO LOW OVER TOWER ANGLE CHANGE Load pin force did not change -1250
enough for the tower angle move-
ment.
8512 85 12 LOAD PIN - FORCE TOO LOW OVER MAIN ANGLE CHANGE Load pin force did not change -1250
enough for the main angle move-
ment.
8513 85 13 LOAD PIN - FORCE TOO LOW OVER MAIN LENGTH TRANSITION Load Pin force did not change -1250
enough for main length move-
ment.
860 86 0 <<< STEERING / AXLE >>>
861 86 1 RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH The Oscillating Axle Pressure - Electrically released Oscillated
DISAGREEMENT Switch indicates pressure while Axles equipped vehicles only.
not driving or does not indicate
pressure while driving and
restricted to transport.
862 86 2 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 86 3 AXLE EXTEND VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Extend Valve.
864 86 4 AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Retract
Valve.
865 86 5 AXLE RETRACT VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Retract Valve.
866 86 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIR- There is a Short to Battery or an
CUIT Open Circuit to the Right Front
Steer Right Valve.
867 86 7 RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Right Valve.
868 86 8 RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Left Valve.
869 86 9 RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Left Valve.
6-130 3121171
Flash
Code
8610 86 10 LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front Steer
Right Valve.
8611 86 11 LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Right Valve.
8612 86 12 LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front Steer
Left Valve.
8613 86 13 LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Left Valve.
8614 86 14 RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Right Valve.
8615 86 15 RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Right Valve.
8616 86 16 RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Left Valve.
8617 86 17 RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Left Valve.
8618 86 18 LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear Steer
Right Valve.
8619 86 19 LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Right Valve.
8620 86 20 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 86 21 LEFT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Left Valve.
8622 86 22 FRONT RIGHT STEER SENSOR - DECOUPLED The Front Right Steer Sensor has
become decoupled.
8623 86 23 FRONT LEFT STEER SENSOR - DECOUPLED The Front Left Steer Sensor has
become decoupled.
8624 86 24 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has
become decoupled.
8625 86 25 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has
become decoupled.
8626 86 26 FRONT LEFT STEER SENSOR - NOT RESPONDING The Front Right Steer Sensor is not
responding to steer commands.
8627 86 27 FRONT RIGHT STEER SENSOR - NOT RESPONDING The Front Left Steer Sensor is not
8628 86 28 REAR LEFT STEER SENSOR - NOT RESPONDING The Rear Right Steer Sensor is not
8629 86 29 REAR RIGHT STEER SENSOR - NOT RESPONDING The Rear Left Steer Sensor is not
3121171 6-131
Flash
Code
8630 86 30 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 86 31 FRONT RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Right Steer Sensor.
8632 86 32 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 86 33 FRONT LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Left Steer Sensor.
8634 86 34 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 86 35 REAR RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Right Steer Sensor.
8636 86 36 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 86 37 REAR LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Left Steer Sensor.
8651 86 51 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT Engine Start is prevented while
there is an Oscillating Axle fault
and vehicle is out of transport
position
876 87 6 WIRE ROPE SERVICE REQUIRED MACHINE SETUP → CABLE
SWITCH = YES;
Wire Rope Service = Enabled
990 99 0 <<< HARDWARE >>>
991 99 LSS WATCHDOG RESET
992 99 LSS EEPROM ERROR
993 99 LSS INTERNAL ERROR - PIN EXCITATION
994 99 LSS INTERNAL ERROR - DRDY MISSING FROM A/D
998 99 8 EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has reported
an EEPROM failure.
9910 99 10 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION The Platform Module software
IMPROPER version is not compatible with the
rest of the system.
9911 9 9 FUNCTIONS LOCKED OUT
9914 99 14 PLATFORM MODULE SOFTWARE UPDATE REQUIRED The Platform Module software
requires an updated.
9915 99 15 CHASSIS TILT SENSOR NOT GAIN CALIBRATED The Chassis Tilt Sensor gain cali-
bration has been lost.
6-132 3121171
Flash
Code
9916 99 16 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain cali-
bration has become corrupted.
9917 99 17 HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST The Platform Module has
reported that its ADS1213 chip
has stopped asserting its inter-
rupt.
9918 99 18 HIGH RESOLUTION A2D FAILURE - REINIT LIMIT The Platform Module has
reported that its ADS1213 chip
had to be reset 3 or more times.
9919 99 19 GROUND SENSOR REF VOLTAGE OUT OF RANGE The Ground Module has reported - Not reported during power-up.
that its sensor reference voltage is
outside acceptable range.
9920 99 20 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE The Platform Module has - Not reported during power-up.
reported that its sensor reference
voltage is outside acceptable
range.
9921 99 21 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY The Ground Module has reported
that its high side driver cutout
failed.
9922 99 22 PLATFORM MODULE FAILURE - HWFS CODE 1 The Platform Module has
reported that the V(Low) FET has
failed.
9923 99 23 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has reported
that the V(Low) FET has failed.
9924 99 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED
9925 99 25 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION The Chassis Module software ver-
IMPROPER sion is not compatible with the
rest of the system.
9926 99 26 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION The BLAM software version is not
IMPROPER compatible with the rest of the
system.
9927 99 27 GROUND MODULE CONSTANT DATA UPDATE REQUIRED The Ground Module constant data
requires an updated.
99285 9 9 LSS - FACTORY CALIBRATION ERROR The load sensor is reporting a fac- Possible sensor hardware issue.
tor calibration issue (internal
error)

form is overloaded.

9929 99 29 MOMENT CONTROL DISABLED Moment Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
9930 99 30 STEER SENSORS NOT CALIBRATED The Steer Sensors have not been - Chassis Module equipped vehi-
calibrated. cles only.
9931 99 31 BOOM SENSORS NOT CALIBRATED The Boom Sensors have not been - BLAM equipped vehicles only.
calibrated.
3121171 6-133
Flash
Code
9932 99 32 LIFT CRACKPOINTS NOT CALIBRATED The Lift Valves have not been cali- - 1200S and 1350S only.
brated.
9933 99 33 TELESCOPE CRACKPOINTS NOT CALIBRATED The Telescope Valves have not - 1200S and 1350S only.
been calibrated.
9934 99 34 DRIVE CRACKPOINTS NOT CALIBRATED The Drive Valves have not been - 1200S and 1350S only.
calibrated.
9935 99 35 BLAM SENSOR SUPPLY OUT OF RANGE HIGH The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is high.
9936 99 36 BLAM SENSOR SUPPLY OUT OF RANGE LOW The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is low.
9937 99 37 LENGTH SENSOR REF VOLTAGE HIGH The Boom Length Sensors supply
voltage is high.
9938 99 38 LENGTH SENSOR REF VOLTAGE LOW The Boom Length Sensors supply
voltage is low.
9939 99 39 BLAM HIGH RES A/D FAILURE The BLAM high resolution analog - BLAM equipped vehicles only.
to digital converter has failed.
9940 99 40 CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH The Chassis Sensors supply volt-
age is high.
9941 99 41 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW The Chassis Sensors supply volt-
age is low.
9942 99 42 BLAM BACKUP COMMUNICATIONS LINK FAULTY The BLAM backup communica- - BLAM equipped vehicles only.
tions link test was activated at -1250
startup, but no communication
connection established/main-
tained.
9943 99 43 BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED The BLAM backup communica- - BLAM equipped vehicles only.
tions link was activated, but no -1250
communication connection
established/maintained.
9944 99 44 CURRENT FEEDBACK GAINS OUT OF RANGE The factory set current feedback
gains are out of range.
9945 99 45 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT The factory set current feedback
checksum is not correct.
9975 99 75 LOAD PIN NOT CALIBRATED The Load Pin has not been cali- -1250
brated.
9977 99 LSS CORRUPT EEPROM
9979 99 79 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 con-
trols will be prevented. This fault
was to insure that the software
will only work for these two mod-
els.
6-134 3121171
Table 6-12. Analyzer Diagnostics Menu
Menu: Submenu: Selection: Description:

DIAGNOSTICS:
SYSTEM:
GM BATTERY (XX.XX) V Displays battery voltage at ground module
PM BATTERY (XX.XX) V Displays battery voltage at platform module
AMB. TEMP (XX) C Displays ambient temperature
PLATFORM SW (CL or OP) Displays the OPEN or CLOSED condition of the ground switch
GROUND SW (CL or OP) Displays the OPEN or CLOSED condition of the platform switch
MODE (GROUND or PLAT) Displays the current operation mode of the machine
ABOVE ELEV. (YES or NO) Displays the current condition of the ABOVE ELEVATION case
LEN SW 1 (CL or OP) Displays the current condition of length switch #1
LEN SW 2 (CL or OP) Displays the current condition of length switch #2
RETRACTED (YES or NO) Displays the status of the RETRACTED case
TRANSPORT (YES or NO) Displays the status of the TRANSPORT case
BR CABLE CUT (OP or CL) Displays the status of the BROKEN CABLE case
BCS (NORMAL or XXXX VIOL) Displays the status of the Boom Control System
MN ENV (NOMINAL or (STOP or VIOL)(TOP or BOT)) Displays the main boom envelope status
TW ENV (NOMINAL or (STOP or VIOL)(FWD or Displays the tower envelope status

BACK))
(HR or ER)(GRAV or PWR)(DOWN or DN)(SS or Displays the current retrieval mode and conditions
NP)(ML or TT)
LENGTH ZONE (A or B or C or d or ERR) Displays the status of the main boom length zone
ANGLE ZONE (1 or 2 or 3 or 4 or 5 or 6 or 7 or 8 or HI) Displays the status of the main boom angle zone
CREEP (NOT ACTIVE or ACTIVE) Displays creep switch status
CRP MODE (NOT ACT or ACTIVE) Displays the current condition of creep mode
SUPER CREEP (OFF or ON) Displays the current condition of super creep mode
TILT (XX.XX) DEG Displays the measured vehicle combined tilt
TILT X (X.X) Displays the measured vehicle tilt of the X axis
TILT Y (X.X) Displays the measured vehicle tilt of the Y axis
AUX POWER (CL or OP) Displays the status of auxiliary power switch
HORN (CL or OP) Displays status of horn switch
BASKET STOWED (YES or NO) Displays the status of the BASKET STOWED switch
SOFT LIMIT (CL or OP) Displays the OPEN or CLOSED condition of the soft touch limit switch
3121171 6-135

SOFT O/R (CL or OP) Displays the OPEN or CLOSED condition of the soft touch over ride switch
GENSET/WELDER (CL or OP) Displays the OPEN or CLOSED condition of the GENSET/WELDER switch
LIGHTS (CL or OP) Displays the OPEN or CLOSED condition of the LIGHTS switch
BSK TILT1 (X.X) Displays the status of basket tilt sensor #1
BSK TILT2 (X.X) Displays the status of basket tilt sensor #2
AXLE RET SW (CL or OP) Displays the OPEN or CLOSED condition of the axle retract switches
AXLE EXT SW (CL or OP) Displays the OPEN or CLOSED condition of the axle extend switches
AXLE LIM SW (RET or EXT) Displays the condition of the AXLE LIMIT SWITCH case
DOS LIM SW (CL or OP) Displays the OPEN or CLOSED condition of the drive orientation switch
CAPACITY SW (500 or 1000) Displays the status of the capacity switch
OSC AXLE P SW (CL or OP) Displays the condition of the axle pressure switch
SKY WELDER (YES or NO) Indicates if the accessory has been included in the boom sensor calibration
SKY CUTTER (YES or NO) Indicates if the accessory has been included in the boom sensor calibration
SKY GLAZIER (YES or NO) Indicates if the accessory has been included in the boom sensor calibration
SKY BRIGHT (YES or NO) Indicates if the accessory has been included in the boom sensor calibration
PIPE RACKS (YES or NO) Indicates if the accessory has been included in the boom sensor calibration
CAMERA MOUNT (YES or NO) Indicates if the accessory has been included in the boom sensor calibration
H OIL TEMP SW (CL or OP) Displays the status of the hot oil temperature switch
ML PILOT P SW (CL or OP) Displays the status of the main lift pilot pressure switch
TRANSPORT DATA:
TRANSPORT (YES or NO) Displays the status of the TRANSPORT case
LENGTH ZONE (A or B or C or d or ERR) Displays the status of the main boom length zone
ANGLE ZONE (1 or 2 or 3 or 4 or 5 or 6 or 7 or 8 or HI) Displays the status of the main boom angle zone
ABOVE ELEV. (YES or NO) Displays the current condition of the ABOVE ELEVATION case
TWR BOOM (OUT or IN) TRN Displays the tower status being within or outside of the transport case
TWR BOOM (EXT or RET) Displays the tower status
TWR BOOM (ABV or BLW) ELE Displays the tower status being above or below of the elevated case
MAIN BOOM (EXT or RET) Displays the main boom status
6-136 3121171

MAIN BOOM (ABV or BLW) ELE Displays the main boom status being above or below of the elevated case
MAIN TRN LENC (CL or OP) Displays the status of the normally open length switch
MAIN TRN LENO (CL or OP) Displays the status of the normally closed length switch
MAIN TRN LEN (A/D or B/C or DISAGREE) Displays the status of the combined length switches
DUAL CAP LENC (CL or OP) Displays the status of the normally open dual capacity switch
DUAL CAP LENO (CL or OP) Displays the status of the normally closed dual capacity switch
DUAL CAP LEN (A or A/B or B or B/C or C/D or D or FLT) Displays the status of the combined dual capacity switches
TWR TRN SW C (CL or OP) Displays the status of the normally open tower transport switch
TWR TRN SW O (CL or OP) Displays the status of the normally closed tower transport switch
TWR TRN SW (CL or OP or FLT) Displays the status of the combined tower transport switches
TWR TR ANG SW (CL or OP) Displays the status of the tower angle switch
MAIN TRN AGLC (CL or OP) Displays the status of the normally open main angle switch
MAIN TRN AGLO (CL or OP) Displays the status of the normally closed main angle switch
MAIN TRN AGL (CL or OP or FLT) Displays the status of the combined main angle switches
LOAD PIN:
MOMENT (XXXXXXX) Displays the calculated value of the moment pin
RATIO (XX.XXX) Displays the calculated value of the lift cylinder vector force ratio
ANGLE (XX.X) Displays the calculated angle of the vector force
V.F. (X) Displays the vector force applied to the moment pin
RAW MOMENT (XXXXXXX) Displays the raw data value of the moment pin
RAW RATIO (XX.XXX) Displays the raw value of the lift cylinder vector force ratio
RAW ANGLE (XX.X) Displays the raw angle of the vector force
RAW V.F. (X) Displays the raw data vector force applied to the moment pin
CAL PT ANGLE (XX.X) Displays the angle of the vector force applied to the moment pin during calibration
CAL PT VECTOR (X) Displays the vector force applied to the moment pin during calibration
CAL PT MOMENT (XXXXXXX) Displays the value of the moment pin recorded during calibration
E FLAGS (#X####) Displays error flags from the moment pin
X (XXX) Displays the calculated horizontal force applied to the moment pin
Y (XXX) Displays the calculated vertical force applied to the moment pin
RAW X (XXX) Displays the horizontal force applied to the moment pin
RAW Y (XXX) Displays the calculated vertical force applied to the moment pin
3121171 6-137

ENVELOPE SENSORS:
TWR LEN1 (X.X)" Displays the measured value of tower length sensor #1
TWR LEN2 (X.X)" Displays the measured value of tower length sensor #2
TWR ANGL1 (XX.X) Displays the measured value of tower angle sensor #1
TWR ANGL2 (XX.X) Displays the measured value of tower angle sensor #2
CYL ANGL (XX.X) Displays the measured value of cylinder angle sensor #2
MN ANGL1 (XX.X) Displays the measured value of main angle sensor #1 to the tower
MN ANGL2 (XX.X) Displays the measured value of main angle sensor #2 to the tower
TO GRAV MN ANGL L (XXXX) Displays the measured value of lowest value main angle sensor to gravity
TO GRAV MN ANGL H (XXXX) Displays the measured value of largest value main angle sensor to gravity
A/D T LEN1 (X) Displays the analog to digital counts of tower length sensor #1
A/D T LEN2 (X) Displays the analog to digital counts of tower length sensor #2
A/D ANG1 (XX.X) Displays the analog to digital counts of tower angle sensor #1
A/D ANG2 (XX.X) Displays the analog to digital counts of tower angle sensor #2
A/D CYL (X) Displays the analog to digital counts of cylinder angle sensor
MN ANG A/D SNSR1 (XXXX) Displays the analog to digital counts of main angle sensor #1
MN ANG A/D SNSR2 (XXXX) Displays the analog to digital counts of main angle sensor #2
MN ANG RAW SNSR1 (X.X) Displays the raw value of main angle sensor #1
MN ANG RAW SNSR2 (X.X) Displays the raw value of main angle sensor #2
RET LEN 1 (X) displays the retracted length of the tower found by sensor #1 during calibration
RET LEN 2 (X) displays the retracted length of the tower found by sensor #2 during calibration
EXT LEN 1 (X) displays the extended length of the tower found by sensor #1 during calibration
EXT LEN 2 (X) displays the extended length of the tower found by sensor #2 during calibration
TRIP LEN (XXXX.X) Displays the length of the tower recorded at the transport trip point during calibra-
tion
TA1 CAL L (X.X) Displays the lowest tower angle #1 value recorded during calibration
TA2 CAL L (X.X) Displays the lowest tower angle #2 value recorded during calibration
TA1 CAL H (X.X) Displays the highest tower angle #1 value recorded during calibration
TA2 CAL H (X.X) Displays the highest tower angle #2 value recorded during calibration
CYL CAL L (X) Displays the lowest cylinder angle value recorded during calibration
CYL CAL H (X) Displays the highest cylinder angle value recorded during calibration
6-138 3121171

MA1 CAL L (X) Displays the lowest main angle #1 value recorded during calibration
MA2 CAL L (X) Displays the lowest main angle #2 value recorded during calibration
MA1 CAL H (X) Displays the highest main angle #1 value recorded during calibration
MA2 CAL H (X) Displays the highest main angle #2 value recorded during calibration
TRIP ANG (X.X) Displays the length of the tower recorded at the transport trip point during calibra-
tion
TWR CYL: LONG Displays type of cylinder installed on machine

CALIBRATION DATA:
LOAD ZERO (X) Displays the value of the moment pin recorded during calibration
LOAD 500LB (X) Displays the value of the moment pin recorded during calibration
BASKET UP (X) Displays the value of the basket up crack point recorded during calibration
BASKET DOWN (X) Displays the value of the basket down crack point recorded during calibration
L FWD DRIVE (XXXX) Displays the value of the left forward drive crack point recorded during calibration
R FWD DRIVE (XXXX) Displays the value of the right forward drive crack point recorded during calibration
L REV DRIVE (XXXX) Displays the value of the left reverse drive crack point recorded during calibration
R REV DRIVE (XXXX) Displays the value of the right reverse drive crack point recorded during calibration
F LT STEER (XXXX) Displays the value of the front left steer crack point recorded during calibration
F RT STEER (XXXX) Displays the value of the front right steer crack point recorded during calibration
R LT STEER (XXXX) Displays the value of the rear left steer crack point recorded during calibration
R RT STEER (XXXX) Displays the value of the rear right steer crack point recorded during calibration
M LIFT UP (XXXX) Displays the value of the main lift up crack point recorded during calibration
M LIFT DOWN (XXXX) Displays the value of the main lift down crack point recorded during calibration
M TELE IN (XXXX) Displays the value of the main telescope in crack point recorded during calibration
M TELE OUT (XXXX) Displays the value of the main telescope out crack point recorded during calibration
BM ANG 1 LO (X) Displays the low value boom angle recorded from sensor 1 during calibration
BM ANG 1 HI (X) Displays the high value boom angle recorded from sensor 1 during calibration
BM ANG 2 LO (X) Displays the low value boom angle recorded from sensor 2 during calibration
BM ANG 2 HI (X) Displays the high value boom angle recorded from sensor 2 during calibration
LEN RETRACT (XXXX) Displays minimum tower length recorded during calibration
LEN WIT (XXXX) Displays the recorded value of tower length at the witness mark found during calibra-
tion
LEN SWITCH (XXXX) Displays the recorded value of tower length at the transport switch found during cal-
ibration
3121171 6-139
Figure 6-17. CANbus Connections Diagram
6.17 CANBUS TROUBLESHOOTING

The PLATFORM MODULE and the CHASSIS MODULE have ”Ter-
minator Resistors” located inside the modules, these resistors
squelch high speed signal reflections in the CANbus transmis-
sion lines. The value of the terminators is determined by wire
properties, this includes the type of insulation and geometry,
combined to determine the perfect value for bus termination.
Improper values or missing terminators allow bus ringing. A
complete CANbus circuit (wired in parallel) is approximately
60 Ohms at the ”T” fitting inside the Ground Station or at the
Boom Length & Angle Module. Each individual circuit from
their respective Module should read approximately 120 Ohm.
For CANbus connections, refer to Figure 6-17., Figure 6-18.,
Figure 6-19., Figure 6-20., and Figure 6-21.
6-140 3121171
A B
PLATFORM MODULE
CANbus Link
C
Figure 6-18. CANbus Connections - Sheet 1 of 4
3121171 6-141
Remove Ground Module J7 plug

and measure the A & B pin of the T
Boom Length &
fitting. This should measure
Angle Module
approximately 60 Ohms for a com-
CANbus Link
plete CANbus Circuit.
Ground Module J7 Platform Module J7

(Black) plug (Black) plug
6-142 3121171
"BEFORE" Slip Ring

Connection
"AFTER" Slip Ring

Connection
3121171 6-143
Chassis Module J1
(Gray) Plug
Chassis Module
CANbus Link
6-144 3121171
Figure 6-22. CANbus Circuit
3121171 6-145
CANbus Communication Failure 4. The analyzer screen should read:
If a problem in the CANbus system is suspected, use the fol-

lowing step-by-step procedure to verify which part of the
CANbus communication system has failed.
CANBUS LINK FROM THE PLATFORM MODULE LOST

Ground position.
5. Press enter twice to reach Logged Help. The screen will

2. Plug the analyzer into the connector inside the Ground read:
control box.
6. Hit ESC to get back to the HELP screen and then use the
arrow button to reach VERSIONS. Hit Enter.
6-146 3121171
7. If the CANbus link from the platform module is lost, you 8. Hit the right arrow button once. The screen will read:
will see the Ground Module SW version, Ground Module
HW version, Ground Module SN, BM SW version, Chassis
SW version, Platform Module SN, but you will not see the
Platform Module SW version or the Platform Module HW
version. The Analyzer screen will read:
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 Plat-
form Module Link only is affected, this means the commu-
nication link between the Platform Module down to the
Chassis Module has been broken, therefore all Canbus links
have to be checked. Remember this link is wired in parallel,
so the Ground Module has lost all MSA communication.
3121171 6-147
Table 6-13. Troubleshooting: Platform Can Communications Lost
STEP ACTION REQUIRED SPEC YES NO

1 Install the Analyzer at the ground station, See Diagnostics / Version See step 2 See step 2
scroll to the ”Diagnostics” sub level menu, Chart
press ”enter” then scroll to the ”Versions”
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 CAN-
bus links check OK.
2 Disconnect the Ground Module J7 deutsche Approximately 60 ohms. CANbus circuit is Reconnect plug and go
plug connection at the "T" fitting inside of complete. Platform to step 3
the ground control station. Perform an ohms Module suspected
check at the ”A” and ”B” pins of the "T" fitting. defective
Inspect the shield wire ”C” for shorts.
3 Make sure the CANbus link wires are See Electrical Schematic in Go to step 4 Wire per Electrical
installed correctly at the Platform Module. Section 7 Schematic
4 Disconnect the platform cannon plug and Continuity Reconnect plug and go Repair or replace plat-
ground cannon plug that holds the CANbus to step 5 form harness.
link. Red (3) Black (2) and Shield (1) perform a
continuity test.
5 Disconnect the deutsche plug connection Approximately 120 ohms. Reconnect plug and go Suspected defective
from the Platform Module at the ”T” fitting to step 6 Platform Module.
inside of the ground station. Perform an
ohms check at the ”A” and ”B” sockets of the
deutsche plug. Inspect the shield wire ”C” for
shorts.
6 Inspect the Platform Module harness con- Continuity Reconnect harness and Repair or replace har-
nection at the ground cannon plug and at go to step 7 ness inside the ground
the ”T”’ fitting inside of the ground control control station.
station.
7 Disconnect the deutsche plug connection Approximately 120 ohms Reconnect plug and go Verify step 7, inspect
from the Boom Length & Angle Module at to step 8 the BLAM to Ground
the ”T’ fitting inside of the ground station. Module harness con-
Perform an ohms check at the ”A” and ”B” nection s at both ”T" fit-
sockets of the deutsche plug. Inspect the ting connections for
shield wire ”C” for shorts. proper continuity and
correct wiring per Elec-
trical schematic.
8 Disconnect all deutsche plug connections at Continuity (NO OHM VAL- Reconnect all deutsche Replace defective ”T"
the "T” fitting in the ground station and the UES) plugs at the "T” fitting fitting plug.
BLAM, perform a continuity test on all ”A” ”B” and go to step 9
and ”C” pins use the singular end of the fit-
ting and cross probe the corresponding let-
ters of the other two connections.
6-148 3121171
Table 6-13. Troubleshooting: Platform Can Communications Lost

9 Disconnect the Chassis Module deutsche Approximately 120 ohms Reconnect deutsche Inspect the harness
plug at the ”T’ fitting below the Boom plug and go to step 10 from the ”T” fitting at
Length & Angle Module. Perform an ohms the BLAM to the Chas-
check at the ”A” and ”B” sockets of the sis Module plug con-
deutsche plug. Inspect the shield wire ”C” for nection at the battery.
shorts. Assure proper continu-
ity and correct wiring
per Electrical Sche-
matic.
10 Disconnect the Chassis Module connection Approximately 120 ohms Reconnect plug and go Inspect the harness
at the right side of the battery at the turnta- to step 11 from the slip ring con-
ble lock pin. Perform an ohms check at the #1 nections at the top and
and #2 connections of the plug. Inspect bottom plug connec-
shield wire #3 for possible short. tions of the swivel.
Assure proper continu-
ity and correct wiring
per Electrical Sche-
matic.
11 Disconnect the Chassis Module connection Approximately 120 ohms Reconnect plug and go Inspect the harness
below the swivel under the machine. Per- to step 12 from the bottom of the
form an ohms check at the #1 and #2 connec- swivel into the Chassis
tions of the plug that is routed to the Chassis Module. Assure proper
Module. Inspect shield wire #3 for possible continuity and wiring r
short. schematic 1870149A.
12 Make sure the Chassis Module CANbus link Electrical Schematic Stop Replace the Chassis
wires are installed correctly at the plug near Module.
the battery, the plug below the swivel and 31
plug at the Chassis Module.
3121171 6-149
CANBUS LINK FROM THE GROUND MODULE LOST 4. The analyzer screen should read:
Ground position.

control box.

read:
6-150 3121171
7. If the CANbus link from the ground module is lost, you 8. Hit the right arrow button once. The screen will read:
will see the Ground Module SW version, Ground Module
HW version, Ground Module SN, BM SW version, Chassis
SW version, Platform Module SN, but you will not see the
Platform Module SW version or the Platform Module HW
version. The Analyzer screen will read:
3121171 6-151
CANBUS LINK FROM THE BOOM LENGTH & ANGLE 4. The analyzer screen should read:
MODULE (BLAM) LOST
Ground position.

control box.

read:
6-152 3121171
7. If the CANbus link from the Boom Length & Angle Mod- TROUBLESHOOTING: BLAM CAN COMMUNICATIONS LOST
ule is lost, you will see the Platform Module SW version,
Platform Module HW Rev, Platform Module SN, Ground NOTE: BLAM CAN COMMUNICATIONS LOST (6/6) (Help Fault Code
Module SW version, Ground Module HW Revision, 6-6) basically means all communication linked from the
Ground Module SN, Chassis SW version, but you will not Ground Module to the Boom Length &: Angle Module is
see the Boom Length & Angle Module SW revision. The lost. This also includes the lift cylinder load moment pin as
Analyzer screen will read: well.
3121171 6-153
Table 6-14. Troubleshooting: BLAM Can Communications Lost

bus links check OK.
2 Disconnect the BLAM J 1 deutsche plug con- Approximately 60 ohms. CANbus circuit is com- Reconnect plug and go
nection at the "T” fitting just above the fuel plete. to step 3
tank. Perform an ohms check at the ”A” and BLAM suspected defec-
”B” pins of the "T” fitting. Inspect the shield tive.
wire ”C” for possible short.
3 Disconnect the Ground Module deutsche Approximately 120 Ohms Reconnect harness and Repair or replace the
plug from ”T” fitting at the BLAM above the go to step 4 Ground Module to
fuel tank. Perform an ohm check at the ”A” BLAM harness.
and ”B” sockets of the deutsche plug. Inspect
the shield wire ”C ” for possible short.
4 Verify the CANbus link signal wires are Electrical Schematic Reconnect plug and go Wire per Electrical
installed correctly at the "T” fitting at the to step 5 Schematic
Ground Module.
5 Verify the lift cylinder load moment harness Continuity Reconnect plug and go Repair or replace Chas-
has good continuity and wired correctly at to step 6 sis Module harness.
the J4 plug on the BLAM.
6 Disconnect the Chassis Module plug con- Approximately l 20 Ohms Reconnect plug and Inspect harness and
nection at the battery and perform an ohm stop connections to the
check at the #1 and #2 socket of the deutsche Chassis Module.
plug. Inspect the shield wire #3 for possible
short.
6-154 3121171
CANBUS LINK FROM THE CHASSIS MODULE LOST 4. The analyzer screen should read:
Ground position.

control box.

read:
3121171 6-155
7. If the CANbus link from the Chassis Module is lost, you 9. Hit the right arrow button once. The screen will read:
will NOT see the Platform Module SW version, Platform
Module HW rev, Platform Module SN, Chassis SW ver-
sion, Boom Length & Angle Module SW version, but you
WILL see the Ground Module SW version, Ground Mod-
ule HW rev, and the Ground Module SN. The analyzer
screen will read:
10. Hit the right arrow button once. The screen will read:
8. Hit the right arrow button once. The screen will read:
6-156 3121171
11. Hit the right arrow button once. The screen will read: TROUBLESHOOTING: CHASSIS CAN COMMUNICATIONS
LOST
NOTE: CHASSIS CAN COMMUNICATIONS LOST (6/6) (Help Fault

Code 6-6) basically means all communication linked from
the Ground Module to the Chassis Module is lost.
3121171 6-157
Table 6-15. Troubleshooting: Chassis Can Communications Lost

bus links check OK.
2 Disconnect the BLAM J1 deutsche plug con- Approximately 60 ohms. CANbus circuit is com- Reconnect plug and go
nection at the "T" fitting just above the fuel plete. Chassis Module to step 3
tank. Perform an ohms check at the ”A” and suspected defective.
”B” pins of the ”T” fitting. Inspect the shield
wire ”C” for possible short.
3 Disconnect the Chassis Module communi- Continuity Reconnect harness and Repair or replace BLAM
cation harness from the BLAM ”T” fitting and go to step 4 and Chassis Module
Chassis Module plug connection at the bat- harness.
tery. Perform a continuity test.
4 Verify the CANbus link signal wires are Electrical Schematic Reconnect plug and go Wire per Electrical
installed correctly at the Chassis Module to step 6 Schematic
plug connection at the battery and at the
plug below the swivel.
5 Verify continuity at the Chassis Module har- Continuity Reconnect plug and go Repair or replace Chas-
ness from the plug connection at the battery to step 6 sis Module harness.
down to the plug connection below the
swivel.
6 Disconnect the Chassis Module plug con- Approximately 120 Ohms Stop Replace Chassis Mod-
nection below the swivel and perform an ule
ohms check at the #1 and #2 of the plug.
Inspect the shield wire #3 plug connection
for possible short.
6-158 3121171
Load Moment Pin Troubleshooting refer to Section 4 for information concerning replacement of
the Load Moment Pin.
The following Troubleshooting Charts outline diagnostic mea-
sures to be taken to diagnose problems within the Load
Moment Pin portion of the JLG Control System. If necessary,
Table 6-16. Load Moment Pin Troubleshooting: Can Communications Lost
STEP FAULT CODE/SYMPTOM REPAIR YES NO

1 6/6 CYLINDER LOAD PIN CAN COMMUNICA- Check for correct and tight Go to step 2 Replace harness.
TIONS LOST wire connections at the (4922826)
deutsch and phoenix con-
nectors of the Load Sensing
Pin harness and perform a
continuity check.
2 Check for loose pins in the Replace the BLAM & Go to step 3
potting of the Boom Length Perform the Boom Sen-
& Angle Module J4 connec- sor calibration process.
tion.
3 Inspect the CANbus link ”T” Go to step 4 Replace ”T” fitting con-
fitting connections at the nector. (4460945)
BLAM & Ground Module. Are
the fittings dry?
4 Inspect the CANbus link ”T” Go to step 5 Replace ”T” fitting con-
fitting connections at the nector. (4460945)
BLAM & Ground Module. Per-
form a continuity check.
5 Check the J1 and J4 plug con- Go to step 6 Position plug correctly.
nections on the BLAM, make
sure the notched plugs line
up with the plug sockets cor-
rectly.
6 Use the Analyzer, scroll – + to Go to step 6 Replace the load
the DIAGNOSTICS menu, moment pin. & Perform
press ENTER, then scroll to the Boom Sensor cali-
the MOMENT menu, and bration process.
press ENTER, check to see i f
Actual / Over / Under
moment values are register-
ing on the screen display.
7 If they are, try boom sensor If the problem still Replace the load
calibration to see if the values exists, verify steps 1-7 moment pin. & Perform
come within the chart. again before contact- the Boom Sensor cali-
ing the JLG Service bration process.
Dept.
3121171 6-159
Table 6-17. Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range

1 8/6 MOMENT PIN HORIZONTAL FORCE OUT Check to see if the platform is Remove excess weight Go to step 2
OF RANGE The horizontal force is out of overloaded in the vertical
allowed range. position. Check the rated
capacity requirement.
2 Check to see if any additional Perform the Boom Sen- Go to step 3
accessories have been added sor calibration process.
to the platform without
proper calibration.
3 Perform the BCS daily check Go to step 4 Perform the Boom Sen-
procedure to make sure the sor calibration process.
boom sections are stopping
correctly at the witness
marks matching their capac-
ity selection.
4 Inspect the job the machine Go to step 5 Position machine cor-
is performing, making sure rectly.
that there is no additional
force applied when the
boom sections are in the hor-
izontal position. Also con-
sider weather conditions
(Wind).
5 Use the Analyzer, scroll to the Go to step 6 Replace the load
DIAGNOSTICS menu, press moment pin. & Perform
ENTER, then scroll to the the Boom Sensor cali-
MOMENT menu, and press bration process.
ENTER, check to see if Actual /
Over / Under moment values
are registering on the screen
display.
Dept.
6-160 3121171
Table 6-18. Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range

1 8/6 MOMENT PIN VERTICAL FORCE OUT OF Check to see if the platform is Remove excess weight Go to step 2
RANGE The vertical force is out of allowed overloaded in the vertical
range. position. Check the rated
capacity requirement.
2 Check to see if any additional Perform the Boom Sen- Go to step 3
accessories have been added sor calibration process.
to the platform without
proper calibration.
3 Perform the BCS daily check Go to step 4 Perform the Boom Sen-
procedure to make sure the sor calibration process.
boom sections are stopping
correctly at the witness
marks matching their capac-
ity selection.
4 Inspect the job the machine Go to step 5 Position machine cor-
is performing, making sure rectly.
that there is no additional
force applied when the
boom sections are in the hor-
izontal position. Also con-
sider weather conditions
(Wind).
5 Use the Analyzer, scroll to the Go to step 6 Replace the load
DIAGNOSTICS menu, press moment pin. & Perform
ENTER, then scroll to the the Boom Sensor cali-
MOMENT menu, and press bration process.
ENTER, check to see if Actual /
Over / Under moment values
are registering on the screen
display.
Dept.
3121171 6-161
NOTES:
6-162 3121171
SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 GENERAL or negative side of the signal and the lead on the other port
goes to the positive side of the signal.
This section contains basic electrical information and sche-
matics to be used for locating and correcting most of the oper- Scale
ating problems which may develop. If a problem should
develop which is not presented in this section or which is not M = Mega = 1,000,000 * (Displayed Number)
corrected by listed corrective actions, technically qualified k = kilo = 1,000 * (Displayed Number)
guidance should be obtained before proceeding with any
maintenance. m = milli = (Displayed Number) / 1,000
μ = micro = (Displayed Number) / 1,000,000
7.2 MULTIMETER BASICS
Example: 1.2 k = 1200 
A wide variety of multimeters or Volt Ohm Meters (VOM) can Example: 50 mA = 0.05 A
be used for troubleshooting your equipment. This section
shows diagrams of a common, digital VOM configured for sev- Voltage Measurement
eral different circuit measurements. Instructions for your VOM
may vary. Please consult the meter operator’s manual for more
information.
Grounding
"Grounding the meter" means to take the black lead (which is
connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the Voltage source.
Backprobing
To "backprobe" means to take the measurement by accessing
a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining cir-
cuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around
the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gen-
tle pull to ensure the wires are still attached to the contact and Figure 7-1. Voltage Measurement (DC)
contacts are seated in the connector.
• If meter is not auto ranging, set it to the correct range
Min/Max (See multimeter’s operation manual)
Use of the "Min/Max" recording feature of some meters can • Use firm contact with meter leads
help when taking measurements of intermittent conditions
while alone. For example, you can read the Voltage applied to
a solenoid when it is only operational while a switch, far from
the solenoid and meter, is held down.
Polarity
Getting a negative Voltage or current reading when expecting
a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and
that the leads are connected to the device under test correctly.
Also check that the lead on the "COM" port goes to the Ground
3121171 7-1
Resistance Measurement Continuity Measurement
Figure 7-3. Continuity Measurement
• Some meters require a separate button press to enable

audible continuity testing
• Circuit power must be turned OFF before testing conti-
Figure 7-2. Resistance Measurement nuity
• First test meter and leads by touching leads together. • Disconnect component from circuit before testing
Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads
tance)
• First test meter and leads by touching leads together.
• Circuit power must be turned OFF before testing resis-
Meter should produce an audible alarm, indicating
tance
continuity
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
7-2 3121171
Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND

TO ELECTRICAL CONNECTIONS
NOTE: Do NOT apply dielectric grease to the following connec-
tions:
• Main Boom Rotary sensor connections (on Celesco Sensor),

• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electrical
connections except for those mentioned above for the follow-
ing reasons:
• To prevent oxidation at the mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level con-
ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-
pound 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
Figure 7-4. Current Measurement (DC)
achieved by using a syringe.
• Set up the meter for the expected current range
NOTE: Over a period of time, oxidation increases electrical resis-
• Be sure to connect the meter leads to the correct jacks tance at the connection, eventually causing circuit failure.
for the current range you have selected
• If meter is not auto ranging, set it to the correct range 2. To prevent shorting, silicone grease must be packed
(See multi meter’s operation manual) around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
• Use firm contact with meter leads applied at the joint where the male and female connec-
tors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
should also be sealed.
NOTE: This condition is especially common when machines are

pressure washed since the washing solution is much more
conductive than water.
3. Anderson connectors for the battery boxes and battery

chargers should have silicone grease applied to the con-
tacts only.
NOTE: Curing-type sealants might also be used to prevent short-

ing and would be less messy, but would make future pin
removal more difficult.
3121171 7-3
7.4 DIELECTRIC GREASE APPLICATION AMP Faston

Dielectric grease helps to prevent corrosion of electrical This connector system is typically used on operator
contacts and improper conductivity between contacts switches at JLG. Follow the general guidance for installa-
from moisture intrusion. Non-waterproof connectors tion.
benefit from the application of dielectric grease.
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 hous- Improper Proper
ing which typically contains sockets contact/female
terminals.
AMP Micro-Fit
• Leave a layer of dielectric grease on the mating face of
the connector, completely covering each connector This connector system is typically used on control mod-
terminal hole. Refer the pictures shown below. ules at JLG. Follow the general guidance for installation.
• Assemble the connector system immediately to pre-
vent moisture ingress or dust contamination.
The following connector systems are specifically
addressed because of their widespread use at JLG. How-
ever, this guidance may be applied to similar devices.
AMP Mate-N-Lok
This connector system is widely used inside enclosures
for general-purpose interconnect. Follow the general Improper Proper
guidance for installation.
AMP Mini Fit Jr

This connector system is typically used on control mod-
ules at JLG. Follow the general guidance for installation.
Improper Proper
Improper Proper
7-4 3121171
Mini Fit Sr Enclosures

This connector system is typically used on control mod- Application of dielectric grease is not required in prop-
ules at JLG. Follow the general guidance for installation. erly 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.
Improper Proper
DIN Connectors
This connector is typically used on hydraulic valves. Fol-
low the installation instructions
Improper Proper
Exceptions
Some waterproof connector applications do benefit
from dielectric grease, and some non waterproof con-
nectors 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.
3121171 7-5
7.5 AMP CONNECTOR Check to be sure the wedge lock is in the open, or as-shipped,
position (See Figure 7-5.). Proceed as follows:
Applying Silicone Dielectric Compound to AMP
Connectors
Silicone Dielectric Compound must be used on the AMP con-
nections for the following reasons:
• To prevent oxidation at the mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level con-
ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-
pound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone
dielectric grease must be packed completely around
male and female pins on the inside of the connector
after the mating of the housing to the header. This is
easily achieved by using a syringe to fill the header with
silicone dielectric compound, to a point just above the
top of the male pins inside the header. When assem-
bling the housing to the header, it is possible that the Figure 7-5. Connector Assembly Figure 1
housing will become air locked, thus preventing the
housing latch from engaging.
1. To insert a contact, push it straight into the appropriate
2. Pierce one of the unused wire seals to allow the trapped circuit cavity as far as it will go (See Figure 7-7.).
air inside the housing to escape.
2. Pull back on the contact wire with a force of 1 or 2 lbs. to
3. Install a hole plug into this and/or any unused wire seal be sure the retention fingers are holding the contact
that has silicone dielectric compound escaping from it. (See Figure 7-7.).
Assembly
Figure 7-6. AMP Connector
7-6 3121171
Figure 7-7. Connector Assembly Figure 2
3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-9.).
Release the locking latches by squeezing them inward
(See Figure 7-8.).
3121171 7-7
Figure 7-10. Connector Disassembly
Disassembly Service - Voltage Reading

5. Insert a 4.8 mm (3/16") wide screwdriver blade between
the mating seal and one of the red wedge lock tabs.
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
6. Pry open the wedge lock to the open position.
7. While rotating the wire back and forth over a half turn It has been common practice in electrical troubleshooting to
(1/4 turn in each direction), gently pull the wire until the probe wires by piercing the insulation with a sharp point. This
contact is removed. practice should be discouraged when dealing with the
AMPSEAL plug assembly, or any other sealed connector sys-
NOTE: The wedge lock should never be removed from the housing tem. The resulting pinholes in the insulation will allow mois-
for insertion or removal of the contacts. ture to invade the system by traveling along the wire strands.
This nullifies the effectiveness of the connector seals and
Wedge Lock could result in system failure.
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.
7-8 3121171
Figure 7-11. Connector Installation
3121171 7-9
7.6 DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal
5. Remove wedgelock using needlenose pliers or a hook

1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.
barrel.
6. To remove the contacts, gently pull wire backwards,
2. Hold connector with rear grommet facing you. while at the same time releasing the locking finger by
3. Push contact straight into connector grommet until a moving it away from the contact with a screwdriver.
click is felt. A slight tug will confirm that it is properly 7. Hold the rear seal in place, as removing the contact may
locked in place. displace the seal.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
7-10 3121171
HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal
8. Grasp contact about 25mm behind the contact crimp

11. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
9. Hold connector with rear grommet facing you.
12. Slide tool along into the insert cavity until it engages
10. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm that it is
13. Pull contact-wire assembly out of connector.
properly locked in place.
Figure 7-17. HD/HDP Unlocking Contacts

Figure 7-15. HD/HDP Locking Contacts Into Position
NOTE: Do Not twist or insert tool at an angle.
NOTE: For unused wire cavities, insert sealing plugs for full envi-
ronmental sealing
3121171 7-11
7.7 TELEMATICS GATEWAY

Personnel using machines equipped with an optional telemat-
ics gateway will be able to view the following data through
their telematics device:
JLG LABEL DESCRIPTION UNIT

Engine Speed Actual engine speed. RPM
Indicates the level of DEF (diesel exhaust fluid) within the DEF tank if the machine is equipped with DEF tank.
DEF Tank Level (If Equipped) • 0% = Empty Percentage (%)
• 100% = Full
• 00 - No Machine Faults
JLG Machine Faults: • 01 - Active Machine Fault

Bit
Active / Not-Active • 10 - Error
• 11 - Not available
Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions. Liters
Total Idle Hours Total time of engine operation during idle conditions. Seconds
Total Engine Hours Total time of engine operation. Seconds
Total Fuel Used Total amount of fuel used during vehicle operation. Liters
Fuel Rate Amount of fuel consumed by engine per unit of time. Liters/Hour
Ratio of fuel volume to the total volume of the fuel storage container. When a low fuel limit switch is present, the fuel level
will indicate "full" until the switch opens, which will then indicate 10% fuel remaining.
Fuel Level Percentage (%)
When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents the total fuel in all fuel storage containers. When Fuel Level
2 is used, Fuel Level 1 represents the fuel level in the primary or left side fuel storage container.
DM1 Engine Faults Shows actual engine fault codes. N/A
GATEWAY MODULE
DIAGNOSTICS PLUG
Telematics-Ready (TCU) Plug
The telematics-ready (TCU) plug is a standard 12-pin Deutsch
connector. Pin-out locations are shown below:
12 1 - BATTERY
11 2 - GROUND
CAN-HI 2 - 10 3
CAN-LO 2 - 9 4 - IGNITION
8 5
7 6
TELEMATICS-READY PLUG
7-12 3121171
3121171 7-13
7-14
MS1619-3 MS1619-1
MS1619-2
X1609
MS1620-1
S1614
MS1618-2
S1615
MS1620-3
MS1620-2
MS1618-3
CO1613-J2
CO1613-J1
X1606
Figure 7-18. Telematics Gateway Harness - Sheet 1 of 3
3121171
X1609 (TCU) MS1620-3 (CAN-T 2)

CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
1 RED 1-0 BAT 16 AWG GXL X1606 (B) A YEL CANH2 18 AWG GXL CO1613-J2 (10)
2 BLK 0-0 GND 16 AWG GXL S1615 (1) B GRN CANL2 18 AWG GXL CO1613-J2 (9)
4 ORN 2-0 IGN 16 AWG GXL S1614 (1)

S1614
9 GRN CANL2 18 AWG GXL MS1619-2 (B)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
10 YEL CANH2 18 AWG GXL MS1619-2 (A)
1 ORN 2-0 IGN 16 AWG GXL X1609 (4)
MS1619-2 (CAN-T 2) 2 ORN 2-1 IGN 16 AWG GXL X1606 (H)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 2 ORN 2-2 IGN 16 AWG GXL CO1613-J1 (12)
A YEL CANH2 18 AWG GXL X1609 (10)
B GRN CANL2 18 AWG GXL X1609 (9)

S1615
MS1619-3 (CAN-T 2) 1 BLK 0-0 GND 16 AWG GXL X1609 (2)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 2 BLK 0-1 GND 16 AWG GXL X1606 (A)
A YEL CANH2 18 AWG GXL MS1620-2 (A) 2 BLK 0-2 GND 16 AWG GXL CO1613-J1 (11)
B GRN CANL2 18 AWG GXL MS1620-2 (B)
MS1618-2 (CAN-T 1)
CO1613-J1 (GATEWAY 1)
A YEL CANH1 18 AWG GXL CO1613-J1 (10)
9 GRN CAN1 18 AWG GXL MS1618-2 (B)
B GRN CANL1 18 AWG GXL CO1613-J1 (9)
11 BLK 0-2 GND 16 AWG GXL S1615 (2) MS1618-3 (CAN-T 1)

12 ORN 2-2 IGN 16 AWG GXL S1614 (2) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
A YEL CANH1 18 AWG GXL X1606 (C)

CO1613-J2 (GATEWAY 2)
B GRN CANL1 18 AWG GXL X1606 (D)
9 GRN CANL2 18 AWG GXL MS1620-3 (B) X1606 (DIAG)

A BLK 0-1 GND 16 AWG GXL S1615 (2)

MS1620-2 (CAN-T 2)
B RED 1-0 BAT 16 AWG GXL X1609 (1)
C YEL CANH1 18 AWG GXL MS1618-3 (A)
A YEL CANH2 18 AWG GXL MS1619-3 (A)
D GRN CANL1 18 AWG GXL MS1618-3 (B)
B GRN CANL2 18 AWG GXL MS1619-3 (B)
H ORN 2-1 IGN 16 AWG GXL S1614 (2)
3121171 7-15
FROM TO
WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE PIN REFERENCE PIN
CAN L2 GRN 18 AWG 1151 GXL MS1619-3 B MS1620-2 B
CAN L2 GRN 18 AWG 151 GXL X1609 9 MS1619-2 B
CAN L1 GRN 18 AWG 157 GXL MS1618-2 B CO1613-J1 9
CAN L2 GRN 18 AWG 225 GXL MS1620-3 B CO1613-J2 9
CAN L1 GRN 18 AWG 1076 GXL MS1618-3 B X1606 D
CAN H2 YEL 18 AWG 155 GXL X1609 10 MS1619-2 A
CAN H2 YEL 18 AWG 233 GXL MS1620-3 A CO1613-J2 10
CAN H1 YEL 18 AWG 157 GXL MS1618-2 A CO1613-J1 10
CAN H2 YEL 18 AWG 1150 GXL MS1619-3 A MS1620-2 A
CAN H1 YEL 18 AWG 1079 GXL MS1618-3 A X1606 C
0-0 GND BLK 16 AWG 1006 GXL X1609 2 S1615 1
0-1 GND BLK 16 AWG 1145 GXL X1606 A S1615 2
0-2 GND BLK 16 AWG 223 GXL CO1613-J1 11 S1615 2
1-0 BAT RED 16 AWG 2150 GXL X1609 1 X1606 B
2-0 IGN ORN 16 AWG 939 GXL X1609 4 S1614 1
2-1 IGN ORN 16 AWG 1212 GXL S1614 2 X1606 H
2-2 IGN ORN 16 AWG 287 GXL CO1613-J1 12 S1614 2
7-16 3121171
3121171 7-17
Figure 7-21. Wiring Harness Installation- Sheet 1 of 7
7-18 3121171
0274670 E
Figure 7-22. Wiring Harness Installation - Sheet 2 of 7
3121171 7-19
HOSE CARRIER WELDMENT

(BOLTED ON TURNTABLE)
TO BOOM
GENERATOR CONTROL BOX
ALTERNATOR OIL TEMP

SWITCH OIL ENGINE
PRESSURE TORQUE SPEED SENSOR
SWITCH CONTROL
HYDRAULIC PUMPS
DRIVE RIGHT DRIVE LEFT

SIDE REVERSE SIDE REVERSE
THROTTLE
ACTUATOR
4 PLS
1
DRIVE LEFT
DRIVE RIGHT SIDE FORWARD
SIDE FORWARD
IN HEAD TYPE
GLOW PLUGS
STARTER
GLOW PLUG
RELAY
DEUTZ EMR2 110V / 220V GENERATOR START RELAY
MODULE INTAKE TYPE
HEATERS
VALVE HARNESS
REF MAIN TERMINAL
BOX ASSEMBLY
HEADLIGHT
THERMOSTAT
MAIN LIFT SWITCH
ENABLE
B.L.A.M.
MODULE
J2 J5
J4 14 PLS
J1 J3
TOWER TELE MAIN LIFT PILOT

TOWER LIFT PRESSURE SWITCH
MAIN
DIAGNOSTIC CONTROL
CONNECTION VALVE
GROUND
CONTROL TOWER TELE PILOT
BOX TOWER LIFT PILOT
MAIN LIFT MAIN DUMP
2 PLS
SWING RIGHT
MAIN TELE PROP.
SWING LEFT
STROBE
ALARM CHASSIS
POWER
RELAY
HORN MAIN
PVG ENABLE TELE IN
AUX PUMP
HEADLIGHT MAIN TELE OUT
HEAD AUX POWER
AND RELAY
TAIL
LIGHT
RELAY
FUEL LEVEL
SENSOR
7-20 3121171
LEFT TOWER
ANGLE
SENSOR #2
TOWER LIFT CYLINDER

ANGLE SENSOR
ENGINE
SPEED SENSOR
HYDRAULIC PUMPS TOWER LIFT CYLINDER

PRESSURE SENSOR
DRIVE RIGHT DRIVE LEFT
SIDE REVERSE SIDE REVERSE
TOP TOWER LENGTH SENSOR #1
TOWER LIFT
4 PLS CYLINDER
LOAD PIN
DRIVE LEFT
SIDE FORWARD
DRIVE RIGHT
SIDE FORWARD
IN HEAD TYPE
GLOW PLUGS BOTTOM TOWER LENGTH SENSOR #2
GLOW PLUG
RELAY
START RELAY
INTAKE TYPE RIGHT TOWER
HEATERS ANGLE SENSOR #1
TAIL LIGHT
SWIVEL
THERMOSTAT
SWITCH
SEE SHEET 4
14 PLS
TOWER LIFT ENABLE

(LOCATED AGAINST
TT SIDESHEET)
TOWER TELE MAIN LIFT PILOT
TOWER LIFT PRESSURE SWITCH
TOWER TELE ENABLE

(STACKED ON TOP OF
TOWER LIFT ENABLE)
MAIN
CONTROL
VALVE
TOWER TELE PILOT TAIL LIGHT

TOWER LIFT PILOT
MAIN LIFT MAIN DUMP
ENGINE HARNESS
REF. MAIN TERMINAL BOX ASS'Y.
SWING RIGHT
MAIN TELE PROP.
SWING LEFT
= See Sheet 7
MAIN
PVG ENABLE TELE IN
MAIN TELE OUT
0274670 E
3121171 7-21
7-22 3121171
0274670 E
3121171 7-23
0274670 E
7-24 3121171
7.8 ELECTRICAL SCHEMATICS
SHEET 1: TABLE OF CONTENTS
SHEET 2: PLATFORM
SHEET 3: TOWER & MAIN BOOM
SHEET 4: GROUND CONTROL
SHEET 5: B.L.A.M.
SHEET 6: CHASSIS
SHEET 7: CAT ENGINE
SHEET 8: DEUTZ ENGINE
SHEET 9: DEUTZ TIER 4 FINAL ENGINE
SHEET 10: PLATFORM SENSOR / SOFT TOUCH

LOW TEMPERATURE CUTOUT OPTION
SHEET 11: CRIBBING HARNESS

ALERT BEACON OPTION
GEN 2 PLAT INTERFACE HARNESS
1001119861-O
SHEET 1 MAE37550O
Figure 7-28. Electrical Schematic - Sheet 1 of 21
3121171 7-25
8 7 6 5 4
ORN/RED 49-10 14 ORN/RED 49-12 2 JIB STOW LIMIT SWITCH

ZONE E2 WHITE
YEL/RED 2-11-1 1
LA
YEL/RED 2-11 13 YEL/RED 2-11
1 JIB INLINE LIMIT SWITCH
YEL/RED 2-11-2
H ORN/RED 49-12 21 ORN/RED 49-11 2
YEL/RED 2-12-1
YEL/RED 2-12-2
ORN/RED 49-80
ORN/RED 49-63
V REF. BASKET LEVEL SENSOR #1

25 17
26 7 1 RED 1 RED
19 2 BLUE 2 WHITE MOUNTED ON RIGHT
IN BROWN 13-1 5 21 ORN/RED 49-68 3 BLACK 3 BLACK SIDE OF BOOM
MAIN TELE OUT BROWN 14-1 6 BRAIDED SHIELD BLK (18)
G RIGHT GRAY 24-1 7
ROTATE
LEFT GRAY 23-1 8
UP PINK 25-1 9 4 BASKET LEVEL SENSOR #2
LEVEL
DOWN PINK 26-1 10
4 ORANGE 1 RED
UP BLUE 27-1 11 35
JIB 5 YELLOW 2 WHITE MOUNTED ON LEFT
DOWN BLUE 28-1 12
33 6 3 BLACK SIDE OF BOOM
ORN/RED 49-81 BLACK
33
Ref.V 4 RED/WHT 55-30 SEE SHEET 10 BRAIDED SHIELD BLK (18)
PUMP 34
POTENTIOMETER WIPER 19 ZONE E2 SEE SHEET 12
6 RED/WHT 55-31 35
10 OR ZONE D3
GND 5 BLACK 13
11 PINK 26-3-1
CREEP 3 2 ORN/RED 49-11 32
12 PINK 25-3-1
YEL/RED 2-10 18
13 RED/WHT 50-2-1
TAN 5-1 1
LEVEL 14 BLK P6
TAN 6-1 2 RED/WHT 50-2-3 5 RED/WHT 50-2-3 PLATFORM DUMP
SEE SHEET 12 OR SEE SHEET 10
ZONE G6
3 15 PINK 25-3-2 PINK 25-3-3 7 PINK 25-3-3 UP
ZONE D3 LEVEL
4
F YELLOW 55-16 16 16 PINK 26-3-2 PINK 26-3-3 6 PINK 26-3-3 DOWN
CRAB STEER
J1 (WHITE)
COORDINATED STEER YELLOW 55-17 17 5 GRAY 23-3 8 GRAY 23-3 LEFT

ROTATE
15 YEL/RED 2-37 20 6 GRAY 24-3 9 GRAY 24-3 RIGHT
500#
CAPACITY 21 25 BLUE 27-3 10 BLUE 27-3 UP
RED/YEL 54-1 JIB
1000# 26 BLUE 28-3 11 BLUE 28-3 DOWN
J7 (BLACK)
BOOM CTL SEL ORN/RED 49-120 22

27 WHITE 60-3 19 WHITE 60-3 RIGHT
JIB SWING
EXT YEL/WHT 43-1 23 28 WHITE 59-3 20 WHITE 59-3 LEFT
AXLE SET
RET YEL/WHT 44-1 24 29 BLACK 12 BLACK
START SWITCH WHT/YEL 48-1 14 2 PTF EMS
AUX POWER BRN/ORN 53-1 15 31 CAN HI RED (18)
ENGINE SPEED 28 30 CAN LO BLACK (18)
WHT/YEL 48-5
TWO SPEED ORN 55-46 27 32 CAN SHIELD
31 3 EMS PTF TO MTB
HORN BLU/ORN 52-1
SOFT TOUCH OVERIDE 1 GND MODE
E ORN/RED 49-40 29
HEAD/TAIL LIGHTS BLU/ORN 52-12 30 8 ORN/RED 49-70 7 BLACK
YEL/RED 2-16-2 8 WHITE
19 ORN/RED 49-4 SEE SHEET 12
ALARM
BLUE 20 BLACK ZONE D3
ZONE E2 SEE SHEET 10
18 ORN/RED 49-69 ZONE H8, F8
3 ORN/RED 49-69-1
9 BLU/ORN 52-4 1 BLU/ORN 52-4 GENERATOR
32 22
6 BRN/WHT 47-4 35 23
3 BRN/WHT 47-3 23 24
FULL
BLU/ORN 52-3
FUEL GAGE
J1 2 BRN/WHT 47-2 24 YEL/RED 2-16-3

3/4 34 6 YEL/RED 2-16-3-1
1 BRN/WHT 47-1 22
1/2 LB
1/4 4 BLACK 25
5 SOFT TOUCH ORN/RED 49-42 16
D 2
4
5 GND FROM GND MODULE
1
J8 (BLACK)
CREEP 1 ORN/RED 49-15 9 GND EMS

J2 (GRAY)
2
FOOTSWITCH/ENABLE 2 YEL/RED 2-21 7
J2
3 BRN/WHT 47-13 21
6 BLACK 18
BOOM CONTROL SYSTEM 1 ORN/RED 49-1000 19
AXLE SET 2 WHT/YEL 39-1 14

DRIVE ORIENTATION J3 3 ORANGE 55-51 30
453KG/1000# CAPACITY 4 RED/YEL 54-3-1 RED/YEL 54-3 13
BROKEN CABLE 5 ORN/RED 49-101 10
C SWING
SYSTEM DISTRESS 6 BRN/WHT 47-12 8
5K
8
AUTO LEVEL SYSTEM 1 BRN/WHT 47-10 20 6
GENERATOR ON 2 BLU/ORN 52-4-1 15 5
J5 (WHITE)
OVERLOAD J4 1
3 ORN/RED 49-100 11
4 PLATFORM SCH.
226KG/500# CAPACITY 4 RED/YEL 54-2 12
2
TILT 5 ORN/RED 49-3 6 LIFT
GLOW PLUG 6 WHT/YEL 48-6 17 5K = 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX
3
7 = 21 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX
= TERMINAL STRIP IN PLATFORM BOX
BLU/ORN 52-3 33 = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNESS DWG.)

31 8
LEFT = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK1 ON HARNESS DWG.)
5 STEER
B 1 ANALYZER POWER RED ORN/RED 49-92 26 6 RIGHT
11 ] ] = 6 POS. MATE-N-LOC IN MTB
J6 (BLACK)
2 ANALYZER RECEIVE GREEN 10 ORN/RED 49-91 28 4

3 ANALYZER TRANSMIT WHITE 9 ORN/RED 49-90 29 2 12 DEUTSCH 19 POS. TWIST LOCK IN MTB.
4 ANALYZER GROUND BLACK/SHIELD ORN/RED 49-89 1
8 27 DRIVE
3 A DEUTSCH 21 POS. TWIST LOCK IN MTB.
14 YEL/RED 2-36
2 7
LEFT WHITE 59-1 TO CHASSIS
JIB SWING YEL/RED 2-10-14 34
RIGHT
WHITE 60-1 1 TO BLAM THRU ENGINE HARNESS
ORANGE 55-50 4
DRIVE ORIENTATION OVERIDE TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS)
YEL/RED 2-16 3
YEL/RED 2-16-1
JIB STOW V BAT.

WHITE 59-60 5
YEL/RED 2-16-2 8
A
SEE SHEET 10
ZONE H8, F8
SHEET 2
8 7 6 5 4
7-26 3121171
5 4 3 2 1
ORN/RED 49-12 2 JIB STOW LIMIT SWITCH
YEL/RED 2-11-1 1 7 BROWN (18) 7

YEL/RED 2-11 9 RED/BLK 9
1 JIB INLINE LIMIT SWITCH
YEL/RED 2-11-2 5 BLUE (18) 5
ORN/RED 49-11 2 H
8 HOLE PLUG 8
BLK (12) 18 BLK/WHT (12) 18
BASKET LEVEL SENSOR #1
1 RED 1 RED
2 BLUE 2 WHITE MOUNTED ON RIGHT
3 BLACK 3 BLACK SIDE OF BOOM
SEE
BRAIDED SHIELD BLK (18) SHEET 3
BLU/ORN 52-11 15 YEL/BLK (18) 15 G
BASKET LEVEL SENSOR #2
1 PLATFORM
4 ORANGE RED
EMS YEL/RED
5 YELLOW 2 WHITE MOUNTED ON LEFT 13 ORN/BLK (18) 13
2-5
6 3 BLACK SIDE OF BOOM
BLACK
YEL/RED
BRAIDED SHIELD BLK (18) 10 ORANGE (12) 10
2-2(12)
RED (18) 1
RED (18) 2
11
BLACK 12
RED/WHT 50-2-1
BLACK (18) 3
RED/WHT 50-2-3 5 RED/WHT 50-2-3 PLATFORM DUMP
BLACK (18) 4 MS509
PINK 25-3-3 7 PINK 25-3-3 UP
LEVEL CANBUS
9
PINK 26-3-3 6 PINK 26-3-3 DOWN
GRAY F
YEL/RED 2-3(16)
10
8 GRAY 23-3 LEFT SHIELD (18) 5
ROTATE
9 GRAY 24-3 RIGHT SHIELD (18) 6
10 BLUE 27-3 UP 7
JIB
11 BLUE 28-3 DOWN 8
19 WHITE 60-3 RIGHT
JIB SWING X1001
20 WHITE 59-3 LEFT GRAY 5
12 BLACK
BLACK 4
X1002
ZONE E8 BLUE 3 CO99
WHITE LSS
RED (18) A 3 RED (18) 3 ZONE H7 2
BLACK (18) B 2 BLACK (18) 2 1
C 1 SHIELD 1
output YEL/RED 2-3-1 4 ORANGE (18) 4
YEL/RED 2-30-1
E
7 BLACK FOOTSWITCH
YEL/RED 2-16-2 8 WHITE GREEN 6 YELLOW (18) 6
ALARM SEE SHEET 12

ZONE D3
SEE SHEET 10
ZONE H8, F8
ORN/RED 49-69-1
BLU/ORN 52-4 GENERATOR
BLU/ORN 52-3
YEL/RED 2-16-3 YEL/RED 2-16-3-1 SEE SHEET 12

6 11 BLU/BLK (18) 11
ZONE D3
14 HOLE PLUG 14
17 HOLE PLUG 17
19 HOLE PLUG 19
2
D
BLACK (12) 16 BLACK (12) 16
YEL/RED 2-1-2 (12) 12 RED (12) 12
PLATFORM WORK LIGHTS OPTION #1

GREEN
CONNECT TO
RED BATTERY PLUS AT
BLACK RED AUXILIARY POWER
20 AMP PUMP MOTOR RELAY
10/3
BLACK
RED
BLACK
GREEN C
PLATFORM WORK LIGHTS OPTION #2
GREEN
CONNECT TO
RED BATTERY PLUS AT
BLACK RED AUXILIARY POWER
14 GA FUSE LINK
PLATFORM SCH. PUMP MOTOR RELAY
10/3
BLACK
RED
= 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX BLACK 15 AMP
= 21 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX GREEN
= 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNESS DWG.)

B
] ] = 6 POS. MATE-N-LOC IN MTB
12 DEUTSCH 19 POS. TWIST LOCK IN MTB.
A DEUTSCH 21 POS. TWIST LOCK IN MTB.
TO CHASSIS
TO BLAM THRU ENGINE HARNESS
TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS)
SHEET 2 1001119861-O
5 4 3 2 1
MAE36290O
3121171 7-27
8 7 6 5 4
4 ORANGE (18) 4 ORANGE (18)

5 BLUE (18) 5 BLUE (18)
H 6 YELLOW (18) 6 YELLOW (18)
7 BROWN (18) 7 BROWN (18)
8 HOLE PLUG 8
9 RED/BLK 9 RED/BLK
10 ORANGE (12) 10 ORANGE (12)
11 BLU/BLK 11 BLU/BLK
SEE 12 RED (12) 12 RED (12)
SHEET 2
13 ORN/BLK (18) 13 ORN/BLK (18)
14 HOLE PLUG 14
15 YEL/BLK(18) 15 YEL/BLK(18)
16 BLACK (12) 16 BLACK (12)

G
17 HOLE PLUG 17
18 BLK/WHT (12) 18 BLK/WHT (12)
19 HOLE PLUG 19
3 RED (18) 3 RED (18)

2 BLACK (18) 2 BLACK (18)
1 SHIELD 1 SHIELD
SHIELD
SHIELD
BLACK
BLACK
RED
RED
4 BLACK (CAN H)
5 GRAY (CAN L)
#1 RIGHT SIDE MAIN
BOOM ANGLE SENSOR 1 BROWN (SHIELD)
2 WHITE (POWER)
3 BLUE (GROUND)
4 BLACK (CAN H)
5 GRAY (CAN L)
#2 LEFT SIDE MAIN 1 BROWN (SHIELD)
BOOM ANGLE SENSOR
E 2 WHITE (POWER)
3 BLUE (GROUND)
#1 DUAL CAPACITY LIMIT SWITCH, MOUNTED ON LEFT SIDE OF BLK

BOOM (TOP SWITCH). THIS SWITCH IS IN THE N.C. POSITION 21 22
WHEN THE MAIN BOOM IS FULLY RETRACTED. WHT BLU/BLK B BLU/BLK 49-130
RED RED A YEL/RED 2-70-7

#2 DUAL CAPACITY LIMIT SWITCH, MOUNTED ON LEFT SIDE OF BLK ORN C ORN 49-131
D BOOM (BOTTOM SWITCH). THIS SWITCH IS OPEN 22 21
WHEN THE MAIN BOOM IS FULLY RETRACTED. WHT
BLK
#1 MAIN BOOM TRANSPORT LIMIT SWITCH, MOUNTED ON THE RIGHT 21 22
SIDE OF MAIN BOOM (TOP SWITCH) THIS SWITCH IS IN THE N.C. WHT BLU B BLU 49-120
POSITION WHEN THE MAIN BOOM IS FULLY RETRACTED. A
RED RED YEL/RED 2-70-8
BLK BRN C BRN 49-121
#2 MAIN BOOM TRANSPORT LIMIT SWITCH, MOUNTED ON THE RIGHT 22 21
SIDE OF MAIN BOOM (BOTTOM SWITCH) THIS SWITCH IS OPEN
WHEN THE MAIN BOOM IS FULLY RETRACTED. WHT
MAIN BOOM ANGLE LIMIT SWITCH
ORN/RED 49-123 N
YEL/RED 2-70-5 B
14 13
MAIN BOOM TRANSPORT
C ANGLE LIMIT SWITCH
21
22
ORN/RED 49-122 R
WHICHEVER IS PRESENT
(EARLY MACHINES HAD LIMIT SWITCH)
BRN (22) 1 YEL/RED 2-70-9 B
MAIN BOOM TRANSPORT WHT (22) 4 ORN/BLK 49-123 N

ANGLE PROXIMITY SENSOR 2 YEL/BLK 49-122 R
BLK (22)
BLUE (22) 3 BLACK E
= 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX


A
TO CHASSIS
SHEET 3
8 7 6 5 4
7-28 3121171
5 4 3 2 1
4 ORANGE (18) 4
5 BLUE (18) 5
6 YELLOW (18) 6
H
7 BROWN (18) 7
8 HOLE PLUG 8
9 RED/BLK (18) 9
10 ORANGE (12) 10
11 BLU/BLK 11
12 RED (12) 12
13 ORN/BLK(18) 13
STROBE LIGHT
14 HOLE PLUG 14
15 YEL/BLK(18) 15 BLU/ORN 52-11 1
16 BLACK (12) 16 2
G
HOLE PLUG 17
18 BLK/WHT (12) 18
HOLE PLUG 19
3 RED (18) 3
2 BLACK (18) 2
1 SHIELD 1
F
BLACK
SHIELD
BLACK
RED
RED
SHIELD
4 BLACK (CAN H)
5 GRAY (CAN L)
#1 RIGHT SIDE MAIN BLACK (14) E BLACK (12) E
BOOM ANGLE SENSOR 1 BROWN (SHIELD)
2 WHITE (POWER) WHT/RED 57-11 J RED/BLK J
3 BLUE (GROUND)
4 BLACK (CAN H)
5 GRAY (CAN L)
#2 LEFT SIDE MAIN 1 BROWN (SHIELD)
BOOM ANGLE SENSOR
2 WHITE (POWER) WHT/RED 57-10 K YELLOW K E
3 BLUE (GROUND)
BLK/WHT (12) G BLK/WHT (12) G
HOLE PLUG H
CAPPED & STOWED HOLE PLUG P

IN HARNESS
HOLE PLUG V
HOLE PLUG W
HOLE PLUG X
RED (12) D RED (12) D
BLK C RED C
RED
21 22 B BLU/BLK 49-130 L
WHT BLU/BLK L BLU/BLK
BLK ORN C ORN 49-131 M ORANGE (18) M
22 21 D
WHT BLACK
BLACK F F
BLK
21 22 S
WHT BLU B BLU 49-120 S BLUE
BLK BRN C BRN 49-121 U BROWN U
22 21
WHT ORN (12) 2-70-5 B ORANGE (12) B
A SHIELD A
N ORN/BLK(18) N
ORN/RED 49-123 N
YEL/RED 2-70-5 B
14 13
R YEL/BLK(18) R
21
C
22
ORN/RED 49-122 R T HOLE PLUG T
BRN (22) 1 YEL/RED 2-70-9 B 14

13
WHT (22) 4 ORN/BLK 49-123 N WHITE ]1]

TOWER BOOM TRANSPORT LIMIT SWITCH 21 22
BLK (22) 2 YEL/BLK 49-122 R ]2]
BLACK
RED ]6]
BLUE (22) 3 BLACK E
B
TOWER & MAIN BOOM SCH.


A
TO CHASSIS
SHEET 3 1001119861-O
5 4 3 2 1
MAE36300O
3121171 7-29
8 7 6 5 4
18
TO BATTERY NEG.
KEYSWITCH
13 YEL/RED 2-5 2 B1
YEL/RED 2-4 (12)
B YEL/RED 2-70-5 (14) 4
10 YEL/RED 2-2 (12) 1
3 B2 YEL/RED 2-1 (12)
YEL/RED 2-30
H
BLACK
GROUND CONTROL BOX
YEL/RED 2-1-1(12)
YEL/RED 2-30-4
4 YEL/RED 2-3-1
9
7 POWER DOWN
RELAY
5
RIGHT GRAY 23-2 TO BLAM 7
ROTATE
LEFT GRAY 24-2 TO BLAM 8 87 87a
ORN/RED 49-102 TO BLAM 9 86 85
30 YEL/RED 2-1-3 (12)
24 HORN GND
17
IN BROWN 13-2 7
MAIN TELE 2 BLU/ORN 52-2 HORN OUTPUT
OUT BROWN 14-2 30
20
M ORN/RED 49-131 6 22
L ORN/RED 49-130 18 RED/WHT 50-2-1
4000 W GENERATOR
3
UP PINK 25-2 17
G LEVEL
DOWN
7 PINK 26-3-1
PINK 26-2 5 5 PINK 25-3-1
START SWITCH WHT/YEL 48-1 4
AUX POWER 14
BRN/ORN 53-2 16
JIB UP BLUE 27-2 19
DOWN 27 BLU/ORN 52-10
BLUE 28-2 8 ALARM
MAIN LIFT UP TAN 3-2 23 HEAD/TAIL LIGHT
DOWN TAN 4-2 J4 87
33 (BLUE) 87a
SWING RIGHT WHITE 22-2 35 26 BLU/ORN 52-12 86 85
LEFT WHITE 21-2 34 18 30
RIGHT WHITE 60-2 20 24 RED 1-1 (12) SEE SHEET 5, ZONE B3
JIB SWING SEE SHEET 6, ZONE B6
LEFT 28
BLACK
WHITE 59-2 9
UP TAN 5-2 10 25 BRN/WHT 47-12 FUEL SENSOR (SIGNAL)
TOWER LIFT
DOWN TAN 6-2 21 6 BLACK SENSOR (GROUND)
YEL/RED 2-40-1 25 13 RED/WHT 50-1 MAIN DUMP
31 RED/WHT 50-2 PVG ENABLE
32 TELE. FLOW CONTROL
F HOURMETER 9 BROWN 55-60
BRN/WHT 47-11-1 12 4 BROWN 13-3 IN
BLACK (10)
MAIN TELE.
ENGINE LOW OIL PRESSURE 16 BROWN 14-3 OUT
BRN/WHT 47-5-1 29
J2 (GRAY)
23 TAN 55-21 MAIN LIFT ENABLE
BLACK
ENGINE HIGH TEMPERATURE BRN/WHT 47-6-1 28 33 TAN 55-31 TOWER LIFT ENABLE
NO CHARGE MAIN LIFT PILOT
BRN/WHT 47-8-3 26 1 TAN 55-22
GLOW PLUGS 12 TAN 55-32 TOWER LIFT PILOT
WHT/YEL 48-6 15
32 BROWN 55-10 TOWER TELE. PILOT
MOMENT CONTROL TEST ORN/RED 49-103 13 35 WHITE 22-3 RIGHT
SWING
AXLES SET WHT/YEL 39-1-1 1 34 WHITE 21-3 LEFT
SEE
PLATFORM OVERLOAD ORN/RED 49-100 14 19 SHEET 7, ZONE C8
500# CAP SHEET 8, ZONE D4
RED/YEL 54-2-1 2 21 WHT/RED 57-11 K
1000# CAP
RED/YEL 54-3-1 27 10 WHT/RED 57-10 J
11 TAN 55-50 TO BLAM MAIN LIFT POWER
BOOM SYSTEM CONTROL ORN/RED 49-101 3
8 BROWN 55-50 TO BLAM TOWER TELE. POWER
E BLACK 31
15 ORN/RED 49-301
N ORN/RED 49-123 11 30 BLACK
R ORN/RED 49-122 22 29 BLACK
J8
GND FROM BATTERY (BLACK)
1
MTB EMS input 2
BLACK (12) GND TO PLATFORM 3 11 WHT/YEL 48-3
16
MTB EMS TO PLATFORM 12 WHT/YEL 48-9
12 YEL/RED 2-1-2(12) 4
8 BLACK (16)
5
YEL/RED 2-3-2 1 TOWER LIFT POWER
3 TAN 55-51
YEL/RED 2-2-1 2 19
20
10 YEL/RED 2-1-88
FOOTSWITCH 15 9
6 YEL/RED 2-21
D MTB MODE SELECT
YEL/RED 2-30 3 30
29
MTB MODE OUTPUT
11 YEL/RED 2-30-1 14
28
YEL/RED 2-40-11 23 20 ORANGE 55-47 6
26 ORANGE 55-45 7
23
RED 9 31
RED 16
ANALOG PWR-A 10
YEL/RED 2-70 (14)
BLUE 18 BLACK (16)

PRESSURE SIG-B 31 BLACK
SENSOR BLACK 4
GND-C CANNOT BE USED 17 J7 24 YEL/RED 20-70-1
CANNOT BE USED 6 (BLACK)
27 6 BROWN 55-1 TOWER TELE. ENABLE
TO BLAM 5 ORN/RED 49-200 22 1
34 2
BLUE
BROWN 4
J1 (WHITE)
35 BRN/WHT 48-1
19 HYD OIL TEMP.
BLACK 25 SENDOR
C YEL/RED 2-61 32 14
]1] YEL/RED 2-60 29 15
]3] 33
22 BLU/ORN 52-5
]2] ORN/RED 49-64 11
YEL/RED 2-20
16
]6] ORN/RED 49-65 35
7 WHT/YEL 48-15
YEL/RED 2-1-99
YEL/RED 2-70-2 (14)
YEL/RED 2-70-3 (14)
]5] 25
CRIBBING OPTION
{ SEE SHEET 11, ZONE G2
SEE SHEET 11, ZONE G2
RED 118
7
30
21
26
TAN 55-23 MAIN LIFT
PILOT PRESSURE
27 ORN 100-1 SEE
3 RED(18) A A RED A A RED 13 SHEET 7, ZONE B3
17
2 BLACK B B B B BLACK 24 34 SHEET 8, ZONE B4
BLACK
1 SHIELD C C SHIELD C C SHIELD 18
32 BRN/WHT 47-8-1 BLACK (14)
5
BROWN BLACK (16) 6
C B A C B A 8 33
BLACK (16) 5 SEE
BLK 117 28 SHEET 7, ZONE C7
BLACK (14) J8-3 2 1 SHEET 8, ZONE D3
ORN/RED 49-121 21
B CE MARKET ONLY
ORN/RED 49-120 12
MDI
13 BRN/ORN 53-3
}
1 ORN 100-1
SHIELD
2 BLACK (CAN LO) SEE SHEET 7, ZONE C7
3 BLACK BROWN 103-1 3 SEE SHEET 8, ZONE D3
RED (CAN HI)
4 RED 4
5 5 1 CE MARKET ONLY
RED
6 6
SHEILD
BLACK
2 MSSO
1 7 3 RED (CAN HI) ORN 101-1
2 8 4 BLACK (CAN LO)
BRN/WHT 47-8-2 9 5 SHIELD ORN 100-2
J12
J3 (BLACK)
10 6
11 7 BLACK A
BLUE 102-1 12 8 12 B
V REF RED 1-3
13 1 RED C
14 V BAT 11 BLACK D ADVANCED
SEE SHEET 7, ZONE C7 4 SHIELD E DIAGNOSTIC
BRN/WHT 47-8 8 PLUGGED F CONNECTOR
A SEE SHEET 8, ZONE C3
U 9 PLUGGED G
2 YEL/RED 2-1-4 H
S 10 3 PLUGGED J
10
11 5 AMP
12 YEL/RED 2-1-4 J7-34, ZONE C7

E BLACK (14)
SHEET 4
8 7 6 5 4
7-30 3121171
5 4 3 2 1
KEYSWITCH
YEL/RED 2-5 2 B1 MTB RED 1-2 (6) 1 GA
YEL/RED 2-4 (12) EMS 30 AMP
YEL/RED 2-70-5 (14) 4
YEL/RED 2-2 (12) 1
3 B2 YEL/RED 2-1 (12)
YEL/RED 2-30
5 AMP
H
YEL/RED 2-30-4
5 AMP
GENERATOR
CONTROL
YEL/RED 2-3-1
RED 1-3 7500 W BOX
GENERATOR B A C
POWER DOWN
RED 1-4 1
RELAY
BLACK 2
TO BLAM 7
BLU/ORN 52-5
YEL/RED 2-70-6 3
YEL/RED 2-20
8 87 YEL/RED 2-2A
BLACK
4
TO BLAM 87a
TO BLAM 9 86 85
30 YEL/RED 2-1-3 (12) TELEMATICS
GENERATOR SEE SHEET 7, ZONE B3

4000 W GENERATOR SEE SHEET 8, ZONE B6 BLU/ORN 52-5
CONTROL
BOX G
SEE SHEET 7, ZONE B3

B A C
5 AMP
BLACK
BLU/ORN 52-5
ALARM SEE SHEET 8, ZONE B6 YEL/RED 2-20
14 GA FUSE LINK
14 GA FUSE LINK
SEE SHEET 5, ZONE B3 POWERMITE
2500 W GENERATOR
BLACK
GENERATOR

87 87a
SEE SHEET 8, ZONE B6 BLU/ORN 52-5 86 85 F
30
BLACK
RED 1-3 (12)

RS 232 BACK-UP RELAY
5 1 8 4
13 14
9 12
WHITE
SEE
GREEN
WHITE
GREEN
RED
RED
SHEET 7, ZONE C8
SHEET 8, ZONE D4
K
BATTERY +
WHT/RED 57-10 J SHEET 7, ZONE B6
SHEET 8, ZONE E6
SHEET 9, ZONE H2
ORN/RED 49-301 E
GREEN
GREEN
BLACK
BLACK
WHITE
WHITE
RED
RED
AUXILIARY POWER
1 PUMP MOTOR
4 8 3 2 7 5 6
M
WHITE 2
GREEN 1 J1-13 BRN/ORN 53-3
BLACK 3
RED ANALYZER POWER 1

GREEN ANALYZER RECEIVE 2
WHITE ANALYZER TRANSMIT 3 TO 30 AMP FUSE
BLACK/SHIELD ANALYZER GROUND 4 (SHEET 5 OF 8,
BATTERY CABLE (1 GA.)

SECT. 8-E)
YEL/RED 2-70 (14)
RED (12)
C
YEL/RED 2-20
YEL/RED 2-70-3 (14)
YEL/RED 2-70-2 (14)
YEL/RED 2-1-99

SEE = TERMINAL STRIP IN PLATFORM BOX
SHEET 7, ZONE B3
SHEET 8, ZONE B4 = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNESS DWG.)
BLACK (14) = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK1 ON HARNESS DWG.)
B+
BLACK (16) 6
BLACK (16) 5 SEE 12 VDC
SHEET 7, ZONE C7 12 DEUTSCH 19 POS. TWIST LOCK IN MTB.
BLACK (14) J8-3 1 BATTERY
2 SHEET 8, ZONE D3
TO CHASSIS
BLK (14) B
}
ORN 100-1 TO BLAM THRU ENGINE HARNESS
SHIELD TO SLIP RING CONNECTOR
BLACK (CAN LO) SEE SHEET 7, ZONE C7
TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS) (SHEET 5 OF 8,
SEE SHEET 8, ZONE D3
RED (CAN HI) SECT. 8-D)
CE MARKET ONLY
MSSO ALL WIRES ARE 18 GA. UNLESS NOTED OTHERWISE. GROUND CONTROL SCH.
ORN 101-1
ORN 100-2
BLACK A
RED 1-3 B
RED C
BLACK D ADVANCED
SHIELD E DIAGNOSTIC
PLUGGED F CONNECTOR
A
PLUGGED G
YEL/RED 2-1-4 H
PLUGGED J
5 AMP
YEL/RED 2-1-4 J7-34, ZONE C7
SHEET 4 1001119861-O
5 4 3 2 1
MAE36310O
3121171 7-31
8 7 6 5 4
TO MTB J7-22 ORN/RED 49-200
DEUTSCH 3 POS. CONNECTOR 3 BLACK/SHIELD BLACK/SHIELD

DEUTSCH 3 POS. CONNECTOR 2 WHITE WHITE
DEUTSCH 3 POS. CONNECTOR 1 GREEN GREEN
RED RED
G J3 GREEN
J5 BROWN
5V REF. 9 RED
ORN/RED 1 10 GREEN
2 11 WHITE
BRN/BLK
3
12 BLACK/SHIELD
A RED 4 6
TOWER BOOM LIFT CYL. ANGLE SENSOR B BLUE 5 4 ORN/RED 49-200 5
C BLACK 6 1 ORANGE 8-3 2
A RED 7 ORANGE 8-2 1
2
TOWER BOOM LENGTH SENSOR #1 TOP C BLUE 8
4 5
B BLACK 9 3
10 6 4
A ORANGE V BAT. 7
TOWER BOOM LENGTH SENSOR #2 BOTTOM C YELLOW 11
8
B BLACK 12
3
10
F BRN/BLK 1
2
J1
DEUTSCH 12 POS. CONNECTOR 10 RED CAN HI 6
BOOM LENGTH ANGLE MODULE

GRAY
DEUTSCH 12 POS. CONNECTOR 11 BLACK CAN LO 7
DEUTSCH 12 POS. CONNECTOR 12 SHIELD CAN SHIELD 8
9
12
DEUTSCH 12 POS. CONNECTOR V BAT.
1 YEL/RED 2-70-2 (14) 5
DEUTSCH 12 POS. CONNECTOR 6 BLACK (14) 4
3
11
4 ORANGE 60-1
J2 BLACK
BRN/BLK V-BAT +
12 ORANGE 7-2
5 6 9 2 11 ORANGE 7-3
E 1
DEUTSCH 12 POS. CONNECTOR 2 YEL/RED 2-70-3 (14)
YEL/RED 2-82 1 ORANGE 1
TO "B+" 9 ORN/RED 49-112 2 YELLOW 2
(SHT 4 OF 8, RED (12) BLACK 3 BLACK 3
SECTION 1-C) BRN/BLK 4 BRN/BLK 4
30 AMP 30
87a YEL/RED 2-70-5 2 3 YEL/RED 2-70-4 (14)
CHASSIS 85 86 2
POWER YEL/RED 2-81 1 RED 1
RELAY 87 1
BLACK ORN/RED 49-111 2 BLUE
8 2
YEL/RED 2-70-6 (14) BLACK 3 BLACK 3
3
BRN/BLK 4 BRN/BLK
TO "GND SPLICE" IN VALVE HARNESS BLACK GND - 4 ORN/RED 49-102

6 5 9 10 11 12 4 2 1 8 3 7 5 GRAY 24-2
TO MTB J1-20 6 GRAY 23-2
TO MTB J1-23
J4 GRAY
D TO "B-" (SHT 4 OF 8, SECTION 1-B) BLACK (14) 1 WHITE 1
2 GREEN 2
3 RED 3
4 BLACK 4
5 BRN/BLK 5
YEL/RED 2-70-4 (14)
ORANGE 55-45
ORANGE 55-47
BLACK (14)
SHIELD
BLACK
RED
8 4 5 6 7 3 2 1 SHIELD C SHIELD
BLACK B BLACK
SLIP RING CONNECTOR TO CHASSIS RED A RED
C
DEUTSCH 12 POS. CONNECTOR 5 BLACK 5 (16)
DEUTSCH 12 POS. CONNECTOR 8 GRAY 23-2 ROTATE LEFT
DEUTSCH 12 POS. CONNECTOR 7 GRAY 24-2 ROTATE RIGHT
9 ORN/RED 49-102 (LOAD PIN PUSH TO TEST NOT USED AT THIS TIME)
12 POS. GND CONNECTOR IN MTB BLACK

TO MTB J1-3 TAN 55-51

TO MTB J2-8 BROWN 55-50

TO MTB J2-11 TAN 55-50

A TO CHASSIS
SHEET 5
8 7 6 5 4
7-32 3121171
5 4 3 2 1
BLACK/SHIELD
WHITE
GREEN
RED
G
J5 BROWN
9 RED ANALYZER POWER 1
10 GREEN ANALYZER RECEIVE 2
11 WHITE ANALYZER TRANSMIT 3
BRN/BLK
12 BLACK/SHIELD ANALYZER GROUND 4

6
4 ORN/RED 49-200 5
1 ORANGE 8-3 2 ORANGE 8-3 LEFT FORWARD DRIVE PUMP
2 ORANGE 8-2 1 ORANGE 8-2 LEFT REVERSE DRIVE PUMP
4 5
3 ORANGE 7-2 RIGHT REVERSE DRIVE PUMP
6 4 RIGHT FORWARD DRIVE PUMP
V BAT. ORANGE 7-3
7
8
3
F
BOOM LENGTH ANGLE MODULE
J2 BLACK
V-BAT +
12 ORANGE 7-2
9 2 11 ORANGE 7-3
1 E
YEL/RED 2-82 1 ORANGE 1 RED #2 LEFT SIDE TOWER BOOM
9 ORN/RED 49-112 2 YELLOW 2 WHITE ANGLE SENSOR
BLACK 3 BLACK 3 BLACK SERIAL OUTPUT
BRN/BLK 4 BRN/BLK 4
2
YEL/RED 2-81 1 RED 1 RED #1 RIGHT SIDE TOWER BOOM
8 ORN/RED 49-111 2 BLUE 2 WHITE ANGLE SENSOR
BLACK 3 BLACK SERIAL OUTPUT
3 BLACK
3
BRN/BLK 4 BRN/BLK
4 ORN/RED 49-102
4 2 1 8 3 7 5 GRAY 24-2
6 GRAY 23-2
J4 GRAY
1 WHITE 1 D
2 GREEN 2
3 RED 3 CAN HI RED
4 BLACK 4 CAN LO BLACK
5 BRN/BLK 5 CAN SHIELD SHIELD
1 2 3 4 5
1 2 3 4 1 2 3 4 1 2 3 4
LIFT
TOWER TOWER MAIN LIFT CYL. PIN
LIFT TELE.
SHIELD C SHIELD
BLACK B BLACK
RED A RED
C
BLACK
TAN 55-51
BLACK
BROWN 55-50
BLACK
TAN 55-50
BLAM SCH.
SHEET 5 1001119861-O
5 4 3 2 1
MAE36320O
3121171 7-33
8 7 6 5 4
1 2 3 4 5 6 7 8
ORANGE (16)
YELLOW (16)
BLACK 14GA
RED 14GA
SHIELD
VIOLET
BLACK
BLACK
RED
10
11
1
9
1
YEL/RED
2 LEFT FRONT AXLE RIGHT FRONT AXLE
SHIELD
BLK 14GA
EXTEND LIMIT SWITCH EXTEND LIMIT SWITCH
BLACK
YEL/RED 14GA
ORANGE 55-47
RED
OSC. AXLE
ORANGE 60-2
ORANGE 55-45
BLACK WHITE BLACK WHITE YEL/RED 2-1-3 LOCK-OUT
3 VALVE
4 ORN/RED 49-104
BLACK WHITE BLACK WHITE YEL/RED 2-1-2

5 ORN/RED 49-105 LEFT REAR AXLE RIGHT REAR AXLE
EXTEND LIMIT SWITCH EXTEND LIMIT SWITCH
6 ORN/RED 49-106
J2 BLACK
F 7 ORN/RED 49-107
9 BRAKE
2 VALVE
SPD
VALVE
10 YEL/WHT 39-2 FRONT AXLE EXTEND
11 YEL/WHT 39-2-43-1 YEL/WHT 43-1 REAR AXLE EXTEND
12 YEL/WHT 40-2-44-1 YEL/WHT 44-1 REAR AXLE RETRACT

E
YEL/WHT 40-2 FRONT AXLE RETRACT
D
1 YELLOW 10-2 RIGHT FRONT STEER RIGHT
2 YELLOW 9-2 RIGHT FRONT STEER LEFT

YEL/RED 2-1-1 (14GA)
3 YELLOW 10-1 LEFT FRONT STEER RIGHT

BLACK 14GA
4 YELLOW 9-1 LEFT FRONT STEER LEFT
5 YELLOW 12-2 RIGHT REAR STEER RIGHT
C
6 YELLOW 11-2 RIGHT REAR STEER LEFT
J5 RUST
7 YELLOW 12-1 LEFT REAR STEER RIGHT
8 YELLOW 11-1 LEFT REAR STEER LEFT

YEL/RED 2-1-6
YEL/RED 2-1-5
9 RED
ORN/RED
SHIELD
BLACK
BLACK
RED
10 GRN
B 11 WHITE
10
11
12
1
12 BLACK
J1 GRAY
4 3 2 1
ANALYZER HARNESS
SHEET 6
8 7 6 5 4
7-34 3121171
5 4 3 2 1
1 2 3 4 5 6 7 8
H
DRIVE ORIENTATION
SWITCH
ORANGE (16)
YELLOW (16)
BLACK 14GA
RED 14GA
SHIELD
VIOLET
BLACK
BLACK
BLACK
RED
YEL/RED 2-1-7 1
BLACK 2
10
11
12
1
9
3
OSC. AXLE
LOCK-OUT
PRESSURE G
SHIELD
YEL/RED
SWITCH 4
BLK 14GA
ORANGE 60-2
RED
J4 GRAY
BLACK
YEL/RED 14GA
ORANGE 55-45
OSC. AXLE
ORANGE 55-47
ORN/RED 49-106
LOCK-OUT
VALVE 5
ORN/RED 6
ORN/RED 7
6
6 PIN
BRAKE 4 BUSS
2 VALVE CONNECTOR
SPD 5
VALVE
2
1 RED 1 RED A
RIGHT FRONT
2 WHITE 2 BLUE B STEER SENSOR
3 BLACK 3 BLACK C
BLACK BRN/BLK 4 BRN/BLK D

4 RED 1 RED A
LEFT FRONT
YEL/RED 2-1-1 (14GA)
6 BLACK 3 BLACK C
BLACK 14GA
J3 GREEN
BLACK BRN/BLK 4 BRN/BLK
7 RED 1 RED A
RIGHT REAR
C
9 BLACK 3 BLACK C
BLACK BRN/BLK 4 BRN/BLK
10 RED 1 RED A
LEFT REAR
YEL/RED 2-1-6
YEL/RED 2-1-5
12 BLACK 3 BLACK C
ORN/RED
SHIELD
BLACK
BLACK
BLACK
BRN/BLK 4 BRN/BLK
RED
B
10
11
12
4
CHASSIS SCH.
J1 GRAY
SHEET 6 1001119861-O
5 4 3 2 1
MAE36330O
3121171 7-35
8 7 6 5 4
H
BOSCH GPA-S ACTUATOR
CAT ENGINE HARNESS
PURPLE/LT GREEN 18
1 SENSOR OUT
BLACK/LT GREEN 18
2 5V RTN
TAN/ORANGE 18
3 DBW +
PINK/WHITE 18
4 DBW -
LT GREEN/RED 18
5 5V EXT
BOSCH_872-860-521 CONN
BOSCH_C-TAB 2 99 00 49262 2 TERMINAL
OIL BOSCH_1 99 00 44435 2 SEAL
PRESSURE RED/BLACK 18
BLACK/LT GREEN 18
G LT BLUE 18
2 BLACK/RED 18
1
RED 18
DEUTSCH_DT06-2S CONN
DEUTSCH_0462-201-16141 TERMINAL PINK/TAN 18
AMP23 DEUTSCH_W2S LOCK GROUND
PINK/WHITE 18 BLACK 14 13MM RING W/
DBW + 1 STAR WASHER
DBW - 2 TAN/ORANGE 18
BLACK 18
STARTER LOCKOUT 3
RED/BLACK 18 PINK/TAN 18
GLOW CONTROL 4
WHITE/BLACK 18
SHUT OFF CONTROL 5
LT GRN/WHT 18 ECM
COLD START CONTROL 6
RED/TAN 16 F2 RED 16
7
10A
8
9
GROUND 10 BLACK 16 WHITE 16
RED/TAN 16
F VBAT 11
TPS 12 PURPLE/LT BLUE 18
13 LT BLUE/PINK 18
LT BLUE 18
OIL PRESSURE 14
PINK/TAN 18
VSW 15 BLACK 18
LT GREEN/RED 18
5V EXT 16
17 COLD START SOLENOID
TAN/WHITE 18 LT GRN/WHT 18 F5 WHITE 16
ECT 18
BLACK/LT GREEN 18 10A
5V RTN 19 TYCO_172128-1 CONNECTOR
BLUE/PINK 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CAN + 20 TYCO_63648-1 TERMINAL
CAN - 21
BLUE/WHITE 18 COLD START
WHITE/PURPLE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CRANK - 22
PURPLE/WHITE 18
CRANK + 23
TAN/WHITE 18 A
LT GRN/WHT 18
AMP_770680_1 CONNECTOR
AMP_770520_1 TERMINAL (TIN PLATED)
BLACK/LT GREEN 18 B ECT
PINK/TAN 18
E PED_12162193 CONNECTOR
PED_12124075 TERMINAL
LT GRN/WHT 18
DIAGNOSTIC CONNECTOR
UNUSED 1 ANA RTN
UNUSED 2 5V REF
UNUSED 3 PC TX
UNUSED 4 PC RX
UNUSED VBAT EPC_1F1T-14A624-AA-004 CONN
5
GTS_0330-930009 TERM (18-29)
UNUSED 6 GROUND GTS_0330-940001 TERM (14-16)
BLUE/PINK 18
7 CAN1 + EPC_E6DB-14A468-DA LOCK
BLUE/WHITE 18
8 CAN1 - EPC_F5AB-14A666-AA CAP
DEUTSCH_0413-204-2005 PLUG
JLG WIRING
D FOR SHUT OFF SOLENOID
BK/W 18 F4
CAT ENGINE CRANK SENSOR 10A
TYCO_172128-1 CONNECTOR
TYCO_63648-1 TERMINAL
WHITE/PURPLE 18
2 CRANK -
SHUT OFF
PURPLE/WHITE 18
1 CRANK +
DEUTSCH_DT04-6P CONN SEE
DEUTSCH_0460-202-16141 TERMINAL SHEET 4 DEUTSCH_DT06-2S CONN
DEUTSCH_W6P LOCK ZONE B5 DEUTSCH_0462-201-16141 TERMINAL
DEUTSCH_114017 CAVITY PLUG DEUTSCH_W2S LOCK
1 YEL/RED 2-1-99 (16)

2 WHT/YEL 48-3 J1-11 ON SHEET 4, ZONE E6
C
VEHICLE
INTERFACE 1
3
4
5
6
RED CAN HI
BLK CAN LO
BRN/WHT 47-8 SHIELD } SEE SHEET 4, ZONE B5
SEE SHEET 4, ZONE A8
RED 1-10
GLOWPLUG
SHEET 7, ZONE G3
(VENDOR WIRING) 86 RELAY 87a
BLACK 30
85 RED 1-10
WHT/YEL 48-15 87
86
TO GLOW PLUG RAIL
B SHEET 7, ZONE H2 BLACK
85
(VENDOR WIRING)
SEE SHEET 4, ZONE E1 RED
VEHICLE
INTERFACE 2 FUEL PUMP RELAY
(LOCATED ON CAT ENGINE)
DEUTSCH_DT04-8PA CONN
DEUTSCH_0460-202-16141 TERMINAL
DEUTSCH_W8P LOCK
DEUTSCH_114017 CAVITY PLUG
1 YEL/RED 2-1-88 J1-10 ON SHEET 4, ZONE D6

BLACK
2
2 BLACK (16) J1-8 ON SHEET 4, ZONE E6

CONNECT TO 3 BLU/ORG 52-5 J1-22 ON SHEET 4, ZONE C6
FUEL PUMP
4 WHT/YEL 48-9 J1-12 ON SHEET 4, ZONE E6
HARNESS FOR FUEL
CAT ENGINE 5 YEL/RED 2-20 SEE SHEET 4, ZONE B5 PUMP
6 BLACK
7 WHT/YEL 48-15 J1-7 ON SHEET 4, ZONE C6
A WHT/YEL 48-8 WHT/YEL 48-8
1
SHEET 7
8 7 6 5 4
7-36 3121171
5 4 3 2 1
GLOW PLUG GLOW PLUG

SOLENOID RAIL
RED 8
H
8MM RING 5MM RING
BOSCH GPA-S ACTUATOR
GLOW PLUG
PURPLE/LT GREEN 18
1 SENSOR OUT
SOLENOID ALTERNATOR
BLACK/LT GREEN 18
2 5V RTN
TAN/ORANGE 18
3 DBW + F3 BLACK/RED 18 UNUSED
PINK/WHITE 18 1
4 DBW - 10A BROWN/WHITE 18 CAT 1073134 CONNECTOR
LT GREEN/RED 18 2
5 5V EXT BROWN/WHITE 18 CAT 1073135 TERMINAL
GLOW 5MM RING 3
BOSCH_872-860-521 CONN
PLUGS
BOSCH_C-TAB 2 99 00 49262 2 TERMINAL
BOSCH_1 99 00 44435 2 SEAL
RED/BLACK 18 2 18-22 GAUGE INSULATED BUTT CONNECTOR
BLACK/RED 18 3 G
RED 18 5 STARTER B+
PINK/TAN 18 1
GROUND 4 RED 14 10MM RING
RED 8
BLACK 14 13MM RING W/ R3- GLOW CONTROL
STAR WASHER
BLACK 18
PINK/TAN 18 F1 PINK 18
5A
ECM ALTERNATOR +
RED/TAN 16 F2 RED 16 VSW RED 16
10A RED 8 7MM RING
87a
30
WHITE 16
87 RED 16
F
LT BLUE/PINK 18 86 R1
STARTER
BLACK 18
85
RELAY
COLD START SOLENOID
LT GRN/WHT 18 F5 WHITE 16
10A STARTER VEHICLE INTERFACE 1
TYCO_172128-1 CONNECTOR
TYCO_63648-1 TERMINAL
COLD START 7MM RING SOLENOID PINK 18 1
VSW
LT BLUE/PINK 18 2
START
BLUE/PINK 18 3
87a CAN +
TAN/WHITE 18 A BLUE/WHITE 18 4
LT GRN/WHT 18 30 CAN -
BROWN/WHITE 18 5
BLACK/LT GREEN 18 B ECT 87 RED 18
6
ALT. EXCITE
UNUSED
PINK/TAN 18 86 DEUTSCH_DT06-6S CONN
PED_12162193 CONNECTOR E
PED_12124075 TERMINAL COLD DEUTSCH_W6S LOCK
LT GRN/WHT 18
85
START DEUTSCH_114017 CAVITY PLUG
DIAGNOSTIC CONNECTOR RELAY

UNUSED 1 ANA RTN
UNUSED 2 5V REF
UNUSED 3 PC TX
UNUSED 4 PC RX
UNUSED VBAT EPC_1F1T-14A624-AA-004 CONN
5
GTS_0330-930009 TERM (18-29)
UNUSED 6 GROUND GTS_0330-940001 TERM (14-16)
BLUE/PINK 18
7 CAN1 + EPC_E6DB-14A468-DA LOCK
BLUE/WHITE 18
8 CAN1 - EPC_F5AB-14A666-AA CAP
DEUTSCH_0413-204-2005 PLUG
SEE VENDOR B+
WHITE/BLACK 18 2 D
SHUT OFF SOLENOID SCHEMATIC DETAIL
D+
BK/W 18 F4 BLACK/WHITE 18 3 CAT ENGINE HARNESS
SHEET 5
CRANK SENSOR TYCO_172128-1 CONNECTOR 10A ZONE G/E2
TYCO_63648-1 TERMINAL RED 18 5
WHITE/PURPLE 18 SHUT OFF
REGULATOR
2 CRANK - PINK/TAN 18 1
PURPLE/WHITE 18
1 CRANK + 4
R2- SHUT OFF RELAY W
DEUTSCH_W2S LOCK
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
STARTER B+
RED 1-10
VEHICLE INTERFACE 2
10MM RING
1
UNUSED
2
GROUND
SEE SHEET 4, ZONE G2 BLU/ORG 52-5 3
SEE SHEET 4, ZONE F2 GENERATOR ENABLE
4
YEL/RED 2-20 5
PLUGGED JLG WIRING
SEE SHEET 4, ZONE B5 GENERATOR POWER
87a SEE SHEET 4, ZONE G1
BLACK 6
GENERATOR GROUND
FOR CAT
WHT/YEL 48-15 7
30 WHT/YEL 48-8 8
FUEL PUMP ENABLE FUEL PUMP
RED 1-10 WHT/YEL 48-8 FUEL PUMP POWER
WHT/YEL 48-15 87 15 AMP
86 SLOW BLO
BLACK FUSE DEUTSCH_DT06-8SA CONN B
85 DEUTSCH_0462-201-16141 TERMINAL
DEUTSCH_W8S LOCK
FUEL PUMP RELAY
(LOCATED ON CAT ENGINE)
SHEET 7 1001119861-O
5 4 3 2 1
MAE36340O
3121171 7-37
8 7 6 5 4
H RECTIFER
B+ FUSIBLE
STATOR LINK
RED 1-1 (8)

STARTER ALTERNATOR
MOTOR
SOL. REGULATOR
STARTER SENSING AND
MOTOR SWITCHING
CIRCUITS D+
G
WHT/YEL 48-13 (8)
WHT/YEL 48-12(12)
BRN/WHT 47-8-1
IN HEAD GLOW PLUGS
BATTERY CABLE (1 GA.)

sol.
sol. DEUTZ EMR2 ENGINE
11
F
WHT/YEL 48-3
WHT/YEL 48-9
BATTERY +
SHEET 4
ZONE E1
E COOLANT 2 8 GRD(TempAll) BLACK (16)
TEMPERATURE 1 9 ADC7(TEMP3) 1
BLACK 0-1 BLACK 0-1
2
A K L B
DIANOSTICS
ENGINE 2 13 SPEED ORN/RED 49-198 ORN/RED 49-199
SPEED 10
EMR2 ENGINE CONTROL TO ENGINE
1 12 GRD (SPEED) ORN/RED 49-199 ORN/RED 49-198

MTB TO EMR2 ENGINE CONTROL
DEUTZ
CAMSHAFT 11
PLUG
YEL/RED 2-1-98
1 23 GRD (ACD2)
CHARGE AIR 2 4 ADC5(TEMP1) CAN HI
PRESSURE 3 25 +5Vref(ADC2) 12
4 24 ADC2 CAN LO
13
1 22 +5Vref(ADC4)
ENGINE OIL
PRESSURE 2 21 ADC4 14
3 20 GND (ADC4) YEL/RED 2-1-99
1 14 ActorOut
EMR 2 15 ActorOut
ACTUATOR 3 17 RackMeasCom
D 4 19 RackMeasSignal
5 18 RackMeasRef
VEHICLE INTERFACE I
YEL/RED 2-1-99 1
WHT/YEL 48-3 VSW
2
RED (18) START
CAN HI 3
BLACK (18) CAN +
CAN LO 4
BRN/WHT 47-8-1 CAN -
5
ALT. EXCITE
6
UNUSED
DEUTSCH_W6S LOCK
VEHICLE
INTERFACE 2
VEHICLE INTERFACE 2
1 1
UNUSED YEL/RED 2-1-88 J1-10 ON SHEET 4, ZO
BLACK (16) 2
GROUND 2 BLACK (16) J1-8 ON SHEET 4, ZON
SEE SHEET 4, ZONE G2 BLU/ORG 52-5 3
GENERATOR ENABLE 3 BLU/ORG 52-5 J1-22 ON SHEET 4, ZO
SEE SHEET 4, ZONE F2 WHT/YEL 48-9 4
GLOW 4 WHT/YEL 48-9 J1-12 ON SHEET 4, ZO
RED 2-20 5
SEE SHEET 4, ZONE G2 GENERATOR POWER 5 YEL/RED 2-20 SEE SHEET 4, ZONE B5
BLACK 6 BLACK
SEE SHEET 4, ZONE G1 GENERATOR GROUND 6
7 7 WHT/YEL 48-15 J1-7 ON SHEET 4, ZON
B PLUGGED
8 8 WHT/YEL 48-8
PLUGGED
DEUTSCH_DT06-8SA CONN DEUTSCH_DT04-8PA CONN

DEUTSCH_0462-201-16141 TERMINAL DEUTSCH_0460-202-16141 TERMINAL
DEUTSCH_W8S LOCK DEUTSCH_W8P LOCK
DEUTSCH_114017 CAVITY PLUG DEUTSCH_114017 CAVITY PLUG
SHEET 7
8 7 6 5 4
7-38 3121171
5 4 3 2 1
DEUTZ EMR2 ENGINE
E
BLACK 0-1
A K L B
DIANOSTICS
ORN/RED 49-199
ORN/RED 49-198
DEUTZ
PLUG
YEL/RED 2-1-98
VEHICLE
INTERFACE 1
DEUTSCH_DT04-6P CONN SEE D

DEUTSCH_0460-202-16141 TERMINAL SHEET 4
DEUTSCH_W6P LOCK ZONE B5
VEHICLE INTERFACE I DEUTSCH_114017 CAVITY PLUG
YEL/RED 2-1-99 1
WHT/YEL 48-3 VSW 1 YEL/RED 2-1-99 (16)
2
RED (18) START 2 WHT/YEL 48-3 J1-11 ON SHEET 4, ZONE E6
3
}
BLACK (18) CAN + 3 RED CAN HI
4
BRN/WHT 47-8-1 CAN - 4 BLK CAN LO SEE SHEET 4, ZONE B5
5
ALT. EXCITE 5 BRN/WHT 47-8 SHIELD
6
UNUSED 6
SEE SHEET 4, ZONE A8
DEUTSCH_W6S LOCK
VEHICLE
INTERFACE 2
VEHICLE INTERFACE 2
UNUSED 1 YEL/RED 2-1-88 J1-10 ON SHEET 4, ZONE D6
BLACK
2
GROUND 2 BLACK (16) J1-8 ON SHEET 4, ZONE E6

GENERATOR ENABLE 3 BLU/ORG 52-5 J1-22 ON SHEET 4, ZONE C6
GLOW 4 WHT/YEL 48-9 J1-12 ON SHEET 4, ZONE E6 NOT PRESENT
FUEL
GENERATOR POWER 5 YEL/RED 2-20 SEE SHEET 4, ZONE B5 PUMP WITH
GENERATOR GROUND 6 BLACK DEUTZ ENGINE
PLUGGED 7 WHT/YEL 48-15 J1-7 ON SHEET 4, ZONE C6
WHT/YEL 48-8 WHT/YEL 48-8 B
1
PLUGGED 8
DEUTSCH_DT06-8SA CONN DEUTSCH_DT04-8PA CONN

DEUTSCH_0462-201-16141 TERMINAL DEUTSCH_0460-202-16141 TERMINAL
DEUTSCH_W8S LOCK DEUTSCH_W8P LOCK
DEUTSCH_114017 CAVITY PLUG DEUTSCH_114017 CAVITY PLUG
SHEET 8 1001119861-O
5 4 3 2 1
MAE36350O
3121171 7-39
8 7 6 5 4
ECM-J2 X999 X1003 EIC BUSSMANN DIODE PACK

BLK 248-33 INJECTOR 1 BLK 248-33 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT)
33 1 1 62 (BLUE)
BLK 248-16 INJECTOR 1 BLK 248-16 INJECTOR 1 1.5mm² YELLOW CONNECTOR
16 2 2 35
BLK 248-48 INJECTOR 4 BLK 248-48 INJECTOR 4 1.5mm² GENERIC
48 3 3 42
BLK 248-18 INJECTOR 4 BLK 248-18 INJECTOR 4 1.5mm² RELAY, POWER MODULE
18 4 4 37
BLK 248-32 INJECTOR 3 BLK 248-32 INJECTOR 3 1.5mm²
32 5 5 38
2 6 6 61
46 7 7 40
3 8 8 41
H 6
BLK 248-5 MPROP ACTUATOR
9 9 2
BLK 248-4 MPROP ACTUATOR BLK 248-5 MPROP ACTUATOR 1.5mm²
5 10 10 20
MS932
RL930-B+
BLK 248-19 EXH GAS RECIRC BLK 248-4 MPROP ACTUATOR 1.5mm²
RL930-1
D
H
G
A
C
B
1
2
1
E
F
4 11 11 19
RL930
BLK 248-20 EXH GAS RECIRC BLK 248-37 ENGINE SPEED CAMSHAFT 0.75mm²
37 12 12 14
BUSBAR
BLK 248-52 ENGINE SPEED CAMSHAFT 0.75mm²
52 13
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm²
BLK 248-23 GLOW SENSE 0.75mm²

ORG 248-23-1 GLOW SENSE 18AWG
YEL 2-1-99 IGNITION 18AWG
53 9
WHT 48-96 FUEL PUMP 14AWG

BLK 248-39 ENGINE SPEED CRANKSHAFT 0.75mm²
39 15
BLK 248-54 ENGINE SPEED CRANKSHAFT 0.75mm²
54 X1000 X1004 21

BLK 248-37 ENG CAM SHLD 248-38 ENGINE SPEED CRANKSHAFT 0.75mm²
38 1 1 1
BLK 148-7 RAIL PRESSURE FUEL BLK 248-52 ENG CAM BLK 248-7 RAIL PRESSURE FUEL 0.75mm²
7 2 2 32
SHLD 248-53 ENG CAM
8 3 3 57
BLK 248-39 ENG CRANK
9 4 4 3
BLK 248-54 ENG CRANK
10 5 5 4
SHLD 248-38 ENG CRANK
11 6 6 5
12 7 7 6
13 8 8 7
14 9 9 8
A [J2] 15 10 10 10
17 11 11 11
ECM CONNECTOR 19 12 12
BLK 248-19 EHXAUST GAS RECIRCULATION 1.5mm²
47
EIC (ENGINE INTERFACE CONNECTION)

G 20 48
21 12
22 59
BLK 248-23 GLOW SENSE
S946
23 X1001 X1005 16
BLK 248-24 BOOST PRESSURE / TEMP 0.75mm² BLK 248-24 BOOST PRESSURE / TEMP 0.75mm²
24 1 1 22
BLK 248-25 RAIL PRESSURE FUEL 0.75mm² BLK 248-25 RAIL PRESSURE FUEL 0.75mm²
25 2 2 31
BLK 248-26 RAIL PRESSURE FUEL 0.75mm² BLK 248-26 RAIL PRESSURE FUEL 0.75mm²
26 3 3 25
BLK 248-27 BOOST PRESSURE / TEMP 0.75mm² BLK 248-27 BOOST PRESSURE / TEMP 0.75mm²
27 4 4 29
BLK 248-28 COOLING TEMPERATURE 0.75mm² BLK 248-28 COOLING TEMPERATURE 0.75mm²
28 5 5 24
BLK 248-29 OIL PRESSURE 0.75mm² BLK 248-29 OIL PRESSURE 0.75mm²
29 6 6 27
30 7 7 33
31 8 8 60
BLK 148-61 FUEL LOW PRESSURE 0.75mm²
34 9 9 17
BLK 248-35 GLOW RELAY CONTROL GND
35 10 10 18
36 11 11 58
1 12 12 30
BLK 248-40 AIR INLET TEMP BLK 248-40 AIR INLET TEMP 0.75mm²
40 28
41 BLK 148-56 AIR INLET TEMP 0.75mm² 34
42 36
BLK 248-43 OIL PRESSURE BLK 248-43 OIL PRESSURE 0.75mm²
43 23
BLK 248-44 OIL PRESSURE BLK 248-44 OIL PRESSURE 0.75mm²
44 26
F 45 39
47 43
49 44
50 45
51 46
BLK 148-72 THROTTLE FLAP 3 0.75mm²
55 49
56 50
BLK 148-38 THROTTLE FLAP 4 0.75mm²
57 52
58 51
59 53
60 54
55
56
ECM-J1
1.5MM (7,29,51,73) 7
8
9
10
11
E 12
BLK 148-13 COOLANT LEVEL SIG
13
S951
14
BLK 148-15-68 CLUTCH SWITCH
15
16
17
S952
18
19
20
21
22
23
24
25
BLK 148-26 FUEL PUMP RELAY CONTROL GND
26
27
28
1.5MM (7,29,51,73) BLK 148-29 COOLANT LEVEL PWR
29
30
31
D 32
33
34
35
36
37 X1002 X1006
BLK 148-38 THROTTLE FLAP 4
38 1 1
39 2 2
40 3 3
41 4 4
42 5 5
43 6 6
BLK 148-44 EXH GAS RECIRC
44 7 7
45 8 8
46 9 9
47 10 10
48 11 11
49 12 12
50
1.5MM (7,29,51,73) 51
52
C 53
GRN CAN 2 LO DIAG CAN LOW S968
YEL CAN 1 HI CUSTOMER CAN HIGH
54
55 S953
BLK 148-56 AIR INLET TEMP
56
BLK 148-57 WATER IN FUEL SW RTN
57
K [J1] 58 X965
YEL CAN 2 HI 120 OHM
59 A A
ECM CONNECTOR 60
GRN CAN 2 LO
B B
BLK 148-61 FUEL LOW PRESSURE
YEL CAN 1 HI
61 C C
62 X966
63
BLK 148-64 WATER IN FUEL SW
64
65
66 X955 X956
67 120 OHM
A A
BLK 148-15-68 CLUTCH SWITCH
68 B B
69 C C
70
71
BLK 148-72 THROTTLE FLAP 3
72
1.5MM (7,29,51,73) 73
B 74 GRN CAN 1 LO
YEL CAN 2 HI DIAG CAN HIGH S969
75
GRN CAN 1 LO CUSTOMER CAN LOW
76
77 S954
X1008 X1010
YEL CAN 2 HI
78 1 1
GRN CAN 2 LO
79 2 2
80 3 3
YEL CAN 1 HI
81 4 4
BLK 148-82 EXH GAS RECIRC GRN CAN 1 LO
82 5 5
SHLD CAN 1 SHLD
83 6 6
84 7 7
BLK 148-85 EXH GAS RECIRC
85 8 8
86
BLK 148-87 COOLANT LEVEL GND
87
BLK 148-88 IGNITION
88
89
90
91
92
93
A 94
RED 148-5 ECM PWR 2.5mm²
5 S944 X1007
RED 148-3 ECM PWR 2.5mm²
3 1 1
RED 148-1 ECM PWR 2.5mm² X1009
1
2.5MM (1-6) BLK 148-2 ECM GND 2.5mm²
2 S945
BLK 148-4 ECM GND 2.5mm²
4
BLK 148-6 ECM GND 2.5mm²
6
SHLD CAN 1 SHLD
NC
SHEET 9
8 7 6 5 4
7-40 3121171
5 4 3 2 1
EIC BUSSMANN DIODE PACK FUEL PUMP 20A (SW), ECM 30A (CONT)
62 (BLUE) YELLOW CONNECTOR
GLOWPLUG SOLENOID GLOWPLUGS
35 GENERIC
150 AMP
42 RELAY, POWER MODULE
37
38
5A 10A
61
40
GENERIC
41
H
87
30
86
85
GENERIC
2
ALTERNATOR
20
B+
MS932
RL930-B+
RL931-85
RL931-87
RL931-87
RL931-30
RL931-86
RL931-87
W
RL930-1
RL930-2
D
H
G
A
C
B
1
2
1
2
E
F
L
19
RL930
EC18
14
BUSBAR
EC241-B+
EC241-W
EC241-L
1
1
BLK 248-23 GLOW SENSE 0.75mm²
13
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²
BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²

9

BATTERY +
150A
15
RED 1-148-135 ECM PWR 8AWG

SHEET 2
RED 48-13 GLOW 8AWG
RED 48-13 GLOW 8AWG

RED 48-14 GLOW 8AWG
RED 48-14 GLOW 8AWG

21
ZONE H3
RED 47-8 ALT EXCITE 16AWG

1
RED - - 4AWG
32
BUSBAR
57
3
4 BUSBAR
5
6
RED - - 2/0AWG
X923
RED - - 2/0AWG
7
1
8
150A
10
11
47
EIC (ENGINE INTERFACE CONNECTION)
48 G
BUSBAR
12 EC971-B+
59 1 M
S946
16 EC971
GENERIC
GENERIC
22 1
31 EC971-B-
25 1
29
24 RL974
WHT 48-3 START 18AWG
27 1 DEUTZ PROVIDED
BLK 000-48-4 ENG GND
33 2
START RELAY
60
17
18
58
30 X901
28 1 VSW
WHT 48-3 START 18AWG
34 2 START
36 3 CAN + (HI)
GRN CAN 1 LO CUSTOMER CAN LO
23
RED 47-8 ALT EXCITE 16AWG
4 CAN - (LOW) VEHICLE INTERFACE 1
26 5 ALT EXCITE
39
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
6 CAN SHIELD (SEE SHEET 8, ZONE D3) F
43
44
45 X902
46 1 EMR4 IGNITION
49 2 GROUND
50 3 GENERATOR ENABLE
52 4 GLOW
51 5 GENERATOR POWER VEHICLE INTERFACE 2

53 6 GENERATOR GROUND
54 7 PLUGGED (SEE SHEET 8, ZONE B4)

55 8 PLUGGED
56
E
S951
S952
X950
YEL 2-48-2 IGNITION
A
B
C
D
E
GRN CAN 1 LO CUSTOMER CAN LO
GRN CAN 2 LO DIAG CAN LOW
F D
S963 S964 YEL CAN 2 HI DIAG CAN HIGH
G DEUTZ DIAGNOSTIC
H
J
K
L
M
X960
YEL CAN 2 HI DIAG CAN HIGH 120 OHM
A A
GRN CAN 2 LO DIAG CAN LOW
B B
C C
X961
SN939 PWR
BLK 148-29 COOLANT LEVEL PWR 0.75mm²
NORMALLY CLOSED
1
COOLANT LEVEL
BLK 148-13 COOLANT LEVEL SIG 0.75mm²

3 SIG
BLK 148-87 COOLANT LEVEL GND 0.75mm²
2
4
GND
X941 X942
WIF SWITCH
BLK 148-64 WATER IN FUEL SW 0.75mm² BLK 148-64 WATER IN FUEL SW 16AWG
1 1 1
BLK 148-57 WATER IN FUEL SW RTN 0.75mm² BLK 148-57 WATER IN FUEL SW RTN 16AWG
2 2
2
SN959
WATER IN FUEL
3 3
BLK 000-48-1 ENG GND 14AWG BLK 000-48-1 ENG GND 14AWG
4 4
FUEL PUMP
1
M
EC958
2 FUEL PUMP
X958A EC958+
WHT 48-96 FUEL PUMP
FUEL PUMP
1 1
B
2
EC958- M
1
X1008 X1010
BLK 000-48-2 ENG GND T920 2 x 5mm 14 AWG RING
YEL CAN 2 HI
1 1
BLK 000-48-1 ENG GND 14AWG
1 GND
GRN CAN 2 LO
2 2
3 3 3/8" 10-12 AWG RING
YEL CAN 1 HI
4 4 X1011
GRN CAN 1 LO BLK 000-148-246 ECM GND 8AWG
5 5 1
SHLD CAN 1 SHLD
6 6
7 7 3/8" 8 AWG RING
8 8
SHEET 9 1001119861-O
5 4 3 2 1
MAE36360O
3121171 7-41
8 7 6 5 4
H
PLATFORM SENSOR
ORN/RED 49-69
SEE 3 YEL/RED P1 ZONE D6
SHT 2
ZONE E6, A7 YEL/RED 2-16-3
PLATFORM SENSOR
6 YEL/RED P8
13
YEL/RED P9 ZONE D6
YEL/RED P2 ZONE E2
OR SEE SHEET 9
ZONE B5
G
SOFT TOUCH AND PLATFORM SENSOR
SEE YEL/RED P3
ORN/RED 49-69 SHT 2
SEE 3 YEL/RED P1 ZONE D6 ZONE F8
SHT 2
ZONE E6, A7 YEL/RED 2-16-3
6 BLK L WHT 5
SOFT
F TOUCH
13 BLK R BLK 4
YEL/RED P9 ZONE D6
YEL/RED P2 ZONE E2
OR SEE SHEET 9
ZONE B5
PLATFORM SENSOR
WHT ORN/RED P4
4
BLK ORN/RED P5
3
E BLK BLK P6
2
WHT YEL/RED P10
1
YEL/RED P1
D
YEL/RED P9
LOW TEMPERATURE CUTOUT OPTION P-J8A

YEL/RED EMS GND 2-1-3
X3
C CONNECT TO P8
2
BLK GND
(MATING CONNECTOR OF J8)
1
MOLEX SHT 1 ZONE D-7

042818-0212
PARKER SENSOR
+X1 YEL/RED EMS GND 2-1-3
YEL/RED EMS GND 2-1-5 YEL/RED EMS GND 2-1-4
1
BLK GND S531
2
3
BLK CAN L
RED CAN H BLK GND
BLK GND
BLK GND
X4
4 B
CONNECT TO X1002
NC S532 A
C SHT 1 ZONE F-6
B BLK CAN L
BLK CAN L BLK CAN L DEUTSCH
S533 RED CAN H
RED CAN H RED CAN H
S534
SHIELD CANSHD X5
SHIELD CANSHD SHIELD CANSHD B
CONNECT TO X1001
X2 S535
A
C SHT 1 ZONE F-6
CONNECT TO J8 2
BLK GND
SHT 1 ZONE D-7 1 DEUTSCH
P-J8
MOLEX
A
LTC OPTION BOOM HARNESS

SHEET 10
8 7 6 5 4
7-42 3121171
5 4 3 2 1
PLATFORM SENSOR
YEL/RED P3 YEL/RED P3 87
1
YEL/RED P9-1 30
1
RELAY, 12V
87a F
1
ORN/RED P5 85
1
ORN/RED P5-1
ORN/RED P4 86
1
PLATFORM SENSOR ORN/RED P4-1
WHT ORN/RED P4
4
BLK ORN/RED P5
3
BLK P6 SEE
BLK 2 SHT 2
E
WHT YEL/RED P10 YEL/RED P2 ZONE F6
1
18 ohm 25W
YEL/RED P1 YEL/RED P1 87
1
YEL/RED P9 YEL/RED P9 D
YEL/RED P9-1 30
1
RELAY, 12V
87a
1
ORN/RED P5-1 85
1
P-J8A ORN/RED P4-1 86
1
X3
2 CONNECT TO P8 C
BLK GND
1 (MATING CONNECTOR OF J8)
MOLEX SHT 1 ZONE D-7
X4
B
A
CONNECT TO X1002
C SHT 1 ZONE F-6
B
DEUTSCH
X5
B
CONNECT TO X1001
A
C SHT 1 ZONE F-6
DEUTSCH
SHEET 10 1001119861-O
5 4 3 2 1
MAE36370O
3121171 7-43
8 7 6 5 4
H ALERT BEACON OPTION HARNESS

12
11
10
9
8
RED - BEACON PWR
7
6
BEACON MODULE
5
4
3
BLK - GROUND
X3 2
RED - BEACON PWR WHT - IGNITION
1 1
BLK - GROUND S1
2 X1
BLK - GROUND
S3
S2
TO ENG DIAG CONN (ORIGINAL)
WHT - CAN SHIELD
BLK - CAN LOW
RED - CAN HIGH
RED - CAN HIGH

BLK - CAN LOW
WHT - CAN SHIELD
RED - CAN HIGH
BLK - CAN LOW
WHT - CAN SHIELD
RED - CAN HIGH
BLK - CAN LOW
WHT - CAN SHIELD
RED - CAN HIGH
BLK - CAN LOW
WHT - CAN SHIELD
WHT - IGNITION
WHT - CAN SHIELD

BLK - CAN LOW
RED - CAN HIGH
RED - BATTERY
BLK - GROUND
WHT - CAN SHIELD

BLK - CAN LOW
RED - CAN HIGH
WHT - IGNITION
WHT - CAN SHIELD

BLK - CAN LOW
RED - CAN HIGH
RED - BATTERY
BLK - GROUND
F
TO ENG DIAG CONN (NEW)

BEACON MODULE
CAN TERMINATOR
X2
X5
X9
X7
X4
12
11
10
9
8
7
6
5
4
3
2
1
1
3
5
2
4
6
11
9
7
12
10
8
J
H
G
F
E
D
C
B
A
C
B
A
J
H
G
F
E
D
C
B
A
HARNESS,GEN 2 PLAT INTERFACE

D
PLTFM SNSR
PLTFM SNSR PLTFM SNSR
RELAY #1 RELAY #2
87a
87a
87
30
85
86
86
85
30
87
4
3
2
1
RL503
RL502
X500
4
3
2
1
C
WHT P1
WHT P9-1
WHT P5-1
WHT P4-1
WHT P4-2
WHT P5-2
WHT P9-2
WHT P3
WHT P5
WHT P4
WHT P6
WHT P10
NOTE:
6 PIN CONNECTOR AND RELAYS LOCATED
ON THE LEFT SIDE OF THE CONTROL PLATFORM BOX.
IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE, SEE SHEET 10.
S191 INTERFACE
X5B KL
S192
WHT P6 BLACK P6
2 SEE SHT 2 ZONE F6
WHT P1 ORN/RED 49-69-1

B 4 SEE SHT 2 ZONE E5
WHT P3 YEL/RED P3
5 SEE SHT 2 ZONE F8
18 OHM
IP144 WHT P2 YEL/RED 2-16-3-1
1 SEE SHT 2 ZONE D3
YEL/RED P2
3 SEE SHT 10 ZONE F6 OR G6
SHEET 11
8 7 6 5 4
7-44 3121171
5 4 3 2 1
CRIBBING HARNESS OPTION

TO CRIBBING MODULE - J2 TO CRIBBING MODULE- J1
H
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
X383
X878
CRIBBING ENABLE LAMP
GRN CANL_7
YEL CANH_5
RED/ORN 116
BLK/ORN 114
1
2
LB373
RED 103
BLK 102
BLK/ORN 114
BLK 113
CRIBBING ENABLE SW G
SW374
RED 115 S369

BLK 102 BLK 117
J7 28 CONNECT TO
RED 103 BLK BLK RED 118 GROUND CONTROLLER (SHEET 4)
J7 33
S370 S371
IP914
MS377-3 INLINE FUSE 5A
GRN CANL_7
1
YEL CANH_5
2
2 YEL CANH_6 YEL CANH_6 J7 13 CONNECT TO
GRN CAN LOW
MS377-2 1 GRN CANL_8 GRN CANL_8 J7 24 GROUND CONTROLLER (SHEET 4)
1
YEL CAN HIGH
2 MS377-1
EXTRACT WIRES FROM F
GROUND CONTROLLER J7-13 & J7-24
AND CONNECT AS SHOWN
(SEE SHEET 4)
(EXISTING HARNESS)
SHEET 11 1001119861-O
5 4 3 2 1
MAE36380O
3121171 7-45
NOTES:
7-46 3121171
3121171
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417
Visit our website for JLG Worldwide Locations

www.jlg.com

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Service and Maintenance Manual

May 31, 2019 - Rev S

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-

Original Issue A - April 15, 2004

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1.5 DIMENSIONAL DATA Deutz BF4M2011

Stowed Height 10 ft (3.05 m) Bore 3.7 in (94 mm)

Wheelbase 12 ft-6 in (3.81 m) Compression Ratio 17.5

Tailswing Firing Order 1-3-4-2

Deutz TCD2.9L4 1.8 MAJOR COMPONENT WEIGHTS

Type Liquid Cooled Component LBS KG

Description Torque Value (Dry) Interval Hours

1.10 HYDRAULIC OIL Table 1-15. UCon Hydrolube HP-5046

Table 1-18. Quintolubric 888-46

Table 1-19. Mobilfluid 424 Specs

1.11 LUBRICATION & OPERATOR MAINTENANCE 2. Swing Gearbox

NOTE: The following numbers correspond to those in Figure 1-1.,

Table 1-21. Lubrication Specifications

NOTE: It is recommended as a good practice to replace all filters

1. Swing Bearing - Remote Lube

Lube Point(s) - Fill Plug

4. A. Wheel Drive Hub - Rexroth (Prior to S/N 100128)

Lube Point(s) - Level/Fill Plug

Lube Point(s) - Level/Fill Plug

A - Red = Filter Restricted; Filter Bypassed

Figure 1-3. Hydraulic Return Filter Condition Indicator - Prior to SN 139396

Red = Filter Restricted; Filter Bypassed

Figure 1-4. Hydraulic Return Filter Condition Indicator - SN 139396 to Present

6. Hydraulic Charge Filter 7. Main Valve Filter

or Lube Point(s) - Replaceable Element

FULL LEVEL (HOT OIL)

FULL LEVEL (COLD OIL)

Lube Point(s) - Replaceable Element

Lube Point(s) - Fill Cap/Spin-on Element

10. Oil Change w/Filter - Deutz D2011

Lube Point(s) - Fill Cap/Spin-on Element (element can be

Lube Point(s) - Replaceable Element

Lube Point(s) - Replaceable Element

Lube Point(s) - Replaceable Element

Lube Point(s) - Replaceable Element