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Service and Maintenance Manual: Models 400S 460SJ

This 3-sentence summary provides the high-level and essential information from the service and maintenance manual document: The document is a service and maintenance manual for models 400S and 460SJ that covers specific serial numbers for those models, with revisions made to the manual over time. The manual contains introduction and safety sections, specifications for the models, general information, and maintenance procedures and schedules to ensure the equipment is safely maintained.

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0% found this document useful (0 votes)

476 views662 pages

Service and Maintenance Manual: Models 400S 460SJ

Uploaded by

Pedro Leon

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 662

Service and Maintenance Manual

Models
400S
460SJ
S/N 0300203771*
S/N 1300007289
& S/N E300000100
to Present
* See inside front cover for exceptions

3121671

November 28, 2018 - Rev E

AS/NZS
This manual also covers the following Serial Numbers.

0300184729 0300203261 0300203580 0300203677

0300200144 0300203262 0300203581 0300203678
0300200145 0300203307 0300203582 0300203679
0300200476 0300203308 0300203583 0300203680
0300200477 0300203351 0300203584 0300203681
0300202446 0300203352 0300203628 0300203724
0300202447 0300203394 0300203629 0300203725
0300202448 0300203395 0300203630 0300203727
0300202449 0300203439 0300203631 0300203728
0300202450 0300203440 0300203632
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 DISCONNECTED DURING
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-

TABLE NO. TITLE PAGE NO.

5-19 Metric Flat Face Port (MFF) - L Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-20 Metric Flat Face Port (MFF) - L Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5-21 Metric Flat Face Port (MFF) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-22 Metric Flat Face Port (MFF) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-23 Metric Flat Face Port (MFF) - L Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-24 Metric Pipe Parallel O-ring Boss (MPP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
5-26 British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-27 British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5-29 British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-30 British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5-31 Flange Code (FL61 & FL62) -Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-32 Flange Code (FL61 & FL62) - Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-33 Cartridge Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5-34 Coil Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5-35 Coil Resistance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
6-1 Analyzer Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6-2 Machine Configuration Programming Information (Software Version P2.10). . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-3 Machine Configuration Programming Settings - 400S (Software Version P2.10). . . . . . . . . . . . . . . . . . . . . . . 6-25
6-4 Machine Configuration Programming Settings - 460SJ (Software Version P2.10). . . . . . . . . . . . . . . . . . . . . . 6-26
6-5 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6-6 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
6-7 SkyGlazier Capacity Reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6-8 Pipe Rack Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6-9 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6-10 Machine Model Adjustment Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6-11 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
7-1 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

3121671 xvii
LIST OF TABLES

TABLE NO. TITLE PAGE NO.

This page left blank intentionally.

xviii 3121671
SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS Table 1-2. Operating Specifications - 460SJ

Table 1-1. Operating Specifications - 400S Maximum Work Load (Capacity):

Unrestricted (CE and Aus) 600 lb (272 kg)
Maximum Work Load (Capacity): Unrestricted (ANSI) 600 lb (272 kg)
Unrestricted (CE & Aus) 600 lb (272 kg)
Maximum Travel Grade (Gradeability)* 45%
Unrestricted (ANSI) 600 lb (272 kg)
Restricted (CE & Aus) 1000 lb (454 kg) Maximum Travel Grade (Side Slope)* 5°
Restricted (ANSI) 1000 lb (454 kg)
Platform Height: 46 ft. 2.6 in. (14.09 m)
Maximum Travel Grade (Gradeability)* 45%
Horizontal Platform Reach: 39 ft. 7 in. (12.07 m)
Maximum Travel Grade (Side Slope)* 5° Turning Radius (Outside) 15 ft. 10 in. (4.8 m)
Platform Height: 40 ft. 6 in. (12.36 m) Turning Radius (Inside) 6 ft. 6 in. (2.0 m)
Horizontal Platform Reach: 33 ft. 3 in. (10.13 m) Overall Width 7 ft. 7 in. (2.3 m)
Turning Radius (Outside) 15 ft. 10 in. (4.8 m) Stowed Height 8 ft. 1 in. (2.47 m)
Turning Radius (Inside) 6 ft. 6 in. (2.0 m) Stowed Length 29 ft. 3 in.(8.91 m)
Overall Width 7 ft. 7 in. (2.3 m) Wheelbase 7 ft. 9.5 in. (2.37 m)
Stowed Height 8 ft. 1 in. (2.47 m) Ground Clearance 12.1 in. (0.3 m)
Stowed Length 24 ft. 10 in. (7.57 m) Tailswing 34 in. (0.86 m)
Wheelbase 7 ft. 9.5 in. (2.37 m) Max. Tire Load 9000 lbs. (4082 kg)
Ground Clearance 12.1 in. (0.3 m) Ground Bearing Pressure 60 psi (4.19 kg/cm2)
Tailswing 34 in. (0.86 m)
Travel Speed 4.25 mph (6.84 km/h)
Max. Tire Load 7200 lbs. (3266 kg)
Gross Machine Weight 16,370 lbs. (7,425 kg)
Ground Bearing Pressure 60 psi (4.19 kg/cm2) Maximum System Voltage 12V
Travel Speed 4.25 mph (6.84 km/h) Max. Hydraulic System Operating Pressure 3000 psi (207 Bar)
Gross Machine Weight 13,425 (6,090 kg) Manual Force
Maximum System Voltage 12V CE 90 lbs. (400 N)
ANSI 100 lbs. (445 N)
Max. Hydraulic System Operating Pressure 3000 psi (207 Bar)
Maximum Wind Speed 28 mph (12.5 m/s)
Manual Force
CE 90 lbs. (400 N) * With boom in stowed position
ANSI 100 lbs. (445 N)
Maximum Wind Speed 28 mph (12.5 m/s)
* With boom in stowed position

3121671 1-1
SECTION 1 - SPECIFICATIONS

1.2 CAPACITIES Table 1-5. Deutz D2.9L4

Table 1-3. Capacities Type Liquid Cooled

Number of Cylinders 4
Fuel Tank 22 gal. (83.3 L)
BHP 48.8 hp@2600 rpm
Hydraulic Tank 36 gal. (136.3 L)
Bore 3.6 in (92 mm)
Hydraulic System (Including Tank) 40 gal. (151.4 L)
Stroke 4.3 in (110 mm)
Drive Hub 24 oz. (0.7 L)
Total Displacement 178 cu. in (2925 cm³)
Drive Brake 27 oz. (0.8 L)
Firing Order 1-3-4-2
Coolant
Deutz 2.9L 3 gal. (11.3L) Engine Oil Capacity 2.4 gal (8.9 L)
Deutz 2011L 2.8 gal. (10.5L) Engine Coolant Capacity 0.79 gal (3 L)
GM 3.0L 2.4 gal. (9.1L) Starter Rating 12 V. 3.2 kW
Kubota 2.2 gal. (8.5L)
Alternator Rating 12 V. 95 Amp.
Glow Plug 12 V. 110 Amp
1.3 ENGINE DATA Min. Low RPM 900
NOTE: RPM Tolerances are ± 50. Max. High RPM 2600
Max. Rated Torque 108 lb. ft (147 Nm) @ 1600rpm
Average Fuel Consumption 0.75 gph (2.84 Lph)
Table 1-4. Deutz D2011L03

Fuel Diesel
No. of Cylinders 3 Table 1-6. GM 3.0L
BHP 48.8 hp @2800 rpm Fuel Gasoline or Gasoline/LP Gas
Bore 3.7 in (94 mm) No. of Cylinders 4
Stroke 4.4 in (112 mm) BHP
Displacement 142 cu. in (2331 cm³) Gasoline 80.5 hp @ 3000 rpm
LP 75.1 hp @ 3000 rpm
Engine Oil Capacity 1.5 gal. (5.5 L)
Bore 4.0 in (101.6 mm)
Starter Rating 12 V. 2.3 kW
Stroke 3.6 in (91.44 mm)
Alternator Rating 14 V. 55 Amp.
Displacement 181 cu.in (3.0 L, 2966 cc)
Glow Plug 12 V. 80 Amp.
Engine Oil Capacity 1.14 gal. (4.3 L)
Min. Low RPM 1000
Engine Coolant Capacity 1 gal. (3.8L)
Max. High RPM 2800
Starter Rating 12 V. 1.5kW
Max. Rated Torque 101 lb. ft. (137 Nm) @ 1700rpm
Alternator Rating 13.5 V. 70 Amp.
Average Fuel Consumption 0.53 gph (2 Lph)
Compression Ratio 9.2:1
Firing Order 1-3-4-2
Max. High RPM 3000
Min. Low RPM 1000
Max. Rated Torque
Gasoline 149.2 lb. ft (202.2 Nm) @ 2200rpm
LP 149.6 lb. ft (202.8 Nm) @ 1600rpm
Average Fuel Consumption 1.10 gph (4.2 Lph)

1-2 3121671
SECTION 1 - SPECIFICATIONS

1.5 HYDRAULIC OIL

Table 1-7. Kubota WG 2503 Table 1-9. Hydraulic Oil
Fuel Gasoline or Gasoline/LP Gas
Hydraulic System S.A.E. Viscosity
No. of Cylinders 4 Operating Temperature Range Grade
BHP +0° to + 180° F (-18° to +83° C) 10W
Gasoline 45.5 kW @2700 rpm
+0° to + 210° F (-18° to +99° C) 10W-20, 10W-30
LP 46 kW @2700 rpm
+50° to + 210° F (+10° to +99° C) 20W-20
Bore 3.46 in (88 mm)
Stroke 4.03 in (102.4 mm)
NOTE: Hydraulic oils must have anti-wear qualities at least to API
Displacement 153 cu. in (2.5L)
Service Classification GL-3, and sufficient chemical stabil-
Engine Oil Capacity 2.5 gal. (9.5 L) ity for mobile hydraulic system service. JLG Ind. recom-
Engine Coolant Capacity 1.4 gal. (5.4L) mends Mobilfluid 424 hydraulic oil, which has an SAE
Starter Rating 12 V. 2.0 kW viscosity index of 152.

Alternator Rating 12 V. 40 Amp NOTE: When temperatures remain consistently below 20° F
Min. Low RPM 700 (-7° C), JLG Industries recommends the use of
Max. High RPM 2700 Mobil DTE-13.
Max. Rated Torque
NOTE: Machines may be equipped with Mobil EAL224H biode-
Gasoline 126 lb. ft(171Nm) @ 1800rpm
gradable and non-toxic hydraulic oil. This is Vegetable oil
LP 131 lb. ft(178 Nm) @ 1400rpm
based and possesses the same antiwear and rust protec-
Average Fuel Consumption 0.935 gph (3.544 Lph) tion characteristics as mineral oils, but will not adversely
affect the ground water or the environment when spilled or
leaked in small amounts. Mobil EAL224H has a viscosity of
1.4 TIRES 34 cSt at 40° C. and viscosity index of 213. The operating
temperature range of this oil is -18° C to +83° C.
Table 1-8. Tires

Size Type Pressure Weight

12 x 16.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg) Table 1-10. Mobilfluid 424 Specs
Foam-Filled N/A 328 lbs. (149 kg)
SAE Grade 10W30
14 x 17.5 Pneumatic 90 psi (6 Bar) 170 lbs. (77.2 kg)
ISO Viscosity Grade 55
Foam-Filled N/A 440 lbs. (200 kg)
Gravity, API 29.0
33/16LL x 16.1 Pneumatic 40 psi (3 Bar) 119.5 lbs. (54 kg)
Density, Lb/Gal. 60°F 7.35
315/55 D20 Foam-Filled N/A 286 lbs. (130 kg)
Pour Point, Max -46°F (-43°C)
Solid N/A 286 lbs. (130 kg)
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

3121671 1-3
SECTION 1 - SPECIFICATIONS

Table 1-11. Mobil DTE 13M Specs Table 1-14. Mobil EAL Environ H 46 Specs

ISO Viscosity Grade #32 Type Synthetic Biodegradable

Specific Gravity 0.877 ISO Viscosity Grade 46
Pour Point, Max -65°F (-54°C)
Specific Gravity @ 15° C 0.874
Flash Point, Min. 482°F (250°C)
Pour Point -49°F (-45°C)
Viscosity
Flash Point 500°F (260°C)
at 40° C 33cSt
at 100° C 6.6 cSt Operating Temp. 20 to 200°F (-29 to 93°C)
at 100° F 169 SUS 7.64 lb/gal
Weight
at 210° F 48 SUS (0.9 kg/L)

cp at -20° F 6,200 Viscosity

Viscosity Index 164 at 40° C 48.8 cSt
at 100° C 7.8 cSt
Viscosity Index 145
Table 1-12. UCon Hydrolube HP-50/46

Type Synthetic Biodegradable Table 1-15. Mobil Hydraulic EAL H 46 Specs

Specific Gravity 1.082 Type Synthetic Biodegradable
Pour Point, Max -58°F (-50°C) ISO Viscosity Grade 46
pH 9.1 Specific Gravity @ 15° C .874
Viscosity Pour Point -27°F (-33°C)
at 0° C (32° F) 340 cSt (1600 SUS)
Flash Point 568°F (298°C)
at 40° C (104° F) 46 cSt (215 SUS)
Operating Temp. 20 to 200°F (-29 to 93°C)
at 65° C (150° F) 22 cSt (106 SUS)
Viscosity Index 170 7.64 lb/gal
Weight
(0.9 kg/L)
Viscosity
Table 1-13. Mobil EAL 224H Specs at 40° C 43.3 cSt
Type Synthetic Biodegradable at 100° C 7.7 cSt
ISO Viscosity Grade 32/46 Viscosity Index 149
Specific Gravity 0.922
Pour Point, Max -25°F (-32°C) Table 1-16. Exxon Univis HVI 26 Specs
Flash Point, Min. 428°F (220°C)
Specific Gravity 32.1
Operating Temp. 0 to 180°F (-17 to 162°C)
Pour Point -76°F (-60°C)
Weight 7.64 lb/gal.
Flash Point 217°F (103°C)
(0.9 kg/liter)
Viscosity
Viscosity
at 40° C 25.8 cSt
at 40° C 37 cSt
at 100° C 9.3 cSt
at 100° C 8.4 cSt
Viscosity Index 376
Viscosity Index 213
NOTE: Mobil/Exxon recommends that this oil be checked
NOTE: Must be stored above 32°F (14°C)
on a yearly basis for viscosity.

1-4 3121671
SECTION 1 - SPECIFICATIONS

1.6 CRITICAL STABILITY WEIGHTS

Table 1-17. Critical Stability Weights

Component lb kg
Battery 66 30
Counterweight (S) 1060 ± 42.4 481.8 ± 19.3
Counterweight (SJ) 2700 ± 54 1227.3 ± 24.5
Tires See Table 1-8, Tires
Platform and Console - 36 x 72 209 95
Platform and Console - 36 x 96 240 109
Platform and Console - Fall Arrest 287 130

3121671 1-5
SECTION 1 - SPECIFICATIONS

2WD Only S/N 0300220610

to Present
5

6
20
4

11
18

2 2

4
12
5

6
7
1 19

2 2

3 3
MAF00560

Figure 1-1. Operator Maintenance and Lubrication Diagram - Deutz 2.9L Engine

1-6 3121671
SECTION 1 - SPECIFICATIONS

Figure 1-2. Operator Maintenance and Lubrication Diagram - Deutz 2011L Engine

3121671 1-7
SECTION 1 - SPECIFICATIONS

2WD Only S/N 0300220610

to Present
5

20 4

2 2

15
6
7
14
1 19

2 2

3 3
MAF00580

Figure 1-3. Operator Maintenance and Lubrication Diagram - GM Engine

1-8 3121671
SECTION 1 - SPECIFICATIONS

Figure 1-4. Operator Maintenance and Lubrication Diagram - Kubota Engine

3121671 1-9
SECTION 1 - SPECIFICATIONS

1.7 MAINTENANCE AND LUBRICATION 2. Wheel Drive Hub

NOTE: The following numbers correspond to those in Figure 1-1.,

Figure 1-2., Figure 1-3. and Figure 1-4.
OIL LEVEL CHECK
AND FILL
Table 1-18. 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.
Lube Point(s) - Level/Fill Plug
EO Engine (crankcase). Gas (5W30)- API SN, -Arctic ACEA AI/BI, A5/B5 - API SM,
Capacity - 24 oz. (0.8 L)(1/2 Full)
SL, SJ, EC, CF, CD - ILSAC GF-4. Diesel (15W40, 5W30 Arctic) - API CJ-4.
Lube - EPGL
OGL Open Gear Lubricant - Mobiltac375 or equivalent. Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation.
3. Drive Brake
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL
CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR
EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUEN-
CIES MUST BE INCREASED ACCORDINGLY.

NOTE: It is recommended as a good practice to replace all filters

at the same time.

1. Swing Bearing - Internal Ball Bearing

Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hours of operation
Comments - Fittings in center of bearing: Remote
Access is optional: Apply grease and rotate in 90
degree intervals until bearing is completely lubri-
cated.
Lube Point(s) - Fill Plug
Capacity - 27 oz. (0.8 L)
Lube - DTE-13M
Interval - Change as necessary.

1-10 3121671
SECTION 1 - SPECIFICATIONS

4. Hydraulic Return Filter 6. Hydraulic Tank

A. Prior to SN 0300220610, Prior to SN E300004218,
Prior to SN 1300007394

Interval - Change after first 50 hours and every 6

months or 300 hours thereafter or whenever Charge
Filter is replaced.
5. Hydraulic Tank Breather Lube Point(s) - Fill Cap
Capacity - 32.5 gal tank (123 L) 40.0 gal system (151 L)
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.

B. SN 0300220610 to Present, SN E300004218 to Pres-

ent

Interval - Change after first 50 hrs. and every 6 months

or 300 hrs. thereafter.
Comments - Remove wing nut and cover to replace.
Under certain conditions, it may be necessary to
replace on a more frequent basis.
MAF01180

Lube Point(s) - Fill Cap

Capacity - 15 Gal. (57 L) to Full Level
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.
Comments - On new machines, those recently
overhauled, or after changing hydraulic oil, operate
all systems a minimum of two complete cycles and
recheck oil level in reservoir.

3121671 1-11
SECTION 1 - SPECIFICATIONS

7. Hydraulic Charge Filter 9. Oil Change w/Filter - Deutz 2.9 L4

Interval - Change after first 50 hours and every 6 MAF01190

months or 300 hours thereafter or as indicated by
Condition Indicator.
Lube Point(s) - Fill Cap/Spin-on Element
8. Oil Change w/Filter - Deutz D2011 Capacity - 2.4 gal (8.9 L)
Lube - EO
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance
with engine manual. Adjust final oil level by mark on
dipstick.
10. Oil Change w/Filter - GM

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 10 Quarts (9.5 L) w/Filter
Lube - EO
Interval - Change every 500 hours or six months, which-
ever comes first.
Comments - Check level daily/Change in accordance
with engine manual. Adjust final oil level by mark on
dipstick.

1-12 3121671
SECTION 1 - SPECIFICATIONS

12. Fuel Filter - Deutz D2.9

MAF01200
Lube Point(s) - Replaceable Element
Lube Point(s) - Fill Cap/Spin-on Element Interval - Every year or 600 hours of operation.
Capacity - 4.5 qt (4.25 L) w/filter
Lube - EO 13. Fuel Filter - Deutz D2011
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.
11. Fuel Pre-Filter - Deutz D2.9

Lube Point(s) - Replaceable Element

Interval - Every year or 500 hours of operation.
Lube Point(s) - Replaceable Element
Interval - Drain water daily; Every year or 600 hours
of operation.

3121671 1-13
SECTION 1 - SPECIFICATIONS

14. Fuel Filter (Gasoline) - GM 17. Radiator Coolant -GM

Lube Point(s) - Fill Cap

Capacity - 2.4 Gallon (9.1 L)
Lube - Anti-Freeze
Interval - Check level daily; change every 1000 hours or
2 years, whichever comes first.

18. Air Filter

Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation.
15. Fuel Filter (Propane) - GM Engine

Lube Point(s) - Replaceable Element

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

19. Swing Drive Hub

Interval - 3 Months or 150 hours of operation
Comments - Replace filter.

16. Radiator Coolant Deutz 2.9

Lube Point - Level/Fill Plug

Capacity - 40 oz. (1.2 L)
Lube Point(s) - Fill Cap Lube - 90w80 Gear Oil
Capacity - 2.9 Gallon (11.3 L) Interval - First change after first 50 hours; Check level
Lube - Anti-Freeze every 3 months or 150 hours of operation; change
Interval - Check level daily; change every 1000 hours or after first 50 hours and every 2 years or 1200 hours
2 years, whichever comes first. of operation thereafter.

1-14 3121671
SECTION 1 - SPECIFICATIONS

20. Wheel Bearings

MAF01210 MAF01230
Lube Point(s) - Fill Cap/Spin-on Element
Lube Point(s) - Repack Capacity - 2.5 gal. (9.5 L) w/filter
Capacity - A/R Lube - EO
Lube - MPG Interval - 3 Months or 150 hours of operation
Interval - Every 2 years or 1200 hours of operation. Comments - Check level daily/Change in accordance
21. Oil Change w/Filter - Kubota with engine manual.
22. Fuel Filter - Kubota

MAF01240

Lube Point(s) - Replaceable Component

Interval - Every year or 600 hours of operation.
MAF01220

3121671 1-15
SECTION 1 - SPECIFICATIONS

23. Engine Coolant - Kubota

Lube Point(s) - Fill Cap
Capacity - 2.25 gal. (8.5 L)
Lube - Anti-Freeze
Interval - Check level daily; change every 1000 hours or
two years, whichever comes first.
24. Fuel Filter (Propane) - Kubota

MAF01250

Interval - Every year or 1000 hours of operation

Comments - Replace filter. Refer to Section 7.6, Propane
Fuel Filter Replacement (Kubota Engine).

1-16 3121671
SECTION 1 - SPECIFICATIONS

Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue

Figure 1-5. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)

3121671 1-17
SECTION 1 - SPECIFICATIONS

To rqu e
Torqu e
Torq ue
Tor que
Torq ue

Figure 1-6. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)

1-18 3121671
SECTION 1 - SPECIFICATIONS

Torq ue
Tor que
Torqu e
Torq ue
Cl amp L oa d
To rqu e
To rque

Figure 1-7. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)

3121671 1-19
SECTION 1 - SPECIFICATIONS

To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e

Figure 1-8. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)

1-20 3121671
SECTION 1 - SPECIFICATIONS

To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue

Figure 1-9. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)

3121671 1-21
SECTION 1 - SPECIFICATIONS

NOTES:

1-22 3121671
SECTION 2 - GENERAL

SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form
and the Inspection and Preventive Maintenance Schedule for
MAINTENANCE items requiring inspection during the performance of these
inspections. Reference the appropriate areas of this manual for
General servicing and maintenance procedures.

This section provides the necessary information needed by Annual Machine Inspection
those personnel that are responsible to place the machine in The Annual Machine Inspection must be performed on an
operation readiness and maintain its safe operating condition. annual basis, no later than thirteen (13) months from the date
For maximum service life and safe operation, ensure that all
of the prior Annual Machine Inspection. JLG Industries recom-
the necessary inspections and maintenance have been com- mends this task be performed by a Factory-Trained Service
pleted before placing the machine into service. With proper Technician. JLG Industries, Inc. recognizes a Factory-Trained
care, maintenance, and inspections performed as per JLG's
Service Technician as a person who has successfully com-
recommendations, and with any and all discrepancies cor- pleted the JLG Service Training School for the subject JLG
rected, 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-
Preparation, Inspection, and Maintenance mance of this inspection.

It is important to establish and conform to a comprehensive Reference the JLG Annual Machine Inspection Form and the
inspection and preventive maintenance program. The follow- Inspection and Preventive Maintenance Schedule for items
ing table outlines the periodic machine inspections and main- requiring inspection during the performance of this inspec-
tenance recommended by JLG Industries, Inc. Consult your tion. Reference the appropriate areas of this manual for servic-
national, regional, or local regulations for further requirements ing and maintenance procedures.
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 Preventive 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 Operation and Safety
shall be performed by a qualified JLG equipment mechanic.
Manual for complete procedures for the Pre-Start Inspection.
JLG Industries, Inc. recognizes a qualified JLG equipment
The Operation and Safety Manual must be read in its entirety
mechanic as a person who, by possession of a recognized
and understood prior to performing the Pre-Start Inspection.
degree, certificate, extensive knowledge, training, or experi-
ence, has successfully demonstrated the ability and profi-
Pre-Delivery Inspection and Frequent Inspection ciency to service, repair, and maintain the subject JLG product
model.
The Pre-Delivery Inspection and Frequent Inspection shall be
performed by a qualified JLG equipment mechanic. JLG Indus- Reference the Preventive Maintenance Schedule and the
tries, Inc. recognizes a qualified JLG equipment mechanic as a appropriate areas of this manual for servicing and mainte-
person who, by possession of a recognized degree, certificate, nance procedures. The frequency of service and maintenance
extensive knowledge, training, or experience, has successfully must be increased as environment, severity and frequency of
demonstrated the ability and proficiency to service, repair, and usage requires.
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.

3121671 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
(See Note) At each Operator change.

Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
(See Note) 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
(See Note) comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
purchased used.

Annual Machine Inspec- Annually, no later than 13 months from the date of Owner, Dealer, or User Factory-Trained Service Service and Maintenance Manual
tion the prior inspection. Technician and applicable JLG inspection form.
(See Note) (Recommended)

Preventive Maintenance At intervals as specified in the Service and Mainte- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
(See Note) nance Manual.

NOTE: Inspections forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are disconnected,
clear adjacent areas as well as the openings and fittings
themselves. As soon as a line or component is discon-
General nected, cap or cover all openings to prevent entry of for-
The following information is provided to assist you in the use eign matter.
and application of servicing and maintenance procedures
3. Clean and inspect all parts during servicing or mainte-
contained in this book.
nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
Safety and Workmanship sure all parts are clean before they are installed. New
parts should remain in their containers until they are
Your safety, and that of others, is the first consideration when
ready to be used.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without
the aid of a mechanical device. Do not allow heavy objects to
Components Removal and Installation
rest in an unstable position. When raising a portion of the 1. Use adjustable lifting devices, whenever possible, if
equipment, ensure that adequate support is provided. mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as near
Cleanliness perpendicular as possible to top of part being lifted.

1. The most important single item in preserving the long 2. Should it be necessary to remove a component on an
service life of a machine is to keep dirt and foreign mate- angle, keep in mind that the capacity of an eyebolt or
rials out of the vital components. Precautions have been similar bracket lessens, as the angle between the sup-
taken to safeguard against this. Shields, covers, seals, porting structure and the component becomes less
and filters are provided to keep air, fuel, and oil supplies than 90 degrees.
clean; however, these items must be maintained on a 3. If a part resists removal, check to see whether all nuts,
scheduled basis in order to function properly. bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.

2-2 3121671
SECTION 2 - GENERAL

Component Disassembly and Reassembly 2. Unless specific torque requirements are given within the
text, standard torque values should be used on heat-
When disassembling or reassembling a component, complete treated bolts, studs, and steel nuts, in accordance with
the procedural steps in sequence. Do not partially disassemble recommended shop practices. (See Torque Chart in Sec-
or assemble one part, then start on another. Always recheck tion 1.)
your work to assure that nothing has been overlooked. Do not
make any adjustments, other than those recommended, with- Hydraulic Lines and Electrical Wiring
out obtaining proper approval.
Clearly mark or tag hydraulic lines and electrical wiring, as well
as their receptacles, when disconnecting or removing them
Pressure-Fit Parts from the unit. This will assure that they are correctly rein-
stalled.
When assembling pressure-fit parts, use a molybdenum disul-
fide base compound or equivalent to lubricate the mating sur- Hydraulic System
face.
1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
Bearings flush the entire system.

1. When a bearing is removed, cover it to keep out dirt and 2. Disassemble and reassemble parts on clean work sur-
abrasives. Clean bearings in nonflammable cleaning sol- face. Clean all metal parts with non-flammable cleaning
vent and allow to drip dry. Compressed air can be used solvent. Lubricate components, as required, to aid
but do not spin the bearing. assembly.

2. Discard bearings if the races and balls (or rollers) are pit- Lubrication
ted, scored, or burned.
Service applicable components with the amount, type, and
3. If bearing is found to be serviceable, apply a light coat of grade of lubricant recommended in this manual, at the speci-
oil and wrap it in clean (waxed) paper. Do not unwrap fied intervals. When recommended lubricants are not avail-
reusable or new bearings until they are ready to install. able, consult your local supplier for an equivalent that meets
or exceeds the specifications listed.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer or Battery
bore, apply pressure to the outer race. If the bearing is to
Clean battery using a non-metallic brush and a solution of
be installed on a shaft, apply pressure to the inner race.
baking soda and water. Rinse with clean water. After cleaning,
thoroughly dry battery and coat terminals with an anti corro-
Gaskets sion compound.
Check that holes in gaskets align with openings in the mating Lubrication and Servicing
parts. If it becomes necessary to hand-fabricate a gasket, use
gasket material or stock of equivalent material and thickness. Components and assemblies requiring lubrication and servic-
Be sure to cut holes in the right location, as blank gaskets can ing are shown in the Lubrication Chart in Section 1.
cause serious system damage.

Bolt Usage and Torque Application

SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING

LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.

1. Always use new replacement hardware when installing

locking fasteners. Use bolts of proper length. A bolt
which is too long will bottom before the head is tight
against its related part. If a bolt is too short, there will
not be enough thread area to engage and hold the part
properly. When replacing bolts, use only those having
the same specifications of the original, or one which is
equivalent.

3121671 2-3
SECTION 2 - GENERAL

2.3 LUBRICATION AND INFORMATION Changing Hydraulic Oil

1. Filter elements must be changed after the first 50 hours
Hydraulic System of operation and every 300 hours (unless specified oth-
1. The primary enemy of a hydraulic system is contamina- erwise) thereafter. If it is necessary to change the oil, use
tion. Contaminants enter the system by various means, only those oils meeting or exceeding the specifications
e.g., using inadequate hydraulic oil, allowing moisture, appearing in this manual. If unable to obtain the same
grease, filings, sealing components, sand, etc., to enter type of oil supplied with the machine, consult local sup-
when performing maintenance, or by permitting the plier for assistance in selecting the proper equivalent.
pump to cavitate due to insufficient system warm-up or Avoid mixing petroleum and synthetic base oils.
leaks in the pump supply (suction) lines. 2. Use every precaution to keep the hydraulic oil clean. If
2. The design and manufacturing tolerances of the compo- the oil must be poured from the original container into
nent working parts are very close, therefore, even the another, be sure to clean all possible contaminants from
smallest amount of dirt or foreign matter entering a sys- the service container. Always clean the mesh element of
tem can cause wear or damage to the components and the filter and replace the cartridge any time the system
generally results in faulty operation. Every precaution oil is changed.
must be taken to keep hydraulic oil clean, including 3. While the unit is shut down, a good preventive mainte-
reserve oil in storage. Hydraulic system filters should be nance measure is to make a thorough inspection of all
checked, cleaned, and/or replaced as necessary, at the hydraulic components, lines, fittings, etc., as well as a
specified intervals required in the Lubrication Chart in functional check of each system, before placing the
Section 1. Always examine filters for evidence of metal machine back in service.
particles.
3. Cloudy oils indicate a high moisture content which per-
Lubrication Specifications
mits organic growth, resulting in oxidation or corrosion. Specified lubricants, as recommended by the component
If this condition occurs, the system must be drained, manufacturers, are always the best choice, however, multi-pur-
flushed, and refilled with clean oil. pose greases usually have the qualities which meet a variety of
4. It is not advisable to mix oils of different brands or types, single purpose grease requirements. Should any question
as they may not contain the same required additives or arise, regarding the use of greases in maintenance stock, con-
be of comparable viscosities. Good grade mineral oils, sult your local supplier for evaluation. Refer to Section 1 for an
with viscosities suited to the ambient temperatures in explanation of the lubricant key designations appearing in the
which the machine is operating, are recommended for Lubrication Chart.
use.

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.

Hydraulic Oil
1. Refer to Section 1 for recommendations for viscosity
ranges.
2. JLG recommends Mobilfluid 424 hydraulic oil, which has
an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE: Start-up of hydraulic system with oil temperatures below -

15°F (-26°C) is not recommended. If it is necessary to start
the system in a sub-zero environment, it will be necessary
to heat the oil with a low density, 100VAC heater to a mini-
mum temperature of -15°F (-26°C).

3. The only exception to the above is to drain and fill the

system with Mobil DTE 13 oil or its equivalent. This will
allow start up at temperatures down to -20°F (-29°C).
However, use of this oil will give poor performance at
temperatures above 120°F (49°C). Systems using DTE 13
oil should not be operated at temperatures above 200°F
(94°C) under any condition.

2-4 3121671
SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST Cylinder Leakage Test

Cylinder oil must be at stabilized ambient temperature
Theory before beginning this test.
When a hydraulic cylinder is supporting a load, cylinder drift
may occur as a result of any of the circumstances below: Measure drift at cylinder rod with a calibrated dial indicator.

• Normal leakage of load holding valves or malfunction of In an area free of obstructions, cylinder must have load
load holding valves. See Cylinder Leakage Test and applied and appropriately positioned to detect drift.
Table 2-2., Cylinder Drift for evaluation. Cylinder leakage is acceptable if it passes this test.
• Damaged or worn piston seals.
• Normal thermal expansion or contraction of the hydraulic Table 2-2. Cylinder Drift
oil within cylinders (See Cylinder Thermal Drift below).
Max. Acceptable Drift
The first two circumstances may result in cylinder movement Cylinder Bore Diameter
in 10 Minutes
due to oil leaking out of the cylinder externally or by leaking
inches mm inches mm
back to tank or due to oil leaking internally from one cylinder
chamber to the other. 3 76.2 0.026 0.66

Thermal expansion or contraction of oil in hydraulic cylinders 3.5 89 0.019 0.48

is a normal occurrence and does not result in oil leaking out of 4 101.6 0.015 0.38
the cylinder or leaking internally from one cylinder chamber 5 127 0.009 0.22
to the other. Thermal expansion or contraction is the tendency
6 152.4 0.006 0.15
for materials to change size in response to a change in temper-
ature. 7 177.8 0.005 0.13
8 203.2 0.004 0.10
9 228.6 0.003 0.08
NOTE: The information is based on 6 drops per minute cylinder
leakage.

Cylinder Thermal Drift

The oil in all hydraulic cylinders will expand or contract due to
thermal effects over time and may result in changes to the
boom and/or platform position while the machine is station-
ary. These effects occur as the cylinder oil changes tempera-
ture, usually from a higher oil temperature as it cools and
approaches the ambient air temperature. Results of these
effects are related to several factors including cylinder length
and change in temperature over the time the cylinder remains
stationary.

3121671 2-5
SECTION 2 - GENERAL

2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT
GUIDELINES NOTE: This instruction applies to repairs, or modifications to the
Filament wound bearings. machine and to welding performed from the machine on
an external structure, or component.
1. Pinned joints should be disassembled and inspected if
the following occurs:
Do the Following When Welding on JLG Equipment
a. Excessive sloppiness in joints.
• Disconnect the battery.
b. Noise originating from the joint during operation.
• Disconnect the moment pin connection (where fitted).
2. Filament wound bearings should be replaced if any of
the following is observed: • Ground only to structure being welded.

a. Frayed or separated fibers on the liner surface. Do NOT Do the Following When Welding on JLG
b. Cracked or damaged liner backing. Equipment
c. Bearings that have moved or spun in their housing.
• Ground on frame and weld on any other area than the
d. Debris embedded in liner surface. chassis.
3. Pins should be replaced if any of the following is • Ground on turntable and weld on any other area than the
observed (pin should be properly cleaned prior to turntable.
inspection):
• Ground on the platform/support and weld on any other
a. Detectable wear in the bearing area. area than the platform/support.
b. Flaking, pealing, scoring, or scratches on the pin sur- • Ground on a specific boom section and weld on any other
face. area than that specific boom section.
c. Rusting of the pin in the bearing area.
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
4. Re-assembly of pinned joints using filament wound valves, electrical wiring, or hoses to be between the
bearings. grounding position and the welded area.
a. Housing should be blown out to remove all dirt and
debris...bearings and bearing housings must be free
of all contamination. FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
b. Bearing/pins should be cleaned with a solvent to PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
remove all grease and oil. Filament wound bearing RING, BOOM WIRE ROPES ETC.).
are a dry joint and should not be lubricated unless
otherwise instructed (i.e. sheave pins).
c. Pins should be inspected to ensure it is free of burrs,
nicks, and scratches which would damage the bear-
ing during installation and operation.

2-6 3121671
SECTION 2 - GENERAL

NOTE: Refer the Operation and Safety Manual for

completion procedures for the Pre-Start Inspection.

(Quarterly) (Yearly)
Inspection Inspection
General
All Decals/Placards Installed, Secure, Legible 9 9
Annual Machine Inspection Due 9
No Unauthorized Modifications or Additions 9 9
All Relevant Safety Publications Incorporated 9 9
General Structural Condition and Welds 2 2
All Fasteners, Pins, Shields, and Covers 1, 2 1, 2
Grease and Lubricate to Specifications 9 9
Function Test of All Systems 9 9
Paint and Appearance 5 5
Stamp Inspection Date on Frame 9
Notify JLG of Machine Ownership 9
Footnotes:
1 Prior to each sale, lease, or delivery
2 In service for 3 months; Out of service for 3 months or more; Purchased used
3 Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating body
4 Replace every 12 years or 7,000 hours
50 Indicates a 50 hour interval required to perform task after initial use of machine. This only occurs once in machine life
250 Indicates a 250 hour interval required to perform task after initial use of machine. This only occurs once in machine life

Performance Codes:
1 - Check for proper and secure: installation, adjustment, or torque
2 - Visual inspection for damage: (cracks, corrosion, abrasions, distortion, excessive wear, broken welds, gouges, chafing and threads showing)
3 - Proper operation
4 - Check for proper sealing, signs of leakage and fluid level
5 - Clean and free of debris
6 - Decals installed and legible
7 - Check for proper tolerances, routing, and lubrication
8 - Fully Charged
9 - Verify/Perform

3121671 2-9
SECTION 2 - GENERAL

1001159163-B
MAF00010

Figure 2-1. Engine Operating Temperature Specifications - Deutz 2.9

2-10 3121671
SECTION 2 - GENERAL

MACHINE OPERAT ION USING NON-JLG APPROVED

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

1001200022-B
MAF00030

Figure 2-2. Engine Operating Temperature Specifications - GM

3121671 2-11
SECTION 2 - GENERAL

NOTICE:
MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINE IN THE
“ENGINE OIL OPERATION CHART” MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE.
1001151190-B
MAF00040

Figure 2-3. Engine Oil Operating Temperature Specifications - Deutz 2011

2-12 3121671
SECTION 2 - GENERAL

1. MACHINE OPERAT ION USING NON-JLG APPROVED

2. SYNTHETIC OIL IS NOT RECOMMENDED.

1001214835-A
MAF00050

Figure 2-4. Engine Operating Temperature Specifications - Kubota

3121671 2-13
SECTION 2 - GENERAL

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 32 141 X
Univis HVI 26 26 376 X
Mobil EAL 224 H 47 212 X X X
Mobil Envirosyn H 46 49 145 X X X
Quintolubric 888-46 50 185 X X X X
NOTICE:
* Readily biodegradable classification indicates one of the following:
MACHINE OPERATION USING NON-JLG APPROVED
CO2 Conversion > 60% per EPA 560/6-82-003 HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF
CO2 Conversion > 80% per CEC-L-33-A-93 THE TEMPERATURE BOUNDARIES OUTLINED IN
THE "HYDRAULIC FLUID OPERATION CHART" MAY
** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203 RESULT IN PREMATURE WEAR OR DAMAGE TO
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval COMPONENTS OF THE HYDRAULIC SYSTEM.

1001206353-B
MAF00020

Figure 2-5. Hydraulic Oil Operating Temperature Specifications

2-14 3121671
SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES AND WHEELS Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a pneu-
matic tire. When selecting and installing a replacement tire,
Tire Inflation ensure that all tires are inflated to the pressure recommended
by JLG. Due to size variations between tire brands, both tires
The air pressure for pneumatic tires must be equal to the air on the same axle should be the same.
pressure that is stenciled on the side of the JLG product or rim
decal for safe and proper operational characteristics. Wheel Replacement
Tire Damage The rims installed on each product model have been designed
for stability requirements which consist of track width, tire
For pneumatic tires, JLG Industries, Inc. recommends that pressure, and load capacity. Size changes such as rim width,
when any cut, rip, or tear is discovered that exposes sidewall or center piece location, larger or smaller diameter, etc., without
tread area cords in the tire, measures must be taken to remove written factory recommendations, may result in an unsafe
the JLG product from service immediately. Arrangements condition regarding stability.
must be made for replacement of the tire or tire assembly.
Wheel Installation
For polyurethane foam filled tires, JLG Industries, Inc. recom- It is extremely important to apply and maintain proper wheel
mends that when any of the following are discovered, mea- mounting torque.
sures must be taken to remove the JLG product from service
immediately and arrangements must be made for replace-
ment of the tire or tire assembly.
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE
TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
• A smooth, even cut through the cord plies which exceeds
SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS
3 in. (7.5 cm) in total length
MATCHED TO THE CONE ANGLE OF THE WHEEL.
• Any tears or rips (ragged edges) in the cord plies which Tighten the lug nuts to the proper torque to prevent wheels
exceeds 1 in. (2.5 cm) in any direction from coming loose. Use a torque wrench to tighten the fasten-
ers. If you do not have a torque wrench, tighten the fasteners
• Any punctures which exceed 1 in. in diameter with a lug wrench, then immediately have a service garage or
dealer tighten the lug nuts to the proper torque. Over-tighten-
• Any damage to the bead area cords of the tire
ing will result in breaking the studs or permanently deforming
the mounting stud holes in the wheels.
If a tire is damaged but is within the above noted criteria, the
tire must be inspected on a daily basis to insure the damage The proper procedure for attaching wheels is as follows:
hasn’t propagated beyond the allowable criteria.
1. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
Tire Replacement
2. Tighten nuts in the following sequence:
JLG recommends a replacement tire be the same size, ply and
brand as originally installed on the machine. Please refer to the
JLG Parts Manual for the part number of the approved tires for
a particular machine model. If not using a JLG approved
replacement tire, we recommend that replacement tires have 8 1
the following characteristics:
3 6
• Equal or greater ply/load rating and size of original
5 4
• Tire tread contact width equal or greater than original
2 9
7
• Wheel diameter, width, and offset dimensions equal to the
original

• Approved for the application by the tire manufacturer

(including inflation pressure and maximum tire load)

3121671 3-1
SECTION 3 - CHASSIS & TURNTABLE

3. The tightening of the nuts should be done in stages. Fol- 3.4 DRIVE ORIENTATION SYSTEM
lowing the recommended sequence, tighten nuts per
wheel torque chart. The Drive Orientation System (DOS) is intended to indicate to
the operator conditions that could make the direction of
movement of the chassis different than the direction of move-
Table 3-1. Wheel Torque Chart ment of the drive/steer control handle. The system indicates to
TORQUE SEQUENCE the operator the need to match the black and white direc-
tional arrows on the platform control panel to the arrows on
1st Stage 2nd Stage 3rd Stage the chassis. The system uses a proximity sensor mounted on
40 ft. lbs. (55 Nm) 96 ft. lbs. (130 Nm) 170 ft. lbs. (230 Nm) the hydraulic oil coupling, an indicator light and an override
switch on the platform display panel. The proximity sensor
trips when the turntable is swung +/- 42 degrees off center of
4. Wheel nuts should be torqued before first road use and
the normal driving position. This occurs roughly when the
after each wheel removal. Check and torque every boom is swung past a rear tire. When the turntable is in the
3 months or 150 hours of operation. normal drive position with the boom between the rear tires,
no indications or interlocks are made. When the machine is
actively driving when the turntable is swung past the switch
3.2 CHASSIS TILT INDICATOR SYSTEM point, the system is ignored until drive/steer is released. When
drive is initiated with the boom swung past the switch point,
The Chassis Tilt Indicator System measures the turntable angle the DOS indicator will flash and the drive/steer functions will
with respect to level ground. The control system interprets the be disabled. The operator must engage the DOS override
reading and compares it to turntable tilt angle value set in the switch to enable drive/steer (High Speed drive will remain dis-
JLG Control System. abled). When the DOS is enabled, the DOS indicator will be
illuminated continuously and a 3-second enable timer will be
When the machine is in transport position, it can travel at up started and will continue for 3 seconds after the end the last
to maximum speed until it tilts more than 8.0°, then the sys- drive/steer command. If the timer expires, the DOS override
tem will limit the drive speed to maximum displacement switch must be re-engaged to enable drive/steer.
mode (low drive speed).

When the machine is out of transport position and the turnta- 3.5 LOCKOUT CYLINDER BLEEDING
ble tilts more than the configured value, the boom functions 1. Start the engine.
can only operate in creep speed mode, and the drive function
is disabled. The operator has to return the machine to trans- 2. Position the turntable to the normal stowed position.
port mode in order to continue to drive the machine. 3. Attach clear tubing to bleeder valve nipple.

Refer Table 6-2, Machine Configuration Programming Informa- 4. Position a small bucket/bottle in front of the lockout cyl-
tion (Software Version P2.10) for details. inder bleeder valve and insert clear tubing.
5. Using a 3/8 in. wrench, loosen the bleeder valve, turning
counterclockwise slowly. Bleed air from the top of lock-
3.3 DRIVE SYSTEM (4WD & 2WD) out cylinder. Capture hydraulic oil until a steady unbro-
ken stream of hydraulic oil is viewed. Tighten/close the
The four wheel drive system consists of one variable displace- bleeder valve while stream of hydraulic oil is running.
ment closed loop pump, four variable displacement piston
motors, gear reduction hubs, and a traction control manifold
that includes three flow dividers/combiners.

The two wheel drive system consists of one variable displace- BLEEDER
ment closed loop pump, two variable displacement piston VALVE
motors, gear reduction hubs, and a traction control manifold
that includes one flow dividers/combiner.

Drive speed is varied by a combination of drive pump dis-

placement, engine speed, and motor displacement. Traction
control is full-time and is present in all drive modes. There are
three drive modes that can be selected at the platform con-
sole. The functionality of the drive system is dependent on the
position of the boom. MAF00520

3-2 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.6 OSCILLATING AXLE SYSTEM 3.7 OSCILLATING AXLE LOCKOUT TEST

The oscillating front axle is attached to the frame by a pivot
pin, which allows all four wheels to remain on the ground
when traveling on rough terrain. There are two lockout cylin- LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS-
ders connected between the frame and the axle. The lockout TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
cylinders allow the axle to oscillate when the boom is in Trans- SUSPECTED.
port Position.
NOTE: Ensure boom is fully retracted, lowered, and centered
The lockout cylinders will hold down the oscillating axle so to
between rear wheels prior to beginning lockout cylinder
prevent its further movement if:
test.
• Main boom rises above elevation by more than 5°; OR
1. Place a 6 in. (15.2 cm) high block with ascension ramp in
• Fly boom telescopes out 12 in. (305 mm) or more.
front of left front wheel.
If the boom is telescoped less than 12 in. (305 mm) and boom
is no more than 5° greater than horizontal (with respect to the 2. From platform control console, start engine.
turntable), the turntable can swing 360° continuously without 3. Place the Drive control lever to the forward position and
locking up the oscillating axle for better traction. carefully drive machine up ascension ramp until left
The boom angle is monitored by the JLG Control System front wheel is on top of block.
through an angle sensor; the fly boom telescope is monitored 4. Carefully activate Telescope or Main Boom Lift control
by two proximity switches mounted on the main boom side. and take the boom out of the transport position.
When the JLG Control System senses the conditions are met, it
sends a signal to the 2-speed/lock up valve to supply pressure 5. Place Drive control lever to Reverse and drive machine
to lock up the cylinders. off of block and ramp.
6. Have an assistant check to see that left front or right rear
wheel remains elevated in position off of ground.
7. Return boom to stowed position. When boom reaches
center, stowed position, lockout cylinders should release
and allow wheel to rest on ground, it may be necessary
to activate Drive to release cylinders.
8. Place the 6 in. (15.2 cm) high block with ascension ramp
in front of right front wheel.
9. Place Drive control lever to Forward and carefully drive
machine up ascension ramp until right front wheel is on
top of block.
10. Repeat steps 4 through 7 to check the opposite side of
the oscillating axle.
11. If lockout cylinders do not function properly, have quali-
fied personnel correct the malfunction prior to any fur-
ther operation.

3121671 3-3
SECTION 3 - CHASSIS & TURNTABLE

9
12
8

11
10 7
9
8

3
4 5 10

3
2
13

MAF00360

1. Bolt 5. Washer 8. Wear Pad 11. Axle

2. Bolt 6. Washer 9. Shim 12. Axle Lockout Cylinder
3. Bearing 7. Bolt 10. Shim 13. Pin
4. Keeper Pin

Figure 3-1. Axle Installation

3-4 3121671
SECTION 3 - CHASSIS & TURNTABLE

11
2
5
12 13

13
2
1
5 6
10

4
2 9
8
12 5 13 7

9
MAF00460

1. Thrust Bearing 5. Keeper Pin 8. Steer Cylinder 11. Kingpin

2. Bolt 6. Washer 9. Link 12. Spindle
3. Bolt 7. Washer 10. Nut 13. Pin
4. Bolt

Figure 3-2. Steer Installation (Without Tow Package)

3121671 3-5
SECTION 3 - CHASSIS & TURNTABLE

18
2
8
19 24

14
2 1
8 10
17

3
26 18

3
26
2 16 25
7 15
19 8 24 13
20

4
9
26 6
26 12
11
23 5 5 21

22
12

MAF00470

1. Thrust Bearing 6. Bearing 11. Washer 15. Steer Cylinder 19. Spindle 23. Link
2. Bolt 7. Pin 12. Washer 16. Link 20. Bracket 24. Pin
3. Bolt 8. Keeper Pin 13. Washer 17. Nut 21. Pivot Plate 25. Bolt
4. Bolt 9. Bolt 14. Pin 18. Kingpin 22. Link 26. Washer
5. Bolt 10. Washer

Figure 3-3. Steer Installation (With Tow Package)

3-6 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.8 WHEEL DRIVE ASSEMBLY NOTE: The drive hub and drive motor assembly weighs approxi-
mately 149 lbs. (68 kg).
Removal 4. Use a supporting device capable of handling the weight
of the drive hub and drive motor, and unbolt the drive
NOTE: The drive motor can be removed through the axle flange as
hub from the frame. Remove the entire assembly from
part of the wheel drive assembly or they can be removed
the machine.
separately through the bottom of the frame while leaving
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 pneumatic tire & wheel assembly weighs approxi- 1. Install a new brake gasket between the drive motor and
mately 170 lbs. (77 kg). The foam-filled tire & wheel assem- drive hub. Apply a coat of JLG Threadlocker P/N 0100011
bly weighs approximately 440 lbs. (200 kg). The solid tire & on capscrews. Install the washers and capscrews to
wheel assembly weighs approximately 286 lbs. (130 kg). secure the drive hub and drive motor, and torque to
70 ft. lbs. (95 Nm).
2. Remove hardware securing wheel and remove wheel 2. Place the drive hub flange against the mounting flange
assembly. Using suitable lifting device lift the wheel on the axle and fasten it in place with the bolts and
assembly and place in a suitable area. washers. Torque the bolts to 190 ft. lbs. (258 Nm).
3. Tag and disconnect the hydraulic lines running to the 3. Using adequate support, install wheel into wheel
drive motor. Cap or plug all openings to ensure no dirt assembly and secure with bolts and washers. Torque the
enters the hydraulic system. lugnuts to 170 ft. lbs. (230 Nm).

DRIVE MOTOR

BRAKE GASKET
DRIVE HUB

WASHER LUGNUT
CAPSCREW

WHEEL

MAF00530

Figure 3-4. Wheel Drive Installation

3121671 3-7
SECTION 3 - CHASSIS & TURNTABLE

3.9 TORQUE HUB Tightening and Torquing Bolts

Roll and Leak Testing

Always roll and leak test Torque-Hubs after assembly to make USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN
sure that the unit’s gears and sealants are working properly. BOLTS BEYOND THEIR TORQUE SPECIFICATION. NEVER USE AN IMPACT
The following information briefly outlines what to look for WRENCH TO TIGHTEN SHOULDER BOLTS. TIGHTEN ALL SHOULDER BOLTS BY
when performing these tests. HAND.
ROLL TEST
1. Tighten (but do not torque) bolt ”A” until snug.
The roll test determines if the unit’s gears rotate freely and
2. Go to opposite side of bolt circle and tighten bolt ”B”
properly. You should be able to rotate gears by applying a con-
until equally snug.
stant force to the roll checker. If you feel more drag in gears
only at certain points, gears are not rolling freely. Examine 3. Continue around bolt circle and tighten remaining bolts.
them for improper installation or defects.
4. Apply specified torque to bolt ”A”.
Some gear packages roll with more difficulty than others. Do
5. Continue around bolt circle and apply equal torque to
not be concerned if gears seem to roll hard as long as they roll
remaining bolts.
with consistency.
LEAK TEST
The purpose of a leak test is to make sure unit is air tight. You
can tell if your unit has a leak if pressure gauge test reading
starts to fall once you have pressurized the unit.
Leaks usually occur at the main seal or wherever O-rings or
gaskets are located. You can usually detect location of a leak
by brushing a soap and water solution around main seal and
where O-rings or gaskets meet unit exterior, then checking for
air bubbles. Replace part immediately if you detect a leak in a
seal, O-ring, or gasket.

Figure 3-5. Bolt Tightening Sequence

3-8 3121671
SECTION 3 - CHASSIS & TURNTABLE

Main Disassembly for “B” Drives Hub-Spindle Disassembly

1. Turn hub (1G) on side, Remove coupling (14) from wide NOTE: Start with large end of hub facing up and large end of spin-
end of spindle (1A). dle facing down.
2. Mark location of shoulder bolt holes on outside of ring
gear and hub for easy realignment when rebuilding.
Remove four shoulder bolts (13) and 12 bolts (12) from
cover (6). UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY.
ALWAYS WEAR EYE PROTECTION.
3. Remove 16 flat washers (16) from cover (6).

4. Lift cover sub-assembly (6) off ring gear (4). Set cover on 1. Remove retaining ring (1I) from around spindle (1A) ia
table with interior side facing up. hub (1G).

2. Remove spacer (1H) from around spindle (1A) in hub

(1G).
SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE OF SHARP
EDGES IN COUNTERBORE WHEN REMOVING O-RING. 3. Set hub (1G), with small end/spindle facing down, on
something that will support the hub’s flange while it lifts
5. Remove O-ring (5) from counterbore around edge of hub up so spindle is not resting on anything. Carefully
cover (6A). Discard O-ring. press or hammer spindle (1A) down and out of hub (1G).

NOTE: If O-ring is not in cover counterbore, it is in ring gear coun- NOTE: If seal (1B) and bearing cone (1D) come out of hub and rest
terbore. Remove it from hub and discard.
on spindle, remove these parts from spindle and set them
aside. Discard seal.
6. Remove thrust washer (11) from counterbore in top of
carrier (3A).
4. If seal and bearing cone did not come out of small end
7. Remove input gear (8) from middle of carrier sub-assem- of hub (1G) when you pressed spindle out of hub,
bly (3). remove seal (1B) and bearing cone (1D) from small end
of hub (1G). Discard seal.
8. Lift ring gear (4) off hub (1G).
5. Bearing cone (1F) should be lying loose in wide end of
9. Lift carrier sub-assembly (3) out of hub (1G).
hub (1G). Remove bearing cone (1F) from inside hub
10. Remove thrust spacer (9) from input shaft (7) in middle (1G).
of spindle (1A).
NOTE: Do not strike counterbore with punch if using a punch and
11. Lift input shaft sub-assembly (7) out of middle of spindle hammer when removing bearing cup.
(1A). Stand input shaft (7A) on splined end.

6. Remove bearing cup (1C) from counterbore in small end

of hub (1G).
UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY.
ALWAYS WEAR EYE PROTECTION. NOTE: Do not strike counterbore with punch if using a punch and
hammer when removing bearing cup.
12. Using retaining ring pliers, remove retaining ring (7B)
from groove on input shaft (7A). 7. Turn hub (1G) over and lift it out of flange-support.
Remove bearing cup (1E) from counterbore in wide end
13. Remove one spacer (7D), one spring (7C), and other
spacer (7D) from input shaft (7A). of hub (1G).

14. Remove thrust washer (11) from around spindle (1A). 8. Turn hub (1G) over onto its small end. Remove two pipe
plugs (1J) from side of hub (1G).
15. Lift internal gear (2) out of hub (1G).
NOTE: If your unit does not have studs, skip this step.
16. Remove O-ring (5) from counterbore in hub (1G). Dis-
card O-ring.
9. Press nine studs (1N) out of stud holes in hub (1G).
17. Main disassembly for ”B” drives is complete.
10. Hub-spindle disassembly is complete.

3121671 3-9
SECTION 3 - CHASSIS & TURNTABLE

6F
7B
6E 7D 27
12
6D 7C 111
6C 7D 110
7
6I 6G
6J 112
6 7A
6G 6B
121 102

2
13 13 122
6A 123
1I 119
1H 104
5A
1F
103

4 1E
106

5 3G
1G 103
3E
17
106

1
3 1N 101
3A
1D
3B
116
16 3C 115
1C
3D
8 3C 109
15 1B
3F 118
11 1A 117
3B
120 107

14 108

114
105 113
124

28
29
MAF00540

Figure 3-6. Drive Hub and Brake Assembly (2WD and 4WD) - Sheet 1 of 2

3-10 3121671
SECTION 3 - CHASSIS & TURNTABLE

1 Spindle/Housing Assembly 3G Roll Pin 7D Thrust Spacer 107 Gasket

1A Spindle 4 Ring Gear 8 Sun Gear 108 Cylinder
1B Seal 5 O-Ring 11 Thrust Washer 109 Piston
1C Bearing Cone 5A O-Ring 12 Bolt 110 Ball Bearing
1D Bearing Cup 6 Cover Assembly 13 Dowel Pin 111 Retaining Ring
1E Bearing Cup 6A Thrust Spacer 14 Coupling 112 Shaft Seal
1F Bearing Cone 6B Cover Plate 15 Input Spacer 113 Capscrew
1G Housing/Ring Gear 6C O-Ring 16 Input Spacer 114 Lockwasher
1H Thrust Washer 6D Disconnect Rod 17 Brake Assembly 115 O-Ring
1I Retaining Ring 6E Disengage Cap 27 O-Ring 116 Backup Ring
1N Wheel Stud 6F Bolt 28 Threaded Rod 117 O-Ring
2 Internal Gear 6G Pipe Plug 29 Nut, 1/2in-13NC 118 Backup Ring
3 Carrier Assembly 6I Rivet 101 Shaft 119 Dowel Pin
3A Carrier 6J I.D. Plate 102 Housing 120 Plug
3B Retaining Ring 7 Input Shaft Assembly 103 Friction Plate 121 Plug
3C Needle Bearing 7A Shaft 104 Pressure Plate 122 Spring (Natural)
3D Thrust Washer 7B Retaining Ring 105 Gasket 123 Spring (Blue)
3E Planet Shaft 7C Spring 106 Outer Plate 124 Gasket
3F Planet Gear

Figure 3-7. Drive Hub and Brake Assembly (2WD and 4WD) - Sheet 2 of 2

3121671 3-11
SECTION 3 - CHASSIS & TURNTABLE

6F
6E 12
6D 3G
6C 3E
6G 1I
6I
6J
6 1H
6G 6B
3
3A 1F

3B
13 13 1E
16 3C
6A
3D
8 3C
1G
15
5A 3F
11
3B
7B 1
7D 1N
4
7C
7D 1D
7
5
1C
7A

2 1A

MAF00550

Figure 3-8. Drive Hub (4WD Front Only) - Sheet 1 of 2

3-12 3121671
SECTION 3 - CHASSIS & TURNTABLE

1 Spindle/Housing Assembly 3 Carrier Assembly 6 Cover Assembly 7A Shaft

1A Spindle 3A Carrier 6A Thrust Spacer 7B Retaining Ring
1B Seal 3B Retaining Ring 6B Cover Plate 7C Spring
1C Bearing Cone 3C Needle Bearing 6C O-Ring 7D Thrust Spacer
1D Bearing Cup 3D Thrust Washer 6D Disconnect Rod 8 Gear, Sun
1E Bearing Cup 3E Planet Shaft 6E Disengage Cap 11 Thrust Washer
1F Bearing Cone 3F Planet Gear 6F Bolt 12 Bolt
1G Housing/Ring Gear 3G Roll Pin 6G Plug, Pipe 13 Pin, Dowel
1H Thrust Washer 4 Ring Gear 6I Rivet 14 Coupling
1I Retaining Ring 5 O-Ring 6J I.D. Plate 15 Input Spacer
1N Wheel Stud 5A O-Ring 7 Input Shaft Assembly 16 Input Spacer
2 Internal Gear

Figure 3-9. Drive Hub (4WD Front Only) - Sheet 2of 2

3121671 3-13
SECTION 3 - CHASSIS & TURNTABLE

1. Hub-Spindle Sub-Assembly 2. Internal Gear A. Cover C. Spring

A. Spindle 3. Carrier Sub-Assembly B. Cover Cap D. Spacer
B. Seal A. Carrier Housing C. Bolt 8. Input Gear
C. Bearing Cup B. Thrust Washer D. Disconnect Cap 9. Thrust Spacer
D. Bearing Cone C. Needle Roller E. Disconnect Rod 11. Thrust Spacer
E. Bearing Cup D. Spacer F. O Ring 12. Bolt
F. Bearing Cone E. Planet Shaft G. O Ring 13. Shoulder Bolt
G. Hub F. Cluster Gear 14. Coupling
H. Pipe Plug
G. Roll Pin 16. Flat Washer
H. Spacer I. ID Plate
I. Retaining Ring 4. Ring Gear 7. Input Shaft Sub Assembly
J. Pipe Plug 5. O Ring A. Seal
N. Stud 6. Cover Sub-Assembly B. Retaining Ring

Figure 3-10. Drive Hub (Cross-Section)

3-14 3121671
SECTION 3 - CHASSIS & TURNTABLE

Cover Disassembly Assemble Carrier

1. Remove two bolts (6C) holding disconnect cap (6D) to 1. Apply grease to inside of one cluster gear (3F) and line one
cover (6A). half of cluster gear with 16 needle rollers (3C).

2. Remove disconnect cap (6D) from on top of cover cap

(6B) and cover (6A).

3. Remove two bolts (6C) holding cover cap (6B) to cover

(6A).

4. Remove cover cap (6B) from cover (6A).

5. Remove disconnect rod (6E) from cover cap (6B).

6. Pry O-ring (6F) out of groove inside cover cap (6B). Dis-
card O-ring.

7. Remove O-ring (6G) from flange of cover cap (6B). Dis- 2. Place spacer (3D) inside cluster gear (3F) so it rests on
card O-ring. top of needle rollers.
8. Remove pipe plug (6H) from cover (6A).

9. Cover disassembly is complete.

Carrier Disassembly
NOTE: Discard old needle rollers and use new ones during reas-
sembly.

1. Using a punch and hammer, drive roll pin (3G) into

planet shaft (3E).

3. Line remaining half of cluster gear (3F) with 16 needle

rollers (3C).
DRIVE ROLL PIN ALL THE WAY INTO PLANET SHAFT OR CARRIER WILL BE
DAMAGED WHEN PLANET SHAFT IS REMOVED.

2. Using a punch and hammer, drive planet shaft (3E) out

of planet shaft hole in carrier housing (3A).

3. When you remove planet shaft (3E) from carrier housing,

one thrust washer (3B), one cluster gear (3F), and one
more thrust washer (3B) will come off planet shaft and
come to rest inside carrier. Remove these parts from
inside carrier.

4. Remove 16 needle rollers (3C) from inside one end of

cluster gear (3F). Discard needle rollers.

5. Remove one spacer (3D) from inside cluster gear (3F).

6. Remove remaining 16 needle rollers (3C) from other side

of cluster gear (3F). Discard needle rollers.

7. Repeat steps 1-6 to remove and disassemble two

remaining cluster gears.

8. At this point carrier disassembly is complete.

3121671 3-15
SECTION 3 - CHASSIS & TURNTABLE

4. Set carrier housing (3A) on table, sideways. Insert a 7. Following cluster gear, place one more thrust washer
planet shaft (3E), roll pin hole last, into one of the planet (3B) onto planet shaft (3E) through opposite planet shaft
shaft holes from roll-pin-holed side of carrier housing hole in carrier housing (3A).
(3A).

8. Use an alignment punch or similar tool to align roll pin

5. Place thrust washer (3B) on end of planet shaft (3E) holes in carrier housing (3A) and planet shaft (3E).
inside carrier. Fit tang of thrust washer into slot on inside
edge of planet shaft hole.

9. Drive roll pin (3G) into aligned roll pin holes in carrier
housing (3A) and planet shaft (3E).
6. Following thrust washer, place cluster gear (3F), large
end toward roll pin hole in carrier housing, on planet
shaft (3E).

10. Repeat steps 1-9 to assemble and install two remaining

cluster gears.
11. At this point carrier sub-assembly is complete.

3-16 3121671
SECTION 3 - CHASSIS & TURNTABLE

Cover Sub-Assembly 4. Set cover (6A) on table, exterior side up. Place cover cap
(6B) on cover (6A). Align pipe plug hole in cover cap over
1. Using disconnect rod, push O-ring (6F) into groove pipe plug hole in cover.
inside cover cap (6B).

5. Place two cover cap bolts (6C) in any two bolt holes 180°
2. Place O-ring (6G) onto cover cap (6B) so it rests against apart on cover cap (6B) and tighten bolts.
flange of cover cap.

6. Using a torque wrench, apply 36 to 49 in. lbs. (4 to 5 Nm) of

3. Insert disconnect rod (6E) into cover cap (6B). torque to both bolts (6C).

3121671 3-17
SECTION 3 - CHASSIS & TURNTABLE

7. With large end down, place disconnect cap (6D) on 10. Apply a light coat of “Never-Seize” to pipe plug (6H) and
cover cap (6B), aligning pipe plug hole in disconnect cap tighten it in pipe plug hole in cover (6A).
over pipe plug hole in cover cap.

11. At this point cover sub-assembly is complete.

8. Place two remaining bolts (6C) in bolt holes in discon-
nect cap (6D) and tighten bolts. Hub-Spindle Sub-Assembly
NOTE: Make sure cup sits square with counterbore before press-
ing.

1. Set hub (1G) on large end. Press bearing cup (1C) into
counterbore in small end of hub (1G).

9. Using a torque wrench, apply 36 to 49 in. lbs. (4 to 5 Nm) of

torque to both bolts (6C).

2. Press nine studs (1N) in stud holes in hub (1G).

3-18 3121671
SECTION 3 - CHASSIS & TURNTABLE

3. Apply a light coat of “Never-Seize” to two pipe plugs (1J) 6. Press seal (1B) in small end of hub (1G).
and tighten them in two pipe plug holes in side of hub
(1G).

7. Oil spindle, then lower hub (1G) small end down, onto
spindle (1A).
NOTE: Make sure cup sits square with counterbore before press-
ing.

4. Turn hub (1G) over to small end. Press bearing cup (1E)
into counterbore in deep end of hub (1G).

8. Press bearing cone (1F) on spindle (1A) in hub (1G).

5. Set hub (1G) on large end. Place bearing cone (1D) into
bearing cup (1C).

3121671 3-19
SECTION 3 - CHASSIS & TURNTABLE

9. Place spacer (1H) on spindle (1A) in hub (1G). Main Assembly

SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE OF SHARP
EDGES IN COUNTERBORE WHEN REMOVING O-RING.

1. Grease O-ring (5) and place it into counterbore in hub

(1G).

NOTE: O-ring may be stretched or pinched together to make it fit

into counterbore.

NOTE: Make sure retaining ring is securely seated in groove.

10. Place retaining ring (1I) over spacer onto spindle (1A) in
hub (1G).

2. Oil exposed surfaces inside hub (1G).

11. At this point hub-spindle sub-assembly is complete.

3. Place internal gear (2) in hub (1G) so its internal splines

mesh with external splines of spindle (1A). Oil internal
gear (2).

3-20 3121671
SECTION 3 - CHASSIS & TURNTABLE

4. Place thrust washer (11) around spindle (1A) so it rests 7. Place other spacer (7D) on smooth end of input shaft
on bottom of internal gear (2). (7A).

5. Stand input shaft (7A) on splined end. Place one spacer

(7D) on smooth end of input shaft (7A).
UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY.
ALWAYS WEAR EYE PROTECTION.

8. Using retaining ring pliers, insert retaining ring (7B) in

groove on input shaft (7A) by compressing spring and
spacers together.

6. Place spring (7C) on smooth end of input shaft (7A).

9. With large splined end down, place input shaft sub-

assembly (7) into spindle (1A).

3121671 3-21
SECTION 3 - CHASSIS & TURNTABLE

10. Place thrust spacer (9) onto input shaft (7). 13. Place carrier sub assembly (3) and ring gear (4) together
into mesh with internal gear (2), aligning “X” marked
shoulder bolt hole in ring gear (4) over one of the shoul-
der bolt holes in hub. Mark location of shoulder bolt
holes on outside of ring gear and hub.

NOTE: You may lift ring gear off hub to align shoulder bolt holes.
Ring gear and carrier are installed together only to keep
punch marks on carrier in place.

11. Set carrier sub-assembly (3) on a flat work surface so

large ends of cluster gears (3F) face up. Locate punch
marks on face of each cluster gear (3F) and position
them at 12 o’clock.

14. With internal splines facing up (counterbore end facing

down), place input gear (8) into mesh with carrier sub-
assembly (3).

Figure 3-11. Cluster Gear Punch Marks

12. With “X” marked side facing up, place ring gear (4)
around cluster gears (3F).

NOTE: This will hold punch marks in position while installing car-
rier into hub.

15. Oil all exposed surfaces inside hub (1G). Place thrust
washer (11) into counterbore in top of carrier.

3-22 3121671
SECTION 3 - CHASSIS & TURNTABLE

19. Place shoulder bolts (13) in four shoulder bolt holes in

cover (6) and hand-tighten.
SHARP EDGES IN COUNTERBORE CAN CUT AND CAUSE INJURY WHEN INSTALL-
ING O-RING.

16. Set cover (6A) on table, interior side up. Grease O-ring (5) and
place in counterbore around edge of cover (6A).

NOTE: O-ring may be stretched or pinched together to make it fit

counterbore.

20. Place remaining 12 flat washers (16) on remaining bolt

holes in cover (6).

17. Place cover sub-assembly (6) on ring gear (4). Align pipe
plug holes before disassembly.

21. Place 12 bolts in remaining bolt holes in cover (6) and

tighten.

18. Place four flat washers (16) on top of bolt holes in cover
sub-assembly.

3121671 3-23
SECTION 3 - CHASSIS & TURNTABLE

22. Torque shoulder bolts (13) 18 to 25 ft. lbs. (25 to 34 Nm). 24. Roll test unit in clockwise and counterclockwise direc-
Torque bolts (12) 18 to 25 ft. lbs. (25 to 34 Nm). tions. Perform same number of turns in each direction as
the ratio of the unit. The ratio is the last two digits of the
model number on the unit’s ID tag.

23. Turn hub (1G) on its side. Insert coupling (14) into end of
spindle (1A).
25. Leak test unit at a pressure of 5 psi (34.47 kPa) for 2 to 3
minutes.

26. At this point main assembly is complete.

3-24 3121671
SECTION 3 - CHASSIS & TURNTABLE

Tool List 3. T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E).

The following specialized tools are used to assemble this unit.
Tool diagrams in this manual are intended for the customer
who may wish to have a tool made. All tools are one piece and
must be made from mild steel. All dimensions are in inches.

NOTE: Tools may be carburized and hardened to improve tool life.

If this is done, tools must be ground on all surfaces labeled
with a “G” on the tool diagram.

1. T-118126 SEAL PRESSING TOOL FOR SEAL (1B).

4. T-109691 ASSEMBLY PRESSING TOOL FOR CONE (1F).

* These tools are for specific seals, cups or cones. There is a

2. T-138903 ASSEMBLY PRESSING TOOL FOR CUP (1C). specific tool for each cup and cone.

3121671 3-25
SECTION 3 - CHASSIS & TURNTABLE

3.10 RE-ALIGN TORQUE HUB INPUT COUPLING 3.11 DRIVE MOTOR

This procedure applies to torque hubs with integral brakes:
Description
Equipment Required Drive motors are low to medium power, two-position axial pis-
ton motors incorporating an integral servo piston. They are
1. Hydraulic power supply (hand pump) capable of pro- designed for operation in open and closed circuit applications.
ducing 200 psi (13.8 bar). The standard control is a direct acting single line hydraulic
control. The integral servo piston controls motor displace-
2. Hydraulic fittings to adapt hydraulic supply to brake ment.
release port on hub.
Motors are spring biased to maximum displacement and
Procedure hydraulically shifted to minimum displacement. Minimum and
maximum displacement can be set with fixed internal stops.
1. Using appropriate fittings, connect a line from hydraulic The large diameter servo piston allows smooth acceleration
power supply to brake port. and deceleration with relatively large circuit orificing.
2. Pressurize brake release port to 155 - 200 psi (10.6 - Bias spring
13.8 bar) to release brake. Servo piston
Minimum
3. Verify brake is released by rotating input coupling or Angle Swashplate
hub spindle. Once brake is released, input coupling is Stop
free to re-align with drive motor.
4. Install drive motor on hub. Release hydraulic pressure at Output
brake release port. Coupling remains in position. Cylinder Shaft
Block
5. Disconnect hydraulic power supply and reconnect line
to brake release port.

Shaft
Seal
Piston
Endcap Slipper Bearing
Valve plate

Figure 3-12. Drive Motor Cross Section

3-26 3121671
SECTION 3 - CHASSIS & TURNTABLE

Shaft Seal Replacement Loop Flushing Valve

REMOVAL REMOVAL
1. Remove snap ring (1) and support washer (2). 1. Remove plug (1) and (2) with 11/16 in. internal hex wrench.

1. Snap Ring
2. Support Washer
3. Shaft Seal

Figure 3-13. Removing Shaft Seal

NOTE: To avoid damaging shaft during removal, install a large 1. Plug 5. O-ring 8. Spring 11. Washer
sheet metal screw into chuck of a slide hammer. Drive 2. Plug 6. O-ring 9. Spring 12. Shift Spool
screw into seal surface and use slide hammer to pull seal. 3. Plug 7. Spring 10. Washer 13. Orifice Poppet
4. O-ring
2. Carefully pry out and discard shaft seal (3).

INSPECT COMPONENTS Figure 3-14. Loop Flushing Spool

2. Use 1/4 in. in hex wrench to remove plug (3).
Inspect new seal, motor housing seal bore, and sealing area on
shaft for rust, wear, and contamination. Polish shaft and clean 3. Remove O-rings (4, 5, and 6).
housing if necessary.
4. Use pliers to remove centering springs (7, 8, and 9).
INSTALLATION 5. Remove spring retaining washers (10 and 11).
1. Cover shaft splines with an installation sleeve to protect 6. Remove shift spool (12).
shaft seal during installation.
7. Remove orifice poppet (13).
2. Install a new shaft seal (3) with cupped side facing
motor. Press seal into housing until it bottoms out. Press 8. Inspect new O-rings and sealing area for rust, wear, or con-
evenly to avoid binding and damaging seal. tamination. Check springs and poppet for wear.

3. Install seal support washer (2). INSTALLATION

4. Install snap ring (1). 1. Install orifice poppet (13).
5. Remove installation sleeve. 2. Install shift spool (12).
3. Install spring retaining washers on springs (10 and 11).
4. Carefully install centering springs (7, 8, and 9).
5. Install new O-rings (6, 4, and 5).
6. Use 1/4 in. hex wrench to torque plug (3) to 20 ft. lbs. (27 Nm).
7. Use 11/16 in. internal hex and torque plugs (2 and 1) to
27 ft. lbs. (37 Nm).

3121671 3-27
SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting

Table 3-2. Excessive Noise and/or Vibration

Item Description Action

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

Table 3-3. System Operating Hot

Item Description Action

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

Table 3-4. Won’t Shift or Slow to Start

Item Description Action

Check signal line to servo control Obstructed or restricted flow through the servo control signal lines could Ensure signal lines are not obstructed or restricted and that signal pressure
port. result in slow shift or no shift conditions within the motor. is adequate to shift the motor.
Check correct supply and drain Supply and drain orifices determine motor shift rate. The smaller the ori- Ensure proper control orifices are installed in motor and check they are not
orifices are properly installed fice, the longer time it takes to shift the motor. Obstruction also increases obstructed. Clean or replace as needed.
and not obstructed. shift times.

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SECTION 3 - CHASSIS & TURNTABLE

Disassembly
17
NOTE: Removal of endcap voids warranty.
19

During assembly, coat all moving parts with a film of

clean hydraulic oil. This ensures parts are lubricated dur-
ing start-up.
15
Replace all O-Rings and gaskets. Lightly lubricate O-rings
with clean petroleum jelly prior to assembly.
14

6
9
5 11
2
7 21
13
3

10 12
8
4

1 16

14. Lock Nut 18. Cavity Plug

15. O-ring Plug 19. Drain Plug
1. Plug 5. O-ring 9. Spring 12. Shift Spool 16. Control Line Plug 20. Drain Plug
2. Plug 6. O-ring 10. Washer 13. Orifice Poppet 17. Control Line Plug 21. Work Port Plug
3. Plug 7. Spring 11. Washer Figure 3-16. Plugs, Fittings, and Speed Sensor
4. O-ring 8. Spring
Figure 3-15. Loop Flushing Spool 8. Remove all fittings from unit. Discard O-rings.
9. Using an 11/16 in. hex wrench, loosen speed sensor lock
1. Using a 11/16 in. wrench, remove plug (1) and (2). nut (14) if equipped and remove speed sensor. Units
2. Using a 5/8 in. hex wrench, remove plug (3). without speed sensor have an O-ring plug (15) installed
in that location; remove it with a 1/4 in. internal hex
3. Remove O-rings (4, 5, and 6). wrench.
4. Using pliers, remove centering springs (7, 8, and 9). 10. Using a 1/4 in. internal hex wrench, remove control line
5. Remove spring retaining washers (10 and 11). plugs (16, 17). Discard O-rings. Using a 3 mm hex
wrench, remove cavity plug (18) (if equipped with two-
6. Remove shift spool (12). line control), from X2 cavity.
7. Remove orifice poppet (13). 11. Using a 5/16 in. internal hex wrench, remove drain plugs
(19, 20). Discard O-rings.
12. If equipped with axial ports, use a 9/16 in. an internal hex
wrench and remove work port plugs (21). Discard O-rings.

3121671 3-29
SECTION 3 - CHASSIS & TURNTABLE

25
22

27
30

23 29
29
26
24
28

22. Screw
23. End Cap 25. Valve Plate 27. O-ring 29. Angle Stop
24. O-ring 26. End Cap 28. O-ring 30. Servo Spring

Figure 3-17. End Cap

Figure 3-18. Valve Plate & Rear Shaft Bearing
13. Using an 8 mm internal hex wrench, remove endcap
screws (22).
14. Remove endcap (23). Remove O-ring (24) from housing DO NOT SCRATCH VALVE PLATE SURFACE.
or endcap.
15. Remove valve plate (25) and timing pin (26) from endcap.
NOTE: When endcap screws are removed, pressure from servo
spring will cause endcap to bind on shaft. Press down on NOTE: Each displacement has a unique valve plate. The last two
portion of endcap covering servo piston and hold endcap
digits of the part number are stamped on its surface.
level while removing.

16. Remove and discard O-rings (27, 28).

17. Remove rear shaft bearing (29) from endcap with a bear-
ing puller.

DO NOT DRIVE BEARING PAST REAR SHAFT JOURNAL. BEARING MAY BECOME
TRAPPED ON SHAFT AND DAMAGED.

NOTE: Bearing may be difficult to remove with a puller. Try this as

an alternative: Pack bearing cavity with heavy grease.
After shaft is removed, insert it into bearing cavity and tap
lightly with a soft mallet on the splined end. Grease will
force out bearing.

18. Remove minimum angle stop (29) and servo spring (30)
from housing.

3-30 3121671
SECTION 3 - CHASSIS & TURNTABLE

33
31

31. Cylinder Kit Assembly

Figure 3-19. Cylinder Kit

19. Turn housing on its side and remove cylinder kit assem-
bly (31). Set assembly aside. Do not to scratch running
surface. 32. Snap Ring
33. Support Washer
NOTE: Grooves on surface of cylinder kit identify its displacement: 34. Shaft Seal

Table 3-5. Displacement Identifiers Figure 3-20. Shaft Seal

# of Grooves Frame L Frame K

20. Turn housing over and remove snap ring (32), retaining shaft
1 25 38 seal, and support washer. Remove support washer (33).
2 30 45 Carefully pry out shaft seal (34). Discard seal.
3 35 -- NOTE: To avoid damaging shaft during seal removal. Install a
large sheet metal screw in chuck of a slide hammer. Drive
screw into seal surface. Use slide hammer to pull seal.

36
35
37

35. Inner Snap Ring

36. Snap Ring
37. Bearing
38. Shaft

Figure 3-21. Shaft & Front Bearing

21. Remove inner snap ring (35) and shaft/bearing assembly.

22. Remove snap ring (36) retaining shaft front bearing. Pull
bearing (37) off shaft (38).

3121671 3-31
SECTION 3 - CHASSIS & TURNTABLE

Lift here
44
39

47
40
48
43
42
49
41

39. Swashplate 50
40. Servo Piston
41. Piston Seal 51
42. O-ring
43. Journal Bearings

Figure 3-22. Swash Plate & Servo Piston

44. Piston 49. Retaining Ring
23. Turn housing over and remove swashplate (39) by lifting 45. Slipper Retainer 50. Block Spring Washer
on end opposite servo lever. 46. Cylinder Block 51. Spiral Retaining Ring
47. Ball Guide 52. Block Spring
24. Remove servo piston (40). Remove piston seal (41) and 48. Holddown Pins 53. Inner Block Spring Washer
O-ring (42) from servo piston. Discard seal and O-ring.
Figure 3-23. Cylinder Kit Disassembly
25. Remove journal bearings (43) from housing. If bearings
will be reused, note location and orientation of each
bearing for reassembly.
26. Remove pistons (44) and slipper retainer (45) from cylin- RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING REQUIRES FORCE
der block (46). OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO MAIN-
TAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS SECURE
NOTE: Pistons are not selectively fitted. Units with high hourly BEFORE ATTEMPTING TO REMOVE SPIRAL RETAINING RING. RELEASE PRES-
usage may develop wear patterns. Number pistons and SURE SLOWLY AFTER RETAINING RING IS REMOVED.
bores for reassembly if they will be reused.
28. Turn block over. Using a press, apply pressure on block
27. Remove ball guide (47), hold-down pins (48), and retain- spring washer (50) to compress block spring enough to
ing ring (49) from cylinder block. safely remove spiral retaining ring (51). Maintain pres-
sure and unwind spiral retaining ring (51). Carefully
NOTE: Most repairs do not require block spring removal. Perform release pressure and remove outer block spring washer
this procedure only if you suspect problems with the block (50), block spring (52), and inner block spring washer
spring. (53) from cylinder block.

3-32 3121671
SECTION 3 - CHASSIS & TURNTABLE

Inspection Table 3-6. Slipper Foot Thickness & End Play

Wash all parts after disassembly (including end-cap and hous- Measurement L Frame K Frame
ing) thoroughly with clean solvent and allow to air dry. Blow
out oil passages in housing and endcap with compressed air. Slipper Foot Thickness 2.71 4.07
Conduct inspection in a clean area and keep all parts free from mm (0.11) (0.16)
contamination. Clean and dry parts again after any rework or Piston/Slipper End Play (in.) 0.15
resurfacing. (0.006)

PISTON BALL GUIDE AND SLIPPER RETAINER

Inspect pistons for damage and discoloration. Discolored pis- Inspect ball guide and slipper retainer for damage, discolor-
tons may indicate excessive heat. Do not reuse. ation, or excessive wear. A discolored ball guide or slipper
retainer indicates excessive heat. Do not reuse.

Slipper retainer

Ball guide

SLIPPERS CYLINDER BLOCK

Inspect running surface of slippers. Replace piston assemblies Measure cylinder block height. Replace blocks worn beyond
with scored or excessively rounded slipper edges. Measure minimum height specification. Inspect running surface of cyl-
slipper foot thickness. Replace piston assemblies with exces- inder block. Replace or resurface worn or scratched blocks.
sively worn slippers. Check slipper axial end-play. Replace pis- Blocks may be resurfaced if resurfacing will not reduce block
ton assemblies with excessive end-play. height below minimum specification shown in Table 3-7, Cyl-
inder Block Measurements.
Minimum slipper foot thickness and maximum axial end-play
are shown in table 3.6.

Table 3-7. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
Cylinder Block Surface Flatness 0.002 0.002 0.002 0.002 0.002
(0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079)

3121671 3-33
SECTION 3 - CHASSIS & TURNTABLE

VALVE PLATE Inspect journal bearings for damage or excessive wear.

Replace journal bearings if scratched, warped, or excessively
Valve plate condition is critical to motor efficiency. Inspect
worn. Polymer wear layer must be smooth and intact.
valve plate surfaces for excessive wear, grooves, or scratches.

Replace or resurface grooved or scratched valve plates. Mea- SHAFT BEARINGS

sure valve plate thickness and replace if worn beyond mini- Inspect bearings for excessive wear or contamination. Rotate
mum specification. bearings while feeling for uneven movement. Bearings should
spin smoothly and freely. Replace bearings that appear worn
Valve plate can be resurfaced if finished thickness is not below or do not rotate smoothly.
minimum specification shown in drawing.
3.83 mm [0.151 in] min.

0.025 mm
[0.001 in]

0.0076 mm
[0.00030 in]
convex max

SHAFT
SWASHPLATE AND JOURNAL BEARINGS Inspect motor shaft. Look for damage or excessive wear on
Inspect running face, servo ball-joint, and swashplate journal output and block splines. Inspect bearing surfaces and sealing
surfaces for damage or excessive wear. surface. Replace shafts with damaged or excessively worn
splines, bearing surfaces, or sealing surfaces.
Some material transfer may appear on these surfaces and is
acceptable providing surface condition meets specifications SERVO PISTON AND MINIMUM ANGLE STOP
shown. Inspect minimum angle stop, servo piston head, and servo pis-
ton ball-socket for damage or excessive wear. Replace as needed.
Measure swashplate thickness from journals to running face.
Replace swashplate if damaged or worn beyond minimum
specification.

0.0025 mm
[0.0001 in]

25.8 mm
LV [1.015 in]

KV 24.6 mm
[0.969 in] LOOP FLUSHING SPOOL
Thickness equality
side to side:
Inspect loop flushing spool. Check for cracks or damage.
0.05 mm [0.002 in] Replace as needed.

3-34 3121671
SECTION 3 - CHASSIS & TURNTABLE

Assembly
1. Install new O-ring (1) and piston seal (2) to servo piston COMPRESSED SPRING MAY FLY OUT AND CAUSE SERIOUS INJURY. COMPRESS-
(3). Install piston seal over O-ring. ING BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE.
USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE
NOTE: Installing piston seal stretches it, making it difficult to EFFORT. ENSURE SPRING IS SECURE BEFORE ATTEMPTING TO INSTALL SPIRAL
install servo piston in its bore. Allow 30 minutes for seal to
RETAINING RING. RELEASE PRESSURE SLOWLY AFTER RETAINING RING IS
relax after installation. To speed up seal relaxation, com- INSTALLED.
press seal by installing piston head in servo cavity in end-
cap and let it stand for at least five minutes. 3. Install inner block spring washer (4), block spring (5),
and outer washer (6) in cylinder block. Using a press,
2 compress block spring enough to expose retaining ring
3
groove. Wind spiral retaining ring (7) into cylinder block.

10
1

9
8

7
1. O-ring
2. Piston Seal
3. Servo Piston

Figure 3-24. Servo Piston 4. Block Spring Washer 9. Holddown Pins

5. Block Spring 10. Ball Guide
6. Outer Washer 11. Piston
2. After piston seal has relaxed, lubricate and install servo 7. Spiral Retaining Ring 12. Slipper Retainer
piston into housing bore. Align piston with ball socket 8. Retaining Ring
facing inside of housing.
Figure 3-25. Cylinder Kit Assembly

4. Turn block over and install retaining ring (8), hold-down

pins (9), and ball guide (10) to cylinder block.

3121671 3-35
SECTION 3 - CHASSIS & TURNTABLE

8. Press front shaft bearing (15) onto shaft (16). Press bear-
ing onto shaft with lettering facing out. Lubricate bear-
IF REUSING PISTONS, INSTALL THEM IN ORIGINAL BLOCK BORES. ing rollers. Install snap-ring (17) on shaft.

5. Install pistons (11) to slipper retainer (12). Install piston/

retainer assembly in cylinder block. Ensure concave sur-
face of retainer seats on the ball guide. Lubricate pis-
tons, slippers, retainer, and ball guide before assembly.
Set cylinder kit aside on a clean surface until needed.
6. Install journal bearings (13) into housing seats. Use
assembly grease to keep bearings seated during assem-
bly. Ensure locating nubs drop into cavities in seats. If
reusing bearings, install them in original location and
orientation. Lubricate journal bearings.

14
13

13
15. Front Shaft Bearing 17. Snap Ring
16. Shaft 18. Snap Ring

Figure 3-27. Shaft and Front Bearing

9. While holding swashplate in place, turn housing on its

side. Install shaft/bearing assembly into housing from
13. Journal Bearings flange end. Install snap ring (18).
14. Swash Plate

Figure 3-26. Swash Plate and Journal Bearing

7. Install swashplate (14) in housing. Tilt swashplate and

guide servo lever ball into its socket in servo piston rod.
Ensure swashplate seats into journal bearings and
moves freely. Lubricate swashplate running surface.

3-36 3121671
SECTION 3 - CHASSIS & TURNTABLE

10. Verify swashplate and bearings are properly seated. 12. Press rear shaft bearing (22) into endcap. Install bearing
Install cylinder kit (19) onto shaft. Install with slippers with letters facing out. Press until bearing surface is
facing swashplate. Rock shaft to align block splines and 0.08 ±0.01 in (2 ±0.25 mm) above endcap surface.
slide cylinder kit into place. Orient motor with shaft
pointing downward and verify cylinder kit, swashplate, 22
23
3 mm
2 mm [0.12 in]
journal bearings, and servo piston are all secure and
[0.08 in]
properly installed.

19
23

19. Cylinder Kit

23
Figure 3-28. Cylinder Kit Installation

11. Lubricate and install servo spring (20), and minimum

angle stop (21) into housing bore.
22. Rear Shaft Bearing
23. Timing Pin
24. Valve Plate

Figure 3-30. Valve Plate and Rear Bearing

13. Install timing pin (23) into bore in endcap. Install pin
20 with groove facing toward or away from shaft. Press pin
until end protrudes 0.12 ±0.01 in (3 ±0.25 mm) above
endcap surface.
14. Install valve plate (24) on endcap. Install valve plate with
yellow surface toward cylinder block. Align slot in valve
plate with timing pin. Apply a liberal coat of assembly
grease to endcap side of valve plate to keep it in place
during installation.

20. Servo Spring

21. Minimum Angle Stop

Figure 3-29. Servo Spring and Minimum Angle Stop

3121671 3-37
SECTION 3 - CHASSIS & TURNTABLE

15. Install endcap (25) on housing with endcap screws (26). 18. Cover shaft splines with an installation sleeve. Install a
Check endcap properly seats on housing without interfer- new shaft seal (27) with cup side facing motor. Press seal
ence. into housing until it bottoms out. Press evenly to avoid
binding and damaging seal. Install seal support washer
(28) and snap ring (29).
IMPROPER ASSEMBLY OF INTERNAL COMPONENTS MAY PREVENT ENDCAP
FROM SEATING PROPERLY. ENSURE O-RINGS SEAT PROPERLY WHEN INSTALL- 29
ING ENDCAP.
28
26
8 mm
35-45 ft.lbs. 27
(47-61 Nm)

27. Shaft Seal

28. Seal Support Washer
29. Snap Ring

Figure 3-32. Shaft Seal

19. Install remaining plugs and fittings to housing. Refer to

drawing below for wrench sizes and torque settings.

25. End Cap

26. Screw

Figure 3-31. End Cap

16. Using an 8 mm internal hex wrench, tighten endcap

screws. Tighten screws in opposite corners slowly and
evenly to compress servo spring and properly seat end-
cap. Torque endcap screws 35 to 45 ft. lbs. (47- 61 Nm).
17. Before installing shaft seal, ensure shaft turns smoothly
with less than 120 in. lbs. (13.5 Nm) of force. If shaft does
not turn smoothly within specified force, disassemble
and check unit.

Figure 3-33. Plugs and Fittings Installation

3-38 3121671
SECTION 3 - CHASSIS & TURNTABLE

20. Install orifice poppet (30). Initial Start-Up Procedures

21. Install shift spool (31). Follow this procedure when starting up a new motor or after
reinstalling a motor.
22. Install spring retaining washers on springs (32 and 33).
Prior to installing motor, inspect for damage incurred during
23. Carefully install centering springs (34, 35, and 36). shipping or storage. Make certain all system components (res-
24. Install new O-rings (37, 38, and 39). ervoir, hoses, valves, fittings, heat exchanger, etc.) are clean
before filling with fluid.
25. Using a 5/8 in. wrench, torque plug (40) to 20 ft. lbs. (27 Nm).
1. Fill reservoir with recommended hydraulic fluid. Always
26. Using a 11/16 in. wrench, torque plugs (41 and 42) to filter fluid through a 10 micron filter when pouring into
27 ft. lbs. (37 Nm). reservoir. Never reuse hydraulic fluid.

37 2. Fill inlet line leading from pump to reservoir. Check inlet

36 line for properly tightened fittings and be certain it is
39 33 free of restrictions and air leaks.
41
34
30 11/16 in
3. Fill pump and motor housing with clean hydraulic fluid.
40 27 ft.lbs.
(37 Nm) Pour filtered oil directly into upper most case drain port.
5/8 in
20 ft.lbs. 4. Install case drain lines into upper most case drain ports
(27 Nm)
to ensure pump and motor stay filled with oil.
31
32 5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres-
35 sure gauge port of pump to monitor system pressure
38
during start up.
42
11/16 in
6. Watch pressure gauge and run engine at lowest possible
27 ft.lbs. speed until system pressure builds to normal levels
(37 Nm) (minimum 160 psi (11 bar)). Once system pressure is
established, increase to full operating speed. If system
pressure is not maintained; shut down engine, deter-
mine cause, and take corrective action.
7. Operate hydraulic system at least fifteen minutes under
30. Orifice Poppet 34. Spring 37. O-ring 40. Plug light load conditions.
31. Shift Spool 35. Spring 38. O-ring 41. Plug
32. Spring 36. Spring 39. O-ring 42. Plug 8. Check and adjust control settings as necessary after
33. Spring installation.

Figure 3-34. Loop Flushing Spool 9. Shut down engine and remove pressure gauge. Replace
plug at charge pressure gauge port.
10. Check fluid level in reservoir; add clean filtered fluid if
necessary. Motor is now ready for operation.

3121671 3-39
SECTION 3 - CHASSIS & TURNTABLE

6
7

3
4
2

1
8

5
9

MAF01150

1. Bolt 4. Bolt 7. Swing Hub and Motor Assembly

2. Bolt 5. Washer 8. Washer
3. Nut 6. Shim 9. Spacer Sleeve

Figure 3-35. Swing System

3-40 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.12 SWING DRIVE HUB Record the release pressure. If brake does not release within
limits shown in Table 3-8, Brake Chart, check to see if it has the
Users of this manual should note that each part mentioned is proper number of springs using the SPRING CHECKING PRO-
followed by an identification number enclosed in parentheses. CEDURE.
These part numbers may be referred to in the Parts List and
Increase to maximum pressure (refer to Table 3-8) and hold at
Assembly Drawing sections of this manual.
that pressure for one minute. If the brake does not leak or lose
Specialized tools used to assemble this unit are noted in the pressure, the unit has passed the brake test. If brake loses pres-
assembly procedures and diagrammed in the Assembly Tools sure, attempt to repair leak using the leak repair procedure at
section. the end of this procedure.
While brake is still released, roll check the unit for one revolu-
Users should familiarize themselves with the procedures for tion of the output member by rotating the tool. Bleed off pres-
roll and leak testing, as well as bolt tightening and torquing sure slowly while rotating the ROLL TEST Tool.
found on the following pages before starting any repairs.
Record the pressure at which the brake locks up. Using a clean
Standard safety practices should be followed during the disas- rag, wipe off excess fluid from around brake port and install
sembly and assembly procedures described. Safety glasses the pipe plug.
and safety shoes should be worn, and heavy, heat resistant
gloves should be used when handling heated components. Be Table 3-8. Brake Chart
especially alert when you see the word CAUTION. This indi-
cates that a particular operation could cause personal injury if Release Release Full Maximum
Brake
not performed properly or if certain safety procedures are not Number Of Pressure Pressure Release Release
Torque
followed. The word NOTE is used to bring attention to certain Springs Minimum Maximum Pressure Pressure
(in-lbs)
procedures or helpful hints that will aid in the disassembly and (psi) (psi) (psi) (psi)
assembly process. 7 75 124 140 2000 472

Brake Test
Prior to brake check remove Motor, Tubing and Elbow as per
Motor disassembly instructions in the following subsections.
To perform a brake check, use a 7/16-20 thread fitting. Install a
hydraulic hand pump with pressure gauge into brake port in
Brake Housing using thread fitting.

Place ROLL TEST Tool into Sun gear (8).

Apply 25 in-lbs (29 kgcm) torque. While trying to rotate tool,

pump the handle on the hydraulic hand pump and increase
the pressure until the brake releases. The brake is released
when you are able to rotate the tool.

3121671 3-41
SECTION 3 - CHASSIS & TURNTABLE

Spring Checking Procedure Brake Leak Repair Procedure

Install two Flat Socket Head Cap Screws 0.250-20 UNC, 1/2 in. Remove brake piston from housing using the Brake Disassem-
length into holes in brake piston. Tighten bolts evenly to bly Procedure.
ensure that brake piston remains straight while being com-
pressed into brake cavity of brake housing. Check O-rings, Backup Rings, and brake cavity in Brake Hous-
ing for damage. If no damage is found, then reinstall Input
Carefully remove retaining ring from brake housing. Slowly
remove bolts evenly from the input brake. Remove the pres- Brake according to Input Brake Installation Procedure under
sure plate from the end of the input brake and check the num- Main Assembly procedure and perform pressure test again. If
ber of springs in brake. If incorrect, correct the count. brake still leaks, contact the service department.

NOTE: Failure to perform this test may result in damaged or inef-

fective brake parts.

Roll and Leak Test

Torque-Hubs should always be roll and leak tested before dis-
assembly (if possible) and after assembly to make sure the
gears, bearings, and seals are working properly. The following
information briefly outlines what to look for when performing
Check for the correct number of these tests.
springs as per Table 3-8.
THE ROLL TEST
The purpose of the roll test is to determine if the unit gears are
rotating consistently, easily and properly. Remove Motor and
release the brake by applying 400 psi to the brake port. To per-
form a roll test, use the recommended tool from table below
(or something equivalent) to apply constant rotational force to
the input of the gearbox. If more drag is felt in the gears only
at certain points, then the gears are not rolling consistently
Install the Pressure Plate using two 0.250-20 UNC flat Socket and easily and should be examined for improper installation
Head Cap Screws. Tighten bolts evenly to ensure that Pressure or defects. Some gear packages roll with more difficulty than
Plate (8M) does not get wedged to the Brake Cylinder.
others. Do not be concerned if the gears in the unit seem to
Install the large retaining ring into groove in Housing making roll hard as long as they roll with consistency. Rotate the gear-
sure that it is seated properly. Remove all bolts from the brake box 36 revolutions both clockwise and counterclockwise.
piston and discard.

NOTE: Use caution when removing bolts as they are subject to

spring pressure. Make sure the retaining ring is secured
before removing bolts.

Re-test the input brake. If release and/or lockup pressures still

do not match the brake chart contact the JLG Service Depart-
ment.

Grease and install O-ring onto motor pilot. Place motor into
brake pilot and line up holes. Check timing marks. Assemble
lift lugs onto hex bolts and assemble hex bolts with lugs
through the motor and brake against the motor flange. Torque
to 80-100 ft. lbs. (108-136 Nm).

Re-test the input brake. If release and/or lockup pressures still

do not match the brake chart contact the JLG Service Depart-
ment.

3-42 3121671
SECTION 3 - CHASSIS & TURNTABLE

THE LEAK TEST Tightening and Torquing Bolts

The purpose of a leak test is to make sure the unit is airtight. To
perform a leak test use the leak test fixture from the table If an air impact wrench is used to tighten bolts, extreme care
below. If the tool is not available, the gearbox must be sealed should be taken to ensure the bolts are not tightened beyond
to perform the test. This can be accomplished by assembling their specified torque. The following steps describe how to
the sealed input device onto the gearbox at the input end and tighten and torque bolts or socket head cap screws in a bolt
replace one of the oil plugs with an air chuck. DO NOT EXCEED circle.
10 PSI PRESSURE DURING THE LEAK TEST. Higher pressure will 1. Tighten (but do not torque) bolt A until snug.
create a false sealing effect in assemblies with lip-seals. The
unit has a leak if the pressure gauge reading on your leak
check fitting starts to fall after the gearbox has been pressur-
BOLT A
ized and allowed to equalize. Leaks will most likely occur at the
pipe plugs, the main seal or wherever o-rings or gaskets are
located. The exact location of a leak can usually be detected by
brushing a soap and water solution around the main seal and
where the o-rings or gaskets meet on the exterior of the unit
and then checking for air bubbles. If a leak is detected in a seal,
o-ring, or gasket, the part must be replaced and the unit
rechecked. Leak test at 10 psi for 20 minutes.

BOLT B

Figure 3-36. Bolt Tightening Sequence

2. Go to the opposite side of the bolt circle and tighten

bolt B until equally snug.
3. Crisscross around the bolt circle and tighten the remain-
ing bolts.
4. Use a torque wrench to apply the specified torque to
bolt A.
5. Using the same sequence, crisscross around the bolt cir-
cle and apply an equal torque to the remaining bolts.

3121671 3-43
SECTION 3 - CHASSIS & TURNTABLE

Lubrication Information Motor Removal

Refer to Figure 3-37. and Figure 3-38.
GENERAL PROPERTIES
The lubricant used should be petroleum based gear fluid con- 1. Place unit on bench with the motor end up.
taining anti-oxidation, anti-foaming and extreme pressure 2. Remove the magnetic Pipe Plug (1P) and drain the oil
additives. The lubricant should have a minimum viscosity out of the gearbox.
index of 95 cst and maintain a minimum viscosity of 40 cst
under normal operating conditions. Some applications require NOTE: Record the condition and volume of the oil.
special considerations; consult the JLG Service Department for
additional information. 3. Remove Hydraulic Tubing Assembly (35) by loosening
fittings on both ends of tube with a wrench.
The table below lists the recommended viscosities for various
4. Using a wrench, loosen jam nuts on Elbow Fittings (30)
ambient operating temperatures. These recommendations are
and remove fittings from Brake Housing (6) and Motor
based on temperature rise of 50° to 100°F at normal operating
Control Valve (32).
conditions.
5. Remove O-ring Pipe Plugs (23) from Motor Control Valve
Table 3-9. Recommended Viscosities For Various Ambient (32).
Operating Temperatures
6. Remove Motor Control Valve (32) from Motor (31) by
Differential Planetary Simple Planetary removing the four Bolts (21) and washers (22).
Ambient AGMA AGMA 7. Remove O-ring (99) between Motor Control Valve (32)
Temperature ISO Index Lubricant ISO Index Lubricant and Motor (31). Discard O-ring.
Number Number
8. With unit resting on bench with Motor (31) end up,
-40° to -5° F(1) VG100 3EP VG100 3EP loosen Hex Bolts (29) and remove Lift Lugs (28) from the
-5° to 40° F VG150 4EP VG100 3EP Motor (31).
40° to105° F VG220/VG320 5EP/6EP VG150/VG220 4EP/5EP 9. Pull Motor (31) straight up and remove Motor (31) from
VG460 7EP VG320 6EP Brake Housing (6).
105° to 150° F(2)
Footnotes 10. Remove O-ring (26) from between Motor (31) and Brake
1. For operation in this ambient temperature range, synthetic oil is recommended with Housing (6). Discard O-ring.
a pour point of 10°F lower than the minimum ambient temperature.
2. For operation in this ambient temperature range, synthetic oil is recommended for
proper lubricant life at elevated temperatures.

MAINTENANCE
Oil amounts for each series of Torque-Hub drives are indicated
in the appropriate series literature. An initial oil change should
be made after the first 50 hours of operation. Subsequent oil
changes should be made at 1,000 hour intervals or annually,
whichever comes first.

Oil temperatures should be not higher than 160° to 180°F for

continuous operation, and no higher than 200°F for intermit-
tent operation. For special applications, please consult the JLG
Service Department.

3-44 3121671
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-37. Swing Motor Valve Removal

Figure 3-38. Swing Motor Removal

3121671 3-45
SECTION 3 - CHASSIS & TURNTABLE

Input Brake Disassembly 3. Lift Brake Piston Assembly (8A) out of the Brake Housing
(6). If the Brake Piston assembly (8A) will not lift out,
Refer to Figure 3-39. apply less than 50 psi air to the Brake port to remove
Brake Piston (8A). Remove the Inner (Rotor) (8J), Outer
1. Insert and tighten the 0.250-20 UNC flat Socket Head (Stator) Plates (8K), from inside Brake Housing (6).
Cap Screws through the Pressure Plate (8M) and into the 4. Remove O-rings (8D, 8F) and Backup Rings (8E, 8H) from
Brake Piston (8A) to compress the springs and relieve the Brake Housing (6).
pressure on the Retaining Ring (8N).
Discard O-rings and Backup Rings.
5. Remove 0.250-20 UNC flat Socket Head Cap Screws and
SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. lift the Pressure Plate (8M) from the Brake Piston (8A).

NOTE: Record the number of springs and mark their locations

NOTE: Ensure Step 1 is completed before doing this next step. before removing them from brake piston.

6. Remove Springs (8L) from the Brake Piston (8A).

2. Using retaining ring pliers, remove Retaining Ring (8N)
which holds the Brake Piston assembly in place.

Figure 3-39. Input Brake Disassembly

3-46 3121671
SECTION 3 - CHASSIS & TURNTABLE

Main Disassembly 5. Remove Thrust Washer (11) from between Brake Hous-
ing (6) and Carrier Sub-Assembly.
Refer to Figure 3-40.
6. Remove Ring Gear (4) from Housing (1G).

7. Remove O-ring (5) from between Ring Gear (4) and

SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. Housing (1G), discard O-ring.

1. Remove Sun Gear (8). 8. Remove Carrier Sub-Assembly.

2. With the unit resting on the Output Shaft (Pinion) (1A), 9. Remove Thrust Washer (11) from between Carrier Sub-
remove the Bolts (12) from the Brake Housing (6). assembly and Internal Gear (2).
3. Remove the Brake Housing (6) from the main assembly.
10. Remove Internal Gear (2).
4. Remove O-ring (5A) from between Brake Housing (6)
and Ring Gear (4). Discard O-Ring.

Figure 3-40. Main Disassembly

3121671 3-47
SECTION 3 - CHASSIS & TURNTABLE

Housing-Shaft Disassembly 4. While supporting the Housing (1G) on the Output Shaft
(1A) end, press the Output Shaft (1A) out of the Housing
Refer to Figure 3-41. (1G).
1. Set the unit on a bench so that the Housing (1G) flange NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by
is down. the Bearing Cone (1D) during this step.

5. Remove the Bearing Cone (1E) from the Housing (1G).

SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. 6. Use a bearing puller to remove the Bearing Cone (1D)
from the Shaft (1A).
2. Using retaining ring pliers remove Retaining Ring (1I)
from groove in Output Shaft (1A) and discard. 7. Bearing Cups (1C & 1F) will remain in Housing (1G).

NOTE: If bearing replacement is necessary, the Bearing Cups (1C &

1F) can be removed with a slide hammer puller or driven
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. out with a punch.

3. Remove Thrust Washer (1H).

Figure 3-41. Housing Shaft Disassembly

3-48 3121671
SECTION 3 - CHASSIS & TURNTABLE

Carrier Disassembly 3. Slide the Planet Gear (3F), the two Thrust Washers (3B)
out of the Carrier (3A).
Refer to Figure 3-42.
4. Using a hammer and punch, drive the pieces of the Roll
1. Drive the Planet Shaft (3E) out of the carrier pin holes; Pin (3G) out of the Planet Shaft (3E) and Carrier (3A).
forcing the Roll Pin (3G) to sheer off.
5. Remove both rows of Needle Bearings (3C) and the
2. Hold on to the Planet Gear (3F) and push the Planet Spacer (3D) from the bore of the Planet Gear (3F).
Shaft (3E) out of the Carrier (3A). The Thrust Washers (3B)
will slide off the shaft as it is removed. 6. Repeat Steps 1 through 5 for the remaining two Cluster
Gears (3F).

Figure 3-42. Carrier Disassembly

3121671 3-49
SECTION 3 - CHASSIS & TURNTABLE

Carrier Assembly 7. Using ample grease to hold them in position, locate

Thrust Washer (3B) onto each side of interior carrier wall
Refer to Figure 3-43. with tangs located into slots in Carrier pads.
1. Apply a liberal coat of grease to the bore of Cluster Gear 8. With large end of Cluster Gear (3F) facing the roll pin
(3F). This will enable the Needle Rollers (3C) to be held in hole in the Carrier, place the Cluster Gear into position in
place during assembly. Carrier (3A) and push Planet Shaft (3E) through the Clus-
2. Install one half of the inside of the Cluster Gear (3F) with ter Gear (3F) without going all the way through the car-
16 Needle Rollers (3C). rier (3A).

NOTE: The last roller installed must be installed end wise. That is, 9. Finish sliding the Planet Shaft (3E) into the Carrier (3A)
the end of the last roller must be placed in between the until roll pin holes of planet shaft and carrier are aligned.
ends of the two rollers that form the space, and then slid Align roll pin hole using a 1/8 in. diameter punch.
parallel to the other rollers into place.
NOTE: The chamfer on the Roll Pin hole should be towards the roll
3. Place one Spacer (3D) on top of the Needle Rollers (3C) pin hole in the Carrier.
inside the Planet Gear (3F).
4. Install the other half of the Cluster Gear (3F) with16 Nee- 10. Drive the roll pin (3G) through Carrier (3A) and into the
dle Rollers (3C). Planet Shaft (3E) until the Roll Pin (3G) is flush with the
bottom of the cast slot in the Carrier (3A) outside diame-
5. Place Carrier (3A) into tool fixture so that one of the roll ter at the Thrust Washer (3B) tang. Use a 1/4" pin punch
pin holes is straight up. to make sure the roll pin (3G) is flush in the slot.
6. Start Planet Shaft (3E), with end opposite roll pin hole
11. Repeat Steps 6 through 10 for the remaining two Cluster
first, through the planet shaft hole in carrier (3A), mak-
Gears (3F).
ing sure that the roll pin hole with the large chamfer in
the planet shaft is straight up.

Figure 3-43. Carrier Assembly

3-50 3121671
SECTION 3 - CHASSIS & TURNTABLE

Housing - Shaft Assembly 7. Start the Bearing Cone (1E) onto the Output Shaft (1A).

Refer to Figure 3-44. 8. Press or tap the Bearing Cone (1E) onto the Output Shaft
(1A) until it is just seated in the Bearing Cup (1F), while
NOTE: Spray a light film of oil on all component parts during rotating the Housing (1G).
assembly. Spray a generous amount of oil on bearings dur-
ing installation. 9. Install Bearing Spacer (1H) onto Output Shaft (1A) and
against Bearing Cone (1F).
1. Press Bearing Cup (1C) into Housing (1G) taking care to
10. Install Retaining Ring (1I) into the groove in the Output
insure cup starts square with the bore of Hub (1G).
Shaft (1A). This Retaining Ring (1I) should never be
2. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing reused in a repair or rebuild.
(1G).
3. Press Seal (1B) into the counterbore of Housing (1G) to
the point where it becomes flush with the Housing (1G) EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
face. Care should be taken to insure Seal (1B) is being
correctly installed (smooth face up). Apply oil to the rub- 11. Tap the Retaining Ring (1I) with a soft metal punch to
ber portion of the seal. ensure that the Retaining Ring (1I) is completely seated
4. Invert Hub (1G) and press Bearing Cup (1F) into counter- in the groove of the Output Shaft (1A).
bore of Housing (1G).
5. Carefully lower Housing (1G) onto the Output Shaft (1A)
until Bearing Cone (1D) contacts the Output Shaft (1A). EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.

6. Press on the small end of the Bearing Cone (1D), being 12. Install O-ring Plug (1P) and torque to 23 to 24 ft. lbs.
careful not to contact the bearing cage, until the Bearing (31 to 32.5 Nm).
Cone (1D) seats on the shoulder of the Output Shaft
(1A).

Figure 3-44. Housing - Shaft Assembly

3121671 3-51
SECTION 3 - CHASSIS & TURNTABLE

Main Assembly 7. After engaging internal gear teeth and before rotating
carrier, look at the Carrier sub-assembly in the main
Refer to Figure 3-45. assembly and insure the timing is correct by locating the
timing marks in the slots in the carrier and at 12 o’clock
1. Slightly tap the Internal Gear (2) with spline side down
on the gear that the timing mark is visible in the carrier
onto Output Shaft (1A) splines to ensure Internal Gear
bore.
(2) is properly seated.
8. Grease and install O-ring (5A) onto Brake Housing (6)
2. Grease and install O-ring (5) onto Housing (1G) o-ring
counterbore.
groove.
9. Install Brake Housing (6) onto Ring Gear (4) by aligning
3. Grease and install Thrust Spacer (11) into counterbore of the bolt holes in brake housing with ring gear holes.
Carrier Sub-assembly on smaller diameter cluster gear
side. The grease should hold the Thrust Spacer (11) in 10. Ensure the pipe plugs in Housing (1G) and Brake Hous-
place for assembly. ing (6) are timed as shown.

4. Place Carrier Sub-assembly onto table oriented as 11. Pull one Cover Bolt (12) and place into the bolt hole and
shown above, with large end of Cluster Gear (3F) facing repeat for remaining bolts.
up. Position all three punch-marks on the face of the
12. Torque Bolts (12) in star pattern to 23-27 ft. lbs.
large gears at 12 o’clock. Timing marks on the two upper
(31-36.5 Nm).
Cluster Gears will be visible through the slots in the Car-
rier if the Cluster Gears are correctly marked. Secure gear 13. Install Input Shaft (8) with spline side up into housing
teeth using timing fixture. bore. Insure the input shaft gear teeth and planet gears
are engaged.
14. Install O-ring plugs (1P) into Brake Housing (6) and
Housing (1G). Torque 23 to 24 ft. lbs. (31 to 32.5 Nm).
15. The unit should now be leak and roll checked as per
instructions in this section.
16. Fill oil through the opening in Brake Housing (6) with
43 oz. (1.3 L) of 80W90 gear oil.

5. Place Ring Gear (4) in to large end of Cluster Gear to

secure timing.
6. Remove Carrier sub-assembly and Ring Gear (4) from
the table and assemble into the Internal gear (2) being
careful to keep the ring gear, or sun gear, in mesh with
the cluster gears.

3-52 3121671
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-45. Main Assembly

3121671 3-53
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-46. Brake Port Alignment

Motor and Brake Assembly 3. Grease O-rings (8D, 8F) and install smaller diameter O-
Ring (8F) into smaller diameter O-Ring groove in Brake
1. Starting with a Stator (8K), alternately stack and install Housing (6) and install larger diameter O-Ring (8D) into
Stators (8K) into Lobes of Brake Housing (6) and Rotors larger diameter O-Ring groove in Brake Housing (6).
(8J) (internal splines) onto splines of Sun Gear (8).
4. Insert smaller diameter Solid Backup Ring (8H) into
NOTE: There should always be a Stator on the top and bottom of smaller groove in Brake Housing (6) between O-Ring
the stack. (8F) and side of groove towards Output Shaft (1A).
5. Insert larger diameter Solid Backup Ring (8E) into groove
2. Insert Brake Piston (8A) completely into Brake Housing
in Brake Housing (6) between O-Ring (8D) and side of
(6) without O-rings (8D, 8F) and Backup Rings (8E, 8H) to
groove towards Motor (31).
check fit of brake. The Brake Piston (8A) should slide into
Brake Housing (6) without being forced. If Brake Piston
(8A) does not fit, check for burrs or size problems before
proceeding.

3-54 3121671
SECTION 3 - CHASSIS & TURNTABLE

NOTE: Refer to the figure below for installing O-Rings (8D), (8F) 13. Grease and install the O-Ring (26) into the Motor (31)
and Back up Rings (8E), (8H). pilot.
14. Install Motor (31) into the Brake Housing (6). Insure the
motor valve mounting face is aligned with the radial
brake release port in the Housing (1G).

6. Lightly grease cylinder walls of Brake Housing (6) and

install Brake Piston (8A) into Brake Housing (6). If neces-
sary, place T-134711 on top of brake and lightly tap until
Brake Piston (8A) contacts brake disk stack.

7. Insert 8 Springs (8L) into Brake Piston (8A) spring holes.

8. Install Pressure Plate (8M) into Brake Housing (6) bore

and onto top of Springs (8L).

9. Insert and tighten the 0.250-20 UNC Flat Head Cap

Screws through the Pressure Plate (8M) and into the
Brake Piston (8A) to compress the springs. Tighten
Socket Head Cap Screws incrementally to evenly com- Figure 3-47. Swing Motor Installation
press the Springs (8L)
15. Install Bolts (29) into Brake Housing (6) through Lifting
Lugs (28) and Motor (31) flange. Torque bolts to
SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. 80-100 ft. lbs. (108.5-135.5 Nm).

10. Using retaining ring pliers, install large Retaining Ring

(8N) into groove in Brake Housing (6) making sure that it
is seated properly.

NOTE: Use caution when installing retaining ring (8N) into Brake
Housing (6). It may cause injury if it slips out of retaining
ring pliers.

11. Remove the Flat Head Cap Screws from the Brake Piston
(8A) incrementally to release the tension of the springs
slowly. Discard Flat Head Cap Screws.

12. The Unit should undergo brake test (as per instructions
in this section).

3121671 3-55
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-48. Motor and Brake Assembly

3-56 3121671
SECTION 3 - CHASSIS & TURNTABLE

Motor Control Valve Installation 5. Install Tube Assembly (35) to elbow fittings as shown in
picture. Torque tube assembly nut to 13-15 ft. lbs. (17.5-
NOTE: Verify o-rings are located in between the motor and valve. 20 Nm). Tighten Jam Nut on Elbow Fitting (30) into 13-
15 ft. lbs. (17.5- 20 Nm). torque.
1. Install O-Rings (99) into counterbore on Motor Valve
6. Install one O-Ring Plug (23) onto Motor Control Valve
face.
(32). Torque to 18-20 ft. lbs. (24.5-27 Nm).
2. Install the Motor Control Valve (32) onto the Motor (31)
using Bolts (21) and Washers (22). Torque Bolts to 7. Install hydraulic test fitting into the other control valve
18-20 ft. lbs. (24.5-27 Nm). Insure the holes in Motor O-ring Plug (23) hydraulic port.
Control Valve (32) are aligned with holes in Motor (31). 8. Perform pressure decay test at "MAXIMUM PRESSURE".
3. Install Elbow Fitting (30) into Brake Housing (6). Insure Hold pressure for 1 minute. If pressure does decay,
the thread fitting o-ring seats onto the Brake Housing remove the pressure and inspect connections and
(6). Rotate the Elbow Fitting (30) to horizontal position retest.
as shown in picture. 9. Remove hydraulic test fitting.
4. Install Elbow Fitting (30) into Motor Valve (32). Insure the 10. Install the o-ring plug (23) onto motor control valve (32).
thread fitting o-ring seats onto the Motor Valve (32). Torque to 18-20 ft. lbs. (24.5-27 Nm).
Rotate the Elbow Fitting (30) to horizontal position as
shown in picture.

Figure 3-49. Swing Motor Valve Installation

3121671 3-57
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-50. Bearing Cone Press Tool

Figure 3-51. Bearing Cone Press Tool

3-58 3121671
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-52. Bearing Cup Press Tool

3121671 3-59
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-53. Lockout Wrench Tool

3-60 3121671
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-54. Bearing Cup Press Tool

3121671 3-61
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-55. Seal Press Tool

3-62 3121671
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-56. Leak Test Adapter Plate

3121671 3-63
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-57. Swing Drive Test Plate

3-64 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.13 SWING MOTOR

Disassembly and inspection

1. Place the Torqlink™ in a soft jawed vice, with coupling
shaft (12) pointed down and the vise jaws clamping
firmly on the sides of the housing (18) mounting flange
or port bosses. Remove manifold port O-Rings (18A) if
applicable.

3. Remove the five, six, or seven special ring head bolts (1)
using an appropriate 1/2 or 9/16 in. 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 in. Allen 4. Remove end cover assembly (2) and seal ring (4). Discard
wrench or 1 in. hex socket required. seal ring.

NOTE: Refer to the appropriate “alternate cover construction” on

the exploded view to determine the end cover construction
being serviced.

3121671 3-65
SECTION 3 - CHASSIS & TURNTABLE

20
18 19

17
21
16
14
15
14
13
12
11
4
10
9

4
8

4
5 7
4
6
3

4
2

MAF01630

1. Bolt 6. Ring 10. Drive Link 14. Thrust Washer 18. Housing
2. End Cover 7. Manifold 11. Coupling Shaft 15. Thrust Bearing 19. Bearing
3. Commutator Seal 8. Rotor Set 12. Woodruff Key 16. Inner Seal 20. Seal
4. Seal Ring 9. Wear Plate 13. Bronze Bushing 17. Backup Washer 21. Backup Washer
5. Commutator and Ring Assembly

Figure 3-58. Swing Motor Assembly

3-66 3121671
SECTION 3 - CHASSIS & TURNTABLE

5. If the end cover (2) is equipped with shuttle valve com- 7. Remove commutator ring (6). Inspect commutator ring
ponents, remove the two previously loosened plugs for cracks, or burrs.
(21).

8. Remove commutator (5) and seal ring (3) Remove seal

ring from commutator, using an air hose to blow air into
ring groove until seal ring is lifted out and discard seal
BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS ring. Inspect commutator for cracks or burrs, wear, scor-
THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE ing, spalling or brinelling. If any of these conditions exist,
REMOVED. replace commutator and commutator ring as a matched
set.
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.

6. Thoroughly wash end cover (2) in proper solvent and

blow dry. Be sure the end cover valve apertures, includ-
ing the internal orifice plug, are free of contamination.
Inspect end cover for cracks and the bolt head recesses
for good bolt head sealing surfaces. Replace end cover
as necessary.

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.

3121671 3-67
SECTION 3 - CHASSIS & TURNTABLE

9. Remove manifold (7) and inspect for cracks surface scor- NOTE: The rotor set (8) components may become disassembled
ing, brinelling or spalling. Replace manifold if any of during service procedures. Marking the surface of the rotor
these conditions exist. A polished pattern on the ground and stator that is facing UP, with etching ink or grease pen-
surface from commutator or rotor rotation is normal. cil before removal from Torqlink™ will ensure correct reas-
Remove and discard the seal rings (4) that are on both sembly of rotor into stator and rotor set into Torqlink™.
sides of the manifold. Marking all rotor components and mating spline compo-
nents for exact repositioning at assembly will ensure maxi-
mum wear life and performance of rotor set and Torqlink™.

NOTE: The manifold is constructed of plates bonded together to

form an integral component not subject to further disas-
sembly for service. Compare configuration of both sides oft
hem an if old to ensure that same surface is reassembled
against the rotor set. NOTE: Series TG Torqlinks™ may have a rotor set with two stator
halves (8B) with a seal ring (4) between them and two sets
10. Remove rotor set (8) and warplane (9), together to retain
of seven vanes (8C). Discard seal ring only if stator halves
the rotor set in its assembled form, maintaining the
become disassembled during the service procedures.
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 NOTE: A polished pattern on the wear plate from rotor rotation is
shift the rotor set on the warplane to work the drive link normal.
out of the rotor (8A) and warplane. Inspect the rotor set
in its assembled form for nicks, scoring, or spalling on 11. Place rotor set (8) and wear plate (9) on a flat surface and
any surface and for broken or worn splines. If the rotor center rotor (8A) in stator (8B) such that two rotor lobes
set component requires replacement, the complete (180 degrees apart) and a roller vane (8C) centerline are
rotor set must be replaced as it is a matched set. Inspect on the same stator centerline. Check the rotor lobe to
the warplane for cracks, brinelling, or scoring. Discard roller vane clearance with a feeler gage at this common
seal ring (4) that is between the rotor set and wearplate. centerline. If there is more than 0.005 in. (0.13 mm) of
clearance, replace rotor set.

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.

3-68 3121671
SECTION 3 - CHASSIS & TURNTABLE

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-
pling shaft if any of these conditions exist.
(18).

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 in. (0.51 mm) diametrically, replace coupling shaft.

14. Check exposed portion of coupling shaft (12) to be sure NOTE: A slight “polish” is permissible in the shaft bearing areas.
Anything more would require coupling shaft replacement.
you have removed all signs of rust and corrosion which
might prevent its withdrawal through the seal and bear-
16. Remove and discard seal ring (4) from housing (18).
ing. Crocus cloth or fine emery paper may be used.
17. Remove thrust bearing (15) and thrust washer (14)
Inspect for wear, brinelling, corrosion and a full comple-
ment of retained rollers.

3121671 3-69
SECTION 3 - CHASSIS & TURNTABLE

18. Remove seal (16) and back up washer (17) from Small 20. Inspect housing (18) assembly for cracks, the machined
Frame, housing (18). Discard both. surfaces for nicks, burrs, brinelling or corrosion. Remove
burrs that can be removed without changing dimen-
sional characteristics. Inspect tapped holes for thread
damage. If the housing is defective in these areas, dis-
card the housing assembly.

21. If the housing (18) assembly has passed inspection to

this point, inspect the housing bearings/bushings (19)
and (13) and if they are captured in the housing cavity
the two thrust washers (14) and thrust bearing (15). The
bearing rollers must be firmly retained in the bearing
cages, but must rotate and orbit freely. All rollers and
thrust washers must be free of brinelling and corrosion.
The bushing (19) or (13) to coupling shaft diameter
clearance must not exceed 0.010 in. (0.025 mm). A bear-
ing, bushing, or thrust washer that does not pass inspec-
tion must be replaced. If the housing has passed this
19. Remove housing (18) from vise, invert it and remove and inspection the disassembly of the Torqlink™ is com-
discard seal (20). A blind hole bearing or seal puller is pleted.
required.

3-70 3121671
SECTION 3 - CHASSIS & TURNTABLE

22. If the bearings, bushing or thrust washers must be

replaced use a suitable size bearing puller to remove
bearing/bushings (19) and (13) from housing (18) with-
out damaging the housing. Remove thrust washers (14)
and thrust bearing (15) if they were previously retained
in the housing by bearing (13).

NOTE: The depth or location of bearing/bushing (13) in relation to

the housing wear plate surface and the depth or location
of bearing/bushing (19) in relation to the beginning of
bearing/bushing counterbore should be measured and
noted before removing the bearings/ bushings. This will
facilitate the correct reassembly of new bearings/bushings.

3121671 3-71
SECTION 3 - CHASSIS & TURNTABLE

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™ dis-
tributors. (Contact your local dealer for availability).

NOTE: Unless otherwise indicated, do not oil or grease parts

before assembly.
NOTE: Bearing mandrel must be pressed against the lettered end
Wash all parts in clean petroleum-based solvents before of bearing shell. Take care that the housing bore is square
assembly. Blow them dry with compressed air. Remove any with the press base and the bearing/bushing is not cocked
paint chips from mating surfaces of the end cover, commuta- when pressing a bearing/bushing into the housing.
tor set, manifold rotor set, wear plate and housing and from
port and sealing areas.

IF THE BEARING MANDREL SPECIFIED IN THE “TOOLS AND MATERIALS

REQUIRED FOR SERVICING” SECTION IS NOT AVAILABLE AND ALTERNATE
METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE
SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY
BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADE-
SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR
QUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COM-
DEATH.
PONENTS WHEN ASSEMBLED.

WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX- BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE
IMUM AIR PRESSURE REQUIREMENTS. HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE
REUSED.
1. If the housing (18) bearing components were removed
for replacement, thoroughly coat and pack a new outer
bearing/bushing (19) with clean corrosion resistant
grease recommended in the material section. Press the
new bearing/bushing into the counterbore at the
mounting flange end of the housing, using the appro-
priate sized bearing mandrel, which will control the
bearing/ bushing depth.

Torqlink™ housings require the use of bearing mandrel

to press bearing/ bushing (19) into the housing to a
required depth of 0.151/0.161 in. (3.84/4.09 mm) from
the end of the bearing counterbore.

3-72 3121671
SECTION 3 - CHASSIS & TURNTABLE

2. The Torqlink™ inner housing bearing/bushing (13) can

now be pressed into its counterbore in housing (18)
flush to 0.03 in. (0.76 mm) below the housing wear plate
contact face. Use the opposite end of the bearing man-
drel that was used to press in the outer bearing/bushing
(19).

3. Press a new dirt and water seal (20) into the housing (18)
outer bearing counterbore.

The Torqlink™ dirt and water seal (20) must be pressed in

until its flange is flush against the housing.

3121671 3-73
SECTION 3 - CHASSIS & TURNTABLE

4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15)
the coupling shaft bore down, clamping against the that was removed from the Torqlink™.
mounting flange.

NOTE: Torqlinks™ require one thrust washer (14) with thrust bear-
5. On the Torqlinks™ assemble a new backup washer (17)
ing (15).The coupling shaft will be seated directly against
and new seal (16) with the seal lip facing toward the
inside of Torqlink™, into their respective counterbores in the thrust
housing (18) if they were not assembled in procedure 2.
7. Apply masking tape around splines or keyway on shaft
(12) to prevent damage to seal.

8. Be sure that a generous amount of clean corrosion resis-

tant grease has been applied to the lower (outer) hous-
ing bearing/bushing (19). Install the coupling shaft (12)
into housing (18), seating it against the thrust bearing
(15) in the housings.

ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE

BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A
NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).

3-74 3121671
SECTION 3 - CHASSIS & TURNTABLE

9. Apply a small amount of clean grease to a new seal ring

(4) and insert it into the housing (18) seal ring groove.
THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC
FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED
GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT
#K-70M.

NOTE: The coupling shaft (12) will be flush or just below the hous-
ing wear plate surface on Torqlinks™ when properly seated.
The coupling shaft must rotate smoothly on the thrust
bearing package.

NOTE: One or two alignment studs screwed finger tight into hous-
ing (18) bolt holes, approximately 180 degrees apart, will
facilitate the assembly and alignment of components as
required in the following procedures.The studs can be
made by cutting off the heads of either 3/8-24 UNF 2A or 5/
16-24 UNF 2A bolts as required that are over 0.5 in. (12.7
mm) longer than the bolts (1) used in the Torqlink™.

10. Install drive link (10) the long splined end down into the
coupling shaft (12) and engage the drive link splines
into mesh with the coupling shaft splines.

NOTE: Use any alignment marks put on the coupling shaft and
drive link before disassembly to assemble the drive link
splines in their original position in the mating coupling
shaft splines.

3121671 3-75
SECTION 3 - CHASSIS & TURNTABLE

11. Assemble wear plate (9) over the drive link (10) and NOTE: The rotor set rotor counterbore side must be down against
alignment studs onto the housing (18). wear plate for drive link clearance and to maintain the
original rotor-drive link spline contact. A rotor set without
a counterbore and that was not etched before disassembly
can be reinstalled using the drive link spline pattern on the
rotor splines if apparent, to determine which side was
down.The rotor set seal ring groove faces toward the wear
plate (9).

14. Apply clean grease to a new seal ring (4) and assemble it
in the seal ring groove in the rotor set contact side of
manifold (7).

12. Apply a small amount of clean grease to a new seal ring

(4) and assemble it into the seal ring groove on the wear
plate side of the rotor set stator (8B).

NOTE: The manifold (7) is made up of several plates bonded

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

NOTE: It may be necessary to turn one alignment stud out of the

housing (18) temporarily to assemble rotor set (8) or mani-
fold (7) over the drive link.

NOTE: If necessary, go to the appropriate, “Rotor Set Component

Assembly Procedure.”

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SECTION 3 - CHASSIS & TURNTABLE

16. Apply grease to a new seal ring (4) and insert it in the
seal ring groove exposed on the manifold.

19. If shuttle valve components items #21, were removed

17. Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one
onto the manifold. end of the valve cavity in the end cover. A 3/16 in. Allen
wrench is required.
20. Assemble a new seal ring (4) into end cover (2) and
assemble end cover over the alignment studs and onto
the commutator set. If the end cover has only 5 bolt
holes be sure the cover holes are aligned with the 5
threaded holes in housing (18).The correct 5 bolt end
cover bolt hole relationship to housing port bosses.

18. Assemble a new seal ring (3) flat side up, into commuta-
tor (5) and assemble commutator over the end of drive
link (10) onto manifold (7) with seal ring side up.

3121671 3-77
SECTION 3 - CHASSIS & TURNTABLE

NOTE: If the end cover has a valve (24) or has five bolt holes, use
the line you previously scribed on the cover to radially align
the end cover into its original position.

21. Assemble the 5 or 7 special bolts (1) and screw in finger

tight. Remove and replace the two alignment studs with
bolts after the other bolts are in place. Alternately and
progressively tighten the bolts to pull the end cover and NOTE: The special bolts required for use with the relief or shuttle
other components into place with a final torque of valve (24) end cover assembly (2) are longer than the bolts
22-26 ft. lbs., (30-35 Nm) 45-55 ft. lbs. (61-75 Nm) for the required with standard and cover assembly. Refer to the
seven 3/8-24 threaded bolts. individual service parts lists or parts list charts for correct
service part number if replacement is required.

22. Torque the two shuttle valve plug assemblies (21) in end
cover assembly to 9-12 ft. lbs. (12-16 Nm) if cover is so
equipped.

Torque the two relief valve plug assemblies (21) in end

cover assembly to 45-55 ft. lbs. (61-75 Nm) if cover is so
equipped.

3-78 3121671
SECTION 3 - CHASSIS & TURNTABLE

One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read-
A disassembled rotor (8A) stator (8B) and vanes (8C) that can- ily assemble into the stator vane pockets.
not be readily assembled by hand can be assembled by the
following procedures.
1. Place stator (8B) onto wear plate (9) with seal ring (4)
side down, after following Torqlink™ assembly proce-
dures 1 through 13. Be sure the seal ring is in place.

EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD
SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.

2. If assembly alignment studs are not being utilized, align 5. Grasp the output end of coupling shaft (12) with locking
stator bolt holes with wear plate and housing bolt holes pliers or other appropriate turning device and rotate
and turn two bolts (1) finger tight into bolt holes coupling shaft, drive link and rotor to seat the rotor and
approximately 180 degrees apart to retain stator and the assembled vanes (8C) into stator (8B), creating the
wear plate stationary. necessary clearance to assemble the seventh or full
complement of seven vanes. Assemble the seven vanes
3. Assemble the rotor (8A), counterbore down if applica-
ble, into stator (8B), and onto wear plate (9) with rotor using minimum force.
splines into mesh with drive link (10) splines.

NOTE: If the manifold side of the rotor was etched during Torqlink
disassembly, this side should be up. If the rotor is not
etched and does not have a counterbore, use the drive link
spline contact pattern apparent on the rotor splines to
determine the rotor side that must be against the wear
plate.

6. Remove the two assembled bolts (1) if used to retain sta-

tor and wear plate.

3121671 3-79
SECTION 3 - CHASSIS & TURNTABLE

3.14 SWING BEARING 6. Verify the dial indicator has not shifted. Record the value
for bearing play.
Swing Bearing Wear Tolerance 7. Return the machine to Figure 3-60., Swing Bearing Wear
Tolerance, Position 1. The dial indicator should to return
See Figure 3-60., Swing Bearing Wear Tolerance. to zero. If the dial indicator does not return to zero, take
1. Position the machine as follows and as seen in Figure 3- corrective action and repeat the test.
60., Swing Bearing Wear Tolerance, Position 1: 8. If the measurement is more than 0.10 in. (4.2 mm),
a. The turntable needs to be centered between the replace the bearing. If the measurement is less than 0.10
rear wheels. in. (4.2 mm), and any of the following conditions exist,
the bearing should be removed, disassembled, and
b. Lift the boom to horizontal and fully extend the inspected.
main boom
a. Metal particles in the grease.
c. Lift the jib to be horizontal
b. Increased drive power required.
d. Keep the jib and platform centered and unloaded
c. Noise.
2. Set up a dial indicator as follows: d. Rough rotation.
a. The dial indicator location is to be at the front center 9. If bearing inspection shows no defects, reassemble and
of the machine, next to the bearing, opposite of the return to service.
tower pivot pin.
b. The magnetic base of the indicator should be posi-
tioned on the frame

c. The indicator point needs positioned to measure

the turntable base plate 2 in. (51 mm) from the root
of the gear tooth. Refer to Figure 3-60., Swing Bear-
ing Wear Tolerance.
3. Zero the dial indicator.
4. Check dial indicator accuracy once positioned, using a
feeler gauge and ensure the dial indicator reading, is the
same as the feeler gauge thickness.
5. Position the machine as follows and as seen in Figure 3-
60., Swing Bearing Wear Tolerance, Position 2:
a. Do not rotate the turntable
b. Raise the main boom to be fully elevated and
retracted
c. Raise the jib to be fully elevated and centered
d. Center the platform and keep it unloaded

3-80 3121671
SECTION 3 - CHASSIS & TURNTABLE

Turntable Bearing Mounting Bolt Condition Check 2. Check the turntable to bearing. Attach bolts as follows:
a. Elevate the fully retracted main boom to full eleva-
tion as shown in Figure 3-60.
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL b. At the positions indicated on Figure 3-59. try and
LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE insert the 0.0015 in. feeler gauge between the bolt
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE head and hardened washer at the arrow indicated
SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. position.
c. Lower the boom to horizontal and fully extend the
NOTE: This check is designed to replace the existing bearing bolt boom.
torque checks on JLG Lifts in service. This check must be d. At the position indicated on Figure 3-59. try and
performed after the first 50 hours of machine operation insert the 0.0015 in. feeler gauge between the bolt
and every 600 hours of machine operation thereafter. If head and hardened washer at the arrow indicated
during this check any bolts are found to be missing or position.
loose, replace missing or loose bolts with new bolts and
torque to the value specified in the torque chart, after lubri-
cating the bolt threads with JLG Threadlocker P/N
0100019. After replacing and retorquing bolt or bolts
recheck all existing bolts for looseness.

1. Check the frame to bearing. Attach bolts as follows:

a. Elevate the fully extended main boom to horizontal
as shown in Figure 3-60.
b. At the positions indicated on Figure 3-59. try and
insert the 0.0015 in. feeler gauge between the bolt
head and hardened washer at the arrow indicated
position.
c. Assure that the 0.0015 in. feeler gauge will not pen-
etrate under the bolt head to the bolt shank. Figure 3-59. Swing Bolt Feeler Gauge Check
d. Swing the turntable 90 degrees, and check some
selected bolts at the new position.
e. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in
all quadrants.

3121671 3-81
SECTION 3 - CHASSIS & TURNTABLE

Measurement
Point

2”
(50.8 mm)

DIAL INDICATOR POINTER LOCATION 1

FEELER GAUGE DIAL INDICATOR

MEASURING POINT MEASURING POINT
POSITION 2

DIAL INDICATOR &

FEELER GAUGE
MEASURING POINT
POSITION 1

Figure 3-60. Swing Bearing Wear Tolerance

3-82 3121671
3121671
CL ROTATION

10 in. (25.4 cm)

CG Gross Weight: 3152 lbs. (1430 kg)

Upper Works above Turntable Bearing

NOTE: Do not lift boom

Attach to hole
in turntable

MAF04420

Figure 3-61. Swing Bearing Removal (400S)

3-83
SECTION 3 - CHASSIS & TURNTABLE
3-84
CG CL ROTATION
Gross Weight: 9591 lbs. (4350 kg)
10 in. (25.4 cm) Upper Works above Turntable Bearing
SECTION 3 - CHASSIS & TURNTABLE

Attach to hole
in turntable

NOTE: Do not lift boom

MAF04430

Figure 3-62. Swing Bearing Removal (460SJ)

3121671
SECTION 3 - CHASSIS & TURNTABLE

Swing Bearing Removal Swing Bearing Installation

1. From ground control station, operate the boom ade- NOTE: The swing bearing approximately weighs 138 lbs. (55 kg).
quately to provide access to frame opening to rotary
coupling. 1. Using suitable lifting equipment, carefully lower the
swing bearing into position on the frame. Ensure the
scribed line of the outer race of the bearing aligns with
the scribed line on the frame. If a new swing bearing is
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY used, ensure that the filler plug fitting is at 90 degrees
PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCK- from the fore and aft center line of the frame.
ING.

2. Attach an adequate support sling to the boom and draw JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS-
all slack from sling. Prop or block the boom if feasible. CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE
ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPER-
3. From inside turntable, remove mounting hardware from ATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS.
rotary coupling mount bracket. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.

4. Tag and disconnect the hydraulic lines from the fittings

2. Apply a light coating of JLG Threadlocker P/N 0100019
on the top of the rotary coupling. Use a suitable con- to the new bearing bolts and loosely install the bolts
tainer to retain any residual hydraulic fluid. Cap or plug and washers through the frame and outer race of bear-
all openings of hydraulic lines and port. ing.
5. Disconnect wiring harness connected to the rotary cou-
pling and tag and disconnect remote grease fitting line
(if equipped). IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED
FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING
6. Attach suitable overhead lifting equipment to the base ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.
of the turntable weldment. See “Swing Bearing Removal
(400S)” 3. Refer to the Torque Sequence diagram as shown in Fig-
ure 3-63., Swing Bearing Torque Sequence. Clean any
7. Use a suitable tool to scribe a line on the inner race of residue off the new bearing bolts, then apply a light
the swing bearing and on the underside of the turnta- coating of JLG Threadlocker P/N 0100019 and install the
ble. This will aid in aligning the bearing upon installa- bolts and washers through the frame and outer race of
tion. Remove the bolts and washers which attach the the bearing. Tighten the bolts to an initial torque of
turntable to the bearing inner race. Discard the bolts. 190 ft. lbs. (258 Nm) w/JLG Threadlocker P/N 0100019.

8. Use the lifting equipment to carefully lift the complete 4. Remove the lifting equipment from the bearing.
turntable assembly from the bearing. Ensure that no 5. Using suitable lifting equipment, carefully position the
damage occurs to the turntable, bearing or frame- turntable assembly above the machine frame.
mounted components.
6. Carefully lower the turntable onto the swing bearing,
9. Carefully place the turntable on a suitably supported ensuring that the scribed line of the inner race of the
trestle. bearing aligns with scribed line on the turntable. If a
new swing bearing is used, ensure that the filler plug fit-
NOTE: The swing bearing approximately weighs 138 lbs. (55 kg). ting is at 90 degrees from the fore and aft center line of
the turntable.
10. Use a suitable tool to scribe a line on the outer race of 7. Clean any residue off the new bearing bolts, then apply
the swing bearing and the frame. This line will aid in a light coating of JLG Threadlocker P/N 0100019 and
aligning the bearing upon installation. Remove the bolts install the bolts and washers through the turntable and
and washers which attach the outer race of the bearing inner race of the bearing.
to the frame. Discard the bolts. Use suitable lifting
equipment to remove the bearing from the frame, then 8. Following the Torque Sequence diagram shown in Fig-
move the bearing to a clean, suitably supported work ure 3-63., Swing Bearing Torque Sequence, tighten the
bolts to a torque of 190 ft. lbs. (258 Nm).
area.
9. Remove the lifting equipment.

3121671 3-85
SECTION 3 - CHASSIS & TURNTABLE

10. Install the rotary coupling mount bracket, apply a light 3. Apply JLG Threadlocker (P/N 0100019) to the pivot bolt
coating of JLG Threadlocker P/N 0100011 to the attach- and torque to 205 ft. lbs. (280 Nm).
ing bolts and secure the mount bracket to the turntable
with the mounting hardware.
11. Connect the hydraulic lines, electrical harness and
remote grease fitting line (if equipped) to the rotary
coupling as tagged prior to removal.
12. At ground control station, use boom lift control to lower
boom to stowed position.
13. Using all applicable safety precautions, activate the
hydraulic system and check the swing system for proper
and safe operation.

Procedure for Setting Swing Gear Backlash

1. Set swing gear backlash to 0.005 - 0.010 in. (0.127 -
0.254 mm) using the following procedure.
2. Place the shim (JLG P/N 1001190964) between the pin-
ion and the bearing on the high spot.

4. Remove the turntable lock pin.

NOTE: The high spot will be marked with yellow paint.

5. Apply JLG Threadlocker (P/N 0100019) to the remaining

swing drive mounting bolts and torque them to
30 ft. lbs. (40 Nm).

3-86 3121671
SECTION 3 - CHASSIS & TURNTABLE

6. Tighten the jack bolt until the pinion is completely snug Swing Bearing Torque Values
against the shim and bearing. After the pinion is snug,
loosen the jack bolt.
1. Outer Race - 190 ft. lbs. (258 Nm) with JLG Threadlocker
P/N 0100019.
2. Inner Race - 190 ft. lbs. (258 Nm) with JLG Threadlocker
P/N 0100019.
3. See Swing Bearing Torquing Sequence.

CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR
LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS
THEREAFTER.

7. Apply JLG Threadlocker (P/N 0100019) to the jack bolt

and jam nut and torque the jack bolt to 50 ft. lbs.
(68 Nm).
8. Tighten the jam nut.

9. Torque the remaining swing drive retaining bolts to

405 ft.lbs. (550 Nm).
10. Remove and discard the shim.

3121671 3-87
SECTION 3 - CHASSIS & TURNTABLE

INSTALL BEARING TO FRAME

WITH POINT OF MINIMUM GEAR BACKLASH
(MARKED WITH YELLOW PAINT)
TOWARDS CENTERLINE OF THE SWING
DRIVE (AS CLOSE TO THE BOLT PATTERN WILL ALLOW)

20 1
16 5

12 9

20 1
8 16 5 13
12 9
8 13
4 17
4 17

18 3
18 3
14 7
10 11
14 6 15 7
2 19

10 11

6 15 ORIENT ZERK TO THIS POSITION

WITH RESPECT TO FORWARD
2 19

FORWARD

Figure 3-63. Swing Bearing Torque Sequence

3-88 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.15 ROTARY COUPLING Table 3-10. Coupling Port Information Table -

(SN 0300203771 through 0300222808)
Use the following procedure to install the seal kit.
1. If not already removed, remove the axle oscillation valve Operating Proof
Port Out Port
from the cylinder barrel. The Shaft of the valve protrudes Description Pressure Pressure
No. let Size
into the barrel and will damage the Shaft and seals if left PSI (Bar) PSI (Bar)
in place. 1 1 -8 Brake 450 (31) 675 (47)
2. Remove Retaining ring (5) from end. 2 1 -6 2 Speed 4500 (310) 675 (47)
3. Remove spacer (4) from the same end. 3 1 -6 Steer 3000(207) 3750 (259)
4. Remove center body (2) from housing (1). 4 1 -6 Steer 3000 (207) 3750 (259)

5. Cut off old Seals (11, 12) positioned on the shaft and 5 1 -16 Drive Reverse 4500 (310) 6750 (465)
Seal (13) on the center body . 6 1 -16 Drive Forward 4500 (310) 6750 (465)
6. Reassemble O-ring (10). 7 1 -8 Axle Release 450 (31) 675 (47)
7. Remove proximity switch. 8 1 -12 Drain 250 (17) 375 (26)

8. Assemble lip seals (11) in direction shown in Figure 3-

64., Rotary Coupling Cutaway.
Table 3-11. Coupling Port Information Table -
9. Heat cap seals (12) in hydraulic oil for 5 minutes at 300° F (SN 0300222809 to Present, SN E300000100 to Present, SN
(149° C). 1300007289 through 1300007393)
10. Assemble cap seals over O-rings
Operating Proof
11. Reinsert center body into housing (lube with hydraulic Port Outl Port
Description Pressure Pressure
oil). No. et Size
PSI (Bar) PSI (Bar)
12. Replace Spacer and snap ring. 1 2 -8 Brake 450 (31) 675 (47)
2 2 -6 2 Speed 450 (310) 675 (47)
3 1 -6 Steer 3000 (207) 4500(310)
4 1 -6 Steer 3000 (207) 4500 (310)
5 1 -16 Drive Reverse 4500 (310) 6750 (465)
6 1 -16 Drive Forward 4500 (310) 6750 (465)
7 1 -8 Axle Release 450 (31) 675 (47)
8 3 -8 Drain 250 (17) 375 (26)

3121671 3-89
SECTION 3 - CHASSIS & TURNTABLE

5
4
13

11
10

10
11

8
9

7
3

MAF06100

1. Housing 6. Torque Lug 11. Seal

2. Center Body 7. Proximity Switch 12. Seal
3. Ring 8. Bolt 13. Seal
4. Spacer 9. Washer
5. Retaining Ring 10. O-ring

Figure 3-64. Rotary Coupling Cutaway

3-90 3121671
SECTION 3 - CHASSIS & TURNTABLE

2 5

5
6 9 4
1
13
5

7 6 10
5

11
5 12
7
3

8
(SN 0300203771 THROUGH 0300222808)

(SN 0300222809 TO PRESENT)

(SN E300000100 TO PRESENT)
(SN 1300007289 THROUGH 1300007393)
MAF01590

1. Bolt 5. Washer 8. Thrust Ring 11. Bolt

2. Bolt 6. Rotary Coupling Assembly 9. Plug 12. Washer
3. Nut 7. Proximity Switch 10. Threaded Spigot 13. Mount
4. Nut

Figure 3-65. Rotary Coupling Installation

3121671 3-91
SECTION 3 - CHASSIS & TURNTABLE

5,8
1
2

2,8
3

3
7 4

1
1
2

4 2

3
5
4
6

8 8
8
7

8 8

MAF01620

Figure 3-66. Rotary Coupling Port Location - (SN 0300203771 through 0300222808)

3-92 3121671
SECTION 3 - CHASSIS & TURNTABLE

5,8

2,7

2,8
3

1
4,6,8

MAF01970

Figure 3-67. Rotary Coupling Port Location - (SN 0300222809 to Present, SN E300000100 to Present,
SN 1300007289 through 1300007393)

3121671 3-93
SECTION 3 - CHASSIS & TURNTABLE

3.16 GENERATOR Overload Protection

STOP ENGINE BEFORE CARRY OUT SCHEDULE MAINTENANCE. STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT
BREAKER.
NOTE: Do often service, if operating in hostile environment.

Maintenance Schedule The circuit breaker protects the generator windings from over-
load. If the circuit breaker opens, generator output stops. If the
EVERY 250 HOURS circuit breaker continues to open, check for faulty equipment
Every 250 hours of operation, check the drive belt for proper connected to the platform receptacles.
tension.

1/2 in.
(13 mm)
CIRCUIT
BREAKER

EVERY 500 HOURS

Every 500 hours of operation, service the generator brushes
and slip rings. Hostile environments may require more fre- Inspecting Brushes, Replacing Brushes and
quent service.
Cleaning Slip Rings
Refer to Figure 3-68., Inspecting Generator Brushes, Replacing
Brushes and Cleaning Slip Rings.

INSPECTING BRUSH POSITION

Inspect brush alignment with slip rings. View alignment
through the air vents in the stator barrel. The brushes must
ride completely on the slip rings.

INSPECTING BRUSHES
Every 500 hours of service, blow out the inside of the genera- Remove the end panel. Inspect the wires. Remove the brush
tor. If operating in a hostile environment, clean monthly. holder assembly. Pull the brushes from the holders.

Replace the brushes if damaged, or if the brush is at or near

minimum length.

CLEANING SLIP RINGS

Visually inspect the slip rings. Under normal use, the rings turn
dark brown.

If the slip rings are corroded or their surface is uneven, remove

the belt to turn the shaft by hand for cleaning.

Clean the rings with 220 grit emery paper. Remove as little
material as possible. If the rings are deeply pitted and do not
clean up, consult generator factory service.

Reinstall the belt, brush holder assembly and end panel.

3-94 3121671
SECTION 3 - CHASSIS & TURNTABLE

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

Figure 3-68. Inspecting Generator Brushes, Replacing Brushes and Cleaning Slip Rings

3121671 3-95
SECTION 3 - CHASSIS & TURNTABLE

Generator Disassembly and Assembly 2. Remove brush holder assembly.

3. Disassemble generator parts shown in Figure 3-69.
Refer to Figure 3-70. and Figure 3-71. to determine if trouble is
in stator, rotor, control box, or combination of these compo- 4. Clean all parts with approved solvent and dry with com-
nents. pressed air, If applicable.
1. Rotor 5. Inspect all part for damage. Replace if necessary.

2. Stator Assembly ASSEMBLY

1. Assemble generator parts using torque values in table.

DO NOT DAMAGE ROTOR OR STATOR WINDINGS DURING DISASSEMBLY AND 2. Reconnect all leads. Use cable ties to secure leads away
ASSEMBLY PROCEDURE. from moving or hot parts.

DISASSEMBLY
1. Mark and disconnect all electrical leads, secure using
cable ties.

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EHIRUHLQVWDOOLQJ EHIRUHLQVWDOOLQJ

7RRO1HHGHG 5PSRVFT

$ LQOE 1P
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Figure 3-69. Generator Disassembly and Assembly

3-96 3121671
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-70. Generator Troubleshooting Circuit Diagram - Sheet 1 of 2

3121671 3-97
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-71. Generator Troubleshooting Circuit Diagram - Sheet 2 of 2

3-98 3121671
3121671
Figure 3-72. Generator Electrical Circuit Diagram

3-99
SECTION 3 - CHASSIS & TURNTABLE
3-100
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-73. Power Board PC1 Electrical Circuit Diagram

3121671
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-74. Power Board PC2 Electrical Circuit Diagram - Sheet 1 of 2

3121671 3-101
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-75. Power Board PC2 Electrical Circuit Diagram - Sheet 2 of 2

3-102 3121671
SECTION 3 - CHASSIS & TURNTABLE

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

Table 3-12. Lead Connection List for Generator

Leads Connections
1A STATOR TO CB1
2A STATOR TO CB1
3A STATOR TO CB1
4A STATOR TO TE1 (C)
5A STATOR TO RC4 (3)
5B PLG2 (C) TO PLG4 (3)
5C RC2 (C) PLG31 (8)
6A STATOR TO RC4 (4)
6B PLG2 (D) TO PLG4 (4)
6C RC2 (D) PLG31 (9)
9A RC5 (B) TO PLG3 (B) (Customer Supplied)
9B RC3 (B) PLG1 (8)
12A PLG2 (E) TO PLG4 (5)
12B RC2 (E) PLG1 (9)
12C RC4 (5) TO BRUSH
13A PLG2 (F) TO PLG4 (6)
13B RC2 (F) PLG31 (4)
13C RC4 (6) TO BRUSH
15A PLG1 (6) TO PLG31 (6)
16A PLG1 (3) TO PLG31 (1)
17A PLG1 (4) TO PLG31 (2)
21A CB1 TO TE1 (F)
21B PLG2 (A) TO PLG4 (1)
21C PLG1 (1) TO RC2 (A)
21D RC4 (1) TO CB1
22A CB1 TO TE1 (E)
22B PLG2 (B) TO PLG4 (2)
22C PLG1 (2) TO RC2 (B)
22D RC4 (2) TO CB1
23A CB1 TO TE1 (D)
42A RC5 (C) TO PLG3 (C) (Customer Supplied)
42B RC3 (C) TO CONNECTION POINT 1
42C PLG31 (7) TO CONNECTION POINT 1
42D PLG1 (5) TO CONNECTION POINT 1
42F END BELL SHROUD TO ENGINE MOUNT
42G CHASSIS TO TE1 (B)
43A RC5 (A) TO PLG3 (A) (Customer Supplied)
43B RC3 (A) TO CONNECTION POINT 2
43C PLG31 (3) TO CONNECTION POINT 2
43D PLG1 (7) TO CONNECTION POINT 2

3121671 3-103
SECTION 3 - CHASSIS & TURNTABLE

3.17 DEUTZ ENGINE

6
8
7

5
9
2
4
3 MAF01640

1. Engine 6. Radiator Mounting

2. Gear Pump 7. Radiator
3. Piston Pump 8. Fan
4. Pump Coupling 9. Fuel Filter
5. Engine Tray 10. Oil FIlter

Figure 3-76. Deutz D2.9L4 Engine Components - Sheet 1 of 2

3-104 3121671
SECTION 3 - CHASSIS & TURNTABLE

11
12

MAF01650

11. Exhaust Pipe 14. Air Filter

12. Muffler 15. ECU module
13. Air Intake Indicator

Figure 3-77. Deutz D2.9L4 Engine Components - Sheet 2 of 2

3121671 3-105
SECTION 3 - CHASSIS & TURNTABLE

6 8

4
3
MAF01700

1. Engine 6. Radiator Mount Plate

2. Gear Pump 7. Oil Cooler
3. Piston Pump 8. Fan
4. Pump Coupling 9. Alternator
5. Engine Tray

Figure 3-78. Deutz D2011 Engine Components - Sheet 1 of 3

3-106 3121671
SECTION 3 - CHASSIS & TURNTABLE

10
11

13 12

MAF01710

10. Exhaust Pipe 13. Air Filter

11. Muffler 14. ECU Module
12. Air Intake Indicator

Figure 3-79. Deutz D2011 Engine Components - Sheet 2 of 3

3121671 3-107
SECTION 3 - CHASSIS & TURNTABLE

MAF01720

15. RelayAssembly 17. Fuel Filter

16. Oil Filter

Figure 3-80. Deutz D2011 Engine Components - Sheet 3 of 3

3-108 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.18 GM ENGINE

8 1

2
4
3
MAF01760

1. Engine 6. Radiator Mounting

2. Gear Pump 7. Radiator
3. Piston Pump 8. Coolant Overflow Container
4. Pump Coupling 9. Alternator
5. Engine Tray

Figure 3-81. GM Engine Components - Sheet 1 of 2

3121671 3-109
SECTION 3 - CHASSIS & TURNTABLE

MAF01770

10. Muffler 12. Fan

11. Air Filter 13. Exhaust Pipe

Figure 3-82. GM Engine Components - Sheet 2 of 2

3-110 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.19 KUBOTA ENGINE

9
8

6
1
7

10
5

2
4 3 12
11
MAF01810

1. Engine 5. Engine Tray 9. Coolant Overflow Container

2. Gear Pump 6. Radiator Mounting 10. Alternator
3. Piston Pump 7. Radiator 11. Forward Solenoid
4. Pump Coupling 8. Fan 12. Reverse Solenoid

Figure 3-83. Kubota Engine Components - Sheet 1 of 2

3121671 3-111
SECTION 3 - CHASSIS & TURNTABLE

15
16 18

MAF01820

13. Fuel Filter 17. Exhaust Pipe

14. Oil Filter 18. Air Filter
15. Air Intake Indicator 19. Fuel Pump
16. Muffler

Figure 3-84. Kubota Engine Components - Sheet 2 of 2

3-112 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.20 DEUTZ ENGINE - D2.9L4 Replacing Engine Oil

NOTE: Refer to engine manufacturer's manual for detailed oper- 1. Allow engine to warm up. Engine oil should reach
ating and maintenance instructions. Limited engine main- approximately 176° F (80° C).
tenance items are presented here for convenience but
2. Make sure machine and engine are level.
detailed engine maintenance items and schedule are
included in the engine manufacturer's manual. 3. Switch off engine.
4. Place oil tray under engine.
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 HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
Power/Emergency Stop switch is pulled on if the ambient air DRAINING.
temperature is less than 50° F (10° C) and the engine coolant
temperature is less than 140° F (60° C). This determination will
occur one second after the Power/Emergency Stop switch has COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.
been pulled on. The lamp and glow plugs will remain ener- DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU-
gized for the period of time specified by the setting in the JLG LATIONS.
Control System. Engine start shall be disabled during this
period. On Deutz engines, the glow plugs will continue (post 5. Open oil drain valve and drain oil.
glow) after the engine has started for three times the machine 6. Close oil drain valve.
digit setting.
7. Pour in new engine oil. Refer to Section 1 for capacity
Check Oil Level and Figure 3-85., Engine Oil Viscosity.
1. Make sure machine and engine are level and switch
engine OFF before checking oil level.
2. Remove oil dipstick and wipe with clean cloth.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level as shown in figure below
with an approved grade and type of oil outlined in
engine manufacturer’s operator’s manual.
5. Replace dipstick until fully seated.

Figure 3-85. Engine Oil Viscosity

3121671 3-113
SECTION 3 - CHASSIS & TURNTABLE

Replacing the Oil Filter Replacing the Fuel Filters

MAF01190
Figure 3-86. Location of the Oil Filter
Figure 3-87. Location of the Fuel Pre-Filter

1. Wipe area around filter to clean any dirt from area.

2. Using a suitable oil filter removal tool, loosen lube oil fil-
ter element and spin off.

Figure 3-88. Location of the Fuel Filter

3. Catch any escaping oil.

4. Clean any dirt from filter carrier sealing surface.

5. Lightly coat new oil filter rubber gasket with clean oil. FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
6. Screw in new filter by hand until gasket is flush.
SYSTEM. DO NOT SMOKE WHEN WORKING ON THE FUEL SYSTEMS.
7. Hand-tighten filter another half-turn. 1. Wipe area around filter to clean any dirt from area.
2. Fuel supply from the fuel tank may need to be blocked
to prevent flow from the fuel tank.
3. Remove fuel filter cartridge.

8. Check oil level.

9. Check oil pressure.

10. Check oil filter cartridge for leaks.

3-114 3121671
SECTION 3 - CHASSIS & TURNTABLE

4. Catch any escaping fuel. 3.21 DEUTZ ENGINE - D2011

NOTE: Refer to engine manufacturer's manual for detailed oper-
ating and maintenance instructions. Limited engine main-
tenance items are presented here for convenience but
detailed engine maintenance items and schedule are
included in the engine manufacturer's manual.

Glow Plugs
If the glow plug option is enabled in the JLG Control System,
the glow plug and indicator lamp will be energized when the
Power/Emergency Stop switch is pulled on if the ambient air
temperature is less than 50° F (10° C) and the engine coolant
temperature is less than 140° F (60° C). This determination will
occur one second after the Power/Emergency Stop switch has
been pulled on. The lamp and glow plugs will remain ener-
gized for the period of time specified by the setting in the JLG
5. Clean dirt from filter carrier sealing surface. Control System. Engine start shall be disabled during this
6. Apply light film of oil or diesel fuel to rubber gasket of period. On Deutz engines, the glow plugs will continue (post
new filter cartridge. glow) after the engine has started for three times the machine
digit setting.
7. Screw in new filter by hand until gasket is flush. Hand-
tighten filter another 3/4 turn.
Check Oil Level
1. Switch the engine off before checking oil level.
2. Make sure the machine and engine are level.
3. Remove the oil dipstick.
4. Wipe the dipstick with non-fibrous, clean cloth.

8. Check for leaks.

3121671 3-115
SECTION 3 - CHASSIS & TURNTABLE

5. Insert the dipstick to the stop and remove again. Check Replacing Engine Oil
the oil level, and if necessary, top the oil level up to the
MAX mark with an approved grade and type of oil as 1. Allow the engine to warm up. The engine oil should
outlined in the engine manufacturer’s operator’s man- reach approximately 176° F (80° C).
ual. Refer to Figure 3-89., Deutz Engine Dipstick.
2. Make sure the machine and engine are level.
3. Switch off the engine.
4. Place an oil tray under the engine.

HOT ENGINE OIL CAN CAUSE BURNS, AVOID CONTACT WITH HOT OIL WHEN
DRAINING.

COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.

DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU-
LATIONS.

0,1,0802,/
/(9(/

0$;,0802,/
/(9(/

5. Open the oil drain valve.

6. Drain the oil.
0,1,080/(9(/ 7. Close the oil drain valve.
2,/+27
0$;,080/(9(/
2,/+27

0,1,080/(9(/
2,/&2/'
0$;,080/(9(/
2,/&2/'

127(+RWRLOFKHFNVVKRXOGQRWEHPDGHXQWLOWKHHQJLQH
KDVEHHQVKXWGRZQIRUDSHULRGRIPLQXWHV

Figure 3-89. Deutz Engine Dipstick

6. Replace the dipstick making sure that it is fully seated in

the dipstick tube to seal off the crankcase.

3-116 3121671
SECTION 3 - CHASSIS & TURNTABLE

8. Pour in new engine oil. Refer to Section 1 for capacity Replacing the Oil Filter
and refer to Figure 3-90., Engine Oil Viscosity for the
proper grade.

1. Wipe the area around the filter to clean any dirt from the
area.
2. Using a suitable oil filter removal tool, loosen lube oil fil-
ter element and spin off.
Figure 3-90. Engine Oil Viscosity

3. Catch any escaping oil.

4. Clean any dirt from filter carrier sealing surface.

3121671 3-117
SECTION 3 - CHASSIS & TURNTABLE

5. Lightly coat new oil filter rubber gasket with clean oil. Replacing the Fuel Filter

6. Manually screw in the new filter until the gasket is flush.

FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON THE FUEL SYSTEMS.
1. Wipe the area around the filter to clean any dirt from the
area.
2. Fuel supply from the fuel tank may need to be blocked
to prevent fuel flow from the tank.
3. Undo the fuel filter cartridge and spin off.
7. Hand-tighten filter another half-turn.
4. Catch any escaping fuel.
8. Check oil level.
5. Clean any dirt from the filter carrier sealing surface.
9. Check oil pressure.
6. Apply a light film of oil or diesel fuel to the rubber gas-
10. Check the oil filter cartridge and make sure there are no ket of the new filter cartridge.
leaks.
7. Manually screw in the new filter until the gasket is flush.
8. Tighten the fuel filter cartridge with a final half-turn.
9. Check for leaks.

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3.22 DEUTZ EMR 2 The EMR2 is equipped with safety devices and measures in the
hardware and software in order to ensure emergency running
The EMR2 consists of the sensors, the control unit and the (Limp home) functions.
actuator. Engine-side controls as well as the JLG Control Sys- In order to switch the engine off, the EMR2 is switched in a de-
tem are connected by means of separate cable harnesses to energized fashion over the ignition switch. A strong spring in
the EMR control unit. the actuator presses the control rod in the de-energized con-
dition into the zero position. As a redundancy measure, an
The sensors attached to the engine provide the electronics in additional solenoid serves for switching off and this, indepen-
the control unit with all the relevant physical parameters In dently of the actuator, also moves the control rod in the de-
accordance with the information of the current condition of energized condition into the zero position.
the engine and the preconditions (throttle position etc.), the
After the programming, that is carried out over the ISO9141
EMR2 controls an actuator that operates the control rod of the
interface, the EMR2 possesses a motor-specific data set and
injection pump and thus doses the fuel quantity in accordance
this is then fixedly assigned to the engine. Included in this are
with the performance requirements.
the various application cases as well as the customer’s wishes
regarding a particular scope of function.
The exact position of the regulating rod is reported back and,
if necessary, is corrected, by means of the control rod travel Each EMR2 module is matched by serial number to the engine.
sensor, situated together with the rotation magnets in a hous- Modules cannot be swapped between engines.
ing of the actuator.

Figure 3-91. EMR 2 Engine Side Equipment

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Figure 3-92. Deutz EMR 2 Troubleshooting Flow Chart

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Figure 3-93. Deutz EMR 2 Vehicle Side Connection Diagram

3-121
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3-122
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Figure 3-94. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

3121671
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Figure 3-95. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

3-123
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SECTION 3 - CHASSIS & TURNTABLE

Figure 3-96. EMR 2 Engine Plug Pin Identification

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Figure 3-97. EMR 2 Vehicle Plug Pin Identification

3121671 3-125
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Figure 3-98. EMR2 Fault Codes - Sheet 1 of 5

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Figure 3-99. EMR2 Fault Codes - Sheet 2 of 5

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3-128
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Figure 3-100. EMR2 Fault Codes - Sheet 3 of 5

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Figure 3-101. EMR2 Fault Codes - Sheet 4 of 5

3-129
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3-130
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Figure 3-102. EMR2 Fault Codes - Sheet 5 of 5

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3.23 GM ENGINE GENERAL MAINTENANCE • Check ignition coil and spark plug cables for hardening,
cracking, chafing, separation, split boot covers and proper
fit.
Maintenance of the Drive Belt
• Replace spark plugs at the proper intervals as prescribed in
The serpentine drive belt utilizes a spring loaded tensioner the engine manufacturer’s manual.
which keeps the belt properly adjusted. The drive belt is an • Check to make sure all electrical components are fitted
integral part of the cooling and charging systems and should securely.
be inspected frequently.
• Check the ground and platform control stations to insure
When inspecting the belts check for: all warning indicator lights are functioning.
• Cracks or breaks
Checking/Filling Engine Oil Level
• Chunking of the belt
• Splits
• Material hanging from the belt AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED FULL MARK)
CAN CAUSE AN OIL LEAK, A FLUCTUATION OR DROP IN THE OIL PRESSURE,
• Glazing and hardening AND ROCKER ARM "CLATTER" IN THE ENGINE.
• Damaged or improperly aligned pulleys
• Improperly performing tensioner
CARE MUST BE TAKEN WHEN CHECKING THE ENGINE OIL LEVEL. OIL LEVEL
Check the belt tensioner by pressing down on the midway MUST BE MAINTAINED BETWEEN THE "ADD" MARK AND "FULL" MARK ON THE
point of the longest stretch between pulleys. The belt should DIPSTICK.
not depress beyond 1/2 in. (13 mm). If the depression is more
than allowable adjust the tension. To ensure that you are not getting a false reading, make sure
the following steps are taken to before check the oil level.
1. Stop the engine if in use.
THE ENGINE MANUFACTURER DOES NOT RECOMMEND THE USE OF "BELT
DRESSING" OR "ANTI SLIPPING AGENTS" ON THE DRIVE BELT. 2. Allow sufficient time (approximately 5 minutes) for the
oil to drain back into the oil pan.
Engine Electrical System Maintenance 3. Remove the dipstick. Wipe with a clean cloth or paper
towel and reinstall. Push the dipstick all the way into the
The engine electrical system incorporates computers and dipstick tube.
microprocessors to control the engine ignition, fuel control,
4. Remove the dipstick and note the oil level.
and emissions. Due to the sensitivity of the computers to good
electrical connections periodic inspection of the electrical wir- 5. Oil level must be between the "FULL" and "ADD" marks.
ing is necessary. When inspecting the electrical system use the
following:

• Check and clean the battery terminal connections and

insure the connections are tight.
• Check the battery for any cracks or damage to the case.
• Check the Positive and Negative battery cables for any cor-
rosion build up, rubbing or chafing, check connection on
the chassis to insure they are tight. Figure 3-103. Engine Oil Dip Stick
• Check the entire engine wire harness for rubbing chafing, 6. If the oil level is below the "ADD" mark, proceed to Step
cuts or damaged connections, repair if necessary. 7 and 8 and reinstall the dipstick into the dipstick tube.
• Check all wire harness connectors to insure they are fully 7. Remove the oil filter cap from the valve rocker arm
seated and locked. cover.
8. Add the required amount of oil to bring the level up to
but not over "FULL" mark on the dipstick.
9. Reinstall the oil fill cap to the valve rocker cover and
wipe away any excess oil.

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Changing the Engine Oil 1. Loosen the worm gear clamp on the coolant line run-
ning into the EPR as shown below and remove the hose
from the EPR. Place a rag under the hose to prevent
coolant from running onto the engine/machine.
WHEN CHANGING THE OIL, ALWAYS CHANGE THE OIL FILTER. CHANGE OIL
WHEN THE ENGINE IS WARM FROM OPERATION AS THE OILS WILL FLOW
FREELY AND CARRY AWAY MORE IMPURITIES.

To change the oil use the following steps:

1. Start the engine and run until it reaches normal operat-
ing temperature.
2. Stop the engine.
3. Remove the drain plug and allow the oil to drain.
4. Remove and discard the oil filter and its sealing ring.
5. Coat the sealing ring on the filter with clean engine oil
and wipe the sealing surface on the filter mounting sur-
face to remove any dust, dirt and debris. Tighten the fil-
ter securely (follow the filter manufacturers
instructions). Do not over tighten.
6. Check the sealing ring on drain plug for any damage,
replace if necessary, wipe the plug with a clean rag, and 2. Remove the radiator cap. Fill the radiator with coolant
wipe the sealing surface on the pan and reinstall the pan until coolant starts to appear from the previously
plug. Do not over tighten. removed hose at the EPR. Reinstall the hose back onto
the EPR and continue to fill radiator with coolant.
7. Fill the crankcase with oil.
8. Start the engine and check for oil leaks.
9. Stop the engine and check the oil level to insure the oil
level is at "FULL".
10. Dispose of the oil and filter in a safe manner.

Coolant Fill Procedure - Dual Fuel Engine

DAMAGE TO THE ENGINE COULD OCCUR IF NOT PROPERLY FILLED WITH COOL-
ANT. LPG FUELED ENGINES ARE MOST PRONE TO CREATING AN AIR LOCK DUR-
ING A COOLANT FILL OPERATION DUE TO THE ELECTRONIC PRESSURE
REGULATOR (EPR) BEING THE HIGHEST POINT IN THE COOLING SYSTEM. AN
EPR THAT APPEARS TO HAVE FROST FORMING ON IT IS A SIGN THAT THE
ENGINE COOLING SYSTEM CONTAINS AIR. THE APPEARANCE AND TEMPERA-
TURE OF THE EPR SHOULD BE MONITORED DURING THE COOLANT FILL OPER- 3. With the radiator cap still removed, start the engine and
ATION. A WARM EPR IS AN INDICATION THAT THE COOLING SYSTEM IS run until the thermostat opens. The thermostat opens at
PROPERLY FILLED AND FUNCTIONING. 170° F (77° C), which can be checked using the JLG
handheld analyzer.

MAKE SURE ENGINE IS COOL BEFORE PERFORMING ANY MAINTENANCE WHILE ENGINE IS RUNNING, AIR AND/OR STEAM MAY BE PRESENT COMING
WORK. FROM THE RADIATOR. THIS IS NORMAL.

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4. After running the engine for 5 minutes after it has 3.24 GM ENGINE DUAL FUEL SYSTEM
reached operating temperature, shut the engine off and
continue to step 5.
NOTE: +20° F (-6.6° C) is the low temperature limit for LP gas, for
both starting and operation. This applies to all LP gas pow-
ered engines.
WITH THE ENGINE RUNNING OR WHEN SHUTTING OFF THE ENGINE, SOME
HEATED COOLANT MAY SPILL OUT DUE TO AIR "BURPING" OUT OF THE SYS-
The Dual Fuel system allows the operator to operate the vehi-
TEM WITH THE RADIATOR CAP OFF.
cle on either gasoline or LPG by positioning a selector switch
5. Next, verify that the 2 coolant hoses on the EPR are in the operator's platform. When the operator places the selec-
warm. If they are not warm repeat step 3 and 4, other- tor switch in the gasoline mode the gasoline fuel pump is
wise continue to step 6. energized. While in the gasoline mode the LPG fuel lock-off is
isolated and will not energize. In addition the gasoline injector
circuit is enabled and injector pulses are provided to each
A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM UPPER RADIA- injector and the ECM calibration for gasoline is also enabled.
TOR HOSE AND A WARM EPR HOSE. IF THE UPPER RADIATOR HOSE AND/OR When the operator selects the LPG mode the Low Pressure
EPR HOSE ARE NOT WARM TO THE TOUCH AFTER THE ENGINE HAS RUN FOR 5-
LPG lock-off is energized and fuel from the LPG tank flows to
8 MINUTES AFTER REACHING OPERATING TEMPERATURE, THE SYSTEM MAY
the Electronic Pressure Regulator (EPR). The EPR receives an
STILL CONTAIN AIR. IT MAY BE NECESSARY TO REPEAT THE ABOVE STEPS.
electronic signal to position the secondary lever for the start or
6. Fill radiator with coolant as needed and install the radia- run positions and when the engine begins to crank the mixer
tor cap. Next, remove the cap off the coolant recovery air valve will rise and fuel will begin flowing to engine. During
bottle and fill just below the HOT FULL line and reinstall this mode the gasoline fuel pump is isolated and will not be
the caps. activated. The primary components of the gasoline dual fuel
system are the gasoline tank, electric fuel pump and filter, fuel
supply line, injector rail and injectors and the fuel pressure
regulator. The primary components of the LPG dual fuel sys-
tem are the LPG fuel tank, in-fuel filter, LPG Low Pressure lock-
off, Electronic Pressure Regulator (EPR) and the fuel mixer
module. The LPG fuel system operates at pressures which
range from 14.0 in. (355.60 mm) of water column up to 312 psi
(21.5 bar).

Components which are shared by both systems include the

Electronic Throttle Control and the ECM. The ECM contains a
dual calibration; one controls the gasoline fuel system during
gasoline operation and one controls the LPG fuel system dur-
ing LPG operation.

Fuel Filter
Propane fuel like all other motor fuels is subject to contamina-
tion from outside sources. Refueling of the equipment’s tank
and removal of the tank from the equipment can inadver-
tently introduce dirt and other foreign matter into the fuel sys-
tem. It is therefore necessary to filter the fuel prior to entering
the fuel system components downstream of the tank. An
inline fuel filter has been installed in the fuel system to remove
the dirt and foreign matter from the fuel. The inline filter is
replaceable as a unit only. Maintenance of the filter is critical to
proper operation of the fuel system and should be replaced as
Section 1. In severe operating condition more frequent
replacement of the filter may be necessary.

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Electric Lock Off Low Pressure Regulator (LPR)

The LPR is a combination vaporizer, pressure regulating
The Electric Lock Off device is an integrated assembly. When
device. The LPR is a negative pressure, two stage regulator that
energized the solenoid opens the valve and allows the Pro-
is normally closed when the engine is not running. When the
pane fuel to flow through the device. The valve opens during engine is cranking or running, a partial vacuum is created in
cranking and run cycles of the engine. The lock off supply volt- the fuel line which connects the regulator to the mixer. This
age is controlled by the engine control module (ECM). partial vacuum opens the regulator permitting fuel to flow to
the mixer.
Propane fuel enters the primary port of the LPR and passes
through the primary jet and into the primary/ exchanger
chamber. As the propane passes through the heat exchanger
the fuel expands and creates pressure inside the chamber. The
pressure rises as the fuel expands when the pressure rises
above 1.5 psi (10.34 kpa), sufficient pressure is exerted on the
primary diaphragm to cause the diaphragm plate to pivot and
press against the primary valve pin thus closing off the flow of
Figure 3-104. Electric Fuel Lock Off fuel. This action causes the flow of fuel into the regulator to be
regulated.
When the engine is cranking, sufficient vacuum will be intro-
EPR Assembly duced into the secondary chamber from the mixer drawing
the secondary diaphragm down onto the spring loaded lever
The EPR assembly is a combination Low Pressure Regulator and opening the secondary valve allowing vaporized fuel to
and a Voice Coil Assembly. The Voice coil is an electronic actu- pass to the mixer. This mechanical action in conjunction with
ator which is controlled by an internal microprocessor. The the EPR reactions causes the downward action on the second-
microprocessor provides output data to the ECM and receives ary lever causing it to open wider allowing more fuel to flow to
input data over a CAN BUS connection. The internal micropro- the mixer.
cessor receives electrical signals from the Fuel Pressure Sensor
FPS and the Fuel Temperature Pressure FTP and communi-
cates the data to the ECM. The ECM uses the FPS and FTP data
THE VOICE COIL SECTION OF THE EPR ASSEMBLY IS AN EMISSIONS CONTROL
to calculate the location of the secondary lever in the LPR and DEVICE AND CANNOT BE REBUILT. IF THE COIL ASSEMBLY FAILS TO OPERATE
sends that data back to the EPR via the CAN BUS. The internal PROPERLY, REPLACE IT WITH AN OEM REPLACEMENT PART ONLY.
microprocessor in the EPR will then output a signal, which
causes the voice coil to move and position the secondary lever
to the correct location.

Figure 3-106. Low Pressure Regulators

1. Pressure Regulator Section 4. Primary Test Port

2. Fuel Inlet 5. Secondary Test Port
3. Coolant Passage 6. Voice Coil Section
Figure 3-105. EPR Assembly

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Air Fuel Mixer Electronic Throttle Control (ETC)

The air valve mixer is an air-fuel metering device and is com- Engine speed and load control is maintained by an ETC device.
pletely self-contained. The mixer is an air valve design, utiliz- Speed and load control are determined by the ECM. Defaults
ing a relatively constant pressure drop to draw fuel into the programmed into the ECM software and throttle position sen-
mixer from cranking to full load. The mixer is mounted in the sors allow the ECM to maintain safe operating control over the
air stream ahead of the throttle control device. engine. The Electronic Throttle Control device or "throttle
body assembly" is connected to the intake manifold of the
When the engine begins to crank, it draws in air with the air engine. The electronic throttle control device utilizes an elec-
valve covering the inlet, negative pressure begins to build. tric motor connected to the throttle shaft. When the engine is
This negative pressure signal is communicated to the top of running electrical signals are sent from the equipment con-
the air valve chamber through 4 vacuum ports in the air valve trols to the engine ECM when the operator depresses an
assembly. A pressure/force imbalance begins to build across equipment function switch. The ECM then sends an electrical
the air valve diaphragm between the air valve vacuum cham- signal to the motor on the electronic throttle control to
ber and the atmospheric pressure below the diaphragm. The increase or decrease the angle of the throttle blade thus
air valve vacuum spring is calibrated to generate from 4.0 in. increasing or decreasing the air/fuel flow to the engine.
(101.6 mm) of water column at start to as high as 14.0 in.
(355.60 mm) of water column at full throttle. The vacuum The electronic throttle control device also incorporates two
being created is referred to as Air Valve Vacuum (AVV). As the internal Throttle Position Sensors (TPS) which provide output
air valve vacuum reaches 4.0 in. (101.6 mm) of water column, signals to the ECM as to the location of the throttle shaft and
the air valve begins to lift against the air valve spring. The blade. The TPS information is used by the ECM to correct
amount of AVV generated is a direct result of the throttle posi- speed and load control as well as emission control.
tion. At low engine speed the air valve vacuum is low and the
air valve position is low thus creating a small venturi for the
fuel to flow. As the engine speed increase the AVV increases
and the air valve is lifted higher thus creating a much larger
venturi. This air valve vacuum is communicated from the mixer
venture to the LPR secondary chamber via the low pressure
fuel supply hose. As the AVV increases in the secondary cham-
ber the secondary diaphragm is drawn further down forcing
the secondary valve lever to open wider.

Figure 3-108. ETC throttle control device

Figure 3-107. Air Fuel Mixer

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Engine Control Module Heated Exhaust Gas Oxygen Sensor

To obtain maximum effect from the catalyst and accurate con- There are two Heated Exhaust Gas Oxygen Sensors (HEGO).
The first HEGO is mounted in the exhaust system downstream
trol of the air fuel ratio the emission certified engine is
of the engine. It is used to measure the amount of oxygen
equipped with an onboard computer or Engine Control Unit present in the exhaust stream and communicate that to the
(ECM). The ECM is a 32 bit controller which receives input data ECM via an electrical signal. The amount of oxygen present in
from sensors fitted to the engine and fuel system and then the exhaust stream indicates whether the fuel/air ratio is too
outputs various signals to control engine operation. rich or too lean. If the HEGO sensor signal indicates that the
exhaust stream is too rich the ECM will decrease or lean the
One specific function of the controller is to maintain "closed fuel mixture during engine operation, if the mixture is too lean
loop fuel control". Closed loop fuel control is accomplished the ECM will richen the mixture. The ECM continuously moni-
when the exhaust gas oxygen sensor (HEGO) mounted in the tors the HEGO sensor output. If a rich or lean condition is pres-
exhaust system sends a voltage signal to the controller. The ent for an extended period of time, and the ECM cannot
controller then calculates any correction that may need to be correct the condition, the ECM will set a diagnostic code and
turn on the MIL light in control box.
made to the air fuel ratio. The controller then outputs signals
to the EPR to correct the amount of fuel being supplied to the The second HEGO is mounted in the exhaust system after the
mixer. At the same time the ECM may correct the throttle muffler. It measures the amount of oxygen in the exhaust sys-
blade position to correct speed and load of the engine. tem after the catalyst treatment has been completed in the
muffler. If the ECM detects that the catalytic action in the muf-
The controller also performs diagnostic functions on the fuel fler is not sufficient and fuel correction cannot correct the mal-
system and notifies the operator of malfunctions by turning function the MIL light is illuminated in the control box and a
on a Malfunction Indicator Light (MIL) mounted in the Ground DTC code will stored in the computer.
Control Station and the Platform Control Station. Malfunctions
in the system are identified by a Diagnostic Code number. In
addition to notifying the operator of the malfunction in the THE HEATED EXHAUST GAS OXYGEN SENSOR IS AN EMISSION CONTROL
DEVICE. IF THE HEGO FAILS TO OPERATE, REPLACE IT WITH AN OEM REPLACE-
system the controller also stores the information about the
MENT PART. THE HEGO SENSOR IS SENSITIVE TO SILICONE OR SILICONE
malfunction in its memory.
BASED PRODUCTS AND CAN BECOME CONTAMINATED. AVOID USING SILICONE
SEALERS OR HOSES TREATED WITH SILICONE LUBRICANTS IN THE AIR
STREAM OR FUEL LINES.

Figure 3-109. LPG Engine Control Unit (ECM)

Figure 3-111. Heated Exhaust Gas Oxygen Sensor

Gasoline Multi Point Fuel Injection System (MPFI)

The primary components of the Gasoline Multi Point Fuel
Injection (MPFI) fuel system are the fuel tank, electric fuel
pump, fuel pressure and temperature sensor manifold, fuel fil-
ter and fuel rail.

Figure 3-110. ECM Assembly

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Gasoline Fuel Pump Fuel Filter

The Gasoline is stored as a liquid in the fuel tank and in drawn After the fuel is drawn into the fuel pump, the fuel flows
into the fuel system by an electric fuel pump. The fuel pump through the gasoline fuel filter. The fuel filter will trap small
will receive a signal from the ECM to prime the fuel system for particles as the fuel passes through the filter to remove debris
approximately 2 seconds prior to start. Priming of the fuel sys- and prevents the fuel pressure and temperature manifold and
tem provides for a quicker start, when the engine begins to fuel injectors from becoming damaged. Maintenance of the
crank. fuel filter is required as indicated in Section 1.

Gasoline Pressure And Temperature Sensor Fuel Injector Rail

Manifold Fuel flows from the fuel pressure and temperature manifold
assembly to the fuel rails where the fuel is delivered to the fuel
This engine is equipped with a fuel injector rail that does not injectors. The fuel rail also contains a Schrader valve which is
have a pressure regulator or a return circuit to the fuel tank. utilized to test the regulated pressure of the fuel system.
Fuel pressure for this engine is regulated by the engine’s ECM.
The ECM receive fuel pressure and temperature feedback from Fuel Injector
the gasoline fuel sensor manifold and uses this information to
control the ground side of the fuel pump. Fuel pressure is reg- The fuel supply is maintained on the top of the injector from
ulated by the ECM pulse width modulating (PWM) the fuel the injector rail. The injector is fed a "pulse" signal through the
pump. The fuel pressure and temperature sensor manifold has wire harness which causes the injector to open. During regular
a return or "bleed" circuit that connects back to the fuel tank. operating conditions the ECM controls the opening and dura-
This circuit is used to bleed off any vapor that develops in the tion of opening of the injector. During lower RPM operation
line and return a small amount of fuel to the tank. The fuel the injector signals or "pulses" are less frequent then when the
comes from the fuel tank and passes through the fuel pump. engine is operating at higher RPMs. The engine has been cali-
Fuel exits the fuel pump, passes through the filter and then brated to deliver the precise amount of fuel for optimum per-
enters the fuel pressure and temperature manifold assembly. formance and emission control.
Fuel flows through the feed circuit and is delivered to the fuel
injector rail. Fuel that enters the bleed circuits through they
bypass valve in the manifold is returned to the fuel tank.

Figure 3-112. Gasoline Fuel Pressure and Temperature

Manifold Assembly

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3.25 GM ENGINE FUEL SYSTEM REPAIR Propane Fuel System Leak Test

Propane Fuel System Pressure Relief

NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK FOR PROPANE FUEL SYS-
TEM LEAKS.
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5
Always inspect the propane fuel system for leaks after per-
BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE
forming service. Check for leaks at the fittings of the serviced
PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING
or replaced component. Use a commercially available liquid
THE PROPANE FUEL SYSTEM COMPONENTS.
leak detector or an electronic leak detector. When using both
methods, use the electronic leak detector first to avoid con-
To relieve propane fuel system pressure:
tamination by the liquid leak detector.
1. Close the manual shut-off valve on the propane fuel
tank.
2. Start and run the vehicle until the engine stalls.
3. Turn the ignition switch OFF.

RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE

THE WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL
LINE.

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Propane Fuel Filter Replacement INSTALLATION

BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE

1 5
INSTALLING NEW SEAL

6 1. Install the mounting plate to lock off o-ring seal.

10 2. If equipped, install the retaining bolt seal.
7
2 3. Install the housing seal.

8 4. Drop the magnet into the bottom of the filter housing.

5. Install the filter into the housing.
3 6. If equipped, install the retaining bolt into the filter hous-
ing.
4 7. Install the filter up to the bottom of the electric lock off.
8. Tighten the filter bowl retainer to 106 in. lbs. (12 Nm).

9 9. Open manual shut-off valve. Start the vehicle and leak

check the propane fuel system at each serviced fitting.
Refer to Propane Fuel System Leak Test.
1. Electric Lock Off Solenoid 6. Fuel Outlet
2. Housing Seal 7. O-ring
3. Filter Magnet 8. Filter
4. Filter Housing 9. Fuel Inlet
5. Electrical Connector 10. Ring
Figure 3-113. Filter Lock Assembly

REMOVAL
1. Relieve the propane fuel system pressure. Refer to Pro-
pane Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
3. Slowly loosen the Filter housing and remove it.
4. Pull the filter housing from the Electric lock off assembly.
5. Remove the filter from the housing.
6. Locate Filter magnet and remove it.
7. Remove and discard the housing seal.
8. If equipped, remove and discard the retaining bolt seal.
9. Remove and discard mounting plate to lock off O-ring
seal.

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SECTION 3 - CHASSIS & TURNTABLE

Electronic Pressure Regulator (EPR) Assembly 11. Remove the (3) three nuts from the EPR isolators and the
EPR mounting bracket.
Replacement
12. Remove the EPR from the bracket.
13. Remove the (3) three mounting isolators.
INSTALLATION

DO NOT USE TEFLON TAPE ON ANY FUEL FITTING. USE A LIQUID PIPE THREAD
SEALANT WHEN INSTALLING FITTINGS.

CHECK ALL THE O-RINGS ON THE VAPOR AND WATER FITTINGS FOR ANY DAM-
AGE REPLACE IF NECESSARY.

LUBE ALL THE O-RINGS WITH AN O-RING LUBE BEFORE INSTALLING.

1. Install the three (3) rubber isolators to the bottom of the

EPR
2. Install the EPR assembly to the bracket and tighten the
retaining nuts.
1. Pressure Regulator Section 4. Primary Test Port
2. Fuel Inlet 5. Secondary Test Port NOTE: Do not over tighten the isolators and cause a separation of
3. Coolant Passage 6. Voice Coil Section the isolators.
Figure 3-114. EPR Assembly
3. Install the fuel temperature sensor into the regulator
The EPR assembly is a made up of two separate components. opening and lock in place with the locking pin, connect
The Voice Coil Section is not serviceable and can only be the electrical connector.
replaced as an assembly. The pressure regulator section is ser- 4. Insert the fuel vapor line and fitting into the regulator
viceable and will be detailed in this section. port and lock in place with the locking pin.
REMOVAL 5. Install both the water hoses and fittings into the regula-
tor and lock in place with the locking pin remove the
1. Relieve the propane fuel system pressure. Refer to Pro-
clamp pliers from the hoses.
pane Fuel System Pressure Relief.
6. Install the electric lock off into the regulator inlet and
2. Disconnect the negative battery cable. tighten into proper location, connect the electrical con-
3. Slowly remove the fuel inlet fitting at the Electric Lock nector.
Off. 7. Connect the fuel supply line and tighten until fully
seated.
NOTE: Residual vapor pressure will be present in the fuel system.
8. Connect the EPR electrical connector.
4. Disconnect the electrical connector to the Electric Lock 9. Open the manual valve.
off.
10. Start the vehicle and leak check the propane fuel system
5. Remove the Electric Lock Off from the regulator. at each serviced fitting Refer to Propane Fuel System
6. Remove the lock pin from the vapor fitting on the regu- Leak Test.
lator housing and remove the fitting and hose and
retain the pin.
7. Remove the lock pin from the pressure sensor on the
regulator housing and remove the Sensor and retain the
pin.
8. Using a clamp pliers pinch off the hoses on the coolant
lines to the regulator.
9. Remove the lock pin from both the water fittings on the
regulator housing and remove the fittings and hoses
and retain the pin.
Figure 3-115. Pressure Regulator Section
10. Disconnect the EPR electrical connector.

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PRESSURE REGULATOR SECTION REMOVAL REMOVAL

1. Remove the EPR refer to EPR Removal Procedure. 1. Disconnect the TMAP electrical connector.
2. Remove the six (6) regulator to voice coil screws using 2. Remove the two retaining bolts.
the special tool and separate the regulator from the 3. Remove the TMAP.
actuator.
INSTALLATION

NOTE: Apply a small amount of O-ring lubricant before

DO NOT REMOVE THE SECONDARY DIAPHRAGM RETAINING PLATE AND DIA- installation.
PHRAGM THIS WILL VOID THE WARRANTY OF THE ACTUATOR SECTION.
1. Install in the TMAP.
PRESSURE REGULATOR SECTION INSTALLATION
2. Tighten retaining bolts to 62 in. lbs. (7 Nm).
1. Install the regulator to the actuator section using the six Start the vehicle and check for proper operation.
(6) retaining screws and tighten 70 in. lbs. (8 Nm).
2. Install the EPR refer to EPR Installation. Electronic Throttle Control Replacement
Temperature Manifold Absolute Pressure (TMAP) See Figure 3-116.
Sensor REMOVAL
1. Disconnect the negative battery cable.
2. Remove the air intake duct.
3. Release the hose clamp on the vapor fuel line and
remove the vapor hose.
4. Disconnect the TMAP electrical connector.
5. Disconnect the electronic throttle control connector.
6. Remove the manifold to throttle body adapter bolts and
remove the throttle body mixer assembly.
7. Pull the throttle body assembly from the adapter.
8. Remove electronic throttle control device.
9. Remove the o-rings gasket and discard.
Figure 3-116. (TMAP) Sensor & Electronic Throttle
Control (ETC)

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INSTALLATION 3. Attach mixer and throttle body together. The two parts
do not bolt together; they will be secured when you
mount it on the intake. Notice the orientation of the air
inlet and throttle body cover.
LIGHTLY LUBRICATE BOTH THROTTLE CONTROL DEVICE TO ADAPTER O-RINGS.

1. Install the o-ring on throttle body. Press it down to the

bottom of the surface.

4. Place gasket on intake manifold and attach mixer/throt-

tle assembly to manifold.
2. Install the two quad seals. Install one seal at a time to
insure the seal does not roll. The seal must sit flat on the
throttle body.

Figure 3-117. Mixer Assembly

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Mixer Replacement Coolant Hose Replacement

See Figure 3-117. REMOVAL
1. Drain the coolant.
REMOVAL
2. Using hose clamp pliers, disconnect both hose clamps
1. Remove the throttle control device Refer to Electronic
on each hose.
Throttle Body Replacement.
3. Remove the hose from each of the fittings.
2. Remove the four (4) bolts to the throttle control device
to mixer adapter bolts. INSTALLATION
3. Remove and discard the mixer to adapter gasket. NOTE: Use hose material and lengths specified by JLG.
INSTALLATION
1. Install the hose clamps to each hose and set the clamp
back on each hose to make installation easier.

COVER THROTTLE BODY ADAPTER OPENING TO PREVENT DEBRIS FROM 2. Fit the hose to the fittings.
ENTERING ENGINE UNTIL REASSEMBLY. 3. Secure by positioning each of the clamps.

1. Install mixer to adapter gasket onto the mixer. Vapor Hose Replacement
2. Install the mixer to the throttle control device to mixer
REMOVAL
adapter and secure with the 4 retaining screws. Tighten
80 in. lbs. (9 Nm). 1. Using hose clamp pliers disconnect both hose clamps.
3. Install throttle body. Refer to “Electronic Throttle Control 2. Remove the vapor hose from each fitting.
Replacement” on page 141.
INSTALLATION
4. Start the engine and leak check all fittings and connec-
tions.
THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED, DO NOT USE HOSE
MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED PARTS.

1. Install hose clamps and set back on each hose.

2. Reinstall the vapor hose to each fitting.
3. Reset clamps.
4. Start engine and check for leaks.

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Engine Control Module Replacement Heated Exhaust Gas Oxygen Sensor Replacement
REMOVAL REMOVAL
1. Disconnect negative battery cable. 1. Disconnect negative battery cable.
2. Remove controller from mounting bracket. 2. Disconnect the O2 sensor electrical connector.
3. Push connector lock back to unlock connector. 3. Using an O2 sensor socket, remove the O2 sensor and
4. Unplug controller and remove. discard.

INSTALLATION INSTALLATION

THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY YOU HAVE THE BEFORE INSTALL THE O2 SENSOR LUBRICATE THREADS WITH ANTI-SEIZE
CORRECT CONTROLLER COMPOUND GM P/N 5613695 OR EQUIVALENT. AVOID GETTING COMPOUND
ON THE SENSOR TIP.
1. Plug connector into controller.
1. Install O2 sensor. Tighten to 30 ft. lbs. (41 Nm).
2. Push lock into place.
2. Start engine.
3. Mount controller into mounting bracket.
3. Check for any DTC codes and clear.
4. Reconnect the battery cable.
4. Verify engine is in closed loop and no warning lights are
5. Start engine. illuminated.
6. Check for any DTC codes and clear.
7. Verify engine is in closed loop and no warning lights are
illuminated.

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3.26 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids

This procedure is intended to diagnose a vehicle operating on
Fuel System Description LPG. If the vehicle will not continue to run on LPG, refer to
Hard Start for preliminary checks. Before proceeding with this
procedure, verify that the vehicle has a sufficient quantity of
fuel and that liquid fuel is being delivered to the LPR. Also,
ensure that the manual shut off valve on the LPG tank is fully
opened and that the excess flow valve has not been activated.
Tools Required:
• 7/16 Open end wrench (for test port plugs).
• DVOM (GM J 39200, Fluke 88 or equivalent).
• 12 volt test light.
Diagnostic Scan Tool

Figure 3-118. EPR Assembly • Diagnostic Display tool.

Pressure Gauges
To maintain fuel and emission control on the LPG fuel system
the Engine Control Units (ECM) relies on numerous engine • IMPCO ITK-2 Test kit.
sensor and output data from the Electronic Pressure Regulator • Water Column Gauge / Manometer (GM 7333-6 or
(EPR). The ECM will then determine the target fuel calibration equivalent).
and command the EPR to reposition the voice coil to the
proper position which, subsequently reposition the secondary • 0-10 PSI Gauge.
lever in the pressure regulator to maintain proper control. The Test Description
EPR and ECM will continue to communicate back and forth
during normal operation. The numbers below refer to step numbers on the diagnostic
table.
In the event that the EPR fails to communicate or the Commu-
nications Area Network (CAN) cable fails to transmit data the 5. This step determines if the LPR requires replacement.
regulator will operate in an open loop configuration. As the air 6. This step determines if the problems are in the mechanical
valve vacuum in the mixer venturi is communicated to the sec- side of the Pressure Regulator or the Electronic Voice Coil.
ondary chamber of the regulator the secondary diaphragm
will be drawn in a downwards motion. This downward motion 10. This step determines if the Mixer requires replacement.
will cause the secondary lever to open thus allowing more fuel 14. This step determines if the Lock Off requires replacement.
to enter the mixer.
17. This step determines if the Fuel Filter requires replacement.
In the (LPR) the fuel is vaporized and the pressure reduced in
two stages. The first stage reduces the pressure to approxi-
mately 1.0 to 3.0 psi (6.8 to 20.6 kPa). The second stage
reduces the pressure to approximately negative 1.5 in. of
water column.
The fuel is then drawn from the secondary chamber of the LPR
by the vacuum generated by air flowing through the mixer.
This vacuum signal is also used to generate lift for the mixer air
valve. This vacuum signal is most commonly referred to as air
valve vacuum. In the mixer, the fuel mixes with the air entering
the engine. This air/ fuel mixture is then drawn into the engine
for combustion.

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Table 3-13. GM LPG Fuel System Diagnosis

STEP ACTION VALUE(S) YES NO

1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2
2 Perform the On Board Diagnostic (OBD) System Check. -- Go to the Go to Step 3
Are any DTCs present in the ECM? applicable DTC Table
3 Verify that the LPG fuel tank has a minimum of 1/4 tank of fuel, that the manual valve is open -- Go to Step 4 --
and the tank quick connect is fully engaged
Does the vehicle have fuel?
4 1. Connect a water column gauge or a manometer to the secondary test port of the low pressure -- Go to Step 5 Go to Step 8
regulator (LPR).
2. Start the engine and allow it to reach operating temperature.
Does the engine start and run?
5 With the engine idling, observe the pressure reading for the LPR secondary pressure. -1.0" to Go to Step 25 Go to Step 6
Does the fuel pressure fluctuate rhythmically OUTSIDE the specified range? -2.0" w.c
6 1. Disconnect the EPR electrical connectors. NOTE: This action will cause a DTC to be set by the -1.0" to Go to Fuel Control System Go to Step 7
ECM -2.0" w.c Diagnosis
2. With the engine idling observe the pressure reading on the secondary test port.
Is the fuel pressure WITHIN the specified range?
7 1. Inspect the air intake stream between the mixer assembly and the throttle body for leaks. -- Go to Step 26 Go to Step 22
2. Inspect the fuel hose connection between the LPR and mixer assembly for damage or leak-
age.
3. Inspect any vacuum hoses for leaks
Was a problem found and corrected?
8 1. Connect a water column gauge or a manometer to the secondary test port of the low pressure -- Go to Step 12 Go to Step 9
regulator (LPR).
2. Crank the engine and observe the pressure reading for the LPR secondary pressure.
Does the fuel pressure indicate a vacuum is present?
9 1. Remove Air induction hose to the mixer -- Go to Step 11 Go to Step 10
2. Observe the air valve for movement while the engine is cranking. Note: Movement of the air
valve will be minimal at cranking speeds.
Does the air valve move when the engine is cranked?
10 1. Inspect the air intake stream to the mixer assembly and the throttle body for vacuum leaks. -- Go to Step 26 Go to Step 24
2. Inspect the vacuum hoses from the mixer for proper connection and condition.
Was a problem found and repaired?
11 Inspect the fuel hose connection between the LPR and the mixer assembly for damage or leak- -- Go to Step 26 Go to Step 12
age.
Was a problem found and repaired?
12 1. Connect a 0-10 psi gauge to the primary test port of the low pressure regulator (LPR). 1- 3 PSI Go to Step 22 Go to Step 13
2. Crank the engine and observe the pressure reading for the LPR primary pressure.
Is the fuel pressure ABOVE the specified value?
13 1. Turn OFF the ignition. -- Go to Step 14 Go to Step 16
2. Disconnect the LPL connector.
3. Install a test light between the pins of the LPL connector.
4. Crank the engine. The test light should illuminate.
Does the test light illuminate?
14 Using a DVOM, check the resistance of the low pressure lock-off (LPL). 12W - 16W Go to Step 15 Go to Step 23
Is the resistance within the specified range?

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Table 3-13. GM LPG Fuel System Diagnosis

STEP ACTION VALUE(S) YES NO

15 1. Turn the ignition OFF. -- Go to Step 23 Go to Step 17
2. Close the manual shut-off valve on the LPG tank.
CAUTION: When disconnecting LPG fuel lines, liquid LPG may be present. Perform this step in a
well ventilated area.
3. Loosen the fuel inlet hose fitting at the inlet of the LPL.
Was fuel present when the fitting was loosened?
16 1. Turn OFF the ignition. -- Go to Step 20 Go to Step 21
2. Connect the test light to chassis ground and probe pin A of the LPL connector.
3. Crank the engine. The test light should illuminate.
Does the test light illuminate?
17 1. Remove the LPG fuel filter / LPL. -- Go to Step 19 Go to Step 18
2. Remove the filter from the LPL.
3. Empty the contents of the inlet side of the LPG fuel filter onto a clean surface.
4. Inspect the contents of the LPG fuel filter for an excessive amount of foreign material or
water. If necessary, locate and repair the source of contamination.
5. Verify the LPG fuel filter is not restricted or plugged.
Was a problem found?
18 The fuel supply system or hoses are plugged or restricted, locate and repair the problem. -- Go to Step 26 --
Is the action complete?
19 Replace the fuel filter. Refer to Fuel Filter Replacement. -- Go to Step 26 --
Is the action complete?
20 Repair the open in the lock-off ground circuit. -- Go to Step 26 --
Is the action complete?
21 Repair the open in the lock-off power circuit. -- Go to Step 26 --
Is the action complete?
22 Replace the low pressure regulator (LPR). Refer to Low Pressure Regulator Replacement. -- Go to Step 26 --
Is the action complete?
23 Replace the lock-off. Refer to Lock-off Replacement. -- Go to Step 26 --
Is the action complete?
24 Replace the mixer assembly. Refer to Fuel Mixer Replacement. -- Go to Step 26 --
Is the action complete?
25 The fuel supply system is operating normally, if a failure of the control solenoids is suspected. -- System OK --
Refer to Fuel Control System Diagnosis.

1. Install the test plug in the LPR secondary chamber.

2. If you were sent to this routine by another diagnostic chart, return to the previous diagnostic
procedure.
Is the action complete?
26 1. Disconnect all test equipment -- System OK --
2. Install the primary and secondary test port plugs.
3. Start the engine.
4. Using SNOOP or equivalent, leak check the test port plugs.
Is the action complete?

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Table 3-14. GM Engine Symptom Diagnosis

Checks Action
Important Preliminary Checks
Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that:
1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL.

Several of the following symptom procedures call for a careful visual and physical check. The visual and physical checks are very important. The
checks can lead to correcting a problem without further checks that may save valuable time.
LPG Fuel System Check 1. Verify the customer complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between lean and rich.

IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operating correctly at that time.
Visual and Physical Checks ² Check all ECM system fuses and circuit breakers.
² Check the ECM ground for being clean, tight and in its proper location.
² Check the vacuum hoses for splits, kinks and proper connections.
² Check thoroughly for any type of leak or restriction.
² Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
² Check for proper installation of the mixer module assembly.
² Check for air leaks at the mixer assembly.
² Check the ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
² Check the wiring for the following items:
- Proper connections, pin. or cuts.
² The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the scan
tool readings do not indicate the problems, then proceed in a logical order, easiest to check or most likely to cause first.
Intermittent
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC).
Preliminary Checks ² Refer to Important Preliminary Checks.
² Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the replacement of good parts.
Faulty Electrical Connections or Wiring ² Faulty electrical connections or wiring can cause most intermittent problems.
² Check the suspected circuit for the following conditions:
- Faulty fuse or circuit breaker
- Connectors poorly mated
- Terminals not fully seated in the connector (backed out)
- Terminals not properly formed or damaged
- Terminal to wires poorly connected
- Terminal tension insufficient.
² Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If necessary, replace all the
connector terminals in the problem circuit in order to ensure the proper contact tension.
² Checking for poor terminal to wire connections requires removing the terminal from the connector body.
Operational Test If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the problem occurs, an abnormal
voltage or scan reading indicates the problem may be in that circuit.

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Table 3-14. GM Engine Symptom Diagnosis

Checks Action
Intermittent Malfunction Indicator Lamp The following components can cause intermittent MIL and no DTC(s):
(MIL) ² A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur
when the faulty component is operating.
² The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
² The ignition secondary voltage shorted to a ground.
² The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to ground.
² The Control Module grounds.
Loss of DTC Memory To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine until the Malfunction Indicator Lamp illuminates.

The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory when the ignition is turned OFF. If the TMAP DTC does not store
and remain, the ECM is faulty
Additional Checks
No Start
DEFINITION: The engine cranks OK, but does not start.
Preliminary Checks Refer to Important Preliminary Checks.
Control Module Checks If a scan tool is available:
² Check for proper communication with both the ECM
² Check the fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
² Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage and/or continuity for
each circuit.
Sensor Checks ² Check the TMAP sensor.
² Check the Magnetic pickup sensor (RPM).
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create a no start condition.
² Check for air intake system leakage between the mixer and the throttle body.
² Verify proper operation of the low pressure lock-off solenoids.
² Check the fuel system pressures. Refer to the LPG Fuel System Diagnosis.
² Check for proper mixer air valve operation.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions.
² Check for the proper ignition voltage output with J 26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS)
² Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
² Check for bare or shorted ignition wires.
² Check for loose ignition coil connections at the coil.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than
the gasoline fuel supply system.
² Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.

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Table 3-14. GM Engine Symptom Diagnosis

Checks Action
Exhaust System Checks ² Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure.
² Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis
Hard Start
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
Preliminary Checks ² Refer to Important Preliminary Checks.
² Make sure the vehicle's operator is using the correct starting procedure.
Sensor Checks ²Check the Engine Coolant Temperature sensor with the scan tool. Compare the engine coolant temperature with the ambient air temperature
on a cold engine. IF the coolant temperature reading is more than 5 degrees greater or less than the ambient air temperature on a cold engine,
check for high resistance in the coolant sensor circuit. Refer to DTC 111
² Check the Crankshaft Position (CKP) sensor.
²Check the Throttle position (TPS) sensor.
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition.
² Verify the excess flow valve in the LPG manual shut-off valve is not tripped.
² Check mixer module assembly for proper installation and leakage.
² Verify proper operation of the low pressure lock-off solenoids.
² Verify proper operation of the EPR
² Check for air intake system leakage between the mixer and the throttle body.
² Check the fuel system pressures. Refer to the Fuel System Diagnosis.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions.
² Check for the proper ignition voltage output with J 26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS)
² Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
² Check for bare or shorted ignition wires.
² Check for moisture in the distributor cap if applicable.
² Check for loose ignition coil connections.
Important:
1. If the engine starts but then immediately stalls, Check the Crankshaft Position (CKP).
2. Check for improper gap, debris or faulty connections.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than the
gasoline fuel supply system.
² Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.
² Check the intake and exhaust manifolds for casting flash.
Exhaust System Checks ² Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure.
² Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in the GM Base Engine Service
Manual

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Table 3-14. GM Engine Symptom Diagnosis

Checks Action
Additional Checks
Cuts Out, Misses
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases which is not normally felt above 1500 RPM. The exhaust has a steady spit-
ting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Checks ² Refer to Important Preliminary Checks.
Ignition System Checks ² Start the engine.
² Wet down the secondary ignition system with water from a spray bottle, and look/listen for arcing or misfiring as you apply water.
² Check for proper ignition output voltage with spark tester J 26792.
² Check for a cylinder misfire.
² Verify that the spark plugs are correct for use with LPG (R42LTS)
² Remove the spark plugs in these cylinders and check for the following conditions:
² Insulation cracks
² Wear
² Improper gap
² Burned electrodes
² Heavy deposits
² Visually/Physically inspect the secondary ignition for the following:
² Ignition wires for arcing, cross-firing and proper routing
² Ignition coils for cracks or carbon tracking
Engine Mechanical Checks ² Perform a cylinder compression check.
² Check the engine for the following:
- Improper valve timing
- Bent pushrods
- Worn rocker arms
- Worn camshaft lobes.
- Broken or weak valve springs.
² Check the intake and exhaust manifold passages for casting flash.
Fuel System Checks ² Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
² Check the condition of the wiring to the low pressure lock-off solenoid.
Additional Check Check for Electromagnetic Interference (EMI).
² EMI on the reference circuit can cause a missing condition.
² Monitoring the engine RPM with a scan tool can detect an EMI.
² A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present.
² If the problem exists, check the routing of the secondary wires and the ground circuit.
Hesitation, Sag, Stumble
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it's
severe enough.
Preliminary Checks Refer to Important Preliminary Checks.
Fuel System Checks ² Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
² Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below specification, there is possibly a
faulty low pressure regulator or a restriction in the fuel system.
² Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
² Check LPL electrical connection
² Check the mixer air valve for sticking or binding.
² Check the mixer module assembly for proper installation and leakage.
² Check the EPR electrical connections.

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Table 3-14. GM Engine Symptom Diagnosis

Checks Action
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a prob-
lem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly.
² Check for the proper ignition voltage output with J 26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS)
² Check for faulty spark plug wires
² Check for fouled spark plugs.
Additional Check ² Check for manifold vacuum or air induction system leaks
² Check the generator output voltage.
Backfire
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Preliminary Check ² Refer to Important Preliminary Checks.
Ignition System Checks Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operat-
ing conditions. The ignition system must be maintained in peak condition to prevent backfire.
² Check for the proper ignition coil output voltage using the spark tester J26792 or the equivalent.
² Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the
wires.
² Check the connection at each ignition coil.
² Check for deteriorated spark plug wire insulation.
² Check the spark plugs. The correct spark plugs for LPG are (R42LTS)
² Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Engine Mechanical Check Important! The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than a
gasoline fuel supply system.
² Check the engine for the following:
- Improper valve timing
- Engine compression
- Manifold vacuum leaks
- Intake manifold gaskets
- Sticking or leaking valves
- Exhaust system leakage
² Check the intake and exhaust system for casting flash or other restrictions.
Fuel System Checks ² Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
Lack of Power, Sluggishness, or Sponginess
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal.
Preliminary Checks ² Refer to Important Preliminary Checks.
² Refer to the LPG Fuel system OBD System Check
² Compare the customer's vehicle with a similar unit. Make sure the customer has an actual problem. Do not compare the power output of the
vehicle operating on LPG to a vehicle operating on gasoline as the fuels do have different drive feel characteristics
² Remove the air filter and check for dirt or restriction.
² Check the vehicle transmission Refer to the OEM transmission diagnostics.

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Table 3-14. GM Engine Symptom Diagnosis

Checks Action
Fuel System Checks ² Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis.
² Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent.
² Check for proper installation of the mixer module assembly.
² Check all air inlet ducts for condition and proper installation.
² Check for fuel leaks between the LPR and the mixer.
² Verify that the LPG tank manual shut-off valve is fully open.
² Verify that liquid fuel (not vapor) is being delivered to the LPR.
Sensor Checks ² Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance. Check for proper operation of the MAP sensor.
² Check for proper operation of the TPS sensor.
Exhaust System Checks ² Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure.
- Check for possible plugged catalytic converter.
Engine Mechanical Check Check the engine for the following:
² Engine compression
² Valve timing
² Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.
Additional Check ² Check the ECM grounds for being clean, tight, and in their proper locations.
² Check the generator output voltage.
² If all procedures have been completed and no malfunction has been found, review and inspect the following items:
² Visually and physically, inspect all electrical connections within the suspected circuit and/or systems.
² Check the scan tool data.
Poor Fuel Economy
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this vehicle at one time, as previously
shown by an by refueling records.
Preliminary Checks ² Refer to Important Preliminary Checks.
² Check the air cleaner element (filter) for dirt or being plugged.
² Visually (Physically) check the vacuum hoses for splits, kinks, and proper connections.
² Check the operators driving habits for the following items:
- Is there excessive idling or stop and go driving?
- Are the tires at the correct air pressure?
- Are excessively heavy loads being carried?
- Is their often rapid acceleration?
² Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
² Suggest that a different operator use the equipment and record the results.
Fuel System Checks ² Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis.
² Check the fuel system for leakage.
Sensor Checks ² Check the Temperature Manifold Absolute Pressure (TMAP) sensor.
Ignition System Checks ² Verify that the spark plugs are correct for use with LPG (R42LTS)
² Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
² Check the ignition wires for the following items:
- Cracking
- Hardness
- Proper connections
Cooling System Checks ² Check the engine thermostat for always being open or for the wrong heat range

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Table 3-14. GM Engine Symptom Diagnosis

Checks Action
Additional Check ² Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual.
² Check for dragging brakes.
Rough, Unstable, or Incorrect Idle, Stalling
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the
engine.
Preliminary Check Refer to Important Preliminary Checks.
Sensor Checks ²Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white powdery coating. The sensor will result in a
high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel delivered to the engine causing a severe drive-
ability problem.
²Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
²Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks ²Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will
help identify the problem.
²Check for a sticking mixer air valve.
²Verify proper operation of the EPR.
²Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
²Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
²Check mixer module assembly for proper installation and connection.
Ignition System Checks ²Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS)
²Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
²Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the
wires.
Additional Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than
the gasoline fuel supply system.
²Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command.
²Check the ECM grounds for being clean, tight, and in their proper locations.
²Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed
resulting in poor idle quality.
Engine Mechanical Check ² Check the engine for the following:
- Broken motor mounts
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes
Surges/Chuggles
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal.
Preliminary Checks Refer to Important Preliminary Checks.
Sensor Checks ² Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance.

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Table 3-14. GM Engine Symptom Diagnosis

Checks Action
Fuel System Checks ² Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will
help identify the problem.
² Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis.
² Verify proper fuel control solenoid operation.
² Verify that the LPG manual shut-off valve is fully open.
² Check the in-line fuel filter for restrictions.
Ignition System Checks ² Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS)
² Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
- Check the Crankshaft Position (CKP) sensor.
Additional Check ² Check the ECM grounds for being clean, tight, and in their proper locations.
² Check the generator output voltage.
² Check the vacuum hoses for kinks or leaks.
² Check Transmission

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Table 3-15. DTC to SPN/FMI Cross Reference Chart

SPN Code FMI Code DTC Description

51 2112 Unable to Reach Higher TPS
51 0 221 TPS 2 Signal Voltage Low
51 1 121 TPS 1 Lower Than TPS 2
51 3 123 TPS 1 Signal Voltage High
51 4 122 TPS 1 Signal Voltage Low
51 7 2111 Unable to Reach Lower TPS
51 31 2135 TPS 1/2 Simultaneous Voltages
94 3 92 Fuel Pump High Voltage
100 1 524 Oil Pressure Low
105 0 127 IAT Higher Than Expected 2
105 3 113 IAT High Voltage
105 4 112 IAT Low Voltage
105 15 111 IAT Higher Than Expected 1
106 4 107 MAP Low Voltage
106 16 108 MAP High Pressure
108 0 2229 BP Pressure High
108 1 129 BP Low Pressure
110 0 217 ECT Higher Than Expected 2
110 3 118 ECT High Voltage
110 4 117 ECT Low Voltage
110 15 116 ECT Higher Than Expected 1
168 15 563 System Voltage High
168 17 562 System Voltage Low
174 3 183 Fuel Temp Gasoline High Voltage
174 4 182 Fuel Temp Gasoline Low Voltage
515 0 1112 Spark Rev Limit
515 15 219 Max Govern Speed Override
515 16 1111 Fuel Rev Limit
628 13 601 Flash Checksum Invalid
629 31 606 COP Failure
629 31 1612 RTI 1 loss
629 31 1613 RTI 2 Loss
629 31 1614 RTI 3 Loss
629 31 1615 A/D Loss
629 31 1616 Invalid Interrupt
630 12 604 RAM Failure
636 2 336 Crank Sync Noise
636 4 337 Crank Loss
636 8 16 Crank Never Synced at Start
639 12 1626 CAN Tx Failure
639 12 1627 CAN Rx Failure
639 13 1628 CAN Address Conflict Failure
639 31 1629 Loss of TSC 1

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Table 3-15. DTC to SPN/FMI Cross Reference Chart

SPN Code FMI Code DTC Description

651 5 261 Injector Driver 1 Open
651 6 262 Injector Driver 1 Shorted
652 5 264 Injector Driver 2 Open
652 6 265 Injector Driver 2 Shorted
653 5 267 Injector Driver 3 Open
653 6 268 Injector Driver 3 Shorted
654 5 270 Injector Driver 4 Open
654 6 271 Injector Driver 4 Shorted
723 2 341 Cam Sync Noise
723 4 342 Cam Sensor Loss
724 10 134 EGO 1 Open/Inactive
1079 3 643 External 5V Reference High
1079 4 642 External 5V Reference Low
1384 31 1625 Shutdown Request
1485 3 687 Power Relay Short to Power
1485 4 686 Power Relay Shorted
1485 5 685 Power Relay Open
5294 4 91 Fuel Pump Low Voltage
520200 0 171 Adaptive Learn High Gasoline
520200 1 172 Adaptive Learn Low Gasoline
520202 0 1161 Adaptive Learn High LPG
520202 1 1162 Adaptive Learn Low LPG
520204 0 1155 Closed Loop Multiplier High Gasoline
520204 1 1156 Closed Loop Multiplier Low Gasoline
520206 0 1151 Closed Loop Multiplier High LPG
520206 1 1152 Closed Loop Multiplier Low LPG
520208 10 154 EGO 2 Open/Inactive
520211 10 420 Gasoline Cat Monitor
520213 10 1165 LPG Cat Monitor
520240 3 188 Fuel Temp LPG High Voltage
520240 4 187 Fuel Temp LPG Low Voltage
520251 3 223 TPS 2 Signal High Voltage
520251 4 222 TPS 2 Signal Low Voltage
520260 0 1171 LPG Pressure Higher Than Expected
520260 1 1172 LPG Pressure Lower Than Expected
520260 3 1174 EPR Voltage Supply High
520260 4 1175 EPR Voltage Supply Low
520260 12 1176 EPR Internal Actuator Fault
520260 12 1177 EPR Internal Circuitry Fault
520260 12 1178 EPR Internal Comm Fault
520260 31 1173 EPR Comm Lost

3121671 3-157
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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

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
29 2 978 1-2-6 Diagnostic fault check of synchronism of Plausibility error between sensor and idle Threshold for error detection is an internal ECU
hand throttle and Low idle switch (LIS). switch threshold.
The accelerator pedal must have detected full
load and idle plausibility at least once.
29 3 932 1-2-6 Diagnostic fault check of short circuit to The signal exceeds the applicable threshold; If the signal is below the applicable threshold
supply voltage signal range violation APP_uRawSRCHiHTLIS_C, the signal range
(signal range check high) of acceleration violation is reset
pedal signal. after the healing debouncing.
In case when the CCP is active (CCP_stActive
=
1)and the reading from the EEPROM
memory is successful, the signal is below the
threshold APP_uHTLISCCPHi[1], a signal
range violation is reset
after debouncing.
29 4 937 1-2-6 Diagnostic fault check of short circuit to The signal is below the applicable threshold; If the signal exceeds the applicable threshold
ground (signal range check low) of signal range violation APP_uRawSRCLoHTLIS_C, the signal range
acceleration pedal signal violation is reset
after the healing debouncing.
In case when the CCP is active (CCP_stActive
=
1)and the reading from the EEPROM
memory is successful, the signal exceeds the
threshold APP_uHTLISCCPLo[1], a signal
range violation is reset
after debouncing.
91 3 935 2-2-6 Analog accelerator pedal sensor 1 or Sensor defect. Check cabling, check accelerator pedal sensor
double accelerator pedal sensor: the Short cut to battery or open loop. and if necessary replace it, check
voltage measured by ECU is out of the connection cable and if necessary repair or
target range or the calculated pedal replace it.
position is implausible compared with the If the signal is below the applicable threshold
position of the second pedal APP_uRaw1SRCHigh_C, the signal range
violation is reset after
the healing debouncing.

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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

91 4 940 2-2-6 Analog accelerator pedal sensor 1 or Short circuit to ground. Check cabling, check accelerator pedal sensor
double accelerator pedal sensor: the and if necessary replace it, check
voltage measured by ECU is out of the connection cable and if necessary repair or
target range or the calculated pedal replace it
position is implausible compared with the If the signal exceeds the applicable threshold
position of the second pedal APP_uRaw1SRCLow_C, the signal range
violation is reset after the healing
91 11 976 2-2-6 Diagnostic fault check of synchronism of Measured voltage of accelerator pedal 1 is out Threshold for error detection is an internal ECU
single potentiometer and Low idle switch of plausible range. threshold.
(LIS). Check cabling, check accelerator pedal and
pedal sensor and if necessary replace it,
check connection cable and if necessary repair
or replace it.
When the PWM period APP_tiPWMPer is in
between APP_tiSRCLoPWMPer_C and
APP_tiSRCHiPWMPer_C .
94 1 474 216 Low fuel pressure: the low fuel pressure Fuel pressure below warning threshold Check low fuel pressure system (fuel feed
calculated by ECU is underneath the target pump, relay , fuse, wiring, sensor) and if
range; the ECU activates a system reaction necessary repair or replace it.
94 3 472 216 Low fuel pressure sensor: the voltage of cable break or short circuit, sensor defective, Check cabling, if sensor not working, check
sensor measured by ECU is out of the target connection cable damaged sensor and if necessary replace it, check
range Short cut to battery or open loop connection cable and if necessary repair or
replace it
94 4 473 216 Low fuel pressure sensor: the voltage of cable break or short circuit, sensor defective, Check cabling, if sensor not working, check
sensor measured by ECU is out of the target connection cable damaged sensor and if necessary replace it, check
range short cut to ground connection cable and if necessary repair or
replace it
97 3 464 228 Fuel filter water level sensor: the voltage of Sensor not connected or sensor defect. Check of wiring and water in fuel sensor.
sensor measured by ECU is out of the target Check cabling, if charge Water in Fuel sensor is
range not working, check sensor and if
necessary replace it,
check connection cable and if necessary repair
or replace it.
97 4 465 228 Fuel filter water level sensor: the voltage of cable break or short circuit, sensor defective, Check sensor and if necessary replace it, check
sensor measured by ECU is out of the target connection cable damaged. connection cable
range. Short cut to ground. and if necessary repair or replace it.
97 12 1157 228 Fuel filter water level sensor: the maximum Water level in fuel pre-filter reservoir over Measure Voltage at Water in Fuel Sensor and
level is exceeded limit renew harness if needed.
(bad fuel quality)

3121671 3-159
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

100 1 736 231 Oil pressure is below the target range Oil pressure too low (pressure below warning Threshold for error detection is an internal ECU
(warning threshold) threshold) threshold.
Check oil level, check engine for oil leakage,
measure oil pressure external to evaluate
sensor value
100 1 737 231 Oil pressure is below the target range (shut Oil pressure 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 leakage,
measure oil pressure external to evaluate
sensor value.
100 3 732 224 Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiring
measured by ECU is out of the target range Check cabling. If sensor not working, check
sensor and if necessary replace it,
check connection cable and if necessary repair
or replace it.
100 4 733 224 Oil pressure sensor: the voltage of sensor Short circuit to ground The sensed raw voltage value
measured by ECU is out of the target range Oil_uRawPSwmp is above
Oil_SRCPSwmp.uMin_C
Check cabling, if sensor not working, check
sensor and if necessary replace it, check
connection cable and if necessary repair or
replace it
No detail information.
102 1 774 223 charge air pressure below lower limit measured charge air pressure below the Check complete air system of engine for mas-
threshold. sive leakage, especially from compressor
to intake air manifold. Check air filter.
Exchange charge air presure sensor.
102 2 88 223 Charge air pressure measured 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 necessary.
102 2 89 223 Charge air pressure measured 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 necessary.
102 2 772 223 Deviation between sensed intake manifold deviation between ambient pressure sensor 1) Exchange boost pressure sensor
pressure is not plausible compared to and charge air pressure sensor at not 2) Exchange ECU
environment pressure. Which sensor is not running engine to high
okay can not be said.
102 3 776 223 Charge air pressure sensor: the measured The Sensor Voltage is above the Threshold. Check cabling, if charge air pressure/
voltage of sensor by ECU is out of the target temperature sensor is not working, check
range sensor
and if necessary replace it, check connection
cable and if necessary repair or replace it.

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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

102 4 777 223 Charge air pressure sensor: the measured The Sensor Voltage is below the Threshold. Check cabling, if charge air pressure/
voltage of sensor by ECU is out of the target temperature sensor is not working, check
range sensor and
if necessary replace it, check connection cable
and if necessary repair or replace it
105 0 996 233 Charge air temperature downstream Charge air temperature (downstream) over Check CAC system and clean it. Check fan
calculated by ECU is above the target warning threshold. functionality.
range. Check cooling performance with temperature
The ECU activates a system reaction. measurement.
105 0 997 233 Charge air temperature downstream Charge air temperature (downstream) over Check CAC system and clean it. Check fan
calculated by ECU is under the shut down the low threshold. functionality. Check cooling performance
threshold. with temperature measurement.
The ECU activates a system reaction.
105 1 992 128 Charged Air cooler down stream Sensed temperature within intake air actual temperature below -40°C?
temperature. manifold exchange sensor
Temperature below lower physical thresh- < threshold.
old.
105 3 994 128 Charge air temperature sensor: the voltage Short circuit to battery. sensor voltage > limit The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- age) > Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it.
105 4 995 128 Charge air temperature sensor: the voltage Short circuit to ground or open load. sensor The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- voltage < limit. age) is below Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if necessary repair
or replace it
107 0 752 136 Air filter differential pressure: the pressure Pressure loss above target range with system Check air filter and if necessary clean or renew
difference of the intake air between the reaction, air filter clogged or defective, it, check cabling, check sensor and if
filter inlet and outlet calculated by ECU is sensor not working, connection cable necessary replace it, check connection cable
above the target range and the ECU damaged and if necessary repair or replace it
activates a system reaction Pressure value above warning threshold
110 0 98 232 Coolant temperature: the coolant tempera- Cooling temperature too high. Coolant Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target temperature above warning threshold. level, check cooling system in general,
range; the ECU activates a system reaction. check thermostat function, check water
pump.
110 0 99 232 Coolant temperature: the coolant Coolant temperature above shut off threshold. Clean radiator, check fan drive, check coolant
temperature calculated by ECU is above the level, check cooling system in general,
target range. check thermostat function, check water
The ECU activates a system reaction. pump.
110 1 93 225 Coolant temperature sensor: the voltage of Suspected components: wiring harness, cool- Check wiring harness and connected Coolant
the sensor measured by ECU is out of the ant temperature sensor. Temp Sens.
target range.

3121671 3-161
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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

110 3 96 225 Coolant temperature sensor: the voltage of Short cut to battery or open load. Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the connection cable and if necessary
target range. repair or replace it.
110 4 97 225 Coolant temperature sensor: the voltage of Voltage Surveillance has found shortcut to Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the Ground at Coolant Temperature Sensor. connection cable and if necessary
target range. repair or replace it
Measure Voltage at Coolant Temperature
Sensor and renew harness if needed.
111 1 101 235 Coolant level: the coolant level calculated Coolant level too low, leakage in cooling Check coolant level, inspect cooling system for
by system, sensor defective, wiring damaged. leakage and if necessary repair it,
ECU is underneath the allowed minimum. check sensor and wiring
157 3 877 147 Rail pressure sensor: the voltage of sensor Short cut to battery. Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. Damaged rail pressure sensor. necessary replace it,
check connection cable and if necessary repair
or replace it.
157 4 878 147 Rail pressure sensor: the voltage of sensor Check cabling, check rail pressure sensor and if Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. necessary replace it, necessary replace it,
check connection cable and if necessary repair check connection cable and if necessary repair
or replace it. or replace it.
164 2 1381 839 Rail pressure safety function is not Rail pressure is still above threshold. Threshold for error detection is an internal ECU
executed correctly threshold.
Reset the fault and at reappearance check ECU
and injection system
168 0 1180 318 Battery voltage: the voltage measured by Battery voltage over limit Check alternator, regulator of alternator and if
ECU is out of the target range necessary replace it, check wiring and
voltage of alternator
168 1 1181 318 Battery voltage: the voltage measured by Battery voltage below limit Check alternator, cabling, contact resistance,
ECU is out of the target range safety fuses, too high load in energy
system, check battery and if necessary replace
it
168 2 47 318 Battery voltage: the voltage measured by If Battery voltage (Ubatt_U) > 17V or 31V for Check wiring harness and connected
ECU is out of the target range, system mor ethan =0.5sec a warning is generated alternator.
reaction is initiated Battery voltage above warning threshold
168 3 45 318 Battery voltage: the voltage measured by Battery voltage above warning threshold Check wiring harness and connected
ECU is out of the target range, system (~38,9Volt), Short cut to battery possible. alternator.
reaction is initiated
168 4 46 318 Battery voltage: the voltage measured by Battery voltage below warning threshold, Check wiring harness and connected
ECU is out of the target range, system Short cut to ground alternator.
reaction is initiated

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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

171 3 417 312 Sensor error SCR-System environment open loop to sensor Check cabling, if environment temperature
temperature; DPF-System air inlet sensor is not working, check sensor
temperature; signal range check high and if necessary replace it, check connection
cable and if necessary repair or replace it.
171 4 418 312 Sensor error SCR-System environment short circuit to Ground Check cabling, if environment temperature
temperature; DPF-System air inlet sensor is not working, check sensor
temperature; signal range check low and if necessary replace it, check connection
cable and if necessary repair or replace it
172 0 1425 226 sensed intake air temperature at air filter > sensed intake air temperature at air filter > Check outside conditions:
physical high limit physical high limit Temperature > Threshold within the intake
air system of the engine?
E.G: engine sucks in air from hot asphalt out of
paver bucket
Sensor positioned within black air filter
housing
above engine lid at hot environmental
conditions and idling or similar?
=> if yes check with application team to
adapt limits
if not check sensor and wiring harness
exchange sensor
172 1 1183 226 sensed air temperature within air intake sensed air temperature within air intake path Cold start and ambient temperature < thresh-
path of engine below physical low limit of engine below physical low limit old
Check wiring harness to AFST-sensor
Exchange AFST-sensor
190 0 389 214 Engine speed: the engine speed calculated Overspeed monitoring during 1 level of FOC check powertrain settings regarding
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed overspeed
activates a system reaction was over Limit.
190 2 421 213 ECU measures a deviation between cam- Offset error between crankshaft and camshaft. Threshold for error detection is an internal ECU
shaft and crankshaft angle to target. threshold, occurs by offset between
crankshaft and camshaft.
Check increment wheel position, clean and
adjust if necessary, check sensor position.
Check Camshaft and Crankshaft senor or
wiring.
190 8 419 212 Camshaft speed sensor: the ECU receives no When disturbed camshaft signal detected. Threshold for error detection is an internal ECU
signal and uses the signal from crankshaft Error in sensor or wiring. threshold, occurs by disturbed camshaft
speed sensor as alternative to calculate the signal.
engine speed Check increment wheel position, clean and
adjust if necessary, check sensor position.
Check Camshaft Sensor or wiring.

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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

190 8 422 212 Sensor crankshaft speed; disturbed signal Error in sensor or wiring. Crankshaft sensor Threshold for error detection is an internal ECU
defect. threshold, occurs by disturbed crankshaft
signal.
Check increment wheel position, clean and
adjust if necessary, check sensor position.
Check Crankshaft Sensor or wiring.
190 11 390 214 Engine speed: the engine speed calculated Overspeed monitoring during 2 level of FOC check powertrain settings regarding
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed overspeed
activates a system reaction was over limit.
190 12 420 212 Camshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no camshaft
speed sensor as alternative to calculate the signal.
engine speed Check increment wheel position, clean and
Threshold: adjust if necessary, check sensor position.
Check Camshaft Sensor or wiring.
190 12 423 212 Crankshaft speed sensor: the ECU receives Error in sensor or wiring. Threshold for error detection is an internal ECU
no signal and uses the signal from threshold, occurs by disturbed or no
camshaft speed sensor as alternative to Crankshaft signal.
calculate the engine speed. Check increment wheel position, clean and
adjust if necessary, check Crankshaft
sensor position or wiring.
190 14 391 214 Engine speed: the engine speed calculated Overspeed monitoring during ORC (Override check powertrain settings regarding
by ECU is above the target range; the ECU conditions) if engine speed was over overspeed
activates a system reaction 2900rpm
190 14 1222 2-1-2 Camshaft- and Crankshaft speed sensor Sensors for engine speed are defect. Threshold for error detection is an internal ECU
signal not available on CAN or defect. threshold.
Check wiring, check cabels and repair or
replace if necessary.
411 0 791 693 delta pressure across venturi in EGR line sensed value of venturi difference pressure > Threshold for error detection is an internal ECU
above physical high limit high limit threshold.
EGR-Valve blocked open
EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect

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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

411 1 792 693 delta pressure across venturi in EGR line sensed value of venturi difference pressure < Threshold for error detection is an internal ECU
below physical low limit low limit threshold.
Check correct mounting of difference pressure
sensor at venturi tube
Exchange difference pressure sensor broken
411 3 795 693 The sensed raw voltage EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure
Air_uRawPEGRDeltaP is above the maxi- sensor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
411 4 381 693 Range check cannot be done or EGR or wiring defect Check wiring harness and connected EGR.
interrupted.
411 4 796 693 The sensed raw voltage value EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta pressure
Air_uRawPEGRDeltaP is above the mini- sensor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
411 11 793 693 DFC is stored in EEPROM and status kept deviation between desired O2 concentration Threshold for error detection is an internal ECU
until check is allowed in intake air manifold threshold.
to be carried out again and the real O2-concentration within intake EGR-Valve mechanically blocked open or
DFC can be reset by service routine 216 air manifold > limit closed EGR-pipe blocked with metall plate
instead sealing downstream EGR-Valve
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
412 3 1007 682 EGR downstream temperature sensor: the Short circuit to battery. sensor voltage > limit Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of Exchange TEGR-sensor.
the target range.
412 4 1008 682 EGR downstream temperature sensor: the Short circuit to ground or open load. sensor Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of voltage < limit Exchange TEGR-sensor.
the target range.
630 12 376 281 Internal hardware monitoring: the ECU Section could not be erased Threshold for error detection is an internal ECU
finds an error during the access to its threshold.
EEPROM memory or works with an There is no healing possible for the error. In
alternative value the every new initialization phase, the
debounce level is set to zero.
If not programmed, EEPROM is defect --> ECU
is defect, reprogram ECU and if
necessary replace it.

3121671 3-165
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

630 12 377 281 Internal hardware monitoring: the ECU Minimum 3 blocks could not be read, EEPROM There is no healing possible for the error. In
finds an error during the access to its has Checksum Error the every new initialization phase, the
EEPROM memory or works with an debounce level is set to zero.
alternative value If not programmed, EEPROM is defect -->ECU
is defect, reprogram ECU and if
necessary replace it
630 12 378 281 Internal hardware monitoring: the ECU Block could not be written for minimum 3 Threshold for error detection is an internal ECU
finds an error during the access to it's times threshold.
EEPROM memory or works with an If not programmed, EEPROM is defect --> ECU
alternative value is defect, reprogram ECU and if
necessary replace it.
639 14 84 271 CAN bus 0: the ECU is not allowed to send CAN BusOff error; CAN 0 (Customer CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff " is threshold.
detected. BusOff bit for CAN A node is set.
Check wiring of CAN bus and if necessary
repair it, check connection cable and if
necessary repair or replace it, check resistance
in
CAN lines (120 Ohm).
651 3 580 154 Injector cyl. 1: the current drop measured Suspected Components: Threshold for error detection is an internal ECU
by injector cylinder 1 threshold.
ECU is above the target range wiring harness, cable break or short circuit, Check wiring harness, injectors and if
sensor defective, connection cable necessary repair/replace it. Use SerDia Injector
damaged test for diagnosis.
651 5 568 154 Injector cyl. 1: interruption of electrical Interruption of electronic connection Injector Threshold for error detection is an internal ECU
connection cyl. 1 threshold.
Check wiring harness, injectors and if
necessary repair/replace it.
652 3 581 155 Injector cyl. 2: the current drop measured Suspected Components: Threshold for error detection is an internal ECU
by injector cylinder 2 threshold.
ECU is above the target range wiring harness, cable break or short circuit, Check wiring harness, injectors and if
sensor defective, connection cable necessary repair/replace it. Use SerDia Injector
damaged test for diagnosis.
652 5 569 155 Injector cyl. 2: interruption of electrical Interruption of electronic connection Injector Threshold for error detection is an internal ECU
connection cyl. 2 threshold.
Check wiring harness, injectors and if
necessary repair/replace it.
653 3 582 156 Injector cyl. 3: the current drop measured Suspected Components: Threshold for error detection is an internal ECU
by injector cylinder 3 threshold.
ECU is above the target range wiring harness, cable break or short circuit, Check wiring harness, injectors and if
sensor defective, connection cable necessary repair/replace it. Use SerDia Injector
damaged test for diagnosis.

3-166 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

653 5 570 156 Injector cyl. 3: interruption of electrical Interruption of electronic connection Injector Threshold for error detection is an internal ECU
connection cyl. 3 threshold.
Check wiring harness, injectors and if
necessary repair/replace it.
654 3 583 161 Injector cyl. 4: the current drop measured Suspected Components: Threshold for error detection is an internal ECU
by injector cylinder 4 threshold.
ECU is above the target range wiring harness, cable break or short circuit, Check wiring harness, injectors and if
sensor defective, connection cable necessary repair/replace it. Use SerDia Injector
test for diagnosis.
654 5 571 161 Injector cyl. 4: interruption of electrical Interruption of electronic connection Injector Threshold for error detection is an internal ECU
connection cyl. 4 threshold.
Check wiring harness, injectors and if
necessary repair/replace it.
655 3 584 162 Injector cyl. 5: the current drop measured Suspected Components: Threshold for error detection is an internal ECU
by injector cylinder 5 threshold.
ECU is above the target range wiring harness, cable break or short circuit, Check wiring harness, injectors and if
sensor defective, connection cable necessary repair/replace it. Use SerDia Injector
test for diagnosis.
655 5 572 162 Injector cyl. 5: interruption of electrical Interruption of electronic connection Injector Threshold for error detection is an internal ECU
connection cyl. 5 threshold.
Check wiring harness, injectors and if
necessary repair/replace it.
656 3 585 163 Injector cyl. 6: the current drop measured Suspected Components: Threshold for error detection is an internal ECU
by injector cylinder 6 threshold.
ECU is above the target range wiring harness, cable break or short circuit, Check wiring harness, injectors and if
sensor defective, connection cable necessary repair/replace it. Use SerDia Injector
test for diagnosis.
656 5 573 163 Injector cyl. 6: interruption of electrical Interruption of electronic connection Injector Threshold for error detection is an internal ECU
connection cyl. 6 threshold.
Check wiring harness, injectors and if
necessary repair/replace it.
676 11 543 263 Cold start aid relay error. Relay defect or wire harness problem Threshold for error detection is an internal ECU
threshold.
check wire harness, replace relay
676 11 544 263 Cold start aid relay open load Relay or wire harness Threshold for error detection is an internal
threshold.
check wire harness, replace relay
677 3 956 512 Start relay (high side power stage): the cur- Short cut HighSide-output to battery. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the threshold.
target range. Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.

3121671 3-167
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

677 3 960 512 Start relay (low side power stage): the cur- Shortcut LowSide-Output to battery. Threshold for error detection is an internal ECU
rent drain measured by ECU is above the threshold.
target range. Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
677 4 957 512 Start relay (high side power stage): Shortcut HighSide-output to ground. Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold.
the target range. Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
677 4 961 512 Start relay (low side power stage): the cur- Shortcut LowSide-Output to ground. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the threshold.
target range. Check cabling and start relay and if necessary
replace it,
check connection cable of terminal 50 and if
necessary repair or replace it.
677 5 958 512 Start relay (low side power stage): the cur- Open circuit/disconnection LowSide-Output. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the threshold.
target range Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
677 12 959 512 Start relay (low side power stage): the cur- Temperature over limit. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the threshold.
target range. Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
691 8 928 928 Supply module heater: PWM time period PWM signal for temperature readout from The Time period of the received PWM signal
out of valid range. supply 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.
729 3 549 263 wiring to the intake air heater device is Intake Air Heater Device: overload, short- Threshold for error detection is an internal ECU
faulty. circuit threshold.
Electrical error, Check wiring to the intake air
heater device.
729 4 551 263 wiring to the air intake heater is faulty Relay (for cold start aid) cable break or short to Threshold for error detection is an internal ECU
ground: threshold.
Electrical error, check wiring to the air intake
heater.

3-168 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

729 5 545 263 The cold start aid relay is according to Relay defect or wire harness problem Threshold for error detection is an internal ECU
wiring faulty. threshold.
Electrical error, check wires
729 12 547 263 The cold start aid relay is overheated, High temperature around the cold start relay. Check the functionality of relay and replace it
which causes this error if needed.
Check the temperature around the cold start
relay during worst case operation.
898 9 305 118 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus scheduling, polar-
TSC1TE ity, short circuit, power interrupt), test
- active protocol of receiver, check CAN functional
range.
1079 13 946 282 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of Pin A19: DEF press / Exh.PressBeforeTurb (P3) working voltage and if necessary correct
the power supply voltage of sensor output / Air Pump Press it,
1. /BrnFuelPressAfterDV2 Pin K19: Fan Speed check connection cable and if necessary repair
Sensor or replace it,
Pin A21: LDF6T / OilPress / LowFuel Press 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 Suspected components
EDC17cv56
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
1080 13 947 282 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of Pin K16: second footpedal working voltage and if necessary correct
the power supply voltage of sensor output Pin A20: Exh.PressAfterTurb/DPFDiffPress/ it, check connection cable and if necessary
2. 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
Suspected components EDC17cv56
Pin A22: Fan Speed Sensor
Pin K45: Position EGR or Intake throttle flap
Pin K46: First footpedal

3121671 3-169
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

1109 2 121 341 Request of engine shut off: the operator Engine Shut Off demand has been ignored by Depending on error requested a shut off.
ignores the engine shut off request within the user
an allowed period.
1136 0 1398 681 ECU internal temperature; temperature Short-Circuit in ECU, ECU heated by hot air Close warm air circuits, replace ECU
measured by ECU is out of the target range

1231 14 85 271 CAN bus 1: the ECU is not allowed to send CAN BusOff error; CAN 1 (Diagnostic CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff " is threshold.
detected BusOff bit for CAN B node is set.
Warning, no diagnostic with SERDIA2010 Check wiring of CAN bus and if necessary
possible. repair it, check connection cable and if
necessary repair or replace it, check resistance
in
CAN lines (120 Ohm).
1235 14 86 271 CAN bus 2: the ECU is not allowed to send CAN BusOff error; CAN 2 (Engine CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff " is threshold.
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
necessary repair or replace it, check resistance
in
CAN lines (120 Ohm).
1237 2 747 145 Override switch switch: the ECU receives a Switch is blocked, taster locked, connection If the Block Button is pressed shorter than the
permanent signal. cable damaged Maximum Plausible pressing Time.
plausbility error "override switch > 250ms Check cabling, if sensor is not working, check
pressed". switch and if necessary replace it, check
connection cable and if necessary repair or
replace it.
1761 0 1593 129 The urea tank level sensor detects a value Suspected components: Urea Quality Sensor Check level sensor and float gauge
higher than the maximum allowed thresh- defect mechanical defect at the float gauge
old
1761 1 1594 129 The DEF tank level sensor detects a value Suspected components: Urea Quality Sensor Check level sensor and float gauge
lower than the minimum allowed defect mechanical defect at the float gauge
threshold
1761 14 1655 138 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] Check urea level => if empty, then fill in urea
threshold of <5% is 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.

3-170 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

1761 14 1656 138 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] Check urea level => if empty, then fill in urea
threshold of <2.5% is 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
SCRUTnk_rVol_mp must change.
Exchange DEF level sensor, if no change of
value or it's implausible.
1761 14 1880 138 The DEF tank level is below the threshold. actual DEF tank level SCRUTnk_rVol_mp [%] Check DEF level => if empty, refill
is 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.
SCRUTnk_rVol_mp must change. Compare
SCRUTnk_rVol_mp to:
1 = SCR_rawUTnkLvl
2 = SCR_rAdapUtnkLvl
3 = SCRUTnk_rActTnkVol
*SCRUTnk_facVolPer_mp
In case of malfunction, exchange DEF level
sensor.
2791 0 1763 415 Internal actuator temperature is above Overheating of EGR actuator during operation. Let EGR actuator cool down and check heat
threshold. accumulation during worst case operation.

2791 2 1753 415 corrupted CAN communication with actua- CAN bus error or faulty EGR actuator. Threshold for error detection is an internal ECU
tor. threshold.
Check other CAN bus components. If no mes-
sage is sent, fix the wiring.
If o.k. exchange EGR actuator.
2791 3 1758 415 Overvoltage at EGR actuator. High voltage from the battery Check battery voltage.

2791 4 1759 415 Undervoltage at EGR actuator. Low voltage from the battery. Check battery voltage.

2791 6 1757 415 Overcurrent to EGR actuator. High voltage from battery. Check battery voltage. Check if EGR is blocked
EGR actuator is blocked or moving very hard. or not running smoothly.
If everything is o.k. change EGR actuator.

3121671 3-171
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

2791 7 1752 415 EGR actuator is mechanically blocked. EGR actuator faulty or blocked. Threshold for error detection is an internal ECU
threshold.
Check the EGR actuator and EGR valve to
mechanical blockage / clean.
Check for free movement of the valve. If it'S
blocked, then exchange the EGR valve.
2791 7 1761 415 EGR actuator spring broken. mechanical damage of spring due to Threshold for error detection is an internal ECU
overstress. threshold.
Exchange EGR actuator.
2791 12 1755 415 Internal electrical fault of EGR actuator. Internal damage of EGR actuator due to high Threshold for error detection is an internal ECU
temperature or electrical wiring issue. threshold.
Exchange EGR actuator.
2791 13 1754 415 EGR actuator can not learn stop positions. Error detection during the learning process. Threshold for error detection is an internal ECU
Possibly only second failure if other EGRTV threshold.
failures occure. Start Serdia Usecase to reset EGR actuator.
Check EGR valve and mounting situation. If
o.k. change EGR actuator.
2791 13 1756 415 EGR actuator can not learn stop positions Interruption of learning process due to Threshold for error detection is an internal ECU
because procedure was interrupted. mechanical damage. threshold.
Start Serdia Usecase to reset EGR actuator.
2791 13 1760 415 Stop positions of EGR valve not o.k. Mechanical damage of EGR actuator. Threshold for error detection is an internal ECU
EGR valve is blocked or moving very hard. threshold.
Start Serdia Usecase to reset EGR actuator.
2791 16 1762 415 Internal actuator temperature above overheating of EGR actuator Let EGR actuator cool down, check heat
threshold. accumulation during worst case operation.

2797 4 1337 565 Injector diagnosis: Timeout of Injector Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
detection cylinder bank 0 threshold.
Check wiring, component, ECU
Note: affected injector has to be evaluated
according to firing order
2797 4 1339 565 Injector test: Short cut to ground on Short-Circuit to ground on component wiring Check wiring, component, ECU
cylinder bank 0 Note: affected injector has to be evaluated
according to firing order
2798 4 1338 566 Injector diagnosis: Timeout of injector Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
detection cylinder bank 1 threshold.
Check wiring, component, ECU
Note: affected injector has to be evaluated
according to firing order
2798 4 1340 566 Injector test: Short cut to ground on Short-Circuit to ground on component wiring Check wiring, component, ECU
cylinder bank 1 Note: affected injector has to be evaluated
according to firing order

3-172 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

3031 0 1135 669 The urea tank temperature sensor detects a Sensed urea tank temperature > physical Case "CANBUS sensor":
value above the maximum allowed thresh- range high limit Check urea tank temperature: really hot?
old Check CANBus-message of DEF sensor urea
tank temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Tank heater permantly on?
Check wiring of DEF-quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really hot?
Check urea tank temperature
SCR_tSensUTnkT Compare urea tank
temperature to EnvT_t or to SCR_tSMT (the
urea temperature
inside the supply module) identical?
Tank heater permantly on?
Check wiring of analog DEF T & Level sensor
3031 1 1136 669 The urea tank temperature sensor detects a sensed urea tank temperature < physical Case "CANBUS sensor":
value lower than the minimum allowed range low limit Check ambient temperature EnvT_t =>
threshold. About
-40 °C? If yes Error could be plausible
Check CANBus-message of DEF sensor urea
tank temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical? Check
wiring of DEF-quality sensor Check quality
sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really that cold?
Check ambient temperature EnvT_t =>
About -40 °C? If yes Error could be plausible
Check urea tank temperature
SCR_tSensUTnkT Check wiring of analog DEF T
& Level sensor Check analog DEF T & Level
sensor
3224 2 129 596 DLC Error of CAN-Receive-Frame AT1IG1Vol Not Used Threshold for error detection is an internal ECU
NOX Sensor (SCR-system upstream cat; threshold.
DPF- system downstream cat); length of Check Nox-Sensor and the wiring from CAN-
frame incorrect. BUS.
3224 9 130 597 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX sensor and sensor connection check
AT1IG1Vol; NOX sensor (SCR-system
upstream cat; DPF-system downstream
cat).

3121671 3-173
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

3234 2 138 114 DLC Error of CAN-Receive-Frame AT1O1Vol Failure of the CAN Bus message NOX downstream sensor and sensor
NOX Sensor (SCR-system downstream cat; connection check
DPF-system downstream cat); length of
frame incorrect.
3234 9 139 117 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX downstream sensor and sensor
AT1OG1Vol; NOX sensor (SCR-system connection check
downstream cat; DPF-system
downstream cat).
3361 3 1077 677 Urea dosing valve (low side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range See substitute function
Check the wiring
3361 3 1078 677 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range Check the wiring
3361 4 1079 677 Urea dosing valve (low side power stage): Fault in the wiring Check the wiring
the current drain measured by ECU is above
the target range
3361 4 1080 677 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range Check the wiring
3361 6 1075 677 Urea dosing valve: the current measured Fault in the wiring Check wiring
value by ECU at the end of the injection is Defect urea dosing injection valve Check the urea dosing injection valve
too high
3519 3 1898 277 The integrated diagnostic of the tempera- Wrong diagnostic of the short circuits logic Check the wiring to the suction unit in the DEF
ture sensor of the Urea Quality Sensor inside the temperature sensor of the UQS CAN tank.
recognized a short circuit to battery. Communication corrupted Check the CAN bus communication of the suc-
The UQS Sensor is an combined sensor of tion unit. In case the communication is
tank temperature, filling grade and DEF corrupt, exchange the suction unit.
quality and it is also an CAN sensor --> no
PIN
3519 4 1899 277 The integrated diagnostic of the tempera- DEF quality sensor in the suction unit of the Check the wiring to the suction unit of the DEF
ture sensor of the Urea Quality Sensor DEF tank.
recognized a short circuit to ground tank is defect Check the CAN bus communication from the
CAN Communication corrupted suction unit. In case the signal is corrupt,
exchange the suction unit in the DEF tank.

3-174 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

3519 12 1895 277 The integrated temperature sensor of the Temperature sensor inside the UQS defect. Check the temperature sensor signal for
Urea Quality Sensor measures higher CAN Communication corrupted. plausibility. In case of improper signal,
temperature than threshold Overheating of the DEF tank due to exchange the suction unit in the tank.
malfunction of the heating valve. Check CAN bus communication for proper
Flow direction is of coolant is wrong due to signal. 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
Overheating of the DEF tank due to heat routing of the hoses. The coolant flow through
transfer the heating valve must be observed according
from neighbor parts. to the shown arrow.
In case all actions above are OK, check the real
temperature in the DEF tank during
worst case condition and improve the installa-
tion of the DEF tank.
3519 13 1908 277 Temperature at UQS out of range the Suspected Components Check temperature system and/or DEF quality
specified thresholds; invalid quality of the Tank heater sensor
temperature DEF sensor
3520 2 1904 2-7-8 Measured DEF Quality from UQS is too low. Suspected components: Urea quality sensor Check that there is liquid urea of known
Quality value received from UQS is < 22 % defect quality in the tank first
for a certain time and a certain number or Wrong installation (measuring air) Urea level Check urea tank level. Add urea until level is at
for measuring conditions not observed for sensor defect least 10 cm above sensor.
a certain time. Non urea filled in tank Ensure that urea is not frozen / sufficient urea
CANBUS problems is liquid
Evaluation conditions for new quality check Check Sensor: Are urea tank temperature and
not fulfilled after one previous mal detection level displayed? Changes the level if you refill
urea?
Check electrical connection
Check CANBus
New quality detection is carried out if urea re-
fill is detected or if an quality evaluation
was triggered and was not finished success-
fully: To provoke a quality measurement: refill
urea, at least 10 % of tank volume
Wait until quality evaluation was carried out,
can take up to 30 minutes => check value. It
should be about 33%
Exchange quality sensor
3520 3 1896 278 The integrated diagnostic of the Urea wiring harness of UQS corrupted Threshold for error detection is an internal ECU
Quality CAN Communication corrupted threshold.
Sensor recognized a short circuit to battery 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.

3121671 3-175
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

3520 4 1897 278 The integrated diagnostic of the Urea wiring harness to the suction unit in the DEF Threshold for error detection is an internal ECU
Quality tank is corrupted threshold.
Sensor recognized a short circuit to ground. 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.
3520 13 1907 278 Urea quality at UQS out of range the Suspected components Check DEF quality and/or DEF quality sensor
specified thresholds; invalid quality of the DEF quality sensor
urea quality DEF
3532 3 1911 127 The urea quality value from the sensor is Suspected Components: UQS defect Check DEF quality and/or sensor.
greater than the maximum physical range
threshold
Comment: tank temperature is measured
by the UQS sensor
3532 4 1912 127 The urea quality value from the sensor is Suspected Components: UQS defect Check DEF quality and/or Sensor.
lower than the minimum physical range
threshold.
3711 12 1455 711 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC
DPF temperature < Threshold 1 temperature, is below or above Exh_tSensOxiCatUs within Stand-still: > 450
Temperature Phy_tPfWgh, the weighted the target temperature towards the end of the °C? If not:
DPF temperature > Threshold 2 towards stand-still main phase. => Check air path of engine: EGR-Valve,
the end of the stand-still main 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

3-176 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

3936 14 1917 2-8-6 Standstill escalation by time. In case the Stand-still request ignored by the operator. Perform Stand-still. If soot load level of DPF
standstill request will not be released Display / stand-still request lamp broken. has increased too high already call service
within to perform stand-still.
50 h by the driver this fault code will be set. In case the DPF soot load level remove DPF
=> Exchange DPF.
4334 0 1122 665 The absolute pressure value of the urea Suspected Components: Urea pump defect Check the urea pump
pump is greater than an applicable Supply module pressure sensor defect Check the supply module pressure sensor
maximal filtered pressure threshold Pump contains dirty parts Clean the urea pump (filter)
4334 1 1123 665 Urea supply module pressure sensor: The Check the urea pump Check the urea pump
absolute pressure value of the urea pump is Check the supply module pressur sensor Check the supply module pressur sensor
less than an applicable minimal filtered Clean the urea pump (filter) Clean the urea pump (filter)
pressure threshold
4334 2 1866 665 absolute difference of sensed urea pump absolute difference of sensed urea pump pres- Check environment pressure sensor (EnvP_p)
pressure (SCR_pAbsSensUPmpP) and sure (SCR_pAbsSensUPmpP) and => plausible value?
ambient pressure (EnvP_p) > limit ambient pressure (EnvP_p) > limit Engine shut-off and immediately re-started?
abs(UPmpP_pDiffPmpEnv_mp) > abs(UPmpP_pDiffPmpEnv_mp) > => Shut-off again. Wait until afterun of
UPmpP_pDiffPmpEnv_C (250 hPa) UPmpP_pDiffPmpEnv_C ECU has finished, re-Start engine
Back-flow line free? Does the urea pump pres-
sure show values < 1000 hPa in SCR
state emptying (64)?
Check revision valve => Does the urea pump
pressure show values < 1000 hPa in SCR
state emptying (64)? => exchange supply
module
Supply module pressure sensor defect =>
exchange supply module
4341 3 1104 675 Urea heater supply line: the current drain electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
4341 4 1105 675 Urea heater supply line: the current drain electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
4341 5 1102 675 Urea heater supply line: the current drain electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
4343 3 1096 673 Urea pressure line heater: the current drain shortcut to battery Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase threshold
is a result error: KWP 1089 Check wiring
broken heating element in pressure line Check heating element

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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

4343 4 1097 673 Urea pressure line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase threshold
is a result error: KWP 1089 Check wiring
Short cut to ground or broken wiring, broken Check heating element
heating element in pressure line
4343 5 1094 673 Urea pressure line heater: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase threshold
is a result error: KWP 1089 Check wiring
Broken wiring, broken heating element in Check heating element
pressure line
4345 3 1092 674 Urea backflow line heater: the current Shortcut 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 threshold
range is a result error: KWP 1089 Check wiring
Short cut to battery or broken wiring, broken Check heating element
heating element in backflow line
4345 4 1093 674 Urea backflow line heater: the current 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 threshold
range is a result error: KWP 1089 Check wiring
Short cut to ground or broken wiring, broken Check heating element
heating element in backflow line
4345 5 1090 674 Urea backflow line 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 threshold
range is a result error: KWP 1089 Check wiring
Broken wiring, broken heating element in Check heating element
backflow line
4360 0 1069 668 The filtered urea cat upstream temperature Sensed temperature upstream SCR > physical Check temperature difference across DOC
is greater than an applicable maximum high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at higher
temperature 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
engine 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

3-178 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

4360 1 1070 668 The filtered temperature before urea cat is Sensed temperature upstream SCR catalyst < Cold start and ambient temperature <
less than an applicable minimum than physical low limit Threshold? Missdetection?
temperature threshold Check wiring harness to UCatUsT-sensor
Exchange UCatUsT-sensor
4360 2 1865 668 Error at static plausibility check: Error at static plausibility check: Check whether temperature sensor upstream
absolute temperature difference of sensed absolute temperature difference of sensed of
temperature upstream SCR catalyst and temperature upstream SCR catalyst and SCR catalyst is physically mounted within
ambient temperature > as static ambient temperature > as static plausibility exhaust pipe
plausibility limit limit If cold start condition can be made sure
at engine cold start (engine was off for at at engine cold start (engine was off for at least (engine was off for at least 8 h) compare
least 8 h), temperature upstream of SCR 8 h), temperature upstream of SCR values of EnvT_t, EngDa_tEng,
catalyst is expected to be identical to catalyst is expected to be identical to ambient Exh_TOxiCatUs, Exh_tOxiCatDs and
ambient temperature => see enable temperature => see enable conditions for SCR_tSensUCatUsT at ignition on, without
conditions for details. details. starting the engine. All identical? Compare
Error at dynamic plausibility check: Error at dynamic plausibility check: values of Exh_TOxiCatUs, Exh_tOxiCatDs and
temperature difference of sensed temperature difference of sensed temperature SCR_tSensUCatUsT after 15 min in constant
temperature upstream SCR catalyst and upstream SCR catalyst and ambient operation point: show all similar values (30 K
ambient temperature < as dynamic temperature < as dynamic plausibility limit tolerance width). Are
plausibility limit dynamic check is blocked dynamic check is blocked if static plausibility ambient temperature and (EnvT_t), cooling
if static plausibility check is already faulty check is already faulty water temperature (EngDa_tEng) plausible?
=> Temperature upstream SCR catalyst => Temperature upstream SCR catalyst must Sensor coated with urea crystalls? Dismount
must be by 40°C higher than ambient be by 40°C higher than ambient urea injector and inspect temperature
temperature if engine runs and a certain temperature if engine runs and a certain delay sensor upstream SCR catalyst visually
delay time has expired. time has expired. Check wiring of sensor
Replace sensor
4361 3 1072 668 Urea catalyst upstream temperature Voltage of temperature sensor upstream SCR Check sensor
sensor: the voltage of sensor measured by catalyst > maximum limit Check wiring
ECU is out of the target range Short circuit to battery Replace UCatUsT-sensor
4361 4 1073 668 Urea catalyst upstream temperature Voltage of temperature sensor upstream SCR Check sensor
sensor: the voltage of sensor measured by catalyst < minimum limit Check wiring
ECU is out of the target range Short circuit to ground Replace UCatUsT-sensor
4365 2 1137 6-6-9 Signal error in case of Urea tank CAN message is not send properly. Check sensor connector
temperature transmitted via CAN-signal Check CANbus
Com_tUTnkT.
4365 3 1138 6-6-9 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The Sensed raw voltage value
SCR_uRawUTnkT
is below SCR_SRCUTnkT.uMax_C. Check
wiring.
4365 3 1914 669 Internal error of DEF quality sensor. Suspected components: DEF quality sensor Check wiring harness and DEF quality sensor
Wiring harness

3121671 3-179
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

4365 4 1139 6-6-9 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The sensed raw voltage value
SCR_uRawUTnkT
is above SCR_SRCUTnkT.uMin_C. Check
wiring.
4365 4 1915 6-6-9 Internal error of DEF quality sensor. Suspected components: DEF quality sensor Check wiring harness and DEF quality sensor
Wiring harness

4366 3 1112 671 Urea tank heating valve: 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 threshold
is a result error: KWP 1089 Check wiring
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
4366 4 1113 671 Urea tank heating valve: the current drain Shortcut to ground Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase threshold
is a result error: KWP 1089 Check wiring
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
4366 5 1110 671 Urea tank heating valve: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase threshold
is a result error: KWP 1089 Check wiring
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
4375 3 1120 666 Urea supply module pump: the current Shortcut 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 threshold
range is a result error: KWP 1089 The hardware detects absence of any short
Broken wiring circuit to battery on the PWM output power
Pump in urea supply module defect stage for the urea pump module actuator
Check wiring
Check pump in the urea supply module
4375 4 1121 666 Urea supply module pump: the current 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 threshold
range is 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 Urea Pump Module Motor Actuator.
The error is updated by setting bit 1 of
measuring point UPmp-
Mot_stPrevTstRslt_mp
Check wiring
Check pump in the urea supply module

3-180 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

4375 5 1118 666 Urea supply module pump: the ECU can not Open load Threshold for error detection is an internal ECU
measure any reaction during pump control Broken wiring threshold
Pump in urea supply module defect The hardware detects the presence of load on
the PWM output power stage for the
urea pump module actuator. Check wiring
Check pump in the urea supply module
4376 3 1131 667 Urea supply module reversal valve: the cur- Shortcut to battery Threshold for error detection is an internal ECU
rent drain measured by ECU is above the Fault in the wiring threshold
target range Reversal valve in the urea supply module Check wiring
defect Check urea supply module
4376 4 1132 667 Urea supply module reversal valve: the cur- Shortcut to ground Threshold for error detection is an internal ECU
rent drain measured by ECU is above the Fault in the wiring threshold
target range Reversal valve in the urea supply module Check wiring
defect Check urea supply module
4376 5 1129 667 Urea supply module reversal valve: the cur- Open load Threshold for error detection is an internal ECU
rent drain measured by ECU is above the Fault in the wiring threshold
target range Reversal valve in the urea supply module Check wiring
defect Check urea supply module
4765 0 1039 683 The exhaust temperature value from the sensed temperature upstream DOC > shut-off Check air path of engine: EGR-Valve, Intake-
sensor before DOC limit Throttle,
is above an applicable upper shutoff Check Turbocharger and Piping each for
thresh- leakage
old and correct function
TOxiCatUs_tShOffThresHiAds_C = Thresh- Check injectors: is an injector got stuck?
old 1 in Normal and Exchange temperature sensor upstream DOC
Heatmodes
(TOxiCatUs_tShOffThresHiRgn_C =
Thresh- old 2
in stand-still)
4765 0 1040 683 The exhaust temperature value from the Sensed temperature upstream DOC > warning Check air path of engine: EGR-Valve, Intake-
sensor before 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

3121671 3-181
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

4768 2 1036 683 Static plausibility check: Static plausibility check: Check ambient temperature => value
The exhaust temperature value from the The exhaust temperature value from the plausible?
sensor before DOC, the exhaust sensor before DOC, the exhaust temperature upstream DOC sensor mounted within exhaust
temperature value from the sensor after value from the sensor after DOC, the line?
DOC, the temperature value from the temperature value from the sensor before T upstream DOC sensor physically mounted in
sensor before SCR-Cat, the environment temperature and correct position upstream DOC? (not
SCR-Cat, the environment temperature the coolant engine temperature their ratios upstream SCR or downstream DOC?)
and the coolant engine temperature their to each other exceed their related thresholds. Check T upstream DOC sensor
ratios to each other exceed their related (difference between temperature after DOC Check other T-sensors within EAT-system
thresholds. and temperature before DOC > Threshold 1 (Exh_tOxiCatDs & UCatUsT_tFlt_mp show
Dynamic plausibility check with difference between temperature befor DOC plausible values? No errors on them?
environment temperature sensor value: and before SCR > Threshold 2
The exhaust temperature value from the difference between temperature after DOC
sensor before DOC is lower than an and
applicable environment temperature before SCR < Threshold 3
threshold difference between temperature after DOC
and ambient temperature < Threshold 4
difference between temperature ambient
temperature and engine temperature <
Threshold 5)
Dynamic plausibility check with environment
temperature sensor value:
The exhaust temperature value from the
sensor
before DOC is lower than an applicable
environment temperature threshold (<
environmental temperature + Threshold 6)

3-182 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

4768 2 1881 683 At engine cold start conditions the sensed Difference temperature of exhaust gas Check whether all exhaust gas temperature
exhaust gas temperature downstream DOC temperature 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
has exceeded the sum of ambient certain limit earlier than the difference and
tempera- temperature of exhaust gas temperature at correct positions.
ture (EnvT_t) + offset (40°C) earlier than upstream DOC and fixed ambient temperature Check the position of the sensor upstream SCR
the sensed exhaust gas at ignition on. which might be physically mounted in the
temperature upstream of DOC wrong position.
(Exh_tSensTOxiCatUs). If cold start condition can be made sure
The check is only performed once each (engine was off for at least 8 h) compare
igni- values of EnvT_t, EngDa_tEng,
tion cycle and only if the start is judged a Exh_TOxiCatUs, Exh_tOxiCatDs and
cold start. SCR_tSensUCatUsT at ignition on, without
Error status is frozen for that ignition cycle. starting the engine. All identical? Then the
No healing possible. sensors itself are okay.
Check exhaust piping for leakage.
Check wiring of sensors
Replace sensors
Check DOC => physically intact?
4768 3 1044 683 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is above upstream DOC
ECU is out of the target range Exh_SRCTOxiCatUs.uMax_C Shortcut to Exchange temperature sensor upstream DOC
battery
4768 4 1045 683 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is upstream DOC
ECU is out of the target range below Exh_SRCTOxiCatUs.uMin_C Shortcut to Exchange temperature sensor upstream DOC
ground
5763 3 1024 594 Actuator of the external EGR valve: the ECU Short cut to battery or open loop. Check cabling, actuator defect, check actuator
detects a short circuit to battery or open and if necessary replace it, check
load. connection cable and if necessary repair or
replace it.
5763 3 1226 594 Actuator EGR-valve: short cut to battery is Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 3 1227 594 Actuator EGR-valve: short cut to battery on Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
ECU pin is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 4 1025 594 Actuator of the external EGR valve: the ECU Short cut to ground Check cabling, actuator defect, check actuator
detects a short circuit to ground. and if necessary replace it, check
connection cable and if necessary repair or
replace it.

3121671 3-183
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

5763 4 1228 594 Actuator EGR-valve: short cut to ground on Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
ECU pin is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 4 1229 594 Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal ECU
ECU pin is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 4 1232 5-9-4 Actuator error EGR-Valve (2.9;3.6) or Monitoring for CY146 Under Voltage. Threshold for error detection is an internal ECU
Throttle-Valve (4.1;6.1;7.8); Voltage below threshold.
threshold Check wiring, component
3.6) Drosselklappe (4.1;6.1;7.8); Voltage
below threshold;
5763 5 1023 5-9-4 Actuator error EGR-Valve; signal range Short circuit to ground. Check wiring, check cabels and repair or
check low, measured current is below replace if necessary, check actuator with
target SERDIA 2010 test for EGR and if necessary
replace it.
5763 6 1014 594 Actuator error EGR-Valve. Signal range Short cut to battery. Check wiring and repair or replace if
check high. necessary, check actuator with SERDIA test for
EGR and if necessary replace it.
5763 6 1022 5-9-4 Actuator error EGR-Valve; signal range Short circuit to battery or open circuit. Check cabling, actuator defect, check actuator
check high, measured current by ECU is and if necessary replace it, check
over target connection cable and if necessary repair or
replace it.
5763 6 1223 594 Actuator EGR-Valve: Open load on ECU out- Open circuit on component wiring Threshold for error detection is an internal ECU
put is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 6 1224 594 Actuator EGR-valve: too high current is Overload on component wiring Threshold for error detection is an internal ECU
going into the actuator. Output is switched threshold.
off Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 6 1230 5-9-4 Actuator error EGR-valve; Overload by Short Circuit over Load Threshold for error detection is an internal ECU
short- circuit threshold.
Check wiring, component
5763 7 1016 594 Actuator position for EGR valve is not Position error of throttle flap (deviation > Threshold for error detection is an internal ECU
plausible, internal error, angular 7%). threshold.
misalignment of the flap. Threshold for error detection, deviation from
setpoint > 7%.
Troubleshooting with SERDIA 2010 Use Case
"EGR Diagnostic".

3-184 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

5763 11 1231 5-9-4 Power stage overtemperature due to high Temperature dependent Over Current Threshold for error detection is an internal ECU
current. threshold.
Check wiring, component
520521 5 1015 594 Actuator error EGR-Valve. Signal range Short cut to ground. Check wiring and repair or replace if
check low. necessary, check actuator with SERDIA test for
EGR and if necessary replace it.
523009 9 825 253 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the number of allowed activations. old of the pressure limiting valve. fault with Serdia.

523009 10 833 2-5-3 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the allowed opening time. old of the pressure limiting valve. fault with Serdia.

523212 9 171 3-3-3 Timeout Error of CAN-Receive-Frame Com Timeout Error (Missing CAN Bus message) Check wiring harness and customer devices
Eng Prt; Engine Protection

523240 9 179 527 Timeout CAN-message FunModCtl; Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus scheduling,
Function Mode Control polarity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
523350 4 565 151 Injector cylinder bank 1: the current drop Short circuit injection bank 1 (all injectors of Threshold for error detection is an internal ECU
measured by ECU is above the target range this bank can be affected) threshold.
Check wiring harness, injectors and if
necessary repair/replace it.
523352 4 566 152 Injector cylinder bank 2: the current drop Short circuit injection bank 2 (all injectors of Threshold for error detection is an internal ECU
measured by ECU is above the target range this bank can be affected) threshold.
Check wiring harness, injectors and if
necessary repair/replace it.
523354 12 567 153 Internal hardware monitoring: the ECU Defective powerstage in ECU Threshold for error detection is an internal ECU
detects an error of its injector high current threshold.
output. Chip of CY33x defect power stage If error is not removable, change ECU.
components
523450 4 839 1-4-3 Diagnostic fault check for min error of COM The sensed raw value is less than the Check cabling, check sensor and if necessary
message. threshold. replace it,
check connection cable and if necessary repair
or replace it.
523470 2 826 146 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check
injection system.

3121671 3-185
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523470 2 827 146 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger Threshold for error detection is an internal ECU
opened due to excessive pressure. threshold of the pressure limiting valve. threshold.
Reset the fault and at reappearance check
injection system.
523470 7 876 146 Rail pressure is out of the expected average Rail pressure is out of the expected average (A) Check rail pressure relief valve and replace
range. range. if necessary.
PRV can not be opened. (B) Check high pressure pumps, pressure relief
valve and metering unit.
(C) Change components if necessary
523470 11 831 146 Rail pressure relief valve can not be opened Rail pressure out of tolerance range (PRV can Threshold for error detection is an internal ECU
due to the rail pressure. not be opened by a pressure peak in this threshold.
operating point) Check rail pressure, check rail pressure sensor
for plausibility, check FCU.
523470 11 832 146 Rail pressure is out of the expected average Averaged rail pressure is outside the expected Threshold for error detection is an internal ECU
range. tolerance range. threshold.
The PRV can not be opened at this Check PRV and replace if necessary.
operating point with a pressure shock.
523470 12 828 146 Rail pressure relief valve: is open. Shutoff Shut Off after PRV Open Threshold for error detection is an internal ECU
conditions. threshold.
Check PRV opening counter and if necessary
replace PRV,
check rail-pressure sensor for plausibility and
if
necessary replace it,
check FCU and if necessary replace it.
523470 12 829 146 Rail pressure relief valve is open. Warning Warning PRV open Threshold for error detection is an internal ECU
conditions. threshold.
Check PRV opening counter and if necessary
replace PRV,
check rail-pressure sensor for plausibility and
if necessary replace it,
check FCU and if necessary replace it.
523470 14 830 146 Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal ECU
threshold.
Only after ECU reset.
Check PRV opening counter and if necessary
replace it,
check rail-pressure sensor for plausibility and
if necessary replace it,
check FCU and if necessary replace it.

3-186 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523550 12 980 515 Terminal 50 was operated for more than 2 Start information 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
Starter control is disabled until this error is start switch and if necessary replace it,
healed. check connection cable and if necessary repair
or replace it.
523601 13 948 282 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of Pin A18: DeltaPressVenturi / Position intake working voltage and if necessary correct
the power supply voltage of sensor output throttle flap it,
3. Pin K20: First footpedal check connection cable and if necessary repair
Pin K21: Air FilterDiffPress or replace it,
Suspected components EDC17cv54 and cv56 if error is not removable, change ECU.
Pin A07: Rail pressure
523612 3 644 555 supply voltage too high not used Threshold for error detection is an internal ECU
threshold.

523612 4 646 555 supply voltage too low not used Threshold for error detection is an internal ECU
threshold.

523612 12 387 555 Internal hardware monitoring: the CPU of Injector shut off demand for the ICO Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged coordinator threshold.
internally; no item will be created in error System responses: Caution! Sequence error, check error memory
memory not for other errors.
523612 12 612 555 Internal hardware monitoring: the CPU of Plausibility check failed (MoCADC_uNTP_mp Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged is higher than MoCADC_uNTPMax_C). threshold.
internally; no item will be created in error If error is still present, exchange ECU.
memory.
523612 12 613 555 Internal hardware monitoring: the CPU of Analysis of test voltage (Value is out of the tar- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged get -> ECU internal error) threshold.
internally; no item will be created in error Check wiring, check connected sensors
memory actuators.
If error is still present, exchange ECU.
523612 12 614 555 Internal hardware monitoring: the CPU of Analysis of the ratio metric correction (Value is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged out of the target -> ECU internal error) threshold.
internally; Check wiring, check connected sensors
no item will be created in error memory actuators.
If error is still present, exchange ECU.
523612 12 615 555 Internal hardware monitoring: the CPU of Error report due to an error in the plausibility Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged of Function Coordination(FC) and threshold.
internally; Monitoring Modul(MM)(ECU internal error) If error is still present, exchange ECU.
no item will be created in error memory

3121671 3-187
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523612 12 616 555 Internal hardware monitoring: the CPU of Error report due to an interrupted SPI Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged communication (ECU internal error) threshold.
internally; no item will be created in error If error is still present, exchange ECU.
memory
523612 12 617 555 Internal hardware monitoring: the CPU of multiple error in complete ROM-test during Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged postdrive detected (ECU internal error) threshold.
internally; no item will be created in error If error is still present, exchange ECU.
memory
523612 12 618 555 Internal hardware monitoring: the CPU of Too less bytes received by monitoring memory Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged from CPU as response (ECU internal threshold.
internally; no item will be created in error error). Loss of synchronization sending bytes If error is still present, exchange ECU.
memory to the monitoring memory from CPU
523612 12 619 555 Internal hardware monitoring: the CPU of Suspected components: Injector Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged ECU threshold.
internally; no item will be created in error wiring harness/connector If error is still present, exchange ECU.
memory
523612 12 620 555 Internal hardware monitoring: the CPU of Error trying to set MM Response time (ECU Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged internal error) threshold.
internally; no item will be created in error If error is still present, exchange ECU.
memory
523612 12 621 555 Internal hardware monitoring: the CPU of Error detected in the internal ECU Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged communication, Too many SPI errors during threshold.
internally; no item will be created in error MoCSOP execution If error is still present, exchange ECU.
memory
523612 12 623 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged the under voltage detection (ECU internal threshold.
internally; no item will be created in error error). Diagnostic fault check to report the If error is still present, exchange ECU.
memory error in undervoltage monitoring
523612 12 624 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged monitoring module (ECU internal error). threshold.
internally; no item will be created in error If error is still present, exchange ECU.
memory
523612 12 625 555 Internal hardware monitoring: the CPU of Time out error trying to set or cancelling the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged alarm task (ECU internal error). Failure setting threshold.
internally; no item will be created in error the alarm task period If error is still present, exchange ECU.
memory
523612 12 627 555 Internal hardware monitoring: the CPU of Error in time monitoring of the shut-off path Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged test (ECU internal error). Diagnostic fault threshold.
internally; no item will be created in error check to report the timeout in the shut If error is still present, exchange ECU.
memory off path test

3-188 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523612 12 628 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged the over voltage detection (ECU internal threshold.
internally; no item will be created in error error). Diagnostic fault check to report the If error is still present, exchange ECU.
memory error
in overvoltage monitoring
523612 12 629 555 The two voltage values (ADC_VAL1, Defect pedal or wiring Threshold for error detection is an internal ECU
ADC_VAL2), detected by threshold.
the accelerator pedal, are not plausible to Check Pedal, repair or exchange the Pedal.
each other. Check wiring.
If error is still present, exchange ECU.
523612 12 630 555 Impermissible offset between the engine Calculated engine speed in level 1/2 Threshold for error detection is an internal ECU
speed of level 2 and level 1 implausible (-> ECU internal error). threshold.
If error is still present, exchange ECU.
523612 12 631 555 Diagnostic fault check to report the Implausible injection energizing time for Threshold for error detection is an internal ECU
plausibility error between level 1 either threshold.
energizing time and level 2 information PiIx or MI1 or PoIx. If error is still present, exchange ECU.
523612 12 632 555 Error in the plausibility of the start of Implausible start of energising of either PiIx or Threshold for error detection is an internal ECU
energising angles MI1 or PoIx. threshold.
If error is still present, exchange ECU.
523612 12 633 555 Error in the plausibility of the energising The energising times of the zero fuel quantity Threshold for error detection is an internal ECU
times of the zero fuel quantity calibration calibration ZFC is out of the target. (-> threshold.
ECU internal error) If error is still present, exchange ECU.
523612 12 634 555 Error in the plausibility of PoI2 efficiency. Error in the plausibility of PoI2 efficiency. Threshold for error detection is an internal ECU
threshold.
If error is still present, exchange ECU.
523612 12 635 555 Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an internal ECU
threshold.
If error is still present, exchange ECU.
523612 12 636 555 Error in the plausibility of PoI3 efficiency. Error in the plausibility of PoI3 efficiency. Threshold for error detection is an internal ECU
threshold.
If error is still present, exchange ECU.
523612 12 637 555 Engine speed: the engine speed calculated Error in the plausibility of current energising Threshold for error detection is an internal ECU
by ECU is above the target range; the ECU time with maximum permitted energising threshold.
activates a system reaction time. Diagnostic fault check to report the error If error is still present, exchange ECU.
due to OverRun
523612 12 638 555 Error in the plausibility of the wave Error in the plausibility of the wave correction Threshold for error detection is an internal ECU
correction parts parts threshold.
If error is still present, exchange ECU.

3121671 3-189
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523612 12 639 555 Plausibility error of the Rail pressure sensor In case the gradient of rail pressure is larger Threshold for error detection is an internal ECU
than the max threshold or lesser than the threshold.
min threshold. Check metering unit or cable.
Rail metering unit defect. Leakage in the Rail Check Rail pressure. Check the Rail System of
System. leakage.
523612 12 640 555 Error in the torque comparison between Error in the torque comparison between the Threshold for error detection is an internal ECU
permissible engine torque and current permissible inner engine torque and the threshold.
actual torque current plausible actual torque. If error is still present, exchange ECU.
523612 12 641 555 Diagnosis of curr path limitation forced by The torque comparison is not plausible with Threshold for error detection is an internal ECU
ECU monitoring level 2 the torque monitoring. threshold.
If error is still present, exchange ECU.
523612 12 642 555 Diagnosis of lead path limitation forced by The setpoint path of the air system is limited Threshold for error detection is an internal ECU
ECU monitoring level 2 by the limitation torque of the functional threshold.
control unit monitoring. If error is still present, exchange ECU.
523612 12 643 555 Diagnosis of set path limitation forced by If the quantity setpoint is exceeds the limit of Threshold for error detection is an internal ECU
ECU monitoring level 2. the torque function. threshold.
If error is still present, exchange ECU.
523612 12 714 555 Error report "WDA wire is active" due to a Error detection by monitoring module Threshold for error detection is an internal ECU
defect query/response communication threshold. Software reset.

523612 12 715 555 Error report "ABE wire is active" due to The reason is that a slow dropping of the Threshold for error detection is an internal ECU
undervoltage detection vehicle electrical system voltage (defective threshold. Software reset.
autobattery)
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due
to an undervoltage recognition.
523612 12 716 555 Error report "ABE wire is active" due to If the ABE/WDA powerstage shut-off is active Threshold for error detection is an internal ECU
overvoltage detection due to an overvoltage detection. threshold. software reset.

523612 12 717 555 Error report "ABE/WDA active" due to an The reason is that a slow dropping of the Threshold for error detection is an internal ECU
unknown reason vehicle electrical system voltage (defective threshold. Software reset.
autobattery)
should not lead the ECU OCWDA's diagnose to
enter an error in the fault memory due to an
undervoltage recognition.
523612 12 1170 555 Internal hardware monitoring: the CPU of Error during positive test (ECU internal error). Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged Diagnostic fault check to report that the threshold.
internally; no item will be created in error positive test failed Reflash ECU. If error is still activ replace ECU.
memory

3-190 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523612 12 1857 555 Fault in the monitoring during the engine wiring is not according DEUTZ requirements Threshold for error detection is an internal ECU
start. Start requested in level 1, but not engine start conditions are not observed threshold.
released in level 2 which leads to no fuel low battery voltage during start check other active errors and fix them.
injection. malfunction of starter check all needed engine start conditions, e.g.
neutral switch.
check the engine speed during starting of the
engine. If it's too low, then check the
battery voltage and then check the starter for
malfunction.
523612 14 973 555 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged threshold.
internally;
no item will be created in error memory.
523612 14 974 555 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged threshold.
internally;
no item will be created in error memory.
523612 14 975 555 Internal hardware monitoring: the CPU of Visibility of SoftwareResets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged threshold.
internally; If possible the software update has to be
no item will be created in error memory done. Replace the ECU.
523613 0 856 134 Rail pressure: the fuel pressure in rail calcu- Pressure governor deviation exceeds the limit- Threshold for error detection is an internal ECU
lated by ECU is below the target range ing value based on the engine speed. threshold.
which is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
523613 0 857 134 Rail pressure: the fuel pressure in rail calcu- maximum positive deviation of rail pressure Threshold for error detection is an internal ECU
lated by ECU is below the target range exceeded concerning set flow of fuel. threshold.
which is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
523613 0 858 134 Rail pressure: the fuel pressure in rail calcu- leakage is detected based on fuel quantity Threshold for error detection is an internal ECU
lated by ECU is above the target range bal- ance. threshold.
which 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

3121671 3-191
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523613 0 859 134 Rail pressure: the fuel pressure in rail calcu- Maximum negative rail pressure deviation Threshold for error detection is an internal ECU
lated by ECU is above the target range with metering unit on lower limit is exceeded. threshold.
which is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
523613 0 862 134 Rail pressure: the fuel pressure in rail calcu- Rail pressure exceeds the limiting value. (A) Check backflow pressure
lated by ECU is above the target range. (B) Check pressure relief valve and metering
unit.
(C) Change components if necessary
523613 1 861 134 Rail pressure: the fuel pressure in rail calcu- Rail pressure falls below the limiting value Threshold for error detection is an internal ECU
lated by ECU is below the target range based on the engine speed. threshold.
which is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
523613 2 864 134 Rail pressure metering unit, Setpoint of Pressure pump delivery quantity in overrun Threshold for detection is an internal ECU
metering unit in overrun mode not plausi- exceeds the threshold based on the pressure. threshold.
ble. (A) Check backflow pressure
(B) Check pressure relief valve and metering
unit.
(C) Change components if necessary
523615 3 594 135 Fuel metering unit: the current drain mea- short circuit to battery high side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 3 596 135 Fuel metering unit: the current drain mea- short circuit to battery low side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 4 595 135 Fuel metering unit: the current drain mea- short circuit to ground high side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 4 597 135 Fuel metering unit: the current drain mea- short circuit to ground low side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 5 592 135 Detecting an open load fault in the wiring harness defective, cable break Threshold for error detection is an internal ECU
metering unit threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.

3-192 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523615 12 593 135 powerstage of metering unit is overheated over temperature Threshold for error detection is an internal ECU
threshold.
Check functionality of metering unit and
replace it if needed.
Check temperature of metering unit and
improve the installation in case of
overheating.
523632 3 1127 665 Urea supply module pressure sensor: the Shortcut to battery Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
523632 4 1128 665 Urea supply module pressure sensor: the Shortcut to ground Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
The sensed raw voltage value
SCR_uRawUPmpP is above
SCR_SRCUPmpP.uMin_C
523632 11 1117 666 Urea supply module pump: the current When the pump motor does not switch to Threshold for error is an internal ECU
drain measured by ECU is above the target pump actuation mode after temperature threshold
range measurement has
been carried out.
523698 11 122 591 Shut off request from supervisory monitor- Engine Shut Off due to supervisory function Threshold for error detection is an internal ECU
ing function. threshold.
Check error memory for additional error code
to find root cause.
Depending on additional error follow the
docu- mented “Take action for repair”.
523718 3 1100 676 Urea heater relay: the current drain mea- Shortcut to battery Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase threshold
it is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
523718 4 1101 676 Urea heater relay: the current drain mea- Shortcut to ground Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase threshold
it is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
523718 5 1098 676 Urea heater relay: the current drain mea- Open load Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase threshold
it is a result error: KWP 1089 Test SCR main relay
Broken wiring Check cabling, if necessary replace relay.
broken relay

3121671 3-193
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523719 4 1109 672 Urea supply module heater: the current Shortcut to ground Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase threshold
range it is a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply
Heating element in supply module defect module
523719 5 1106 672 Urea supply module heater: the current Open load Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase threshold
range is a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply
Heating element in supply module defect module
523720 8 925 148 Supply module heater: Duration of switch uty cycle for temperature readout from supply When the received supply module heater
on is too long. module heater to the control unit is out temperature duty cycle SCR_rSMT is out of
of range; Supply module defect, fault in the the failurerange (SCR_rSMFailMax_C <
wiring. SCR_rSMHtrT < SCR_rSMFailMin_C)
Supply module check and replace if necessary.
Check the wiring.
523720 8 926 148 Supply module heater: Dutycycle timing Duty cycle for temperature readout from When the received supply module heater duty
over error threshold. supply module heater to the control unit is not cycle SCR_rSMHtrT is in the valid range
valid. (SCR_r-
Supply module defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
523721 8 930 689 Supply module heater: Duty cycle timing Duty cycle for temperature readout from Supply module check and replace if necessary.
over error threshold. supply module to the control unit is out of Check the wiring.
range.
Supply module defect, fault in the wiring.
523721 8 931 689 Supply module heater: Duty cycle timing Duty cycle for temperature readout from When the received supply module duty cycle
out of valid range. supply module to the control unit is not valid. SCR_rSMT is in the valid range (SCR_rSMTVld-
Supply module defect, fault in the wiring. Min_C <= SCR_rSMT <=
SCR_rSMTVldMax_C), OR in the failure
range (SCR_rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C)
Supply module check and replace if necessary.
Check wiring.
523721 11 927 689 Supply module heater: temperature Duty cycle for temperature readout from Threshold for detection is an internal ECU
measurement not available. supply module heater to the control unit is not threshold.
available. No erasing in the current driving cycle.
Supply module defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.

3-194 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523722 8 929 691 Supply module heater: Faulty PWM signal PWM Signal for temperature readout from Threshold for error detection is an internal ECU
from supply module. supply module to the control unit is not threshold.
valid. Supply modul defect, fault in the wiring. When valid Sync followed by temperature
information signal is received AND valid sync
and temperature signal for both information
is received one after the other.
Supply module check and replace if necessary.
Check the wiring.
523776 9 291 119 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Threshold for error detection is an internal ECU
TSC1TE - active threshold.
Check CAN Bus cabling (Bus scheduling, polar-
ity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
523777 9 292 119 Message TSC1-TE has been missing Passive timeout Error (Missing CAN Bus mes- Check CAN Bus cabling (Bus scheduling,
(passive) sage) polarity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range, check actuator
523895 13 559 1-5-8 Missing or wrong injector adjustment Missing or wrong injector adjustment value Threshold for error detection is an internal ECU
value programming (IMA) injector 1 (in for cyl. 1. threshold.
firing order). Check correct injector adjustment value (IMA).
Use SERDIA UseCase to check it.
523896 13 560 1-5-8 Missing or wrong injector adjustment Missing or wrong injector adjustment value Threshold for error detection is an internal ECU
value programming (IMA) injector 2 (in for cyl. 2 threshold.
firing order). check dataset and flash correct injector
adjuste- ment value (IMA). Use SERDIA
UseCase to check it.
523897 13 561 1-5-8 Missing or wrong injector adjustment Missing or wrong parametrisation of injector Threshold for error detection is an internal ECU
value programming (IMA) injector 3 (in adjustment cyl. 3. threshold.
firing order). Check correct injector adjustment value (IMA).
523898 13 562 1-5-8 Missing or wrong injector adjustment Missing or wrong injector adjustment value Threshold for error detection is an internal ECU
value programming (IMA) injector 4 (in for cyl. 4. threshold.
firing order). Check correct injector adjustment value (IMA).
523899 13 563 1-5-8 Missing or wrong injector adjustment Missing or wrong injector adjustment value Threshold for error detection is an internal ECU
value programming (IMA) injector 5 (in for cyl. 5. threshold.
firing order). Check correct injector adjustment value (IMA).
523900 13 564 1-5-8 Missing or wrong injector adjustment Missing or wrong injector adjustment value Threshold for error detection is an internal ECU
value programming (IMA) injector 6 (in for cyl. 6. threshold.
firing order). Check correct injector adjustment value (IMA).

3121671 3-195
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523912 4 73 7-2-2 @ engines < 4l: The sensed raw voltage value is below the The sensed raw voltage value
Throttle valve error, Open Load or Short cut minimum 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-
lower limit reached. pressure valve
523924 4 42 167 Overload at Pins O_V_RH2x: A01, K74, Suspected components: Threshold for error detection is an internal ECU
K91. Components on A01, K74, K91 cannot 1- Pin K91: threshold.
be activated. Clutch switch, Brake switch, Engine brake Check wiring harness and connected loads on
Internal ECU power stage switched off. demand, Regeneration activation, Parking pins A01, K74, K91 and/or reflash ECU.
brake, Gearbox N, Fan control 1 If error is still present, exchange ECU.
2- Pin K74:
Boost air cooler bypass or electrical fuel pump
relay, Fan control 2/fuel valve for flame
star
523925 3 38 731 Short circuit to battery error of actuator Suspected Components: Check wiring harness and connected loads on
relay 1- Lamps K57: Warn Ash Charge, Diagnostic, pins A88, K57.
2. Components on Pin A88, K57 cannot be Warn Coolant Temp/Level, Warn Oil,
activated. Warn Boost Air, Warn Air Filter, Warn Water in
Internal ECU power stage switched off. Fuel, SCR, Regeneration, Engine
Running.
2- Relay Preheat A88
3- Exhaust Flap A88
523925 4 43 731 Short circuit to ground actuator release 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
running, diagnostic
523926 4 44 732 Short circuit to ground actuator release 4. Suspected components: Fan, Wiring harness Threshold for error detection is an internal ECU
Overload at Pins O_V_PCV: A90 threshold.
Check wiring harness and connected loads on
pin A90.
If error is still present, exchange ECU.
523927 3 40 733 Short circuit to battery error of actuator Suspected Components: Check wiring harness and connected loads on
relay 1- Urea Pump A04 pins A04, A05.
2. Components on Pin A04, A05 cannot be 2- SCR Heater A05
activated.
Internal ECU power stage switched off.

3-196 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523935 12 168 763 Timeout Error of CAN-Transmit-Frame Fault is detected if a TimeOut of the EEC3VOL1 Check wiring harness and customer nodes
EEC3VOL1; Engine send messages frame has occured.

523936 12 169 764 Timeout Error of CAN-Transmit-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
EEC3VOL2; Engine send messages

523938 9 133 766 Timeout Error (BAM to packet) for CAN- Failure of the CAN Bus message NOX sensor and sensor connection check
Receive-Frame AT1IGCVol1 information;
factors & Sensor calibration for NOX Sensor
(SCR-system upstream cat; DPF-system
downstream cat).
523939 9 134 766 Broadcast Announce Message of the Defective Nox sensor, faulty parameterization NOX sensor and sensor connection check
calibration message
of the upstream catalytic NOx sensor has
failed.
Timeout Error (BAM to BAM) for CAN-
Receive-Frame AT1IGCVol1 information.
factors & Sensor calibration for NOX Sensor
(SCR-system upstream cat, DPF-system
downstream cat).
523940 9 135 766 Timeout Error (PCK2PCK) for CAN-Receive- Failure of the CAN Bus message NOX sensor and sensor connection check
Frame AT1IGCVol1 information; factors &
Sensor calibration for NOX Sensor (SCR-sys-
tem upstream cat; DPF-system
downstream cat).
523941 9 140 767 Timeout Error (BAM to packet) for CAN- Timeout Error (Missing CAN Bus message) NOX downstream sensor and sensor
Receive-Frame AT1OGCVol2 information; connection check
factors & Sensor calibration for NOX Sensor
(SCR-system downstream cat; DPF-system
downstream cat)
523942 9 141 767 Timeout Error (BAM to BAM) for CAN- Defective Nox sensor, faulty parameterization. NOX downstream sensor and sensor
Receive-Frame AT1OGCVol2 information, connection check.
Calibration message 1 of the after catalyst
NO sensor has failed.
Factors & Sensor calibration for NOX Sensor
(SCR-system downstream cat, DPF-system
downstream cat)
523943 9 142 767 Timeout Error (PCK2PCK) for CAN-Receive- The fault is detected when a timeout error in NOX downstream sensor and sensor
Frame AT1OGCVol2 information; factors & packet 2 of NOxSenVol2Rx frame occurs. connection check
Sensor calibration for NOX Sensor (SCR-sys-
tem downstream cat; DPF-system
downstream cat)

3121671 3-197
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

523960 0 1011 771 Physical range check high for EGR cooler Sensed temperature downstream EGR-cooler EGR-Valve blocked open
downstream temperature. > limit. EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
Check Nox-sensor upstream SCR catalyst dp
venturi sensor defect
523960 1 1012 771 Physical range check low for EGR cooler sensor voltage > lower limit EGR-Valve blocked open
downstream temperature. EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
Check Nox-sensor upstream SCR catalyst dp
venturi sensor defect
523982 0 360 737 Power stage diagnosis disabled; Indicating Power stage diagnostic can be deactivated Check wiring, check alternator, check cables
that battery voltage is not high. due to too high battery voltage. and repair or replace if necessary.

523982 1 361 737 Power stage diagnosis disabled; Indicating Power stage diagnostic can be deactivated Check wiring, check alternator, check cables
that battery voltage is not low. due to too low battery voltage. and repair or replace if necessary.

523984 3 1239 788 Actuator relay 5: the voltage measured by Short-Circuit to battery to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
Check wiring, component, ECU
523986 4 1241 176 Actuator relay 4: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
Check wiring, component, ECU
523987 4 1242 791 Actuator relay 5: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
Check wiring, component, ECU
524050 11 1434 8-3-6 CAN; not used not used not used
524051 11 1435 8-3-7 CAN; not used not used not used
524057 2 1505 8-4-3 Low fuel pressure: the low fuel pressure Fuel pressure below warning threshold Threshold for error detection is an internal ECU
calculated 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
necessary repair or replace it.

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Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524063 3 1558 869 SCR heater main relay; short circuit to Short-Circuit to battery on wiring to Check wiring, component
battery component
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 4 1559 869 Connection between heating valve (Y31) Faulty wiring, faulty heater relay (K27-K31), Disconnect plug from heating valve (Y31) and
on 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
short cut to ground. wiring of Y31 to the control unit Pin A:92.
Threshold 1 < If error is no longer present, you have to check
SCRHtr_rUHtrMeasRatio_mp < Threshold the wiring of Y31 via relay K31
2 and possibly the heating cables and relay
(K27- K30).
524063 5 1555 869 Urea backflow line heater: broken wiring Open Load on wiring to component Check wiring, component
detected
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 5 1556 869 Urea main relay: broken wiring detected relay defect Check wiring, component
Threshold 1 < relay not connected wiring harness broken
SCRHtr_rUHtrMeasRatio_mp < Threshold problems with supply voltage
2
524063 5 1557 869 Urea pressure line heater: broken wiring Open load on wiring to component Check wiring, component
detected
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 5 1560 869 SCR relay for suction line not connected relay defect Check wiring, component
Threshold 1 < relay not connected wiring harness broken
SCRHtr_rUHtrMeasRatio_mp < Threshold problems with supply voltage
2
524063 5 1561 869 Open load on wiring to component Open load on wiring to component Check wiring, component
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 5 1562 869 SCR heater tank; open load Open load on wiring to component Check wiring, component

3121671 3-199
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524063 12 1646 869 SCR supply module temperature is not Suspected components: Check
reaching a threshold before a calibratable Enviroment temperature sensor defect Environment temperature sensor
time is exceeded. SCR supply module temperature sensor defect SCR supply module temperature sensor
Corresponding to the environmental Tem- SCR supply module electrical heater defect SCR supply module electrical heater
perature a specific defrosting time is given.
After starting the defrosting a clock counter
is starting. Does the counter reach the
given defrosting time limit, an error will be
detected. Is the temperature reached in
time the clock counter will be reset
Example: by using the calibrated tempera-
ture/time curve --> environmental
temperature 0°C --> defrosting time limit
6000s --
> if the clock counter reaches 6000s the
error will
be detected
524065 0 1565 892 The relativ pressure value of the exhaust sensed presure upstream SCR catalyst > Check for crystallisation in exhaust line
gas from the urea cat upstream physical 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

3-200 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524065 1 1566 892 The realitiv pressure value of the exhaust sensed pressure upstream SCR catalyst > Check correct connection from exhaust line to
gas from the urea cat upstream sensor is physical high range limit of (exhaust volume pressure sensor upstream SCR catalyst:
less 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
environment possible
Check exhaust line: any leakages upstream of
SCR catalyst?
Check wiring of pressure sensor upstream SCR
catalyst
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-
Catalyst
524065 2 1598 892 Comparison of urea cat upstream exhaust absolute value of difference between sensed Check electric connector: 4h pin open / new
gas- and environment pressure, the pressure upstream SCR catalyst and connector type used?
difference should not exceed a certain limit environmental pressure > limit pressure exchange from inside electrical
abs(UCatUsP_pDiffEnvCat_mp) > Thresh- abs(UCatUsP_pDiffEnvCat_mp) > Threshold connector with the environment possible?
old water in sensor?
sensor frozen?
Check wiring of pressure sensor upstream SCR
catalyst
Exchange pressure sensor upstream SCR
catalyst
Check intake manifold pressure sensor
(Air_pCACDs)
Check ambient pressure sensor (EnvP_p)
524065 3 1569 892 voltage of pressure sensor upstream SCR > voltage of pressure sensor upstream SCR > Check wiring of pressure sensor upstream SCR
voltage high limit voltage high limit catalyst
Check pressure sensor upstream SCR catalyst
Exchange pressure sensor upstream SCR
catalyst
524065 4 1570 892 voltage of pressure sensor upstream SCR < voltage of pressure sensor upstream SCR < Check wiring of pressure sensor upstream SCR
voltage low limit voltage low limit catalyst. Check pressure sensor
upstream SCR catalyst. Exchange pressure
sensor upstream SCR catalyst

3121671 3-201
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524067 0 1581 894 Filtered urea supply module heater sensed temperature of supply module heater Compare SCR_tSMT with SCR_tSMHtrT. Both
temperature value is above an applicable >physical high range limit show the same value?
maximum heater temperature threshold of Check urea tank temperature
the supply module (SCR_tAdapUTnkT). Very hot (> 70°C), urea
The temperature is read out via the PWM tank heater
signal of the urea pump. That is only permanet on?
possible in status init of the SCR-system Does the pump never stop working? Check
short after ignition was switched on. When wiring to supply module
that state is Compare SCR_tSMT with SCR_tSMHtrT. Both
left the sensed temperature value is frozen. show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module heater temperature sensor
defect
Supply module heater defect
Supply module defect
524067 0 1585 894 Filtered urea supply module temperature sensed temperature of urea within supply Compare SCR_tSMT with SCR_tSMHtrT. Both
value (SCR_tSMT) is above an applicable module > 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
The temperature is read out via the PWM tank heater
signal of the urea pump. That is only permanent on?
possible in status init of the SCR-system Does the pump never stop working? Check
short after ignition was switched on. When wiring to supply module
that state is Compare SCR_tSMT with SCR_tSMHtrT. Both
left the sensed temperature value is frozen. show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module temperature sensor defect
Supply module heater defect
Supply module defect
524067 1 1582 894 Filtered urea supply module heater sensed temperature of supply module heater Check ambient temperature EnvT_t < Thresh-
temperature value is below an applicable < old?
minimum heater temperature threshold of threshold Compare SCR_tSMT with SCR_tSMHtrT Check
the supply module wiring with regard to supply module heater
The temperature is read out via the PWM exchange urea pump unit
signal of the urea pump. That is only Supply module heater temperature sensor
possible in status init of the SCR-system defect
short after ignition was switched on. When Supply module defect
that state is
left the sensed temperature value is frozen.

3-202 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524067 1 1586 894 Filtered urea supply module temperature sensed temperature of urea within supply Check ambient temperature EnvT_t < thresh-
(SCR_tSMT) value is below an applicable module < physical low range limit old?
minimum temperature threshold of the Compare SCR_tSMT with SCR_tSMHtrT Check
supply module wiring with regard to supply module heater
The temperature is read out via the PWM exchange urea pump unit
signal of the urea pump. That is only Supply module temperature sensor defect
possible in status init of the SCR-system Supply module defect
short after ignition was switched on. When
that state is
left the sensed temperature value is frozen.
524067 2 1867 894 absolute difference of sensed temperature absolute difference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT,
of supply module heater temperature and supply module heater temperature and EnvT_t and CEngTds_t and
ambient temperature ambient temperature SCR_tAdapUTnkT => All identical? If not:
UPmpT_tDiffPmpHtrAmb_mp > UPmpT_tDiffPmpHtrAmb_mp > threshold Has the machine been brought from cold envi-
threshold ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Supply module temperature sensor defect
Problem at Supply module unit (broken?) =>
exchange supply module
524067 2 1868 894 absolute difference of sensed temperature absolute difference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT,
of supply module temperature and supply module temperature and ambient EnvT_t and CEngTds_t and
ambient 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
Supply module temperature sensor defect
Problem at Supply module unit (broken?) =>
exchange supply module
524074 9 1533 246 Open load sensor internally at NOx-sensor Open load sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
dismounting. => If water inside, replace
sensor.
Check mounting position of sensor and judge
it regarding condense water formation /
agglomeration.
Check wiring harness
Exchange sensor

3121671 3-203
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524075 11 1534 247 Short circuit sensor internally at NOx- Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
sensor 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? Rearrange if critical and
possible
Check wiring harness
Exchange sensor
524076 9 1535 248 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
NOx Sensors are CAN Sensors --> no HW Check NOx-Sensor upstream SCR catalyst:
Pin on the ECU 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
524077 11 1536 249 Short circuit sensor internally at NOx- Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
sensor downstream SCR downstream SCR threshold.
NOx Sensors are CAN Sensors --> no HW Check NOx-Sensor upstream SCR catalyst:
Pin on the ECU water inside? Shake out sensor after
dismounting. => If water inside, replace
sensor.
Check mounting position of sensor and judge
it regarding condense water formation /
agglomeration.
Check wiring harness
Exchange sensor

3-204 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524078 9 1537 255 Lambda value of NOx-Sensor downstream sensed lambda value of Nox-sensor down- Check whether NOx-sensor downstream SCR
SCR is out of range. stream SCR catalyst is > physical high limit catalyst is physically mounted within the
When the filtered Lambda concentration ComRxSCR_rCanLamDs_mp > threshold exhaust line
value at the sensor Check Lambda values of NOx-sensor down-
(ComRxSCR_rFltLamDs_mp) is greater stream SCR catalystat at idle conditions,
than 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
Check NOx-sensor downstream SCR catalyst
itself
Replace NOx-sensor downstream SCR catalyst
524079 9 1538 256 sensed lambda value of NOx-sensor down- sensed lambda value of NOx-sensor down- Compare to ComRxSCR_rCanLamUs_mp.
stream SCR catalyst is < physical low limit stream SCR catalyst is < physical low limit ComRxSCR_rCanLamDs_mp must be almost
ComRxSCR_rCanLamDs_mp < threshold ComRxSCR_rCanLamDs_mp < threshold 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
Check NOx-sensor downstream SCR catalyst
wiring
Check NOx-sensor downstream SCR catalyst
itself
Replace NOx-sensor downstream SCR catalyst

3121671 3-205
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524080 9 1539 257 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check whether NOx-sensor upstream SCR
upstream SCR catalyst is > physical high SCR catalyst is > physical high limit catalyst is physically mounted within the
limit ComRxSCR_rCanLamUs_mp > Threshold exhaust line
ComRxSCR_rCanLamUs_mp > Threshold Check Lambda values of NOx-sensor upstream
SCR catalystat at idle conditions,
ComRxSCR_rCanLamUs_mp < Threshold?
Compare to ComRxSCR_rCanLamDs_mp.
Must be almost identical
Check CANBus of NOx-sensor upstream SCR
cat-
alyst
Check NOx-sensor upstream SCR catalyst
wiring Check NOx-sensor upstream SCR
catalyst itself Replace NOx-sensor upstream
SCR catalyst
524081 9 1540 258 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check air path of engine: EGR-Valve, Intake-
upstream SCR catalyst is < physical low SCR catalyst is < physical low limit Throttle, Turbocharger and Piping each
limit ComRxSCR_rCanLamUs_mp < ComRxSCR_rCanLamUs_mp < Threshold for leakage and correct function
Threshold Check injection system of engine. Injector
stuck?
Check CANBus of NOx-sensor upstream SCR
catalyst
Check NOx-sensor upstream SCR catalyst
wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
524083 9 1542 261 sensed NOx-value of NOx-sensor down- sensed Nox-value of Nox-sensor downstream Check CANBus of NOx-sensor downstream SCR
stream SCR catalyst < Threshold SCR catalyst < physical low limit catalyst
Check NOx-sensor downstream SCR catalyst
wiring
Check NOx-sensor downstream SCR catalyst
itself
Replace NOx-sensor downstream SCR catalyst
524085 9 1544 912 sensed Nox-value of Nox-sensor upstream sensed Nox-value of Nox-sensor upstream SCR Check CANBus of NOx-sensor upstream SCR
SCR catalyst < Threshold catalyst < physical low limit catalyst
Check NOx-sensor upstream SCR catalyst
wiring Check NOx-sensor upstream SCR
catalyst itself Replace NOx-sensor upstream
SCR catalyst
524100 9 1666 924 Timeout error of CAN-Transmit-Frame Open load on CANBUS wiring. Check wiring, component.
Com- DPFHisDat.

3-206 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524104 9 1676 928 Timeout error of CAN-Receive-Frame Com- Time out of Check CANBUS EAT Control Threshold for error detection is an internal ECU
RxDPFCtl. CM1 Module Customer Receive Receive threshold.
Message. Message, PGN65348. Check CANBUS EAT Control Receive Message,
The message is not received. PGN65348.
CM1 Module Customer Receive Message.
524118 9 1672 9-4-2 Timeout error of CAN-Receive-Frame If the frame CM1 message is not transmitted Check CAN Bus cabling (Bus scheduling,
ComRxCM1 successfully polarity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
524121 9 1683 9-4-5 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus scheduling,
RxTrbChActr polarity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
524125 9 1687 9-4-9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus scheduling,
TxTrbChActr polarity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
524141 7 1827 192 DEF dosing valve is blocked with While SCR system is starting up and fter urea Check electrical connection of urea injector:
crystallized 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
injector works properly. The test is repeated is faulty:
up - remove urea injector from exhaust line:
to 3 times before an error is set. - check for crystallisation direct on injector
SCRSysPresMon_stPresDropDet_mp = 0 noz- zle / plate
while SCRCo_stStatus_mp = 16. - rinse it thoroughly in water
Suspected component: - remount urea injector and conduct SERDIA
wiring harness use-case "injection test"
DEF dosing valve If the error is still active, then exchange urea
The error is stored into the EEPROM of the ECU injector.
and status at ECU shut down is regained at
ignition on.

3121671 3-207
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524141 7 1858 192 DEF dosing valve is blocked with While SCR system is starting up and fter urea Check electrical connection of urea injector:
crystallized 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
injector works properly. The test is repeated is faulty:
up to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 - check for crystallisation direct on injector
while SCRCo_stStatus_mp = 16. noz- 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 regained at injector.
ignition on.
524147 13 1639 966 No proper urea pressure level could be This error shows up, if no proper urea pressure Make sure that frozen lines, pump or tank can
build up within the SCR system state "Fill level could be build up within the SCR be excluded!
Lines" system state "Fill Lines" => Check whether there is urea in the urea tank
=> SCRCo_stStatus_mp = 1 within some SCRCo_stStatus_mp = 1 within some Check urea lines:
miuntes minutes Once the urea pump pressure has All lines connected? The right lines connected
exceeded the threshold the error is declared as to the correct places?
okay. Suction line blocked?
Suspected components: Suction line blocked No leakage? Not also urea to the outside but
PWM Powerstage has a defect and a default also air into the lines, especially in the
value which leads not to a rising pressure suction line!
Pump Pressure sensor defect pump filter Perform service routine "pressure test":
contains dirty parts reverting valve Does the urea pump work? => check wiring
continously open harness & PWM signal for pump
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

3-208 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524152 2 1874 971 CAN message is not received fora definite CAN message is not received for a definite Check eletrical connection oif urea quality sen-
time => error is set. As soon as the time sor
message is received the error heals. => error is set. As soon as the message is Check engine CAN bus
received the error heals. Check urea quality sensor itself
Exchange urea quality sensor
524153 2 1875 997 CAN message is not received for a definite CAN message is not received for a definite Check eletrical connection of suction unit sen-
time => error is set. As soon as the time sor (combined sensor with tank level and
message is received the error heals. => error is set. As soon as the message is tank temperature) Check engine CAN bus
received the error heals. Check level sensor itself Exchange suction unit
524156 9 1705 972 Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus scheduling,
ComRxEBC2 from wheel speed sensor. Defect on wheel speed sensor. polarity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
Replace the wheel speed sensor.
524177 7 1863 995 The error shows up, if no proper urea This error shows up, if no proper urea presure Make sure that DEF lines, pump and tank are
pressure could be build up within the SCR could be build up within the SCR system not frozen.
system state "Fill Lines" => SCRCo_stStatus_mp = Check for DEF level in the tank. Check DEF
state "Fill Lines" => SCRCo_stStatus_mp 1. lines:
= 3 cases can lead to the error: Are all DEF lines connected?
1. Case A: increasing pressure is detected within Is the suction line blocked?
15s the check has passed => no error Is ther any leakage? Not only urea to the
Case B: The pressure threshold was not outside but also air into the lines, especially in
reached within the 60s but case A was not the suction line!
positiv. Perform SERDIA usecase "pressure test":
Case C: The minimum pressure of 3000 hPa Does the DEF pump work? => check wiring
was not reached within the 60s. harness & PWM signal for pump.
Does the urea pressure increase? All errors are
already healed?
If still unsuccessful so far:
Check urea pressure sensor: At ignition on and
SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
Check DEF pump filter: Is any dirt inside?
Suspected components: 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

3121671 3-209
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524178 7 1864 996 The urea pump is not able to control the The urea pump controller is not able to control Make sure that DEF lines, pump and tank are
urea pressure between 9bar and 11 bar. the urea pressure between 9bar and 11 not 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
- Reverting valve continously open to the correct places?
- Urea suction line, backflow line broken or Suction line blocked?
connection 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 SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
- Check reverting valve
- Check DEF pump filter: dirt inside? Suspected
components:
DEF pump broken
Reverting valve continously open
DEF suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
DEF pump pressure sensor broken
524190 14 1891 272 Not enough urea in tank or low urea quality Low DEF tank level Check DEF level in tank. If there is no DEF, refill
or hardware tampering failure is detected Low DEF quality up to volume above the warning
or 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
malfunctions.
524191 14 1892 273 A low DEF tank level or a low DEF quality is Low DEF tank level Threshold for error detection is an internal ECU
detected or hardware tampering (system Low DEF quality threshold.
components are pinched off ) or hardware Hardware Tampering is active Check the DEF level in tank. If there is no DEF,
failures as shortcut to battery, shortcut to Hardware Failure is active refill up above the warning level.
ground Check DEF quality filled in the tank.
etc. are detected. Check other errors based on hardware
tampering or failure.

3-210 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524193 8 1893 275 The total time in standstill-regeneration Stand-still mode is very often aborted by the Read out stand-still statistics => see service
mode exceeds the long-limit threshold operator. manual:
within last 500h total engine run time. The Stand-still mode does not reach required Stand-still operation finished or often
error is activated if the engine runs to many temperature level and regeneration level is interrupted by driver / engine shut-off? =>
times in Standstill regeneration. therefore reached after a short time again Run 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
temperature level:
Check engine air path: Intake Throttle, EGR-
Valve
and turbocharger okay?
Any leakage in engine air intake system or
exhaust gas system?
Check temperature sensors within exhaust
system: upstream DOC, downstream DOC
If soot load level of DPf allow it:
Perform Stand-still and check reached
temperature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min stand-
still main phase 590°C are reached?
Temperature 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

3121671 3-211
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524194 8 1894 276 The total time in standstill-regeneration Stand-still mode is aborted / interrupted too Read out stand-still statistics => see service
mode exceeds the long-limit threshold: often by the operator manual:
2,5h stand-still operation within 50h total Stand-still is required too often due to Stand-still operation finished or often
motor run time. miscalculation in the soot model interrupted by driver / engine shut-off? =>
The error is activated if the engine runs to Stand-still mode does not reach temperature Run stand-still and instruct operator
much time in short Standstill regeneration. 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
temperature level:
Check engine air path: Intake Throttle, EGR-
Valve
and turbocharger okay?
Any leakage in engine air intake system or
exhaust gas system?
Check temperature sensors within exhaust
system: upstream DOC, downstream DOC
If soot load level of DPF allows it:
Perform Stand-still and check reached
temperature level upstream and downstream
DOC: T upstream DOC in the range of 480-
550°C? Downstream DOC after 25 min stand-
still main phase 590°C are reached?
Temperature 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

3-212 3121671
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

524195 14 1900 279 The standstill request of detected Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line and
crystallization is ignored for more than reached a level which indicates crystallization inspect visually the injector and the
5h(>300min) inside of exhaust line. exhaust line for urea crystallization upstream
This will be activated if there is a standstill The error detection depends on the sensed of
request activated by Crystallization pres- SCR catalyst:
Monitoring. sure upstream of the SCR catalyst and If crystallization can be clearly seen, then
the calculated exhaust volume flow through stand- still must be processed.
the mixer pipe. Has the engine been operated in low load for
In case of error is set, but no crystallization can longer time? If yes, then it could be the reason
be found in the mixing pipe, a possible for crystallization.
reason can be the defect sensors: Does the NOx-Sensors work properly?
- exhaust pressure & temperature upstream of Compare
the SCR catalyst, ComRxSCR_rNOxUs to ComRxSCR_rNOxDs,
- the ambient pressure when ComRxSCR_stNOxRdyUs = 1 &
- the exhaust mass flow => Check air path ComRxSCR_stNOxRdyDs = 1 (Warm engine
system 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
status "stand-by" (no dosing),
SCRT_tCatAvrgExhGs_mp < 225°C:
ComRxSCR_rNOxUs = ComRxSCR_rNOxDs
Clean urea injector: rinse it thourougly under
water
Check EGR-Path: difference pressure sensor at
venturi 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?

3121671 3-213
SECTION 3 - CHASSIS & TURNTABLE

Table 3-16. Deutz Engine Fault Codes

Deutz Blink
SPN FMI Description Possible Cause Action
Code Code

5232719 3 1108 672 Urea supply module heater: the current Short circuit to battery Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase threshold
range it is a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply
Heating element in supply module defect module

3-214 3121671
SECTION 3 - CHASSIS & TURNTABLE

3.27 COUNTERWEIGHT
If the counterweight has been removed, ensure the retaining
bolts are torqued to the proper value as shown in Figure 3-
119., Counterweight.

400S :

B, C

460S J :

B, C

MAF 01850

A. Counterweight
B. Apply JLG Threadlocker P/N 0100019 to Bolt Threads and to Threads in Counterweight.
C. Torque to 346 ft. lbs. (469 Nm).

Figure 3-119. Counterweight

3121671 3-215
SECTION 3 - CHASSIS & TURNTABLE

NOTES:

3-216 3121671
SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM

4.1 BOOM SYSTEMS the creep speed mode. With the exception of the speed cut-
back, this is a warning system only. The machine will continue
to function. The operator is responsible to prevent the
Platform Control Enable System machine from attaining an unstable position. The stable con-
The platform controls make use of a time dependent enable dition of the machine is when high engine and high speed is
circuit to limit the time availability of enabled controls. When allowed (at low boom angles).
the footswitch is depressed, the controls are enabled and the
operator has 7 seconds to operate any control. The controls Transport Position Interlock System (CE only)
will remain enabled as long as the operator continues to use
The transport position interlock system uses the Transport
any function and will remain enabled 7 seconds after the last
Position Sensing System to sense when the boom is out of the
function has been used. While the controls are live, the
transport (nearly stowed) position. The articulated jib of the
enabled light will be illuminated in the platform display panel.
460SJ may be in any position. All controls are simultaneously
When the time limit has been reached, the enabled light will
functional when the booms are within the transport position
turn off and the controls will be disabled. To continue use of
as on the standard machine. When the booms are outside of
the machine the controls must be re-enabled to start the timer
the transport position, the control functions are interlocked to
system over again. This is done by releasing all functions, then
prevent simultaneous operation of any boom function with
releasing and re-depressing the footswitch.
drive/steer, for CE only.

Platform Load Sensing System (LSS) (If Equipped) The first function set to be operated in this mode, becomes
The Platform Load Sensing System consists of four load cells, the master function set. In other words, while operating drive/
mounted between the boom and platform support, and a steer functions the boom functions are inoperable. Likewise,
dedicated CAN Bus harness connecting the sensor to the plat- while operating boom functions drive/steer functions are
form console. The operator selects the modes (restricted or inoperable. In addition to being an interlock, this system also
un-restricted zones) he wishes to work in using a dual capacity disallows high speed operation while the booms are beyond
switch on the platform control. The indicators in platform con- the transport position. While in this position, the machine will
trol changes to match the selection. respond in the same way as described in the “Above Elevation
Cutout System” does. As described in the Positive Opening
This system measures the weight in the platform and check if Switch System, the stable condition of the machine is when
it exceeds the capacity limit according to the mode currently the use of multiple function operation is allowed (at low boom
selected. angles and short boom lengths).
The LSS weight reading plays no role in determining the dual
capacity control actions. It will set correct trigger value for
weight based on dual capacity switch locations. If the load in Function Speed Control System
platform exceeds the trigger value, the platform overload indi- The platform controls for the platform rotation, platform level-
cator will flash, the platform alarm will sound at 5 seconds on / ing, jib lift, and main boom telescoping are controlled through
2 seconds off, and all platform controls (except emergency a common infinitely variable speed control knob. This knob
descent) will be disabled. provides a common control signal allowing a smooth ramp up,
controlled maximum output speed, and ramp down. Each
Above Elevation (Above Horizontal) - Drive Speed function has its own personality settings allowing the charac-
teristics of each function to be modified using the standard
Cutback System analyzer. Not all functions will respond the same to the
The above elevation cutout system uses the same angle sen- changes in the function speed knob position.
sor mounted in the pivot end of the lift cylinder to sense when
the boom is raised substantially above horizontal. The articu-
lated jib of the 460SJ may be in any position. When above ele-
vation, the drive motors are automatically restricted to their
maximum displacement position (slow speed).
When used in conjunction with the tilt indicator system, and
depending upon machine setup, the elevation sensor will
cause an alarm to sound and automatically put the machine in

3121671 4-1
SECTION 4 - BOOM & PLATFORM

Main Boom Lift End of Stroke Dampening Transport Position Sensing System
When the lift cylinder is activated to lower or raise the main The transport position sensing system is consisted of a boom
boom, the UGM monitors the main boom angle through an angle sensor (this sensor has built-in redundancy to meet
angle sensor. When the boom is approaching maximum angle safety related regulations) mounted in the pivot end of the lift
and is within 5° of end of stroke, the UGM will slow down the cylinder, and two boom length proxy switches mounted near
travelling speed of the cylinder to provide end of stroke damp- the pivot end of the base boom. The system uses these three
ening by controlling hydraulic valve flow rate of the lift cylin- sensor/switches combination to sense if the boom is in the
der. The damping rate can be adjusted by personal settings position associated with high speed travel. The control circuit
through JLG hand analyzer. reads two redundant angular sensor signals from the boom
angle sensor.
Jib Lift End of Stroke Dampening Above transport angle is recognized when one angular sensor
The Jib Lift cylinder is constructed in a way that causes the Jib signal from the boom angle sensor reads more than 5° greater
Lift cylinder oil flow to be restricted by an orifice while lower- than horizontal (with respect to the turntable), and resets to
ing the jib near the end of stroke at minimum elevation. This within transport position when both angular sensor signals
restriction reduces the speed of the function just before bot- read less than 3° greater than horizontal (with respect to the
toming out the cylinder. turntable).
Transport length is recognized when any one of the two
Machine Safety Override (MSSO) (CE Only) length switches reads more than 12 in. (30.5 cm) extension of
The Machine Safety System Override allows the boom and jib fly boom. During failures of either of the two length switches,
to be lowered in the event that a machine safety system is pre- the system will sense a disagreement. Then it will assume the
venting machine operation. This system uses an additional boom is extended out past the limit. The position of the articu-
button found on the Ground Panel to allow all boom functions lated jib is not considered.
to function from the Ground Station with the engine running.
When MSSO is used, an event will be logged in the JLG Control This system is used to control the following systems:
System and will require service access to clear. • Above Elevation (Above Horizontal) - Drive Speed Cutback
System
• Drive/Steer – Boom Function Interlock System – CE Only
• Oscillating Axle lock up System
• Lift cylinder end of stroke electrical damping stop
The transport position sensing system uses the following com-
ponents:
• Boom angle sensor
• Boom length sensors

4-2 3121671
SECTION 4 - BOOM & PLATFORM

TELESCOPE RETRACTED SENSORS Out of transport:

The Telescope Retracted Sensors measures boom length to The Sensor 1 (left proximity sensor, refer Figure 4-1.) is nor-
control drive speed and the oscillating axle. The two proximity mally open sensor in out of transport condition. LED for Sen-
sensors are used as a safety measure in case one sensor fails. sor 1 is OFF when out of transport condition.
The telescope retracted sensors are mounted on the left side The Sensor 2 (right proximity sensor, refer Figure 4-1.) is nor-
of main boom as shown in Figure 4-3. mally closed sensor in out of transport condition. LED for Sen-
sor 2 is ON when out of transport condition.
In transport:
• The telescope retracted sensors measure the fly boom
The Sensor 1 (left proximity sensor, refer Figure 4-1.) is nor- extension is more than 12 in. (30.5 cm), drive speed is
mally open sensor which is closed in transport condition. LED reduced and oscillating axle is locked.
for Sensor 1 is ON in transport condition. NOTE: In Out Of Transport condition, Using Analyzer under DIAG-
NOSTICS/SYSTEM, TELE RETRAC SW 1 will read OPEN and
The Sensor 2 (right proximity sensor, refer Figure 4-1.) is nor-
TELE RETRAC SW 2 will read OPEN.
mally closed sensor which is open in transport condition. LED
for Sensor 2 is OFF in transport condition.

• The telescope retracted sensors measure the fly boom

extension is less than 12 in. (30.5 cm), drive speed and
oscillating axle are not affected.

NOTE: In Transport condition, Using Analyzer under DIAGNOS-

TICS/SYSTEM, TELE RETRAC SW 1 will read CLOSED and
TELE RETRAC SW 2 will read CLOSED.

Figure 4-1. Telescope Retracted Sensors

3121671 4-3
SECTION 4 - BOOM & PLATFORM

Telescope Retracted Sensors Circuit

Telescope Retracted
Ground Control Module In transport Sensor 1

Retracted Switch

12V Power

Ground

Retracted Switch
Telescope Retracted
Sensor 2

Telescope Retracted
Ground Module Control Out of transport: Sensor 1

Retracted Switch

12V Power

Ground

Retracted Switch
Telescope Retracted
Sensor 2

Figure 4-2. Telescope Retracted Sensors Circuit

4-4 3121671
SECTION 4 - BOOM & PLATFORM

SEE DETAIL B SENSOR 2

SENSOR 1

SEE DETAIL A

DETAIL B

ROTARY ANGLE SENSOR

MUST ACTIVATE WHEN THE BOOM
ANGLE IS AS SPECIFIED BELOW:
DUAL CAPACITY: 51˚±2˚
ABOVE ELEVATION: 5˚±2˚
RESET ABOVE ELEVATION: 3˚±2˚

DETAIL A 1001170642-F
MAF06530

Figure 4-3. Transport Proximity Switch Installation

3121671 4-5
SECTION 4 - BOOM & PLATFORM

DUAL CAPACITY SENSORS - 400S ONLY Restricted Capacity 1000 lbs (454 kg):
The Dual Capacity selection and indicator system consists of a The Sensor 1 (left proximity sensor, refer Figure 4-4.) is nor-
capacity mode toggle switch on platform control box, a set of mally open sensor in unrestricted capacity condition. LED for
fly boom proximity sensors and a main angle boom sensor. Sensor 1 is OFF in this mode.
The system prevents the platform from entering the unre-
The Sensor 2 (right proximity sensor, refer Figure 4-4.) is nor-
stricted 600 lbs (272 kg) zone if the restricted 1000 lbs (454 kg) mally closed sensor in unrestricted capacity condition. LED for
mode is selected. The dual capacity sensors are located on the Sensor 2 is OFF in this mode.
right side of main boom as shown in Figure 4-6.
• The Machine Control Unit will not allow the platform to go
Unrestricted capacity 600 lbs (272 kg): beyond boundaries of the restricted zone. It will allow
retraction of the fly boom or lifting up of the main boom.
The Sensor 1 (left proximity sensor, refer Figure 4-4.) is nor- The restricted capacity envelope is shown in Figure 4-4.
mally open sensor which is closed in unrestricted capacity
NOTE: In Restricted capacity zone, Using Analyzer under DIAG-
condition. LED for Sensor 1 is ON in this mode.
NOSTICS/SYSTEM, CAPACITY SW 1 will read OPEN and
The Sensor 2 (right proximity sensor, refer Figure 4-4.) is nor- CAPACITY SW 2 will read OPEN.
mally closed sensor which is open in unrestricted capacity
condition. LED for Sensor 2 is OFF in this mode.

• The Machine Control Unit will allow the platform to go any-

where in the working envelope. The unrestricted capacity
working envelope is shown in Figure 4-4.

NOTE: In Unrestricted capacity zone, Using Analyzer under DIAG-

NOSTICS/SYSTEM, CAPACITY SW 1 will read OPEN and
CAPACITY SW 2 will read OPEN.

Figure 4-4. Dual Capacity Sensors

4-6 3121671
SECTION 4 - BOOM & PLATFORM

Dual Capacity Sensor Circuit

Unrestricted capacity 600 lbs (272 kg)

Dual Capacity
Ground Control Module Sensor 1

Capacity Switch

12V Power

Ground

Capacity Switch
Dual Capacity
Sensor 2

Restricted capacity 1000 lbs (454 kg)

Dual Capacity
Ground Control Module Sensor 1

Capacity Switch

12V Power

Ground

Capacity Switch
Dual Capacity
Sensor 2

Figure 4-5. Dual Capacity Sensors Circuit

3121671 4-7
SECTION 4 - BOOM & PLATFORM

SEE DETAIL A

CAPACITY LENGTH
LEFT PROX.

COVER

CAPACITY LENGTH
RIGHT PROX.

DETAIL A
1001173233-D
MAF01560

Figure 4-6. Capacity Switch Installation

4-8 3121671
SECTION 4 - BOOM & PLATFORM

4.2 PLATFORM NOTE: The platform support weighs approximately 132 lbs.
(60 kg).

Platform/Support Removal 3. Using a suitable device, support the platform support.

4. Remove the bolts and washers securing the support to
CENTER BOLT the rotator.

ROTATOR

BOLTS

LOCKNUT

PLATFORM SUPPORT

MAF06340 MAF06360

Figure 4-7. Location of Components

1. Disconnect electrical cable from control console. 5. Using a suitable brass drift and hammer, remove the
center bolt and locknut.
NOTE: The platform weighs approximately 176 lbs. (80 kg).

2. Remove the bolts securing the platform to the platform

support, then remove the platform.

MAF06370

MAF06350
6. Remove the platform support from rotator.

3121671 4-9
SECTION 4 - BOOM & PLATFORM

Platform/Support Installation 5. Position the platform on the platform support and

install the bolts securing the platform to the platform
NOTE: The platform support weighs approximately 132 lbs. support. See Figure 4-8. and Figure 4-9.
(60 kg).

1. Using a suitable device, support the platform support

and position it on the rotator.
2. Install the rotator center bolt and locknut.

MAF06350

6. Connect the electrical harness to the platform control

console.

MAF06370

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

securing the support to the rotator and install the bolts.

MAF06360

4. Torque the nut on the rotator center bolt and the retain-
ing bolts. See Figure 4-8. and Figure 4-9.

NOTE: The platform weighs approximately 176 lbs. (80 kg).

4-10 3121671
SECTION 4 - BOOM & PLATFORM

NOTE: If any rotator bolts are replaced, all bolts on the

A, B, D
rotator should be retorqued.

C, D 0272070-H
MAF06730

A Torque to 40 ft. lbs. (55 Nm)

B JLG Threadlocker P/N 0100011
C Torque to 586 ft. lbs. (795 Nm)
D Check torque every 150 hours of operation
E Torque to 75 ft. lbs. (102 Nm)

Figure 4-8. Platform Support Torque Values (Without LSS)

3121671 4-11
SECTION 4 - BOOM & PLATFORM

NOTE: If any rotator bolts are replaced, all bolts on the

rotator should be retorqued.
A,B,D

SINGLE CELL LSSS

1001167596-J
C,D MAF01540

A Torque to 40 ft. lbs. (55 Nm)

B JLG Threadlocker P/N 0100011
C Torque to 586 ft. lbs. (795 Nm)
D Check torque every 150 hours of operation
E Torque to 65 ft. lbs (88 Nm)

Figure 4-9. Platform Support Torque Values (Single Cell LSS)

4-12 3121671
SECTION 4 - BOOM & PLATFORM

4.3 ROTATOR AND PLATFORM LEVEL CYLINDER 460SJ

1. Remove the Platform and Platform Support. Refer Sec-
Removal tion 4.2 - Platform.
Refer Figure 4-10., Removal/Installation of Components - Rota- 2. Extend the fly boom section out to gain access to the
tor and Platform Level Cylinder. platform level cylinder pin.
400S 3. Tag and disconnect hydraulic lines to rotator. Use suit-
able container to retain any residual hydraulic fluid. Cap
1. Remove the Platform and Platform Support. Refer Sec- or plug all openings of hydraulic lines and ports.
tion 4.2 - Platform.
NOTE: The rotator weighs approximately 66 lbs. (30 kg).
2. Extend the fly boom section out to gain access to the
platform level cylinder pin.
NOTE: The jib assembly weighs approximately 816 lbs. (370 kg).
3. Tag and disconnect hydraulic lines to rotator. Use suit-
able container to retain any residual hydraulic fluid. Cap 4. Supporting the rotator and jib assembly, remove hard-
or plug all openings of hydraulic lines and ports. ware from pin #1. Using a suitable brass drift and ham-
mer remove pin #1 from the jib assembly.
NOTE: The rotator weighs approximately 55 lbs. (25 kg).
5. Remove the hardware from pin #2. Using a suitable
4. Supporting the rotator, remove hardware from pin #1. brass drift and hammer, remove pin #2 from the jib
Using a suitable brass drift and hammer remove pin #1. assembly and remove the rotator.

NOTE: The platform level cylinder weighs approximately 66 lbs. NOTE: The platform level cylinder weighs approximately 66 lbs.
(30 kg). (30 kg).

5. Supporting the platform level cylinder, remove the 6. Supporting the platform level cylinder, remove the
hardware from pin #2. Using a suitable brass drift and hardware from pin #3. Using a suitable brass drift and
hammer, remove pin #2 from the fly boom and remove hammer remove pin #3 from the jib assembly.
the rotator. 7. Remove the hardware from pin #4. Using a suitable
6. Tag and disconnect hydraulic lines to platform level cyl- brass drift and hammer remove pin #4 from the fly
inder. Use suitable container to retain any residual boom. Remove the platform level cylinder.
hydraulic fluid. Cap or plug all openings of hydraulic
lines and ports.
7. Remove the hardware from pin #3. Using a suitable
brass drift and hammer remove pin #3 from the fly
boom and remove platform level cylinder.

3121671 4-13
SECTION 4 - BOOM & PLATFORM

ROTATOR

1
JIB

460SJ

3
ROTATOR
PLATFORM LEVEL
CYLINDER

4
1
2

400S

PLATFORM LEVEL
CYLINDER

MAF01880

Figure 4-10. Removal/Installation of Components - Rotator and Platform Level Cylinder

4-14 3121671
SECTION 4 - BOOM & PLATFORM

Installation 460SJ
Refer Figure 4-10., Removal/Installation of Components - Rota- NOTE: The platform level cylinder weighs approximately 66 lbs.
tor and Platform Level Cylinder. (30 kg).
400S 1. Support the platform level cylinder. Using a soft head
NOTE: The platform level cylinder weighs approximately 66 lbs. mallet, install pin #4 to the fly boom. Install hardware
(30 kg). securing pin #4.

NOTE: The jib assembly weighs approximately 816 lbs. (370 kg).
1. Support the platform level cylinder. Using a suitable
brass drift and hammer, install pin #3 to the fly boom. 2. Support the jib assembly. Using a soft head mallet install
Install hardware securing pin #3. pin #3 to jib assembly. Install hardware securing pin #3.
NOTE: The rotator weighs approximately 55 lbs. (25 kg). NOTE: The rotator weighs approximately 66 lbs. (30 kg).
2. Support the rotator. Using a suitable brass drift and 3. Support the rotator. Using a soft head mallet, install pin
hammer, install pin #2 to the fly boom. Install hardware #2 to the jib assembly. Install hardware securing pin #2.
securing pin #2.
4. Using head mallet install pin #1 to jib assembly and
3. Using a suitable brass drift and hammer, install pin #1 to install the rotator. Install hardware securing pin #1 and
the rotator. Install hardware securing pin #1 and torque torque to 40 ft. lbs. (55 Nm).
to 40 ft. lbs. (55 Nm).
5. Remove cap or plugs from openings of hydraulic lines
4. Remove cap or plugs from openings of hydraulic lines and ports and connect hydraulic lines to rotator and
and ports and connect hydraulic lines to rotator and platform level cylinder as tagged during removal.
platform level cylinder as tagged during removal.

3121671 4-15
SECTION 4 - BOOM & PLATFORM

4.4 MAIN BOOM POWERTRACK 6. With powertrack supported and using all applicable
safety precautions, remove bolts #2, and #3 securing rail
to the carrier tube and push tube. Remove powertrack
Removal from boom.
1. Disconnect wiring harness connectors located in turnta-
ble. Installation
2. Tag and disconnect hydraulic lines from connectors at 1. Using suitable lifting equipment, adequately support
boom assembly. Use suitable container to retain any the powertrack weight along entire length.
residual hydraulic fluid. Cap or plug all openings of
hydraulic lines and ports. NOTE: The powertrack weighs approximately 44 lbs. (20 kg).
3. Remove hydraulic lines and electrical cables from pow-
ertrack. 2. With powertrack supported and using all applicable
safety precautions, align and install bolts #2 and #3
4. Using suitable lifting equipment, adequately support securing rail to the carrier tube and push tube.
powertrack weight along entire length.
3. Install bolts #1 securing the push tube on the fly boom.
NOTE: The powertrack weighs approximately 44 lbs. (20 kg).
4. Remove cap or plugs from opening of hydraulic lines
5. Remove bolts #1 securing the push tube on the fly and port connect all hydraulic lines and electrical cable
boom. to the powertrack as tagged during removal.

PUSH TUBE

MAF01890

Figure 4-11. Location of Components - Powertrack

4-16 3121671
SECTION 4 - BOOM & PLATFORM

PUSH TUBE

SEE DETAIL B
POWERTRACK
ASSEMBLY

POWERTRACK
ASSEMBLY

SEE DETAIL A

DETAIL B

WEAR PAD

DETAIL A

SUPPORT PLATE

1001165538-D
MAF01550

Figure 4-12. Powertrack Installation

3121671 4-17
SECTION 4 - BOOM & PLATFORM

Powertrack Maintenance 2. Repeat step 1 and remove screw from other side of
track. Remove bar/poly roller from powertrack.
REMOVE LINK
NOTE: Hoses shown in powertrack are for example only. Actual
hose and cable arrangements are different.

1. Clamp bar and poly roller tightly so they do not spin

when removing screw. With a small 1/4 in. ratchet and a
T-20 torx bit, remove 8-32 x 0.500 screw from one side.

4-18 3121671
SECTION 4 - BOOM & PLATFORM

NOTE: It may be necessary to loosen fixed end brackets from

machine to move track section enough to disconnect links.
REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE-
VENT DAMAGE.

3. To remove a link, rivets holding links together must be

removed. Use a right-angle pneumatic die grinder with
a 1/4 in. ball double cut bur attachment.

4. Insert tool into rolled over end of rivet. Grind out middle
of rivet until rolled over part of rivet falls off. Repeat for
all rivets to be removed.

5. After grinding it may be necessary to use a center punch

with a hammer to remove rivet.

3121671 4-19
SECTION 4 - BOOM & PLATFORM

6. Insert flat head screwdriver between links. Twist and pull 7. Remove link from other section of powertrack using
links apart. screwdriver.

4-20 3121671
SECTION 4 - BOOM & PLATFORM

INSTALL NEW LINK 2. Spread half-shear (female) end of new link and slide cut-
out end of track section into it. Use a screwdriver if nec-
1. Squeeze cut-out end of new link into half-shear (female) essary.
end of track section.

3. After new link is installed round half-shears do not fit

properly in cut-outs.

3121671 4-21
SECTION 4 - BOOM & PLATFORM

4. Pull moving end over track so new connection is posi- 6. Push pin through center hole then slide washer on pin.
tioned in curve of powertrack. Round half-shears will
rotate into cut-outs.

7. Install snap ring in groove on pin. Repeat pin installation

steps for all center holes with rivets removed.

5. Parts shown below connect new link to powertrack.

4-22 3121671
SECTION 4 - BOOM & PLATFORM

NOTE: Make sure snap rings are seated in pin groove and closed 2. Pull up on other end of round bar and slide new poly
properly. roller on bar.

Correct Incorrect

1. Install new 8-32 x 0.500 self-threading torx head screw

in end of new aluminum round bar. Torque to
18-20 in. lbs. (2-2.25 Nm).

3121671 4-23
SECTION 4 - BOOM & PLATFORM

3. Install new 8-32 x 0.500 self threading screw on other REPLACE FIXED END BRACKETS
side. Torque to 18-20 in. lbs. (2-2.25 Nm).

REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE-

VENT DAMAGE.

1. Remove rivets as shown in link removal instructions on

page 4-19.

NOTE: When tightening screws make sure screw head is seated

against link with no space in between link and underside of
screw head.

4-24 3121671
SECTION 4 - BOOM & PLATFORM

2. Parts used: Bracket Center Pin and Center Pin Snap Ring. REPLACE MOVING END BRACKETS

3. Take new bracket and install bracket center pin and

snap ring. Repeat on other bracket if replacing it.
REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE-
VENT DAMAGE.

1. Remove existing pins and center rivet. Remove rivet as

shown in link removal instructions on page 4-19. Repeat
on other bracket if replacing it.

NOTE: When installing snap rings make sure they are seated in
pin groove and closed properly.

Correct Incorrect

3121671 4-25
SECTION 4 - BOOM & PLATFORM

2. Install center pin with snap ring in new bracket. NOTE: When installing snap rings make sure they are seated in
pin groove and closed properly.

Correct Incorrect

4. Make sure both brackets rotate correctly.

3. Install radius pins and snap rings in original locations.
Repeat with other moving end if replacing it.

4-26 3121671
SECTION 4 - BOOM & PLATFORM

4.5 BOOM ASSEMBLY 4. Remove bolt and keeper pin from main lift cylinder pin
#1. Using a suitable brass drift and hammer, remove the
cylinder pin #1 securing main lift cylinder to main boom.
Removal
NOTE: The master cylinder weighs approximately 66 lbs. (30 kg).
NOTE: The 400S main boom assembly weighs approximately
1300 lbs. (600 kg). The 460SJ main boom assembly weighs
approximately 1700 lbs. (790 kg). 5. Remove bolt and keeper pin from master cylinder pin
#2. Using a suitable brass drift and hammer, remove the
1. Remove the jib and platform assembly. Refer to cylinder pin #2 securing master cylinder to main boom.
Section 4.2 - Platform and Section 4.6 - Jib (460SJ Only).
6. Remove bolt and keeper pin from main boom pin #3.
2. Using suitable lifting device, adequately support boom Using a suitable brass drift and hammer, remove the pin
assembly weight along entire length. #3 securing main boom to turntable.

3. Attach an adequate supporting device to the main lift 7. Tag and disconnect hydraulic lines from telescope cylin-
cylinder and master cylinder to support its weight. der. Use suitable container to retain any residual hydrau-
lic fluid. Cap or plug all openings of hydraulic lines and
NOTE: The main lift cylinder weighs approximately 260 lbs.
ports.
(118 kg).
8. Using all applicable safety precautions, carefully lift
boom assembly clear of turntable and lower to ground
or suitably supported work surface.

3 MASTER CYLINDER

MAIN LIFT
CYLINDER

1 MAF01900

Figure 4-13. Main Boom Removal

3121671 4-27
SECTION 4 - BOOM & PLATFORM

Disassembly NOTE: The telescope cylinder weighs approximately 367 lbs.

(166 kg).
1. Using a portable power source, attach hose to telescope
cylinder port block. Using all applicable safety precau- 5. Using a suitable lifting device, remove telescope cylin-
tions, activate hydraulic system and extend cylinder to der from boom.
gain access to cylinder rod retaining pin. Shut down
6. Tag and disconnect all hoses and wires from front of fly
hydraulic system.
boom and bottom of base boom for reassembly.
7. Remove hardware securing the front wear pads on base
boom section, remove wear pads.

TELESCOPE CYLINDER

MAF01910

2. Carefully disconnect hydraulic hose from retract port of

cylinder. There will be initial weeping of hydraulic fluid
which can be caught in a suitable container. After initial
discharge, there should be no further leakage from the
retract port.
3. Remove hardware securing telescope cylinder pin to Fly
Boom. Using a suitable brass drift and hammer, remove MAF01960
the telescope cylinder pin securing telescope cylinder to
fly boom. 8. Using a suitable lifting device, remove fly boom from
base boom section.
4. Remove hardware securing telescope cylinder to the
base boom section. NOTE: The 400S fly boom section weighs approximately 290 lbs.
(131 kg). The 460SJ fly boom section weighs approximately
350 lbs. (159 kg).

MAF01920

4-28 3121671
SECTION 4 - BOOM & PLATFORM

9. If necessary, remove the wear pads from the rear of the Assembly
fly boom section.
1. Using JLG threadlocker P/N 0100011 or equivalent,
install the bottom wear pads and shims as noted during
disassembly on the rear of the fly section. Install the rest
of the wear pads on the rear of the fly boom but do not
install the shims or torque them at this time.

MAF01940

Inspection
1. Inspect all boom pivot pins for wear, scoring or other
damage, and for tapering or ovality. Replace pins as nec- MAF01940
essary.
2. Using a suitable lifting equipment, lift and slide tele-
2. Inspect lift cylinder pins for wear, scoring or other dam- scope cylinder into the aft end of fly boom. Align attach-
age, and for tapering or ovality. Ensure pin surfaces are ment holes in fly boom section with hole in rod end of
protected prior to installation. Replace pins as neces- telescope cylinder.
sary.
3. Install telescope cylinder pin and secure with retaining
3. Inspect telescope cylinder rod attach pin for wear, scor- rings.
ing or other damage. Replace pin as necessary.
4. Inspect inner diameter of boom pivot bushings for scor-
ing, distortion, wear or other damage. Replace bushings
as necessary.
5. Inspect wear pads for wear.
6. Inspect all threaded components for damage such as
stretching, thread deformation, or twisting. Replace as
necessary.
7. Inspect structural units of boom assembly for bending,
cracking, separation of welds, or other damage. Replace
boom sections as necessary.

MAF01950

3121671 4-29
SECTION 4 - BOOM & PLATFORM

4. Using suitable lifting equipment, slide fly boom assem- 6. Using JLG threadlocker P/N 0100011 or equivalent,
bly into the base section until the telescope cylinder install wear pads at front end of base boom. Using
attach point aligns with holes in side of base section. shims, adjust the adjustable wear pads to zero clear-
ance. Adjust pads alternately side to side, so that fly
NOTE: The 400S fly boom section weighs approximately 660 lbs. boom section is centered in base boom section.
(300 kg). The 460SJ fly boom section weighs approximately
720 lbs. (325 kg).

5. Align bolt holes at aft end of base boom section with

telescope cylinder port block. Secure telescope cylinder
with hardware.

MAF01960
MAF01920
7. Retract boom section fully. Using shims, adjust wear
pads at aft end of boom section to zero clearance.
Adjust pads alternately side to side, so that fly boom sec-
tion is centered in base boom section.
8. Disconnect auxiliary power source from telescope cylin-
der.

4-30 3121671
SECTION 4 - BOOM & PLATFORM

Installation 4. Extend the master cylinder by using auxiliary power if

required. Install the master cylinder rod end pin #2 into
NOTE: The 400S main boom alone weighs approximately 1300 the base boom. Using a soft head mallet, install mount-
lbs. (600 kg). The 460 SJ main boom alone weighs approxi- ing hardware secured to the master cylinder rod end pin
mately 1700 lbs. (790 kg) into the base boom section.

1. Using all applicable safety precautions, carefully lift NOTE: The main boom lift cylinder weighs approximately
boom assembly to align the pivot holes in the boom 260 lbs. (118 kg).
with those of the turntable.
2. Using a soft head mallet, install the pivot pin #3 into the 5. Using an adequate supporting device, align the main
turntable. Install the bolt and keeper pin securing the boom lift cylinder with the mounting holes on the boom
boom pivot pin #3 to the turntable. section.
3. Using an adequate supporting device, align the master
6. Extend the main boom lift cylinder by using auxiliary
cylinder with the mounting holes on the boom and
power if required. Using a soft head mallet, install hard-
turntable.
ware to secure the main boom lift cylinder rod end pin
NOTE: The master cylinder weighs approximately 66 lbs. (30 kg). #1 into the base boom section.

NOTE: When installing the master cylinder rod end pin, insert the 7. Remove cap or plugs and connect hydraulic lines to tele-
keeper hardware pin to prevent the pin from inserting too scope cylinder as tagged during removal. Torque hose
far. fittings to 40 ft. lbs. (55 Nm).

3 MASTER CYLINDER

MAIN LIFT
CYLINDER

1 MAF01900

Figure 4-14. Main Boom Installation

3121671 4-31
SECTION 4 - BOOM & PLATFORM

4.6 JIB (460SJ ONLY) Inspection

NOTE: When inspecting pins and bearings Refer to Section 2.5 -
Removal
Pins and Composite Bearing Repair Guidelines.
1. For platform and support removal see Section 4.2 - Plat-
form. 1. Inspect fly boom pivot pin for wear, scoring, tapering
and ovality, or other damage. Replace pins as necessary.
NOTE: The jib assembly weighs approximately 816 lbs. (370 kg).
Using a suitable lifting device, support the jib assembly. 2. Inspect fly boom pivot attach points for scoring, taper-
ing and ovality, or other damage. Replace pins as neces-
2. Position the jib level with ground. sary.
3. Tag and disconnect hydraulic lines from platform level 3. Inspect inner diameter of fly boom pivot bearings for
cylinder and jib lift cylinder. Use suitable container to scoring, distortion, wear, or other damage. Replace bear-
retain any residual hydraulic fluid. Cap or plug all open-
ings as necessary.
ings of hydraulic lines and ports.

4. Remove mounting hardware from platform level cylin- 4. Inspect lift cylinder attach pin for wear, scoring, tapering
der pin #1. Using a suitable brass drift and hammer, and ovality, or other damage. Ensure pin surfaces are
remove the cylinder pin from jib assembly. protected prior to installation. Replace pins as neces-
sary.
5. Remove mounting hardware from jib assembly boom
pivot pin #2. Using a suitable brass drift and hammer, 5. Inspect inner diameter of rotator attach point bearings
remove the pivot pin from boom assembly. Remove the for scoring, distortion, wear, or other damage.
jib assembly from the machine.
6. Inspect all threaded components for damage such as
Disassembly stretching, thread deformation, or twisting. Replace as
necessary.
1. Remove mounting hardware from jib pivot pins #3 and
#4. Using a suitable brass drift and hammer, remove the 7. Inspect structural units of jib boom assembly for bend-
pins from jib pivot weldment. ing, cracking, separation of welds, or other damage.
Replace boom sections as necessary.
2. Remove mounting hardware from rotator support pins
#5 and #6. Using a suitable brass drift and hammer,
remove the pins from rotator support. Assembly
3. Remove mounting hardware from lift cylinder pin #7. 1. Align rod end of lift cylinder with attach holes in jib
Using a suitable brass drift and hammer, remove the cyl- assembly. Using a soft head mallet, install cylinder pin
inder pin from articulating jib boom. #7 into jib and secure with mounting hardware.
JIB BOOM PIVOT
2 4 2. Align rotator support with attach hole in jib assembly.
Using a soft head mallet, install rotator support pin #6
into jib and secure with mounting hardware.
JIB
3. Align bottom tubes with attach holes in rotator support.
7
Using a soft head mallet, install rotator support pin #5
1 into jib assembly and secure with mounting hardware.
PLATFORM 3
LEVEL 4. Align jib assembly with attach hole in jib boom pivot
CYLINDER
weldment. Using a soft head mallet, install rotator sup-
port pin #4 into jib assembly and secure with mounting
JIB LIFT
CYLINDER hardware.
6 5. Align bottom tubes with attach holes in jib boom pivot
5 weldment. Using a soft head mallet, install rotator sup-
MAE17191
port pin #3 into jib boom pivot weldment and secure
with mounting hardware.

4-32 3121671
SECTION 4 - BOOM & PLATFORM

Installation 4.7 BOOM CLEANLINESS GUIDELINES

1. Align jib boom pivot weldment with attach holes in fly Following are guidelines for internal boom cleanliness for
boom assembly. Using a soft head mallet, install pivot machines that are used in excessively dirty environments.
pin #2 into fly boom assembly and secure with mount-
1. JLG recommends use of the JLG Hostile Environment
ing hardware.
Package if available to keep internal portions of a boom
2. Align the platform level cylinder with attach holes in jib cleaner and to help prevent dirt and debris from enter-
boom pivot weldment. Using a soft head mallet, install ing the boom. This package reduces amount of contam-
platform level cylinder pin #1 into jib pivot weldment ination which can enter the boom but does not
and secure with mounting hardware. eliminate the need for more frequent inspections and
maintenance when used in these types of environ-
JIB BOOM PIVOT ments.
2 4
2. JLG recommends you follow all guidelines for servicing
JIB your equipment in accordance with instructions out-
lined in the JLG Service & Maintenance Manual for your
machine. Periodic maintenance and inspection is vital to
7
proper operation of the machine. The frequency of ser-
1 vice and maintenance must be increased as environ-
PLATFORM 3
ment, severity and frequency of usage requires.
LEVEL
CYLINDER 3. Debris and foreign matter inside the boom can cause
premature failure of components and should be
JIB LIFT removed. Methods to remove debris should always be
CYLINDER done using all applicable safety precautions outlined in
6 JLG Service & Maintenance Manuals.

5 4. The first attempt to remove debris from inside the boom

MAE17191 must be to utilize pressurized air to blow debris toward
the nearest exiting point from the boom. Make sure all
debris is removed before operating machine.
3. Remove cap or plugs from openings of hydraulic lines
5. If pressurized air cannot dislodge debris, then water
and ports and connect hydraulic lines to platform level
with mild solvents applied via a pressure washer can be
cylinder and jib lift cylinder as tagged during removal.
used. Again the method is to wash the debris toward the
nearest exiting point from the boom. Make sure all
debris is removed, that no “puddling” of water has
occurred, and boom internal components are dry prior
to operating machine. Make sure you comply with all
federal and local laws for disposing wash water and
debris.
6. If pressurized air or washing does not remove debris,
disassemble boom in accordance to instructions out-
lined in the JLG Service & Maintenance Manual to
remove debris.

3121671 4-33
SECTION 4 - BOOM & PLATFORM

4.8 BOOM SHIMMING PROCEDURE 2. Positions #7/8 must match positions #3/4. Verify that
no more shims will fit on either side.
NOTE: When installing wear pads, the wear pad bolt lengths may
need to be adjusted as shim thicknesses are adjusted. Bolt
lengths should be flush or up to one thread below the sur-
face of the insert.

1. Measure and take note of the inside width and inside

height of the base boom opening for reference later in
this procedure.

2. Install the side wear pads on the fly boom and shim as
required to match the corresponding dimension
recorded in Step 1 within +0/-1.2 mm. Shims should be
divided as evenly as possible between the sides of the
boom. The number of shims installed at position #1
must match with position #2, and position #3 must
match position #4 as shown below. Take note to how
many shims are installed in each position.

Figure 4-16. Base Boom Wear Pads

NOTE: Do not use a wedge to install more shims than will fit with
the use of a pry bar. This may result in the boom being
shimmed too tight. The use of pry bars should only be used
to finish installing a shim that can be installed by hand
more than half of its length.

8. Install the top wear pads and shims into the base boom
leaving a gap of 0 mm to 1.2 mm between the top of the
fly boom and the inside of the base boom.

Figure 4-15. Fly Boom Wear Pads

3. Install the top wear pads and shims on the fly boom.

4. Install the bottom wear pads on the fly boom and shim
as required to obtain the total base boom dimension
within +0/-1.2 mm of the corresponding dimension
from Step 1.

5. Slide the fly boom into the base boom, leaving 1 to 2

meters exposed.

6. Install the bottom wear pads and shims into the end of
the base boom.

7. Install the side pads and shims into the base boom. Dis-
tribute shims to each side to match the distribution
noted in Step 2. Positions #5/6 must match positions #1/

4-34 3121671
SECTION 4 - BOOM & PLATFORM

4.9 ROTATOR ASSEMBLY The shaft is supported radially by the large main radial bearing
and the lower radial bearing. Axially, the shaft is separated
from the housing by the main and lower thrust washers. The
Theory of Operation end cap is adjusted for axial clearance and locked in position
by set screws or pins.
The rotary actuator is a simple mechanism that uses the slid-
ing spline operating concept to convert axial piston motion The actuators are equipped with factory installed counterbal-
into powerful shaft rotation. Each actuator is composed of a ance valves, which performs four major functions.
housing with integrated gear ring (1) and only two moving • Protects the actuator in the event of overload.
parts: the central shaft with integrated bearing tube and
• Enables the actuator to hold position without drifting
mounting flange (2), and the annular piston sleeve (3). Helical when external loads are applied.
spline teeth machined on the shaft engage matching splines
on the inside diameter of the piston. The outside diameter of • Reduces hydraulic backlash by pressuring the hydraulic
the piston carries a second set of splines, of opposite hand, fluid.
which engage with matching splines in the housing. As Provides a constant controlled rate of rotation in over-center
hydraulic pressure is applied, the piston is displaced axially load conditions.
within the housing similar to the operation of a hydraulic cyl-
inder while the splines cause the shaft to rotate. When the
control valve is closed, oil is trapped inside the housing, pre-
venting piston movement and locking the shaft in position.

Bars indicate starting positions of piston and Applying fluid pressure will displace the piston axially
shaft. Arrows indicate direction they will rotate. while the helical gearing causes the piston and shaft
The housing with integral ring gear remains sta- to rotate simultaneously.
tionary.
The double helix design compounds rotation: shaft
rotation is about twice that of the piston. Applying
pressure to the opposite port will return the piston
and shaft

3121671 4-35
SECTION 4 - BOOM & PLATFORM

Required Tools Making a Seal Tool

The seal tool is merely a customized standard flat head screw-
Upon assembly and disassembly of the actuator there are driver.
basic tools required. The tools and their intended functions are
as follows:
2. 4.
3. TO AVOID INJURY BE CAREFUL WHILE HANDLING THE HOT SCREWDRIVER.
1.
1. Heat the flat end with a torch until it glows.
5.
2. Secure the heated end of the screwdriver in a vise and
bend the heated end to a slight radius.
12.
13.
11. 3. Round off all sharp edges of the heated to a polished fin-
6. 8. ish. The tool may be modified slightly to your own per-
sonal preference. To avoid injury be careful while
7. handling the hot screwdriver.
16.
14. 15.
9. 10.

1. PIPE VISE Before Disassembly

2. HEX WRENCH - Removal and replacement of port plugs Inspect the actuator for corrosion prior to disassembly. Severe
and setscrews. corrosion can make it difficult to remove the lock pins (109)
and unthread the end cap (04). If corrosion is evident, soak the
3. ASSORTED SCREWS lock pins and end cap with penetrating oil for several hours
before disassembly.
4. SAFETY GLASSES
Disassembly is considerably easier if the actuator is firmly
5. END CAP REMOVAL TOOLS (provided with Helac seal secured to the work bench. A pipe vise or mounting fixture
kit). work well.
6. DRILL

7. FLASHLIGHT - Helps to locate and examine timing

marks, component failure and overall condition.

8. RUBBER MALLET - Removal and installation of shaft and

piston sleeve assembly.

9. PLASTIC MANDREL

10. PRY BAR - Removal of end cap and manual rotation of

shaft.

11. FELT MARKER - Highlights the timing marks and outline

troubled areas.

12. T-HANDLE SCREW EXTRACTOR

13. HEX WRENCH SET - Removal and replacement of port

plugs and setscrews (106 &110).

14. SEAL TOOLS - Removal and installation of seals and wear

guides. Directions to make a seal tool are provided
below making a Seal Tool.

15. PUNCH

16. DOWEL PINS - Removal and installation of end cap.

4-36 3121671
SECTION 4 - BOOM & PLATFORM

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 106. Port Plug 200. T-Seal 302. Wear Guide 401. Counterbalance Valve
2. Shaft 109. Lock Pin 202. T-Seal 304. Thrust Washer 420. Bushing
3. Piston Sleeve 113. Capscrew 204. O-ring 421 Bushing
4. End Cap 205. Cup Seal
206. Exclusion Seal
207. Backup Ring

Figure 4-17. Rotator - Exploded View

3121671 4-37
SECTION 4 - BOOM & PLATFORM

420.1

01 A

420.2

202

200

400

02 204 207

421
421

04
205

206 206

304 302 03 103

2
302 205 304
A
109 106 113
2 2 4

401

VIEW A-A
90°

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 106. Port Plug 202. T-Seal 304. Thrust Washer 401. Counterbalance Valve
3. Piston Sleeve 109. Lock Pin 204. O-ring 420.1 Bushing
4. End Cap 113. Capscrew 205. Cup Seal 420.2 Bushing
206. Exclusion Seal 421 Bushing
207. Backup Ring

Figure 4-18. Rotator - Assembly Drawing

4-38 3121671
SECTION 4 - BOOM & PLATFORM

Disassembly 3. Remove the lock pins using an ”Easy Out” (a size #2 is

shown). If the pin will not come out with the ”Easy Out”,
use 5/16 in. drill bit to a depth of 1/2 in. (12.7 mm) to drill
out the entire pin.
SECURE PRODUCT TO SLOTTED TABLE OR VISE.

CONTENTS UNDER PRESSURE. WEAR APPROVED EYE PROTECTION. USE CAU-

TION WHEN REMOVING PORT PLUGS AND FITTINGS.

MAKE SURE WORK AREA IS CLEAN.

1. Remove the cap screws (113) over end cap lock pins
(109).

4. Install the end cap (4) removal tools provided with the
Helac seal kit.

2. Using a 1/8 in. (3.18 mm) drill bit, drill a hole in the cen-
ter of each lock pin to a depth of approximately 3/16 in.
(4.76 mm).

5. Using a metal bar, or similar tool, unscrew the end cap

(4) by turning it counter clockwise.

3121671 4-39
SECTION 4 - BOOM & PLATFORM

6. Remove the end cap (4) and set aside for later 8. Every actuator has timing marks for proper engage-
inspection. ment.

7. Remove the stop tube if equipped. 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.

4-40 3121671
SECTION 4 - BOOM & PLATFORM

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
now be timing marks on the housing (1) ring gear, the end 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.

3121671 4-41
SECTION 4 - BOOM & PLATFORM

16. To remove the main pressure seals (205), it is easiest to 19. Remove the piston O.D. seal (202) from the piston.
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).

4-42 3121671
SECTION 4 - BOOM & PLATFORM

Inspection 3. Inspect the wear guide condition and measure thick-

ness (not less than 0.123 in. or 3.12 mm).

SMALL OR MINOR SURFACE SCRATCHES CAN BE CAREFULLY POLISHED.

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 in. or
2.34 mm).

3121671 4-43
SECTION 4 - BOOM & PLATFORM

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 o-ring) into the 5. Install the wear guide (302) on the end cap (4) and
groove on the shaft (2) and end cap (4) around the out- shaft (2).
side edge of the thrust washer (304).

4-44 3121671
SECTION 4 - BOOM & PLATFORM

6. Install the O-ring (204) and back-up ring (207) into the 8. Beginning with the inner seal (200) insert one end of b/u
inner seal groove on the end cap (4). ring in the lower groove and feed the rest in using a cir-
cular motion. Make sure the wedged ends overlap cor-
rectly.
Repeat this step for the outer seal (202).

7. 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. 9. Insert the piston (3) into the housing (1) as shown, until
the outer piston seal (202) is touching inside the hous-
Each T-seal has 2 back-up rings (see drawing for orienta- ing bore.
tion).

3121671 4-45
SECTION 4 - BOOM & PLATFORM

10. Looking from the angle shown, rotate the piston (3) until 12. Install the shaft (2) into the piston (3). Be careful not to
the marks you put on the piston and the housing (1) damage the seals. Do not engage the piston gear teeth
during disassembly line up as shown. Using a rubber yet.
mallet, tap the piston into the housing up to the point
where the gear teeth meet.

13. Looking from the view shown, use the existing timing
11. Looking from the opposite end of the housing (1) you marks to line up the gear teeth on the shaft (2) with the
can see if your timing marks are lining up. When they do, gear teeth on the inside of the piston (3). Now tap the
tap the piston (3) in until the gear teeth mesh together. flange end of the shaft with a rubber mallet until the
Tap the piston into the housing the rest of the way until gear teeth engage.
it bottoms out.

4-46 3121671
SECTION 4 - BOOM & PLATFORM

14. Install 2 bolts in the threaded holes in the flange. Using a 17. Install the 0-ring (204) and back-up ring (207) into the
bar, rotate the shaft in a clockwise direction until the inner seal groove on the end cap (4).
wear guides are seated inside the housing bore.

AS THE SHAFT IS ROTATED, BE CAREFUL NOT TO DISENGAGE THE PISTON AND

HOUSE GEARING.

18. Thread the end cap (4) onto the shaft (2) end. Make sure
the wear guide remains in place on the end cap as it is
threaded into the housing (1).

15. Install the stop tube onto the shaft end, if equipped.
Stop tube is an available option to limit the rotation of
an actuator.
16. Coat the threads on the end of the shaft with anti-seize
grease to prevent galling.

3121671 4-47
SECTION 4 - BOOM & PLATFORM

19. Tighten the end cap (4). In most cases the original holes 21. Insert the set screws (113) over the lock pins. Tighten
for the lock pins will line up. them to 25 in. lbs. (2.825 Nm).

20. Place the lock pins (109) provided in the Helac seal kit in
the holes with the dimple side up. Then, using a punch,
tap the lock pins to the bottom of the hole.

4-48 3121671
SECTION 4 - BOOM & PLATFORM

Installing Counterbalance Valve Threadlocker P/N 0100011 should be applied to the

shank of the three bolts at the time of installation.
Refer to Figure 4-19., Rotator Counterbalance Valve.
4. Torque the 1/4 in. bolts 110 to 120 in. lbs. (12.4 to
1. Make sure the surface of the actuator is clean, free of any 13.5 Nm). Do not torque over 125 in. lbs. (14.1 Nm).
contamination and foreign debris including old JLG Torque the 5/16 in. bolts 140 in. lbs. (15.8 Nm). Do not
Threadlocker P/N 0100011. torque over 145 in. lbs. (16.3 Nm).
2. Make sure the new valve has the o-rings in the counter- 5. Make sure the valve is seated against the housing valve
bores of the valve to seal it to the actuator housing. flat. If it is raised up on any side or corner, remove the
3. The bolts that come with the valve are grade 8 bolts. valve to determine what the obstruction is. If possible,
New bolts should be installed with a new valve. JLG test this using a hydraulic hand pump or electric test.

Figure 4-19. Rotator Counterbalance Valve

3121671 4-49
SECTION 4 - BOOM & PLATFORM

Greasing Thrust Washers Testing the Actuator

1. After the actuator is assembled but before it is put into If the equipment is available, the actuator should be tested on
service, the thrust washer area must be packed with a hydraulic test bench. The breakaway pressure — the pres-
Lithium grease. sure at which the shaft begins to rotate — should be approxi-
mately 400 psi (28 bar). Cycle the actuator at least 25 times at
2. There are two grease ports located on both the shaft 3000 psi (210 bar) pressure. After the 25 rotations, increase the
flange and the end cap. They are plugged with cap pressure to 4500 psi (315 bar) to check for leaks and cracks.
screws (113) or set screws. Remove the grease port Perform the test again at the end of the rotation in the oppo-
screws from the shaft flange and end cap. (See exploded site direction.
view)
TESTING THE ACTUATOR FOR INTERNAL LEAKAGE
If the actuator is equipped with a counterbalance valve, plug
the valve ports. Connect the hydraulic lines to the housing
ports. Bleed all air from the actuator (see Installation and
Bleeding) Rotate the shaft to the end of rotation at 3000 psi
(210 bar) and maintain pressure. Remove the hydraulic line
from the non-pressurized side.
Continuous oil flow from the open housing port indicates
internal leakage across the piston. Replace the line and rotate
the shaft to the end of rotation in the opposite direction.
Repeat the test procedure outlined above for the other port. If
there is an internal leak, disassemble, inspect and repair.

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
CAP SCREWS INSERTED INTO THE SHAFT FLANGE TO TURN THE SHAFT IN THE
DESIRED DIRECTION.

3. Insert the tip of a grease gun into one port and apply
grease to the shaft flange. Continue applying until
grease flows from the opposite port. Cycle the actuator
five times and apply grease again. Repeat this process
on the end cap. Insert the cap screws into the grease
ports and tighten to 25 in. lbs. (2.8 Nm).

4-50 3121671
SECTION 4 - BOOM & PLATFORM

Installation and Bleeding 2. With an operator in the platform, open both bleed nip-
ples 1/4 turn. Hydraulically rotate the platform to the
After installation of the actuator on the equipment, it is impor- end of rotation (either clockwise or counterclockwise),
tant that all safety devices such as tie rods or safety cables are and maintain hydraulic pressure. Oil with small air bub-
properly reattached. bles will be seen flowing through the tubes. Allow a 1/2
gallon of fluid to be purged from the actuator.
To purge air from the hydraulic lines, connect them together
to create a closed loop and pump hydraulic fluid through 3. Keep the fittings open and rotate the platform in the
them. Review the hydraulic schematic to determine which opposite direction to the end position. Maintain hydrau-
hydraulic lines to connect. The linear feet and inside diameter lic pressure until an additional 1/4 gallon of fluid is
of the hydraulic supply lines together with pump capacity will pumped into the container.
determine the amount of pumping time required to fully
purge the hydraulic system. 4. Repeat steps 2 & 3. After the last 1/2 gallon is purged,
close both bleed nipples before rotating away from the
Bleeding may be necessary if excessive backlash is exhibited end position.
after the actuator is connected to the hydraulic system. The
following steps are recommended when a minimum of two
gallons (8 liters) is purged.
1. Connect a 3/16 in. inside diameter x 5/16 in. outside
diameter x 5 foot clear, vinyl drain tube to each of the
two bleed nipples. Secure them with hose clamps. Place
the vinyl tubes in a clean 5-gallon container to collect
the purged oil. The oil can be returned to the reservoir
after this procedure is completed.

3121671 4-51
SECTION 4 - BOOM & PLATFORM

4.10 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:
1. Operate the telescope out function, then activate Sky-
Consult the following illustrations to determine which type
Guard sensor.
of SkyGuard the machine is equipped with. Regardless of
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 Operation is allowed regardless of SkyGuard activation.

0"%

SkyGuard SkyLine™

0"$
SkyGuard SkyEye™

THE MACHINE OPERATOR IS REQUIRED TO PERFORM A DAILY FUNCTION TEST

TO ENSURE PROPER OPERATION OF THE SKYGUARD SYSTEM.

4-52 3121671
SECTION 4 - BOOM & PLATFORM

SOFT TOUCH ONLY Engage the SkyGuard sensor and observe the Analyzer to
If Soft Touch only is selected in machine setup (refer to Table determine if the switch/relay closes.
6-2), machine will treat the Soft Touch/SkyGuard override
If the status of the switch/relay remains OPEN while the Sky-
switch as if it is a Soft Touch switch.
Guard sensor is actively engaged, it is possible the sensor has
SKYGUARD NOT SELECTED IN MACHINE SETUP failed and should be replaced immediately.
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
DIAGNOSTICS: FEATURES  SKYGUARD INPUTS menu to • 2563 - switch disagreement fault
determine additional SkyGuard fault information.

Table 4-1. SkyGuard Function Table

Boom
Drive Drive Boom Boom Boom Basket Basket
Steer Swing Lift Jib Lift
Forward Reverse Lift Up Tele Out Tele In Level Rotate
Down
R*/C** R C R R R R C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* DOS Enabled
* * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active

3121671 4-53
SECTION 4 - BOOM & PLATFORM

4.11 PLATFORM ROTATE BLEED PROCEDURE 3. Loosen hydraulic hose end at port P1 of platform rotator
1 turn (use existing paint mark as a reference).
NOTE: This procedure will have to be performed any time a com-
ponent is removed or replaced in the platform rotate
hydraulic circuit.

General Notes & Precautions

• Wear appropriate eye protection.
• Engine must be turned off when loosening & tightening
hydraulic connections.
• Ensure persons and objects are clear of the platform area
prior to starting the engine and activating platform rotate
function.
• Place appropriate pan and absorbent mats under platform
rotator to collect hydraulic fluid.
4. Activate platform rotate right for approximately 10 sec-
Procedure onds (the platform will rotate slowly).
1. Activate platform rotate right until end of stroke and 5. Activate platform rotate left until end of stroke.
hold for 5 seconds.
6. Repeat steps 4 & 5 until air is removed.
7. Tighten hydraulic hose end at port P1 of platform rota-
tor to 14 ft. lbs. (19 Nm).

8. Activate platform rotate right until end of stroke and

hold for 5 seconds.
9. Loosen hydraulic hose end at port P2 of platform rota-
tor.
2. Activate platform rotate left until end of stroke and hold
for 5 seconds.

4-54 3121671
SECTION 4 - BOOM & PLATFORM

4.12 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 SHOWING:
GAP 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 4-20. Bolt-On External Fall Arrest Cable Tension

• Fittings & Brackets: Ensure all fittings are tight and there are
no signs of fractures. Inspect brackets for any damage.
IF THE BOLT-ON EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL
OR IS OTHERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND • Attachment Ring: No cracks or signs of wear are accept-
THE PLATFORM FULLY INSPECTED BEFORE RETURNING TO SERVICE. REFER TO able. Any signs of corrosion requires replacement.
THE SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES.
• Attaching Hardware: Inspect all attaching hardware to
THE BOLT-ON EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL
ensure there are no missing components and hardware is
INSPECTION AND CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICA-
properly tightened.
TION MUST BE PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER.
• Platform Rails: No visible damage is acceptable.
Inspection Before Use
The Bolt-On External Fall Arrest system must be inspected Installation
before each use of the aerial work platform. Replace compo-
nents if there are any signs of wear or damage. 1. Install the retaining hardware (bolts, nuts, and washers)
and secure the brackets to the platform rail. Tighten the
Before each use, perform a visual inspection of the following nuts but do not torque them yet.
components:
BOLT

WASHER

NUT

3121671 4-55
SECTION 4 - BOOM & PLATFORM

2. Attach the fall arrest cable to the right hand bracket 5. Use the two jam nuts to prevent the cable from rotating
Using the attaching bolt and nut. Orient the bolt as while the nut is tightened. Tighten the nut until the bel-
shown below. Do not tighten the nut so cable can still leville washers are fully compressed and no gap is pres-
rotate. ent at the outside diameter of the washers. Ensure the
cable has not rotated during tightening.
BOLT
NUT

6. Tighten the first jam nut against the retaining nut to

keep the nut from loosening. Tighten the remaining jam
3. Install the Attachment Ring onto the cable. nut against the first jam nut.
7. Torque the nuts and bolts securing the brackets to
4. Without twisting the fall arrest cable, pull it thru the left
15 ft.lbs. (20 Nm).
hand bracket and mark the top of the swaged cable end.
Install the fall arrest cable through the left hand bracket
and secure it using the belleville washers, washer, retain-
ing nut, and jam nuts. Orient the hardware as shown
below and with the belleville washers so the gap is pres-
ent at the outside diameter of the washers. install the
nuts onto the cable finger tight so the mark on the cable
does not move.

WASHER
BELLEVILLE
NUT WASHER

JAM NUT

4-56 3121671
SECTION 4 - BOOM & PLATFORM

7
1,2,3,4

5
1. Belleville Washer
2. Washer
3. Hex Nut
6
4. Jam Nut
5. LH Bracket
6. Attachment Ring
7. Cable
8. RH Bracket
9. Decal

Figure 4-21. Bolt-On External Fall Arrest System

3121671 4-57
SECTION 4 - BOOM & PLATFORM

NOTES:

4-58 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

SECTION 5. BASIC HYDRAULICS INFORMATION & SCHEMATICS

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

NOTE: All o-ring fittings must be pre-lubricated with hydraulic oil

prior to assembly.

Cup and Brush

The following is needed to correctly oil the o-ring in this man-
ner:

• A small container for hydraulic oil

• 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.

3121671 5-1
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512

TORQUE SPECIFICATION
Tapered Thread Types
NPTF = national tapered fuel (Dry Seal) per SAE J476/J512

Figure 5-4. SAE Thread

ORFS = o-ring face seal per SAE J1453

Figure 5-1. NPTF thread

BSPT = British standard pipe tapered per ISO7-1

Figure 5-5. ORFS Thread

MBTL = metric flareless bite type fitting, pressure rating L
(medium) per ISO 8434, DIN 2353
MBTS = metric flareless bite type fitting, pressure rating S
(high) per ISO 8434, DIN 2353

Figure 5-2. BSPT thread

Figure 5-6. MTBL-MBTS Thread

Straight Thread Types, Tube and Hose Connections BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
JIC = 37° flare per SAE J514

Figure 5-3. JIC Thread

Figure 5-7. Bulkhead Thread

3121671 5-3
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 5-9. ORB-MPP Thread

Tightening Methods
Torque = Application of a twisting force to the applicable con-
nection by use of a precise measurement instrument (i.e.
MFF = metric flat face port per ISO 9974-1 torque wrench).

BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852- Finger Tight = The point where the connector will no longer
2 thread onto the mating part when tightened by hand or fin-
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 Nm). Also referred to as ‘Hand Tight.’
TFFT = Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by hand (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 5-8. MFF-BSPP Thread

5-4 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 5-10. 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.

3121671 5-5
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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
NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
the male pipe threads if not already applied. Ensure the
applicable for the following material configurations:
first 1 to 2 threads are uncovered to prevent system con-
tamination.
• STEEL fittings with STEEL mating components
3. Assemble connection hand tight. • STEEL fittings with ALUMINUM or BRASS mating compo-
4. Mark fittings, male and female. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR. mating components.

Table 5-1. NPTF Pipe Thread

TYPE/FITTING IDENTIFICATION
Turns From Finger
Thread Size ØA*
Material Dash Size Tight (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
STEEL, ALUMINUM, OR BRASS MATING C

4 1/4 - 18 0.54 13.61 2 to 3

6 3/8 - 18 0.67 17.05 2 to 3
8 1/2 - 14 0.84 21.22 2 to 3
12 3/4 - 14 1.05 26.56 2 to 3
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
OMPONENTS

24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5

32 2 - 11 1/2 2.37 60.09 1.5 to 2.5

* ØA thread dimension for reference only.

** See FFWR and TFFT Methods subsection for TFFT procedure requirements.

5-6 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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

NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN-

Table 5-2. BSPT Pipe Thread

TYPE/FITTING IDENTIFICATION
Turns From Finger
Thread Size ØA*
MATERIAL Dash Size Tight (TFFT)**
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH

4 1/4 - 19 0.52 13.16 2 to 3

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

8 1/2 - 14 0.83 20.96 2 to 3

12 3/4 - 14 1.04 26.44 2 to 3
MATING COMPONENTS

16 1 - 11 1.31 33.25 1.5 to 2.5

20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5

* ØA thread dimension for reference only.

** See Appendix B for TFFT procedure requirements.

3121671 5-7
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table 5-3, 37° Flare
(JIC)Thread - Steel or Table 5-4, 37° Flare (JIC)Thread -
1. Inspect the flare for obvious visual squareness and con- Aluminum/Brass while using the Double Wrench
centricity issues with the tube OD. Ensure surface is Method per Double Wrench Method. Refer to FFWR and
smooth, free of rust, weld and brazing splatter, splits, TFFT Methods for procedure requirements if using the
dirt, foreign matter, or burrs. If necessary replace fitting 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 compo-
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
• ALUMINUM or BRASS fittings with STEEL mating compo-
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
nents
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.

5-8 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-3. 37° Flare (JIC)Thread - Steel

Type/Fitting Identification Torque

Flats from
Thread Wrench
MATERIAL

ØA* ØB* [Ft-Lb] [N-m]

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

4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4

5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
UN-LUBRICATED THREADS

6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2

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

3121671 5-9
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass

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 4 4 5 5 6 7 --
3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4

5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methodsfor FFWR procedure requirements.

5-10 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 compo-
3. Tighten fitting by hand until hand tight. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. mating components.

3121671 5-11
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-5. 45° Flare (SAE) - Steel

TYPE/FITTING IDENTIFICATION Torque

Thread
MATERIAL

ØA* ØB* [Ft-Lb] [N-m]

Dash Size Size
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19
STEEL MATING COMPONENTS;
UN-LUBRICATED THREADS
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
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methodsfor FFWR procedure requirements.

Table 5-6. 45° Flare (SAE) - Aluminum/Brass

TYPE/FITTING IDENTIFICATION Torque

Thread
MATERIAL

ØA* ØB* [Ft-Lb] [N-m]

Dash Size Size
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12
UN-LUBRICATED THREADS
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
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methods for TFFT procedure requirements.

5-12 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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

4. Place the tube assembly against the fitting body so that • ALUMINUM or BRASS fittings with ALUMINUM or
the flat face comes in contact with the o-ring. Hand BRASS mating components
thread the nut onto the fitting body.
Table 5-7. O-ring Face Seal (ORFS) - Steel

Flats from Wrench

TYPE/FITTING IDENTIFICATION Torque
Resistance (F.F.W.R)**
MATERIAL

Thread Size ØA* ØB* [Ft-Lb] [N-m] Swivel &

Dash Size Tube Nuts
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Hose Ends

4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
STEEL MATING COMPONENTS;
UN-LUBRICATED THREADS
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
20 111/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
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
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methodsfor FFWR procedure requirements.

3121671 5-13
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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

Flats from Wrench

TYPE/FITTING IDENTIFICATION Torque
Resistance (F.F.W.R)**
MATERIAL

Dash Thread Size ØA* ØB* [Ft-Lb] [N-m] Swivel &

Tube Nuts
Size (UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Hose Ends

4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS FITTINGS OR

UN-LUBRICATED THREADS

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

MATING COMPONENTS;
ALUMINUM/BRASS

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

12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
20 111/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
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
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methods for FFWR procedure requirements.

5-14 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 5-9, DIN
24°Cone (MBTL & MBTS) while using the Double Wrench
Method. The tube must not turn with the nut.

3121671 5-15
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-9. DIN 24°Cone (MBTL & MBTS)

DIN 24° CONE FLARELESS BITE FITTING

TYPE/FITTING IDENTIFICATION
(With or Without o-ring)

Thread M Torque Flats from

MATERIAL

Tube O.D. ØA* ØB* C* ØD* Wrench

Size
TYPE

[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
28 M36 x 2 33.90 36.00 7.50 28.20 1.5 to 1.75
STEEL FITTINGS WITH STEEL MATING COMPONENTS

characteristics of the connection.

35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
Refer to the specific procedure
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
in the
Thread M Torque Flats from
Tube O.D. ØA* ØB* C* ØD* Wrench
Size
TYPE

[Ft-Lb] [N-m]
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75
DIN 24° CONE FLARELESS BITE (MBTS) FITTING

8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75

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

5-16 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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.

3121671 5-17
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-10. Bulkhead Fittings (BH) - INCH

FASTENING JAM NUT

TYPE/FITTING IDENTIFICATION
for Bulkhead Connectors
Torque
MATERIAL

Thread Size
TYPE

Dash Size [Ft-Lb] [N-m]

(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
O-RING FACE SEAL (ORFS)

8 13/16-16 55 58 61 75 79 83
BULKHEAD FITTING

10 1-14 85 90 94 115 122 127

12 1 3/16-12 135 142 149 183 193 202
14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Torque
Thread Size
TYPE

Dash Size [Ft-Lb] [N-m]

STEEL FITTINGS

(UNF) Min Nom Max Min Nom Max

3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
37° FLARE (JIC) BULKHEAD FITTING

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

5-18 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-11. Bulkhead Fittings (BH) - METRIC

FASTENING JAM NUT

TYPE/FITTING IDENTIFICATION
for Bulkhead Connectors

Connecting Tube Torque

Thread M Size
MATERIAL TYPE O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
DIN 24° CONE FLARELESS BITE

10 M16 x 1.5 22 23 24 30 31 33
(MBTL) BULKHEAD FITTING

12 M18 x 1.5 35 37 39 47 50 53
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
STEEL FITTINGS

Connecting Tube Torque

Thread M Size
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING

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

3121671 5-19
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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

5-20 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-12. O-ring Boss (ORB) - Table 1 of 6

HEX TYPE PLUGS & STUD ENDS

TYPE/FITTING IDENTIFICATION
with 37° (JIC) or L series DIN (MBTL) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 23 25 26 32 34 35

STEEL FITTINGS WITH STEEL MATING

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
TYPE/FITTING IDENTIFICATION
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 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

4 7/16-20 0.44 11.11 14 15 16 19 20 22

MATING COMPONENTS; UN-LUBRICATED THREADS

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.

3121671 5-21
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-13. O-ring Boss (ORB) - Table 2 of 6

STUD ENDS
TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) 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 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 26 27 28 35 37 38
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 30 32 33 40 43 45

STEEL FITTINGS WITH STEEL MATING

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
TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) 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 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

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

MATING COMPONENTS; UN-LUBRICATED THREADS

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
* 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.

5-22 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-14. O-ring Boss (ORB) - Table 3 of 6

ADJUSTABLE STUD END

TYPE/FITTING IDENTIFICATION
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 (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
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 21 22 23 28 30 31

STEEL FITTINGS WITH STEEL MATING

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
TYPE/FITTING IDENTIFICATION
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 (39) (41) (43) 4 5 5
3 3/8-24 0.37 9.52 (65) (69) (72) 7 8 8
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

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

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 14 15 15 19 20 20

3121671 5-23
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-15. O-ring Boss (ORB) - Table 4 of 6

ADJUSTABLE STUD END

TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) 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 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 30 32 33 40 43 45

STEEL FITTINGS WITH STEEL MATING

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
TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) 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 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

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

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 20 21 21 27 28 28

5-24 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-16. O-ring Boss (ORB) - Table 5 of 6

TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
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
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 14 15 16 19 20 22

STEEL FITTINGS WITH STEEL MATING

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
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
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
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

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

MATING COMPONENTS; UN-LUBRICATED THREADS

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
* 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.

3121671 5-25
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-17. O-ring Boss (ORB) - Table 6 of 6

ZERO LEAK GOLD®

TYPE/FITTING IDENTIFICATION
HOLLOW HEX PLUGS
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
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
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 9 10 11 12 14 15

STEEL FITTINGS WITH STEEL MATING

6 9/16-18 0.56 14.28 11 12 13 15 16 18

8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
ZERO LEAK GOLD®
TYPE/FITTING IDENTIFICATION
HOLLOW HEX PLUGS
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
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
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

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

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 9 10 11 12 14 15

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

5-26 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 are
ment) for instructions. 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
• STEEL fittings with ALUMINUM or BRASS mating compo-
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE
nents
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
• ALUMINUM or BRASS fittings with STEEL mating compo-
3. Pre-lubricate the o-ring with Hydraulic Oil. nents
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
by hand until contact. 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 counterbore of the port.

3121671 5-27
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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
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 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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

5-28 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-19. Metric Flat Face Port (MFF) - L Series - Table 2 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 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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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
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 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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

3121671 5-29
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
TYPE/FITTING IDENTIFICATION
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS

Thread M Connecting Torque Torque Torque

MATERIAL 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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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
Thread M Connecting Torque Torque Torque
MATERIAL 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 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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

5-30 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3

FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) 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
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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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
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
M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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

3121671 5-31
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 STUD
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS
ENDS with (ORFS) or S series DIN (MBTS) opposite end
with (ORFS) or S series DIN (MBTS) 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 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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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
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 17 18 19 23 24 26 17 18 19 23 24 26
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386

5-32 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-23. Metric Flat Face Port (MFF) - L Series - Table 3 of 3

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
TYPE/FITTING IDENTIFICATION
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS

Thread M Connecting Torque Torque Torque

MATERIAL 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 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 -- -- -- -- -- --
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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 -- -- -- -- -- --
Thread M Connecting Torque Torque Torque
MATERIAL 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 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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 -- -- -- -- -- --

3121671 5-33
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 pre-installed, 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:
• STEEL fittings with ALUMINUM or BRASS mating compo-
nents
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE • ALUMINUM or BRASS fittings with STEEL mating compo-
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
3. Pre-lubricate the o-ring with Hydraulic Oil.
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
7. Inspect to ensure the o-ring is not pinched and the
by hand until contact.
washer is seated flat on the counterbore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
Assembly for proper assembly.

5-34 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-24. Metric Pipe Parallel O-ring Boss (MPP)

STUD ENDS STUD ENDS

TYPE/FITTING IDENTIFICATION
with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end

Thread M Connectin Torque Torque

MATERIAL

Size g 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
M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
STEEL FITTINGS WITH STEEL MATING COMPONENTS;

M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
UN-LUBRICATED THREADS

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
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING

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
COMPONENTS; UN-LUBRICATED THREADS

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

3121671 5-35
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 pre-installed, 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
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE
• STEEL fittings with ALUMINUM or BRASS mating compo-
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE
nents
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
• ALUMINUM or BRASS fittings with STEEL mating compo-
3. Pre-lubricate the o-ring with Hydraulic Oil. nents
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
by hand until contact. 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 counterbore of the port.

5-36 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-25. British Standard Parallel Pipe Port (BSPP) - 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

BSPP Thread Connecting Torque Torque

MATERIAL G 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
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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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 Thread Connecting Torque Torque
MATERIAL G 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
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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

3121671 5-37
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-26. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3

FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE STUD
TYPE/FITTING IDENTIFICATION STUD ENDS ENDS
with 37° (JIC) or L series DIN (MBTL) opposite end with 37° (JIC) or L series DIN (MBTL) opposite end

BSPP Thread Connecting Torque Torque

MATERIAL G 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
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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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 Thread Connecting Torque Torque
MATERIAL G 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
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings

5-38 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-27. British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
TYPE/FITTING IDENTIFICATION
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
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings

3121671 5-39
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3

FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end

BSPP Thread Connecting Torque Torque

MATERIAL G 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
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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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 Thread Connecting Torque Torque
MATERIAL G 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
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings

5-40 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-29. British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3

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

BSPP Thread Connecting Torque Torque

MATERIAL G 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
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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

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 Thread Connecting Torque Torque
MATERIAL G 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
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings

3121671 5-41
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-30. British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS

TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
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
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 Service Manual.
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 Service Manual.
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings

5-42 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Assembly Instructions for Flange Connections:

(FL61 and FL62)
1. Make sure sealing surfaces are free of rust, splits,
scratches, dirt, foreign matter or burrs.
2. Install o-ring as per “O-ring Installation (Replacement)” .
3. Pre-lubricate the o-ring with Hydraulic Oil.
4. Position flange and clamp halves.
5. Place lock washers on bolt and bolt through clamp
halves.
6. Tighten all bolts by hand.
7. Torque bolts in diagonal sequence in two or more incre-
ments to the torque listed on Table 5-31and Table 5-32.

3121671 5-43
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners

STEEL 4-BOLT FLANGE SAE J518

TYPE/FITTING IDENTIFICATION
(INCH FASTENERS)

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

20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101

24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Bolt Fastener Torque for Flanges Equipped with GRADE 5 Fastener Torque for Flanges Equipped with GRADE 8
Inch
Flange Size A* Thread Screws 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 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
CODE 62 SPLIT FLANGE (FL62)

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.

5-44 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners

STEEL 4-BOLT FLANGE SAE J518

TYPE/FITTING IDENTIFICATION
(INCH FASTENERS)

Bolt Fastener Torque for Flanges Equipped with CLASS Fastener Torque for Flanges Equipped with CLASS
Inch Flange Flange Size A* Thread 8.8 Screws 10.9 Screws
TYPE SAE Dash Size [Ft-Lb] [N-m] [Ft-Lb] [N-m]
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
CODE 61 SPLIT FLANGE (FL61)

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
Bolt Fastener Torque for Flanges Equipped with CLASS Fastener Torque for Flanges Equipped with CLASS
Inch Flange Flange Size A* Thread 8.8 Screws 10.9 Screws
TYPE SAE Dash Size [Ft-Lb] [N-m] [Ft-Lb] [N-m]
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
CODE 62 SPLIT FLANGE (FL62)

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.

3121671 5-45
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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 5-11. 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 5-11. Double Wrench Method

5-46 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

FFWR and TFFT Methods Adjustable Stud End Assembly

For Adjustable Stud End Connections; the following assembly
FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed:

1. Tighten the swivel nut to the mating fitting until no lat- 1. Lubricate the o-ring with a light coat of hydraulic oil.
eral movement of the swivel nut can be detected; finger 2. Position #1 – The o-ring should be located in the groove
tight condition. adjacent to the face of the backup washer. The washer
and o-ring should be positioned at the extreme top end
2. Mark a dot on one of the swivel hex nut flats and of the groove as shown.
another dot in line on the connecting tube adapter. See
Figure B.1. 3. Position #2 – Position the locknut to just touch the
backup washer as shown. The locknut in this position
3. Use the double wrench method per Appendix A, turn will eliminate potential backup washer damage during
the swivel nut to tighten as shown in Figure 5-11. The the next step.
nut is to be rotated clockwise the number of hex flats as
4. Position #3 – Install the connector into the straight
defined by the applicable Table in Section 5.0.
thread box port until the metal backup washer contacts
the face of the port as shown.
4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering 5. Position #4 – Adjust the connector to the proper posi-
the dots, to indicate the connection has been properly tion by turning out (counterclockwise) up to a maxi-
tightened. See Figure 5-12. mum of one turn as shown to provide proper alignment
with the mating connector, tube assembly, or hose
assembly.
6. Position #5 – Using two wrenches, use the backup
wrench to hold the connector in the desired position
and then use the torque wrench to tighten the locknut
to the appropriate torque.
7. Visually inspect, where possible, the joint to ensure the
o-ring is not pinched or bulging out from under the
washer and that the backup washer is properly seated
flat against the face of the port.

Figure 5-12. FFWR Method

TFFT (TURNS FROM FINGER TIGHT METHOD)

1. Tighten the swivel nut to the mating fitting until no lat-

eral movement of the swivel nut can be detected; finger
tight condition.

2. Mark a dot on one of the swivel hex nut flats and

another dot in line on the connecting tube adapter.

3. Use the double wrench method per Appendix A, turn

the swivel nut to tighten. The nut is to be rotated clock-
wise the number of turns as defined by the applicable
Table in Section 5.0.

4. After the connection has been properly tightened, mark

a straight line across the connecting parts, not covering
the dots, to indicate the connection has been properly
tightened.

3121671 5-47
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Figure 5-13. Adjustable Stud End Assembly

O-ring Installation (Replacement) 4. In ORB; ensure o-ring is properly seated in groove. On

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

1. Inspect o-ring for tears or nicks. If any are found replace

o-ring.

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

the same but are of different material, different hard-
ness, or are slightly different diameters or widths.

3. Use a thread protector when replacing o-rings on fit-

tings.

5-48 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.3 HYDRAULIC CYLINDERS ASSEMBLY

NOTE: Prior to cylinder assembly, ensure that the proper cylinder
Axle Lockout Cylinder seal kit is used. See your JLG Parts Manual.

DISASSEMBLY NOTE: Apply a light film of hydraulic oil to all components prior to
assembly.

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK

SURFACE IN A DIRT FREE WORK AREA.
WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.
IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
ROD CAN FALL OUT OF BARREL AND CAUSE INJURY OR DAMAGE TO THE
EQUIPMENT. BE CAREFUL WHEN REMOVING AXLE CYLINDER. OPENING BLEED 1. Install two new wear rings, wiper seal and rod seal in
barrel bore grooves. Make sure they are not twisted.
VALVE CAN CAUSE ROD TO FALL OUT OF BARREL.
1. Open bleeder valve. Rotate rod and remove from barrel. 2. Lubricate rod bore with clean hydraulic fluid.

2. Remove two wear rings, wiper seal and rod seal from
grooves of barrel bore. Do not scratch barrel bore.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE ROD. AVOID PULL
3. Remove counterbalance valve and plugs. ING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE ROD AND
CYLINDER BARREL SURFACES.
CLEANING AND INSPECTION
3. Insert and push the rod into top of barrel bore, rotate to
1. Inspect bore and rod for scoring, pitting, or excessive
install the rod into barrel bore.
wear.
4. Install plugs and counterbalance valve. Torque the plugs
2. Remove minor surface blemishes with wet sandpaper.
to 22-24 ft. lbs. (30-33 Nm) and counterbalance valve to
3. Pitting requires replacement of barrel and rod. 22 ft. lbs. (30 Nm).
5. Bleed system.

3121671 5-49
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

2**
4*

2**

5
3

1
*Torque to 22ft. lbs. (30 Nm)
**Torque to 22-24 ft. lbs. (30-33 Nm)

MAF00060

1. Rod 5. Barrel
2. Plug 6. Wear Ring
3. Bleeder Valve 7. Rod Seal
4. Counterbalance Valve 8. Wiper seal

Figure 5-14. Axle Lockout Cylinder

5-50 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Platform Level Cylinder 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using a hook spanner wrench,
DISASSEMBLY unscrew the cylinder head from the barrel.

BARREL
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA. CYLINDER HEAD

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. PUNCH
MARKS
2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
MAF00070

3. Remove the counterbalance valves and plugs from the

cylinder port block. Discard o-rings. Figure 5-16. Cylinder Head Removal

4. Place the cylinder barrel into a suitable holding fixture. 6. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.
ROD SUPPORT

PROTECTED ROD CLAMP

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
BARREL CLAMP HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

7. With the barrel clamped securely, apply pressure to the

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

ROD SUPPORT

SUPPORT TABLE
SUPPORT TABLE

Figure 5-15. Cylinder Barrel Support

Figure 5-17. Cylinder Rod Support

3121671 5-51
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

21 21
20
19*

18*
17

14 16
15

11 13
8
7
6
12
3**

4
5
9

17 *Torque to 30-35 ft. lbs. (41-47 Nm)

**Torque to 549 ft. lbs. (745 Nm)

17 MAF00080

1. Barrel 6. Rod Seal 10. Backup Ring 14. Piston Seal 18. Counterbalance Valve
2. Rod 7. Backup Ring 11. O-ring 15. Ball 19. Counterbalance Valve
3. Head 8. Bearing 12. Piston 16. Setscrew 20. Plug
4. Wiper Seal 9. O-ring 13. O-ring 17. Bushing 21. Plug
5. Retaining Ring

Figure 5-18. Platform Level Cylinder

5-52 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8. 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.
9. Loosen and remove the setscrew and ball which
attaches the piston to the rod. 2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Briteor
10. Screw the piston counterclockwise by hand and remove equivalent. Replace rod if necessary.
the piston from cylinder rod.
3. Inspect threaded portion of rod for excessive damage.
11. Remove and discard the piston seal and o-ring. Dress threads as necessary.
12. Remove the rod from the holding fixture. Remove the 4. Inspect inner surface of cylinder barrel tube for scoring
cylinder head. Discard the o-rings, backup ring, rod seal, or other damage. Check inside diameter for tapering or
bearing, retaining ring and wiper seal. ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
6. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as
necessary.
7. Inspect threaded portion of piston for damage. Dress
threads as necessary.
8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring, taper-
ing, ovality or other damage. Replace if 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,
tapering, ovality or other damage. Replace if necessary.
13. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.
a. Thoroughly clean hole (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to bear-
ing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.

3121671 5-53
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.

NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.

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

applicable cylinder head groove.

Figure 5-19. Composite Bearing Installation

14. Inspect port block fittings and holding valve. Replace if

necessary.
15. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair if necessary.
16. Inspect piston rings for cracks or other damage. Replace
if necessary.

Figure 5-20. Rod Seal Installation

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
O-RING BACKUP RING O-RING

RETAINING
RING

WIPER SEAL

BEARING ROD SEAL BACKUP RING

MAF00090
Figure 5-21. Cylinder Head Seal Installation

5-54 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

2. Use a soft mallet to tap a new wiper seal into the appli-
cable cylinder head groove. Install a new retaining ring PISTON SEAL
and bearing into the applicable inside diameter of the
cylinder head groove.

O-RING MAF00110
Figure 5-24. Piston Seal Kit Installation

9. Position the cylinder barrel in a suitable holding fixture.

Figure 5-22. Wiper Seal Installation

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,

3. Place a new o-rings and backup ring in the applicable
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
outside diameter groove of the cylinder head.
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
O-RING

10. With barrel clamped securely, and while adequately sup-

porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston loading piston seal are not
O-RING damaged or dislodged.

11. Continue pushing the rod into the barrel until the cylin-
der head can be inserted into the cylinder barrel.

12. Screw the cylinder head into the barrel using a hook
spanner wrench and torque cylinder head to 549 ft. lbs.
BACKUP RING
MAF00100 (745 Nm).
Figure 5-23. Installation of Head Seal Kit
13. Caulk at the machined area of the cylinder barrel end so
4. Carefully install the cylinder head on the rod, ensuring that it locks the cylinder head in place and it does not
that the wiper seal, retaining ring and rod seals are not unscrew from the barrel.
damaged or dislodged. Push the head along the rod to
the rod end.

5. Using suitable protection, clamp the cylinder rod in a

vise or similar holding fixture as close to piston as possi-
ble.

6. Place a new o-ring in the applicable inside diameter of MAF00120

the piston. Figure 5-25. Caulking

7. Carefully thread the piston on the cylinder rod, ensuring

that the o-ring is not damaged or dislodged and hand 14. After the cylinder has been reassembled, the rod should
tight. Secure using ball and setscrew. be pushed all the way in (fully retracted) prior to the
reinstallation of any holding valve or valves.
8. Remove the cylinder rod from the holding fixture. Place
new piston seal in the outer piston diameter groove. (A 15. Install the new o-rings and plugs into the cylinder port
tube, with I.D. slightly larger than the O.D. of the piston block. Install the counterbalance valves in the rod port
is recommended to install the solid seal). block and torque to 30-35 ft. lbs. (41-47 Nm).

3121671 5-55
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Jib Lift Cylinder (460SJ Only) 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
DISASSEMBLY inder head retainer capscrews, and remove capscrews
from cylinder barrel.

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK

SURFACE IN A DIRT FREE WORK AREA.
CAPSCREWS
1. Connect a suitable auxiliary hydraulic power source to
the cylinder port block fitting.
WASHER
RING

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

SLIGHTLY TO AVOID TRAPPING PRESSURE. PUNCH
MARKS
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. Remove the counterbalance valves and plugs from the
cylinder port block. Discard o-rings. Figure 5-27. Capscrew Removal

4. Place the cylinder barrel into a suitable holding fixture. 6. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.
ROD SUPPORT

PROTECTED ROD CLAMP

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
BARREL CLAMP
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

7. With the barrel clamped securely, apply pressure to the

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

ROD SUPPORT

SUPPORT TABLE
SUPPORT TABLE

Figure 5-26. Cylinder Barrel Support

Figure 5-28. Cylinder Rod Support

5-56 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

6** 7 22

7
7
6**

8 11
13
14
10
14
13
15 16
16 12
17
18
2
21 5
19
20
3
4***

*Torque to 5 ft. lbs. (7 Nm)

**Torque to 50-55 ft. lbs. (68-75 Nm)
***Torque to 20 ft. lbs. (27 Nm)

23
MAF00130

1. Barrel 7. Plug 13. Guidelock Ring 19. Rod Seal

2. Head 8. Plug 14. Hydrolock Seal 20. Wiper Seal
3. Washer Ring 9. Capscrew 15. Backup Ring 21. Wear Ring
4. Capscrew 10. Piston 16. O-ring 22. Bushing
5. Rod 11. Tapered Bushing 17. O-ring 23. Bushing
6. Counterbalance Valve 12. Spacer 18. Backup Ring

Figure 5-29. Jib Lift Cylinder (460SJ Only)

3121671 5-57
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8. 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.
9. Insert the capscrews in the threaded holes in the outer
piece of the tapered bushing. Progressively tighten the 2. Inspect the cylinder rod for scoring, tapering, ovality, or
capscrews until the bushing is loose on the piston. other damage. If necessary, dress rod with Scotch Brite
10. Remove the bushing from the piston. or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive damage.

Dress threads as necessary.
PISTON
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
TAPERED ovality. Replace if necessary.
ROD BUSHING
5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
CAPSCREW essary.

6. Inspect threaded portion of piston for damage. Dress

threads as necessary.

7. Inspect seal and o-ring grooves in piston for burrs and

sharp edges. Dress applicable surfaces as necessary.
Figure 5-30. Tapered Bushing Removal
8. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace as
11. Screw the piston counterclockwise, by hand, and
necessary.
remove the piston from cylinder rod.
12. Remove and discard the piston o-rings, seal rings, 9. Inspect seal and o-ring grooves in head for burrs and
backup rings, hydrolock seals and guidelock rings. sharp edges. Dress applicable surfaces as necessary.

13. Remove piston spacer from the rod. 10. Inspect cylinder head outside diameter for scoring or
other damage and ovality and tapering. Replace as nec-
14. Remove the rod from the holding fixture. Remove the
essary.
cylinder head. Discard the o-ring, backup ring, rod seal,
wear ring and wiper seal.
11. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.

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

etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to bear-
ing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.

5-58 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.

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

applicable cylinder head groove.

Figure 5-31. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

dress inside diameter surface with Scotch Brite or equiv-
alent.
13. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
14. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair as necessary.
15. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary. Figure 5-32. Rod Seal Installation

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

O-RING BACKUP RING

WIPER SEAL

WEAR RING ROD SEAL

MAF00140

Figure 5-33. Cylinder Head Seal Installation

3121671 5-59
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

2. Use a soft mallet to tap a new wiper seal into the appli- 10. Install the bolts in tapered bushing.
cable cylinder head groove. Install a new wear ring into
11. Assemble the tapered bushing loosely into the piston
the applicable cylinder head groove.
and insert capscrews through the drilled holes in the
bushing and into the tapped holes in the piston.

PISTON
TAPERED
BUSHING
ROD
CAPSCREW

Figure 5-34. Wiper Seal Installation

3. Place a new o-ring and backup ring in the applicable

outside diameter groove of the cylinder head.
Figure 5-36. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in rota-

tion to 5 ft.lbs. (7 Nm).
13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4 in. diameter) as follows:
a. Place the shaft against the cylinder rod and in
contact with the bushing in the spaces between the
capscrews.
b. Tap each space once; this means the tapered
bushing is tapped 3 times as there are 3 spaces
between the capscrews.

Figure 5-35. Installation of Head Seal Kit

4. Install washer ring onto rod, carefully install the cylinder PISTON
head on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the CAPSCREW
rod to the rod end, as applicable.
ROD
5. Carefully slide the piston spacer on the rod.
TAPERED
6. Using suitable protection, clamp the cylinder rod in a BUSHING
vise or similar holding fixture as close to piston as possi-
ble.
7. Place new o-ring and backup rings in the inner piston BRASS SHAFT
diameter groove.
Figure 5-37. Seating the Tapered Bearing
8. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and backup rings are not
damaged or dislodged.
9. Thread piston onto rod end and install the tapered
bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

5-60 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

14. Rotate the capscrews evenly and progressively in 17. Position the cylinder barrel in a suitable holding fixture.
rotation to 5 ft.lbs. (7 Nm).

15. Remove the cylinder rod from the holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
18. With barrel clamped securely, and while adequately sup-
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION
porting the rod, insert the piston end into the barrel cyl-
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
inder. Ensure that the piston loading o-ring hydrolock
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. seals and guidelock rings are not damaged or dislodged.
19. Continue pushing the rod into the barrel until the cylin-
der head can be inserted into the barrel cylinder.

PISTON
ROD
SPACER
HEAD
BARREL WASHER RING
Figure 5-38. Hydrolock Piston Seal Installation

ROD
16. Place new hydrolock seal and guidelock rings in the
outer piston diameter groove. (A tube, with I.D. slightly
larger than the O.D. of the piston is recommended to
install the solid seal). CA1SCREW

Figure 5-40. Rod Assembly Installation

HYDROLOCK GUIDELOCK HYDROLOCK
SEAL RING SEAL 20. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head using the washer ring
and bolts. Torque bolts to 20 ft.lbs. (27 Nm).
21. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the re-
installation of any holding valve or valves.
22. Install the counterbalance valves and fittings in the rod
port block, using new o-rings as applicable. Torque
valves to 50-55 ft.lbs. (68-75 Nm).

MAF00150

Figure 5-39. Piston Seal Kit Installation

3121671 5-61
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Main Lift Cylinder (SN 0300203771 through 5. Loosen and remove the setscrew which attaches the cyl-
inder head to barrel. Using a pin-face spanner wrench,
0300243703, SN E300000100 through E300005607) unscrew the cylinder head from the barrel.

DISASSEMBLY BARREL
CYLINDER HEAD

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.

SETSCREW
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING
PRESSURE.
2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power source. MAF00160

Adequately support the cylinder rod, if applicable.

Figure 5-42. Cylinder Head Removal
3. Remove the orifice plug, check valve, pressure compen-
sator valve, cartridge valves and plugs from the cylinder 6. Attach a suitable pulling device to the cylinder rod port
port block. Discard o-rings. block end or cylinder rod end, as applicable.

4. Place the cylinder barrel into a suitable holding fixture.

ROD SUPPORT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
PROTECTED ROD CLAMP CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

BARREL CLAMP 7. With the barrel clamped securely, apply pressure to the
rod pulling device and carefully withdraw the complete
rod assembly from the cylinder barrel.
ROD SUPPORT

SUPPORT TABLE

Figure 5-41. Cylinder Barrel Support

Figure 5-43. Cylinder Rod Support

5-62 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8
1**

8
17

10*** 4
13****
12 1**
11

6
7 18 19
14* 18

19
15 22
2 23
16
9 24
15

20
21
3*****
25

* Torque to 9 ft. lbs. (12 Nm)

** Torque to 13 ft. lbs. (18 Nm)
*** Torque to 25 ft. lbs. (34 Nm) 26
****Torque to 35 ft. lbs. (47 Nm)
*****Torque to 300 ft. lbs. (407 Nm)

26
MAF00170

1. Plug 7. Piston 12. Orifice Plug 17. Pressure Compensator Valve 22. Wear Ring
2. Setscrew 8. Bushing 13. Cartridge Valve 18. Backup Ring 23. Rod Seal
3. Cylinder Head 9. Spacer 14. Capscrew 19. O-ring 24. Wiper Seal
4. Barrel 10. Check Valve 15. Guidelock Ring 20. O-ring 25. O-ring
5. Rod 11. Pressure Compensator Valve 16. Hydrolock Seal 21. Backup Ring 26. Bushing
6. Tapered Bushing

Figure 5-44. Main Lift Cylinder (SN 0300203771 through 0300204034)

3121671 5-63
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8
1**

8
13

14*** 9
12****
3
1**
11

7 17 18
4* 17

18
15 23
6 24
16
19 25
15

20
21
2*****
22

* Torque to 9 ft. lbs. (12 Nm)

** Torque to 13 ft. lbs. (18 Nm)
*** Torque to 25 ft. lbs. (34 Nm) 26
****Torque to 35 ft. lbs. (47 Nm)
*****Torque to 300 ft. lbs. (407 Nm)

26
MAF00180

1. Plug 7. Piston 12. Cartridge Valve 17. Backup Ring 22. O-ring
2. Cylinder head 8. Bushing 13. Pressure Compensator Valve 18. O-ring 23. Wear Ring
3. Orifice Plug 9. Barrel 14. Check Valve 19. Spacer 24. Rod Seal
4. Capscrew 10. Rod 15. Guidelock Ring 20. O-ring 25. Wiper Seal
5. Tapered Bushing 11. Pressure Compensator Valve 16. Hydrolock Seal 21. Backup Ring 26. Bushing
6. Setscrew

Figure 5-45. Main Lift Cylinder (SN 0300204035 through 0300226846, SN E300000100 through E3000004457)

5-64 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8
1

13
1 3 9
15 14

5
7 18
19
4* 18

19
16 20

6 24
17
12 25
16

21
22
2**
23

* Torque to 7-9 ft. lbs. (9-12 Nm)

** Torque to 275-325 ft. lbs. (373-441 Nm)

11
MAF00190

1. Plug 6. Setscrew 11. Bushing 16. Guidelock Ring 21. O-ring

2. Cylinder head 7. Piston 12. Spacer 17. Hydrolock Seal 22. Backup Ring
3. Orifice Plug 8. Bushing 13. Check Valve 18. Backup Ring 23. O-ring
4. Capscrew 9. Barrel 14. Plug 19. O-ring 24. Rod Seal
5. Tapered Bushing 10. Rod 15. Plug 20. Wear Ring 25. Wiper Seal

Figure 5-46. Main Lift Cylinder (SN 0300226847 through 0300243703,

SN E3000004458 through E300005607)

3121671 5-65
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8. 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
solvent.
9. Remove capscrews from drilled holes.
2. Inspect the cylinder rod for scoring, tapering, ovality, or
10. Insert the capscrews in the threaded holes in the outer other damage. If necessary, dress rod with Scotch Brite
piece of the tapered bushing. Progressively tighten the or equivalent. Replace rod if necessary.
capscrews until the bushing is loosen on the piston.
3. Inspect threaded portion of rod for excessive damage.
11. Remove the bushing from the piston. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
PISTON ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
TAPERED
threads as necessary.
ROD BUSHING 6. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as
necessary.
CAPSCREW
7. Inspect threaded portion of piston for damage. Dress
threads as necessary.
8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring,
tapering, ovality or other damage. Replace if necessary.
Figure 5-47. Tapered Bushing Removal
10. Inspect threaded portion of head for damage. Dress
12. Screw the piston counterclockwise by hand and remove
threads as necessary.
the piston from cylinder rod.
11. Inspect seal and o-ring grooves in head for burrs and
13. Remove piston spacer from the rod. Remove and discard
sharp edges. Dress applicable surfaces as necessary.
the o-ring from the spacer.
12. Inspect cylinder head outside diameter for scoring,
14. Remove and discard the piston o-rings, backup rings,
tapering, ovality or other damage. Replace if necessary.
hydrolock seal, and guidelock ring.
13. If applicable, inspect rod and barrel bearings for signs of
15. Remove the rod from the holding fixture. Remove the
correct excessive wear or damage. Replace if necessary.
cylinder head. Discard the o-rings, backup rings, wear
rings, rod seal and wiper seal. a. Thoroughly clean hole (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to bear-
ing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.

5-66 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.

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

applicable cylinder head groove.

Figure 5-48. Composite Bearing Installation

14. Inspect spacer for burrs and sharp edges. If necessary,
dress inside diameter surface with Scotch Brite or equiv-
alent.
15. Inspect port block fittings and holding valve. Replace if
necessary.
16. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair if necessary.
17. Inspect piston rings for cracks or other damage. Replace
if necessary.
Figure 5-49. Rod Seal Installation

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

WEAR RING
O-RING
O-RING

ROD SEAL

BACKUP RING WIPER SEAL

MAF00200

Figure 5-50. Cylinder Head Seal Installation

3121671 5-67
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

2. Use a soft mallet to tap a new wiper seal into the appli- NOTE: When installing the tapered bushing, piston and mating
cable cylinder head groove. Install new wear rings into end of rod must be free of oil.
the applicable inside diameter of the cylinder head
groove. 10. Insert the tapered bushing into piston.

11. Assemble the tapered bushing loosely into the piston

and insert capscrews through the drilled holes in the
bushing and into the tapped holes in the piston.

PISTON
TAPERED
BUSHING
ROD
CAPSCREW
Figure 5-51. Wiper Seal Installation

3. Place new o-rings and backup ring in the applicable out-

side diameter groove of the cylinder head.

Figure 5-53. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in rota-

tion to 9 ft. lbs. (12 Nm).
O-RING O-RING
13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4 in. diameter) as follows:

a. Place the shaft against the cylinder rod and in con-

tact with the bushing in the spaces between the
BACKUP RING capscrews.
MAF00210

b. Place the shaft against the cylinder rod and in con-

Figure 5-52. Installation of Head Seal Kit tact with the bushing in the spaces between the
capscrews.
4. Carefully install the cylinder head on the rod, ensuring
that the backup rings, wear rings, rod seals and wiper
seals are not damaged or dislodged. Push the head
along the rod to the rod end.
PISTON
5. Place a new o-ring in the inside diameter groove of
spacer.
CAPSCREW
6. Install the spacer tube onto the cylinder rod.
ROD
7. Place a new o-ring and backup ring in the inner piston
diameter groove. TAPERED
BUSHING
8. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to piston as possi-
ble.
BRASS SHAFT
9. Carefully thread the piston on the cylinder rod, hand
tight, ensuring that the o-ring and backup ring is not
damaged or dislodged. Figure 5-54. Seating the Tapered Bearing

5-68 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

14. Rotate the capscrews evenly and progressively in rota- 17. Position the cylinder barrel in a suitable holding fixture.
tion to 9 ft. lbs. (12 Nm).
15. Remove the cylinder rod from the holding fixture.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION
18. With barrel clamped securely, and while adequately sup-
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
porting the rod, insert the piston end into the barrel cyl-
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.
inder. Ensure that the piston loading o-ring hydrolock
seals and guidelock rings are not damaged or dislodged.
19. Continue pushing the rod into the barrel until the cylin-
der head can be inserted into the barrel cylinder.
20. Apply anti-seize to the threads of the cylinder head.
21. Screw the cylinder head into the barrel using a pin-face
spanner wrench. Torque as shown in Figure 5-44.,
Figure 5-45. and Figure 5-46. as per respective cylinder.
22. Align the cylinder head with the barrel and install the
Figure 5-55. Hydrolock Piston Seal Installation setscrew in the hole.

16. Place new hydrolock seal and guidelock rings in the 23. After the cylinder has been reassembled, the rod should
outer piston diameter groove. (A tube, with I.D. slightly be pushed all the way in (fully retracted) prior to the
larger than the O.D. of the piston is recommended to reinstallation of any holding valve or valves.
install the solid seal). 24. Apply Loctite #222 to the orifice plug.

HYDROLOCK GUIDELOCK HYDROLOCK 25. Install the orifice plug, plug, check valve and pressure
SEAL RING compensator valve in the rod port block. Torque as
SEAL
shown in Figure 5-44., Figure 5-45. and Figure 5-46. as
per respective cylinder.
26. Install the new o-rings and plugs into the cylinder port
block. Torque as shown in Figure 5-44., Figure 5-45. and
Figure 5-46. as per respective cylinder.

MAF00220

Figure 5-56. Piston Seal Kit Installation

3121671 5-69
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Main Lift Cylinder (SN 0300243704 to Present, 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using a hook wrench, unscrew the
SN E300005608 to Present) cylinder head from the barrel.

DISASSEMBLY BARREL
CYLINDER HEAD

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.

PUNCH
MARKS
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING
PRESSURE.
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source. MAF00230
Adequately support the cylinder rod, if applicable. Figure 5-58. Cylinder Head Removal
3. Remove the check valve, cartridge valves, orifice plug
and plugs from the cylinder port block. Discard o-rings. 6. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.
4. Place the cylinder barrel into a suitable holding fixture.

ROD SUPPORT
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
PROTECTED ROD CLAMP HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
BARREL CLAMP
7. With the barrel clamped securely, apply pressure to the
rod pulling device and carefully withdraw the complete
rod assembly from the cylinder barrel.
ROD SUPPORT

SUPPORT TABLE

Figure 5-57. Cylinder Barrel Support

Figure 5-59. Cylinder Rod Support

5-70 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5
7

9 5
3*

5
8 6** 2
4
13***

14
10
11
10
12
15
16
17

18
19
20
21
22
23
24
25
26
27

* Torque to 19-21 ft. lbs. (26-29 Nm)

** Torque to 75-85 ft. lbs. (102-115 Nm) 9
*** Torque to 15 ft. lbs. (20 Nm)

9
MAF00240

1. Rod 7. Plug 13. Setscrew 18. O-ring 23. Buffer Ring

2. Barrel 8. Check Valve 14. Ball 19. Backup Ring 24. Rod Seal
3. Cartridge Valve 9. Bushing 15. O-ring 20. O-ring 25. Backup Ring
4. Orifice Plug 10. Wear Ring 16. Spacer 21. Cylinder Head 26. Wiper Seal
5. Plug 11. Piston Seal 17. O-ring 22. Bearing 27. Retaining Ring
6. Cartridge Valve 12. Piston

Figure 5-60. Main Lift Cylinder (SN 0300243704 to Present, SN E300005608 to Present)

3121671 5-71
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8. 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.
9. Loosen and remove the setscrew which attaches the pis-
ton to the rod. 2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
10. Screw the piston counterclockwise by hand, and remove or equivalent. Replace rod if necessary.
the piston from cylinder rod.
3. Inspect threaded portion of rod for excessive damage.
11. Remove and discard the piston o-ring, wear rings, and Dress threads as necessary.
piston seal.
4. Inspect inner surface of cylinder barrel tube for scoring
12. Remove piston spacer from the rod. Remove and discard or other damage. Check inside diameter for tapering or
the o-ring from the spacer. ovality. Replace if necessary.
13. Remove the rod from the holding fixture. Remove the 5. Inspect threaded portion of barrel for damage. Dress
cylinder head. Discard the o-rings, backup rings, rod threads as necessary.
seal, bearing, buffer seal and wiper seal.
6. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
essary.
7. Inspect threaded portion of piston for damage. Dress
threads as necessary.
8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring, taper-
ing, ovality or other damage. Replace if 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,
tapering, ovality or other damage. Replace if necessary.
13. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace if necessary.
a. Thoroughly clean hole (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to bear-
ing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.

5-72 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.

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

applicable cylinder head groove.

Figure 5-61. Composite Bearing Installation

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
ROD
BUFFER SEAL
BEARING RING
WIPER SEAL

RETAINING
RING
O-RING BACKUP O-RING
RING
MAF00250

Figure 5-63. Cylinder Head Seal Installation

3121671 5-73
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

2. Use a soft mallet to tap a new wiper seal into the appli- 9. Place new wear rings and piston seal in the outer piston
cable cylinder head groove. Install new bearing, buffer diameter groove. (A tube, with I.D. slightly larger than
ring, backup ring and retaining ring into the applicable the O.D. of the piston is recommended to install the
inside diameter of the cylinder head groove. solid seal).

WEAR RING

Figure 5-64. Wiper Seal Installation PISTON SEAL

MAF00270
Figure 5-66. Piston Seal Kit Installation
3. Place new o-rings and backup ring in the applicable out-
side diameter groove of the cylinder head.
10. Position the cylinder barrel in a suitable holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,

O-RING HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
O-RING
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

11. With barrel clamped securely, and while adequately sup-

BACKUP RING porting the rod, insert the piston end into the barrel cyl-
MAF00260 inder. Ensure that the piston loading wear rings and
Figure 5-65. Installation of Head Seal Kit piston seal are not damaged or dislodged.

4. Carefully install the cylinder head on the rod, ensuring 12. Continue pushing the rod into the barrel until the cylin-
that the wiper seal, backup ring, retaining ring and rod der head can be inserted into the barrel cylinder.
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable. 13. Screw the cylinder head into the barrel using a hook
wrench and torque the cylinder head.
5. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to piston as possi- 14. Caulk at the machined area of the cylinder barrel end so
ble.
that it locks the cylinder head in place and it does not
6. Place a new o-ring in the inside diameter groove of unscrew from the barrel.
spacer. Install the spacer tube onto the cylinder rod.
7. Carefully thread the piston on the cylinder rod, hand
tight, ensuring that the o-ring and backup rings are not
damaged or dislodged. Secure using setscrew and ball.
Torque setscrew to 15 ft. lbs. (20 Nm).
8. Remove the cylinder rod from the holding fixture.
MAF00120

Figure 5-67. Caulking

15. Install the new o-rings, plugs, check valve, cartridge

valves, pressure compensator valve and orifice plug in
the cylinder port block. Torque as per values shown in
Figure 5-60.

5-74 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Master Cylinder 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using a hook spanner wrench,
DISASSEMBLY unscrew the cylinder head from the barrel.
BARREL

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK CYLINDER HEAD

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

PUNCH
SLIGHTLY TO AVOID TRAPPING MARKS
PRESSURE.
2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
MAF00280
3. Remove the plugs from the cylinder ports.
Figure 5-69. Cylinder Head Removal
4. Place the cylinder barrel into a suitable holding fixture.
6. Attach a suitable pulling device to the cylinder rod port
ROD SUPPORT
block end or cylinder rod end, as applicable.
PROTECTED ROD CLAMP

BARREL CLAMP 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.

7. With the barrel clamped securely, apply pressure to the

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

SUPPORT TABLE
SUPPORT TABLE

Figure 5-68. Cylinder Barrel Support

Figure 5-70. Cylinder Barrel Support

3121671 5-75
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

17 18

18
1

16
13 15

14
11
8
7
6
12
3*

4
5
9

2
17

* Torque to 549 ft. lbs. (745 Nm)

17 MAF00290

1. Barrel 6. Rod Seal 11. O-ring 15. Ball

2. Rod 7. Backup Ring 12. Piston 16. Setscrew
3. Cylinder Head 8. Bearing 13. Piston Seal 17. Bushing
4. Wiper Seal 9. O-ring 14. O-ring 18. Bushing
5. Retaining Ring 10. Backup Ring

Figure 5-71. Master Cylinder

5-76 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8. 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
solvent.
9. Loosen and remove the setscrew and ball which
attaches the piston to the rod. 2. Inspect the cylinder rod for scoring, tapering, ovality or
other damage. If necessary, dress rod with Scotch Brite
10. Screw the piston counterclockwise, by hand, and or equivalent. Replace rod if necessary.
remove the piston from cylinder rod.
3. Inspect threaded portion of rod for excessive damage.
11. Remove and discard the piston seal and o-ring. Dress threads as necessary.
12. Remove the rod from the holding fixture. Remove the 4. Inspect inner surface of cylinder barrel tube for scoring
cylinder head. Discard the o-rings, backup rings, rod or other damage. Check inside diameter for tapering or
seal, bearing, retaining ring, and wiper seal. ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
6. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as
necessary.
7. Inspect threaded portion of piston for damage. Dress
threads as necessary.
8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring,
tapering, ovality or other damage. Replace if 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,
tapering or ovality other damage. Replace if necessary.
13. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace if necessary.
a. Thoroughly clean hole (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to
bearing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.

3121671 5-77
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.

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

applicable cylinder head groove.

Figure 5-72. Composite Bearing Installation

14. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair as necessary.
15. Inspect piston rings for cracks or other damage. Replace
if necessary.

Figure 5-73. Rod Seal Installation

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
ROD O-RING
BEARING SEAL

WIPER SEAL

RETAINING
RING

BACKUP
O-RING RING
MAF00300

Figure 5-74. Cylinder Head Seal Installation

5-78 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

MAF00320

Figure 5-75. Wiper Seal Installation

Figure 5-77. Installation of Piston Seal Kit
3. Place new o-rings and backup ring in the applicable out-
side diameter groove of the cylinder head. 11. Position the cylinder barrel in a suitable holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,

HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
O-RING
O-RING
12. With barrel clamped secured and adequately support-
ing the rod, insert the piston end into the barrel cylinder.
Ensure that the piston loading o-ring and piston seal is
not damaged or dislodged.
BACKUP RING
MAF00310
13. Continue pushing the rod into the barrel until the cylin-
Figure 5-76. Installation of Head Seal Kit der head can be inserted into the barrel cylinder.

4. Carefully install the cylinder head on the rod, ensuring 14. Screw the cylinder head into the barrel using a hook
that the wiper seal, bearing, retaining ring, backup ring spanner wrench and torque cylinder head to 549 ft. lbs.
and rod seals are not damaged or dislodged. Push the (745 Nm).
head along the rod to the rod end, as applicable.
15. Caulk at the machined area of the cylinder barrel end so
5. Using suitable protection, clamp the cylinder rod in a that it locks the cylinder head in place and it does not
vise or similar holding fixture as close to piston as unscrew from the barrel.
possible.

6. Place new o-ring in the applicable inside diameter of the

piston.

7. Carefully thread the piston on the cylinder rod, hand

tight, ensuring that the o-ring and backup rings are not
damaged or dislodged.
MAF00120

8. Install the setscrew and ball on the piston and attach the Figure 5-78. Caulking
piston on the rod.

9. Remove the cylinder rod from the holding fixture. 16. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the
10. Place new piston seal in the outer piston diameter reinstallation of any plugs.
groove. (A tube, with I.D. slightly larger than the O.D. of
the piston is recommended to install the solid seal). 17. Install the plugs in the cylinder ports.

3121671 5-79
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Steer Cylinder 5. Using a hook spanner, loosen the cylinder head on both
ends of the rod. Remove the cylinder heads from the
DISASSEMBLY barrel and the rod.

BARREL
CYLINDER HEAD
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.
PUNCH
2. Operate the hydraulic power source and extend the MARKS
cylinder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. Remove the plugs from the cylinder ports. Discard Figure 5-80. Cylinder Head Removal
o-rings.
6. Remove and discard the wiper seal, rod seal, backup
4. Place the cylinder barrel into a suitable holding fixture.
ring, bearing, and o-ring from both the cylinder head.
ROD SUPPORT
7. Attach a suitable pulling device to the cylinder rod port
PROTECTED ROD CLAMP
block end or cylinder rod end, as applicable.

BARREL CLAMP

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.
SUPPORT TABLE
ROD SUPPORT
Figure 5-79. Cylinder Barrel Support
SUPPORT TABLE

Figure 5-81. Cylinder Barrel Support

9. Remove and discard the piston seal form the rod.

5-80 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

10
9
8
7
5
6 2
3

11
1

12
11

3
6
5
7
8
9
MAF00330

1. Barrel 5. Rod Seal 9. O-ring

2. Rod 6. Backup Ring 10. Piston Seal
3. Cylinder Head 7. Bearing 11. Plug
4. Wiper Seal 8. O-ring

Figure 5-82. Steer Cylinder

3121671 5-81
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

CLEANING AND INSPECTION

1. Clean all parts thoroughly in an approved cleaning WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.
solvent. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
2. Inspect the cylinder rod for scoring, tapering, ovality or
other damage. If necessary, dress rod with Scotch Brite
2. Use a soft mallet to tap a new wiper seal into the appli-
or equivalent. Replace rod if necessary.
cable cylinder head groove. Install a new bearing and
3. Inspect inner surface of cylinder barrel tube for scoring backup ring into the applicable inside diameter of the
or other damage. Check inside diameter for tapering or cylinder head groove.
ovality. Replace if necessary.
4. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
5. Inspect cylinder head inside diameter for scoring,
tapering, ovality or other damage. Replace if necessary.
6. Inspect threaded portion of head for damage. Dress
threads as necessary.
7. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
8. Inspect cylinder head outside diameter for scoring, Figure 5-84. Wiper Seal Installation
tapering or ovality other damage. Replace if necessary.
3. Place new o-rings in the applicable outside diameter
9. Inspect port block fittings and valves. Replace if neces- groove of the cylinder heads.
sary.
4. Place new piston seal in the applicable groove of the
10. Inspect the oil ports for blockage or the presence of dirt rod.
or other foreign material. Repair as necessary.
5. With barrel clamped secured and adequately support-
ASSEMBLY ing the rod, insert the rod into the barrel cylinder.

NOTE: Prior to cylinder assembly, ensure that the proper cylinder 6. Carefully install the cylinder head on both the side of the
seal kit is used. See the respective JLG Parts Manual. rod, ensuring that the wiper and rod seals are not dam-
aged or dislodged. Push the heads along the rod to the
NOTE: Apply a light film of hydraulic oil to all components prior to barrel, as applicable.
assembly. 7. Install new plugs into the cylinder port block.

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

applicable cylinder head groove.

Figure 5-83. Rod Seal Installation

5-82 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Telescope Cylinder 6. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen and
DISASSEMBLY remove the capscrews securing the wearpad plate and
cylinder head to the barrel. Remove the hardware secur-
ing the wear pads to the plate. Remove the wear pads.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA. WEAR PAD
BARREL
1. Connect a suitable auxiliary hydraulic power source to
the cylinder port block fitting. WEAR PAD PLATE

CAPSCREW

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

SLIGHTLY TO AVOID TRAPPING
PRESSURE.
2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable. PUNCH
MARKS
CYLINDER
3. Remove the capscrews securing the valve block to the HEAD
barrel end of the cylinder. Remove the valve assembly.
MAF00340
4. Remove the counterbalance valves, shuttle valve and
plugs from the valve block and cylinder port block. Dis-
card o-rings. Figure 5-86. Cylinder Head Removal
5. Place the cylinder barrel into a suitable holding fixture. 7. Attach a suitable pulling device to the cylinder rod port
ROD SUPPORT block end or cylinder rod end, as applicable.

PROTECTED ROD CLAMP

BARREL CLAMP 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.
ROD SUPPORT

SUPPORT TABLE SUPPORT TABLE

Figure 5-85. Cylinder Barrel Support

Figure 5-87. Cylinder Rod Support

3121671 5-83
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

12
16 13 11
12

2*** 15 13
12
31
18**** 12 14

4
1 32
5 29
17* 32
18****
24
25 30 26
24 28 27
7 33
30
20 21
10
22 9 21
8 19
23
3**

*Torque to 9 ft. lbs. (12 Nm)

* *Torque to 20 ft. lbs. (27 Nm) 6
** *Torque to 129 in. lbs. (15 Nm)
****Torque to 23 ft. lbs. (31 Nm)

MAF00350

1. Tapered Bushing 7. Spacer 13. Plug 19. Capscrew 24. Wear Ring 29. O-ring
2. Capscrew 8. Cylinder Head 14. Counterbalance Valve 20. Nut 25. Piston Seal 30. O-ring
3. Capscrew 9. Plate 15. Shuttle Valve 21. Washer 26. Wear Ring 31. O-ring
4. Barrel 10. Wear Pad 16. Counterbalance Valve 22. O-ring 27. Wiper Seal 32. Backup Ring
5. Piston 11. Valve Block 17. Capscrew 23. Backup Ring 28. Rod Seal 33. Wear Ring
6. Rod 12. Plug 18. Plug

Figure 5-88. Telescope Cylinder

5-84 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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
solvent.
10. Remove capscrews from drilled holes.
2. Inspect the cylinder rod for scoring, tapering, ovality, or
11. Insert the capscrews in the threaded holes in the outer other damage. If necessary, dress rod with Scotch Brite
piece of the tapered bushing. Progressively tighten the or equivalent. Replace rod if necessary.
capscrews until the bushing is loosen on the piston.
3. Inspect threaded portion of rod for excessive damage.
12. Remove the bushing from the piston. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
PISTON ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
TAPERED threads as necessary.
ROD BUSHING
6. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as
necessary.
CAPSCREW
7. Inspect threaded portion of piston for damage. Dress
threads as necessary.
8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring,
tapering, ovality or other damage. Replace if necessary.
Figure 5-89. Tapered Bushing Removal
10. Inspect threaded portion of head for damage. Dress
13. Screw the piston counterclockwise, by hand, and
threads as necessary.
remove the piston from cylinder rod.
11. Inspect seal and o-ring grooves in head for burrs and
14. Remove and discard the piston o-ring, seal rings, backup
sharp edges. Dress applicable surfaces as necessary.
rings and wear rings.
12. Inspect cylinder head outside diameter for scoring,
15. Remove piston spacer from the rod. Remove and discard
tapering, ovality or other damage. Replace if necessary.
the o-rings from the spacer.
13. If applicable, inspect rod and barrel bearings for signs of
16. Remove the rod from the holding fixture. Remove the
correct excessive wear or damage. Replace if necessary.
cap and the cylinder head. Discard the o-rings, backup
ring, wear rings, rod seal and wiper seal. a. Thoroughly clean hole (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to bear-
ing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.

3121671 5-85
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.

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

applicable cylinder head groove.

Figure 5-90. Composite Bearing Installation

14. Inspect spacer for burrs and sharp edges. If necessary,
dress inside diameter surface with Scotch Brite or equiv-
alent.
15. Inspect o-ring groove in spacer for burrs and sharp
edges. Dress applicable surfaces as necessary.
16. Inspect port block fittings and holding valve. Replace if
necessary.
17. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair if necessary.
Figure 5-91. Rod Seal Installation
18. Inspect piston rings for cracks or other damage. Replace
if necessary.

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
ROD SEAL
O-RING
WEAR RING

WIPER SEAL

WEAR RING BACKUP RING MAF00370

Figure 5-92. Cylinder Head Seal Installation

5-86 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

11. Assemble the tapered bushing loosely into the piston

and insert capscrews through the drilled holes in the
bushing and into the tapped holes in the piston.

PISTON
TAPERED
BUSHING
ROD
CAPSCREW
Figure 5-93. Wiper Seal Installation

3. Place new o-ring and backup ring in the applicable out-

side diameter groove of the cylinder head.

Figure 5-95. Tapered Bushing Installation

O-RING 12. Tighten the capscrews evenly and progressively in

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

13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4 in. diameter) as follows:
BACKUP RING
a. Place the shaft against the cylinder rod and in
MAF00380 contact with the bushing in the spaces between the
capscrews.
Figure 5-94. Installation of Head Seal Kit b. Place the shaft against the cylinder rod and in
contact with the bushing in the spaces between the
4. Carefully install the cylinder head on the rod, ensuring
capscrews.
that the wear ring, rod seal and wiper seal are not dam-
aged or dislodged. Push the head along the rod to the
rod end.

5. Place new o-rings in the applicable inside diameter PISTON

groove of spacer.

6. Install the spacer tube onto the cylinder rod ensuring CAPSCREW
that the o-rings are not damaged or dislodged.
ROD
7. Place a new o-ring and backup rings in the inner piston
diameter groove. TAPERED
BUSHING
8. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to piston as
possible.
BRASS SHAFT
9. Carefully thread the piston on the cylinder rod till it
abuts the spacer, ensuring that the o-ring and backup
ring is not damaged or dislodged. Figure 5-96. Seating the Tapered Bearing

3121671 5-87
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

14. Rotate the capscrews evenly and progressively in rota- 18. With barrel clamped securely, and while adequately sup-
tion to 9 ft. lbs. (12 Nm). porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston loading o-ring and seal ring
15. Remove the cylinder rod from the holding fixture.
are not damaged or dislodged.
16. Position the cylinder barrel in a suitable holding fixture.
19. Continue pushing the rod into the barrel until the cylin-
17. Place new piston seal and wear rings in the outer piston der head can be inserted into the barrel cylinder.
diameter groove. (A tube, with I.D. slightly larger than
20. Install wear pads onto the wearpad plate using bolts,
the O.D. of the piston is recommended to install the
washers and nuts.
solid seal).
21. Apply JLG Threadlocker P/N 0100011 to the capscrews.
WEAR RING
Secure the cylinder head to the barrel using the plate
and capscrews. Torque capscrews to 20 ft. lbs. (27 Nm).
22. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the
reinstallation of any holding valve or valves.
23. Install the new o-rings and plugs in the cylinder port
block. Torque to 23 ft. lbs. (31 Nm).
24. Install the counterbalance and shuttle valves onto the
valve block.
25. Apply JLG Threadlocker P/N 0100011 to the capscrews.
PISTON SEAL MAF00390 Install the valve assembly at the barrel end of the cylin-
der and secure using capscrews. Torque to 129 in. lbs.
Figure 5-97. Piston Seal Kit Installation (15 Nm).

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,

HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

5-88 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.4 PRESSURE SETTING PROCEDURE 3. If necessary, loosen jam nut and adjust the Main System
Relief valve clockwise to increase and counter-clockwise
Cold temperatures have a significant impact on pressure read- to decrease.
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.

Main System Relief

1. Install a pressure gauge at MP1 port of the Main Control
Valve capable of reading pressures up to 4000 psi
(275 Bar).

Steer Left Relief

1. Install a pressure gauge at port MP1 of the Main Control
Valve capable of reading pressures up to 4000 psi
(275 Bar).

2. Activate telescope in function continuously

at end of stroke. Observed pressure should
be 3000 ± 75 psi (207 ± 6 Bar).

2. Activate Steer Left function

continuously at end of stroke.
Observed pressure should be
2750 ± 75 psi (190 ± 6 Bar).

3121671 5-89
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. If necessary, loosen jam nut and adjust the Steer Left 3. If necessary, loosen jam nut and adjust the Steer Right
Relief valve clockwise to increase and counterclockwise Relief valve clockwise to increase and counterclockwise
to decrease. to decrease.

NOTE: Steer left pressure at port 24 is 2500 psi (173 Bar); a gauge NOTE: Steer Right pressure at port 23 is 2500 psi (173 Bar); a
may be placed there for troubleshooting. gauge may be placed there for troubleshooting.

Steer Right Relief Swing Relief

1. Install a pressure gauge at port MP1 of the Main Control 1. Install a pressure gauge at port MP1 of the Main Control
Valve capable of reading pressures up to 4000 psi Valve capable of reading pressures up to 3000 psi
(275 Bar). (207 Bar).

2. Activate Steer Right function 2. Activate Boom Swing Right or Left

continuously at end of stroke. function continuously against the
Observed pressure should be stop or lock. Observed pressure
2750 ± 75 psi (190 ± 6 Bar). should be 1700 ± 50 psi (117 ± 4
Bar).

5-90 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. If necessary, loosen jam nut and adjust the Boom Swing 3. If necessary, loosen jam nut and adjust the Jib Lift Down
Relief valve clockwise to increase and counterclockwise Relief valve clockwise to increase and counterclockwise
to decrease. to decrease.

NOTE: Boom Swing Right pressure at port 15 and Boom Swing Platform Level Up Relief
Left pressure at port 16 is 1600 psi (110 Bar); a gauge may
be placed there for troubleshooting. The Platform Level Up relief is set at the vendor and does not
normally need checked or adjusted. If necessary, the following
Jib Lift Down Relief (460SJ only) procedure may be utilized for trouble shooting purposes:
1. Lift the main boom up enough to allow the platform to
1. Install a pressure gauge at port M34 of the Main Control
be fully leveled up.
Valve capable of reading pressures up to 3000 psi
(207 Bar). 2. Activate Level Up to end of stroke.

3. Remove the hose from the Level Up port on the main

control valve (Port 37) - "T" a pressure gauge capable of
reading pressures up to 4000 psi (275 Bar) onto this port
and reconnect the hose.

BOTTOM OF MAIN CONTROL VALVE

2. Activate Jib Lift Down function continu-

ously at end of stroke. Observed pres-
sure should be 1200 ± 50 psi (83 ± 4 Bar).

BOTTOM OF MAIN CONTROL VALVE

3121671 5-91
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

4. Activate Main Boom Lift Down function using Auxiliary 3. Remove the hose from the Level Down port on the main
Mode continuously until fully lowered. Observed pres- control valve (Port 38) - "T" a pressure gauge capable of
sure should be 3200 ± 80 psi (220 ± 6 Bar). reading pressures up to 3000 psi (207 Bar) onto this port
and reconnect the hose.
5. If necessary, loosen jam nut and adjust the Platform
Level Up Relief valve clockwise to decrease and counter-
clockwise to increase.

BOTTOM OF MAIN CONTROL VALVE

4. Activate Platform Level Down function

continuously at end of stroke. Observed
pressure should be 2000 ± 50 psi (138 ± 4
Bar).

5. If necessary, loosen jam nut and adjust the Platform

Level Down Relief valve clockwise to decrease and coun-
ter-clockwise to increase.
6. Remove "T" and the gauge and reinstall the hose.

Platform Level Down Relief

The Platform Level Down relief is set at the vendor and does
not normally need checked or adjusted. If necessary, the fol-
lowing procedure may be utilized for trouble shooting pur-
poses:
1. Lift the main boom up enough to allow the platform to
be fully leveled down.
2. Activate Level Down to end of stroke.

6. Remove "T" and the gauge and reinstall the hose.

5-92 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

7
6 11

1
8

10
14
12
2
5
3

1001162531-F
MAF00400

1. Level Up 6. Not Used 11. Swing Left

2. Level Down 7. Rotate Left 12. Not Used
3. Tele In 8. Rotate Right 13. Not Used
4. Tele Out 9. Main Lift Up 14. Main Dump
5. Not Used 10. Swing Right

Figure 5-98. Main Control Valve Identification (400S) - Sheet 1 of 2

3121671 5-93
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

21
22
18
19

1001162531-F
MAF00410

15. Rotate Left 19. Steer Right Relief 23. Flow Regulator
16. Steer Left 20. Flow Regulator 24. Check Valve
17. Steer Right 21. Level Up Relief
18. Steer Left Relief 22. Level Down Relief

Figure 5-99. Main Control Valve Identification (400S) - Sheet 2 of 2

5-94 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

14
11

9
8
6

10
1

14
7
5
2 3

1001162532-F
MAF00420

1. Level Up 5. Jib Down 9. Swing Right 13. Flow Regulator

2. Level Down 6. Rotate Left 10. Swing Left 14. Flow Regulator
3. Tele In 7. Rotate Right 11. Steer Left 15. Pressure Compensator
4. Tele Out 8. Main Lift Up 12. Swing Relief

Figure 5-100. Main Control Valve Identification (460SJ) - Sheet 1 of 2

3121671 5-95
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

24
16 25

21 22
23

19
27
20

1001162532-F
MAF00430

16. Flow Control 20. Main Dump 24. Level Up Relief

17. Jib Lift Relief 21. Steer Relief 25. Level Down Relief
18. Jib Up 22. Steer Left Relief 26. Check Valve
19. Steer Right 23. Steer Right Relief 27. Flow Regulator

Figure 5-101. Main Control Valve Identification (460SJ) - Sheet 2 of 2

5-96 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

A, 3
D D F C C J C C, 3

A, 3 C F B

F J

H H 1001162531-F
1001162532-F
MAF00440

Figure 5-102. Main Control Valve Torque Values - Sheet 1 of 2

3121671 5-97
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

G, 3
C, 2 C, 2 C, 2 H F

3 2 2 C H H F J E
C, 1 C, 2

1 2

1001162531-F
1001162532-F
J MAF00450
J I
Table 5-34. Coil Torque Values
Table 5-33. Cartridge Torque Values Ft. lbs. Nm
Ft. lbs. Nm 1 4.5 6
A 48 65 2 4.5 6
B 43 58 3 6 8
C 38 51
Table 5-35. Coil Resistance Values
D 35 47
Temperature Resistance
E 30 41
1 20° C 6.2
F 28 38
2 20° C 8.8
G 25 34
3 20° C 7.1
H 13 18
I 12 16
J 8 11

Figure 5-103. Main Control Valve Torque Values - Sheet 2 of 2

5-98 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.5 DRIVE PUMP PRE-FILL PROCEDURE 4. If machine is NOT equipped with a hydraulic oil cooler
option,
The case of the hydraulic drive pump, MUST be pre-filled
a. Locate a case access port on the hydraulic drive
before starting the engine. Failure to do so can cause prema-
pump. Preferably one located at or near the top or
ture failure of the pump.
upper sides of the pump.
1. Fill the hydraulic reservoir. b. Using the proper wrench, remove the o-ring plug to
allow air to escape from the hydraulic drive pump
2. Determine if the hydraulic oil tank sight level gauge is case.
higher than other hydraulic components.
c. Hydraulic oil will flow by gravity from the hydraulic
a. Determine if the hydraulic oil tank sight level gauge tank to the drive pump.
is higher than the hydraulic drive pump assembly. d. When hydraulic oil starts to flow out this port, the
b. Determine if the hydraulic oil tank sight level gauge pump is full.
is higher than all hydraulic hose loops or routings e. Re-install the o-ring plug and torque.
between the hydraulic tank and the drive pump
assembly. 5. Pre-filling of the hydraulic drive pump is complete.

c. If sight level gauge is the highest hydraulic oil level

point, proceed to step 3.
d. If sight level gauge is NOT the highest hydraulic oil
level point, low pressure air may need to be applied
to the hydraulic oil tank (fill cap via air regulator) in
conjunction with step 4 to get hydraulic oil to move
over the air locks created by these high spots.

3. If the machine is be equipped with a hydraulic oil cooler

option:

a. Determine if there is a hydraulic ‘tee’ fitting installed

at the hydraulic drive pump that has a ‘cap’ fitting
attached to it. (this will generally be at or near the
top of the hydraulic drive pump body). This ‘cap’ fit-
ting is to be used to manually fill the hydraulic drive
pump case.
b. Remove ‘cap’ fitting.
c. Fill hydraulic drive pump case with hydraulic oil.
d. Reattach and torque ‘cap’ fitting.
e. Prefilling of the hydraulic drive pump w/oil cooler
option is complete (Step #4 can be omitted at this
point).s

3121671 5-99
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.6 HYDRAULIC SCHEMATICS

8 7 6 5 4

PLATFORM ROTATOR
LEVEL CYLINDER TELESCOPE CYLINDER

V2
MASTER CYLINDER

V1
V1 V2

20 psi

OPTIONAL HYDRAULIC OIL COOLER

F DRIVE PUMP

38 37 36 35 31

3200 psi

FUNCTION PUMP
2000 psi

0.031 in 0.2 GPM

E AXLE VALVE

P11

43 psi 0.028 in
0.062 in
0.02 in

MP1 P1

21 22 27 T11

D
OPTIONAL HYDRAULIC OIL COOLER

AXLE OSCILLATION CYLINDER

A B A B

TRACTION VALVE
C 1 6 4 7 2 8 M11

STEER CYLINDER
0.028 in 0.035 in 0.028 in

325 psi
5 3 12 9 10 11

AXLE OSCILLATION CYLINDER

A B A B

SHEET 1
8 7 6 5 4

Figure 5-104. Hydraulic Schematic - Sheet 1 of 8

5-100 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5 4 3 2 1

LIFT CYLINDER
H

PLATFORM ROTATOR
LEVEL CYLINDER TELESCOPE CYLINDER

SWING MOTOR
V2

V1
V1 V2

V1 V2

MAIN CONTROL VALVE

38 37 36 35 31 32 18 17 15 16 23 2500 psi 24

3200 psi

2500 psi
2000 psi

0.031 in 0.2 GPM 1450 psi

5 psi 25 psi

1.5 GPM
E

P11

0.028 in
0.062 in
3000 psi

MP1 P1 P2 T1

27 T11

AUXILIARY PUMP

AXLE OSCILLATION CYLINDER

A B

2 8 M11 C

STEER CYLINDER
0.028 in

10 11

AXLE OSCILLATION CYLINDER

A B

1001178276-C
SHEET 1 MAF00480
5 4 3 2 1

Figure 5-105. Hydraulic Schematic - Sheet 2 of 8

3121671 5-101
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8 7 6 5 4

PLATFORM ROTATOR
LEVEL CYLINDER TELESCOPE CYLINDER JIB CYLINDER

V2
MASTER CYLINDER

V1 V2
V1
V1 V2

20 psi

OPTIONAL HYDRAULIC OIL COOLER

F DRIVE PUMP

38 37 36 35 M34 34 33 31

3200 psi 1200 psi

FUNCTION PUMP
2000 psi

0.031 in 0.2 GPM

E AXLE VALVE

P11

43 psi 0.028 in
0.062 in
0.02 in

MP1 P1

21 22 27 T11

D
OPTIONAL HYDRAULIC OIL COOLER

AXLE OSCILLATION CYLINDER

A B A B

TRACTION VALVE
C 1 6 4 7 2 8 M11

STEER CYLINDER
0.028 in 0.035 in 0.028 in

325 psi
5 3 12 9 10 11

AXLE OSCILLATION CYLINDER

A B A B

SHEET 2
8 7 6 5 4

Figure 5-106. Hydraulic Schematic - Sheet 3 of 8

5-102 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5 4 3 2 1

LIFT CYLINDER
H

PLATFORM ROTATOR
LEVEL CYLINDER TELESCOPE CYLINDER JIB CYLINDER

SWING MOTOR
V2

V1 V2
V1
V1 V2

V1 V2

MAIN CONTROL VALVE

38 37 36 35 M34 34 33 31 32 18 17 15 16 23 2500 psi 24

3200 psi 1200 psi

2500 psi
2000 psi

0.031 in 0.2 GPM 1450 psi

5 psi 25 psi

1.5 GPM
E

P11

0.028 in
0.062 in
3000 psi

MP1 P1 P2 T1

27 T11

AUXILIARY PUMP

AXLE OSCILLATION CYLINDER

A B

2 8 M11 C

STEER CYLINDER
0.028 in

10 11

AXLE OSCILLATION CYLINDER

A B

1001178276-C
SHEET 2 MAF00490
5 4 3 2 1

Figure 5-107. Hydraulic Schematic - Sheet 4 of 8

3121671 5-103
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8 7 6 5 4

PLATFORM ROTATOR
LEVEL CYLINDER TELESCOPE CYLINDER

V2
MASTER CYLINDER

V1
V1 V2

20 psi

OPTIONAL HYDRAULIC OIL COOLER

F DRIVE PUMP

38 37 36 35 31

3200 psi

FUNCTION PUMP
2000 psi

0.031 in 0.2 GPM

E AXLE VALVE

P11

43 psi 0.028 in
0.062 in
0.02 in

MP1 P1

21 22 27 T11

D
OPTIONAL HYDRAULIC OIL COOLER

AXLE OSCILLATION CYLINDER

A B

TRACTION VALVE
C 1 6 4 2 8 M11

STEER CYLINDER
0.052 in

325 psi
12 10 11

AXLE OSCILLATION CYLINDER

A B

SHEET 3
8 7 6 5 4

Figure 5-108. Hydraulic Schematic - Sheet 5 of 8

5-104 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5 4 3 2 1

LIFT CYLINDER
H

PLATFORM ROTATOR
LEVEL CYLINDER TELESCOPE CYLINDER

SWING MOTOR
V2

V1
V1 V2

V1 V2

MAIN CONTROL VALVE

38 37 36 35 31 32 18 17 15 16 23 2500 psi 24

3200 psi

2500 psi
2000 psi

0.031 in 0.2 GPM 1450 psi

5 psi 25 psi

1.5 GPM
E

P11

0.028 in
0.062 in
3000 psi

MP1 P1 P2 T1

27 T11

AUXILIARY PUMP

AXLE OSCILLATION CYLINDER

2 8 M11 C

STEER CYLINDER
0.052 in

10 11

AXLE OSCILLATION CYLINDER

SHEET 3 1001178276-C
MAF00500
5 4 3 2 1

Figure 5-109. Hydraulic Schematic - Sheet 6 of 8

3121671 5-105
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

8 7 6 5 4

PLATFORM ROTATOR
LEVEL CYLINDER TELESCOPE CYLINDER JIB CYLINDER

V2
MASTER CYLINDER

V1 V2
V1
V1 V2

20 psi

OPTIONAL HYDRAULIC OIL COOLER

F DRIVE PUMP

38 37 36 35 M34 34 33 31

3200 psi 1200 psi

FUNCTION PUMP
2000 psi

0.031 in 0.2 GPM

E AXLE VALVE

P11

43 psi 0.028 in
0.062 in
0.02 in

MP1 P1

21 22 27 T11

D
OPTIONAL HYDRAULIC OIL COOLER

AXLE OSCILLATION CYLINDER

A B

TRACTION VALVE
C 1 6 4 2 8 M11

STEER CYLINDER
0.052 in

325 psi
12 10 11

AXLE OSCILLATION CYLINDER

A B

SHEET 4
8 7 6 5 4

Figure 5-110. Hydraulic Schematic - Sheet 7 of 8

5-106 3121671
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5 4 3 2 1

LIFT CYLINDER
H

PLATFORM ROTATOR
LEVEL CYLINDER TELESCOPE CYLINDER JIB CYLINDER

SWING MOTOR
V2

V1 V2
V1
V1 V2

V1 V2

MAIN CONTROL VALVE

38 37 36 35 M34 34 33 31 32 18 17 15 16 23 2500 psi 24

3200 psi 1200 psi

2500 psi
2000 psi

0.031 in 0.2 GPM 1450 psi

5 psi 25 psi

1.5 GPM
E

P11

0.028 in
0.062 in
3000 psi

MP1 P1 P2 T1

27 T11

AUXILIARY PUMP

AXLE OSCILLATION CYLINDER

2 8 M11 C

STEER CYLINDER
0.052 in

10 11

AXLE OSCILLATION CYLINDER

SHEET 4 1001178276-C
MAF00510
5 4 3 2 1

Figure 5-111. Hydraulic Schematic - Sheet 8 of 8

3121671 5-107
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

NOTES:

5-108 3121671
SECTION 6 - JLG CONTROL SYSTEM

SECTION 6. JLG CONTROL SYSTEM

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

The Control System may be accessed utilizing a custom

The JLG designed Control System is a 12 volt based control designed, hand held analyzer (Analyzer Kit, JLG part no.
unit installed on the boom lift. 2901443) which will display two lines of information at a time,
The JLG Control System has reduced the need for exposed ter- by scrolling through the program.
minal strips, diodes and trimpots and provides simplicity in

Analyzer Display

Enter Key
Escape Key
Stores and selects Top Level, Sub
To return home or access pre-
Level, and item menus
vious menu

Left & Right Arrow Keys

Up & Down Arrow Keys
Used to move between Top Level, Sub
Value Selector
Level, and item menus

Figure 6-1. Hand Held Analyzer

3121671 6-1
SECTION 6 - JLG CONTROL SYSTEM

To Connect the JLG Control System Analyzer Using the Analyzer

1. Connect the four pin end of the cable supplied with the With the machine power on and the analyzer connected prop-
analyzer, to the motor controller module located in the erly, the analyzer will display the following:
platform box or at the power module and connect the
remaining end of the cable to the analyzer.

NOTE: The cable has a four pin connector at each end of the cable;
the cable cannot be connected backwards.

2. Power up the Control System by turning the lower key to

the platform or ground position and pulling both emer-
gency stop buttons on.

HELP:
PRESS ENTER

At this point, using the RIGHT and LEFT arrow

keys, you can move between the top level menu items. To

select a displayed menu item, press ENTER . To cancel a

selected menu item, press Escape ; then you will be able

to scroll using the right and left arrow keys to select a different
menu item.

6-2 3121671
SECTION 6 - JLG CONTROL SYSTEM

The top level menus are as follows: When a top level menu is selected, a new set of menu items
may be offered: for example:
HELP
DIAGNOSTICS DRIVE
ACTIVATE TEST BOOM
ACCESS LEVEL SYSTEM
PERSONALITIES DATALOG
MACHINE SETUP VERSIONS
LEVEL VEHICLE (level 1 only)
CALIBRATIONS (view only)
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected menu. In
If you press ENTER , at the HELP: PRESS ENTER display, some cases, such as DRIVE, the next level is the parameter or
and a fault is present, the analyzer display will scroll the fault information to be changed. Refer to the flow chart for what
across the screen. If there was no fault detected, the display menus are available within the top level menus. You may only
will read: HELP: EVERYTHING OK. If powered up at the view the personality settings for selected menus while in
ground station, the display will read: GROUND OK. access level 2. Remember, you may always cancel a selected

If ENTER is pressed again, the display moves to the fol- menu item by pressing the ESCAPE key.
lowing display:
Changing the Access Level of the Hand Held
Analyzer
When the analyzer is first connected, you will be in Operator
Access which enables you to only view most settings which
cannot be changed until you enter a password to advance to a
lower level. This ensures that a setting cannot be accidentally
altered. To change the access level, the correct password must
be entered. To enter the password, scroll to the ACCESS LEVEL
menu. For example:

LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the last fault the system
has seen, if any are present. You may scroll through the fault
logs to view what the last 25 faults were. Use the right and left
arrow keys to scroll through the fault logs. To return to the

beginning, press ESCAPE two times. STARTUP (2/1)

indicates a power up.

ACCESS LEVEL:
CODE 00000

3121671 6-3
SECTION 6 - JLG CONTROL SYSTEM

Adjusting Parameters Using the Hand Held

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

Use the UP or DOWN arrow key to enter the sec-

ond digit of the password which is 33271.

Once the correct password is displayed, press ENTER .

The access level should display the following, if the password
was entered correctly:

DRIVE:
ACCEL 1.5s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if the UP

arrow is pressed when at the maximum value nor will

the value decrease if the DOWN arrow is pressed and

the value is at the minimum value for any particular personal-
ity. If the value does not change when pressing the up and
MENU:
down arrows, check the access level to ensure you are at
SERVICE ACCESS
access level 1.
Repeat the above steps if the correct access level is not dis-
played or you can not adjust the personality settings.

6-4 3121671
SECTION 6 - JLG CONTROL SYSTEM

Machine Setup There is a setting that JLG strongly recommends that you do
not change. This setting is so noted below:
ELEVATION CUTBACK
When a machine digit item is selected, press the UP or

DOWN arrow keys to adjust its value, for example:

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF
YOUR MACHINE.

ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC-

TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES
INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI-
MUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM THESE COMPONENTS. IF
ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT
BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

GROUND ALARM:
2 = DRIVE
The effect of the machine digit value is displayed along with
its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
sound when driving. There are certain settings allowed to
install optional features or select the machine model.
When selection the machine model to match the size of the
machine, the personality settings will all default to the factory
recommended setting.

NOTE: Refer to Personality Ranges/Defaults for the recommended

factory settings.

NOTE: Password 33271 will give you access to level 1, which will
permit you to change all machine personality settings.

3121671 6-5
SECTION 6 - JLG CONTROL SYSTEM

Tilt Sensor Calibration 4. Using the arrow keys, navigate to the Tilt Sensor calibra-

Refer to Figure 6-2., Tilt Sensor Location.

tion as shown below and press ENTER .

DO NOT CALIBRATE THE TILT SENSOR EXCEPT ON A LEVEL SURFACE.

1. Place the machine on a firm, level surface.

2. Using the analyzer, go to Service Access level. Refer to
Changing the Access Level of the Hand Held Analyzer in
this section.
3. Using the arrow keys, navigate to Calibrations Menu as

shown below and press ENTER .

the screen will then read:

6-6 3121671
SECTION 6 - JLG CONTROL SYSTEM

5. When the sensor is calibrated in that position, the screen 7. When the calibration is complete the screen will read as
will read: shown below. Return the machine to the travel position.

6. Swing the machine 180 degrees, making sure the boom

is centered and in the transport position, and ENTER

. The screen will read:

3121671 6-7
SECTION 6 - JLG CONTROL SYSTEM

TILT SENSOR

MAIN VALVE
HARNESS

ELECTRICAL
PANEL

GROUND
CONTROL

MAF00600

Figure 6-2. Tilt Sensor Location

6-8 3121671
SECTION 6 - JLG CONTROL SYSTEM

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

Figure 6-5. Engine Diagnostic Screen

Figure 6-3. Splash Screen

The Diagnostic Screen will show active and inactive faults

from the JLG Control System on the screen. An asterisk (*)
will be displayed to show active faults.

Figure 6-4. Diagnostic Screen

3121671 6-9
SECTION 6 - JLG CONTROL SYSTEM

INDICATOR LAMP

ENGINE HOURS FUEL LEVEL

NAVIGATE BACK ARROW NAVIGATE FORWARD ARROW

NAVIGATION BUTTONS

Figure 6-6. Ground Control Console Display Gauge

6-10 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations

ABBREVIATION MEANING ABBREVIATION MEANING

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

3121671 6-11
SECTION 6 - JLG CONTROL SYSTEM

Table 6-1. Analyzer Abbreviations

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

6-12 3121671
SECTION 6 - JLG CONTROL SYSTEM

Figure 6-7. Analyzer Connecting Points

3121671 6-13
SECTION 6 - JLG CONTROL SYSTEM

Connector Pin Function Type

1 UNUSED (PROPORTIONAL FUEL RACK ACTUATOR) DIGITAL OUTPUT
2 OSCILLATING AXLE VALVE #2 DIGITAL OUTPUT
3 DRIVE FORWARD / LEFT TRACK DRIVE FORWARD VALVE DIGITAL OUTPUT
4 UNUSED (GROUND) GROUND INPUT
5 UNUSED (GROUND) GROUND INPUT
6 DRIVE REVERSE / LEFT TRACK DRIVE REVERSE VALVE DIGITAL OUTPUT
7 OSCILLATING AXLE VALVE #1 DIGITAL OUTPUT
8 UNUSED (GROUND) GROUND INPUT
9 MSSO SWITCH GROUND GROUND INPUT
10 ECU POWER DIGITAL OUTPUT
11 START RELAY DIGITAL OUTPUT
12 ENGAGE GLOW PLUGS RELAY DIGITAL OUTPUT
13 APU ENABLE RELAY DIGITAL OUTPUT
14 UNUSED (ENGINE COOLANT TEMPERATURE SENSOR) ANALOG INPUT
15 UNUSED (ENGINE OIL PRESSURE SENSOR) ANALOG INPUT
16 UNUSED (ENGINE SPEED SENSOR) FREQUENCY INPUT
17 UNUSED (ENGINE SPEED SENSOR GROUND) GROUND INPUT
J1
18 UNUSED (ENGINE GROUND) GROUND INPUT
(Natural)
19 UNUSED (GROUND) GROUND INPUT
20 2 SPEED VALVE DIGITAL OUTPUT
21 UNUSED (TOWER ELEVATION SWITCH #2) DIGITAL INPUT
22 GENERATOR ENABLE RELAY DIGITAL OUTPUT
23 BRAKE VALVE DIGITAL OUTPUT
24 UNUSED N/C N/C
25 UNUSED (RESERVED FOR RS-485 HIGH) SERIAL I/O
26 UNUSED (RESERVED FOR RS-485 LOW) SERIAL I/O
27 BRAKE / 2 SPEED VALVE GROUND GROUND INPUT
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 UNUSED (GROUND) GROUND INPUT
34 TELESCOPE RETRACTED SWITCH #2 DIGITAL INPUT
35 CAPACITY LENGTH SWITCH #2 DIGITAL INPUT

Connector Pin Function Type

1 UNUSED (STEER DUMP VALVE) DIGITAL OUTPUT
2 GROUND ALARM DIGITAL OUTPUT
PIN 1
3 UNUSED (TOWER TELESCOPE IN VALVE) DIGITAL OUTPUT
4 MAIN TELESCOPE IN VALVE DIGITAL OUTPUT
5 PLATFORM LEVEL UP VALVE DIGITAL OUTPUT
6 FUEL SENSOR GROUND GROUND INPUT
7 PLATFORM LEVEL DOWN VALVE DIGITAL OUTPUT
8 FRONT STEER RIGHT / RIGHT TRACK DRIVE REVERSE VALVE DIGITAL OUTPUT
9 AUX MAIN LIFT DOWN / TOWER LIFT DOWN VALVE DIGITAL OUTPUT
10 PLATFORM ROTATE LEFT VALVE DIGITAL OUTPUT
11 MAIN LIFT UP VALVE DIGITAL OUTPUT
12 JIB LIFT UP VALVE DIGITAL OUTPUT
13 MAIN DUMP VALVE DIGITAL OUTPUT
14 MAIN TELESCOPE / PLATFORM LEVEL VALVES GROUND GROUND INPUT
15 UNUSED (TOWER TELESCOPE OUT VALVE) DIGITAL OUTPUT
16 MAIN TELESCOPE OUT VALVE DIGITAL OUTPUT
17 PLATFORM ROTATE / JIB LIFT VALVE GROUND GROUND INPUT PIN 1
J2
18 UNUSED (STEER DUMP VALVE GROUND) GROUND INPUT
(Gray)
19 FRONT LEFT STEER / RIGHT TRACK DRIVE FORWARD VALVE DIGITAL OUTPUT
20 TOWER LIFT UP VALVE DIGITAL OUTPUT
21 AUX MAIN LIFT DOWN / PLATFORM ROTATE RIGHT VALVE DIGITAL OUTPUT
22 MAIN LIFT DOWN VALVE DIGITAL OUTPUT
23 AUX TOWER LIFT DOWN / JIB LIFT DOWN VALVE DIGITAL OUTPUT
24 UNUSED (CONFIGURATION #2) DIGITAL INPUT
25 FUEL SENSOR SIGNAL ANALOG INPUT
26 HEAD / TAIL LIGHT ENABLE RELAY DIGITAL OUTPUT
27 GROUND ALARM / HORN OUTPUT DIGITAL OUTPUT
28 STEER VALVES GROUND GROUND INPUT
29 GROUND ALARM GROUND GROUND INPUT
30 MAIN DUMP VALVE GROUND GROUND INPUT
31 FLOW CONTROL VALVE DIGITAL OUTPUT
32 UNUSED (REAR STEER RIGHT VALVE) DIGITAL OUTPUT
33 UNUSED (REAR STEER LEFT VALVE) DIGITAL OUTPUT
34 SWING LEFT VALVE DIGITAL OUTPUT
35 SWING RIGHT VALVE DIGITAL OUTPUT

Connector Pin Function Type

1 DRIVE / LEFT TRACK DRIVE VALVES CURRENT FEEDBACK GROUND INPUT
2 AUX DOWN / RIGHT TRACK DRIVE VALVES CURRENT FEEDBACK GROUND INPUT
3 UNUSED (CABLE BRAKE SWITCH GROUND) GROUND INPUT
4 SWING VALVES CURRENT FEEDBACK GROUND INPUT
5 TOWER LIFT / AUX DOWN VALVES CURRENT FEEDBACK GROUND INPUT MOUNTING HARDWARE TORQUE
6 FLOW CONTROL VALVE CURRENT FEEDBACK GROUND INPUT
J3 7 GROUND ALARM POWER VBAT OUTPUT NOT TO EXCEED 72 IN-LBS.
(Black) 8 UNUSED (CABLE BRAKE SWITCH) DIGITAL INPUT
9 CRIBBING ENABLE SWITCH DIGITAL INPUT
10 UNUSED (INPUT) DIGITAL INPUT
11 UNUSED (CONFIGURATION #1) DIGITAL INPUT
12 UNUSED (+5 VOLTS) VOLTAGE OUTPUT
13 UNUSED (INPUT) ANALOG INPUT
14 MAIN LIFT VALVES CURRENT FEEDBACK GROUND INPUT

1001170094-H
MAF00610

Figure 6-8. Ground Control Module - Sheet 1 of 3

6-14 3121671
SECTION 6 - JLG CONTROL SYSTEM

Connector Pin Function Type

1 PLATFORM EMS DIGITAL INPUT
2 PLATFORM MODE DIGITAL INPUT
3 GROUND MODE DIGITAL INPUT
4 BOOM ANGLE SENSOR #1 ANALOG INPUT
5 UNUSED (ENGINE SPEED SENSOR) VOLTAGE OUTPUT
6 CAN1 TERMINATOR TERM I/O
7 BOOM ANGLE SENSOR #2 ANALOG INPUT
8 UNUSED (INPUT) ANALOG INPUT
9 BOOM ANGLE SENSOR GROUND GROUND INPUT
10 TILT SENSOR GROUND GROUND INPUT
11 TOWER ELEVATION SWITCH DIGITAL INPUT
12 OSCILLATING AXLE SWING SWITCH #1 DIGITAL INPUT
13 CAN1 HIGH SERIAL I/O
14 GROUND MODE POWER TO PLATFORM DIGITAL INPUT
PIN 1 15 FOOTSWITCH DIGITAL INPUT
16 BOOM ANGLE SENSOR POWER VOLTAGE OUTPUT
17 CAN1 TERMINATOR TERM I/O
J7
18 CAN1 SHIELD GROUND INPUT
(Black)
19 IGNITION RELAY GROUND GROUND INPUT
20 OSCILLATING AXLE SWING SWITCH #2 ANALOG INPUT
21 TELESCOPE RETRACTED SWITCH #1 DIGITAL INPUT
22 UNUSED (INPUT) DIGITAL INPUT
23 CAPACITY LENGTH SWITCH #1 DIGITAL INPUT
24 CAN1 LOW SERIAL I/O
25 GROUND DISPLAY GROUND GROUND INPUT
26 UNUSED (+5 VOLTS) VOLTAGE OUTPUT
27 UNUSED (+5 VOLTS) VOLTAGE OUTPUT
28 TELESCOPE RETRACTED SWITCH GROUND GROUND INPUT
29 GROUND DISPLAY POWER VBAT OUTPUT
30 UNUSED (BATTERY VOLTAGE) VBAT OUTPUT
31 UNUSED (BATTERY VOLTAGE) VBAT OUTPUT
32 TRANSPORT SWITCHES POWER VBAT OUTPUT
33 TELESCOPE RETRACTED SWITCH POWER VBAT OUTPUT
34 TILT SENSOR POWER VBAT OUTPUT
35 DOS SWITCH DIGITAL INPUT

Connector Pin Function Type

1 UNUSED FREQUENCY INPUT
2 UNUSED FREQUENCY INPUT
3 CAN2 HIGH SERIAL I/O
J12 4 CAN2 LOW SERIAL I/O
(RED) 5 CAN2 SHIELD GROUND INPUT
6 CAN2 TERMINATOR TERM I/O
7 CAN2 TERMINATOR TERM I/O
8 MSSO SWITCH DIGITAL INPUT
MOUNTING HARDWARE TORQUE
NOT TO EXCEED 72 IN-LBS.

1001170094-H
MAF00620

Figure 6-9. Ground Control Module - Sheet 2 of 3

3121671 6-15
SECTION 6 - JLG CONTROL SYSTEM

Connector Pin Function Type

1 MODULE GROUND GROUND OUTPUT
J8 2 MODULE POWER VBAT INPUT
(Black) 3 GROUND TO PLATFORM MODULE GROUND INPUT
4 POWER TO PLATFORM MODULE VBAT OUTPUT

PIN 1

Connector Pin Function Type

1 CRIBBING ENGAGED INDICATOR DIGITAL OUTPUT
2 SYSTEM DISTRESS INDICATOR DIGITAL OUTPUT
3 GLOWPLUG INDICATOR DIGITAL OUTPUT
4 ENGINE START SWITCH DIGITAL INPUT
5 PLATFORM LEVEL DOWN SWITCH DIGITAL INPUT
6 PLATFORM ROTATE LEFT SWITCH DIGITAL INPUT
7 MAIN TELESCOPE IN SWITCH DIGITAL INPUT
8 JIB LIFT DOWN SWITCH DIGITAL INPUT
9 UNUSED (JIB LEFT SWITCH) DIGITAL INPUT
10 TOWER LIFT UP SWITCH DIGITAL INPUT
11 UNUSED (TOWER TELESCOPE IN SWITCH) DIGITAL INPUT
12 UNUSED (OUTPUT) DIGITAL OUTPUT
13 LOW FUEL INDICATOR DIGITAL OUTPUT
14 PLATFORM OVERLOADED INDICATOR DIGITAL OUTPUT
15 UNUSED (BOOM MALFUNCTION INDICATOR) DIGITAL OUTPUT
16 AUXILIARY POWER / FUNCTION ENABLE SWITCH DIGITAL INPUT
17 PLATFORM LEVEL UP SWITCH DIGITAL INPUT
J4
18 PLATFORM ROTATE RIGHT SWITCH DIGITAL INPUT
(Blue)
19 JIB LIFT UP SWITCH DIGITAL INPUT
20 UNUSED (JIB RIGHT SWITCH) DIGITAL INPUT
21 TOWER LIFT DOWN SWITCH DIGITAL INPUT
22 UNUSED (TOWER TELESCOPE OUT SWITCH) DIGITAL INPUT
23 MAIN LIFT UP SWITCH DIGITAL INPUT
24 UNUSED (BATTERY VOLTAGE) VBAT OUTPUT
25 SWITCHES POWER VBAT OUTPUT
26 BATTERY LOW / NOT CHARGING INDICATOR DIGITAL OUTPUT
27 UNUSED (OUTPUT) DIGITAL OUTPUT
28 ENGINE HIGH COOLANT TEMPERATURE INDICATOR DIGITAL OUTPUT
29 ENGINE LOW OIL PRESSURE INDICATOR DIGITAL OUTPUT
30 MAIN TELESCOPE OUT SWITCH DIGITAL INPUT
31 INDICATORS GROUND GROUND INPUT
32 INDICATORS GROUND GROUND INPUT
33 MAIN LIFT DOWN SWITCH DIGITAL INPUT
34 SWING LEFT SWITCH DIGITAL INPUT
35 SWING RIGHT SWITCH DIGITAL INPUT

1001170094-H
MAF00630

Figure 6-10. Ground Control Module - Sheet 3 of 3

6-16 3121671
SECTION 6 - JLG CONTROL SYSTEM

CONNECTOR PIN ASSIGNMENT FUNCTION

1 UNUSED (JIB RIGHT SWITCH) DIGITAL INPUT
2 UNUSED (JIB LEFT SWITCH) DIGITAL INPUT
3 UNUSED (POWER) HS DIGITAL INPUT
4 DOS OVERRIDE SWITCH HS DIGITAL INPUT
5 UNUSED LAMP OUTPUT
6 CHASSIS TILTED INDICATOR LAMP OUTPUT
7 FUNCTION ENABLE INDICATOR LAMP OUTPUT
8 VEHICLE SYSTEM DISTRESS INDICATOR LAMP OUTPUT
9 CREEP SPEED INDICATOR LAMP OUTPUT
10 UNUSED (BROKEN CABLE INDICATOR) LAMP OUTPUT
11 PLATFORM OVERLOADED INDICATOR LAMP OUTPUT
12 500 / 600 LB CAPACITY INDICATOR LAMP OUTPUT
13 1000 LB CAPACITY INDICATOR LAMP OUTPUT
14 DOS INDICATOR LAMP OUTPUT
15 GENERATOR ON INDICATOR LAMP OUTPUT
16 SOFT TOUCH / SKYGUARD INDICATOR LAMP OUTPUT
17 GLOW PLUG ENGAGED INDICATOR LAMP OUTPUT
J2 18 INDICATOR GROUND GROUND
GRAY 19 UNUSED (LOW BATTERY INDICATOR) LAMP OUTPUT
20 UNUSED LAMP OUTPUT
21 LOW FUEL INDICATOR LAMP OUTPUT
22 1/4 FUEL LEVEL INDICATOR LAMP OUTPUT
23 3/4 FUEL LEVEL INDICATOR LAMP OUTPUT
24 1/2 FUEL LEVEL INDICATOR LAMP OUTPUT
25 INDICATOR GROUND GROUND
26 ANALYZER POWER ANALYZER POWER
27 ANALYZER GROUND ANALYZER GROUND
28 ANALYZER RX ANALYZER RX
29 ANALYZER TX ANALYZER TX
30 UNUSED (POWER) BATTERY VOLTAGE
31 SOFT TOUCH POWER BATTERY VOLTAGE
32 LSS POWER BATTERY VOLTAGE
33 OPTION POWER BATTERY VOLTAGE
34 UNUSED (POWER) BATTERY VOLTAGE
35 FULL FUEL LEVEL INDICATOR LAMP OUTPUT

CONNECTOR PIN ASSIGNMENT FUNCTION

1 TOWER LIFT UP SWITCH DIGITAL INPUT
2 TOWER LIFT DOWN SWITCH DIGITAL INPUT
3 UNUSED (TOWER TELESCOPE IN SWITCH) DIGITAL INPUT
4 UNUSED (TOWER TELESCOPE OUT SWITCH) DIGITAL INPUT
5 MAIN TELESCOPE IN SWITCH DIGITAL INPUT
6 MAIN TELESCOPE OUT SWITCH DIGITAL INPUT
7 PLATFORM ROTATE RIGHT SWITCH DIGITAL INPUT
8 PLATFORM ROTATE LEFT SWITCH DIGITAL INPUT
9 PLATFORM LEVEL UP SWITCH DIGITAL INPUT
10 PLATFORM LEVEL DOWN SWITCH DIGITAL INPUT
11 JIB LIFT UP SWITCH DIGITAL INPUT
12 JIB LIFT DOWN SWITCH DIGITAL INPUT
13 SPEED PUMP POTENTIOMETER GROUND GROUND
14 ENGINE START SWITCH DIGITAL INPUT
15 AUXILIARY POWER SWITCH DIGITAL INPUT
16 UNUSED (CRAB STEER SELECT SWITCH) DIGITAL INPUT
17 UNUSED (COORDINATED STEER SELECT SWITCH) DIGITAL INPUT
J1 18 SWITCH POWER BATTERY VOLTAGE
NATURAL 19 UNUSED DIGITAL INPUT
20 SOFT TOUCH SWITCH DIGITAL INPUT
21 UNUSED (CAPACITY SELECT SWITCH) DIGITAL INPUT
22 UNUSED DIGITAL INPUT
23 SKYGUARD INPUT #2 SWITCH DIGITAL INPUT
24 UNUSED DIGITAL INPUT
25 UNUSED DIGITAL INPUT
26 UNUSED DIGITAL INPUT
27 MAX SPEED SWITCH DIGITAL INPUT
28 MAX TORQUE SWITCH DIGITAL INPUT
29 SOFT TOUCH / SKYGUARD OVERRIDE BUTTON DIGITAL INPUT
30 HEAD / TAIL LIGHT SWITCH DIGITAL INPUT
31 HORN BUTTON DIGITAL INPUT
32 CREEP SWITCH DIGITAL INPUT
33 FUEL SELECT SWITCH DIGITAL INPUT
34 SPEED PUMP POTENTIOMETER POWER +7 REFERENCE VOLTAGE
35 SPEED PUMP POTENTIOMETER SIGNAL DIGITAL INPUT

1001157196-F
MAF01160

Figure 6-11. Platform Module - Sheet 1 of 2

3121671 6-17
SECTION 6 - JLG CONTROL SYSTEM

CONNECTOR PIN ASSIGNMENT FUNCTION

1 LIFT / SWING JOYSTICK POWER SUPPLY VOLTAGE
2 LIFT CENTER TAP INPUT
3 LIFT SIGNAL INPUT
J5 4 SWING SIGNAL INPUT
NATURAL 5 SWING CENTER TAP INPUT
6 UNUSED INPUT
7 LIFT / SWING JOYSTICK GROUND GROUND
8 UNUSED (GROUND) GROUND

CONNECTOR PIN ASSIGNMENT FUNCTION

1 DRIVE / STEER JOYSTICK POWER SUPPLY VOLTAGE
2 DRIVE CENTER TAP INPUT
3 DRIVE SIGNAL INPUT
J6 4 STEER SIGNAL INPUT
BLACK 5 STEER LEFT INPUT
6 STEER RIGHT INPUT
7 DRIVE / STEER JOYSTICK GROUND GROUND
8 UNUSED (GROUND) GROUND

CONNECTOR PIN ASSIGNMENT FUNCTION

1 GROUND MODE GROUND MODE
2 PLATFORM EMS PLATFORM EMS
3 PLATFORM EMS TO GROUND MODULE PLATFORM MODE
4 FOOTSWITCH POWER BATTERY VOLTAGE
5 GENERATOR SWITCH POWER BATTERY VOLTAGE
6 UNUSED (JIB BLOCK LIMIT SWITCH POWER) BATTERY VOLTAGE
7 SKYGUARD POWER BATTERY VOLTAGE
8 FOOTSWITCH DISENGAGE DIGITAL INPUT
9 GENERATOR SWITCH DIGITAL INPUT
10 UNUSED (+7 VOLTS) +7 REFERENCE VOLTAGE
11 UNUSED ANALOG INPUT
12 UNUSED ANALOG INPUT
13 UNUSED ANALOG INPUT
14 UNUSED (GROUND) GROUND
15 UNUSED (+7 VOLTS) +7 REFERENCE VOLTAGE
16 LSS GROUND GROUND
17 UNUSED (JIB BLOCK LIMIT SWITCH) HS DIGITAL INPUT
J7 18 SKYGUARD INPUT #1 SWITCH HS DIGITAL INPUT
BLACK 19 PLATFORM ALARM LAMP OUTPUT
20 PLATFORM ALARM GROUND GROUND
21 UNALLOCATED UNALLOCATED
22 UNALLOCATED UNALLOCATED
23 UNUSED (VALVES GROUND) GROUND
24 SKYGUARD GROUND GROUND
25 UNALLOCATED UNALLOCATED
26 UNALLOCATED UNALLOCATED
27 UNALLOCATED UNALLOCATED
28 UNALLOCATED UNALLOCATED
29 OPTION GROUND GROUND
30 CAN LOW CAN LOW
31 CAN HIGH CAN HIGH
32 CAN SHIELD CAN SHIELD
33 UNALLOCATED UNALLOCATED CONNECTOR PIN ASSIGNMENT FUNCTION
34 UNALLOCATED UNALLOCATED 1 MODULE GROUND GROUND
35 UNUSED (GROUND) GROUND
J8 2 MODULE POWER BATTERY VOLTAGE

1001157196-F
MAF01170

Figure 6-12. Platform Module - Sheet 2 of 2

6-18 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information (Software Version P2.10)

Configuration Default
Number Description
Label/Digit Number

MODEL NUMBER: 0 ????: Visible only on a Non-Configured UGM.

1
1 400S 1

2 400SC

3 450AJ

MARKET: 1 USA 1
2
2 ANSI EXPORT

3 CSA

4 CE

5 AUSTRALIA

6 JAPAN

7 GB
* Certain model selections will limit market options.

ENGINE: 1 KUBOTA D1105

3
2 GM DUAL FUEL: GM/PSI 0.97 Dual Fuel (Tier 3)z

3 KUBOTA DUAL FUEL

4
4 DEUTZ EMR2: (Tier 4i)

5 DEUTZ EMR4: (Tier 4f)

* Only visible under certain model selections.
* Certain model selections will limit engine options.
* Certain market selections will limit engine options.

FLYWHEEL TEETH: 1 98 TEETH: 98 flywheel teeth. 1

* This menu item is not visible.

GLOW PLUG: 1 NO GLOW PLUGS: No glow plugs installed.

5*
2 IN-CYLINDER: Glow plugs installed in each cylinder. 2
* This menu item is not visible.

3121671 6-19
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information (Software Version P2.10)

Configuration Default
Number Description
Label/Digit Number

STARTER LOCKOUT: 1 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be 1
6* attempted at any time during pre-glow.

2 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre-
glow is finished.
* Only visible for Engine Selection = Kubota D1105, Deutz EMR2 or Deutz EMR4.

ENGINE SHUTDOWN: 1 DISABLED: No engine shutdown.

7
2 ENABLED: Shutdown engine for high coolant temperature fault or low oil pressure fault. 2

FUEL CUTOUT: 1 ONE RESTART: One restart with limited run time when near Empty.
8*
2 ENGINE STOP: No starting permitted when near Empty.

3 NONE

4 RESTART: Restarts allowed with limited run time when near Empty. 4
*Only visible for Engine Selection = Kubota D1105, Deutz EMR2 or Deutz EMR4.
* Only visible if Fuel Level Menu selection is not NONE.

6-20 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information (Software Version P2.10)

Configuration Default
Number Description
Label/Digit Number
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions tocreep when tilted more than 5 degrees and above
9* elevation; alsoreduces drive speed to creep.

2 4.5 DEGREES: Reduces the maximum speed of all boom functions to creepwhen tilted more than 4.5 degrees and above
elevation; also reduces drivespeed to creep.

3 4 DEGREES: Reduces the maximum speed of all boom functions to creepwhen tilted more than 4 degrees and above
elevation; also reduces drivespeed to creep.

4 3 DEGREES: Reduces the maximum speed of all boom functions to creepwhen tilted more than 3 degrees and above
elevation; also reduces drivespeed to creep.

5 5 DEG + 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, drive, telescope out and lift up.

6 4.5 DEG + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4.5 degrees and
above elevation; also disallows tower lift up, drive, telescope out and lift up.

7 4 DEG + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees and above
elevation; also disallows tower lift up, drive, telescope out and lift up.

8 3 DEG + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees and above
elevation; also disallows tower lift up, drive, telescope out and lift up.

9 5 DEG + DRV CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 5 9
degrees and above elevation; also reduces drive speed to creep when drive reversal is allowed, drive is
disallowed otherwise.

10 4.5 DEG + DRV CT: Reduces the maximum speed of all boom functions to creep when tilted more than 4.5 degrees and
above elevation; also reduces drive speed to creep when drive reversal is allowed, drive is disallowed otherwise.

11 4 DEG + DRV CUT: 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 when drive reversal is allowed, drive is disallowed otherwise.

12 3 DEG + DRV CUT: 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 when drive reversal is allowed, drive is disallowed otherwise..
* Certain market selections will limit tilt options and alter default setting.
* Drive Reversal feature of X DEG + DRV CUT does not apply to crawlers.
Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the machine is also above elevation..

JIB: 1 NO: No jib installed.

10
2 YES: Jib installed, which has up and down movements only. 2
* Certain model selections will limit visibility.

SOFT TOUCH: 1 NO: No Soft Touch system installed. 1

11
2 YES: Soft Touch system installed.

3121671 6-21
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information (Software Version P2.10)

Configuration Default
Number Description
Label/Digit Number

SKYGUARD: 1 NO: No SkyGuard system installed.

12
2 YES: SkyGuard system installed. 2

GEN SET/WELDER: 1 NO: No generator installed. 1

13
2 BELT DRIVE: Belt driven setup.

GEN SET CUTOUT: 1 MOTION ENABLED: Motion enabled when generator is ON. 1
14*
2 MOTION CUTOUT: Motion cutout in platform mode only.
* Only visible if Gen Set / Welder Menu selection is not NO.

H & T LIGHTS: 1 NO: No head and tail lights installed. 1

15*
2 YES: Head and tail lights installed.
* Only visible under certain model selections.

LOAD SYSTEM: 1 NO: No load sensor installed. 1

16*
2 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).

3 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).

4 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5 sec ON, 2 sec
OFF).

5 SPECIAL 1: Functions in creep, overload lamp lit, disables telescope out & 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.

FUNCTION CUTOUT: 1 NO: No drive cutout. 1

17*
2 BOOM CUTOUT: Boom function cutout while driving above elevation.

3 DRIVE CUTOUT: Drive & steer cutout above elevation.

4 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
* Only visible under certain market selections.
* Certain market selections will limit function cutout options or alter default setting.

6-22 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information (Software Version P2.10)

Configuration Default
Number Description
Label/Digit Number

GROUND ALARM: 1 NO: No ground alarm installed.

18*
2 DRIVE: Travel alarm sounds when the drive function is active.

3 DESCENT: Descent alarm sounds when lift down is active.

4 MOTION: Motion alarm sounds when any function is active. 4

DRIVE TYPE: 1 4WD: 4 wheel drive. 1

19*
2 2WD: 2 wheel drive.
* Only visible under certain model selections.

DISPLAY UNITS: 1 METRIC: Celsius, Kilograms, KiloPascal.

20*
2 IMPERIAL: Fahrenheit, Pounds, Pounds/in2. 2
* Certain market selections will alter default setting.

CLEARSKY: 1 NO: ClearSky (telematics) options is disabled. 1

21
2 YES: ClearSky (telematics) option is enabled.
* Only visible under certain model selections.

CRIBBING OPTION: 1 NO: Cribbing Option is disabled. 1

22
2 YES: Cribbing Option is enabled.
* Only visible under certain model selections.
* Only visible under certain market selections.

ALERT BEACON: 1 OFF FOR CREEP 1

23
2 IN CREEP 20FPM

TEMP CUTOUT: 1 NO: No Low Temp Cutout system installed. 1

24
2 YES: Low Temp Cutout system installed.
* Only visible under certain market selections.

PLAT LVL OVR CUT: 1 NO: Platform Level functions above elevation. 1
25
2 YES: Platform Level does not function above elevation.

ALARM / HORN: 1 SEPARATE: Ambient alarm installed.

26
2 COMBINED: Single Horn / Alarm installed. 2

3121671 6-23
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information (Software Version P2.10)

Configuration Default
Number Description
Label/Digit Number
TELE CUTBACK: 1 NO: Telescope Cutback Option is disabled. 1
27
2 YES: Telescope Cutback Option is enabled.
* Only visible under certain model selections.

FUEL LEVEL: 1 NONE: Fuel Level Switch / Sensor is not installed.

28
2 SWITCH: Fuel Level Switch is installed.

3 SENSOR: Fuel Level Sensor is installed. 3

* Only visible under certain model selections.

WATER IN FUEL 1 NO: Water in Fuel Sensor is not installed. 1

SESNOR:
26 2 YES: Water in Fuel Sensor is installed.
* Only visible under certain market selections.
* Only visible for Engine Selection = Deutz EMR4.
1001193425-F

6-24 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Machine Configuration Programming Settings - Table 6-3. Machine Configuration Programming Settings -
400S (Software Version P2.10) 400S (Software Version P2.10)

ANSI Export
ANSI Export

Australia
ANSI USA
Australia
ANSI USA

Japan
CSA
Japan
400S

CE
CSA
400S

CE
Model Number 1 1 1 1 1 1 Head & Taillights 1 1 1 1 1 1
Market 1 2 3 4 5 6 2 2 2 2 2 2
Engine X X X X X X Load System 1 1 1 1 1 1

2 2 2 X X 2 X 2 X X X 2
3 3 3 X X 3 X 3 X X 3 3
4 4 4 4 4 4 X 4 X 4 X 4
5 5 5 5 5 5 X X X X X X
Flywheel Teeth X X X X X X Function Cutout 1 1 1 X 1 1
Glow Plug 2 2 2 2 2 2 X 2 2 2 2 2

Starter Lockout 1 1 1 1 1 1 3 3 3 X 3 3
2 2 2 2 2 2 X X X X X X
Engine Shutdown 1 1 1 1 1 1 Ground Alarm 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2
Fuel Cutout 1 1 1 1 1 1 3 3 3 3 3 3
2 2 2 2 2 2 4 4 4 4 4 4

X X X X X X Drive Type 1 1 1 1 1 1
4 4 4 4 4 4 X X X X X X
Tilt 1 1 1 1 1 1 Display Units 1 1 1 1 1 1

X X X X X X 2 2 2 2 2 2

3 3 3 3 3 3 Clearsky 1 1 1 1 1 1

4 4 4 4 4 4 2 2 2 2 2 2

5 5 5 5 5 5 Cribbing Option 1 X X X X X
6 6 6 6 6 6 2 X X X X X
7 7 7 7 7 7 Alert Beacon 1 1 1 1 1 1
8 8 8 8 8 8 2 2 2 2 2 2
9 9 9 9 9 9 Temp Cutout 1 1 1 1 1 1

X X X X X X X 2 X 2 X X
11 11 11 11 11 11 Plat Lvl Ovr Cut 1 1 1 1 1 1
12 12 12 12 12 12 2 2 2 2 2 2
Jib 1 1 1 1 1 1 Alarm/Horn 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2
Soft Touch 1 1 1 1 1 1 TELE CUTBACK X X X X X X
2 2 2 2 2 2 X X X X X X
SkyGuard 1 1 1 1 1 1 FUEL LEVEL X X X X X X
2 2 2 2 2 2 X X X X X X
Gen Set / Welder 1 1 1 1 1 1 3 3 3 3 3 3
2 2 2 2 2 2 WATER IN FUEL SENSOR X 1 X X X X
Gen Set Cutout 1 1 1 1 1 1 X 2 X X X X
2 2 2 2 2 2 BOLD BLUE TEXT indicates the default setting. Plain text indicates another available
selection. RED ITALIC TEXT indicates the default when option is factory installed.
SHADED CELLS indicate hidden menu or selection.

3121671 6-25
SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Machine Configuration Programming Settings - Table 6-4. Machine Configuration Programming Settings -
460SJ (Software Version P2.10) 460SJ (Software Version P2.10)

ANSI Export
ANSI Export

Australia
ANSI USA
Australia
ANSI USA

Japan
CSA
Japan
460SJ

CE
CSA
460SJ

CE
Model Number 1 1 1 1 1 1 Head & Taillights 1 1 1 1 1 1
Market 1 2 3 4 5 6 2 2 2 2 2 2
Engine X X X X X X Load System 1 1 1 1 1 1

2 2 2 X X 2 X 2 X X X 2
3 3 3 X X 3 X 3 X X 3 3
4 4 4 4 4 4 X 4 X 4 X 4
5 5 5 5 5 5 X X X X X X
Flywheel Teeth X X X X X X Function Cutout 1 1 1 X 1 1
Glow Plug 2 2 2 2 2 2 X 2 2 2 2 2

X X X X X X Drive Type 1 1 1 1 1 1

4 4 4 4 4 4 2 2 2 2 2 2

Tilt 1 1 1 1 1 1 Display Units 1 1 1 1 1 1

X X X X X X 2 2 2 2 2 2

3 3 3 3 3 3 Clearsky 1 1 1 1 1 1

4 4 4 4 4 4 2 2 2 2 2 2

5 5 5 5 5 5 Cribbing Option 1 X X X X X

X X X X X X 2 X X X X X
7 7 7 7 7 7 Alert Beacon 1 1 1 1 1 1
8 8 8 8 8 8 2 2 2 2 2 2
9 9 9 9 9 9 Temp Cutout 1 1 1 1 1 1

6-26 3121671
3121671
MENU: MENU: MENU: MENU: MENU: MENU: MENU:
HELP PRESS ENTER DIAGNOSTICS SYSTEM TEST OPERATOR ACCESS PERSONALITIES MACHINE SETUP CALIBRATIONS

HELP: (001) See Figure 6-14. SYSTEM TEST: See Figure 6-18. See Figure 6-20. See Figure 6-21.
CODE XXXXX
SYSTEM OK ACTIVATE?

LOG: *(XXXXX) See Figure 6-19.

X:XXXXXXXXXXXXXX
See Figure 6-15.

See Figure 6-16.

See Figure 6-17.

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon
machine configuration.

Figure 6-13. Analyzer Flow Chart (Software Version P2.10)

6-27
SECTION 6 - JLG CONTROL SYSTEM
SECTION 6 - JLG CONTROL SYSTEM

MENU : HELP : ( 001 )

HELP: PRESS ENTER SYSTEM OK

LOG : *( XXXXX )
X: XXXXXXXXXXXXXX

MENU : DIAGNOSTICS: DIAGNOSTICS :

DIAGNOSTICS DRIVE / STEER BOOM FUNCTIONS

DRIVE DEMAND SWING DEMAND JIB LIFT DEMAND TO

DIAGNOSTICS :
FORWARD XXX % LEFT XXX % UP XXX % ENGINE

DRIVE OUTPUT STEER TYPE SWING OUTPUT JIB LIFT OUTPUT

FORWARD XXX % NORMAL LEFT XXX % UP XXX %

DRIVE OUT mA BRAKES STATUS SWING OUTPUT mA PLAT LVL DEMAND

FORWARD XXXXmA LOCKED LEFT XXXXmA UP XXX %

DRIVE FDBK Ma TRACTION LOCK SWING FDBK mA PLAT LVL OUTPUT

XXXXmA OUTPUT OFF XXXXmA UP XXX %

STEER DEMAND 2 WD OUTPUT TWR LIFT DEMAND PLAT LVL OUT mA

LEFT XXX % OFF UP XXX % UP XXXXmA

STEER OUTPUT 2 SPEED OUTPUT TWR LIFT OUTPUT PLAT LVL UP FDBK
LEFT XXX% OFF UP XXX % XXXXmA

LT TRACK DEMAND DRIVE MODE TWR LIFT OUT mA PLAT LVL DN FDBK
FORWARD XXX % MID ENGINE UP XXXXmA XXXXmA

LT TRACK OUTPUT DRV ORIENT TT SW TWR LIFT FDBK mA PLAT ROT DEMAND
FORWARD XXX % CLOSED XXXXmA LEFT XXX %

LT TRACK OUT mA DRV ORIENT MODE TWR LIFT DN AUX PLAT ROT OUTPUT
FORWARD XXXmA INLINE OFF LEFT XXX %

LT TRACK FDBK mA DRV ORIENT STATE LIFT DEMAND FLW CNTRL OUT mA
FORWARD XXXmA REQUIRED UP XXX % XXXXmA

RT TRACK DEMAND DRV ORNT OVR SW LIFT OUTPUT FLW CNTRL FBK mA
FORWARD XXX % CLOSED UP XXX % XXXXmA

RT TRACK OUTPUT CRIBBING MODE SW LIFT OUTPUT mA LF PRS REL OUTPT

FORWARD XXX % CLOSED UP XXXXmA OFF

RT TRACK OUT mA CRIBBING MODE LIFT FDBK mA MAIN DUMP OUTPUT

FORWARD XXXmA DISABLED XXXXmA OFF

RT TRACK FDBK mA LIFT DN AUX STEER DUMP OUTPT

FORWARD XXXmA OFF OFF

DRV / ST JS ENABLE TELE DEMAND TELE IN DUMP

CLOSED OUT XXX % OFF

TELE OUTPUT TELE OUT DUMP

OUT XXX % OFF

NOTE: The layout shown includes all possible ana- TELE OUTPUT mA FUNCTION SPEED
OUT XXXXmA SETTING : XXX %
lyzer screens. Please note that some screens
may not be available depending upon
TELE FDBK mA CREEP SW
machine configuration. XXXXmA CLOSED

CREEP MODE 1001186299-I

OFF MAF01040

Figure 6-14. Analyzer Flow Chart - Diagnostics (Software Version P2.10) - Sheet 1 of 4

6-28 3121671
SECTION 6 - JLG CONTROL SYSTEM

FROM TO
DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS :
DIAGNOSTICS :
BOOM FUNCTIONS ENGINE SYSTEM OPER CONTROL

OPERATING STATE UGM BATTERY PLAT ANGLE 2 RAW CREEP SW

STOPPED XX . XV XX . X% CLOSED

GLOW PLUG PLATFORM MODULE ELEVATION MODE CREEP MODE

NOT ACTIVE BATTERY : XX . XV NOT ABOVE OFF

COOLANT TEMP UGM TEMP TELE CUTBACK SW CHASSIS TILT

XXXC XXXC OPEN XXX . XDEG

ENGINE OIL PRESS PLATFORM SELECT TELE RETRAC SW 1 CHASSIS TILT

XXXKPA KEYSWITCH : OPEN OPEN X- AXIS : XXX . XDEG

FUEL SELECTION GROUND SELECT TELE RETRAC SW 2 CHASSIS TILT

STATUS : GAS KEYSWITCH : OPEN OPEN Y - AXIS : XXX . XDEG

FUEL PRESS STATION CONTROL TELE RETRACT SW GENSET / WELDER SW

XXXKPA GROUND OPEN OPEN

AMBIENT TEMP FOOTSWITCH INPUT RETRACTED MODE GENSET ENABLE

XXXC GROUND : OPEN NOT RETRACTED OUTPUT : OFF

FUEL LEVEL FOOTSWITCH INPUT CAPACITY SW 1 H&T LIGHTS SW

FULL PLATFORM: OPEN OPEN OPEN

ALLOWED STARTER BOOM ANGLE CAPACITY SW 2 H&T LIGHTS OUT

CRANK TIME : XXXs XX . XDEG OPEN OFF

ENGINE SPEED BOOM ANGLE 1 RAW CAPACITY MODE SOFT TOUCH INPUT
ACTUAL : XXXXRPM XXXXCOUNTS RESTRICTED OPEN

ENGINE SPEED BOOM ANGLE 2 RAW SWING SW 1 SKYGUARD INPUTS

TARGET : XXXXRPM XXXXCOUNTS OPEN OPEN

FUEL ACTUATOR BOOM ELEV SW 1 SWING SW 2 SKYGUARD INPUT 1

OUTPUT : XXXXmA OPEN OPEN OPEN

FUEL ACTUATOR BOOM ELEV SW 2 OSC AXLE SW 1 SKYGUARD INPUT 2

FDBK : XXXXmA OPEN OPEN OPEN

THROTTLE OUTPUT BOOM ELEV SW OSC AXLE SW 2 AMBIENT TEMP

OFF OPEN OPEN XXXX

TOWER ELEV SW OSC AXLE LOW TEPERATURE

OPEN LOCKED CUTOUT : ACTIVE

PLATFORM ANGLE : TRANSPORT MODE MSSO

XXX . XDEG IN TRANSPORT INACTIVE

PLAT ANGLE 1 RAW WIRE ROPE

XX . X% SWITCH : CLOSED 1001186299-I
MAF01050

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon
machine configuration.

Figure 6-15. Analyzer Flow Chart - Diagnostics (Software Version P2.10) - Sheet 2 of 4

3121671 6-29
SECTION 6 - JLG CONTROL SYSTEM

FROM 2 2
DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : TO
SYSTEM OPER CONTROLS PLATFORM LOAD CAN STATISTICS CALIBRATION DATA DIAGNOSTICS :
DATALOG

JOYSTICK DRIVE PLATFORM LOAD CAN 1 STATISTICS 2 UGM TILT 1 X 2

FORWARD XXX % STATE : OK RX / SEC : XXXXX XXXX COUNTS

JOYSTICK STEER PLAT LEVEL UP SW PLATFORM LOAD CAN 1 STATISTICS 2 UGM TILT 1 Y 2
LEFT XXX % OPEN ACTUAL : XXXXKG TX / SEC : XXXXX XXXX COUNTS

JOYSTICK SWING PLAT LEVEL DN SW PLATFORM LOAD 2 CAN 1 STATISTICS 2 UGM TILT 2 X 2
LEFT XXX % OPEN GROSS: XXXXKG BUS OFF : XXXXX XXXX COUNTS

JOYSTICK LIFT PLAT ROT LEFT SW PLATFORM LOAD 2 CAN 1 STATISTICS 2 UGM TILT 2 Y 2
UP XXX % OPEN OFFSET : XXXKG PASSIVE : XXXXX XXXX COUNTS

DRV ORNT OVR SW PLAT ROT RGHT SW PLATFORM LOAD 2 CAN 1 STATISTICS 2 TILT X 2
OPEN OPEN OFFSET 1 : XXXKG MSG ERROR : XXXXX XX . X DEG

FUEL SELECT SW MAX SPEED SW PLATFORM LOAD 2 CAN 2 STATISTICS 2 TILT Y 2

OPEN OPEN OFFSET 2 : XXXKG RX / SEC : XXXXX XX . X DEG

START SWITCH MAX TORQUE SW PLATFORM LOAD 2 CAN 2 STATISTICS 2

OPEN OPEN ACCESSORY XXXKG TX / SEC : XXXXX

APU DESCENT SW CREEP SW PLATFORM LOAD 2 CAN 2 STATISTICS 2

OPEN CLOSED UNRSTRICT XXXXKG BUS OFF : XXXXX

AUX DESCENT SW HORN SW PLATFORM LOAD 2 CAN 2 STATISITICS 2

OPEN OPEN RSTRICT XXXXKG PASSIVE : XXXXX

SWING LEFT SW H&T LIGHTS SW PLATFORM LOAD 2 CAN 2 STATISTICS 2

OPEN OPEN CELL 1 : XXXKG MSG ERROR : XXXXX

SWING RIGHT SW GENSET/ WELDER SW PLATFORM LOAD 2

OPEN OPEN CELL 2 : XXXKG

TOWER LIFT UP SW SG OVERRIDE SW PLATFORM LOAD 2

OPEN OPEN CELL 3 : XXXKG

TOWER LIFT DN SW ST OVERRIDE SW PLATFORM LOAD 2

OPEN OPEN CELL 4 : XXXKG

LIFT UP SW SG / ST OVRRIDE SW PLATFORM LOAD 2

OPEN OPEN RAW 1 : XXXXKG

LIFT DN SW MSSO SW PLATFORM LOAD 2

OPEN OPEN RAW 2 : XXXXKG

TELE IN SW CAPACITY SW
OPEN OPEN

TELE OUT SW STEER CRAB SW

OPEN OPEN

JIB LIFT UP SW STEER COORD SW

OPEN OPEN

JIB LIFT DN SW
OPEN
1001186299-I
MAF01060

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration.

Figure 6-16. Analyzer Flow Chart - Diagnostics (Software Version P2.10) - Sheet 3 of 4

6-30 3121671
SECTION 6 - JLG CONTROL SYSTEM

FROM DIAGNOSTICS : DIAGNOSTICS :

DIAGNOSTICS :
CALIBRATION DATA DATALOG VERSIONS

DATALOG TIME UGM

ON XXXH XXM SOFTWARD XX . XX

DATALOG TIME DATALOG CYCLES UGM

ENGINE XXXH XXM DRVE REV XXXXX CNST DATA XX . XX

DATALOG TIME DATALOG CYCLES UGM

DATALOG CYCLES
ENABLD XXXH XXM STEER LT XXXXX HARDWARD REV XX
UGM ON XXXXX

DATALOG TIME DATALOG CYCLES UGM

DATALOG CYCLES
AUX XXXH XXM STEER RT XXXXX S / N XXXXXX
GND OPS XXXXX

DATALOG TIME DATALOG CYCLES UGM

DATALOG CYCLES
DRIVE XXXH XXM SWING LT XXXXX P / N XX - XXXXXX - XX
PLAT OPS XXXXX

DATALOG TIME DATALOG CYCLES PLATFORM MODULE

DATALOG CYCLES
DRV MS XXXH XXM SWING RT XXXXX SOFTWARE XX . XX
AUX OPS XXXXX

DATALOG TIME DATALOG CYCLES PLATFORM MODULE

DATALOG CYCLES
DRV MT XXXH XXM TOWER UP XXXXX HARDWARE REV XX
GEN ON XXXXX

DATALOG TIME DATALOG CYCLES PLATFORM MODULE

DATALOG CYCLES
DRV ME XXXH XXM TOWER DN XXXXX S / N XXXXXX
BOOM TR XXXXX

DATALOG TIME DATALOG CYCLES LSS MODULE

DATALOG CYCLES
STEER XXXH XXM LIFT UP XXXXX SOFTWARE XX . XX
BOOM UP XXXXX

DATALOG TIME DATALOG CYCLES LSS MODULE

DATALOG CYCLES
SWING XXXH XXM LIFT DN XXXXX HARDWARE REV XX
TOWER UP XXXXX

DATALOG TIME DATALOG CYCLES TCU MODULE

DATALOG CYCLES
TOWER XXXH XXM TELE IN XXXXX SOFTWARE XX . XX
TELE TR XXXXX

DATALOG TIME DATALOG CYCLES TCU MODULE

DATALOG CYCLES
LIFT XXXH XXM TELE OUT XXXXX HARDWARE REV XX
DUAL CAP XXXXX

DATALOG TIME DATALOG CYCLES TCU MODULE

DATALOG : MAX
TELE XXXH XXM JIB UP XXXXX S / N XXXXXX
UGM TEMP XXXX

DATALOG TIME DATALOG CYCLES GROUND DISPLAY

DATALOGl : MIN
JIB XXXH XXM JIB DOWN XXXXX SOFTWARE XX . XX
UGM TEMP XXXX

DATALOG TIME DATALOG CYCLES ANALYZER

DATALOG : MAX
LEVEL XXXH XXM LEVEL UP XXXXX ANALYZER XX . XX
UGM VOLT XXXV

DATALOG TIME DATALOG CYCLES

DATALOG : MACHINE
ROTATE XXXH XXM LEVEL DN XXXXX
RENTAL XXXH XXM

DATALOG TIME DATALOG CYCLES 2

DATALOG : ERASE
GEN XXXH XXM ROT LEFT XXXXX
MACHINE RENTAL ?

DATALOG CYCLES DATALOG CYCLES 2

CLEAR RENTAL :
DRVE FWD XXXXX ROT RIGHT XXXXX 1001186299-I
YES : ENTER , NO : ESC
MAF01070

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon
machine configuration.

Figure 6-17. Analyzer Flow Chart - Diagnostics (Software Version P2.10) - Sheet 4 of 4

3121671 6-31
SECTION 6 - JLG CONTROL SYSTEM

FROM
MENU:
DIAGNOSTICS

MENU: SYSTEM TEST :

SYSTEM TEST ACTIVATE ?

MENU: ACCESS LEVEL:

OPERATOR ACCESS CODE XXXXX

PERSONALITIES : PERSONALITIES : TO
MENU: PERSONALITIES : PERSONALITIES :
PERSONALITIES:
PERSONALITIES DRIVE LEFT TRACK RIGHT TRACK SWING TOWER LIFT

DRIVE LEFT TRACK RIGHT TRACK SWING

ACCEL XXXXmA / S ACCEL X . XS ACCEL X . XS ACCEL X . Xs

DRIVE MAX SPEED DRIVE TO STOP LEFT TRACK RIGHT TRACK SWING
ACCEL XXXXmA / S DECEL XXXXmA / S DECEL X . XS DECEL X . XS DECEL X . Xs

DRIVE DRIVE ME / MT LEFT TRACK RIGHT TRACK SWING

DECEL XXXXmA / S MIN XXXXmA FWD MIN XXXXmA FWD MIN XXXXmA LEFT MIN XXXXmA

DRIVE MAX SPEED DRIVE MAX TORQUE LEFT TRACK RIGHT TRACK SWING
DECEL XXXXmA / S MAX XXXXmA FWD MAX XXXXmA FWD MAX XXXXmA LEFT MAX XXXXmA

DRIVE DRIVE MID ENGINE LEFT TRACK RIGHT TRACK SWING

MIN XXXXxmA MAX XXXXmA FWD ELV XXXXmA FWD ELV XXXXmA LT CREEP XXXXmA

DRIVE MAX SPEED DRIVE MT ELEV LEFT TRACK RIGHT TRACK SWING
MIN XXXXxmA MAX XXXXmA FWD CREEP XXXXmA FWD CREEP XXXXmA RIGHT MIN XXXXmA

DRIVE DRIVE ME ELEV LEFT TRACK RIGHT TRACK SWING

MAX XXXXxmA MAX XXXXmA REV MIN XXXXmA REV MIN XXXXmA RIGHT MAX XXXXmA

DRIVE MAX SPEED DRIVE MAX TORQUE LEFT TRACK RIGHT TRACK SWING
MAX XXXXmA CREEP XXXXmA REV MAX XXXXmA REV MAX XXXXmA RT CREEP XXXXmA

DRIVE ME / MT DRIVE MID ENGINE LEFT TRACK RIGHT TRACK

ACCEL XXXXmA / S CREEP XXXXmA REV ELV XXXXmA REV ELV XXXXmA
TO
MENU :
MACHINE SETUP DRIVE ME / MT LEFT TRACK RIGHT TRACK
DECEL XXXXmA / S REV CREEP XXXXmA REV CREEP XXXXmA 1001186299-I
MAF01080

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon
machine configuration.

Figure 6-18. Analyzer Flow Chart - Personalities (Software Version P2.10) - Sheet 1 of 2

6-32 3121671
SECTION 6 - JLG CONTROL SYSTEM

FROM
PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES :
PERSONALITIES :
TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL
SWING

TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL

ACCEL X . Xs ACCEL X . Xs ACCEL X . Xs ACCEL X . Xs ACCEL X . Xs

TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL

DECEL X . Xs DECEL X . Xs DECEL X . Xs DECEL X . Xs DECEL X . Xs

TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL

UP MIN XXXXma UP MIN XXXXmA IN MIN XXXmA UP MIN XXXXmA UP MIN XXXXmA

TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL

UP MAX XXXXmA UP MAX XXXXmA IN MAX XXXXmA UP MAX XXXXmA UP MAX XXXXmA

TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL

UP CREEP XXXXmA UP CREEP XXXXmA IN CREEP XXXmA UP CREEP XXXXmA UP CREEP XXXXmA

TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL

DOWN MIN XXXXmA DOWN MIN XXXXmA IN CUTBK XXXmA UP CUTBK XXXmA DOWN MIN XXXXmA

TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL

DOWN MAX XXXXmA DOWN MAX XXXXmA OUT MIN XXXmA DOWN MIN XXX % DOWN MAX XXXXmA

TOWER LIFT LIFT TELESCOPE JIB LIFT PLATFORM LEVEL

DN CREEP XXXXmA DN CREEP XXXXmA OUT MAX XXXXmA DOWN MAX XXX % DN CREEP XXXXmA

TOWER LIFT LIFT TELESCOPE JIB LIFT

DN SOFT XXXXmA DN SOFT XXXXmA OUT CREEP XXXmA DOWN CREEP XXX %

LIFT TELESCOPE JIB LIFT

UP SOFT XXXXmA OUT CUTBK XXXmA DN CUTBK XXXmA

PERSONALITIES : PERSONALITIES : PERSONALITIES : 2 PERSONALITIES : PERSONALITIES : PERSONALITIES :

PLATFORM ROTATE GROUND MODE ENGINE RPM ALARM / HORN TEMPERATURE CUT PLATFORM LOAD

PLATFORM ROTATE GROUND MODE ENGINE RPM 2 HORN VOLUME LOW TEPERATURE PLATFORM OVRLD
ACCEL X . Xs SWING LT XXXXmA GEN SET XXXXRPM XXX % CUTOUT SET : XXXC XXXX

PLATFORM ROTATE GROUND MODE ALARM VOLUME PLATFORM OVRLD

DECEL X . Xs SWING RT XXXXmA XXX % RESTRICT XXXX

PLATFORM ROTATE GROUND MODE

LEFT MIN XXXXmA TOWER UP XXXXmA

PLATFORM ROTATE GROUND MODE GROUND MODE

LEFT MAX XXXXmA TWR DOWN XXXXmA JIB UP XXXXmA

PLATFORM ROTATE GROUND MODE GROUND MODE

LT CREEP XXXXmA LIFT UP XXXXmA JIB DOWN XXX %

PLATFORM ROTATE GROUND MODE GROUND MODE

RIGHT MIN XXXXmA LIFT DOWN XXXXmA PLTLVL UP XXXXmA

PLATFORM ROTATE GROUND MODE GROUND MODE

RIGHT MAX XXXXmA TELE IN XXXXmA PLTLVL DN XXXXmA

PLATFORM ROTATE GROUND MODE GROUND MODE

RT CREEP XXXXmA TELE OUT XXXXmA PLT ROT XXXXmA 1001186299-I
MAF01090

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon
machine configuration.

Figure 6-19. Analyzer Flow Chart - Personalities (Software Version P2.10) - Sheet 2 of 2

3121671 6-33
SECTION 6 - JLG CONTROL SYSTEM

FROM
MENU:
PERSONALITIES

MENU: MODEL MARKET ENGINE STARTER LOCKOUT ENGINE SHUTDOWN

MACHINE SETUP 340 AJ ANSI USA KUBOTA D 1105 DISABLED ENABLED

FUEL CUTOUT TILT JIB 4 WHEEL STEER SOFT TOUCH

ONE RESTART 5 DEGREES YES NO NO
MENU :
CALIBRATIONS

SKYGUARD GEN SET / WELDER GEN SET CUTOUT H & T LIGHTS CABLE SWITCH
YES BELT DRIVE MOTION ENABLED NO NO

LOAD SYSTEM FUNCTION CUTOUT GROUND ALARM DRIVE TYPE DISPLAY UNITS
NO NO NO 4 WD IMPERIAL

CLEARSKY CRIBBING OPTION ALERT BEACON TEMP CUTOUT PLAT LVL OVR CUT
NO NO OFF FOR CREEP NO NO

DUAL CAPACITY ALARM / HORN TELE CUTBACK FUEL LEVEL WATER IN FUEL
NO COMBINDED NO NONE SESNOR YES

1001186299-I
MAF01100

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon
machine configuration.

Figure 6-20. Analyzer Flow Chart - Machine setup (Software Version P2.10)

6-34 3121671
SECTION 6 - JLG CONTROL SYSTEM

LOAD SENSING :
LVL UP TO STOP CALIBRATING… PLATFORM EMPTY ? UNRSTRICT XXXKGS

PLATFORM ANGLE : 2 PLATFORM ANGLE : 2 LOAD SENSING : 2 2

LOAD SENSING :
CALIBRATING… PLT LVL DN ? ACCESSORY XXXKGS RSTRICT XXXKGS

PLATFORM ANGLE : 2 PLATFORM ANGLE : 2 LOAD SENSING : 2 2

LOAD SENSING :
PLT LVL UP ? CAL COMPLETE CALIBRATING… CAL COMPLETE

PLATFORM ANGLE : 2 PLATFORM ANGLE : 2 LOAD SENSING : 2 2

LOAD SENSING :
LVL DN TO STOP CAL FAILED SKY GLAZIER ? NO CAL FAILED 1001186299-I
MAF01110

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration.

Figure 6-21. Analyzer Flow Chart - Calibrations (Software Version P2.10)

3121671 6-35
SECTION 6 - JLG CONTROL SYSTEM

6.2 LSS SYSTEM

The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF
form load via a sensor mounted in the platform support struc- THE FOLLOWING CONDITIONS OCCUR:
ture. If the actual platform load exceeds the selected Rated
Load, the following will occur: a. LSS Sensor removal or replacement
1. The Overload Visual Warning Indicator will b. Addition or removal of certain platform mounted
flash at the selected control position (plat- accessories. (Refer to Calibration)
form or ground). c. Platform is removed, replaced, repaired or shows
evidence of impact.
2. The Platform and Ground Alarms will sound 5 seconds
On, and 2 seconds Off.
THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION VERIFICATION
3. All normal movement will be prevented from the plat-
NOT TO EXCEED 6 MONTHS FROM PREVIOUS VERIFICATION. REFER TO TEST-
form control position (optional - ground control func-
ING & EVALUATION.
tions may be prevented).
4. Further movement is permitted by: All calibration procedures are menu driven through the use of
a JLG Analyzer.
a. Removing the excess platform load until actual plat-
form load is less than Rated Load.
b. Operation of the overriding emergency system
(Auxiliary Power Unit).
c. By an authorized person at the ground control posi-
tion (optional - ground control functions may be
prevented).

6-36 3121671
SECTION 6 - JLG CONTROL SYSTEM

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 6-5, 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 6-5. 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.
??? if LSS is not calibrated.
PLATFORM LOAD (service*) ACCESSORY XXX.X KG Stored accessory weight.
??? if LSS is not calibrated.
PLATFORM LOAD (service*) UNRESTRICT XXX.X KG UGM will set Unrestricted Rated Load as defined by Machine 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

3121671 6-37
SECTION 6 - JLG CONTROL SYSTEM

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).

6-38 3121671
SECTION 6 - JLG CONTROL SYSTEM

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 6-6, 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 6-6. Accessory Weights

Accessory Weight
SkyWelder (stick welder) 70 lb (32 kg)
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.

3121671 6-39
SECTION 6 - JLG CONTROL SYSTEM

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:

6-40 3121671
SECTION 6 - JLG CONTROL SYSTEM

12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-8. 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 6-7, SkyGlazier Capacity Reduc- 500 lb (227 kg) 400 lb (181 kg) n/a
tions and Table 6-8, 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 6-7, SkyGlazier Capacity Reduc-
tions and Table 6-8, Pipe Rack Capacity Reductions.

Table 6-7. 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.

3121671 6-41
SECTION 6 - JLG CONTROL SYSTEM

14. Press ENTER . If calibration is successful, the screen

will read:

6-42 3121671
SECTION 6 - JLG CONTROL SYSTEM

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).

3121671 6-43
SECTION 6 - JLG CONTROL SYSTEM

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 6-9. 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.

6-44 3121671
SECTION 6 - JLG CONTROL SYSTEM

6.3 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.
2. Position the Platform/Ground select switch to the
desired position.
3. Plug the analyzer into the connector coming from the
ground control module or from the platform console.

NOTE: If performing the procedure from the platform console, the

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

4. Pull out the Emergency Stop switch.

5. The analyzer screen should read:

10. Press ENTER .

11. Use the left arrow key or right arrow key

arrow to reach MSSO RESET.

6. Use the arrow button to reach OPERATOR ACCESS. Press

Enter .
7. Enter the Access Code, 33271.
8. Use the right Arrow key to reach MENU: CALIBRATIONS.

Press Enter .

3121671 6-45
SECTION 6 - JLG CONTROL SYSTEM

12. Press Enter . The screen will read:

13. Press Enter . The JLG Control System will reset an

active 873 DTC and the MSSO System will be reset. Press

Escape to return to the CALIBRATIONS menu.

6-46 3121671
SECTION 6 - JLG CONTROL SYSTEM

6.4 MACHINE MODEL ADJUSTMENT DRIVE (ABOVE ELEVATION)

1. Test should be done on a smooth,
Adjustment Notes level surface. The Drive Select
Switch should be in the "Max
1. Personality settings can be adjusted anywhere within
Speed" position.
the adjustment range in order to achieve optimum
machine performance. 2. The boom should be > 10° above horizontal to ensure
the drive is operating in Max Torque mode.
2. Stop watch should be started with the function move-
ment, not with actuation of the joystick or switch. 3. Results should be recorded for a 15.2m (50ft) course.
3. Drive speeds should be set to the values below regard- 4. Drive forward, record time
less of the tire size.
5. Drive Reverse, record time
4. All speed tests are run from the platform, these speeds
6. Turn Platform Speed Control Knob fully
do not reflect the ground control operation.
counterclockwise to enter Creep mode.
5. The Function Speed Control knob must
be at full speed (turned clockwise com-
pletely) unless noted.

7. Creep light on Panel must be energized.

6. Some flow control functions may not

work with the Function Speed Control
knob clicked into the creep position.
8. Verify that machine will Drive Forward and Reverse.
9. Return Knob to fully clockwise.
7. Functional speeds may vary due to cold thick hydraulic
oil. Test should be run with the oil temperature above
38° C (100° F)

Machine Orientation When Performing Test

DRIVE (BELOW ELEVATION)
1. Test should be done on a smooth,
level surface. The Drive Select
Switch should be in the "Max
Speed" position.
2. Start approximately 7.6m (25 ft) from starting point so
the unit is at a maximum speed when starting the test.
3. Results should be recorded for a 61m (200ft) course.
4. Drive forward, "High Speed", record time
5. Drive Reverse, "High Speed", record time

3121671 6-47
SECTION 6 - JLG CONTROL SYSTEM

SWING MAIN LIFT

1. Boom at full elevation, Telescope retracted. Swing Right 1. Main Lift in stowed position, Telescope Retracted.
until over rear axle or end stop (if equipped).
2. Main Lift Up, record time.
2. Swing Left 360° or end stop (if equipped), record time.
3. Main Lift Down, record time.
3. Swing Right 360° or end stop (if equipped), record time.
4. Turn Platform Speed Control Knob fully
4. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode.
counterclockwise to enter Creep mode.

5. Creep light on Panel must be energized.

6. Verify that machine will Lift Up and Down.

6. Verify that machine will swing left and right.
7. Return Knob to fully clockwise.
7. Return Function Speed Knob to fully
clockwise.

TELESCOPE
TOWER LIFT
1. Main Lift at full elevation, Telescope Retracted.
1. Tower Lift in stowed position, Telescope Retracted.
2. Telescope Out, record time.
2. Tower Lift Up, record time.
3. Telescope In, record time.
3. Tower Lift Down, record time.
4. Turn Platform Speed Control Knob fully
4. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode.
counterclockwise to enter Creep mode.

5. Creep light on Panel must be energized.

6. Verify that machine will Telescope In

and Out.
6. Verify that machine will Tower Up and
7. Return Knob to fully clockwise.
Down. Return Knob to fully clockwise.

6-48 3121671
SECTION 6 - JLG CONTROL SYSTEM

JIB LIFT NOTE: When the platform speed control knob is turned fully coun-
terclockwise. The platform rotate may not work, this is
1. Platform level and centered with the boom. Jib Lift acceptable.
Down until stop.
2. Jib Lift Up, record time.
3. Jib Lift Down, record time.
4. Turn Platform Speed Control Knob fully
counterclockwise to enter Creep mode.

5. Creep light on Panel must be energized.

6. Verify that machine will Jib Lift Up and Down.

7. Return Knob to fully clockwise.

PLATFORM ROTATE
1. Platform level, Rotate Platform Right until stop
2. Platform Left, record time.
3. Platform Right, record time.
4. Turn Platform Speed Control Knob fully
counterclockwise to enter Creep mode.

5. Creep light on Panel must be energized.

6. Verify that machine will Platform Rotate Left and Right.

7. Return Knob to fully clockwise.

3121671 6-49
SECTION 6 - JLG CONTROL SYSTEM

Table 6-10. Machine Model Adjustment Speeds

400S / 460SJ MODEL TIME RANGES

FUNCTION ADJUSTMENT RANGES MODEL (IN SECONDS)
DEFAULTS 400S 460SJ
DRIVE
Accel 25 – 2000mA/s 300mA/s
Decel 25 – 2000mA/s 800 mA/s
Min 250 – 1000mA 725 mA
Max 250 – 1400mA 1175 mA 30 – 34 30 – 34
Drive to Stop Decel 25 – 2000mA/s 400 mA/s
MT: Elevated Max 250 – 1200mA 890 mA 795 mA 68 – 85 68 – 85
ME: Elevated Max 250 – 1200mA 990 mA 835mA 68 – 85 68 – 85
Max Torque Creep 250 – 1200mA 890 mA 795 mA
Mid Engine Creep 250 – 1200mA 990 mA 835mA
ME = Max Engine, MT = Max Torque
SWING
Accel 0 – 5s 2.2 s
Decel 0 – 5s 1.2s
LEFT Min 250 – 1400mA 420 mA
Max 250 – 1400mA 860 mA 70 – 90 70 – 90
Creep 250 – 1400mA 650 mA
RIGHT Min 250 – 1400mA 400 mA
Max 250 – 1400mA 800 mA 70 – 90 70 – 90
Creep 250 – 1400mA 650 mA
LIFT
Accel 0 – 5s 1.5 s
Decel 0 – 5s 0.8 s
UP Min 250 – 1400mA 400 mA
Max 250 – 1400mA 900 mA 33 – 40 34 – 41
Creep 250 – 1400mA 600 mA
DOWN Min 250 – 1400mA 380 mA
Max 250 – 1400mA 750 mA 33 – 40 34 – 41
Creep 250 – 1400mA 500 mA
Soft Down 250 – 1400mA 450 mA
Soft Down 250 – 1400mA 450 mA
TELECOPE
Accel 0 – 5s 1s
Decel 0 – 5s 0.8 s
IN Min 250 – 1400mA 415 mA
Max 250 – 1400mA 890 mA 33 – 40 33 – 40
Creep 250 – 1400mA 580 mA
OUT Min 250 – 1400mA 415 mA
Max 250 – 1400mA 780 mA 33 – 40 33 – 40
Creep 250 – 1400mA 525 mA

6-50 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-10. Machine Model Adjustment Speeds

400S / 460SJ MODEL TIME RANGES

FUNCTION ADJUSTMENT RANGES MODEL (IN SECONDS)
DEFAULTS 400S 460SJ
JIB LIFT
Accel 0 – 5s 1.2 s
Decel 0 – 5s 0.5 s
UP Min 250 – 1400mA 350 mA
Max 250 – 1400mA 690 mA 18 – 22 18 – 22
Creep 250 – 1400mA 500 mA
DOWN Min 250 – 1400mA 350 mA
Max 250 – 1400mA 630 mA 18 – 22 18 – 22
Creep 250 – 1400mA 450 mA
PLATFORM LEVEL
Accel 0 – 5s 0s
Decel 0 – 5s 0s
UP Min 250 – 1400mA 400 mA
Max 250 – 1400mA 600 mA
Creep 250 – 1400mA 600 mA
DOWN Min 250 – 1400mA 400 mA
Max 250 – 1400mA 600 mA
Creep 250 – 1400mA 600 mA
PLATFORM ROTATE
Accel 0 – 5s 0s
Decel 0 – 5s 0s
LEFT Min 250 – 1400mA 500 mA
Max 250 – 1400mA 600 mA 20 – 25 20 – 25
Creep 250 – 1400mA 600 mA
RIGHT Min 250 – 1400mA 500 mA
Max 250 – 1400mA 600 mA 20 – 25 20 – 25
Creep 250 – 1400mA 600 mA
GROUND MODE
SWING Left 250 – 1400mA 855 mA
Right 250 – 1400mA 795 mA
LIFT Up 250 – 1400mA 895 mA
Down 250 – 1400mA 745 mA
TELESCOPE In 250 – 1400mA 885 mA
Out 250 – 1400mA 775 mA
JIB Up 250 – 1400mA 685 mA
Down 250 – 1400mA 625 mA
PLATFORM Up / Down 250 – 1400mA 595 mA
PLATFORM Left / Right 250 – 1400mA 595 mA
1001193361-F

3121671 6-51
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
Note: "Controls Initialized" means all controls have been released / returned to neutral, and the machine enable (footswitch) has been released.
EVERYTHING OK 0011 Machine is in Platform Mode; No response required for X X
The UGM determines no problems exist this DTC
GROUND MODE OK 0021 Machine is in Ground Mode; No response required for X X
The UGM determines no problems exist this DTC
RUNNING AT CUTBACK – OUT 00101 Machine is in the Out of Transport position Response described in Machine is not in the Out of Transport posi- X X
OF TRANSPORT POSITION Drive Modes section tion
FSW OPEN 00111 Machine is in Platform Mode; The UGM shall not Enable Controls initialized X X
Any of the following Platform inputs become active the Machine
after power up, but before Machine Enabled:
Drive joystick is not in the neutral position
Steer;
Lift and/or Swing joystick is not in the neutral position;
Tower Lift (340AJ, 450AJ);
Telescope;
Platform Level;
Platform Rotate;
Jib Lift (if MACHINE SETUP > JIB = YES)
RUNNING AT CREEP - CREEP 00121 Machine is in Platform Mode; The UGM shall limit the Platform Creep switch input = Low X X
SWITCH OPEN Platform Creep switch input = HIGH; machine to Creep speed
DTC 0013 is not active
RUNNING AT CREEP - TILTED 00131 Machine is in Platform Mode; The UGM shall limit the Not all of the trigger conditions are met X X
AND ABOVE ELEVATION The Boom is Above Elevation; machine to Creep speed;
Machine chassis is considered Tilted If MACHINE SETUP > TILT
= (angle) + CUT, response
described in Tilted Output
Cutouts section
LOAD SENSOR READING UNDER 0015 LSS has been calibrated and the UGM has determined Ensure platform is not resting on the ground
WEIGHT that the load sensing system reading is less than -50lbs or is not leveled at an extreme negative
for 2 seconds. If the load sensing system determines angle.
that the reading is greater than -50lbs for 5 seconds this
fault will no longer be annunciated. Re-calibrate the load sensing system if the
above items are not a factor.
No control system interlocks present when DTC is
active.
FUEL LEVEL LOW – ENGINE 0031 Engine Shutdown has occurred due to Fuel Level = Response described in Power Cycled X X
SHUTDOWN EMPTY condition. Fuel Shutdown section
APU ACTIVE 0035 Auxiliary Power/Emergency Descent Mode is active Response described in Auxiliary Power/Emergency Descent Mode X X
Auxiliary Power/Emer- is not active
gency Descent Mode sec-
tion

6-52 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
FUNCTION PREVENTED - FUNC- 0036 Machine is in Ground Mode; The UGM shall not Enable Controls initialized X X
TION SELECTED BEFORE Any of the following Ground inputs become active after the Machine
GROUND ENABLE power up, but before Machine Enabled:
Lift;
Swing;
Tower Lift (340AJ, 450AJ);
Telescope;
Platform Level;
Platform Rotate;
Jib Lift (if MACHINE SETUP > JIB = YES)
SKYGUARD ACTIVE – FUNC- 0039 MACHINE SETUP > SKYGUARD = YES; Response described in Not all of the trigger conditions are met X X
TIONS CUTOUT Machine is in Platform Mode; SkyGuard section
SkyGuard Enabled
KEYSWITCH FAULTY 212 UGM Ground Mode input J7-3 input = High; The UGM shall assume a (J7-3 input = LOW) or (J7-2 input = LOW) X X
UGM Platform Mode input J7-2 input = High station selection of
Ground
FSW FAULTY 213 The ground footswitch input and platform footswitch The UGM shall not Enable Power Cycled X X
input have been both HIGH or both LOW for greater the Machine
than or equal to 1 second
FUNCTION PROBLEM - HORN 221 Machine is in Platform Mode; The UGM shall prohibit The Horn switch input = Low X X
PERMANENTLY SELECTED The Horn switch input = High at Startup Horn;
Ground and Platform
Alarm are still permitted
FUNCTION PROBLEM - STEER 224 Machine is in Platform Mode; The UGM shall prohibit The Steer Left switch input = Low; X X
LEFT PERMANENTLY SELECTED The Steer Left switch input = High at Startup Steer Left and Right; Steer Left and Right and full Drive speed
The UGM shall limit Drive permitted after controls are initialized
to Creep
FUNCTION PROBLEM - STEER 225 Machine is in Platform Mode; The UGM shall prohibit The Steer Right switch input = Low; X X
RIGHT PERMANENTLY The Steer Right switch input = High at Startup Steer Left and Right; Steer Left and Right and full Drive speed
SELECTED The UGM shall limit Drive permitted after controls are initialized
to Creep
STEER SWITCHES FAULTY 227 The Steer Left switch input = High; The UGM shall prohibit The Steer Left switch input = Low; X X
The Steer Right switch input = High; Steer; The Steer Right switch input = Low;
(detectable in Platform or Ground mode) The UGM shall limit Drive Steer and full Drive speed permitted after
to Creep controls are initialized
FSW INTERLOCK TRIPPED 2211 Machine is in Platform Mode; The UGM shall disable The footswitch is released X X
The Footswitch is active for more than seven seconds Machine Enable
with no Drive, Steer, or Boom commands

3121671 6-53
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
DRIVE LOCKED - JOYSTICK 2212 Machine is in Platform Mode; If triggered by the Drive If triggered by the Drive joystick not being in X X
MOVED BEFORE FOOTSWITCH The UGM detects one of the following conditions: joystick not being in the the neutral position at Startup, then (Drive
Drive joystick is not in the neutral position at Startup; neutral position at joystick is returned to its neutral position)
Drive joystick is not in the neutral position when Foot- Startup, the UGM shall and (Drive and Steer permitted after con-
switch becomes active or while DTC 2213, 2221 or 2223 prohibit Drive and Steer. trols initialized)
is active
If triggered by the Drive If triggered by the Drive joystick not being in
joystick not being in the the neutral position when Footswitch
neutral position when becomes active or while DTC 2213, 2221 or
Footswitch becomes 2223, then controls initialized
active or while DTC 2213,
2221 or 2223 is active, the
UGM shall not Enable the
Machine
STEER LOCKED - SELECTED 2213 Machine is in Platform Mode; The UGM shall not Enable Controls initialized X X
BEFORE FOOTSWITCH A Steer input is active when Footswitch becomes active the Machine
or while DTC 2212, 2221 or 2223 is active
D/S JOY. OUT OF RANGE HIGH 2216 The PM detects that the Drive or Steer joystick signal The UGM shall prohibit The PM no longer reports the fault X X
voltage > 8.1V and reports the fault to the UGM. Drive;
Brake release and Steer
still permitted
D/S JOY. CENTER TAP BAD 2217 The PM detects that the Drive or Steer center tap volt- The UGM shall prohibit The PM detects that the drive/steer center X X
age is not between 3.31 volts and 3.75 volts and reports Drive; tap voltage is between 3.31 and 3.75 volts
the fault to the UGM Brake release and Steer and no longer reports the fault to the UGM
still permitted
L/S JOY. OUT OF RANGE HIGH 2219 The PM detects that the Lift or Swing joystick signal If the Machine is in Plat- The PM detects that the Lift and Swing joy- X X
voltage > 8.1V and reports the fault to the UGM. form Mode, the UGM shall stick signal voltage is < 8.1V and no longer
prohibit Lift and Swing reports the fault to the UGM
L/S JOY. CENTER TAP BAD 2220 The PM detects that the Lift or Swing center tap voltage If the Machine is in Plat- The PM detects that the lift/swing center X X
is not between 3.31 volts and 3.75 volts and reports the form Mode, the UGM shall tap voltage is between 3.31 and 3.75 volts
fault to the UGM prohibit Lift and Swing and no longer reports the fault to the UGM
LIFT/SWING LOCKED - JOY- 2221 Machine is in Platform Mode; If triggered by the Lift If triggered by the Lift and/or Swing joystick X X
STICK MOVED BEFORE FOOT- The UGM detects one of the following conditions: and/or Swing joystick not not being in the neutral position at Startup,
SWITCH Lift and/or Swing joystick is not in the neutral position being in the neutral posi- then (Lift and/or Swing joystick is returned
at Startup; tion at Startup, the UGM to its neutral position) and (Lift and Swing
Lift and/or Swing joystick is not in the neutral position shall prohibit Lift and permitted after controls initialized)
when Footswitch becomes active or while DTC 2212, Swing.
2213 or 2223 is active If triggered by the Lift and/or Swing joystick
If triggered by Lift and/or is not in the neutral position when Foot-
Swing joystick is not in the switch becomes active or while DTC 2212,
neutral position when 2213 or 2223 is active, then controls initial-
Footswitch becomes ized
active or while DTC 2212,
2213 or 2223 is active, the
UGM shall not Enable the
Machine
WAITING FOR FSW TO BE OPEN 2222 Machine is in Platform Mode; The UGM shall not Enable Controls initialized X X
Footswitch is active at Start Up the Machine

6-54 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
FUNCTION SWITCHES LOCKED - 2223 Machine is in Platform Mode; The UGM shall not Enable Controls initialized X X
SELECTED BEFORE ENABLE Any of the following Platform inputs are active when the Machine
Footswitch becomes active or while DTC 2212, 2213 or
2221 is active:
Tower Lift;
Telescope;
Platform Level;
Platform Rotate;
Jib Lift (if MACHINE SETUP > JIB = YES)
FOOTSWITCH SELECTED 2224 Machine is in Platform Mode; The UGM shall prohibit The Platform Engine Start switch input = X X
BEFORE START The engine is stopped; Engine Start Low;
Startup time has expired;
The Footswitch is active before the Platform Engine
Start switch input = High
FUNCTION PROBLEM - PLAT- 2247 Machine is in Platform Mode; The UGM shall prohibit The Platform Rotate Left switch input = X X
FORM ROTATE LEFT PERMA- The Platform Rotate Left switch input = High at Startup Platform Rotate Left and Low;
NENTLY SELECTED Right Platform Rotate Left and Right permitted
after controls are initialized
FUNCTION PROBLEM - PLAT- 2248 Machine is in Platform Mode; The UGM shall prohibit The Platform Rotate Right switch input = X X
FORM ROTATE RIGHT PERMA- The Platform Rotate Right switch input = High at Platform Rotate Left and Low;
NENTLY SELECTED Startup Right Platform Rotate Left and Right permitted
after controls are initialized
FUNCTION PROBLEM - JIB LIFT 2249 Machine is in Platform Mode; The UGM shall prohibit Jib The Jib Lift Up switch input = Low; X X
UP PERMANENTLY SELECTED MACHINE SETUP > JIB = YES; Lift Up and Down Jib Lift Up and Down permitted after con-
The Jib Lift Up switch input = High at Startup trols are initialized
FUNCTION PROBLEM - JIB LIFT 2250 Machine is in Platform Mode; The UGM shall prohibit Jib The Jib Lift Down switch input = Low; X X
DOWN PERMANENTLY MACHINE SETUP > JIB = YES; Lift Up and Down Jib Lift Up and Down permitted after con-
SELECTED The Jib Lift Down switch input = High at Startup trols are initialized
FUNCTION PROBLEM - TELE- 2251 Machine is in Platform Mode; The UGM shall prohibit The Telescope In switch input = Low; X X
SCOPE IN PERMANENTLY The Telescope In switch input = High at Startup Telescope In and Out Telescope permitted after controls are ini-
SELECTED tialized
FUNCTION PROBLEM - TELE- 2252 Machine is in Platform Mode; The UGM shall prohibit The Telescope Out switch input = Low; X X
SCOPE OUT PERMANENTLY The Telescope Out switch input = High at Startup Telescope In and Out Telescope permitted after controls are ini-
SELECTED tialized
FUNCTION PROBLEM - TOWER 2257 Machine is in Platform Mode; The UGM shall prohibit The Tower Lift In switch input = Low; X
LIFT UP PERMANENTLY The Tower Lift Up switch input = High at Startup Tower Lift Up and Down Tower Lift Up and Down permitted after
SELECTED controls are initialized
FUNCTION PROBLEM - TOWER 2258 Machine is in Platform Mode; The UGM shall prohibit The Tower Lift Down switch input = Low; X
LIFT DOWN PERMANENTLY The Tower Lift Down switch input = High at Startup Tower Lift Up and Down Tower Lift Up and Down permitted after
SELECTED controls are initialized
FUNCTION PROBLEM - PLAT- 2262 Machine is in Platform Mode; The UGM shall prohibit The Platform Level Up switch input = Low; X X
FORM LEVEL UP PERMANENTLY The Platform Level Up switch input = High at Startup Platform Level Up and Platform Level Up and Down permitted
SELECTED Down after controls are initialized
FUNCTION PROBLEM - PLAT- 2263 Machine is in Platform Mode; The UGM shall prohibit The Platform Level Down switch input = X X
FORM LEVEL DOWN PERMA- The Platform Level Down switch input = High at Platform Level Up and Low;
NENTLY SELECTED Startup Down Platform Level Up and Down permitted
after controls are initialized

3121671 6-55
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
FUNCTION PROBLEM - DOS 2264 Machine is in Platform Mode; No response required for The DOS Override switch input = Low X X
OVERRIDE PERMANENTLY The DOS Override switch input = High at Startup this DTC
SELECTED
FUNCTION PROBLEM - SOFT 2286 [(MACHINE SETUP > SKYGUARD = YES) or (MACHINE No response required for The Soft Touch / SkyGuard Override switch X X
TOUCH / SKYGUARD OVERRIDE SETUP > SOFT TOUCH = YES)]; this DTC input = Low
PERMANENTLY SELECTED Machine is in Platform Mode;
The Soft Touch / SkyGuard Override switch input = High
at Startup
FUNCTION SWITCHES FAULTY - 234 The UGM detects one of the following conditions (con- Disable whichever boom None of the boom controls that trigger this X X
CHECK DIAGNOSTICS/BOOM tinuous monitoring): functions whose boom fault have both of their direction inputs
The machine is in Ground Mode and both direction control inputs are trigger- engaged at the same time
inputs of the following boom controls are engaged at ing the fault. If Engine
the same time: Engine Start/Aux, Telescope, Platform Start/Aux at fault, disable
Level, Platform Rotate, Jib Lift, Tower Lift, Lift, or Swing. Engine Start but permit
The machine is in Platform Mode and both direction Auxiliary Power/Emer-
inputs of the following boom controls are engaged at gency Descent.
the same time: Engine Start/Aux, Telescope, Platform
Level, Platform Rotate, Jib Lift (MACHINE SETUP > JIB =
YES), Tower Lift (340AJ, 450AJ); or for Drive Mode –
Max Speed/Max Torque
FUNCTION SWITCHES LOCKED - 235 The UGM detects one of the following conditions: The UGM not enable Aux- The applicable APU/Auxiliary Descent X X
SELECTED BEFORE AUX POWER The machine is in Ground Mode and the engine is iliary Power/ Emergency switch is disengaged or all applicable con-
stopped and the ground APU/Function Enable switch Descent mode trol inputs become disengaged or the
becomes engaged while a Ground control input is engine state becomes ENGINE RUNNING
already engaged.
The machine is in Platform Mode and the engine is
stopped and the platform APU/Auxiliary Descent
switch becomes engaged while a Platform control
input is already engaged.
FUNCTION SWITCHES LOCKED - 236 The UGM detects one of the following conditions: The UGM shall prohibit The selected station’s start switch is no lon- X X
SELECTED BEFORE START The machine is in Ground Mode and the engine is Engine Start ger engaged
SWITCH stopped and any configured boom control is already
engaged and the ground start switch changes from not
engaged to engaged
The machine is in Platform Mode and the engine is
stopped and any drive/steer or configured boom con-
trol is already engaged and the footswitch is not
engaged and the platform start switch changes from
not engaged to engaged
START SWITCH LOCKED - 237 The start switch for the selected station is engaged dur- The UGM shall prohibit The selected station’s start switch is no lon- X X
SELECTED BEFORE KEYSWITCH ing the UGM startup sequence Engine Start ger engaged
FUNCTION PROBLEM - 2310 Machine is in Ground Mode; The UGM shall prohibit Controls initialized X X
GROUND ENABLE PERMA- The Ground Enable switch input = High at Startup Engine Start;
NENTLY SELECTED The UGM shall not Enable
the Machine
BOOM ANGLE SENSOR – NOT 2343 The Boom Angle Sensor has not been calibrated The UGM shall assume the Boom angle sensor calibrated X X
CALIBRATED Boom is Above Elevation;
The UGM shall report a
faulted boom angle of 90
degrees

6-56 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
BOOM ANGLE SENSOR - OUT OF 2344 The UGM detects that Boom Angle Sensor #1 or Boom The UGM shall assume the Power Cycled X X
RANGE HIGH Angle Sensor #2 signal voltage > 4.5V. Boom is Above Elevation;
The UGM shall report a
faulted boom angle of 90
degrees
BOOM ANGLE SENSOR - OUT OF 2345 The UGM detects that Boom Angle Sensor #1 or Boom The UGM shall assume the Power Cycled X X
RANGE LOW Angle Sensor #2 signal voltage < 0.5V. Boom is Above Elevation;
The UGM shall report a
faulted boom angle of 90
degrees
BOOM ANGLE SENSOR – NOT 2346 The UGM detects the following conditions: The UGM shall assume the Power Cycled X X
RESPONDING The UGM detects < 1 deg change of Boom Angle Boom is Above Elevation;
Main Lift Up or Main Lift Down output value ≥ Creep The UGM shall report a
output value faulted boom angle of 90
Main Lift Up or Main Lift Down has been active longer degrees
than 5 seconds.
FUNCTION PROBLEM - JIB LIFT 2370 Machine is in Ground Mode; The UGM shall prohibit Jib The Jib Lift Up switch input = Low; X X
UP PERMANENTLY SELECTED MACHINE SETUP > JIB = YES; Lift Up and Down Jib Lift Up and Down permitted after con-
The Jib Lift Up switch input = High at Startup trols are initialized
FUNCTION PROBLEM - JIB LIFT 2371 Machine is in Ground Mode; The UGM shall prohibit Jib The Jib Lift Down switch input = Low; X X
DOWN PERMANENTLY MACHINE SETUP > JIB = YES; Lift Up and Down Jib Lift Up and Down permitted after con-
SELECTED The Jib Lift Down switch input = High at Startup trols are initialized
FUNCTION PROBLEM - SWING 2372 Machine is in Ground Mode; The UGM shall prohibit The Swing Left switch input = Low; X X
LEFT PERMANENTLY SELECTED The Swing Left switch input = High at Startup Swing Left and Right Swing Left and Right permitted after con-
trols are initialized
FUNCTION PROBLEM - SWING 2373 Machine is in Ground Mode; The UGM shall prohibit The Swing Left switch input = Low; X X
RIGHT PERMANENTLY The Swing Right switch input = High at Startup Swing Left and Right Swing Left and Right permitted after con-
SELECTED trols are initialized
BOOM ANGLE SENSOR DIS- 2396 The UGM detects that Boom Angle Sensor #1 and Boom The UGM shall assume the Power Cycled X X
AGREEMENT Angle Sensor #2 readings disagree ≥ 2.5 deg for longer Boom is Above Elevation
than 5 seconds; and will report a faulted
Do not report if DTC 2343 is active boom angle of 90 degrees
FUNCTION PROBLEM – TOWER 23105 Machine is in Ground Mode; The UGM shall prohibit The Tower Lift Up switch input = Low; X
LIFT UP PERMANENTLY The Tower Lift Up switch input = High at Startup Tower Lift Up and Down Tower Lift Up and Down permitted after
SELECTED controls are initialized
FUNCTION PROBLEM – TOWER 23106 Machine is in Ground Mode; The UGM shall prohibit The Tower Lift Down switch input = Low; X
LIFT DOWN PERMANENTLY The Tower Lift Down switch input = High at Startup Tower Lift Up and Down Tower Lift Up and Down permitted after
SELECTED controls are initialized
FUNCTION PROBLEM - LIFT UP 23107 Machine is in Ground Mode; The UGM shall prohibit The Lift Up switch input = Low; X X
PERMANENTLY SELECTED The Lift Up switch input = High at Startup Lift Up and Down Lift Up and Down permitted after controls
are initialized
FUNCTION PROBLEM - LIFT 23108 Machine is in Ground Mode; The UGM shall prohibit The Lift Down switch input = Low; X X
DOWN PERMANENTLY The Lift Down switch input = High at Startup Lift Up and Down Lift Up and Down permitted after controls
SELECTED are initialized
FUNCTION PROBLEM - TELE- 23109 Machine is in Ground Mode; The UGM shall prohibit The Telescope In switch input = Low; X X
SCOPE IN PERMANENTLY The Telescope In switch input = High at Startup Telescope In and Out Telescope In and Out permitted after con-
SELECTED trols are initialized

3121671 6-57
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
FUNCTION PROBLEM - TELE- 23110 Machine is in Ground Mode; The UGM shall prohibit The Telescope Out switch input = Low; X X
SCOPE OUT PERMANENTLY The Telescope Out switch input = High at Startup Telescope In and Out Telescope In and Out permitted after con-
SELECTED trols are initialized
FUNCTION PROBLEM - PLAT- 23111 Machine is in Ground Mode; The UGM shall prohibit The Platform Level Up switch input = Low; X X
FORM LEVEL UP PERMANENTLY The Platform Level Up switch input = High at Startup Platform Level Up and Platform Level Up and Down permitted
SELECTED Down after controls are initialized
FUNCTION PROBLEM - PLAT- 23112 Machine is in Ground Mode; The UGM shall prohibit The Platform Level Down switch input = X X
FORM LEVEL DOWN PERMA- The Platform Level Down switch input = High at Platform Level Up and Low;
NENTLY SELECTED Startup Down Platform Level Up and Down permitted
after controls are initialized
FUNCTION PROBLEM - PLAT- 23113 Machine is in Ground Mode; The UGM shall prohibit The Platform Rotate Left switch input = X X
FORM ROTATE LEFT PERMA- The Platform Rotate Left switch input = High at Startup Platform Rotate Left and Low;
NENTLY SELECTED Right Platform Rotate Left and Right permitted
after controls are initialized
FUNCTION PROBLEM - PLAT- 23114 Machine is in Ground Mode; The UGM shall prohibit The Platform Rotate Right switch input = X X
FORM ROTATE RIGHT PERMA- The Platform Rotate Right switch input = High at Platform Rotate Left and Low;
NENTLY SELECTED Startup Right Platform Rotate Left and Right permitted
after controls are initialized
TELESCOPE RETRACT 23154 The UGM detects the following conditions: The UGM shall assume the Power Cycled X
SWITCHES - DISAGREEMENT Telescope Retracted Switch #1 and Telescope Retracted Boom is Not Retracted
Switch #2 readings disagree for longer than 5 seconds;
Telescope In or Telescope Out output value ≥ Creep out-
put value
SWING SWITCHES - DISAGREE- 23155 The UGM detects the following conditions: The UGM shall assume the Power Cycled X
MENT Swing Switch #1 and Swing Switch #2 readings dis- Boom is Swung
agree for longer than 5 seconds;
Swing Left or Swing Right value ≥ Creep output value
FUNCTION PROBLEM – MSSO 23163 The MSSO switch input = Low at Startup No response required for Power Cycled X X
PERMANENTLY SELECTED this DTC
BOOM ANGLE SENSOR - SINGLE 23170 Single point Boom Angle calibration is successfully No response required for Fault shall be retentive through Power X X
POINT CALIBRATION PER- completed this DTC Cycled;
FORMED Can be reset if CALIBRATIONS > BOOM
ANGLE is successfully completed
CAPACITY LENGTH SWITCHES - 23173 Dual Capacity is configured; The UGM shall assume Power Cycled X
DISAGREEMENT The UGM detects the following conditions: Dual Capacity = 600#
Capacity Length Switch #1 and Capacity Length Switch
#2 readings disagree for longer than 5 seconds;
Telescope In or Telescope Out output value ≥ Creep out-
put value

6-58 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
AMBIENT TEMPERATURE SEN- 241 MACHINE SETUP > TEMP CUTOUT = YES; The UGM shall set Low Ambient Temperature sensor reading > - X X
SOR – OUT OF RANGE LOW Ambient Temperature sensor reading ≤ -50C Temperature Cutout state 50C;
= Faulty Full Speed permitted after controls are ini-
tialized
If the Machine is in Plat-
form Mode and if the
Boom is Above Elevation;
The UGM shall suspend
motion;
The UGM shall limit the
machine to Creep speed
after controls initialized

If the Machine is in Plat-

If the Machine is in Ground

Mode;
No response required for
this DTC

3121671 6-59
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
AMBIENT TEMPERATURE SEN- 242 MACHINE SETUP > TEMP CUTOUT = YES; The UGM shall set Low Ambient Temperature sensor reading < X X
SOR – OUT OF RANGE HIGH Ambient Temperature sensor reading ≥ 85C Temperature Cutout state 85C;
= Faulty Full Speed permitted after controls are ini-
tialized
If the Machine is in Plat-
form Mode and if the
Boom is Above Elevation;
The UGM shall suspend
motion;
The UGM shall limit the
machine to Creep speed
after controls initialized

If the Machine is in Plat-

If the Machine is in Ground

Mode;
No response required for
this DTC
MODEL CHANGED – HYDRAU- 259 The MACHINE SETUP > MODEL NUMBER is changed Disable all machine and Power Cycled X X
LICS SUSPENDED – CYCLE EMS using the analyzer engine functions (i.e.,
command engine shut-
down and do not permit
start)
GENERATOR MOTION CUTOUT 2513 MACHINE SETUP > GEN SET = BELT DRIVE; The UGM shall not Enable Not all of the trigger conditions are met X X
ACTIVE MACHINE SETUP > GEN SET CUTOUT = MOTION CUT- the Machine
OUT;
The platform Generator Switch is engaged
Footswitch State = Depressed
The machine is in Platform mode
BOOM PREVENTED – DRIVE 2514 MACHINE SETUP > FUNCTION CUTOUT = BOOM CUT- The UGM shall prohibit all Not all of the trigger conditions are met X X
SELECTED OUT; boom functions
Drive or Steer is already engaged;
The boom is Above Elevation
The operator is attempting to activate one of the boom
functions
DTC 2514 supercedes DTC 2518 if drive/steer and boom
functions are both active when machine transitions
from Below Elevation to Above Elevation.

6-60 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
DRIVE PREVENTED – ABOVE 2516 MACHINE SETUP > FUNCTION CUTOUT = DRIVE CUTOUT The UGM shall prohibit Not all of the trigger conditions are met X X
ELEVATION The boom is Above Elevation Drive and Steer
The operator is attempting to activate Drive or Steer
DRIVE PREVENTED – TILTED & 2517 MACHINE SETUP > FUNCTION CUTOUT = DRIVE CUT The UGM shall prohibit Not all of the trigger conditions are met X X
ABOVE ELEVATION E&T Drive and Steer
The boom is Above Elevation
The chassis is considered Tilted
The operator is attempting to activate Drive or Steer
DRIVE PREVENTED – BOOM 2518 MACHINE SETUP > FUNCTION CUTOUT = BOOM CUT- The UGM shall prohibit Not all of the trigger conditions are met X X
SELECTED OUT Drive and Steer
The boom is Above Elevation
Any boom function is already active
The operator attempts to activate Drive or Steer
DRIVE & BOOM PREVENTED - 2549 MACHINE SETUP > SOFT TOUCH = YES; Response detailed in Soft Not all of the trigger conditions are met X X
SOFT TOUCH ACTIVE Machine is in Platform Mode; Touch section
Soft Touch State = Enabled
SKYGUARD SWITCH – DIS- 2563 MACHINE SETUP > SKYGUARD = YES; Response detailed in Sky- [{SkyGuard inputs (Platform Module J7-18 X X
AGREEMENT Machine is in Platform Mode; Guard section = High) and (Platform Module J1-23 =
[(SkyGuard input #1 Platform Module J7-18) ≠ (Sky- High)} and (Footswitch State = Not
Guard input #2 Platform Module J1-23)] > 160ms Depressed)]
TEMPERATURE CUTOUT ACTIVE 2568 Low Temperature Cutout = Active If the Boom is Above Ele- Low Temperature Cutout = Inactive; X X
– AMBIENT TEMPERATURE TOO vation; Full Speed permitted after controls are ini-
LOW The UGM shall suspend tialized
motion;
The UGM shall limit the
machine to Creep speed
after controls initialized

If the Machine is in Plat-

form Mode and if the
Boom is not Above Eleva-
tion;
The UGM shall limit
Swing, Tower Lift (340AJ.
450AJ), Tele, Lift, Plat-
form Rotate, Platform
Level, and Jib Lift (if
MACHINE SETUP > JIB =
YES) to Creep speed
PLATFORM LEVEL PREVENTED 2576 Platform Level Override Cutout = Enabled; The UGM shall suspend Controls initialized X X
– ABOVE ELEVATION The Platform Level Up or Down switch input = High; Platform Level Up and
Footswitch is active Down commands;
The UGM shall prohibit
Platform Level Up and
Down
RUNNING AT CREEP - PLAT- 2587 The control system has determined that the platform is
FORM LEVELED UNDER leveled under and is being considered to be in a load-
ing/unloading position. Boom, Tower, and Level Over-
ride functions will operate at creep speed.

3121671 6-61
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
BRAKE – SHORT TO BATTERY 331 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X X
Drive and Brake outputs.
BRAKE – OPEN CIRCUIT 332 The UGM detects an open circuit at this output No response required for Power Cycled X X
this DTC
LIFT UP VALVE – OPEN CIRCUIT 334 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
Lift Up and Down com- Full speed Lift Up and Down permitted after
mand and revert to Open controls are initialized
Loop Current control for
Lift;
The UGM shall limit Lift Up
and Down to Creep speed
after controls initialized
LIFT DOWN VALVE – OPEN CIR- 336 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
CUIT Lift Up and Down com- Full speed Lift Up and Lift Down permitted
mand and revert to Open after controls are initialized
Loop Current control for
Lift;
The UGM shall prohibit
Lift Up;
The UGM shall limit Lift
Down to Creep speed after
controls initialized
GROUND ALARM – SHORT TO 3311 The UGM detects a short to battery at this output No response required for Power Cycled X X
BATTERY this DTC
MAIN DUMP VALVE – SHORT TO 3358 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
GROUND Main Dump
MAIN DUMP VALVE – OPEN 3359 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
CIRCUIT Swing (340AJ, 400S, Full speed Swing (340AJ, 400S, 450AJ),
450AJ), Tower Lift Up Tower Lift Up (340AJ, 450AJ), Lift Up, Tele-
(340AJ, 450AJ), Lift Up, scope (400S, 450AJ, 18RS, 24RS) Jib Lift
Telescope (400S, 450AJ, (400S, 450AJ), Platform Rotate (400S,
18RS, 24RS), Jib Lift 450AJ) and Platform Level (400S,
(400S, 450AJ); Platform 450AJ)permitted after controls are initial-
Rotate (400S, 450AJ) and ized
Platform Level (400S,
450AJ);
The UGM shall limit Tower
Lift Up (340AJ, 450AJ),
Telescope (400S, 450AJ,
18RS, 24RS), Lift Up, Plat-
form Rotate (400S,
450AJ), Platform Level
(400S, 450AJ), and Jib Lift
(400S, 450AJ) to Creep
speed after controls ini-
tialized

6-62 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
MAIN DUMP VALVE – SHORT TO 3360 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X X
BATTERY Main Dump, Steer (400S,
450AJ), Swing (340AJ,
400S, 450AJ), Tower Lift
Up (340AJ, 450AJ), Lift
Up, Telescope (400S,
450AJ, 18RS, 24RS), Jib
Lift (400S, 450AJ), Plat-
form Level (400S, 450AJ)
and Platform Rotate
(400S, 450AJ)
BRAKE – SHORT TO GROUND 3361 The UGM detects a short to ground at this output Disable UGM Drive/Steer Power Cycled X X
and Brake outputs
START SOLENOID – SHORT TO 3362 UGM detects a short to ground at this output Engine Start attempt shall Power Cycled X X
GROUND not be permitted.
START SOLENOID – OPEN CIR- 3363 UGM detects an open circuit at this output; if MACHINE No response required for Power Cycled X X
CUIT SETUP > ENGINE = DUAL FUEL ECU, only evaluate until this DTC
first Start is attempted for each power cycle due to pos-
sibility of ECU opening ground solenoid return path to
disable Start and causing erroneous diagnostics.
START SOLENOID – SHORT TO 3364 UGM detects a short to battery at this output Disable UGM Engine Start Power Cycled X X
BATTERY by deenergizing Fuel
Actuator (Kubota) or
sending Engine Shut-
down command (CAN-
based ECUs)
STEER DUMP VALVE – SHORT 3365 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled
TO GROUND Steer Dump
TWO SPEED VALVE - SHORT TO 3368 The UGM detects a short to ground at this output Disable UGM 2 Speed out- Power Cycled X X
GROUND put.
If in Max Speed drive
mode, switch to Max
Torque; disable Max
Speed drive mode
TWO SPEED VALVE - OPEN CIR- 3369 The UGM detects an open circuit at this output If in Max Speed drive Power Cycled X X
CUIT mode, switch to Max
Torque; disable Max
Speed drive mode
TWO SPEED VALVE - SHORT TO 3370 The UGM detects a short to battery at this output If in Max Speed drive Power Cycled X X
BATTERY mode, switch to Max
Torque; disable Max
Speed drive mode. Ramp
and limit drive speed to
Creep value for associated
drive mode:
The UGM shall disable
Drive when the Boom is
Above Elevation.

3121671 6-63
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
GEN SET/WELDER – SHORT TO 3373 MACHINE SETUP > GEN SET = BELT DRIVE and the UGM Disable UGM Generator Power Cycled X X
GROUND detects a short to ground at this output output. Do not Enable
generator functionality or
set Engine to Generator
RPM.
GEN SET/WELDER – OPEN CIR- 3374 MACHINE SETUP > GEN SET = BELT DRIVE and the UGM No response required for Power Cycled X X
CUIT detect an open circuit at this output this DTC
GEN SET/WELDER – SHORT TO 3375 MACHINE SETUP > GEN SET = BELT DRIVE and the UGM Disable UGM Generator Power Cycled X X
BATTERY detects a short to battery at this output output, but UGM shall
consider Generator
always excited (enabled)
and restrict engine to
Generator RPM. If
MACHINE SETUP >
GENSET CUTOUT =
MOTION CUTOUT, disre-
gard cutout and permit
motion.
HEAD TAIL LIGHT – SHORT TO 3376 MACHINE SETUP > H & T LIGHTS =YES and the UGM Disable UGM H&T Light Power Cycled X X
GROUND detects a short to ground at this output relay output
HEAD TAIL LIGHT – OPEN CIR- 3377 MACHINE SETUP > H & T LIGHTS =YES and the UGM No response required for Power Cycled X X
CUIT detects an open circuit at this output this DTC
HEAD TAIL LIGHT – SHORT TO 3378 MACHINE SETUP > H & T LIGHTS =YES and the UGM Disable UGM H&T Light Power Cycled X X
BATTERY detects a short to battery at this output relay output
PLATFORM LEVEL UP VALVE – 3382 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
SHORT TO GROUND Platform Level Up;
(340AJ, 400S, 450AJ) The
UGM shall limit Platform
Level Down to Creep
speed
PLATFORM LEVEL UP VALVE – 3383 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
OPEN CIRCUIT Platform Level Up and (340AJ, 400S, 450AJ) Full speed Platform
Down; Level Up and Down permitted after controls
(340AJ, 400S, 450AJ) The are initialized
UGM shall limit Platform
Level Up and Down to
Creep speed after controls
initialized;
(18RS, 24RS) Platform
Level Up and Down per-
mitted after controls are
initialized
PLATFORM LEVEL UP VALVE – 3384 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X X
SHORT TO BATTERY Platform Level Up, Level
Down, and Flow Control
PLATFORM LEVEL DOWN VALVE 3388 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
– SHORT TO GROUND Platform Level Up and
Down

6-64 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
PLATFORM LEVEL DOWN VALVE 3389 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
– OPEN CIRCUIT Platform Level Up and (340AJ, 400S, 450AJ) Full speed Platform
Down; Level Up and Platform Level Down permit-
The UGM shall prohibit ted after controls are initialized
Platform Level Up;
(340AJ, 400S, 450AJ) The
UGM shall limit Platform
Level Down to Creep
speed after controls ini-
tialized;
(18RS, 24RS) Platform
Level Down permitted
after controls are initial-
ized
PLATFORM LEVEL DOWN VALVE 3390 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X X
– SHORT TO BATTERY Platform Level Up, Level
Down, and Flow Control
PLATFORM ROTATE LEFT VALVE 3394 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X
– SHORT TO GROUND Platform Rotate Left and
Right
PLATFORM ROTATE LEFT VALVE 3395 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X
– OPEN CIRCUIT Platform Rotate Left and (340AJ, 400S, 450AJ) Full speed Platform
Right; Rotate Left and Right permitted after con-
(340AJ, 400S, 450AJ) The trols are initialized
UGM shall limit Platform
Rotate Left and Right to
Creep speed after controls
initialized;
(18RS, 24RS) Platform
Rotate Left and Right per-
mitted after controls are
initialized
PLATFORM ROTATE LEFT VALVE 3396 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X
– SHORT TO BATTERY Platform Rotate Left,
Right and Flow Control
Valve outputs
PLATFORM ROTATE RIGHT 3397 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X
VALVE – SHORT TO GROUND Platform Rotate Left and
Right

3121671 6-65
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
PLATFORM ROTATE RIGHT 3398 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X
VALVE – OPEN CIRCUIT Platform Rotate Left and (340AJ, 400S, 450AJ) Full speed Platform
Right; Rotate Left and Right permitted after con-
(340AJ, 400S, 450AJ) The trols are initialized
UGM shall limit Platform
Rotate Left and Right to
Creep speed after controls
initialized;
(18RS, 24RS) Platform
Rotate Left and Right per-
mitted after controls are
initialized
PLATFORM ROTATE RIGHT 3399 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X
VALVE – SHORT TO BATTERY Platform Rotate Left,
Right and Flow Control
Valve outputs
JIB LIFT UP VALVE - SHORT TO 33100 MACHINE SETUP > JIB = YES; The UGM shall prohibit Jib Power Cycled X
GROUND The UGM detects a short to ground at this output Lift Up;
The UGM shall limit Jib Lift
Down to Creep speed
JIB LIFT UP VALVE - OPEN CIR- 33101 MACHINE SETUP > JIB = YES; The UGM shall suspend Jib The UGM no longer detects open circuit; X
CUIT The UGM detects an open circuit at this output Lift Up and Down; Full speed Jib Lift Up and Down permitted
The UGM shall limit Jib Lift after controls are initialized
Up and Down to Creep
speed after controls ini-
tialized
JIB LIFT UP VALVE - SHORT TO 33102 MACHINE SETUP > JIB = YES; The UGM shall prohibit Jib Power Cycled X
BATTERY The UGM detects a short to battery at this output Lift Up, Down and Flow
Control
JIB LIFT DOWN VALVE - SHORT 33103 MACHINE SETUP > JIB = YES; The UGM shall prohibit Jib Power Cycled X
TO GROUND The UGM detects a short to ground at this output Lift Up and Down
JIB LIFT DOWN VALVE - OPEN 33104 MACHINE SETUP > JIB = YES; The UGM shall suspend Jib The UGM no longer detects open circuit; X
CIRCUIT The UGM detects an open circuit at this output Lift Up and Down; Jib Lift Up permitted after controls are ini-
The UGM shall prohibit Jib tialized
Lift Up; Full speed Jib Lift Down permitted after
The UGM shall limit Jib Lift controls are initialized
Down to Creep speed after
controls initialized
JIB LIFT DOWN VALVE - SHORT 33105 MACHINE SETUP > JIB = YES; The UGM shall prohibit Jib Power Cycled X
TO BATTERY The UGM detects a short to battery at this output Lift Up, Down and Flow
Control
TOWER LIFT UP VALVE – SHORT 33106 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X
TO GROUND Tower Lift Up;
The UGM shall limit Tower
Lift Down Creep speed

6-66 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
TOWER LIFT UP VALVE – OPEN 33107 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X
CIRCUIT Tower Lift Up and Down Full speed Tower Lift Up and Down permit-
command and revert to ted after controls are initialized
Open Loop Current control
for Tower Lift;
The UGM shall limit Tower
Lift Up and Down to Creep
speed after controls ini-
tialized
TOWER LIFT DOWN VALVE – 33109 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X
SHORT TO GROUND Tower Lift Up and Down
TOWER LIFT DOWN VALVE – 33110 The UGM shall suspend The UGM no longer detects open circuit; X
OPEN CIRCUIT The UGM detects an open circuit at this output Tower Lift Up and Down Tower Lift Up permitted after controls are
command and revert to initialized;
Open Loop Current control Full speed Tower Lift Down permitted after
for Tower Lift; controls are initialized
The UGM shall prohibit
Tower Lift Up;
The UGM shall limit Tower
Lift Down to Creep speed
after controls initialized
SWING RIGHT VALVE – SHORT 33118 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
TO GROUND Swing Left and Right
SWING RIGHT VALVE – OPEN 33119 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
CIRCUIT Swing Left and Right com- Full speed Swing Left and Right permitted
mand and revert to Open after controls are initialized
Loop Current control for
Swing;
The UGM shall limit Swing
Left and Right to Creep
speed after controls ini-
tialized
TELESCOPE IN VALVE – SHORT 33120 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X X
TO BATTERY Telescope In, Out and Flow
Control
SWING LEFT VALVE – SHORT TO 33122 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
GROUND Swing Left and Right
TELESCOPE OUT VALVE – 33123 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X X
SHORT TO BATTERY Telescope In, Out and Flow
Control
LIFT VALVES – SHORT TO BAT- 33182 The UGM detects a short to battery at either the Lift Up The UGM shall prohibit Power Cycled X X
TERY or Lift Down valve Lift Up and Down;
The UGM shall open the
Lift Current Feedback low
side FET

3121671 6-67
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
TELESCOPE OUT VALVE – OPEN 33186 The UGM detects an open circuit at this output (340AJ, 400S, 450AJ) The UGM no longer detects open circuit; X X
CIRCUIT The UGM shall suspend Full speed Telescope In and Out permitted
Telescope In and Out after controls are initialized

(18RS, 24RS) The UGM

shall suspend Telescope In
and Out command and
revert to Open Loop Cur-
rent control for Telescope

The UGM shall limit Tele-

scope In and Out to Creep
speed after controls ini-
tialized
TELESCOPE OUT VALVE – 33188 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
SHORT TO GROUND Telescope Out;
Tele In speed limited to
Creep
TELESCOPE IN VALVE – OPEN 33189 The UGM detects an open circuit at this output (340AJ, 400S, 450AJ) The UGM no longer detects open circuit; X X
CIRCUIT The UGM shall suspend Telescope Out permitted after controls are
Telescope In and Out initialized;
Full speed Telescope In permitted after con-
(18RS, 24RS) The UGM trols are initialized
shall suspend Telescope In
and Out command and
revert to Open Loop Cur-
rent control for Telescope

The UGM shall prohibit

Telescope Out;
The UGM shall limit Tele-
scope In to Creep speed
after controls initialized
TELESCOPE IN VALVE – SHORT 33190 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
TO GROUND Telescope In and Out
APU PUMP RELAY - OPEN CIR- 33276 The UGM detects an open circuit at this output No response required for Power Cycled X X
CUIT this DTC
APU PUMP RELAY - SHORT TO 33277 The UGM detects a short to battery at this output Disable UGM APU Pump Power Cycled X X
BATTERY relay output
APU PUMP RELAY - SHORT TO 33278 The UGM detects a short to ground at this output Disable UGM APU Pump Power Cycled X X
GROUND relay output
GLOWPLUG – OPEN CIRCUIT 33279 MACHINE SETUP > ENGINE ≠ DUAL FUEL ECM No response required for Power Cycled X X
MACHINE SETUP > ENGINE ≠ DEUTZ EMR4 this DTC
MACHINE SETUP > GLOW PLUG ≠ NO
The UGM detects an open circuit at this output
GLOWPLUG – SHORT TO BAT- 33280 MACHINE SETUP > ENGINE ≠ DUAL FUEL ECM Disable UGM Glow Plug Power Cycled X X
TERY MACHINE SETUP > ENGINE ≠ DEUTZ EMR4 relay output
MACHINE SETUP > GLOW PLUG ≠ NO
The UGM detects a short to battery at this output

6-68 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
GLOWPLUG – SHORT TO 33281 MACHINE SETUP > ENGINE ≠ DUAL FUEL ECM Disable UGM Glow Plug Power Cycled X X
GROUND MACHINE SETUP > ENGINE ≠ DEUTZ EMR4 relay output
MACHINE SETUP > GLOW PLUG ≠ NO
The UGM detects a short to ground at this output
LIFT – CURRENT FEEDBACK 33287 The Engine State = ENGINE RUNNING; The UGM shall suspend Power Cycled X X
READING TOO LOW The UGM commanded current > 250mA; Lift Up and Down com-
The difference between the commanded current and mand and revert to Open
the measured feedback current > [the larger of Loop Current control for
(125mA) or (15% of the commanded function Max)] Lift;
for longer than 1 second The UGM shall limit Lift Up
and Down to Creep speed
after controls initialized
SWING LEFT VALVE – OPEN CIR- 33295 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
CUIT Swing Left and Right com- Full speed Swing Left and Right permitted
mand and revert to Open after controls are initialized
Loop Current control for
Swing;
The UGM shall limit Swing
Left and Right to Creep
speed after controls ini-
tialized
FLOW CONTROL VALVE – OPEN 33314 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
CIRCUIT Flow Control and revert to Full speed Telescope, Jib Lift Up, Jib Lift
Open Current loop control Down (400S, 450AJ), Platform Rotate and
for Flow Control; Platform Level permitted after controls are
The UGM shall limit Tele- initialized
scope, Jib Lift Up, Jib Lift
Down (400S, 450AJ), Plat-
form Rotate and Platform
Level to Creep speed after
controls initialized
FLOW CONTROL VALVE – 33315 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X X
SHORT TO BATTERY Flow Control, Telescope,
Jib Lift Up (permitted if
operating in Auxiliary
Power/Emergency
Descent mode), Jib Lift
Down (permitted if oper-
ating in Auxiliary Power/
Emergency Descent
mode)(400S, 450AJ),
Platform Rotate and Plat-
form Level
FLOW CONTROL VALVE – 33316 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
SHORT TO GROUND Flow Control, Telescope,
Jib Lift Up, Jib Lift Down
(400S, 450AJ), Platform
Rotate and Platform Level

3121671 6-69
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
DRIVE FORWARD VALVE – 33317 The UGM shall suspend The UGM no longer detects open circuit; X X
OPEN CIRCUIT The UGM detects an open circuit at this output Drive Forward and Full speed Drive Forward and Reverse per-
Reverse command and mitted after controls are initialized
revert to Open Current
loop control for Drive;
The UGM shall limit Drive
Forward and Reverse to
Creep speed after controls
initialized
DRIVE VALVES – SHORT TO BAT- 33318 The UGM detects a short to battery at either the Drive The UGM shall prohibit Power Cycled X X
TERY Forward or Drive Reverse valve. Drive Forward and
Reverse;
The UGM shall open the
Drive Current Feedback
low side FET
DRIVE FORWARD VALVE – 33319 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
SHORT TO GROUND Drive Forward and
Reverse
DRIVE REVERSE VALVE – OPEN 33320 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit; X X
CIRCUIT Drive Forward and Full speed Drive Forward and Reverse per-
Reverse command and mitted after controls are initialized
revert to Open Current
loop control for Drive;
The UGM shall limit Drive
Forward and Reverse to
Creep speed after controls
initialized
DRIVE REVERSE VALVE – SHORT 33322 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
TO GROUND Drive Forward and
Reverse
DRIVE – CURRENT FEEDBACK 33331 The Engine State = ENGINE RUNNING; The UGM shall suspend Power Cycled X X
READING TOO LOW The UGM commanded current > 250mA; Drive Forward and
The difference between the commanded current and Reverse command and
the measured feedback current > [the larger of revert to Open Current
(125mA) or (15% of the commanded function Max)] loop control for Drive;
for longer than 1 second The UGM shall limit Drive
Forward and Reverse to
Creep speed after controls
initialized
LIFT UP VALVE – SHORT TO 33406 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
GROUND Lift Up;
The UGM shall limit Lift
Down Creep speed
LIFT DOWN VALVE – SHORT TO 33407 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
GROUND Lift Up and Down

6-70 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
DRIVE – LOSS OF CURRENT 33410 Measured feedback current < 225mA while PWM out- The UGM shall suspend Power Cycled X X
FEEDBACK put > 40% for a period of 100ms. Drive Forward and
Reverse command and
revert to Open Current
loop control for Drive;
The UGM shall limit Drive
Forward and Reverse to
Creep speed after controls
initialized
SWING VALVES – SHORT TO 33412 The UGM detects a short to battery at either the Swing The UGM shall prohibit Power Cycled X X
BATTERY Right or Swing Left valve Swing Left and Right;
The UGM shall open the
Swing Current Feedback
low side FET
TOWER LIFT – CURRENT FEED- 33413 The Engine State = ENGINE RUNNING; The UGM shall suspend Power Cycled X
BACK READING TOO LOW The UGM commanded current > 250mA; Tower Lift Up and Down
The difference between the commanded current and command and revert to
the measured feedback current > [the larger of Open Loop Current control
(125mA) or (15% of the commanded function Max)] for Tower Lift;
for longer than 1 second The UGM shall limit Tower
Lift Up and Down to Creep
speed after controls ini-
tialized
SWING – CURRENT FEEDBACK 33414 The Engine State = ENGINE RUNNING; The UGM shall suspend Power Cycled X X
READING TOO LOW The UGM commanded current > 250mA; Swing Left and Right com-
The difference between the commanded current and mand and revert to Open
the measured feedback current > [the larger of Loop Current control for
(125mA) or (15% of the commanded function Max)] Swing;
for longer than 1 second The UGM shall limit Swing
Left and Right to Creep
speed after controls ini-
tialized
FLOW CONTROL VALVE – CUR- 33415 The Engine State = ENGINE RUNNING; The UGM shall suspend Power Cycled X X
RENT FEEDBACK READING TOO The UGM commanded current > 250mA; Flow Control and revert to
LOW The difference between the commanded current and Open Current loop control
the measured feedback current > [the larger of for Flow Control;
(125mA) or (15% of the commanded function Max)] The UGM shall limit Tele-
for longer than 1 second scope, Jib Lift Up; Jib Lift
Down (400S, 450AJ), Plat-
form Rotate and Platform
Level to Creep speed after
controls initialized

3121671 6-71
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
TOWER LIFT – CURRENT FEED- 33416 Measured feedback current < 225mA while PWM out- The UGM shall suspend Power Cycled X
BACK READING LOST put > 40% for a period of 100ms. Tower Lift Up and Down
command and revert to
Open Loop Current control
for Tower Lift;
The UGM shall limit Tower
Lift Up and Down to Creep
speed after controls ini-
tialized
LIFT – CURRENT FEEDBACK 33417 Measured feedback current < 225mA while PWM out- The UGM shall suspend Power Cycled X X
READING LOST put > 40% for a period of 100ms. Lift Up and Down com-
mand and revert to Open
Loop Current control for
Lift;
The UGM shall limit Lift Up
and Down to Creep speed
after controls initialized
SWING – CURRENT FEEDBACK 33418 Measured feedback current < 225mA while PWM out- The UGM shall suspend Power Cycled X X
READING LOST put > 40% for a period of 100ms. Swing Left and Right com-
mand and revert to Open
Loop Current control for
Swing;
The UGM shall limit Swing
Left and Right to Creep
speed after controls ini-
tialized
FLOW CONTROL VALVE – CUR- 33419 Measured feedback current < 225mA while PWM out- The UGM shall suspend Power Cycled X X
RENT FEEDBACK READING LOST put > 40% for a period of 100ms. Flow Control and revert to
Open Current loop control
for Flow Control;
The UGM shall limit Tele-
scope In and Out, Jib Lift
Up and Down (400S,
450AJ), Platform Rotate
Right and Left and Plat-
form Level Up and Down
to Creep speed after con-
trols initialized
TOWER LIFT VALVES – SHORT 33425 The UGM detects a short to battery at either the Tower The UGM shall prohibit Power Cycled X
TO BATTERY Lift Up or Tower Lift Down valve. Tower Lift Up and Down;
The UGM shall open the
Tower Lift Current Feed-
back low side FET
AUXILIARY LIFT DOWN VALVE - 33537 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X X
SHORT TO GROUND Aux Lift Down
AUXILIARY LIFT DOWN VALVE - 33538 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit X X
OPEN CIRCUIT Aux Lift Down;
Aux Lift Down permitted
after controls are initial-
ized

6-72 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
AUXILIARY LIFT DOWN VALVE - 33539 The UGM detects a short to battery at this output The UGM shall prohibit Power Cycled X
SHORT TO BATTERY Aux Lift Down;
The UGM shall open the
Auxiliary low side FET
AUXILIARY TOWER LIFT DOWN 33540 The UGM detects a short to ground at this output The UGM shall prohibit Power Cycled X
VALVE - SHORT TO GROUND Aux Tower Lift Down
AUXILIARY TOWER LIFT DOWN 33541 The UGM detects an open circuit at this output The UGM shall suspend The UGM no longer detects open circuit X
VALVE - OPEN CIRCUIT Aux Tower Lift Down;
Aux Tower Lift Down per-
mitted after controls are
initialized
OSCILLATING AXLE #1 VALVE - 33543 The UGM detects a short to ground at this output UGM shall disable Oscil- Power Cycled X X
SHORT TO GROUND lating Axle #1 valve and
Oscillating Axle #2 valve
outputs;
The UGM shall Lock the
Oscillating Axle
OSCILLATING AXLE #1 VALVE - 33544 The UGM detects an open circuit at this output UGM shall disable Oscil- Power Cycled X X
OPEN CIRCUIT lating Axle #1 valve and
Oscillating Axle #2 valve
outputs;
The UGM shall Lock the
Oscillating Axle
OSCILLATING AXLE #1 VALVE - 33545 The UGM detects a short to battery at this output UGM shall disable Oscil- Power Cycled X X
SHORT TO BATTERY lating Axle #1 valve and
Oscillating Axle #2 valve
outputs;
The UGM shall Lock the
Oscillating Axle
OSCILLATING AXLE #2 VALVE - 33546 The UGM detects a short to ground at this output UGM shall disable Oscil- Power Cycled X X
SHORT TO GROUND lating Axle #1 valve and
Oscillating Axle #2 valve
outputs;
The UGM shall Lock the
Oscillating Axle
OSCILLATING AXLE #2 VALVE - 33547 The UGM detects an open circuit at this output UGM shall disable Oscil- Power Cycled X X
OPEN CIRCUIT lating Axle #1 valve and
Oscillating Axle #2 valve
outputs;
The UGM shall Lock the
Oscillating Axle
OSCILLATING AXLE #2 VALVE - 33548 The UGM detects a short to battery at this output UGM shall disable Oscil- Power Cycled X X
SHORT TO BATTERY lating Axle #1 valve and
Oscillating Axle #2 valve
outputs;
The UGM shall Lock the
Oscillating Axle

3121671 6-73
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
AUXILIARY VALVES - SHORT TO 33567 The UGM detects a short to battery at either the Aux Lift The UGM shall prohibit Power Cycled X
BATTERY Down or Aux Tower Lift Down valve Aux Lift Down and Aux
Tower Lift Down;
The UGM shall open the
Auxiliary low side FET
AUXILIARY - CURRENT FEED- 33568 Measured feedback current < 225mA while output is The UGM shall suspend Power Cycled X X
BACK READING LOST active for a period of 100ms. Aux Lift Down and Aux
Tower Down (450AJ);
Aux Lift Down and Aux
Tower Down (450AJ) per-
mitted after controls are
initialized
ECM PULL DOWN RESISTOR - 33575 MACHINE SETUP > ENGINE = DEUTZ EMR4; The UGM shall send the Power Cycled X X
OPEN CIRCUIT Pull down resister not detected Engine Shutdown com-
mand
PLATFORM ROTATE LEFT VALVE 349 The PM detects an open circuit at this output and The UGM shall suspend The PM no longer detects open circuit; X
– OPEN CIRCUIT reports it to the UGM commands to PM for Plat- Full speed Platform Rotate Right and Left
form Rotate Right and permitted after controls are initialized
Left;
The UGM shall limit Plat-
form Rotate Right and Left
to Creep speed after con-
trols are initialized
PLATFORM ROTATE LEFT VALVE 3410 The PM detects a short to battery at this output and The UGM shall disable Power Cycled X
– SHORT TO BATTERY reports it to the UGM commands to PM for Plat-
form Rotate Right and
Left;
The UGM shall prohibit
Flow Control
PLATFORM ROTATE LEFT VALVE 3411 The PM detects a short to ground at this output and The UGM shall disable Power Cycled X
– SHORT TO GROUND reports it to the UGM commands to PM for Plat-
form Rotate Right and Left
PLATFORM ROTATE RIGHT 3412 The PM detects an open circuit at this output and The UGM shall suspend The PM no longer detects open circuit; X
VALVE – OPEN CIRCUIT reports it to the UGM commands to PM for Plat- Full speed Platform Rotate Right and Left
form Rotate Right and permitted after controls are initialized
Left;
The UGM shall limit Plat-
form Rotate Right and Left
to Creep speed after con-
trols are initialized
PLATFORM ROTATE RIGHT 3413 The PM detects a short to battery at this output and The UGM shall disable Power Cycled X
VALVE – SHORT TO BATTERY reports it to the UGM commands to PM for Plat-
form Rotate Right and
Left;
The UGM shall prohibit
Flow Control
PLATFORM ROTATE RIGHT 3414 The PM detects a short to ground at this output and The UGM shall disable Power Cycled X
VALVE – SHORT TO GROUND reports it to the UGM commands to PM for Plat-
form Rotate Right and Left

6-74 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
JIB LIFT UP VALVE – OPEN CIR- 3415 MACHINE SETUP > JIB = YES The UGM shall suspend The PM no longer detects open circuit; X
CUIT The PM detects an open circuit at this output and commands to PM for Jib Full speed Jib Lift Up and Down permitted
reports it to the UGM Lift Up and Down; after controls are initialized
The UGM shall limit Jib Lift
Up and Down to Creep
speed
JIB LIFT UP VALVE – SHORT TO 3416 MACHINE SETUP > JIB = YES The UGM shall disable Power Cycled X
BATTERY The PM detects a short to battery at this output and commands to PM for Jib
reports it to the UGM Lift Up and Down;
The UGM shall prohibit
Flow Control
JIB LIFT UP VALVE – SHORT TO 3417 MACHINE SETUP > JIB = YES The UGM shall disable Power Cycled X
GROUND The PM detects a short to ground at this output and commands to PM for Jib
reports it to the UGM Lift Up;
The UGM limits Jib Lift
Down to Creep speed
JIB LIFT DOWN VALVE – OPEN 3418 MACHINE SETUP > JIB = YES The UGM shall suspend The PM no longer detects open circuit; X
CIRCUIT The PM detects an open circuit at this output and commands to PM for Jib Jib Lift Up permitted after controls are ini-
reports it to the UGM Lift Up and Down; tialized
The UGM shall prohibit Jib Full speed Jib Lift Down permitted after
Lift Up; controls are initialized
The UGM shall limit Jib Lift
Down to Creep speed
JIB LIFT DOWN VALVE – SHORT 3419 MACHINE SETUP > JIB = YES The UGM shall disable Power Cycled X
TO BATTERY The PM detects a short to battery at this output and commands to PM for Jib
reports it to the UGM Lift Up and Down;
(450AJ) The UGM shall
prohibit Flow Control
JIB LIFT DOWN VALVE – SHORT 3420 MACHINE SETUP > JIB = YES The UGM shall disable Power Cycled X
TO GROUND The PM detects a short to ground at this output and commands to PM for Jib
reports it to the UGM; detection occurs for PWM output Lift Up and Down
approximately ≤ 15% or for STG condition.
FUEL SENSOR - SHORT TO BAT- 431 UGM fuel sensor analog input J2-25 detects a voltage Energize fuel sensor per Power Cycled X
TERY OR OPEN CIRCUIT higher than 2.50 volts (A/D > 512) System Indicators
FUEL SENSOR - SHORT TO 432 UGM fuel sensor analog input J2-25 detects a voltage Energize fuel sensor per Power Cycled X
GROUND less than or equal to 0.3 volts (A/D < 61) System Indicators
ENGINE TROUBLE CODE 437 An engine with a CAN engine controller is configured in Report and log in Help Power Cycled X X
MACHINE SETUP If [(MACHINE SETUP >
The engine controller reports a J1939 fault DEUTZ EMR2) or
(MACHINE SETUP >
DEUTZ EMR4) and
SPN:FMI = 535:7], pro-
hibit engine cranking

3121671 6-75
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
HIGH ENGINE TEMP 438 An engine with a CAN engine controller is not config- MACHINE SETUP > Power Cycled X X
ured in MACHINE SETUP: ENGINE SHUTDOWN =
The Engine State = ENGINE RUNNING > 10 seconds ENABLED then shutdown
The coolant temperature is greater than or equal to the the engine
configured engines max allowed temperature. The Activate High Engine
maximum allowed temperature > 110ºC. Temperature indicator J4-
An engine with a CAN engine controller is configured in 28
MACHINE SETUP:
ECM transmits a J1939 DM1 message for an engine
coolant high temperature critical fault (SPN:FMI 110:0)
on CAN2 or uses the J1939 Transport Protocol every one
second to send this information if multiple engine
faults exist.
NO ALTERNATOR OUTPUT 4310 The Engine State = ENGINE RUNNING > 10 seconds and Activate the No Charge UGM system voltage > 11.7 volts X X
UGM system voltage < 11.5 volts for 10 seconds indicator J4-26 per Sys-
tem Indicators
LOW OIL PRESSURE 4311 An engine with a CAN engine controller is not config- MACHINE SETUP > Power Cycled X X
ured in MACHINE SETUP ENGINE SHUTDOWN =
The Engine State = ENGINE RUNNING > 10 seconds ENABLED then shutdown
The engine oil pressure is LOW (debounce 3s). the engine
An engine with a CAN engine controller is configured in Activate the Low Oil Pres-
MACHINE SETUP sure indicator J4-29
ECM transmits a J1939 DM1 message for an engine oil
low pressure critical fault (SPN:FMI 100:1) on CAN2 or
uses the J1939 Transport Protocol every one second to
send this information if multiple engine faults exist.
ENGINE COOLANT – LOW LEVEL 4334 MACHINE SETUP > ENGINE = DEUTZ EMR4; MACHINE SETUP > Power Cycled X X
ECM transmits a J1939 DM1 message for an engine ENGINE SHUTDOWN =
coolant low level fault (SPN:FMI 111:1) on CAN2 or uses ENABLED then shutdown
the J1939 Transport Protocol every one second to send the engine;
this information if multiple engine faults exist. Activate High Engine
Temperature indicator J4-
28
WATER IN FUEL 4375 The engine has shut down because an unacceptable Water in fuel filter for water or in fuel or
amount of water has been detected in the fuel or there water in fuel sensor.
is an issue with the water in fuel sensor.

If operating in platform mode, platform alarm will

sound continuously and low fuel indicator will flash.

If operating in ground mode, the ground alarm will

sound

6-76 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
FUNCTIONS PREVENTED - 4376 Engine Oil Warm Up is active because the engine was
ENGINE OIL WARM UP ACTIVE 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 prevented until Engine Oil

Warm Up is complete.
BATTERY VOLTAGE TOO LOW – 441 The UGM detects that its supply voltage is less than 9 Disable all UGM valve out- Voltage is greater than 9.25 volts X X
SYSTEM SHUTDOWN volts puts except those used
Engine State ≠ ENGINE CRANKING during APU/Emergency
Auxiliary Power/Emergency Descent Mode is not active Descent [Tower Lift Down,
Lift Down, Swing (400S,
450AJ, 24RS), Jib Lift Up/
Down (MACHINE SETUP >
JIB= YES)]. If MACHINE
SETUP > H&T LIGHTS =
YES or > ENGINE ≠ DUAL
FUEL ECM turn off lights
BATTERY VOLTAGE TOO HIGH – 442 The UGM detects that its supply voltage > 16.0 volts Disable all UGM and Plat- Power Cycled X X
SYSTEM SHUTDOWN form outputs until voltage
< 15.75 volts and do not
permit Machine Enable
LSS BATTERY VOLTAGE TOO 443 MACHINE SETUP > LOAD SYSTEM ≠ NO The load sensor has deter- Check for issue with sensor supply voltage. X X
HIGH The UGM detects that the LSS reports supply voltage > mined that its supply volt-
16.0V age is too high (> 16V).

The machine will assume

the platform is over-
loaded.
LSS BATTERY VOLTAGE TOO 444 MACHINE SETUP > LOAD SYSTEM ≠ NO The load sensor has deter- Check for issue with sensor supply voltage. X X
LOW The UGM detects that the LSS reports supply voltage < mined that its supply volt-
9.0V age is too low (> 8V).

The machine will assume

the platform is over-
loaded.
BATTERY VOLTAGE LOW 445 The UGM detects that its supply voltage < 11 volts for 5 No response required for Voltage is greater than 11.25 volts X X
seconds. this DTC
Engine State ≠ ENGINE CRANKING
Auxiliary Power/Emergency Descent Mode is not active
Glow Plugs are not energized
LSS BATTERY VOLTAGE - INI- 4479 The shear beam is reporting a Sensor Supply Voltage Possible sensor hardware
TIALIZATION ERROR Initialization Error issue.

The machine will assume the platform is overloaded.

This fault, once annunciated is latched within a given

key cycle.

3121671 6-77
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
LSS BATTERY VOLTAGE - NOT 4480 The shear beam is reporting a Sensor Supply Voltage Possible sensor hardware
CALIBRATED calibration error. issue.

The machine will assume the platform is overloaded.

This fault, once annunciated is latched within a given

key cycle.
CANBUS FAILURE – PLATFORM 662 UGM does not receive any CAN messages from the PM in The UGM shall suspend CAN messages are received from the PM X X
MODULE 250ms motion;

If MACHINE SETUP > GEN-

ERATOR, the UGM shall
disable to turn off genera-
tor relay output and
assume generator off
state.

If MACHINE SETUP >

ENGINE = DUAL FUEL and
> H & T LIGHTS = YES,
state of switch prior to loss
of CAN Bus 1 shall be
retained until CAN Bus 1 is
restored or power cycled.

Reactivation of Foot-
switch is required after
CAN Bus 1 is restored to
obtain Machine Enable.

(340AJ, 450AJ) If the

Machine is in Ground
Mode, the UGM shall dis-
able commands to PM for
Jib Lift Up and Down, Plat-
form Rotate Right and
Left;
CANBUS FAILURE – LOAD SENS- 663 MACHINE SETUP > LOAD SYSTEM ≠ NO The control system has Check wiring to load sensor. X X
ING SYSTEM MODULE UGM does not receive any CAN messages from the LSS lost communication with
module in 1000ms the load sensing system
load pin.

The machine will assume

the platform is over-
loaded.

6-78 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
CANBUS FAILURE – ENGINE 666 An engine with a CAN engine controller is configured in UGM shall set Target CAN messages are received from the engine X X
CONTROLLER MACHINE SETUP engine RPM = Mid- controller;
No CAN messages are received from the engine control- Engine if Engine State ≠ UGM shall require re-activation of Foot-
ler for more than 250ms ENGINE STOPPED, and switch (Platform Mode) or Ground Enable
assume Engine Controller (Ground Mode) to enable functions and
reporting mid-Engine; resume operation.
otherwise, Engine State =
ENGINE STOPPED. If
engine state = ENGINE
STOPPED at time of CAN
loss, UGM shall permit one
start attempt. If engine
state ≠ ENGINE STOPPED
at time of CAN loss, UGM
shall decel all functions. If
MACHINE SETUP > GEN-
ERATOR ≠ NO, Generator
Relay output to be turned
off until re-enabled by
operator after CAN is re-
established.
CANBUS FAILURE – EXCESSIVE 6613 More than 22 error frames per second for 4 seconds or No response required for Power Cycled X X
CANBUS ERRORS more than 500 Buss Off conditions since last power this DTC
cycle.
CANBUS FAILURE – TCU MOD- 6622 MACHINE SETUP > CLEARSKY = YES No response required for Not all of the trigger conditions are met X X
ULE No CAN2 messages are received from the TCU module this DTC
for more than 30 seconds
CANBUS FAILURE – CHASSIS 6635 UGM does not receive any CAN messages from the The UGM shall consider CAN messages are received from the Chassis X X
TILT SENSOR Chassis Tile Sensor in 250ms the machine Tilted; tilt Sensor and controls are initialized
UGM reports a combined
chassis tilt angle of 90
degrees;
UGM shall report individ-
ual axis readings as??
CANBUS FAILURE - GROUND 6651 UGM does not receive any CAN messages from the No response required for CAN messages are received from the Ground X X
DISPLAY Ground Display in 250ms this DTC Display

3121671 6-79
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
CANBUS FAILURE – TEMPERA- 6657 MACHINE SETUP > TEMP CUTOUT = YES; The UGM shall set Low CAN messages are received from the Ambi- X X
TURE SENSOR UGM does not receive any CAN messages from the Temperature Cutout state ent Temperature sensor
Ambient Temperature sensor in 250ms = Faulty

If the Machine is in Plat-

form Mode and if the
Boom is Above Elevation;
The UGM shall suspend
motion;
The UGM shall limit the
machine to Creep speed
after controls initialized

If the Machine is in Plat-

If the Machine is in Ground

Mode;
No response required for
this DTC
REMOTE CONTRACT MANAGE- 681 MACHINE SETUP > CLEARSKY = YES Response detailed in Cleared by ClearSky TCU X X
MENT OVERRIDE – ALL FUNC- Value set by ClearSky TCU Remote Contract Man-
TIONS IN CREEP agement section.
CHASSIS TILT SENSOR NOT CAL- 813 The UGM detects one of the follow conditions: The UGM shall consider Tilt sensor calibrated X X
IBRATED The tilt sensor has not been calibrated; the machine Tilted
For 400S, 450AJ, the Tilt Sensor source Address is 0xC0; UGM reports a combined
For 400S, 450AJ, the Tilt Sensor Serial number does not chassis tilt angle of 90
match degrees;
UGM shall report individ-
ual axis readings
CHASSIS TILT SENSOR OUT OF 814 Fault CHASSIS TILT SENSOR NOT CALIBRATED (813) is No additional action Not all of the trigger conditions are met. X X
RANGE not present and Tilt sensor measurement > 19º for 4 required beyond Tilted
seconds. Not to be reported during Tilt Sensor calibra- requirements specified
tion. elsewhere;
UGM reports a combined
chassis tilt angle of 90
degrees;
UGM shall report individ-
ual axis readings

6-80 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
TILT SENSOR STAGNANT 818 The UGM detects the following conditions: The UGM shall consider Power Cycled X X
The X axis or Y axis filtered readings change by < ±0.1º the machine Tilted;
in 5 second; UGM reports a combined
Drive Forward or Drive Reverse output value is ≥ Creep chassis tilt angle of 90
output value; degrees;
Do not report if DTC 823 is active The UGM reports individ-
ual axis readings
LSS CELL #1 ERROR 821 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Not all of the trigger conditions are met X X
Load System is the 4-Cell LSS; State = Overloaded
The UGM detects that LSS is reporting error with Cell #1
LSS CELL #2 ERROR 822 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Not all of the trigger conditions are met X X
Load System is the 4-Cell LSS; State = Overloaded
The UGM detects that LSS is reporting error with Cell #2
LSS CELL #3 ERROR 823 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Not all of the trigger conditions are met X X
Load System is the 4-Cell LSS; State = Overloaded
The UGM detects that LSS is reporting error with Cell #3
LSS CELL #4 ERROR 824 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Not all of the trigger conditions are met X X
Load System is the 4-Cell LSS; State = Overloaded
The UGM detects that LSS is reporting error with Cell #4.
LSS HAS NOT BEEN CALIBRATED 825 The load sensing system is configured but has not been UGM to set Platform Load Calibrate the load sensing system. X X
calibrated. State = Overloaded

The machine will assume the platform is overloaded.

RUNNING AT CREEP – PLAT- 826 Machine Setup > LOAD SYSTEM = WARN ONLY Refer to Table 7-1 for Not all of the trigger conditions are met X X
FORM OVERLOADED The platform is Overloaded machine response.
Ground mode is active with Auxiliary Power/Emer-
gency Descent mode not active or Platform mode is
active
DRIVE & BOOM PREVENTED – 827 The Platform is Overloaded and Refer to Table 7-1 for Not all of the trigger conditions are met X X
PLATFORM OVERLOADED Machine Setup > LOAD SYSTEM = CUTOUT PLATFORM, machine response.
Platform Mode is active, and conditions of Table 7-1
apply.
-or-
The Platform is Overloaded and Machine Setup > LOAD
SYSTEM = CUTOUT ALL and conditions of Table 7-1
apply.
LIFT UP & TELE OUT PREVENTED 828 MACHINE SETUP > LOAD SYSTEM = SPECIAL 1 Refer to Table 7-1 for Not all of the trigger conditions are met X X
– PLATFORM OVERLOADED Platform Mode is active machine response.
The platform is Overloaded
LSS READING UNDER WEIGHT 8211 LSS has been calibrated and the UGM has determined Ensure platform is not resting on the ground X X
that the load sensing system reading is underweight or is not leveled at an extreme negative
while a period of time while operating drive or boom angle.
lift up at speeds greater than creep OR the UGM has
determined that the load sensing system reading is less Re-calibrate the load sensing system if the
than -1.5 x Gross Platform Weight. above items are not a factor.

The machine will assume the platform is overloaded.

This fault, once annunciated is latched within a given
key cycle.

3121671 6-81
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
LSS SENSOR DISAGREEMENT 8218 The control system has determined that the difference Attempt to re-calibrate the load sensing X X
between the calculated load for sensor 1 and sensor 2 system.
differ by more than 50lbs OR the internal strain gauge
sensor 1 gross platform weight reading and the inter- Possible sensor hardware issue.
nal strain gauge sensor 2 gross platform weight read-
ing differ by more than 200lbs.

If the platform is not considered to be overloaded boom

functions will be restricted to creep.

This fault, once annunciated is latched within a given

key cycle.
LSS SENSOR - OUT OF RANGE 8219 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
HIGH Load System is the 1-Cell LSS; State = Overloaded
Strain Gauge 1 or 2 reports Out of Range High error
LSS SENSOR - OUT OF RANGE 8220 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
LOW Load System is the 1-Cell LSS; State = Overloaded
Strain Gauge 1 or 2 reports Out of Range Low error
LSS SENSOR - OUT OF CALIBRA- 8221 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
TION Load System is the 1-Cell LSS; State = Overloaded
Strain Gauge 1 or 2 reports Not Calibrated error
LSS STRAIN GAUGE 1 - STAG- 8222 The control system has determined that the strain Possible sensor hardware issue.
NANT gauge 1 reading in the load sensor is stagnant (not
changing).

If the platform is not considered to be overloaded boom

functions will be restricted to creep..

If DTC 8223 is active in combination with DTC 8222 the

machine will assume the platform is overloaded.

This fault, once annunciated is latched within a given

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

If the platform is not considered to be overloaded boom

functions will be restricted to creep.

If DTC 8222 is active in combination with DTC 8223 the

machine will assume the platform is overloaded.

This fault, once annunciated is latched within a given

key cycle.

6-82 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

This fault, once annunciated is latched within a given

key cycle.

3121671 6-83
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

This fault, once annunciated is latched within a given

key cycle.

6-84 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

This fault, once annunciated is latched within a given

key cycle.

3121671 6-85
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
LSS NOT DETECTING CHANGE 8236 The control system has determined that the load sensor Possible sensor hardware issue.
reading has not deviated by more than 1lb for 5s while
operating drive or boom functions at greater than creep
speed.

This fault, once annunciated is latched within a given

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

If the platform is not overloaded the machine will be

placed in to creep.

If DTC 8238 is also active the machine will assume the

platform is overloaded.

This fault, once annunciated is latched within a given

key cycle.
LSS STRAIN GAUGE 2 - A/D 8238 The shear beam is reporting an internal issue with the Possible sensor hardware issue.
DEFECT strain gauge 2 sensor.

If the platform is not overloaded the machine will be

placed in to creep.

If DTC 8237 is also active the machine will assume the

platform is overloaded.

This fault, once annunciated is latched within a given

key cycle.
FRONT LEFT STEER VALVE – 8639 The UGM detects an open circuit at this output Steer Left and Right speed Power Cycled X X
OPEN CIRCUIT limited to Creep (340AJ,
400S, 450AJ);
No response required for
this DTC (18RS, 24RS)
FRONT LEFT STEER VALVE – 8640 The UGM detects a short to battery at this output Disable UGM Drive For- Power Cycled X X
SHORT TO BATTERY ward/Reverse and Steer
Left/Right outputs
FRONT LEFT STEER VALVE – 8641 The UGM detects a short to ground at this output Disable UGM Steer Left Power Cycled X X
SHORT TO GROUND and Right outputs
FRONT RIGHT STEER VALVE – 8642 The UGM detects an open circuit at this output Steer Left and Right speed Power Cycled X X
OPEN CIRCUIT limited to Creep(340AJ,
400S, 450AJ);
No response required for
this DTC (18RS, 24RS)
FRONT RIGHT STEER VALVE – 8643 The UGM detects a short to battery at this output Disable UGM Drive For- Power Cycled X X
SHORT TO BATTERY ward/Reverse and Steer
Left/Right outputs
FRONT RIGHT STEER VALVE – 8644 The UGM detects a short to ground at this output Disable UGM Steer Left Power Cycled X X
SHORT TO GROUND and Right outputs

6-86 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
MACHINE SAFETY SYSTEM 873 MSSO = Active Response described in Fault shall be retentive through Power X X
OVERRIDE OCCURRED MSSO Influence on Cycled;
Machine Operation sec- Can be reset only with an Analyzer via the
tion CALIBRATIONS > MSSO > MSSO RESET
menu
LSS WATCHDOG RESET 991 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
Load System is the 4-Cell LSS; State = Overloaded
UGM detects LSS report of an anomaly exists that has
caused a WatchDog Timer reset.
LSS EEPROM ERROR 992 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
Load System is the 4-Cell LSS; State = Overloaded
UGM detects LSS report of an anomaly that exists in the
LSS EEPROM
LSS INTERNAL ERROR – PIN 993 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
EXCITATION Load System is the 4-Cell LSS; State = Overloaded
UGM detects LSS report of improper excitation voltage
LSS INTERNAL ERROR – DRDY 994 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
MISSING FROM A/D Load System is the 4-Cell LSS; State = Overloaded
UGM detects LSS report of an anomaly that exists in the
LSS A/D converter operations.
EEPROM FAILURE - CHECK ALL 998 The UGM has detected an anomaly in EEPROM Disable all machine and Power Cycled X X
SETTINGS engine functions (i.e.,
command engine shut-
down and do not permit
start); reset the section of
EEPROM where the failure
occurred to defaults.
FUNCTIONS LOCKED OUT - 9910 The UGM software version type is ‘P’ or ‘B’ Activate the platform Not all of the trigger conditions are met X X
PLATFORM MODULE SOFT- The UGM has received valid version information from alarm continuously
WARE VERSION IMPROPER the PM Creep mode is active
The PM software version type is ‘P’ or ‘B’ If Platform Mode is active,
The UGM software major version number does not disable all Drive, Steer,
match the major version number of the platform soft- and Boom functions and
ware do not permit Machine
Enable
FUNCTION LOCKED OUT - LSS 9911 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
MODULE SOFTWARE VERSION Load System is the 4-Cell LSS; State = Overloaded
IMPROPER The UGM determines that the LSS software version is
not compatible with existing code.
CHASSIS TILT SENSOR NOT GAIN 9915 The tilt sensor gain calibration values recorded to flash The UGM reports a faulted Valid values are present X X
CALIBRATED memory during Phoenix International’s manufactur- chassis tilt angle of 90
ing test are not present degrees
PLATFORM SENSOR REF VOLT- 9920 The PM detects that its reference voltage is out of range If in Platform mode, Lift/ Power Cycled X X
AGE OUT OF RANGE and reports the fault to the UGM Swing and Drive shall be
place in Creep. All other
functions shall operate
normally.

3121671 6-87
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
GROUND MODULE FAIL- 9921 The engine is not running Disable all Drive/Steer Power Cycled X X
URE:HIGH SIDE DRIVER CUTOUT The engine is not cranking and Boom functions
FAULTY The UGM footswitch input J7-15 is LOW except Tower Lift Down
The machine is in Platform Mode (340AJ, 450AJ), Lift
The Main Dump output J2-13 is detected as HIGH via Down, and Jib Lift Down
the analog feedback 300ms after it is attempted to be (340AJ).
activated during the one time startup test of the UGM
hardware shutoff circuitry
PLATFORM MODULE FAILURE: 9922 The PM detects that its V(low) FET has failed and No response required for Power Cycled X X
HWFS CODE 1 reports this fault to the UGM this DTC
FUNCTIONS LOCKED OUT - 9924 The machine is powered up and no model has been Display??? or NO MODEL at Power Cycled X X
MACHINE NOT CONFIGURED selected yet in the MACHINE SETUP menu Analyzer MACHINE SETUP
menu MACHINE SETUP-
>MODEL NUMBER
Do not report any other
faults
Disable all machine and
engine functions (i.e.,
command engine shut-
down and do not permit
start)
GROUND MODULE CONSTANT 9927 The UGM detects one of the following conditions when Disable all machine and A different application code or constant X X
DATA UPDATE REQUIRED software type is ‘P’ or ‘B’: engine functions (i.e., data version is programmed so that the val-
The Version Verification Word #1 or the Version Verifica- command engine shut- ues match
tion Word #2 values located in the constant data sector down and do not permit Power Cycled
of flash memory (found on constant data spreadsheet start)
tab pstConstantDataVersion) do not match the values
located in the code area of flash memory
The Version Major value located in the constant data
sector of flash memory (found on constant data
spreadsheet tab pstConstantDataVersion) does not
match the value located in the code area of flash mem-
ory
CURRENT FEEDBACK GAINS 9944 One or more of the current feedback gains that are cal- A gain of 1 is used for the Power Cycled X X
OUT OF RANGE culated and written to flash memory during the PIC factory gain(s) that was
manufacturing test process are detected as being out of out of range; all functions
range shall be placed in Creep
mode.
CURRENT FEEDBACK CALIBRA- 9945 The current feedback gains checksum that is calculated Disable all machine and Power Cycled X X
TION CHECKSUM INCORRECT and written to flash memory during the PIC manufac- engine functions (i.e.,
turing test process is detected as being incorrect command engine shut-
down and do not permit
start).

6-88 3121671
SECTION 6 - JLG CONTROL SYSTEM

Table 6-11. Diagnostic Trouble Code Chart

Fault Condition/Trigger
Required Control
(For configurable items, fault applies only if Conditions Required for Movement

450AJ
400S
Help Message DTC Response or State
configured. All listed conditions to be met and/or to Clear Fault
Assignment
unless stated otherwise)
MACHINE CONFIGURATION 9949 UGM has detected an anomaly in EEPROM with regard UGM to prompt operator Power Cycled and EEPROM data in associ- X X
OUT OF RANGE – CHECK ALL to the Machine Setup configuration. to correct issue via Ana- ated area is changed
SETTINGS lyzer and disable all
machine and engine func-
tions (i.e., command
engine shutdown and do
not permit start).until
EEPROM data in corrupted
area is changed.
LSS CORRUPT EEPROM 9977 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
Load System is the 4-Cell LSS; State = Overloaded
and one of the following conditions:
UGM determines LSS-stored values for Unloaded
weight in Indirect 0x100≠ 0x108 or
UGM determines LSS-stored values for Accessory
weight in Indirect 0x102≠ 0x10A
UGM determines LSS-stored checksum1 (0x10F) ≠
checksum 2 (0x107)
FUNCTIONS LOCKED OUT - 9979 Ground software has been installed on a UGM with a Disable all machine and Power Cycled X X
GROUND MODULE SOFTWARE ST10F274 processor (Hardware Rev < 6), which does engine functions (i.e.,
VERSION IMPROPER not have guaranteed flash storage in the sector where command engine shut-
Constant Data is written. down and do not permit
start)
GROUND MODULE VLOW FET 9986 VLow FET determined to be failed because all Digital Disable all machine and Power Cycled X X
FAILURE Inputs are high; UGM unable to read high-sensing engine functions (i.e.,
inputs. command engine shut-
down and do not permit
start).
LSS INTERNAL ERROR 99171 MACHINE SETUP > LOAD SYSTEM ≠ NO; UGM to set Platform Load Power Cycled X X
Load System is the 1-Cell LSS; State = Overloaded
Strain Gauge 1 or 2 reports Initialization, Defect or Not
Installed error
LSS - FACTORY CALIBRATION 99285 The load sensor is reporting a factor calibration issue Possible sensor hardware issue.
ERROR (internal error)

The machine will assume the platform is overloaded.

This fault, once annunciated is latched within a given

key cycle.

3121671 6-89
SECTION 6 - JLG CONTROL SYSTEM

NOTES:

6-90 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL Polarity
This section contains basic electrical information and sche- Getting a negative Voltage or current reading when expecting
matics to be used for locating and correcting most of the oper- a positive reading frequently means the leads are reversed.
ating problems which may develop. If a problem should Check what reading is expected, the location of the signal and
develop which is not presented in this section or which is not that the leads are connected to the device under test correctly.
corrected by listed corrective actions, technically qualified Also check that the lead on the "COM" port goes to the Ground
guidance should be obtained before proceeding with any or negative side of the signal and the lead on the other port
maintenance. goes to the positive side of the signal.

NOTE: Some of the procedures/connectors shown in this section Scale

may not be applicable to all models.
M = Mega = 1,000,000 * (Displayed Number)

7.2 MULTIMETER BASICS k = kilo = 1,000 * (Displayed Number)

A wide variety of multimeters or Volt Ohm Meters (VOM) can m = milli = (Displayed Number) / 1,000
be used for troubleshooting your equipment. This section
shows diagrams of a common, digital VOM configured for sev- μ = micro = (Displayed Number) / 1,000,000
eral different circuit measurements. Instructions for your VOM
Example: 1.2 kW = 1200 W
may vary. Please consult the meter operator’s manual for more
information. Example: 50 mA = 0.05 A

Grounding Voltage Measurement

"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
contacts are seated in the connector.
Figure 7-1. Voltage Measurement (DC)
Min/Max
• If meter is not auto ranging, set it to the correct range
Use of the "Min/Max" recording feature of some meters can
(See multimeter’s operation manual)
help when taking measurements of intermittent conditions
while alone. For example, you can read the Voltage applied to • Use firm contact with meter leads
a solenoid when it is only operational while a switch, far from
the solenoid and meter, is held down.

3121671 7-1
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND

TO ELECTRICAL CONNECTIONS
NOTE: This section is not applicable for battery terminals.

JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE-
RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.

NOTE: Do NOT apply dielectric grease to the following connec-

tions:

• Main Boom Rotary sensor connections (on Celesco Sensor),

• LSS Modules connections,

• Deutz EMR 2 ECM connection.

Silicone Dielectric Compound must be used on all electrical

connections except for those mentioned above for the follow-
ing reasons:

• To prevent oxidation at the mechanical joint between male

and female pins.

• To prevent electrical malfunction caused by low level con-

Figure 7-4. Current Measurement (DC) ductivity between pins when wet.

Use the following procedure to apply Silicone Dielectric Com-

• Set up the meter for the expected current range.
pound to the electrical connectors. This procedure applies to
• Be sure to connect the meter leads to the correct jacks all plug connections not enclosed in a box. Silicone grease
should not be applied to connectors with external seals.
for the current range you have selected.
1. To prevent oxidation, silicone grease must be packed
• If meter is not auto ranging, set it to the correct range
completely around male and female pins on the inside
(See multi meter’s operation manual). of the connector prior to assembly. This is most easily
achieved by using a syringe.
• Use firm contact with meter leads.
NOTE: Over a period of time, oxidation increases electrical resis-
tance at the connection, eventually causing circuit failure.

2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connec-
tors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
should also be sealed.

NOTE: This condition is especially common when machines are

pressure washed since the washing solution is much more
conductive than water.

3121671 7-3
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

3. Anderson connectors for the battery boxes and battery Deutsch HD, DT, DTM, DRC Series
chargers should have silicone grease applied to the con-
tacts only. The Deutsch connector system is commonly used for harsh
environment interconnect. Follow the installation instructions.
NOTE: Curing-type sealants might also be used to prevent short-
ing and would be less messy, but would make future pin
removal more difficult.

When applied to electrical connections, dielectric grease helps

to prevent corrosion of electrical contacts and improper con-
ductivity between contacts from moisture intrusion. Open and
sealed connectors benefit from the application of dielectric
grease.
Dielectric grease shall be applied to all electrical connectors at
the time of connection (except those noted under Exclusions).

Installation of Dielectric Grease

Before following these instructions, refer to excluded connec-
tor types (See Exclusions below).
1. Use dielectric grease in a tube for larger connection AMP Seal
points or apply with a syringe for small connectors.
The AMP Seal connector system is used on the Control ADE
2. Apply dielectric grease to plug/male connector housing Platform and Ground Modules.
which typically contains sockets contact/female termi-
nals (fill it approximately ½ full; see example below). Apply dielectric grease to the male contact. If trapped air pre-
vents the connector from latching, pierce one of the unused
3. Leave a thin layer of dielectric grease on the face of the wire seals. After assembly, install a seal plug (JLG #4460905) to
connector. prevent moisture ingress.
4. Assemble the connector system immediately to prevent Note that seal plugs may be installed by the wire harness man-
moisture ingress or dust contamination. ufacturer if an unused wire seal becomes compromised (wire
5. Pierce one of the unused wire seals prior to assembly if inserted in the wrong cavity during assembly and then cor-
the connector system tends to trap air (i.e. AMP Seal) rected).
and then install a seal plug. .

Figure 7-5. Application to Male Contacts

7-4 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

DIN Connectors
This connector is typically used on hydraulic valves. Follow the
installation instructions.

MAF01580
Figure 7-6. Use of Seal Plugs

AMP Mate-N-Lok
This connector system is widely used inside enclosures for
general purpose interconnect. Follow the installation instruc-
tions.

MAF01570

3121671 7-5
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Exclusions Engine Control unit connectors

A limited number of connectors do not benefit from dielectric These connectors use back-seals for moisture integrity. How-
grease, or may be permanently damaged by application. ever, the low-force contacts cannot displace dielectric grease
Dielectric grease may not be required in properly sealed and create electrical contact. It is possible to use solvents (i.e.
enclosures. contact cleaner or mineral spirits) for the removal of improp-
erly applied dielectric grease. The EMR4 engine control mod-
Brad Harrison / Phoenix Contact M12 ule from Deutz employs this connector system (for example).
The connector uses gold contact material to resist corrosion
and an o-ring seal for moisture integrity. If dielectric grease is
mistakenly applied to this connector system, the low-force
contacts cannot displace the grease to achieve electrical con-
tact. Once contaminated, there is no practical way to remove
the dielectric grease (replacement of female contacts
required). The JLG Load Sensing System and Rotary Angle Sen-
sors are examples of components with the M12 connector sys-
tem.

Sealed Enclosures
Figure 7-7. Brad-Harrison M12 Application of dielectric grease is not required in properly
sealed enclosures. To meet criteria, the enclosure must be
rated to at least IP66 (dust tight; protected from powerful jets
of water). The enclosure must be fitted with a high quality,
continuous gasket and all wiring must pass through cable
entrances.

Figure 7-8. Phoenix Contact M12

MAF01600

7-6 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

MIL-C-5015 spec connectors MOLEX CMC series connectors

Crown Connector Inc’s recommendation is to not use dielec- The CMC connector family is a sealed, high-density connec-
tric grease for this series connector. For similar model series tion system using matte-seal technology for CP 0.635 and 1.50
connectors, the manufacturer should be contacted for confir- mm terminals. To guarantee IP6K7 and IP6K9 sealing, a seal
mation before applying dielectric grease. A typical application plug option is used. However, the low-force contacts cannot
for this connector is on David Clark Intercom connections in displace dielectric grease and create electrical contact. It is
Aerial Work Platforms. possible to use solvents (i.e. contact cleaner or mineral spirits)
for the removal of improperly applied dielectric grease. The
flexbox control modules from JDES employ this connector sys-
tem (for example).

3121671 7-7
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.4 AMP CONNECTOR 1. To insert a contact, push it straight into the appropriate
circuit cavity as far as it will go (See Figure 7-11.).
Assembly 2. Pull back on the contact wire with a force of 1 or 2 lbs. to
be sure the retention fingers are holding the contact
Check to be sure the wedge lock is in the open, or as-shipped,
(See Figure 7-11.).
position (See Figure 7-9.). Proceed as follows:

Figure 7-9. Connector Assembly Figure 1

Figure 7-10. AMP Connector

7-8 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-11. 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 7-13.).
Release the locking latches by squeezing them inward
(See Figure 7-12.).

Figure 7-13. Connector Assembly Figure 4

Figure 7-12. Connector Assembly Figure 3

3121671 7-9
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-14. Connector Disassembly

Disassembly Service - Voltage Reading

1. Insert a 4.8 mm (3/16 in.) wide screwdriver blade
between the mating seal and one of the red wedge lock
tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

2. Pry open the wedge lock to the open position. It has been common practice in electrical troubleshooting to
3. While rotating the wire back and forth over a half turn probe wires by piercing the insulation with a sharp point. This
(1/4 turn in each direction), gently pull the wire until the practice should be discouraged when dealing with the
contact is removed. AMPSEAL plug assembly, or any other sealed connector sys-
tem. The resulting pinholes in the insulation will allow mois-
NOTE: The wedge lock should never be removed from the housing ture to invade the system by traveling along the wire strands.
for insertion or removal of the contacts. This nullifies the effectiveness of the connector seals and
could result in system failure.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.

7-10 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-15. Connector Installation

3121671 7-11
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly

A B
A B

C
C D
Figure 7-16. DT/DTP Contact Installation Figure 7-17. DT/DTP Contact Removal

5. Remove wedgelock using needle nose 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. They may go in either way.

NOTE: The receptacle is shown - use the same procedure for plug.

7-12 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly

A B A B

C C
Figure 7-18. HD/HDP Contact Installation Figure 7-20. HD/HDP Contact Removal

1. Grasp contact about 25mm behind the contact crimp

4. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
2. Hold connector with rear grommet facing you.
5. Slide tool along into the insert cavity until it engages
3. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm that it is
6. Pull contact-wire assembly out of connector.
properly locked in place.

Figure 7-21. HD/HDP Unlocking Contacts

Figure 7-19. HD/HDP Locking Contacts Into Position
NOTE: Do Not twist or insert tool at an angle.
NOTE: For unused wire cavities, insert sealing plugs for full envi-
ronmental sealing.

3121671 7-13
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.6 TELEMATICS GATEWAY

Personnel using machines equipped with an optional telemat-
ics gateway will be able to view the following data through
their telematics device:

JLG LABEL DESCRIPTION UNIT

Engine Speed Actual engine speed. RPM
Indicates the level of DEF (diesel exhaust fluid) within the DEF tank if the machine is equipped with DEF tank.
DEF Tank Level (If Equipped) • 0% = Empty Percentage (%)
• 100% = Full
• 00 - No Machine Faults

JLG Machine Faults: • 01 - Active Machine Fault

Bit
Active / Not-Active • 10 - Error
• 11 - Not available
Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions. Liters
Total Idle Hours Total time of engine operation during idle conditions. Seconds
Total Engine Hours Total time of engine operation. Seconds
Total Fuel Used Total amount of fuel used during vehicle operation. Liters
Fuel Rate Amount of fuel consumed by engine per unit of time. Liters/Hour
Ratio of fuel volume to the total volume of the fuel storage container. When a low fuel limit switch is present, the fuel level
will indicate "full" until the switch opens, which will then indicate 10% fuel remaining.
Fuel Level Percentage (%)
When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents the total fuel in all fuel storage containers. When Fuel Level
2 is used, Fuel Level 1 represents the fuel level in the primary or left side fuel storage container.
DM1 Engine Faults Shows actual engine fault codes. N/A

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

7-14 3121671
3121671
MS1619-3 MS1619-1

MS1619-2
X1609

MS1620-1

S1614
MS1618-2
S1615
MS1620-3
MS1620-2
MS1618-3
CO1613-J2
CO1613-J1

X1606

Figure 7-22. Telematics Gateway Harness - Sheet 1 of 3

7-15
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO

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)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
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)
10 YEL CANH1 18 AWG GXL MS1618-2 (A)

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)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO

9 GRN CANL2 18 AWG GXL MS1620-3 (B) X1606 (DIAG)

10 YEL CANH2 18 AWG GXL MS1620-3 (A)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO

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)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
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)

Figure 7-23. Telematics Gateway Harness - Sheet 2 of 3

7-16 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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

Figure 7-24. Telematics Gateway Harness - Sheet 3 of 3

3121671 7-17
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

TURNTABLE
HARNESS

MAIN VALVE
HARNESS

ELECTRICAL
PANEL

SEE DETAIL D
(SHEET 2)

GROUND
CONTROL

1001173646-I
1001168010-K
1001220381-B
1001219866-B
MAF01290

Figure 7-25. Electrical Installation - Sheet 1 of 5

7-18 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

FUSE BOX IS PART

OF HARNESS

X450
ENABLE
X282
B+
DECAL INSIDE
DETAIL D THE FUSE BOX

JIB SWITCH
LOCATION

CONSOLE BOX ASSY

GROUND CONTROL
GROUND PANEL HARNESS
CONTROL
1001173646-I
1001168010-K
1001220381-B
1001219866-B
MAF01300

Figure 7-26. Electrical Installation - Sheet 2 of 5

3121671 7-19
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HV293
HV292
SEE DETAIL B

HV96
SPEED HV97
BRAKE
DETAIL B
HV439

HV377

LIFT CYL VALVE

JIB UP ROTATE LEFT

MAIN TELE OUT MAIN LIFT UP
STEER LEFT
LEVEL UP
STEER RIGHT
MAIN DUMP

LEVEL DOWN
MAIN TELE IN F SWING LEFT
JIB DOWN
SWING RIGHT
ROTATE RIGHT 1001173646-I
1001168010-K
FLOW CONTROL 1001220381-B
1001219866-B
MAF01310

Figure 7-27. Electrical Installation - Sheet 3 of 5

7-20 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SEE DETAIL C

J4 J1

J3 J2

1B 1A
MSSO SW531 - 2
MSSO SW531 - 1

3
B

2B
DETAIL C 2A

1001173646-I
1001168010-K
1 1001220381-B
1001219866-B
MAF01320

Figure 7-28. Electrical Installation - Sheet 4 of 5

3121671 7-21
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SEE DETAIL A

MOTION ALARM
DESCENT HORN

GROUND CONTROLLER

DUAL AXIS SENSOR

1001172757-E
MAF01330
DETAIL A
Figure 7-29. Electrical Installation - Sheet 5 of 5

7-22 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.7 WIRING HARNESS CONNECTOR LABELS AND Table 7-1. Wiring Harness Connector Labels
WIRING HARNESSES Component Category Label
Alarms
Connector Labels Audible AH
Horns
Connectors between harnesses are identified by the prefix "X"
Batteries
and a sequentially assigned number. An optional suffix (letters Battery BT
& numbers) may be added when multiple terminations occur Battery Terminals
at one device or when there are optional connections. Ground
Examples: Control Module LSS CO
Platform
X25 connects to X25 in another harness.
Alternator
X65A, X65B connect to different portions of one device
Cold Start
X163 connects to X163A in ANSI and X163B in CE machines Controller
Coolant Temp
Component Labels
Engine Fuel Pump EC
Every component on the vehicle has a unique identification. A Fuel Solenoid
standard prefix letter is assigned according to the table below,
followed by a unique sequential number. An optional suffix Glow Plugs
(letters & numbers) may be added when multiple terminations Oil Pressure
occur at one device. Starter
Terminals that are not loaded into connectors are considered Fuse FC
independent components and labeled in the same fashion. Fuse & CB Fuse FC Fusible Link FC
Circuit Breaker CB
Board
Cluster
Gauge & Display Hour meter GD
LMI
Speedometer
Inline Resistor R
Diode D
Electronic
Joystick & Steering JS
Hydraulic
Dome
Headlights
Lights LB
Simple
Taillights
Membrane Panel MP
Radio
Speakers
Miscellaneous MS
Splice Blocks
T-Connectors

3121671 7-23
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Table 7-1. Wiring Harness Connector Labels

7-24 3121671
3121671
SW03
PLATFORM ROTATE
SW09-1 SW09-2 LB478- LB478+
CO01-J8 X175 HORN SKYGAURD WARNING SKYGAURD WARNING
HORN SW19 SW624
CO01-J7 ANALIZER AH11- SW88 SW173 SW86 JIB LIFT DUAL CAPACITY
ALARM ENGINE SPEED FUEL SELECT TOWER LIFT SW02
MS16 BLACK SW174
AH11+ MAIN TELE DRIVE ORIENTATION
ALARM SW04
LEVEL OVERRIDE

SW05
X305A START/AUX
SW733 SW155-2
1-480704-0 HEAD AND TAIL
X304A GD153-J3 LIGHTS
X303A
CO01-J1 CO01-J2 GD153-J4
NATURAL GRAY SW21-2 SW155-1
SW14-2B HEAD AND TAIL LIGHTS
X687 SOFT TCH/SKY GUARD E STOP
SHEET 2, 3, 4, 5 SINGLE CELL LSS SHEET 6, 7, 8 SW21-1 GD153-J2 SW14-1B
SOFT TCH/SKY GUARD GD153-J1 E STOP SHEET 9, 10, 11
1001164353-I
MAF00910

Figure 7-30. Platform Control Box Harness - Sheet 1 of 12

7-25
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7-26
CO01-J8 X175
ANALYZER
CO01-J7 AH11-
BLACK ALARM
MS16
AH11+
ALARM
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X305A

X304A
X303A
CO01-J2
CO01-J1 GRAY
NATURAL

X687
SINGLE CELL LSS
1001164353-I
MAF00920

Figure 7-31. Platform Control Box Harness - Sheet 2 of 12

3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X305A X304A
CONN WIRE CONN WIRE
WIRE LABEL GAUGE JACKET TO WIRE LABEL GAUGE JACKET TO
POS COLOR POS COLOR
1 WHT 1-35 GENERATORSWITCH 18AWG GXL CO01-J7 (9) 1
2 WHT 1-38 GEN ON SWITCH 18AWG GXL CO01-J7 (5) J1939
2 GRN CAN 20AWG MS16 (5)
3 CABL
1-39 FOOT SW J1939
4 WHT 18AWG GXL CO01-J7 (8) 3 YEL CAN 20AWG MS16 (2)
DISENGAGED CABL
5 WHT 1-40 FOOT SW 18AWG GXL CO01-J7 (4) 4 WHT 1-44 EMS 18AWG GXL CO01-J7 (3)
6 5
7 WHT 1-90 SG POWER 18AWG GXL CO01-J7 (7) 6
8 BLK 1-86 SG GND 18AWG GXL CO01-J7(24) 7
9 WHT 1-85 ST POWER 18AWG GXL CO01-J2(31) 8
10 WHT 1-87 SG INPUT 1 18AWG GXL CO01-J7(18) 9 WHT 1-62 EMS B+ 18AWG GXL SW14-1B(1B)
11 WHT 1-88 SG INPUT 2 18AWG GXL CO01-J1(23) 10
12 WHT 1-91ST SWITCH 18AWG GXL CO01-J1 (20) 11 WHT 1-37GROUNDMODE 18AWG GXL CO01-J7 (1)
13 12 WHT 1-1 18AWG GXL CO01-J8 (2)
14 WHT 1-551 18AWG GXL X305A (15) 13
15 WHT 1-551 18AWG GXL X305A (14) 14
15
16 BLK 000-10-14 GND 12AWG GXL CO01-J8 (1)
X303A
17
CONN WIRE
WIRE LABEL GAUGE JACKET TO 18
POS COLOR
1 WHT 1-41PLATF ROTATE LEFT 18AWG GXL CO01-J7(33) 19
1-42 PLATF ROTATE
2 WHT 18AWG GXL CO01-J7(34)
RIGHT X175 ANALIZER
3 WHT 1-36 JIB UP 18AWG GXL CO01-J7(25) CONN WIRE
WIRE LABEL
4 WHT 1-43JIB DOWN 18AWG GXL CO01-J7(26) POS COLOR GAUGE JACKET TO
5 BLK 000-10-11VALVES GND 18AWG GXL CO01-J7(23) CO01-J2
1 WHT 1-66 POWER 18 AWG GXL
6 BLK 000-10-34OPTIONGND 18AWG GXL CO01-J7(29) (26)
7 WHT 1-89 OPTION POWER 18AWG GXL CO01-J2(33) CO01-J2
2 WHT 1-81 RECEIVE 18 AWG GXL
(28)
8 YEL CAN 20AWG J1939 CABL MS16 (3)
CO01-J2
9 GRN CAN 20AWG J1939 CABL MS16 (6) 3 WHT 1-82 TRANSMIT 18 AWG GXL
(29)
10
CO01-J2
11 BLK 000-10-30-2 LSS GND 18AWG GXL S688 (2) 4 BLK 000-10-12 GND 18 AWG GXL
(27)
12 WHT 1-33-2 LSS PWR 18AWG GXL S689 (2)

Figure 7-32. Platform Control Box Harness - Sheet 3 of 12

3121671 7-27
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

CO01-J2 GRAY CO01-J7 BLACK

CONN WIRE CONN WIRE
WIRE LABEL WIRE LABEL
POS COLOR GAUGE JACKET TO POS COLOR GAUGE JACKET TO
1 1 WHT 1-37 GROUND MODE 18AWG GXL X304A (11)
2 SW14-2B
2 WHT 1-45 PLATF EMS 18AWG GXL
3 (2B)
1-67 PLTF ORIENT 3 WHT 1-44EMS 18AWG GXL X304A (4)
4 WHT 18AWG GXL SW174 (1)
OVERRIDE 4 WHT 1-40 FOOT SW 18AWG GXL X305A (5)
5 5 WHT 1-38GEN ON SWITCH 18AWG GXL X305A (2)
6 WHT 1-20 TILT 18AWG GXL GD153-J4 (5) 6
7 WHT 1-32 FT SWITCH ENABLE 18AWG GXL GD153-J2 (2) 7 WHT 1-90 SG POWER 18AWG GXL X305A (7)
8 WHT 1-25 SYSTEM DISTRESS 18AWG GXL GD153-J3 (6) 8 WHT 1-39 FOOT SW DISENGAGED 18AWG GXL X305A (4)
9 WHT 1-24CREEP 18AWG GXL GD153-J2 (1) 9 WHT 1-35GENERATOR SWITCH 18AWG GXL X305A (1)
10 10
1-22 PLATFORM 11
11 WHT 18AWG GXL GD153-J4 (3)
OVERLOAD 12
12 WHT 1-21 500#/600# MODE 18AWG GXL GD153-J4 (4) 13
13 WHT 1-271000# MODE 18AWG GXL GD153-J3 (4) 14
14 WHT 1-28 DRIVE ORIENT SW 18AWG GXL GD153-J3 (3) 15
15 WHT 1-23 GENERATOR ON 18AWG GXL GD153-J4 (2) 16 BLK 000-10-30LSS GND 18AWG GXL S688 (1)
1-31SOFT TCH/SKY 17
16 WHT 18AWG GXL LB478+ (1)
GUARD
18 WHT 1-87SG INPUT1 18AWG GXL X305A (10)
17 WHT 1-29 GLOW PLUG 18AWG GXL GD153-J4 (6)
19 WHT 1-34PLATALRM 18AWG GXL AH11+ (1)
18 BLK 000-10-27 GND 18AWG GXL GD153-J2 (6)
20 WHT 000-10-16PLAT ALARM GND 18AWG GXL AH11- (1)
19
21
20 WHT 1-92 DRIVE DISABLE 18AWG GXL GD153-J3 (1)
22
21 WHT 1-30 LOW FUEL 18AWG GXL GD153-J2 (3)
23 BLK 000-10-11 VALVES GND 18AWG GXL X303A (5)
22 WHT 1_498 1/4 FUEL 18AWG GXL GD153-J1 (1)
24 BLK 1-86SG GND 18AWG GXL X305A (8)
23 WHT 1_499 3/4 FUEL 18AWG GXL GD153-J1 (3)
25 WHT 1-36 JIB UP 18AWG GXL X303A (3)
24 WHT 1_500 1/2 FUEL 18AWG GXL GD153-J1 (2)
26 WHT 1-43JIB DOWN 18AWG GXL X303A (4)
25 BLK 1_497FUEL GND 18AWG GXL GD153-J1 (4)
27
26 WHT 1-66 POWER 18AWG GXL X175 (1)
28
27 BLK 000-10-12 GND 18AWG GXL X175 (4)
29 BLK 000-10-34OPTION GND 18AWG GXL X303A (6)
28 WHT 1-81 RECEIVE 18AWG GXL X175 (2)
J1939
29 WHT 1-82 TRANSMIT 18AWG GXL X175 (3) 30 GRN CAN 20AWGJ MS16 (4)
CABL
30 J1939
31 YEL CAN 20AWGJ MS16 (1)
31 WHT 1-85 ST POWER 18AWG GXL X305A (9) CABL
32 WHT 1-33 LSS PWR 18AWG GXL S689 (1) 32
33 WHT 1-89 OPTION POWER 18AWG GXL X303A (7) 33 WHT 1-41 PLATF ROTATE LEFT 18AWG GXL X303A (1)
34 34 WHT 1-42 PLATF ROTATE RIGHT 18AWG GXL X303A (2)
35 WHT 1_501 FUEL FULL 18AWG GXL GD153-J1 (6) 35

Figure 7-33. Platform Control Box Harness - Sheet 4 of 12

7-28 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

CO01-J8 MS16
CONN WIRE CONN WIRE
WIRE LABEL WIRE LABEL GAUGE JACKET TO
POS COLOR GAUGE JACKET TO POS COLOR
1 BLK 000-10-14 GND 12AWG GXL X304A (16) J1939
1 YEL CAN 20AWG CO01-J7(31)
2 WHT 1-1 18AWG GXL X304A (12) CABLE
J1939
2 YEL CAN 20AWG X304A (3)
CABLE
J1939
AH11- ALARM 3 YEL CAN 20AWG X303 A (8)
CABLE
CONN WIRE J1939
WIRE LABEL 4 GRN CAN 20AWG CO01-J7(30)
POS COLOR GAUGE JACKET TO CABLE
000-10-16 PLAT ALARM CO01-J7 J1939
1 WHT 18 AWG GXL 5 GRN CAN 20AWG X304 A (2)
GND (20) CABLE
J1939
6 GRN CAN 20AWG X303 A (9)
CABLE
X687 7 GRY CAN LO 20AWG CABLE X687 (5)
CONN WIRE 8
WIRE LABEL GAUGE JACKET TO
POS COLOR 9
1 10 BLK CAN HI 20 AWG CABLE X687 (4)
2 WHT LSS PWR 20AWG CABLE S689 (2) 11
3 BLU LSS GND 20AWG CABLE S688 (2) 12
4 BLK CAN H1 20AWG CABLE MS16 (10)
5 GRY CAN LO 20AWG CABLE MS16 (7)

AH11+ ALARM
CONN WIRE
WIRE LABEL
POS COLOR GAUGE JACKET TO
CO01-J7
1 WHT 1-34 PLAT ALRM 18AWG GXL
(19)

Figure 7-34. Platform Control Box Harness - Sheet 5 of 12

3121671 7-29
7-30
LB478+
SKYGAURD WARNING

SW03
SW09-1 PLATFORM ROTATE
HORN
LB478-
SW88 SKYGAURD WARNING
ENGINE SPEED
SW09-2
HORN SW86
SW173 TOWER LIFT
FUEL SELECT

SW04
LEVEL
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SW733
1-480704-0

GD153-J3

GD153-J4
SOFT TCH/SKY GUARD
SW21-2

SW21-1
SOFT TCH/SKY GUARD
1001164353-I
MAF00930

Figure 7-35. Platform Control Box Harness - Sheet 6 of 12

3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SW88 ENGINE SPEED SW733 PUMP POT

CONN WIRE CONN WIRE
WIRE LABEL GAUGE JACKET TO WIRE LABEL GAUGE JACKET TO
POS COLOR POS COLOR
1 WHT 1-11 MIN SPEED 18AWG GXL CO01-J1(28) 1
2 WHT 1-70 SWITCHES PWR 18AWG GXL CO01-J1(18) 2 WHT 1-101 RSII PORT 2 18AWG GXL CO01-J1(32)
2 WHT 1-80 SWITCHES PWR 18AWG GXL SW04 (2) 3 WHT 1-102SWITCHES PWR 18AWG GXL SW09-2 (1)
3 WHT 1-12 MAX SPEED 18AWG GXL CO01-J1(27) 3 WHT 1-80 SWITCHES PWR 18AWG GXL SW174 (2)
4 4 WHT 1-105 POT CCW 18AWG GXL CO01-J1(34)
5 5 WHT 1-103 POT CW 18AWG GXL CO01-J1(13)
6 6 WHT 1-104 POT W 18AWG GXL CO01-J1(35)

SW04 LEVEL
SW09-2 HORN
CONN WIRE
WIRE LABEL GAUGE JACKET TO CONN WIRE
POS COLOR WIRE LABEL GAUGE JACKET TO
POS COLOR
1 WHT LEVELDOWN 18AWG GXL CO01-J1(10)
2 WHT 1-73 SWITCHES PWR 18AWG GXL SW173 (2) 1 WHT 1-102 SWITCHES PWR 18AWG GXL SW733 (3)
2 WHT 1-80 SWITCHES PWR 18AWG GXL SW88 (2) 1 WHT 1-87 SWITCHES PWR 18AWG GXL SW21-2 (1)
3 WHT 1-8 LEVEL UP 18AWG GXL CO01-J1 (9)
4
5 SW09-1 HORN
6 CONN WIRE
WIRE LABEL GAUGE JACKET TO
POS COLOR
1 WHT 1-2 HORN 18AWG GXL CO01-J1(31)
GD153-J3
CONN WIRE
WIRE LABEL GAUGE JACKET TO
POS COLOR
SW173 FUEL SELECT
1 WHT 1-92 DRIVE DISABLE 18AWG GXL CO01-J2(20)
CONN WIRE
2 WIRE LABEL
POS COLOR GAUGE JACKET TO
3 WHT 1-28 DRIVE ORIENT SW 18AWG GXL CO01-J2(14)
1
4 WHT 1-27 1000# MODE 18AWG GXL CO01-J2(13)
2 WHT 1-73 SWITCHES PWR 18 AWG GXL SW04 (2)
5
2 WHT 1-74 SWITCHES PWR 18 AWG GXL SW03 (2)
6 WHT 1-25 SYSTEM DISTRESS 18AWG GXL CO01-J2 (8)
3 WHT 1-68 FUEL SELECT 18 AWG GXL CO01-J1 (33)
4
5
6

Figure 7-36. Platform Control Box Harness - Sheet 7 of 12

3121671 7-31
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

GD153-J4 SW86 TOWER LIFT

CONN WIRE CONN WIRE
WIRE LABEL WIRE LABEL
POS COLOR GAUGE JACKET TO POS COLOR GAUGE JACKET TO
1 1 WHT 1-17TOWER DOWN 18 AWG GXL CO01-J1 (2)
CO01-J2 2 WHT 1-72 SWITCHES PWR 18 AWG GXL SW03 (2)
2 WHT 1-23 GENERATOR ON 18 AWG GXL
(15) 2 WHT 1-78 SWITCHES PWR 18 AWG GXL SW19 (2)
1-22 PLATFORM CO01-J2 3 WHT 1-16 TOWER UP 18 AWG GXL CO01-J1 (1)
3 WHT 18 AWG GXL
OVERLOAD (11)
4
CO01-J2
4 WHT 1-21 500#/600# MODE 18 AWG GXL 5
(12)
6
5 WHT 1-20 TILT 18 AWG GXL CO01-J2 (6)
CO01-J2
6 WHT 1-29 GLOW PLUG 18 AWG GXL
(17) SW21-1
SOFT TCH/SKY GUARD
CONN WIRE
WIRE LABEL
SW03 PLATFORM ROTATE POS COLOR GAUGE JACKET TO
CONN WIRE CO01-J1
WIRE LABEL 1 WHT 1-4 SOFT TOUCH 18 AWG GXL
POS COLOR GAUGE JACKET TO (29)
1 WHT 1-7 PLTF ROTATE LEFT 18 AWG GXL CO01-J1 (8)
2 WHT 1-72 SWITCHES PWR 18 AWG GXL SW86 (2) LB478- SKYGAURD WARNING
2 WHT 1-74 SWITCHES PWR 18 AWG GXL SW173 (2) CONN WIRE
WIRE LABEL
3 WHT 1-6 PLTF ROTATE RIGHT 18 AWG GXL CO01-J1 (7) POS COLOR GAUGE JACKET TO
4 GD153-J2
1 BLK 000-10-501 GND 18 AWG GXL
(6)
5
6

LB478+ SKYGAURD WARNING

CONN WIRE
SW21-2 WIRE LABEL
POS COLOR GAUGE JACKET TO
SOFT TCH/SKY GUARD
1-31 SOFT TCH/SKY CO01-J2
CONN WIRE 1 WHT 18 AWG GXL
WIRE LABEL GUARD (16)
POS COLOR GAUGE JACKET TO
1 WHT 1-87 SWITCHES PWR 18 AWG GXL SW09-2 (1)

Figure 7-37. Platform Control Box Harness - Sheet 8 of 12

7-32 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-33
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SW19 SW624
JIB LIFT DUAL CAPACITY

SW02
MAIN TELE SW174
DRIVE ORIENTATION OVERRIDE

SW05
START/AUX

SW155-2
HEAD AND TAIL LIGHTS

SW155-1
HEAD AND TAIL LIGHTS
SW14-2B
E STOP

GD153-J2 SW14-1B
E STOP

GD153-J1
1001164353-I
MAF00940

Figure 7-38. Platform Control Box Harness - Sheet 9 of 12

7-34 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

GD153-J2 SW14-1B E STOP

CONN WIRE
CONN WIRE WIRE LABEL
WIRE LABEL POS COLOR GAUGE JACKET TO
POS COLOR GAUGE JACKET TO
1B WHT 1-62 EMS B+ 18 AWG GXL X304A (9)
1 WHT 1-24 CREEP 18 AWG GXL CO01-J2 (9)
1-32 FT SWITCH
2 WHT 18 AWG GXL CO01-J2 (7)
ENABLE
SW02 MAIN TELE
3 WHT 1-30 LOW FUEL 18 AWG GXL CO01-J2 (21)
CONN WIRE
4 WIRE LABEL
POS COLOR GAUGE JACKET TO
5 1 WHT 1-5 TELE OUT 18 AWG GXL CO01-J1 (6)
6 BLK 000-10-27 GND 18 AWG GXL CO01-J2 (18) 2 WHT 1-71 SWITCHES PWR 18 AWG GXL SW155-2 (1)
6 BLK 000-10-501 GND 18 AWG GXL LB478- (1) 2 WHT 1-76 SWITCHES PWR 18 AWG GXL SW19 (2)
3 WHT 1-3 TELE IN 18 AWG GXL CO01-J1 (5)
4
GD153-J1
5
CONN WIRE
WIRE LABEL 6
POS COLOR GAUGE JACKET TO
CO01-J2
1 WHT 1_498 1/4 FUEL 18 AWG GXL
(22)
CO01-J2 SW19 JIB LIFT
2 WHT 1_500 1/2 FUEL 18 AWG GXL CONN WIRE
(24) WIRE LABEL
CO01-J2 POS COLOR GAUGE JACKET TO
3 WHT 1_499 3/4 FUEL 18 AWG GXL CO01-J1
(23) 1 WHT 1-14 JIB DOWN 18 AWG GXL
CO01-J2 (12)
4 BLK 1_497 FUEL GND 18 AWG GXL 2 WHT 1-76 SWITCHES PWR 18 AWG GXL SW02 (2)
(25)
5 2 WHT 1-78 SWITCHES PWR 18 AWG GXL SW86 (2)
CO01-J2 CO01-J1
6 WHT 1_501 FUEL FULL 18 AWG GXL 3 WHT 1-13 JIB UP 18 AWG GXL
(35) (11)
4
5
6

Figure 7-39. Platform Control Box Harness - Sheet 10 of 12

3121671 7-35
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SW624 DUAL CAPACITY SW155-2

CONN WIRE HEAD AND TAIL LIGHTS
WIRE LABEL
POS COLOR GAUGE JACKET TO CONN WIRE
WIRE LABEL
1 POS COLOR GAUGE JACKET TO
2 WHT 1-75 SWITCHES PWR 18AWG GXL SW174 (2) 1 WHT 1-71 SWITCHES PWR 18AWG GXL SW02 (2)
2 WHT 1-79 SWITCHES PWR 18AWG GXL SW05 (2) 1 WHT 1-77 SWITCHES PWR 18AWG GXL SW05 (2)
3 WHT 1-50 DUAL CAPACITY 18AWG GXL CO01-J1 (21)
4 SW174
5 DRIVE ORIENTATION OVERRIDE
6 CONN WIRE
WIRE LABEL
POS COLOR GAUGE JACKET TO
1-67 PLTF ORIENT
SW05 START/AUX 1 WHT 18AWG GXL CO01-J2 (4)
OVERRIDE
CONN WIRE 2 WHT 1-75 SWITCHES PWR 18AWG GXL SW624 (2)
WIRE LABEL
POS COLOR GAUGE JACKET TO
2 WHT 1-80 SWITCHES PWR 18AWG GXL SW733 (3)
1 WHT 1-10 AUX POWER 18AWG GXL CO01-J1 (15)
3
2 WHT 1-77 SWITCHES PWR 18AWG GXL SW155-2 (1)
4
2 WHT 1-79 SWITCHES PWR 18AWG GXL SW624 (2)
5
3 WHT 1-9 START SWITCH 18AWG GXL CO01-J1 (14)
6
4
5
SW14-2B E STOP
6
CONN WIRE
WIRE LABEL
POS COLOR GAUGE JACKET TO
SW155-1 2B WHT 1-45 PLATF EMS 18AWG GXL CO01-J7 (2)
HEAD AND TAIL LIGHTS
CONN WIRE
WIRE LABEL
POS COLOR GAUGE JACKET TO
1 WHT 1-15 HEAD LIGHTS 18AWG GXL CO01-J1 (30)

Figure 7-40. Platform Control Box Harness - Sheet 11 of 12

7-36 3121671
SW21-2

3121671
SW21-1
SW03 SW86 SW19 SW02

SW733

SW155-2
SW88
SW04 GD153-J3 SW155-1
SW14-1B

SW174
GD153-J4
SW09-2 SW14-2B
SW09-1 LB478+ GD153-J1 SW05
LB478- SW624
SW173 GD153-J2

CO01-J7
MS16

CO01-J8

X303A
X687
AH11+
X305A
X304A
AH11-
CO01-J2 CO01-J1 1001164353-I
MAF00950
X175

Figure 7-41. Platform Control Box Harness - Sheet 12 of 12

7-37
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7-38
X491
LSS CAN LO
X489
LSS POWER

X510

X511
CAN SHIELD
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 SLR SHLD 22AWG SHLD X510 (1)

X494
X489 LSS GROUND
LSS POWER
X490
CONN WIRE WIRE LSS CAN HI
GAUGE JACKET TO
POS COLOR LABEL X510
1 RED POWER 22 AWG GXL X510 (2)
CONN WIRE WIRE
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

GAUGE JACKET TO
POS COLOR LABEL
X494 2 RED POWER 22 AWG GXL X489 (1) X511
4 WHT CAN_HI 24 AWG GXL X490 (1) LSS CAN SHIELD
LSS GROUND 5 BLU CAN_LO 24 AWG GXL X491 (1)
CONN WIRE WIRE 3 BLK V- 22 AWG GXL X494 (1)
GAUGE JACKET TO
POS COLOR LABEL 1 SLR SHLD 22 AWG SHLD X511 (1)
1 BLK V- 22 AWG GXL X510 (3)

X491
LSS CAN LO
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1 BLU CAN_LO 24 AWG GXL X510 (5)

X490
LSS CAN HI
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
1001175244 D
1 WHT CAN_HI 24 AWG GXL X510 (4)

Figure 7-42. LSS Harness

3121671
3121671
1 HOLE PLUG 1 HOLE PLUG
2 GREEN/J1939 2 GREEN/J1939
3 YELLOW/J1939 3 YELLOW/J1939
4 ORANGE 4 ORANGE
5 BLUE 5 BLUE
6 YELLOW 6 YELLOW
7 BROWN 7 BROWN
8 HOLE PLUG 8 HOLE PLUG
9 RED/BLK 9 RED/BLK
10 ORANGE 12GA 10 ORANGE 12GA
11 BLU/BLK 11 BLU/BLK
12 RED 12GA 12 RED 12GA
13 ORN/BLK 13 ORN/BLK
14 HOLE PLUG 14 HOLE PLUG
15 YEL/BLK 15 YEL/BLK
16 BLACK 12GA 16 BLACK 12GA
17 HOLE PLUG 17 HOLE PLUG
18 BLK/WHT 12GA 18 BLK/WHT 12GA
19 HOLE PLUG 19 HOLE PLUG

1001176952-C
MAF00960

Figure 7-43. Main Boom Harness

7-39
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7-40
1 HOLE PLUG 1 HOLE PLUG
2 GREEN/J1939 2 GREEN/J1939
3 YELLOW/J1939 3 YELLOW/J1939
4 ORANGE 4 ORANGE
5 BLUE 5 BLUE
6 YELLOW 6 YELLOW
7 BROWN 7 BROWN
8 HOLE PLUG 8 HOLE PLUG
9 RED/BLK 9 RED/BLK
10 ORANGE 12GA 10 ORANGE 12GA
11 BLU/BLK 11 BLU/BLK
12 RED 12GA 12 RED 12GA
13 ORN/BLK 13 ORN/BLK
14 HOLE PLUG 14 HOLE PLUG
15 YEL/BLK 15 YEL/BLK
16 BLACK 12GA 16 BLACK 12GA
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

17 HOLE PLUG 17 HOLE PLUG

18 BLK/WHT 12GA 18 BLK/WHT 12GA
19 HOLE PLUG 19 HOLE PLUG
1001176953-C
MAF00970

Figure 7-44. Main Boom with Jib Harness

3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-45. Tele In Proximity Switches Harness

3121671 7-41
7-42
SN571 X615B
CONN WIRE WIRE
GAUGE JACKET TO CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO
POS COLOR LABEL
1 YEL/BLK CABLE 18 AWG TFFN X615B (1)
1 YEL/BLK CABLE 18 AWG TFFN SN467 (1)
2 BLU/BLK CABLE 18 AWG TFFN X615B (6)
2 BRN/BLK CABLE 18 AWG TFFN SN467 (3)
3 BRN/BLK CABLE 18 AWG TFFN X615B (5)
3 BLU/BLK CABLE 18 AWG TFFN SN467 (2)

4 ORN/BLK CABLE 18 AWG TFFN SN571 (1)

SN467
5 BLK/RED CABLE 18 AWG TFFN SN571 (3)
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL 6 BLU/RED CABLE 18 AWG TFFN SN571 (2)
1 ORN/BLK CABLE 18 AWG TFFN X615B (1)

2 BLU/RED CABLE 18 AWG TFFN X615B (3)

3 BLK/RED CABLE 18 AWG TFFN X615B (2)

SN467
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X615B
SN571

1001173807 C

Figure 7-46. Capacity Proximity Switches Harness

3121671
3121671
LB280

C069-J12

C069-J7
SHEET 8, 9, 10
MS131
MS647
X513B
SN476 X102A
X479

CO69-J1 X181A

X126
MS325
HC292
X10 HV97
SHEET 4, 5, 6, 7 X513B X183A

X615A C069-J8 X281

SW118-2B X282
MS650 SW118-2B FC631
HC293
X450
HC96

SW118-2A HV94
X616A SW118-1B SW531-2 HV95
SW531-1 SW104-B
SW104-3
SW104-1 GD414 SHEET 11, 12, 13

X615A

X530

1001164818-O
MAF00980
SHEET 2, 3

Figure 7-47. Turntable Harness - Sheet 1 of 14

7-43
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X615A

X616A
TELESCOPE
RETRACTED
PROX SENSOR

SN471
MAIN BOOM
ANGLE SENSOR

X530
GENERATOR
CONNECTOR

1001164818-O
MAF00990

Figure 7-48. Turntable Harness - Sheet 2 of 14

7-44 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X615A SN471
CONN WIRE
CONN WIRE WIRE LABEL GAUGE JACKET TO
WIRE LABEL GAUGE JACKET TO POS COLOR
POS COLOR
A BLK 000-40-78 GND 18 AWG GXL S294 (2)
1 WHT 4-168 PWR 12V 18 AWG GXL S468 (2)
B WHT 4-106 PWR 5V 18 AWG GXL CO69-J7 (4)
2 BLK 000-40-167 GND 18 AWG GXL S469 (2)
C WHT 4-86 BM ANGLE SEN 1 18 AWG GXL CO69-J7 (7)
3 WHT 4-115 CAPACITY 1 18 AWG GXL CO69-J7 (23)
D WHT 4-87 BM ANGLE SEN 2 18 AWG GXL S295 (2)
4 WHT 4-114 PWR 12V 18 AWG GXL S468 (1)
E BLK 000-40-79 GND 18 AWG GXL S294 (2)
5 BLK 000-40-98 GND 18 AWG GXL S469 (1)
F WHT 4-112 PWR 5V 18 AWG GXL S294 (2)
6 WHT 4-167 CAP PROX 2 18 AWG GXL CO69-J1 (35)
7
X530
8
CONN WIRE
WIRE LABEL GAUGE JACKET TO
POS COLOR
X616A 1 YEL 4-82 GEN IGN 18 AWG GXL FC631 (41)
CONN WIRE 2 WHT 4-74 GEN ON 18 AWG GXL CO69-J1 (22)
WIRE LABEL GAUGE JACKET TO
POS COLOR
3 BLK 000-40-161 GEN GND 18 AWG GXL MS647 (5)
1 BLK 4-111 PWR 12V 18 AWG GXL S469 (2)
2 WHT 000-40-77 GND 18 AWG GXL CO69-J7 (21)
3 WHT 4-110 PROX 1 18 AWG GXL S468 (2)
4 BLK 4-113 PWR 12V 18 AWG GXL S469 (2)
5 WHT 000-40-80 GND 18 AWG GXL CO69-J1 (34)
6 BLK 4-117 PROX 2 18 AWG GXL S469 (2)

Figure 7-49. Turntable Harness - Sheet 3 of 14

3121671 7-45
7-46
LB280
STROBE LIGHT MS650
IGN POWER
CO69-J7
UGM J7

MS647
CO69-J12 NEGATIVE BUS
UGM J12

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 YEL CAN 1 HI 18 AWG J1939 CABLE X102A (3) 1 BLK 000-40-64 BATT GND 16 AWG GXL 1
2 1 BLK 000-40-8 MODL GND 10 AWG GXL 1
3 GRN CAN 1 LO 18 AWG J1939 CABLE X102A (2) 2 RED 4-35 IGN 12 AWG GXL 2
4 GRN CAN 1 LO 18 AWG J1939 CABLE CO69-J7 (24) 3 BLK 000-40-12 PLATF GND 12 AWG GXL 3
5 4 YEL 4-36 MODL PWR 14 AWG GXL 4
6
7
X102A
8
CONN WIRE
9 WIRE LABEL GAUGE JACKET To
POS COLOR
10 GRN CAN 1 LO 20 AWG J1939 CABLE SN476 (4)
1
11 YEL CAN 1 HI 20 AWG J1939 CABLE SN476 (3)
2 GRN CAN 1 LO 18 AWG J1939 CABLE MS131 (3)
12 YEL CAN 1 HI 18 AWG J1939 CABLE CO69-J7 (13)
3 YEL CAN 1 HI 18 AWG J1939 CABLE MS131 (1)
4 WHT 4-43 PLTF EMS 18 AWG GXL S121 (2)
MS325 5
CONN WIRE 6 WHT 4-52 FOOT SW 18 AWG GXL CO69-J7 (15)
WIRE LABEL GAUGE JACKET To
POS COLOR 7
1 8
2 9 RED 4-552 16 AWG GXL FC631 (34)
3 GRN CAN2 LO 20 AWG J1939 CABLE CO69-J12 (4) 10
4 GRN CAN2 LO 20 AWG J1939 CABLE X183A (4) 11 WHT 4-53 GROUND MODE 18 AWG GXL CO69-J7 (14)
5 YEL CAN2 HI 20 AWG J1939 CABLE CO69-J12 (3) 12 RED 4-71 12 AWG GXL FC631 (37)
6 YEL CAN2 HI 20 AWG J1939 CABLE X183A (3) 13
7 YEL CAN2 HI 20 AWG J1939 CABLE X429 (C) 14
8 YEL CAN2 HI 20 AWG J1939 CABLE GD414 (3) 15
9 GRN CAN2 LO 20 AWG J1939 CABLE X429 (D) 16 BLK 000-40-12 PLATF GND 12 AWG GXL CO69-J8 (3)
10 GRN CAN2 LO 20 AWG J1939 CABLE GD414 (4) 17
11 18
12 19

Figure 7-53. Turntable Harness - Sheet 7 of 14

3121671 7-49
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X513B
CRIBBING ENABLE

X429
DIAGNOSTIC FUSE BOX
CONNECTOR
FC631

SW118-2B

SW118-1A

SW118-2A

SW118-1B

SW531-1
SW531-2

SW104-3

SW104-1

SW104-B

GD414
MDI/HOURMETER
1001164818-O
MAF01010

Figure 7-54. Turntable Harness - Sheet 8 of 14

7-50 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X513B SW118-1B

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 BLK 000-40-43 CF 16 AWG GXL S171 (2) 1B RED 4-46 12 AWG GXL SW104-B (1)
2
3
SW531-1
4
CONN WIRE
5 WIRE LABEL GAUGE JACKET To
POS COLOR
6
1 WHT 4-163 MSSO 18 AWG GXL 63119-1

X429
SW531-2
CONN WIRE
WIRE LABEL GAUGE JACKET To CONN WIRE
POS COLOR WIRE LABEL GAUGE JACKET To
POS COLOR
A BLK 000-40-11 NEGATIVE 18 AWG GXL MS647 (4)
1 BLK 000-40-162 GND 18 AWG GXL 4460259
B RED 4-65 PWR 18 AWG GXL S18 (2)
C YEL CAN2 HI 20 AWG J1939 CABLE MS325 (7)
D GRN CAN2 LO 20 AWG J1939 CABLE MS325 (9) SW104-3
E CONN WIRE
WIRE LABEL GAUGE JACKET To
F POS COLOR
G 1 RED 4-51 12 AWG GXL FC631 (38)
H WHT 4-66 IGN 18 AWG GXL FC631 (40) 1 WHT 4-51 PLTFM ENABLE 18 AWG GXL IP103 (1)
J

SW104-1
SW118-2B CONN WIRE
WIRE LABEL GAUGE JACKET To
POS COLOR
CONN WIRE
WIRE LABEL GAUGE JACKET To
POS COLOR 1 RED 4-169 MODE SEL 12 AWG GXL FC631 (42)
2B RED 4-47 SW-118-2B 10 AWG GXL S123 (1) 1 RED Apr-40 12 AWG GXL FC631 (29)

GD414
SW118-1A
CONN WIRE
CONN WIRE WIRE LABEL GAUGE JACKET To
WIRE LABEL GAUGE JACKET To POS COLOR
POS COLOR
1 BLK 000-40-51 GND 18 AWG GXL CO69-J7 (25)
1A RED 4-37 SW118-1A 12 AWG GXL FC631 (9)
2 RED 4-97 PWR 18 AWG GXL S15 (2)
3 YEL CAN2 HI 20 AWG J1939 CABLE MS325 (8)
SW118-2A 4 GRN CAN2 LO 20 AWG J1939 CABLE MS325 (10)
CONN WIRE 5
WIRE LABEL GAUGE JACKET To
POS COLOR 6
2A RED 4-175 SW118-2A 10 AWG GXL S123 (1) NC
2A RED 4-50 18 AWG GXL FC631 (35)

Figure 7-55. Turntable Harness - Sheet 9 of 14

3121671 7-51
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

FC631
FC631
CONN WIRE
WIRE LABEL GAUGE JACKET To
CONN WIRE POS COLOR
WIRE LABEL GAUGE JACKET To
POS COLOR
34 RED 4-552 16 AWG GXL X102A (9)
1 BLK 000-40-13 GND 18 AWG GXL CO69-J7 (19) SW118-2A
2 RED 4-166 12 AWG GXL S621 (2) 35 RED 4-50 18 AWG GXL
(2A)
3
4 36 YEL 4-72 IGN 18 AWG GXL MS650 (2)
5 37 RED 4-71 12 AWG GXL X102A (12)
6 38 RED 4-51 12 AWG GXL SW104-3 (1)
7 39 RED 4-65 PWR 18 AWG GXL S18 (2)
8 40 WHT 4-66 IGN 18 AWG GXL X429 (H)
SW118-1A 41 YEL 4-82 GEN IGN 18 AWG GXL X530 (1)
9 RED 4-37 SW118-1A 12 AWG GXL
(1A) 42 RED 4-169 MODE SEL 12 AWG GXL SW104-1 (1)
10 WHT 4-170 18 AWG GXL S509 (2) 43
11 44
12 45 YEL 4-81 GEN IGN 18 AWG GXL MS650 (5)
13 46 RED 4-169-1 MODE SOL 18 AWG GXL CO69-J7 (3)
14 47 RED 4-563 LIGHT OPT 18 AWG GXL S621 (2)
15 48
16
17
SW104-B
18
19 CONN WIRE
WIRE LABEL GAUGE JACKET To
POS COLOR
20
21 1 RED 4-46 12 AWG GXL SW118-1B (1B)
22
23
24
25 RED 4-39 18 AWG GXL S509 (1)
26 WHT 4-38 18 AWG GXL S509 (1)
27
28 RED 4-350 12 AWG GXL S621 (1)
29 RED 4-40 12 AWG GXL SW104-1 (1)
30 WHT 4-41 18 AWG GXL S121 (2)
31
32 RED 4-35 IGN 12 AWG GXL CO69-J8 (2)
33 RED 4-550 12 AWG GXL S621 (1)

Figure 7-56. Turntable Harness - Sheet 10 of 14

7-52 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-53
7-54
X479
OSC AXLE #2 DOS X181A
ENGINE IGN POWER

HV292 X183A
OSC VALVE #1 ENGINE CONNECTIONS
X281
MODULE GROUND
HV97 NEGATIVE BUS GROUND
BRAKE
X282
B+ AUX
PUMP RELAY

X450 HV293
AUX PUMP OSC VALVE #2
RELAY ENABLE

HV96
2 SPEED
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HV95
DRIVE FORWARD

HV94
DRIVE REVERSE
1001164818-O
MAF01020

Figure 7-57. Turntable Harness - Sheet 11 of 14

3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X479 X281

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 WHT 4-116 POWER 12V 18 AWG GXL CO69-J7 (32) 1 BLK 000-40-8 MODL GND 10 AWG GXL CO69-J8 (1)
2 WHT 4-92 DOS SW 18 AWG GXL CO69-J7 (35) 1 BLK 000-40-81 16 AWG GXL MS647 (6)

X181A HV94
CONN WIRE CONN WIRE
WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 WHT 4-94 EMR4 IGNITION 18 AWG GXL CO69-J1 (10) 1 WHT 4-4 DRIVE REVERSE 16 AWG GXL CO69-J1 (6)
2 BLK 000-40-557 GND 18 AWG GXL MS647 (7) 2 BLK 000-40-41 CF 16 AWG GXL S171 (1)
3
4 WHT 4-80 GLOW PLUG 16 AWG GXL CO69-J1 (12)
HV95
5
6 CONN WIRE
WIRE LABEL GAUGE JACKET To
7 POS COLOR
8 1 WHT 4-3 DRIVE FORWARD 16 AWG GXL CO69-J1 (3)
2 BLK 000-40-40 CF 16 AWG GXL S171 (1)

X183A

CONN WIRE HV96

WIRE LABEL GAUGE JACKET To
POS COLOR CONN WIRE
WIRE LABEL GAUGE JACKET To
1 YEL 4-84 IGN 18 AWG GXL MS650 (4) POS COLOR
2 WHT 4-67 START 16 AWG GXL CO69-J1 (11) 1 WHT 4-2 TWO SPEED 18 AWG GXL CO69-J1 (20)
J1939 2 BLK 000-40-2 GND 18 AWG GXL S98 (1)
3 YEL CAN2 HI 20 AWG MS325 (6)
CABLE
J1939
4 GRN CAN2 LO 20 AWG MS325 (4)
CABLE
5 RED 4-76 ALT EXCITE 16 AWG GXL CO69-J1 (32)
6

Figure 7-58. Turntable Harness - Sheet 12 of 14

3121671 7-55
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HV293 X450

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 WHT 4-120 OSC AXL V 2 18 AWG GXL CO69-J1 (2) 1 WHT 4-78 AUX PUMP 16 AWG GXL CO69-J1 (13)
2 BLK 000-40-72 18 AWG GXL S300 (2)

X282
HV97 CONN WIRE
WIRE LABEL GAUGE JACKET To
CONN WIRE POS COLOR
WIRE LABEL GAUGE JACKET To
POS COLOR 4-49 B+ AUX PMP
1 RED 10 AWG GXL IP136 (2)
1 WHT 4-1 BRAKE 18 AWG GXL CO69-J1 (23) 10AWG
2 BLK 000-40-1 GND 18 AWG GXL S98 (1)

HV292

CONN WIRE
WIRE LABEL GAUGE JACKET To
POS COLOR
1 WHT 4-121 OSC AXL V 1 18 AWG GXL CO69-J1 (7)
2 BLK 000-40-73 18 AWG GXL S300 (2)

Figure 7-59. Turntable Harness - Sheet 13 of 14

7-56 3121671
3121671
LB280
SW104-3
SW531-2 SW104-1
SW531-1 SW104-B
SW118-1B
SW118-2B
SW118-1A
GD414 HV293
SW118-2A
HV292
HV97
X450 HV96
FC631
X126
X10
S123 X282
CO69-J1
SN476
CO69-J8
X429
HV95
HV94
CO69-J7 X281
X102A
MS131 X479
MS325
CO69-J12
X513B

MS650 X530

MS647 SN471 X183A

X181A

X615A
X616A

1001164818-O
MAF01030

Figure 7-60. Turntable Harness - Sheet 14 of 14

7-57
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7-58
HV377

CO69-J3

X473

HV379
HV382
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HX439 HV374
HV375 HV383
CO69-J3 HV381

HV371

HV372

X513A
HV380
HV364
HV373
HV365
HV376
HV378
HV376

AH387 SHEET 5, 6, 7
AH387 SHEET 2, 3, 4

1001166963-H
Figure 7-61. Main Valve Harness - Sheet 1 of 7 MAF01120

3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-59
7-60
HV377

CO69-J3

X473

HX439

CO69-J3
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X513A

AH387 1001166963-H
MAF01130
AH387

Figure 7-62. Main Valve Harness - Sheet 2 of 7

3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

CO69-J2 CO69-J3

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 1 BLK 000-40-44 CF 18 AWG GXL X513A (1)
2 000-40-49 AUX TWR
2 BLK 18 AWG GXL HV439 (2)
3 LIFT DOWN
4 WHT 4-19 MAIN TELE IN 18 AWG GXL HV371 (1) 3
5 WHT 4-8 LEVEL UP 18 AWG GXL HV381 (1) 4 BLK 000-40-38 CF 18 AWG GXL S389 (2)
6 BLK 000-40-45 18 AWG GXL X474 (1) 5
7 WHT 4-11 LEVEL DOWN 18 AWG GXL HV380 (1) 6 BLK 000-40-33 CF 18 AWG GXL HV375 (2)
8 WHT 4-21 STEER RIGHT 18 AWG GXL HV373 (1) 7 WHT 4-30 ALRM 18 AWG GXL AH387 (A)
4-103 MAIN LIFT 8
9 WHT 18 AWG GXL HV439 (1)
DOWN AUX 9 WHT 4-105 CRIBBING 18 AWG GXL X513A (3)
10 WHT 4-9 ROTATE LEFT 18 AWG GXL HV383 (1) 10 WHT 5-101 JUMP ENABLE 18 AWG GXL X513A (4)
11 WHT 4-24 MAIN LIFT UP 18 AWG GXL HV376 (1) 11
12 WHT 4-12 JIB UP 18 AWG GXL HV364 (1) 12
13 WHT 4-14 MAIN DUMP 18 AWG GXL HV366 (1) 13
14 BLK 000-40-7 GND 18 AWG GXL S386 (2) 14 BLK 000-40-35 CF 18 AWG GXL S388 (2)
15
16 WHT 4-20 MAIN TELE OUT 18 AWG GXL HV372 (1)
HV439
17 BLK 000-40-5 GND 18 AWG GXL S384 (2)
18 CONN WIRE
WIRE LABEL GAUGE JACKET To
POS COLOR
19 WHT 4-22 STEER LEFT 18 AWG GXL HV374 (1)
4-103 MAIN LIFT
20 1 WHT 18 AWG GXL CO69-J2 (9)
DOWN AUX
21 WHT 4-10 ROTATE RIGHT 18 AWG GXL HV382 (1)
000-40-49 AUX TWR
4-104 MAIN LIFT 2 BLK 18 AWG GXL CO69-J3 (2)
22 WHT 18 AWG GXL HV377 (1) LIFT DOWN
DOWN
23 WHT 4-13 JIB DOWN 18 AWG GXL HV365 (1)
24 HV377
25 WHT 4-75 FUEL SENSOR 18 AWG GXL X473 (1) CONN WIRE
WIRE LABEL GAUGE JACKET To
4-102 HEAD & TAIL POS COLOR
26 WHT 18 AWG GXL X513A (2)
LIGHTS 4-104 MAIN LIFT
1 WHT 18 AWG GXL CO69-J2 (22)
27 WHT 4-29 ALRM 18 AWG GXL AH387 (B) DOWN
28 BLK 000-40-53 GND 18 AWG GXL S415 (2) 2 BLK 000-40-63 CF 18 AWG GXL S388 (2)
000-40-10 ALRM
29 BLK 18 AWG GXL AH387 (C)
GND
X473
30 BLK 000-40-25 GND 18 AWG GXL HV366 (2)
31 WHT 4-23 FLOW CONTROL 18 AWG GXL HV375 (1) CONN WIRE
WIRE LABEL GAUGE JACKET To
32 POS COLOR
33 1 WHT 4-75 FUEL SENSOR 18 AWG GXL CO69-J2 (25)
34 WHT 4-27 SWING LEFT 18 AWG GXL HV379 (1)

Figure 7-63. Main Valve Harness - Sheet 3 of 7

3121671 7-61
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

AH387 X513A

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
A WHT 4-30 ALRM 18 AWG GXL CO69-J3 (7) 1 BLK 000-40-44 CF 18 AWG GXL CO69-J3 (1)
B WHT 4-29 ALRM 18 AWG GXL CO69-J2 (27) 4-102 HEAD & TAIL
2 WHT 18 AWG GXL CO69-J2 (26)
000-40-10 ALRM LIGHTS
C BLK 18 AWG GXL CO69-J2 (29)
GND 3 WHT 4-105 CRIBBING 18 AWG GXL CO69-J3 (9)
4 WHT 5-101 JUMP ENABLE 18 AWG GXL CO69-J3 (10)
5
X474
6
CONN WIRE
WIRE LABEL GAUGE JACKET To
POS COLOR
1 WHT 4-30 ALRM 18 AWG GXL CO69-J3 (7)

Figure 7-64. Main Valve Harness - Sheet 4 of 7

7-62 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-63
7-64
HV379

HV382
HV374
HV375 HV383

HV381

HV371

HV372
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HV380

HV364
HV373

HV365
HV376
HV378

HV376
1001166963-H
MAF01140

Figure 7-65. Main Valve Harness - Sheet 5 of 7

3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HV374 STEER LEFT HV364 SWING LEFT

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 WHT 4-22 STEER LEFT 18 AWG GXL CO69-J2 (19) 1 WHT 4-12 JIB UP 18 AWG GXL CO69-J2 (12)
2 BLK 000-40-32 GND 18 AWG GXL S415 (1) 2 BLK 000-40-23 18 AWG GXL S384 (1)

HV372 MAIN TELE OUT

HV382 PLTF ROT R
CONN WIRE
WIRE LABEL GAUGE JACKET To CONN WIRE
POS COLOR WIRE LABEL GAUGE JACKET To
POS COLOR
1 WHT 4-20 MAIN TELE OUT 18 AWG GXL CO69-J2 (16)
1 WHT 4-10 ROTATE RIGHT 18 AWG GXL CO69-J2 (21)
2 BLK 000-40-21 18 AWG GXL S386 (1)
2 BLK 000-40-20 18 AWG GXL S384 (1)

HV375 FLOW CONTROL

HV365 JIB DOWN
CONN WIRE
WIRE LABEL GAUGE JACKET To CONN WIRE
POS COLOR WIRE LABEL GAUGE JACKET To
POS COLOR
1 WHT 4-23 FLOW CONTROL 18 AWG GXL CO69-J2 (31)
1 WHT 4-13 JIB DOWN 18 AWG GXL CO69-J2 (23)
2 BLK 000-40-33 CF 18 AWG GXL CO69-J3 (6)
2 BLK 000-40-24 18 AWG GXL S384 (2)

HV380 PLTF LVL DOWN

HV376 MAIN LIFT UP
CONN WIRE
WIRE LABEL GAUGE JACKET To CONN WIRE
POS COLOR WIRE LABEL GAUGE JACKET To
POS COLOR
1 WHT 4-27 SWING LEFT 18 AWG GXL CO69-J2 (34)
1 WHT 4-24 MAIN LIFT UP 18 AWG GXL CO69-J2 (11)
2 BLK 000-40-39 CF 18 AWG GXL S389 (1)
2 BLK 000-40-34 CF 18 AWG GXL S388 (1)

HV379 SWING LEFT

CONN WIRE
WIRE LABEL GAUGE JACKET To
POS COLOR
1 WHT 4-27 SWING LEFT 18 AWG GXL CO69-J2 (34)
2 BLK 000-40-39 CF 18 AWG GXL S389 (1)

Figure 7-66. Main Valve Harness - Sheet 6 of 7

3121671 7-65
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HV378 SWING RIGHT HV381 PLTF LVL UP

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 WHT 4-26 SWING RIGHT 18 AWG GXL CO69-J2 (35) 1 WHT 4-8 LEVEL UP 18 AWG GXL CO69-J2 (5)
2 BLK 000-40-37 CF 18 AWG GXL S389 (1) 2 BLK 000-40-22 18 AWG GXL S386 (1)

HV383 PLTF ROT L HV373 STEER RIGHT

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 WHT 4-9 ROTATE LEFT 18 AWG GXL CO69-J2 (10) 1 WHT 4-21 STEER RIGHT 18 AWG GXL CO69-J2 (8)
2 BLK 000-40-19 18 AWG GXL S384 (1) 2 BLK 000-40-32 GND 18 AWG GXL S415 (1)

HV366 MAIN DUMP HV371 MAIN TELE IN

CONN WIRE CONN WIRE

WIRE LABEL GAUGE JACKET To WIRE LABEL GAUGE JACKET To
POS COLOR POS COLOR
1 WHT 4-14 MAIN DUMP 18 AWG GXL CO69-J2 (13) 1 WHT 4-19 MAIN TELE IN 18 AWG GXL CO69-J2 (4)
2 BLK 000-40-25 GND 18 AWG GXL CO69-J2 (30) 2 BLK 000-40-31 18 AWG GXL S386 (1)

Figure 7-67. Main Valve Harness - Sheet 7 of 7

7-66 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-67
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-68. Ground Control Panel Harness - Sheet 1 of 5

7-68 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001167108 I
T920
S951
S952
X965

X955

S954
S953
S969
S968
S945
S944

Figure 7-69. Ground Control Panel Harness - Sheet 2 of 5

3121671 7-69
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-70. Ground Control Panel Harness - Sheet 3 of 5

7-70 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-71. Ground Control Panel Harness - Sheet 4 of 5

3121671 7-71
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-72. Ground Control Panel Harness - Sheet 5 of 5

7-72 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-73
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-73. Deutz T4i Harness - Sheet 1 of 4

7-74 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-74. Deutz T4i Harness - Sheet 2 of 4

3121671 7-75
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-75. Deutz T4i Harness - Sheet 3 of 4

7-76 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-76. Deutz T4i Harness - Sheet 4 of 4

3121671 7-77
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-77. Deutz T4F Harness - Sheet 1 of 12

7-78 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-79
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

ECM-J2

ECM-J1

1001167108 I

Figure 7-78. Deutz T4F Harness - Sheet 3 of 11

7-80 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

ECM-J1 ECM-J2
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL CONN WIRE WIRE
GAUGE JACKET TO
1 RED 148-1 ECM PWR 2.5 mm² FLRYW S944 (2) POS COLOR LABEL
2 BLK 148-2 ECM GND 2.5 mm² FLRYW S945 (2) 1
3 RED 148-3 ECM PWR 2.5 mm² FLRYW S944 (2)
2 BLK 248-2 INJECTOR 3 1.5 mm² FLRYW EIC (61)
4 BLK 148-4 ECM GND 2.5 mm² FLRYW S945 (2)
3 BLK 248-3 INJECTOR 2 1.5 mm² FLRYW EIC (41)
5 RED 148-5 ECM PWR 2.5 mm² FLRYW S944 (2)

6 BLK 148-6 ECM GND 2.5 mm² FLRYW S945 (2) 4 BLK 248-4 MPROP ACTUATOR 1.5 mm² FLRYW EIC (19)

7 5 BLK 248-5 MPROP ACTUATOR 1.5 mm² FLRYW EIC (20)

8
6
9

10 7 BLK 248-7 RAIL PRESSURE FUEL 0.75 mm² FLRYW EIC (32)
11
8
12
9
13 BLK 148-13 COOLANT LEVEL SIG 0.75 mm² FLRYW SN939 (3)

14 10
15 BLK 148-15-68 CLUTCH SWITCH 0.75 mm² FLRYW ECM-J1 (68)
11
16
12
17

18 13
19
14
20
15
21

22 16 BLK 248-16 INJECTOR 1 1.5 mm² FLRYW EIC (35)

23
17
24
18 BLK 248-18 INJECTOR 4 1.5 mm² FLRYW EIC (37)
25

26 BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75 mm² FLRYW RL930 (2) 19 BLK 248-19 EHXAUST GAS RECIRCULATION 1.5 mm² FLRYW EIC (47)
27
20 BLK 248-20 EHXAUST GAS RECIRCULATION 1.5 mm² FLRYW EIC (48)
28 BLK 148-28 START RTN 0.75 mm² FLRYW EIC (2)
21
29 BLK 148-29 COOLANT LEVEL PWR 0.75 mm² FLRYW SN939 (1)

30 22
31
23 BLK 248-23 GLOW SENSE 0.75 mm² FLRYW MS932 (E)
32
24 BLK 248-24 BOOST PRESSURE / TEMP 0.75 mm² FLRYW EIC (22)
33

34 25 BLK 248-25 RAIL PRESSURE FUEL 0.75 mm² FLRYW EIC (31)
35 BLK 148-35-2 START 0.75 mm² FLRYW S1001 (1)
26 BLK 248-26 RAIL PRESSURE FUEL 0.75 mm² FLRYW EIC (25)
36
27 BLK 248-27 BOOST PRESSURE / TEMP 0.75 mm² FLRYW EIC (29)
37

38 BLK 148-38 THROTTLE FLAP 4 0.75 mm² FLRYW EIC (52) 28 BLK 248-28 COOLING TEMPERATURE 0.75 mm² FLRYW EIC (24)
39
29 BLK 248-29 OIL PRESSURE 0.75 mm² FLRYW EIC (27)
40
41 30

42 31
43
32 BLK 248-32 INJECTOR 3 1.5 mm² FLRYW EIC (38)
44 BLK 148-44 EHXAUST GAS RECIRCULATION 0.75 mm² FLRYW EIC (50)
33 BLK 248-33 INJECTOR 1 1.5 mm² FLRYW EIC (62)
45

46 34
47
35 BLK 248-35 GLOW RELAY CONTROL GND 0.75 mm² FLRYW RL931-85 (1)
48

49 36

50 37 BLK 248-37 ENGINE SPEED CAMSHAFT 18 AWG CABLE EIC (14)

51
38 SHLD 248-38 ENGINE SPEED CRANKSHAFT 18 AWG CABLE EIC (1)
52

53 GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE S968 (1) 39 BLK 248-39 ENGINE SPEED CRANKSHAFT 18 AWG CABLE EIC (15)

54 YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE S953 (1) 40 BLK 248-40 AIR INLET TEMP 0.75 mm² FLRYW EIC (28)
55
41
56 BLK 148-56 AIR INLET TEMP 0.75 mm² FLRYW EIC (34)

57 BLK 148-57 WATER IN FUEL SW RTN 0.75 mm² FLRYW X941 (2) 42

58 43 BLK 248-43 OIL PRESSURE 0.75 mm² FLRYW EIC (23)

59
44 BLK 248-44 OIL PRESSURE 0.75 mm² FLRYW EIC (26)
60

61 BLK 148-61 FUEL LOW PRESSURE 0.75 mm² FLRYW EIC (17) 45

62 46 BLK 248-46 INJECTOR 2 1.5 mm² FLRYW EIC (40)

63
47
64 BLK 148-64 WATER IN FUEL SW 0.75 mm² FLRYW X941 (1)
48 BLK 248-48 INJECTOR 4 1.5 mm² FLRYW EIC (42)
65
66 49
67
50
68 BLK 148-15-68 CLUTCH SWITCH 0.75 mm² FLRYW ECM-J1 (15)

69 51

70 52 WHT 248-52 ENGINE SPEED CAMSHAFT 18 AWG CABLE EIC (13)

71
53 SHLD 248-53 ENGINE SPEED CAMSHAFT 18 AWG CABLE EIC (9)
72 BLK 148-72 THROTTLE FLAP 3 0.75 mm² FLRYW EIC (49)

BLK 54 WHT 248-54ENGINE SPEED CRANKSHAFT 18 AWG CABLE EIC (21)

73 148-73 START SIG 0.75 mm² FLRYW EIC (3)

74 55
75 YEL CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE S969 (1)
56
76 GRN CAN 1 LO CUSTOMER CAN LOW 18 AWG J1939 CABLE S954 (1)
57
77

78 58
79
59
80

81
60

82 BLK 148-82 EHXAUST GAS RECIRCULATION 0.75 mm² FLRYW EIC (51)

85 BLK 148-85 EHXAUST GAS RECIRCULATION 0.75 mm² FLRYW EIC (46)

87 BLK 148-87 COOLANT LEVEL GND 0.75 mm² FLRYW SN939 (2)

88 BLK 148-88 IGNITION 0.75 mm² FLRYW S946 (2)

90
91

92
93

NC SHLD CAN 1 SHLDCUSTOMER CAN SHIELD 18 AWG J1939 CABLE X901 (6)

Figure 7-79. Deutz T4F Harness - Sheet 2 of 11

3121671 7-81
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

S951
X955
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
CONN WIRE WIRE
GAUGE JACKET TO
1 YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE S953 (2) POS COLOR LABEL

A YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE S953 (2)
2 YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE X901 (3)
B GRN CAN 1 LOCUSTOMER CAN LOW 18 AWG J1939 CABLE S954 (2)
2 YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE X950 (M)
C

S952
CONN WIRE WIRE
GAUGE JACKET TO
X965
POS COLOR LABEL

1 GRN CAN 1 LO CUSTOMER CAN LOW 18 AWG J1939 CABLE S954 (2) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
2 GRN CAN 1 LO CUSTOMER CAN LO 18 AWG J1939 CABLE X901 (4) A YEL CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE S969 (2)

2 GRN CAN 1 LO CUSTOMER CAN LO 18 AWG J1939 CABLE X950 (F) B GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE S968 (2)

S968
CONN WIRE WIRE
GAUGE JACKET TO
T920
POS COLOR LABEL
CONN WIRE WIRE
1 GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE ECM-J1 (53) GAUGE JACKET TO
POS COLOR LABEL
2 GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE S963 (1) 1 BLK 000-148-246 ECM GND 8 AWG GXL S945 (1)

2 GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE X965 (B) BLK
1 000-48-1 ENG GND 14 AWG GXL X941 (4)

1 BLK 000-48-2 ENG GND 18 AWG GXL X950 (B)

S969 1 BLK 000-48-3 GND 18 AWG GXL X999 (2)

CONN WIRE WIRE

GAUGE JACKET TO
POS COLOR LABEL

1 YEL CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE ECM-J1 (75)

YEL
S944
2 CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE S964 (1)
CONN WIRE WIRE
GAUGE JACKET TO
2 YEL CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE X965 (A) POS COLOR LABEL

1 RED 1-148-135 ECM PWR 8 AWG GXL RL930-2 (1)

2 RED 148-1 ECM PWR 2.5 mm² FLRYW ECM-J1 (1)

S953
CONN WIRE WIRE 2 RED 148-3 ECM PWR 2.5 mm² FLRYW ECM-J1 (3)
GAUGE JACKET TO
POS COLOR LABEL
1 YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE ECM-J1 (54) 2 RED 148-5 ECM PWR 2.5 mm² FLRYW ECM-J1 (5)

2 YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE S951 (1)

2 YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE X955 (A)
S945
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL

S954 1 BLK 000-148-246 ECM GND 8 AWG GXL T920 (1)

CONN WIRE WIRE BLK

POS COLOR LABEL
GAUGE JACKET TO 2 148-2 ECM GND 2.5 mm² FLRYW ECM-J1 (2)

1 GRN CAN 1 LO CUSTOMER CAN LOW 18 AWG J1939 CABLE ECM-J1 (76) 2 BLK 148-4 ECM GND 2.5 mm² FLRYW ECM-J1 (4)
2 GRN CAN 1 LO CUSTOMER CAN LOW 18 AWG J1939 CABLE S952 (1)
2 BLK 148-6 ECM GND 2.5 mm² FLRYW ECM-J1 (6)
2 GRN CAN 1 LO CUSTOMER CAN LOW 18 AWG J1939 CABLE X955 (B)

Figure 7-80. Deutz T4F Harness - Sheet 4 of 11

7-82 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X950 RL930
CONN WIRE WIRE CONN WIRE WIRE
GAUGE JACKET TO GAUGE JACKET TO
POS COLOR LABEL POS COLOR LABEL

YEL 1 YEL 2-48-4 18 AWG GXL S946 (2)

A 2-48-2 IGNITION 18 AWG GXL S946 (1)

2 BLK 148-26 0.75 mm² FLRYW ECM-J1 (26)

B BLK 000-48-2 ENG GND 18 AWG GXL T920 (1)

C
D
E
RL930-2
F GRN CAN 1 LO CUSTOMER CAN LO 18 AWG J1939 CABLE S952 (2) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
G GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE S963 (2) 1 RED 1-148-135 ECM PWR 8 AWG GXL S944 (1)

H YEL CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE S964 (2)

J
RL930-1
K
CONN WIRE WIRE
L GAUGE JACKET TO
POS COLOR LABEL
M YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE S951 (2) 1 WHT 48-96 FUEL PUMP 14 AWG GXL X941 (3)

S946 RL931-85
CONN WIRE WIRE
GAUGE JACKET TO CONN WIRE WIRE
POS COLOR LABEL GAUGE JACKET TO
POS COLOR LABEL
1 YEL 2-48-1 IGNITION 16 AWG GXL MS932 (H) 1 BLK 248-35 GLOW RELAY CONTROL GND 0.75 mm² FLRYW ECM-J2 (35)

1 YEL 2-48-2 IGNITION 18 AWG GXL X950 (A)

2 YEL 2-48-3 IGNITION 18 AWG GXL RL931-86 (1)

RL931-87
2 YEL 2-48-4 IGNITION 18 AWG GXL RL930 (1)
CONN WIRE WIRE
GAUGE JACKET TO
2 BLK 148-88 IGNITION 0.75 mm² FLRYW ECM-J1 (88) POS COLOR LABEL

1 ORG 248-23-1 GLOW SENSE 18 AWG GXL MS932 (F)

MS932
RL931-87
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL CONN WIRE WIRE
GAUGE JACKET TO
A POS COLOR LABEL
B 1 RED 48-13 GLOW 8 AWG GXL EC18 (1)
C
D

E BLK 248-23 GLOW SENSE 0.75 mm² FLRYW ECM-J2 (23)

RL931-87
F ORG 248-23-1 GLOW SENSE 18 AWG GXL RL931-87 (1)
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
G YEL 2-1-99 IGNITION 18 AWG GXL X902 (1)
1 RED 48-14 GLOW 8 AWG GXL EC18 (2)
H YEL 2-48-1 IGNITION 16 AWG GXL S946 (1)

S964 RL931-86
CONN WIRE WIRE CONN WIRE WIRE
GAUGE JACKET TO GAUGE JACKET TO
POS COLOR LABEL POS COLOR LABEL

1 YEL CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE S969 (2) 1 YEL 2-48-3 IGNITION 18 AWG GXL S946 (2)

2 YEL CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE X950 (H)

YEL
2 CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE X960 (A)
X960
CONN WIRE WIRE
GAUGE JACKET TO
S963 POS COLOR LABEL

A YEL CAN 2 HI DIAG CAN HIGH 18 AWG J1939 CABLE S964 (2)
CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
B GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE S963 (2)
1 GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE S968 (2)
C
2 GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE X950 (G)

2 GRN CAN 2 LO DIAG CAN LOW 18 AWG J1939 CABLE X960 (B)

Figure 7-81. Deutz T4F Harness - Sheet 5 of 11

3121671 7-83
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-82. Deutz T4F Harness - Sheet 6 of 11

7-84 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

EIC X999
CONN WIRE WIRE CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL GAUGE JACKET TO
POS COLOR LABEL
1 SHLD 248-38 18 AWG CABLE ECM-J2 (38)
1 BLK 148-35-3 - 18 AWG GXL S1001 (1)
2 BLK 148-28 0.75 mm² FLRYW ECM-J1 (28)
2 BLK 000-48-3 GND 18 AWG GXL T920 (1)
3 BLK 148-73 0.75 mm² FLRYW ECM-J1 (73)

4
5
S1001
6
7 CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
8
1 BLK 148-35-2 START 0.75 mm² FLRYW ECM-J1 (35)
9 SHLD 248-53 18 AWG CABLE ECM-J2 (53)

10 1 BLK 148-35-3 - 18 AWG GXL X999 (1)

11
2 BLK 148-35-1 START 18 AWG GXL X901 (2)
12

13 WHT 248-52 18 AWG CABLE ECM-J2 (52)

14 BLK 248-37 18 AWG CABLE ECM-J2 (37) X941

15 BLK 248-39 18 AWG CABLE ECM-J2 (39) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
16
1 BLK 148-64 WATER IN FUEL SW 0.75 mm² FLRYW ECM-J1 (64)
17 BLK 148-61 0.75 mm² FLRYW ECM-J1 (61)

18 2 BLK 148-57 WATER IN FUEL SW RTN 0.75 mm² FLRYW ECM-J1 (57)

19 BLK 248-4 1.5 mm² FLRYW ECM-J2 (4)

3 WHT 48-96 FUEL PUMP 14 AWG GXL RL930-1 (1)
20 BLK 248-5 1.5 mm² FLRYW ECM-J2 (5)
4 BLK 000-48-1 ENG GND 14 AWG GXL T920 (1)
21 WHT 248-54 18 AWG CABLE ECM-J2 (54)

22 BLK 248-24 0.75 mm² FLRYW ECM-J2 (24)

23 BLK 248-43 0.75 mm² FLRYW ECM-J2 (43) X902

24 BLK 248-28 0.75 mm² FLRYW ECM-J2 (28) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
25 BLK 248-26 0.75 mm² FLRYW ECM-J2 (26)
1 YEL 2-1-99 IGNITION 18 AWG GXL MS932 (G)
26 BLK 248-44 0.75 mm² FLRYW ECM-J2 (44)

27 BLK 248-29 0.75 mm² FLRYW ECM-J2 (29)

28 BLK 248-40 0.75 mm² FLRYW ECM-J2 (40) X901

29 BLK 248-27 0.75 mm² FLRYW ECM-J2 (27) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
30
1
31 BLK 248-25 0.75 mm² FLRYW ECM-J2 (25)
2 BLK 148-35-1 START 18 AWG GXL S1001 (2)
32 BLK 248-7 0.75 mm² FLRYW ECM-J2 (7)
3 YEL CAN 1 HI CUSTOMER CAN HIGH 18 AWG J1939 CABLE S951 (2)
33
4 GRN CAN 1 LO CUSTOMER CAN LO 18 AWG J1939 CABLE S952 (2)
34 BLK 148-56 0.75 mm² FLRYW ECM-J1 (56)

BLK 5 RED 47-8 ALT EXCITE 16 AWG GXL EC241-L+ (1)

35 248-16 1.5 mm² FLRYW ECM-J2 (16)

36 6 SHLD CAN 1 SHLD CUSTOMER CAN SHIELD 18 AWG J1939 CABLE ECM-J1 (NC)

37 BLK 248-18 1.5 mm² FLRYW ECM-J2 (18)

38 BLK 248-32 1.5 mm² FLRYW ECM-J2 (32)

39 EC241-L+
40 BLK 248-46 1.5 mm² FLRYW ECM-J2 (46) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
41 BLK 248-3 1.5 mm² FLRYW ECM-J2 (3)
1 RED 47-8 ALT EXCITE 16 AWG GXL X901 (5)
42 BLK 248-48 1.5 mm² FLRYW ECM-J2 (48)

43
44
45 EC18
46 BLK 148-85 0.75 mm² FLRYW ECM-J1 (85) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
47 BLK 248-19 1.5 mm² FLRYW ECM-J2 (19)
1 RED 48-13 GLOW 8 AWG GXL RL931-87 (1)
48 BLK 248-20 1.5 mm² FLRYW ECM-J2 (20)
2 RED 48-14 GLOW 8 AWG GXL RL931-87 (1)
49 BLK 148-72 0.75 mm² FLRYW ECM-J1 (72)

50 BLK 148-44 0.75 mm² FLRYW ECM-J1 (44)

51 BLK 148-82 0.75 mm² FLRYW ECM-J1 (82) SN939

52 BLK 148-38 0.75 mm² FLRYW ECM-J1 (38) CONN WIRE WIRE
GAUGE JACKET TO
POS COLOR LABEL
53
1 BLK 148-29 COOLANT LEVEL PWR 0.75 mm² FLRYW ECM-J1 (29)
54
55 BLK
2 148-87 COOLANT LEVEL GND 0.75 mm² FLRYW ECM-J1 (87)
56
57 3 BLK 148-13 COOLANT LEVEL SIG 0.75 mm² FLRYW ECM-J1 (13)
58 4
59
60

61 BLK 248-2 1.5 mm² FLRYW ECM-J2 (2)

62 BLK 248-33 1.5 mm² FLRYW ECM-J2 (33)

Figure 7-83. Deutz T4F Harness - Sheet 7 of 11

3121671 7-85
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SN939

X999

EIC

S1001

EC18
X901

X941
X902
EC241-L+

1001167108 I

Figure 7-84. Deutz T4F Harness - Sheet 8 of 11

7-86 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

WIRE WIRE LENGTH FROM TO

COLOR JACKET
NO GAUGE (mm) REFERENCE PIN REFERENCE PIN
000-148-246 ECM GND BLK 8 GXL 85 T920 1 S945 1
000-48-1 ENG GND BLK 14 GXL 17 T920 1 X941 4
000-48-2 ENG GND BLK 18 GXL 22 T920 1 X950 B
000-48-3 GND BLK 18 GXL 40 T920 1 X999 2
1-148-135 ECM PWR RED 8 GXL 96 RL930-2 1 S944 1
2-1-99 IGNITION YEL 18 GXL 26 MS932 G X902 1
2-48-1 IGNITION YEL 16 GXL 11 MS932 H S946 1
2-48-2 IGNITION YEL 18 GXL 8 X950 A S946 1
2-48-3 IGNITION YEL 18 GXL 10 RL931-86 1 S946 2
2-48-4 IGNITION YEL 18 GXL 13 RL930 1 S946 2
47-8 ALT EXCITE RED 16 GXL 74 EC241-L+ 1 X901 5
48-14 GLOW RED 8 GXL 65 RL931-87 1 EC18 2
48-96 FUEL PUMP WHT 14 GXL 25 RL930-1 1 X941 3
148-13 COOLANT LEVEL SIG BLK 0.75 FLRYW 165 ECM-J1 13 SN939 3
148-15-68 CLUTCH SWITCH BLK 0.75 FLRYW 1 ECM-J1 15 ECM-J1 68
148-1 ECM PWR RED 2.5 FLRYW 11 S944 2 ECM-J1 1
148-26 FUEL PUMP RELAY CONTROL GND BLK 0.75 FLRYW 109 RL930 2 ECM-J1 26
148-28 START RTN BLK 0.75 FLRYW 149 ECM-J1 28 EIC 2
148-29 COOLANT LEVEL PWR BLK 0.75 FLRYW 166 ECM-J1 29 SN939 1
148-2 ECM GND BLK 2.5 FLRYW 12 S945 2 ECM-J1 2
148-35-1 START BLK 18 GXL 5 X901 2 S1001 2
148-35-2 START BLK 0.75 FLRYW 93 ECM-J1 35 S1001 1
148-35-3 - BLK 18 GXL 33 S1001 1 X999 1
148-38 THROTTLE FLAP 4 BLK 0.75 FLRYW 148 EIC 52 ECM-J1 38
148-3 ECM PWR RED 2.5 FLRYW 11 ECM-J1 3 S944 2
148-44 EHXAUST GAS RECIRCULATION BLK 0.75 FLRYW 149 EIC 50 ECM-J1 44
148-4 ECM GND BLK 2.5 FLRYW 12 ECM-J1 4 S945 2
148-56 AIR INLET TEMP BLK 0.75 FLRYW 148 EIC 34 ECM-J1 56
148-57 WATER IN FUEL SW RTN BLK 0.75 FLRYW 98 X941 2 ECM-J1 57
148-5 ECM PWR RED 2.5 FLRYW 11 S944 2 ECM-J1 5
148-61 FUEL LOW PRESSURE BLK 0.75 FLRYW 149 EIC 17 ECM-J1 61
148-64 WATER IN FUEL SW BLK 0.75 FLRYW 97 X941 1 ECM-J1 64
148-6 ECM GND BLK 2.5 FLRYW 12 S945 2 ECM-J1 6
148-72 THROTTLE FLAP 3 BLK 0.75 FLRYW 148 EIC 49 ECM-J1 72
148-73 START SIG BLK 0.75 FLRYW 147 ECM-J1 73 EIC 3
148-82 EHXAUST GAS RECIRCULATION BLK 0.75 FLRYW 150 EIC 51 ECM-J1 82
148-85 EHXAUST GAS RECIRCULATION BLK 0.75 FLRYW 148 EIC 46 ECM-J1 85
148-87 COOLANT LEVEL GND BLK 0.75 FLRYW 169 ECM-J1 87 SN939 2
148-88 IGNITION BLK 0.75 FLRYW 97 ECM-J1 88 S946 2
248-16 INJECTOR 1 BLK 1.5 FLRYW 147 ECM-J2 16 EIC 35
248-18 INJECTOR 4 BLK 1.5 FLRYW 147 ECM-J2 18 EIC 37
248-19 EHXAUST GAS RECIRCULATION BLK 1.5 FLRYW 146 ECM-J2 19 EIC 47
248-20 EHXAUST GAS RECIRCULATION BLK 1.5 FLRYW 147 ECM-J2 20 EIC 48
248-23-1 GLOW SENSE ORG 18 GXL 19 MS932 F RL931-87 1
248-23 GLOW SENSE BLK 0.75 FLRYW 109 MS932 E ECM-J2 23
248-24 BOOST PRESSURE / TEMP BLK 0.75 FLRYW 148 ECM-J2 24 EIC 22
248-25 RAIL PRESSURE FUEL BLK 0.75 FLRYW 148 ECM-J2 25 EIC 31
248-26 RAIL PRESSURE FUEL BLK 0.75 FLRYW 148 ECM-J2 26 EIC 25

Figure 7-85. Deutz T4F Harness - Sheet 9 of 11

3121671 7-87
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

WIRE WIRE LENGTH FROM TO

COLOR JACKET
NO GAUGE (mm) REFERENCE PIN REFERENCE PIN
248-27 BOOST PRESSURE / TEMP BLK 0.75 FLRYW 148 ECM-J2 27 EIC 29
248-28 COOLING TEMPERATURE BLK 0.75 FLRYW 149 ECM-J2 28 EIC 24
248-29 OIL PRESSURE BLK 0.75 FLRYW 146 ECM-J2 29 EIC 27
248-2 INJECTOR 3 BLK 1.5 FLRYW 147 ECM-J2 2 EIC 61
248-32 INJECTOR 3 BLK 1.5 FLRYW 148 ECM-J2 32 EIC 38
248-33 INJECTOR 1 BLK 1.5 FLRYW 148 ECM-J2 33 EIC 62
248-35 GLOW RELAY CONTROL GND BLK 0.75 FLRYW 106 RL931-85 1 ECM-J2 35
248-37 ENGINE SPEED CAMSHAFT BLK 18 CABLE 148 ECM-J2 37 EIC 14
248-38 ENGINE SPEED CRANKSHAFT SHLD 18 CABLE 146 EIC 1 ECM-J2 38
248-39 ENGINE SPEED CRANKSHAFT BLK 18 CABLE 146 ECM-J2 39 EIC 15
248-3 INJECTOR 2 BLK 1.5 FLRYW 147 ECM-J2 3 EIC 41
248-40 AIR INLET TEMP BLK 0.75 FLRYW 147 ECM-J2 40 EIC 28
248-43 OIL PRESSURE BLK 0.75 FLRYW 146 ECM-J2 43 EIC 23
248-44 OIL PRESSURE BLK 0.75 FLRYW 149 ECM-J2 44 EIC 26
248-46 INJECTOR 2 BLK 1.5 FLRYW 147 ECM-J2 46 EIC 40
248-48 INJECTOR 4 BLK 1.5 FLRYW 147 ECM-J2 48 EIC 42
248-4 MPROP ACTUATOR BLK 1.5 FLRYW 146 ECM-J2 4 EIC 19
248-52 ENGINE SPEED CAMSHAFT WHT 18 CABLE 147 ECM-J2 52 EIC 13
248-53 ENGINE SPEED CAMSHAFT SHLD 18 CABLE 149 ECM-J2 53 EIC 9
248-54 ENGINE SPEED CRANKSHAFT WHT 18 CABLE 147 ECM-J2 54 EIC 21
248-5 MPROP ACTUATOR BLK 1.5 FLRYW 147 ECM-J2 5 EIC 20
248-7 RAIL PRESSURE FUEL BLK 0.75 FLRYW 147 ECM-J2 7 EIC 32
48-13 GLOW RED 8 GXL 67 RL931-87 1 EC18 1
CAN 1 HI CUSTOMER CAN HIGH YEL 18 J1939 CABLE 59 X950 M S951 2
CAN 1 HI CUSTOMER CAN HIGH YEL 18 J1939 CABLE 29 S953 2 S951 1
CAN 1 HI CUSTOMER CAN HIGH YEL 18 J1939 CABLE 55 X901 3 S951 2
CAN 1 HI CUSTOMER CAN HIGH YEL 18 J1939 CABLE 15 ECM-J1 54 S953 1
CAN 1 HI CUSTOMER CAN HIGH YEL 18 J1939 CABLE 6 S953 2 X955 A
CAN 1 LO CUSTOMER CAN LO GRN 18 J1939 CABLE 64 X901 4 S952 2
CAN 1 LO CUSTOMER CAN LOW GRN 18 J1939 CABLE 18 S954 2 S952 1
CAN 1 LO CUSTOMER CAN LO GRN 18 J1939 CABLE 69 X950 F S952 2
CAN 1 LO CUSTOMER CAN LOW GRN 18 J1939 CABLE 16 ECM-J1 76 S954 1
CAN 1 LO CUSTOMER CAN LOW GRN 18 J1939 CABLE 6 S954 2 X955 B
CAN 1 SHLD CUSTOMER CAN SHIELD SHLD 18 J1939 CABLE 99 X901 6 ECM-J1 NC
CAN 2 HI DIAG CAN HIGH YEL 18 J1939 CABLE 12 S964 2 X960 A
CAN 2 HI DIAG CAN HIGH YEL 18 J1939 CABLE 10 X950 H S964 2
CAN 2 HI DIAG CAN HIGH YEL 18 J1939 CABLE 14 ECM-J1 75 S969 1
CAN 2 HI DIAG CAN HIGH YEL 18 J1939 CABLE 79 S964 1 S969 2
CAN 2 HI DIAG CAN HIGH YEL 18 J1939 CABLE 7 S969 2 X965 A
CAN 2 LO DIAG CAN LOW GRN 18 J1939 CABLE 14 S963 2 X960 B
CAN 2 LO DIAG CAN LOW GRN 18 J1939 CABLE 12 X950 G S963 2
CAN 2 LO DIAG CAN LOW GRN 18 J1939 CABLE 13 ECM-J1 53 S968 1
CAN 2 LO DIAG CAN LOW GRN 18 J1939 CABLE 80 S963 1 S968 2
CAN 2 LO DIAG CAN LOW GRN 18 J1939 CABLE 8 S968 2 X965 B

Figure 7-86. Deutz T4F Harness - Sheet 10 of 11

7-88 3121671
3121671
ECM-J2 ECM-J1

RL931-87 RL931-85
RL930 RL931-87 RL931-87
RL931-86 T920
RL-930-1
RL930-2

SN939

S963
S952 S951
S964

X950

S944 S946
S945 X955 X961
X956
S968 X960
E1C
S969 EC241-L+
S953 MS932
S1001
S954 X901
X966 X941
X965 X902

EC18

X999

1001167108 I

Figure 7-87. Deutz T4F Harness - Sheet 11 of 11

7-89
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-88. GM Engine Harness - Sheet 1 of 2

7-90 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-89. GM Engine Harness - Sheet 2 of 2

3121671 7-91
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

RL-503
RL-502 SNSR RELAY 1
SNSR RELAY 2

X506
R501

X505

X7B-8

X7B-11

X500
PLTFM SNSR

1001192292-B
MAF01260

Figure 7-90. Skyguard Harness - Sheet 1 of 2

7-92 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

RL-503 - SNSR RELAY 1 X505

CONN WIRE CONN WIRE
WIRE LABEL WIRE LABEL
POS COLOR GAUGE JACKET TO POS COLOR GAUGE JACKET TO
30 WHT P9 18AWG GXL X505 (1) 1 WHT P2 18AWG GXL R501 (1)
30 WHT P9-1 18AWG GXL RL-502 (30) 1 WHT P9 18AWG GXL RL-503 (30)
85 WHT P5-1 18AWG GXL RL-502 (85)
86 WHT P4-1 18AWG GXL RL-502 (86) X7B-8
87 WHT P1 18AWG GXL X506 (1) CONN WIRE
WIRE LABEL
87a POS COLOR GAUGE JACKET TO
1 WHT P6 18AWG GXL X500 (2)
R501
CONN WIRE
WIRE LABEL X7B-11
POS COLOR GAUGE JACKET TO
1 WHT P2 18AWG GXL X505 (1) CONN WIRE
WIRE LABEL
POS COLOR GAUGE JACKET TO
2 WHT P10 18AWG GXL X500 (1)
1 WHT P3 18AWG GXL RL-502 (87)

RL-502 - SNSR RELAY 2

X500 - PLTFM SNSR
CONN WIRE
WIRE LABEL GAUGE JACKET CONN WIRE
POS COLOR TO WIRE LABEL
POS COLOR GAUGE JACKET TO
30 WHT P9-1 18AWG GXL RL-503 (30)
1 WHT P10 18AWG GXL R501 (2)
85 WHT P5 18AWG GXL X500 (4)
2 WHT P6 18AWG GXL X7B-8 (1)
85 WHT P5-1 18AWG GXL RL-503 (85)
3 WHT P4 18AWG GXL RL-502 (86)
86 WHT P4 18AWG GXL X500 (3)
4 WHT P5 18AWG GXL RL-502 (85)
86 WHT P4-1 18AWG GXL RL-503 (86)
87 WHT P3 18AWG GXL X7B-11 (1)
87a

X506
CONN WIRE
WIRE LABEL
POS COLOR GAUGE JACKET TO
1 WHT P1 18AWG GXL RL-503 (87)

Figure 7-91. Skyguard Harness - Sheet 2 of 2

3121671 7-93
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

T185

SW396

T186

T186 T185

1001232714-A
MAF01270

T186 SW396
CONN WIRE CONN WIRE
WIRE LABEL WIRE LABEL GAUGE JACKET
POS COLOR GAUGE JACKET TO POS COLOR TO
1 WHT 4-105 CRIBBING 18AWG TFFN SW396 (3) 1
2 YEL 4-85 IGN 18 AWG TFFN T185 (1)
3 WHT 4-105 CRIBBING 18 AWG TFFN T186 (1)
T185 4
CONN WIRE 5
WIRE LABEL
POS COLOR GAUGE JACKET TO
6
1 YEL 4-85 IGN 18AWG TFFN SW396 (2)

Figure 7-92. Cribbing Enable Harness

7-94 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-95
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-93. Chassis Head and Tail Lights Harness - Sheet 1 of 3

7-96 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-94. Chassis Head and Tail Lights Harness - Sheet 2 of 3

3121671 7-97
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-95. Chassis Head and Tail Lights Harness - Sheet 3 of 3

7-98 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-99
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-96. Chassis Work Lights Harness- Sheet 1 of 3

7-100 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-97. Chassis Work Lights Harness - Sheet 2 of 3

3121671 7-101
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-98. Chassis Work Lights Harness - Sheet 3 of 3

7-102 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.8 ELECTRICAL SCHEMATICS

SHEET 2: PLATFORM
PLATFORM CONTROL BOX HARNESS WITHOUT SKYGUARD
SHEET 3: PLATFORM AND BOOM COMPONENTS
LSS HARNESS 450/400
BOOM CONTROL CABLE, NO JIB, 460SJ W/ JIB
TELE IN PROX SWITCHES
600/1000# CAPACITY PROX SWITCHES CABLE
SHEET 4: CHASSIS, TURNTABLE
TURNTABLE HARNESS
SHEET 5: GROUND USER INTERFACE
MAIN VALVE HARNESS
GROUND CONTROL PANEL HARNESS
SHEET 6: ENGINE SCHEMATIC DEUTZ - T4i
DEUTZ T4i ENGINE HARNESS
BATTERY CABLE KIT - T4i
SHEET 7: ENGINE SCHEMATIC DEUTZ T4F
DEUTZ T4F ENGINE HARNESS
BATTERY CABLE KIT - T4F
SHEET 8: ENGINE SCHEMATIC GM
GM ENGINE HARNESS
BATTERY CABLE KIT - GM
SHEET 9: SKYGUARD
SHEET 10: PLATFORM CHASSIS HEAD AND TAIL PLATF WORKLIGHTS, CLEAR SKY
PLATFORM WORK LIGHTS
CHASSIS HEAD AND TAIL LIGHTS
CHASSIS WORK LIGHTS
SHEET 11: NOT USED
SHEET 12: NOT USED
SHEET 13: KUBOTA ENGINE KUBOTA
ENGINE HARNESS
ALTERNATOR CABLE
BATTERY CABLE KIT
SHEET 14: PLATFORM
PLATFORM CONTROL BOX HARNESS
WITH SKYGUARD

Figure 7-99. Electrical Schematic - Sheet 1 of 25

3121671 7-103
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

PUMP POT

SOFT TCH/SKY GUARD

H
HORN OVERRIDE

SW21-1

SW21-2
SW09-1

SW09-2

1
1

1
SW120
2
1
3
5
6
4

WHT 1-102 SWITCHES PWR

WHT 1-87 SWITCHES PWR

WHT 1-102 SWITCHES PWR

BLK 000-10-14 GND

WHT 1-105 POT CCW
WHT 1-103 POT CW

WHT 1-4 SOFT TOUCH

WHT 1-80 SWITCHES PWR

WHT 1-104 POT W

WHT 1-101 RSII PORT 2

WHT 1-2 HORN

Sheet_9-[3,G]

WHT 1-1

CO01-J8
2
1
DRIVE ORIENTATION

SW174
6
OVERRIDE SW

CO01-J1
G 5 WHT 1-91 ST SWITCH
20 SOFT TOUCH SWITCH PLATFORM ALARM 19
WHT 1-34 PLAT ALRM
4 WHT 1-88 SG INPUT 2 WHT 000-10-16 PLAT ALARM GND
23 SKYGUARD INPUT #2 SWITCH PLATFORM ALARM GROUND 20
WHT 1-75 SWITCHES PWR WHT 1-4 SOFT TOUCH WHT 1-35 GENERATOR SWITCH
3 29 SOFT TOUCH / SKYGUARD OVERRIDE BUTTON GENERATOR SWITCH 9
WHT 1-80 SWITCHES PWR WHT 1-2 HORN
2 WHT 1-38 GEN ON SWITCH
31 HORN BUTTON GENERATOR SWITCH POWER 5
WHT 1-67 PLTF ORIENT OVERRIDE WHT 1-105 POT CCW WHT 1-39 FOOT SW DISENGAGED
1 34 SPEED PUMP POTENTIOMETER POWER FOOTSWITCH DISENGAGE 8
WHT 1-104 POT W WHT 1-40 FOOT SW
35 SPEED PUMP POTENTIOMETER SIGNAL FOOTSWITCH POWER 4
SKYGUARD GROUND BLK 1-86 SG GND
SW624 26 24
WHT 1-103 POT CW WHT 1-87 SG INPUT1
DUAL CAPACITY

6 13 SPEED PUMP POTENTIOMETER GROUND SKYGUARD INPUT #1 SWITCH 18

BLK 000-10-34 OPTION GND
5 16 GROUND 29
WHT 1-41 PLATF ROTATE LEFT
4 17 PLATFORM ROTATE LEFT VALVE 33
WHT 1-50 DUAL CAPACITY WHT 1-42 PLATF ROTATE RIGHT
3 19 PLATFORM ROTATE RIGHT VALVE 34
WHT 1-75 SWITCHES PWR
2 3 28
1 22 27
4 35
WHT 1-79 SWITCHES PWR JIB UP VALVE WHT 1-36 JIB UP
24 25
WHT 1-101 RSII PORT 2 JIB DOWN VALVE WHT 1-43 JIB DOWN
32 CREEP SWITCH 26
VALVES GROUND BLK 000-10-11 VALVES GND
SW05 25 23
WHT 1-50 DUAL CAPACITY LSS GROUND BLK 000-10-30 LSS GND
6 21 DUAL CAPACITY 16
WHT 1-9 START SWITCH
START/AUX

5 14 ENGINE START SWITCH CAN SHIELD 32

WHT 1-10 AUX POWER CAN HIGH YEL CAN
4 15 AUXILIARY POWER SWITCH 31
WHT 1-9 START SWITCH WHT 1-15 HEAD LIGHTS CAN LOW GRN CAN
30 HEAD / TAIL LIGHT SWITCH 30
F 3
WHT 1-79 SWITCHES PWR WHT 1-3 TELE IN
5 MAIN TELESCOPE IN SWITCH 22
2
WHT 1-10 AUX POWER WHT 1-5 TELE OUT
1 6 MAIN TELESCOPE OUT SWITCH 21
WHT 1-13 JIB UP
11 JIB UP SWITCH 17
WHT 1-77 SWITCHES PWR WHT 1-14 JIB DOWN
12 JIB DOWN SWITCH 15
WHT 1-16 TOWER UP
1 TOWER LIFT UP SWITCH 14
HEAD AND TAIL

WHT 1-17 TOWER DOWN

2 TOWER LIFT DOWN SWITCH 13
WHT 1-77 SWITCHES PWR WHT 1-6 PLTF ROTATE RIGHT WHT 1-37 GROUND MODE
LIGHTS

1 7 PLATFORM ROTATE RIGHT SWITCH GROUND MODE 1

SW155-2 WHT 1-7 PLTF ROTATE LEFT
8 PLATFORM ROTATE LEFT SWITCH 12
WHT 1-15 HEAD LIGHTS WHT 1-68 FUEL SELECT
1 33 FUEL SELECT SWITCH 11
SW155-1 WHT 1-8 LEVEL UP
9 PLATFORM LEVEL UP SWITCH 10
WHT 1-71 SWITCHES PWR WHT LEVEL DOWN WHT 1-90 SG POWER
10 PLATFORM LEVEL DOWN SWITCH SKYGUARD POWER 7
WHT 1-11 MIN SPEED
SW02 28 MAX ENGINE TORQUE SWITCH 6
WHT 1-70 SWITCHES PWR PLATFORM EMS TO GROUND BOARD WHT 1-44 EMS
6 18 SWITCHES POWER 3
WHT 1-12 MAX SPEED WHT 1-45 PLATF EMS
MAIN TELE

5 27 MAX ENGINE SPEED SWITCH PLATFORM EMS 2

4 CO01-J7
WHT 1-3 TELE IN
3
WHT 1-71 SWITCHES PWR WHT 1-46
2 6
WHT 1-5 TELE OUT
1 5
WHT 1-76 SWITCHES PWR PLATFORM MODULE WHT 1-51
8
WHT 1-47
4
SW19 BLK 000-10-17 GND
E 6
7
WHT 1-48
3
5 WHT 1-49
JIB LIFT

1
DRIVE ORIENTATION OVERRIDE SWITCH

VEHICLE SYSTEM DISTRESS INDICATOR

4 WHT 1-52 S31

SOFT TOUCH / SKYGUARD INDICATOR

WHT 1-13 JIB UP 2
3
WHT 1-76 SWITCHES PWR CO01-J6
GLOW PLUG ENGAGED INDICATOR
PLATFORM OVERLOAD INDICATOR

2
WHT 1-14 JIB DOWN
1
FUNCTION ENABLE INDICATOR

WHT 1-78 SWITCHES PWR

GENERATOR ON INDICATOR

1000# CAPACITY INDICATOR

600# CAPACITY INDICATOR

8
CREEP SPEED INDICATOR

FUEL 3/4 FULL INDICATOR

FUEL 1/2 FULL INDICATOR
FUEL 1/4 FULL INDICATOR
CHASSIS TILT INDICATOR

6
FUEL FULL INDICATOR
LOW FUEL INDICATOR

ANALYZER TRANSMIT

SOFT TOUCH POWER

SW86 5
INDICATOR GROUND

INDICATOR GROUND

ANALYZER GROUND
ANALYZER GROUND
ANALYZER RECEIVE
WHT 1-54 S29

ANALYZER POWER
6 1
TOWER LIFT

WHT 1-57
DOS INDICATOR

OPTION POWER

5 4
BLK 000-10-18 GND
4 7
WHT 1-16 TOWER UP WHT 1-58
3 3
WHT 1-78 SWITCHES PWR WHT 1-59
2 2
WHT 1-17 TOWER DOWN S30
1 CO01-J5

WHT 1-72 SWITCHES PWR

SW03
PLATFORM ROTATE

CO01-J2

12
11
15

10
13
14
19
20
30
33
34
18
21

35
25
23
24
22
16
26
28
29
27
32
31

6
6

1
2
3
5
8

7
9

5
D
WHT 1-32 FT SWITCH ENABLE

WHT 1-31 SOFT TCH/SKY GUARD

WHT 1-67 PLTF ORIENT OVERRIDE

4
WHT 1-6 PLTF ROTATE RIGHT
WHT 1-82 TRANSMIT

3
BLK 1_497 FUEL GND

WHT 1-72 SWITCHES PWR

WHT 1_501 FUEL FULL
WHT 1-22 PLATFORM OVERLOAD

WHT 1-81 RECEIVE

WHT 1-23 GENERATOR ON

WHT 1-89 OPTION POWER

WHT 1_500 1/2 FUEL

WHT 1_498 1/4 FUEL
WHT 1_499 3/4 FUEL

2
WHT 1-7 PLTF ROTATE LEFT
WHT 1-66 POWER
WHT 1-25 SYSTEM DISTRESS
WHT 1-29 GLOW PLUG

WHT 1-27 1000# MODE

WHT 1-28 DRIVE ORIENT SW

WHT 1-24 CREEP

WHT 1-92 DRIVE DISABLE

BLK 000-10-27 GND

1
WHT 1-21 500#/600# MODE

WHT 1-30 LOW FUEL

WHT 1-85 ST POWER

WHT 1-20 TILT

WHT 1-74 SWITCHES PWR

WHT 1-33 LSS PWR
BLK 000-10-12 GND

SW173
6
FUEL SELECT

WHT 1-74 SWITCHES PWR

5
4
WHT 1-68 FUEL SELECT
3
WHT 1-73 SWITCHES PWR
2
1
[7,G]

SW04
WHT 1-31 SOFT TCH/SKY GUARD

6
5
LEVEL

4
C 3
WHT 1-8 LEVEL UP WHT 1-82 TRANSMIT
WHT 1-81 RECEIVE

WHT 1-73 SWITCHES PWR BLK 000-10-12 GND

WHT 1-66 POWER

2
WHT LEVEL DOWN
1

WHT 1-80 SWITCHES PWR

SW88 BLK 000-10-501 GND

ENGINE SPEED

6
5
WHT 1-80 SWITCHES PWR
4
LB122+
GD153-J4

GD153-J3

GD153-J2

GD153-J1

LB122-

WHT 1-12 MAX SPEED

3
WHT 1-70 SWITCHES PWR
X175

2
1

1
6
5
4
3
2
1

6
5
4
3
2
1

WHT 1-11 MIN SPEED

1
1
2
3
4
GROUND
N/C
N/C
LOW FUEL
ENABLE
CRIBBING ENABLE

NO CHARGE
ENGINE HIGH TEMPERATURE
SPARE
ENGINE LOW OIL PRESSURE
ENGINE PREHEAT
TILT
500# MODE
PLATFORM OVERLOAD
GENERATOR
CREEP

SYSTEM FAULT
BROKEN CABLE
1000# MODE
DRIVE ORIENTATION
AXLE SET
GLOW PLUG

SOFT TOUCH
FOOT SWITCH ENABLE

ANALYZER PORT
SKYGAURD
WARNING

FAULT CABLE ORIENTATION OIL PRESSURE

TEMPERATURE
LOW FUEL CRIBBING ENABLE SYSTEM BROKEN 1000# MODE DRIVE AXLE SET ENGINE LOW
ENGINE HIGH

Y G Y R G Y G R
Y
PREHEAT OVERLOAD
NO CHARGE GLOW PLUG CREEP ENGINE TILT 500# MODE PLATFORM GENERATOR FOOT SWITCH

G G Y R Y R G R
G

LED LIGHTS

SHEET 2

1 2 3 4 5

Figure 7-100. Electrical Schematic - Sheet 2 of 25

7-104 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

WHT 1-34 PLAT ALRM

AH11+ H

ALARM
1
AH11-
WHT 000-10-16 PLAT ALARM GND
1
BLK 000-10-14 GND

X305A
WHT 1-35 GENERATOR SWITCH
1
WHT 1-38 GEN ON SWITCH
2
WHT 1-1

3
WHT 1-39 FOOT SW DISENGAGED
4
WHT 1-40 FOOT SW
5
CO01-J8

6
7 TO SHEET 3, G1
2
1

8
WHT 1-85 ST POWER X305B
9
WHT 1-34 PLAT ALRM
SOFT TOUCH SWITCH PLATFORM ALARM 19 10
SKYGUARD INPUT #2 SWITCH PLATFORM ALARM GROUND 20
WHT 000-10-16 PLAT ALARM GND
11 G
WHT 1-35 GENERATOR SWITCH WHT 1-91 ST SWITCH
SOFT TOUCH / SKYGUARD OVERRIDE BUTTON GENERATOR SWITCH 9 12
WHT 1-38 GEN ON SWITCH
HORN BUTTON GENERATOR SWITCH POWER 5 13
WHT 1-39 FOOT SW DISENGAGED WHT 1-551
SPEED PUMP POTENTIOMETER POWER FOOTSWITCH DISENGAGE 8 14
WHT 1-40 FOOT SW WHT 1-551
SPEED PUMP POTENTIOMETER SIGNAL FOOTSWITCH POWER 4 15
SKYGUARD GROUND BLK 1-86 SG GND
24 Sheet_9-[3,G]
SKYGUARD INPUT #1 SWITCH WHT 1-87 SG INPUT1
SPEED PUMP POTENTIOMETER GROUND 18 Sheet_9-[1,G]
BLK 000-10-34 OPTION GND
GROUND 29
WHT 1-41 PLATF ROTATE LEFT
PLATFORM ROTATE LEFT VALVE 33 X303A
WHT 1-42 PLATF ROTATE RIGHT WHT 1-89 OPTION POWER
PLATFORM ROTATE RIGHT VALVE 34 [4,C] 7
BLK 000-10-34 OPTION GND
28 6
WHT 1-41 PLATF ROTATE LEFT
27 1
WHT 1-42 PLATF ROTATE RIGHT
35 2
JIB UP VALVE WHT 1-36 JIB UP WHT 1-36 JIB UP
25 3
WHT 1-43 JIB DOWN WHT 1-43 JIB DOWN TO SHEET 3, G5
CREEP SWITCH JIB DOWN VALVE 26 4
VALVES GROUND BLK 000-10-11 VALVES GND BLK 000-10-11 VALVES GND X303B
23 5
LSS GROUND BLK 000-10-30 LSS GND BLK 000-10-30 LSS GND BLK 000-10-30-2 LSS GND
DUAL CAPACITY 16 11
WHT 1-33 LSS PWR S125 WHT 1-33-2 LSS PWR
ENGINE START SWITCH CAN SHIELD 32 12
CAN HIGH YEL CAN S127 YEL CAN
AUXILIARY POWER SWITCH 31 8
CAN LOW GRN CAN GRN CAN
HEAD / TAIL LIGHT SWITCH 30 9
MAIN TELESCOPE IN SWITCH 22 10
MAIN TELESCOPE OUT SWITCH 21
F
JIB UP SWITCH 17 X687
BLU LSS GND
JIB DOWN SWITCH 15 3
WHT LSS PWR
TOWER LIFT UP SWITCH 14 2 TO SHEET 3, F8
TOWER LIFT DOWN SWITCH 13 1
GROUND MODE WHT 1-37 GROUND MODE 2 X 6 BUSS BAR GRY CAN LO LSS X691
PLATFORM ROTATE RIGHT SWITCH 1 5
BLK CAN HI
PLATFORM ROTATE LEFT SWITCH 12 4
FUEL SELECT SWITCH 11
PLATFORM LEVEL UP SWITCH 10

10
11
12
WHT 1-90 SG POWER

1
2
3

4
5
6
7
8
9
MS16
PLATFORM LEVEL DOWN SWITCH SKYGUARD POWER 7 Sheet_9-[1,G]
MAX ENGINE TORQUE SWITCH 6
PLATFORM EMS TO GROUND BOARD WHT 1-44 EMS

GRY CAN LO
SWITCHES POWER 3

BLK CAN HI
PLATFORM EMS WHT 1-45 PLATF EMS
MAX ENGINE SPEED SWITCH 2

YEL CAN
YEL CAN
YEL CAN

GRN CAN
GRN CAN
GRN CAN
CO01-J7
BLK 000-10-14 GND
WHT 1-46 WHT 1-1
ELECTRONIC JOYSTICK
STEER

6 RIGHT
5
PLATFORM MODULE WHT 1-51
DRIVE / STEER

LEFT
8
WHT 1-47
4 X304A
BLK 000-10-17 GND WHT 1-1
7 12
DRIVE

WHT 1-48
3
WHT 1-49 WHT 1-50
16 E
1 1
DRIVE ORIENTATION OVERRIDE SWITCH

VEHICLE SYSTEM DISTRESS INDICATOR

WHT 1-52 S31 GRN CAN

SOFT TOUCH / SKYGUARD INDICATOR

2 2
YEL CAN
CO01-J6 3
GLOW PLUG ENGAGED INDICATOR
PLATFORM OVERLOAD INDICATOR

WHT 1-44 EMS

4
FUNCTION ENABLE INDICATOR

5
GENERATOR ON INDICATOR

1000# CAPACITY INDICATOR

GRN 2-5 FOOT SW

600# CAPACITY INDICATOR

8 Sheet_3-[3,G] 6
CREEP SPEED INDICATOR

FUEL 3/4 FULL INDICATOR

FUEL 1/2 FULL INDICATOR
FUEL 1/4 FULL INDICATOR
CHASSIS TILT INDICATOR

WHT 1-53
6 10 TO SHEET 3, C1
ELECTRONIC JOYSTICK

WHT 1-55
FUEL FULL INDICATOR

WHT 1-37 GROUND MODE

LOW FUEL INDICATOR

ANALYZER TRANSMIT

SOFT TOUCH POWER

SWING

5 11
INDICATOR GROUND

INDICATOR GROUND

ANALYZER GROUND
ANALYZER GROUND
ANALYZER RECEIVE

WHT 1-54 WHT 1-57 X103A BOOM CABLE

LIFT AND SWING

S29
ANALYZER POWER

1 18
WHT 1-57 BLK 000-10+19 GND WHT 1-62 EMS B+
DOS INDICATOR

OPTION POWER

4 9
BLK 000-10-18 GND
7 15
WHT 1-58
3 7
WHT 1-59 BLK 000-10-20 GND
2 13
LIFT

S30 WHT 1-58

CO01-J5 8
WHT 1-56
14
WHT 1-59
17
19
CO01-J2

12
11
15

10
13
14
19
20
30
33
34
18
21

35
25
23
24
22
16
26
28
29
27
32
31
6

1
2
3
5
8

7
9
WHT 1-32 FT SWITCH ENABLE

WHT 1-31 SOFT TCH/SKY GUARD

WHT 1-67 PLTF ORIENT OVERRIDE

D
WHT 1-82 TRANSMIT
BLK 1_497 FUEL GND
WHT 1_501 FUEL FULL
WHT 1-22 PLATFORM OVERLOAD

WHT 1-81 RECEIVE

WHT 1-23 GENERATOR ON

WHT 1-89 OPTION POWER

WHT 1_500 1/2 FUEL

WHT 1_498 1/4 FUEL
WHT 1_499 3/4 FUEL

WHT 1-66 POWER

WHT 1-25 SYSTEM DISTRESS
WHT 1-29 GLOW PLUG

WHT 1-27 1000# MODE

WHT 1-28 DRIVE ORIENT SW

WHT 1-24 CREEP

WHT 1-92 DRIVE DISABLE

BLK 000-10-27 GND

WHT 1-21 500#/600# MODE

WHT 1-30 LOW FUEL

WHT 1-85 ST POWER

WHT 1-20 TILT

WHT 1-33 LSS PWR SW14-1B

SW14-1A
BLK 000-10-12 GND WHT 1-62 EMS B+
1B
1A
E STOP
PLATFORM
2A
WHT 1-45 PLATF EMS
2B
SW14-2A
SW14-2B
[7,G]

WHT 1-31 SOFT TCH/SKY GUARD

WHT 1-82 TRANSMIT

WHT 1-81 RECEIVE

BLK 000-10-12 GND

C
WHT 1-66 POWER

BLK 000-10-501 GND

LB122+
GD153-J4

GD153-J3

GD153-J2

GD153-J1

LB122-

X175
1

1
6
5
4
3
2
1

6
5
4
3
2
1

1
2
3
4
GROUND
N/C
N/C
LOW FUEL
ENABLE
CRIBBING ENABLE

NO CHARGE

SPARE
ENGINE LOW OIL PRESSURE
ENGINE PREHEAT
TILT
500# MODE
PLATFORM OVERLOAD
GENERATOR
CREEP

SYSTEM FAULT
BROKEN CABLE
1000# MODE

ENGINE HIGH TEMPERATURE

DRIVE ORIENTATION
AXLE SET
GLOW PLUG

SOFT TOUCH
FOOT SWITCH ENABLE

ANALYZER PORT
SKYGAURD
WARNING

B
FAULT CABLE ORIENTATION OIL PRESSURE
LOW FUEL CRIBBING ENABLE SYSTEM BROKEN 1000# MODE DRIVE AXLE SET ENGINE LOW

Y G Y R G Y G R

PREHEAT OVERLOAD
GLOW PLUG CREEP ENGINE TILT 500# MODE PLATFORM GENERATOR FOOT SWITCH

G G Y R Y R G R

LED LIGHTS

1001165354-N
SHEET 2 MAF01360

4 5 6 7 8

Figure 7-101. Electrical Schematic - Sheet 3 of 25

3121671 7-105
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

OPTION OPTION OPTION

FOOT SWITCH
SOFT SOFT
GENERATOR SWITCH
TOUCH TOUCH

1
2
3
SW35

SN540

SN541
1
2
3
4

1
2
3
4
BLK 2-3 FOOT SW DISENGAGED 16AWG
1
2
3
4
5
6
SW34

WHT 2-4 FOOT SW 16AWG

GRN 2-5 FOOT SW 16AWG

WHT
BLK SW
WHT PWR

BLK SW
WHT 2-1 GEN ON
1
WHT 2-2 GEN SW PWR TO SHEET 2 F8
2 1
MS16 PIN 12 T536
3 Sheet_2-[7,E]
BLK 2-3 FOOT SW DISENGAGED 16AWG
4
WHT 2-4 FOOT SW 16AWG TO SHEET 2 F8
TO SHEET 2 5 1
MS16 PIN 9 T537
6
X305A
7
G 8
WHT PWR T534
9 7 1
10 6 1
11 1
BLK SW
12 2
13 TO SHEET 2 3
BLK SW
14 11
15 X303A 12
X305B 4
8
5
9
10
X303B

X524
BLK 000-3-14 GND 22AWG BLK 000-3-14 GND 22AWG
3 3
RED 3-13 PWR 22AWG RED 3-13 PWR 22AWG LSS MODULE
2 2
TO SHEET 2, F8 4
YEL 3-21 CAN HI YEL 3-21 CAN HI
4 SINGLE CELL
GRN 3-22 CAN LO GRN 3-22 CAN LO
5 5
X687 SHIELD SHIELD OPTION
1 1
X691

1
GRN
2
YEL
3
ORN
4
BLU
5
YEL
6
BRN
7
8
RED/BLK
TO SHEET 2 9
ORN 10 AWG
10
X304A BOOM CABLE BLU/BLK
11
RED 12 AWG
12
ORN/BLK
13
14
YEL/BLK
15
BLK 12 AWG
16
17
BLK/WHT 12 AWG
18
C 19
X103A
CAPACITY LENGTH CAPACITY LENGTH TELE
RIGHT PROX 1 LEFT PROX 2 LEFT PROX 1

+ - + - + -
SN467

SN465
SN571
1
2
3

1
2
3
1
2
3
ORN/BLK CABLE
BLU/RED CABLE
BLK/RED CABLE

BRN/BLK CABLE
BLU/BLK CABLE
YEL/BLK CABLE

ORN/BLK
BLU/RED
BLK/RED

B
ORN/BLK CABLE
BLU/RED CABLE
BLK/RED CABLE

BRN/BLK CABLE
BLU/BLK CABLE
YEL/BLK CABLE

ORN/BLK
BLU/RED
BLK/RED
X615B

1
3
2
1
3
2
4
6
5
7
8

DUAL CAPACITY LENGTH

A PROXIMITY SENSOR
SHEET #4
ZONE D8
X615A

1 2 3 4 5

Figure 7-102. Electrical Schematic - Sheet 4 of 25

7-106 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

OPTION
OPTION OPTION
FOOT SWITCH
SOFT SOFT LOW TEMP
TOUCH TOUCH CUTOUT SENSOR

CAN LO
CAN HI
PWR
GND
1
2
3
SW35

SN540

SN541
1
2
3
4

1
2
3
4

1
2
4
3
BLK 2-3 FOOT SW DISENGAGED 16AWG

SN533
WHT 2-4 FOOT SW 16AWG
GRN 2-5 FOOT SW 16AWG

WHT
BLK SW

YEL 80-5
GRN 81-5
WHT PWR

BLK SW

WHT 3-26
WHT 1-43
TO SHEET 2 F8
1
MS16 PIN 12 T536
Sheet_2-[7,E]

TO SHEET 2 F8
1
MS16 PIN 9 T537 G
T534
7 1
T535
6 1
1
2
TO SHEET 2 3
11
X303A 12
4
8
5
9
10
X303B

X651
1
2
YEL CAN HI LSS 3
4
5
6
OPTION
7
8
GRN CAN LO LSS
9
10
4 CELL LSS
11
X524 YEL CAN HI LSS 12
BLK 000-3-14 GND 22AWG TO F5 X303B PIN 8 1 SHLD LSS GND
3 NC
RED 3-13 PWR 22AWG
2 LSS MODULE T391
GRN CAN LO LSS
YEL 3-21 CAN HI SINGLE CELL TO F5 X303B PIN 9 1
4
GRN 3-22 CAN LO T392
5
TO F5 X303B PIN 10
SHLD LSS GND YEL/RED LSS PWR X652
SHIELD
1 OPTION 1 1
T393 BLK LSS GND
TO F5 X303B PIN 12 1
YEL/RED LSS PWR 2
E
3
T395
BLK LSS GND 4
TO F5 X303B PIN 11 1 5
T394
6
7
8
9
10
11
12

X102B
1
GRN
2
YEL
3
ORN
4
BLU
5
YEL
6
BRN
7
8
RED/BLK
9 TO SHEET 4
ORN 10 AWG
10
BLU/BLK X102A BOOM CABLE
11
RED 12 AWG
12
ORN/BLK
13
14
YEL/BLK
15
BLK 12 AWG
16
17
BLK/WHT 12 AWG
18
C
19

CAPACITY LENGTH CAPACITY LENGTH TELE TELE

RIGHT PROX 1 LEFT PROX 2 LEFT PROX 1 RIGHT PROX 2

+ - + - + - + -
SN467

SN465
SN571

SN625
1
2
3

1
2
3

1
2
3
1
2
3
ORN/BLK CABLE
BLU/RED CABLE
BLK/RED CABLE

BRN/BLK CABLE
BLU/BLK CABLE
YEL/BLK CABLE

ORN/BLK
BLU/RED
BLK/RED

BRN/BLK
BLU/BLK
YEL/BLK

B
ORN/BLK CABLE
BLU/RED CABLE
BLK/RED CABLE

BRN/BLK CABLE
BLU/BLK CABLE
YEL/BLK CABLE

ORN/BLK
BLU/RED
BLK/RED

BRN/BLK
BLU/BLK
YEL/BLK

X616B
X615B

1
3
2
4
6
5
1
3
2
4
6
5
7
8

DUAL CAPACITY LENGTH

A
TELESCOPE RETRACTED
PROXIMITY SENSOR PROXIMITY SENSOR
SHEET #4 SHEET #4
ZONE D8 ZONE E8
X615A X616A
1001165354-N
SHEET 3 MAF01370

4 5 6 7 8

Figure 7-103. Electrical Schematic - Sheet 5 of 25

3121671 7-107
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

F1 F2 F3 F4 F5 F6 F7

15A
15A

5A
5A
5A

5A
ENGINE PIVOT POINT

1
X281
WHT 4-1 BRAKE

28
37
33
38
34
39
35
40
36
45
41
46
42
32
BRAKE

1
S98

[4,B]
BLK 000-40-1 GND
2

[5,B]
BLK 000-40-81 16AWG
HV97

RED 4-552 16AWG

RED 4-51 12AWG

RED 4-169 MODE SEL 12AWG

RED 4-71 12AWG

WHT 4-66 IGN

YEL 4-36 MODL PWR 12AWG

YEL 4-82 GEN IGN

YEL 4-81 GEN IGN
RED 4-550 12AWG

YEL 4-72 IGN

RED 4-169-1 MODE SOL

RED 4-350 12AWG
RED 4-35 IGN 12AWG

RED 4-65 PWR

2 SPEED

H HV96

RED 4-50
BLK 000-40-2 GND

BLK 000-40-64 BATT GND 16AWG

DRIVE FORWARD

BLK 000-40-8 MODL GND 10AWG

WHT 4-2 TWO SPEED
1

BLK 000-40-40 CF 16AWG

1
WHT 4-3 DRIVE FORWARD 16AWG
2

[4,B]
HV95 S171
BLK 000-40-43 CF 16AWG
Sheet_5-[4,C]
DRIVE REVERSE

HV94
BLK 000-40-41 CF 16AWG
2
WHT 4-4 DRIVE REVERSE 16AWG
1 BLK 000-40-12 PLATF GND 12AWG

[5,B]
[5,B]

[2,F]
[5,B]
[5,B]
CO69-J8
OSC AXLE #2

1
2
3
4
WHT 4-120 OSC AXL V 2
VALVE 2

1
CO69-J1
2
19

GROUND TO PLATFORM MODULE

MODULE POWER
MODULE GROUND

POWER TO PLATFORM MODULE

HV293 BLK 000-40-3 GND
S300
5 BRAKE/2 SPEED VALVE GROUND
WHT 4-1 BRAKE
23 BRAKE VALVE
WHT 4-2 TWO SPEED
OSC AXLE #1

20 2 SPEED VALVE
G
VALVE 1

HV292 WHT 4-3 DRIVE FORWARD 16AWG

3 DRIVE FORWARD VALVE
2 WHT 4-4 DRIVE REVERSE 16AWG
WHT 4-121 OSC AXL V 1 6 DRIVE REVERSE VALVE
1 WHT 11-1 FUEL SELECT
1
WHT 4-120 OSC AXL V 2
2 OSCILLLATING AXLE VALVE #2
4
WHT 4-121 OSC AXL V 1
7 OSCILLLATING AXLE VALVE #1
BLK 000-40-162 GND
1 8
MSSO

SW531-2 BLK 000-40-162 GND

9 MSSO GROUND
WHT 4-163 MSSO
1 [6,E] 16
SW531-1 WHT 4-78 AUX PUMP 16AWG
AUX PUMP RELAY 1 13 APU ENABLE RELAY
X450 14
X181A 15
WHT 4-94 EMR4 IGNITION WHT 4-94 EMR4 IGNITION
1 10 ECU POWER
BLK 000-40-557 GND WHT 4-80 GLOW PLUG 16AWG
2 12 ENGINE GLOW PLUG RELAY
3 17
WHT 4-80 GLOW PLUG 16AWG
4 18
5 21
WHT 4-5 POWER
6 1 28 ANALYZER POWER
ANALYZER

WHT 4-6 RECEIVE

7 2 29 ANALYZER RS-232 RX
WHT 11-1 FUEL SELECT WHT 4-7 TRANSMIT
8 3 30 ANALYZER RS-232 TX
BLK 000-40-4 GND
F 4 31 ANALYZER GROUND
X126 24
3
BLK 000-40-161 GEN GND
25
UNIVERSAL GROUND MODULE
GENERATOR WHT 4-74 GEN ON WHT 4-74 GEN ON
2 22 GENERATOR ENABLE RELAY
CONNECTOR YEL 4-82 GEN IGN
1 [5,G] 26
X530 27
WHT 4-67 START 16AWG
11 ENGINE START RELAY
RED 4-76 ALT EXCITE 16AWG
32 ALTERNATOR EXCITATION
BLK 102 CNFG1 GND
Sheet_5-[4,C] 33 GROUND
WHT 4-117 PROX 2
[7,E] 34 TELESCOPE RETRACTED SWITCH #2
WHT 4-167 CAP PROX 2
[7,D] 35 CAPACITY LENGTH SWITCH #2

CO69-J2
10
21
14
28
30
5
7
12
E 23
13
20
9
3
15
4
16
8
TO SHEET 5 19
31
CO69-J2 11
22
35
34
1
2
17
33
24
18
D 26
32
25
6
29
27
CO69-J3

CO69-J4
10

11
12
13

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
1
5
6

4
7
3
9
2
8

1
2
3
4
5
6
7
8
9

TO SHEET 5 TO SHEET 5

CO69-J3 CO69-J4
C
[5,H]

Sheet_9-[1,E]

[5,G]
[5,H]

[5,G]

[5,G]
[5,H]
BLK 000-40-64 BATT GND 16AWG

S18
BLK 000-40-14 STRB GND

RED 4-65 PWR

YEL 4-54 STRB LIGHT

B
BLK 000-40-47 OSC VLVs GND
RED 4-76 ALT EXCITE 16AWG

BLK 000-40-161 GEN GND

BLK 000-40-14 STRB GND
BLK 000-40-11 NEGATIVE

BLK 000-40-81 16AWG

BLK 000-40-11 NEGATIVE

YEL 4-36 MODL PWR 12AWG
WHT 4-67 START 16AWG

BLK 000-40-557 GND

BLK 00-40-558 GND

YEL 4-54 STRB LIGHT

GRN CAN2 LO

YEL 4-81 GEN IGN

GRN CAN2 LO

WHT 4-66 IGN

YEL CAN2 HI

YEL CAN2 HI
[5,G]
YEL 4-84 IGN

YEL 4-84 IGN

YEL 4-85 IGN

YEL 4-72 IGN

RED 4-65 PWR

LB280
2
1
X183A

MS647

X429
1
2
3
4
5
6

MS650
1
2
3
4
5
6
7
8
9
10
11
12

J
B
G
F
E
D
C
H
A
1
2
3
4
5
6
7
8
9
10
11
12

ENGINE CONNECTORS
DIAGNOSTIC
CONNECTOR

NEGATIVE BUS
4460836 STROBE
IGN POWER
LIGHT
A 4460836

SHEET 4

1 2 3 4 5

Figure 7-104. Electrical Schematic - Sheet 6 of 25

7-108 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8
FUSE BOX
TO B+ AUX
R4
F1 F2 F3 F4 F5 F6 F7 F8 F9 D1 D2 D3
R3 R2
R1 MTB SELECT SWITCH PUMP RELAY
MTB EMS

3A
15A
15A

1
5A
5A

X282

RED 4-49 B+ AUX PMP 10AWG

ENGINE PIVOT POINT
85 85 30

1
86 87 30 87a 85 86 87 30 87a 86 87 87a 85 86 87 30 87a

X281

28
37
33
38
34
39
35
40
36
45
41
46
42
47
43
48
44
29
25
30
26
31
27
19
24
15
16
23
20
17
22
13
14
21
18

10
32

3
4

8
5

1
2
9
6
[4,B]

[5,B]
BLK 000-40-81 16AWG

WHT 4-170
RED 4-552 16AWG
RED 4-51 12AWG

RED 4-37 SW118-1A 12AWG

RED 4-39
RED 4-169 MODE SEL 12AWG

RED 4-563 LIGHT OPT

WHT 4-41
WHT 4-38
RED 4-71 12AWG

BLK 000-40-13 GND

WHT 4-66 IGN

RED 4-169 MODE SEL 12AWG

YEL 4-82 GEN IGN
YEL 4-36 MODL PWR 12AWG

YEL 4-81 GEN IGN

RED 4-550 12AWG

YEL 4-72 IGN

RED 4-166 12AWG

RED 4-169-1 MODE SOL
RED 4-350 12AWG

SW118-1B
SW118-1A

SW118-2A
SW118-2B
RED 4-40 12AWG
RED 4-35 IGN 12AWG

RED 4-65 PWR

1B
1A

2A
2B
SW104-B

SW104-B1
SW104-1

SW104-3
H

SW104-2

SW104-4
RED 4-50
BLK 000-40-64 BATT GND 16AWG

1
BLK 000-40-8 MODL GND 10AWG

RED 4-175 SW118-2A 10AWG

RED 4-47 SW-118-2B 10AWG
RED 4-37 SW118-1A 12AWG
RED 4-46 12AWG
RED 4-46 12AWG

30A
WHT 4-51 PLTFM ENABLE
RED 4-40 12AWG
S509

IP136
RED 4-51 12AWG

RED 4-50
[4,B]
S621

S123
RED 4-563 LIGHT OPT

BLK 000-40-12 PLATF GND 12AWG

[5,B]
[5,B]

[2,F]
[5,B]
[5,B]
CO69-J8
1
2
3
4

BLK 000-40-12 PLATF GND 12AWG X102A

26 16
GROUND TO PLATFORM MODULE
MODULE POWER
MODULE GROUND

POWER TO PLATFORM MODULE

RED 4-71 12AWG

BRAKE/2 SPEED VALVE GROUND 12 12
BRAKE VALVE 31 5
RED 4-169-1 MODE SOL RED 4-552 16AWG
2 SPEED VALVE GROUND MODE 3 9
DRIVE FORWARD VALVE 27 7
G

X102B BOOM CABLE

DRIVE REVERSE VALVE 11 8
BLK 000-40-13 GND
IGNITION RELAY GROUND 19 13
BLK 000-40-76 GND
OSCILLLATING AXLE VALVE #2 BOOM ANGLE SENSOR GROUND 9 10

TO SHEET 3
WHT 4-133 CAN1 TERM
CAN1 TERMINATOR 17 14
WHT 4-42 PLTF EMS
OSCILLLATING AXLE VALVE #1 PLATFORM EMS 1 17
WHT 4-52 FOOT SW S121
FOOTSWITCH 15 18
WHT 4-53 GROUND MODE WHT 4-43 PLTF EMS
MSSO GROUND GROUND MODE POWER TO PLATFORM 14 4
WHT 4-52 FOOT SW
20 6
WHT 4-123 GND WHT 4-53 GROUND MODE
APU ENABLE RELAY TILT SENSOR GROUND 10 11
WHT 4-110 PROX 1
TELESCOPE RETRACTED SWITCH #1 21 19

IP103
5 15
YEL CAN 1 HI

5A
ECU POWER 30 3
GRN CAN 1 LO
ENGINE GLOW PLUG RELAY 8 2
CAN1 TERMINATOR 6 1
WHT 4-132 PLAT MODE
PLATFORM MODE 2
YEL CAN 1 HI
CAN1 HIGH 13 MS131
GRN CAN 1 LO YEL CAN 1 HI
ANALYZER POWER CAN1 LOW 24 1
ANALYZER RS-232 RX 18 2
WHT 4-118 PWR 5V YEL CAN 1 HI 20AWG
ANALYZER RS-232 TX BOOM ANGLE SENSOR POWER 16 11
WHT 4-108 VCC YEL CAN 1 HI

3 x 4 Buss Bar
ANALYZER GROUND TILT SENSOR POWER 34
GRN CAN 1 LO
12 F
22 3

CAN 1
UNIVERSAL GROUND MODULE BOOM ANGLE SENSOR #1 4
WHT 4-86 BM ANGLE SEN 1 GRN CAN 1 LO
4
WHT 4-87 BM ANGLE SEN 2
GENERATOR ENABLE RELAY BOOM ANGLE SENSOR #2 7 9
WHT 4-119 PWR 12V GRN CAN 1 LO 20AWG
TELESCOPE RETRACTED SWITCH POWER 33 10
BLK 000-40-75 GND
TELESCOPE RETRACTED SWITCH GROUND 28 5
WHT 4-115 CAPACITY 1
ENGINE START RELAY CAPACITY LENGTH SWITCH #1 23 SN476 6
WHT 4-116 POWER 12V
ALTERNATOR EXCITATION TRANSPORT SWITCHES POWER 32 7

TILT SENSOR
WHT 4-108 VCC

CAN BASED
WHT 4-92 DOS SW
GROUND DOS SWITCH 35 1 8
BLK 000-40-51 GND WHT 4-123 GND GND
TELESCOPE RETRACTED SWITCH #2 GROUND DISPLAY GROUND 25 2
RED 4-97 PWR YEL CAN 1 HI 20AWG B+
CAPACITY LENGTH SWITCH #2 GROUND DISPLAY POWER 29 3
GRN CAN 1 LO 20AWG CAN-L
CO69-J7 4
CAN-H
WHT 4-163 MSSO
MSSO SWITCH 8 [2,G]
WHT 4-96 CAN2 TERM X10
CAN2 TERMINATOR 7 RED 4-65 PWR
1
CAN2 TERMINATOR 6 BLK 00-40-558 GND
2 UNIVERSAL
CAN2 SHIELD 5
GRN CAN2 LO
RED 4-97 IGN
3 TELEMATICS
CAN2 LOW 4 WHT 4-51-1 PLTFM ENABLE
YEL CAN2 HI 4
CAN2 HIGH 3
2
1 X616A
CO69-J12
WHT 4-111 PWR 12V
1
TELESCOPE RETRACTED
E
BLK 000-40-77 GND
2 PROXIMITY SENSOR
WHT 4-110 PROX 1
3 SHEET #3
WHT 4-113 PWR 12V
4 ZONE C5/6
BLK 000-40-80 GND
5 X616B
S468 WHT 4-117 PROX 2
[3,F] 6

S469

SN471
BLK 000-40-78 GND

ANGLE SENSOR
A
WHT 4-106 PWR 5V

MAIN BOOM
S295
B
S294 WHT 4-86 BM ANGLE SEN 1
C
BLK 000-40-79 GND
E
WHT 4-112 PWR 5V
F
WHT 4-87 BM ANGLE SEN 2
D

X615A
D
WHT 4-168 PWR 12V
1 DUAL CAPACITY LENGTH
BLK 000-40-167 GND
2 PROXIMITY SENSOR
WHT 4-115 CAPACITY 1
3 SHEET #3
WHT 4-114 PWR 12V ZONE C5
4
BLK 000-40-98 GND X615B
5
WHT 4-167 CAP PROX 2
[3,F] 6
7
8

OSC AXLE #2
X479 X478 1
WHT 4-116 POWER 12V

DOS
1 1 2
WHT 4-92 DOS SW
2 2 3
CO69-J3

CO69-J4

4
10

11
12
13

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

RED 4-97 IGN

1
5
6

4
7
3
9
2
8

1
2
3
4
5
6
7
8
9

CABLE
SN289

TO SHEET 5 TO SHEET 5 RED 4-97 PWR S15

CO69-J3 CO69-J4
C

TO ENGINE
PIVOT GND STUD
BLK 000-40-51 GND
RED 4-97 PWR

YEL CAN2 HI
[5,H]

GRN CAN2 LO
GD414
Sheet_9-[1,E]

NC
6
5
4
3
2
1
[5,G]
[5,H]

[5,G]

[5,G]
[5,H]
BLK 000-40-64 BATT GND 16AWG

S18
BLK 000-40-14 STRB GND

RED 4-65 PWR

YEL 4-54 STRB LIGHT

B
BLK 000-40-47 OSC VLVs GND

BLK 000-40-161 GEN GND

BLK 000-40-14 STRB GND
BLK 000-40-11 NEGATIVE

BLK 000-40-81 16AWG

BLK 000-40-11 NEGATIVE

YEL 4-36 MODL PWR 12AWG
BLK 000-40-557 GND

GRN CAN2 LO

GRN CAN2 LO
YEL CAN2 HI

GRN CAN2 LO
GRN CAN2 LO
YEL CAN2 HI
BLK 00-40-558 GND

YEL CAN2 HI
YEL CAN2 HI
YEL 4-54 STRB LIGHT

YEL 4-81 GEN IGN

GRN CAN2 LO

WHT 4-66 IGN

YEL CAN2 HI
[5,G]
YEL 4-84 IGN

YEL 4-85 IGN

YEL 4-72 IGN

MDI/HOURMETER
RED 4-65 PWR
LB280

MS325
2
1

8
7
6
5
10
9
4
3
12
11
2
1
MS647

X429
MS650
1
2
3
4
5
6
7
8
9
10
11
12

J
B
G
F
E
D
C
H
A
1
2
3
4
5
6
7
8
9
10
11
12

DIAGNOSTIC
CONNECTOR 3 x 4 Buss Bar
NEGATIVE BUS CAN 2
4460836 STROBE
IGN POWER
LIGHT
4460836 A

1001165354-N
SHEET 4 MAF01380
5 6 7 8

Figure 7-105. Electrical Schematic - Sheet 7 of 25

3121671 7-109
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

MAIN VALVE
HARENSS
PLTF ROT L

HV383
BLK 000-40-19 TO SHEET 4
2
WHT 4-9 ROTATE LEFT
1
CO69-J2
PLTF ROT R

HV382 CO69-J2
BLK 000-40-20 WHT 4-9 ROTATE LEFT TO SHEET 4
2 10 PLATFORM ROTATE LEFT VALVE
WHT 4-10 ROTATE RIGHT WHT 4-10 ROTATE RIGHT
1 21 PLATFORM ROTATE RIGHT VALVE
BLK 000-40-5 GND CO69-J4
G WHT 4-12 JIB UP
17 PLATFORM ROTATE / JIB LIFT VALVES GROUN
S384 12 JIB UP VALVE
WHT 4-13 JIB DOWN
HV364 23 JIB DOWN VALVE
JIB UP

BLK 000-40-23 BLK 000-40-25 GND MAIN TELESCOPE OUT SWITCH 30

2 30 MAIN DUMP VALVE GROUND
WHT 4-12 JIB UP WHT 4-14 MAIN DUMP SWITCHES POWER 25
1 13 MAIN DUMP VALVE
MAIN TELESCOPE IN SWITCH 7
20
PLATFORM ROTATE RIGHT SWITCH 18
2 PLATFORM ROTATE LEFT SWITCH 6
JIB DOWN

HV365 24
BLK 000-40-24 WHT 4-19 MAIN TELE IN PLATFORM LEVEL UP SWITCH 17
2 4 MAIN TELESCOPE IN VALVE
WHT 4-13 JIB DOWN BLK 000-40-7 GND 18 AWG PLATFORM LEVEL DOWN SWITCH 5
1 14 MAIN TELESCOPE / PLATFORM LEVEL VALVES GROUND
WHT 4-20 MAIN TELE OUT ENGINE START SWITCH 4
16 MAIN TELESCOPE OUT VALVE
WHT 4-8 LEVEL UP AUXILIARY POWER/FUNCTION ENABLE SWITCH 16
MAIN DUMP

5 PLATFORM LEVEL UP VALVE

WHT 4-11 LEVEL DOWN JIB UP SWITCH 19
HV366 7
BLK 000-40-25 GND PLATFORM LEVEL DOWN VALVE 8
2 BLK 000-40-53 GND JIB DOWN SWITCH
WHT 4-14 MAIN DUMP 28 STEER VALVES GROUND
MAIN LIFT UP SWITCH 23
1 3
MAIN LIFT DOWN SWITCH 33
15
35
MAIN TELE IN

WHT 4-21 STEER RIGHT SWING RIGHT SWITCH

8 FRONT STEER RIGHT VALVE
HV371 WHT 4-22 STEER LEFT SWING LEFT SWITCH 34
BLK 000-40-31 19 FRONT STEER LEFT VALVE
2 WHT 4-23 FLOW CONTROL 10
WHT 4-19 MAIN TELE IN 31FLOW CONTROL GROUND
1 WHT 4-24 MAIN LIFT UP 21
11 MAIN LIFT UP VALVE
WHT 4-104 MAIN LIFT DOWN 11
22 MAIN LIFT DOWN VALVE
MAIN TELE OUT

S386 22
F WHT 4-26 SWING RIGHT
WHT 4-27 SWING LEFT
35 SWING RIGHT VALVE
12
HV372 34 SWING LEFT VALVE
BLK 000-40-21 INDICATORS GROUND 32
2 1
WHT 4-20 MAIN TELE OUT WHT 4-103 MAIN LIFT DOWN AUX LOW FUEL INDICATOR 13
1 9 AUX POWER MAIN LIFT DOWN VALVE
GLOWPLUG INDICATOR 3
MAIN VALVE BANK

33
INDICATORS GROUND 31
PLTF LVL UP

18
CRIBBING ENABLED INDICATOR 1
HV381 26 HEAD/TAIL LIGHT ENABLE RELAY
BLK 000-40-22 PLATFORM OVERLOADED INDICATOR 14
2 32
WHT 4-8 LEVEL UP WHT 4-75 FUEL SENSOR BATTERY LOW/NOT CHARGING INDICATOR 26
1 25 FUEL SENSOR SIGNAL
BLK 000-40-45 ENGINE LOW OIL PRESSURE INDICATOR 29
6 FUEL SENSOR GROUND
PLTF LVL DOWN

ENGINE HIGH COOLANT TEMPERATURE INDICATOR 28

29GROUND ALARM GROUND SYSTEM DISTRESS INDICATOR 2
HV380 27GROUND ALARM
BLK 000-40-30 27
2
WHT 4-11 LEVEL DOWN 9
1
20
15
MAIN LIFT DOWN

24
HV377 XCO69-J4
BLK 000-40-63 CF
2
WHT 4-104 MAIN LIFT DOWN
1
MAIN LIFT DOWN

E TO SHEET 4
HV439
C069-J3
AUX

BLK 000-40-49 AUX TWR LIFT DOWN

2 CO69-J3
WHT 4-103 MAIN LIFT DOWN AUX
1 BLK 000-40-49 AUX TWR LIFT DOWN
2 AUXILIARY DOWN CURRENT FEEDBACK
MAIN LIFT UP

5
BLK 000-40-33 CF
6 FLOW CONTROL VALVE CURRENT FEEDBACK
HV376 BLK 000-40-35 CF
BLK 000-40-34 CF S388 14 MAIN LIFT VALVES CURRENT FEEDBACK
2 BLK 000-40-38 CF
WHT 4-24 MAIN LIFT UP 4 SWING VALVES CURRENT FEEDBACK
1
3
WHT 4-30 ALRM
7GROUND ALARM POWER
STEER RIGHT

BLK 000-40-44 CF
1
HV373 S415
BLK 000-40-32 GND 8
2 WHT 4-105 CRIBBING
WHT 4-21 STEER RIGHT 9 CRIBBING ENABLE SWITCH
1 WHT 5-101 JUMP ENABLE
10 JUMP ENABLE
BLK 102 CNFG1 GND
11 GROUND
STEER LEFT

12
HV374
WHT 4-102 HEAD & TAIL LIGHTS

BLK 000-40-32 GND 13

2
WHT 4-22 STEER LEFT
1
WHT 5-101 JUMP ENABLE
FLOW CONTROL

D
BLK 102 CNFG1 GND
WHT 4-105 CRIBBING

HV375
BLK 000-40-44 CF

BLK 000-40-33 CF
2
WHT 4-23 FLOW CONTROL
1
SWING RIGHT

HV378 S389
BLK 000-40-37 CF
2
WHT 4-26 SWING RIGHT
1
X513A
SWING LEFT

HV379
BLK 000-40-39 CF
1
2
3
4
5
6

2
WHT 4-27 SWING LEFT
1
2
3
4
5
6
X513B

1
BLK 000-40-43 CF 16 AWG

WHT 4-105 CRIBBING

BLK 102 CNFG1 GND

BLK 000-40-10 ALRM GND

C
WHT 4-29 ALRM
WHT 4-30 ALRM
SN472 X473

X474

Sheet_4-[1,H]

Sheet_9-[1,D]

Sheet_4-[3,F]
1
1

AH387
2
1

C
B
A

ALARM

FUEL
B SENSOR

SHEET 5

1 2 3 4 5

Figure 7-106. Electrical Schematic - Sheet 8 of 25

7-110 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

H
GROUND CONTROL
PANEL HARNESS
MAIN TELE ROTATE LEVEL IGNITION START JIB MAIN LIFT SWING
AUX POWER

TO SHEET 4

SW141

SW140

SW142

SW143

SW144

SW145

SW146
1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6
CO69-J2
CO69-J2
TO SHEET 4

WHT 5-27

WHT 5-28

WHT 5-29

WHT 5-31

WHT 5-32
10 PLATFORM ROTATE LEFT VALVE

WHT 5-30
WHT 5-28

WHT 5-29

WHT 5-30

WHT 5-31
WHT 5-27

WHT 5-32
21 PLATFORM ROTATE RIGHT VALVE
CO69-J4
17 PLATFORM ROTATE / JIB LIFT VALVES GROUN
G
12 JIB UP VALVE
23 JIB DOWN VALVE WHT 5-2 TELE OUT
MAIN TELESCOPE OUT SWITCH 30
30 MAIN DUMP VALVE GROUND WHT 5-26 SWITCH POWER
SWITCHES POWER 25
13 MAIN DUMP VALVE WHT 5-1 TELE IN
MAIN TELESCOPE IN SWITCH 7
20 WHT 5-3 ROTATE RIGHT
PLATFORM ROTATE RIGHT SWITCH 18
2 PLATFORM ROTATE LEFT SWITCH 6 WHT 5-4 ROTATE LEFT
24 WHT 5-5 LEVEL UP
PLATFORM LEVEL UP SWITCH 17
4 MAIN TELESCOPE IN VALVE WHT 5-6 LEVEL DOWN
PLATFORM LEVEL DOWN SWITCH 5
14 MAIN TELESCOPE / PLATFORM LEVEL VALVES GROUND WHT 5-9 IGNITION START
ENGINE START SWITCH 4
16 MAIN TELESCOPE OUT VALVE WHT 5-8 AUX POWER
AUXILIARY POWER/FUNCTION ENABLE SWITCH 16
5 PLATFORM LEVEL UP VALVE WHT 5-10 JIB UP
JIB UP SWITCH 19
7 PLATFORM LEVEL DOWN VALVE WHT 5-11 JIB DOWN
JIB DOWN SWITCH 8
28 STEER VALVES GROUND WHT 5-12 MAIN LIFT UP
MAIN LIFT UP SWITCH 23
3 WHT 5-13 MAIN LIFT DOWN
MAIN LIFT DOWN SWITCH 33
15 WHT 5-14 SWING RIGHT
SWING RIGHT SWITCH 35
8 FRONT STEER RIGHT VALVE WHT 5-15 SWING LEFT
SWING LEFT SWITCH 34
19 FRONT STEER LEFT VALVE
10
31FLOW CONTROL GROUND
21
11 MAIN LIFT UP VALVE
11
22 MAIN LIFT DOWN VALVE
22
35 SWING RIGHT VALVE
12
F
34 SWING LEFT VALVE BLK 000-50-2 GND
INDICATORS GROUND 32
1 WHT 5-36 LO LVL FUEL
LOW FUEL INDICATOR 13
9 AUX POWER MAIN LIFT DOWN VALVE WHT 5-24 GLOW PLUG
GLOWPLUG INDICATOR 3
33 BLK 000-50-1 GND
INDICATORS GROUND 31
18 WHT 5-23 CRIBBING ENABLED
CRIBBING ENABLED INDICATOR 1
26 HEAD/TAIL LIGHT ENABLE RELAY WHT 5-25 PLATFORM OVERLOAD
PLATFORM OVERLOADED INDICATOR 14
32 WHT 5-22 NO CHARGE
BATTERY LOW/NOT CHARGING INDICATOR 26
25 FUEL SENSOR SIGNAL WHT 5-20 ENGINE LOW OIL PRES
ENGINE LOW OIL PRESSURE INDICATOR 29
6 FUEL SENSOR GROUND WHT 5-21 ENGINE HIGH TEMP
ENGINE HIGH COOLANT TEMPERATURE INDICATOR 28
29GROUND ALARM GROUND SYSTEM DISTRESS INDICATOR 2 WHT 5-35 SYSTEM FAULT
27GROUND ALARM
27
9
20
15
24
XCO69-J4

GD486-J4

GD486-J3

GD486-J2

GD486-J1
6
5
4
3
2
1

6
5
4
3
2
1

6
5
4
3
2
1
TO SHEET 4 E

GROUND
N/C
N/C
GLOW PLUGS
ENABLE
CRIBBING ENABLE

NO CHARGE
LOW FUEL LEVEL
GND
ENGINE LOW OIL PRESSURE
ENGINE PREHEAT
SYSTEM FAULT
500# MODE
ENGINE HIGH TEMPERATURE
ENGINE LOW OIL PRESSURE
NO CHARGE

SYSTEM FAULT
BROKEN CABLE
PLATFORM OVERLOAD
DRIVE ORIENTATION
AXLE SET
CRIBBING ENABLED

SOFT TOUCH
FOOT SWITCH ENABLE
C069-J3
CO69-J3
BLK 000-40-49 AUX TWR LIFT DOWN
2 AUXILIARY DOWN CURRENT FEEDBACK
5
BLK 000-40-33 CF
6 FLOW CONTROL VALVE CURRENT FEEDBACK
BLK 000-40-35 CF
14 MAIN LIFT VALVES CURRENT FEEDBACK
BLK 000-40-38 CF
4 SWING VALVES CURRENT FEEDBACK
3
WHT 4-30 ALRM
7GROUND ALARM POWER
BLK 000-40-44 CF
1 DRIVE VALVES CURRENT FEEDBACK /LEFT TRACK DRIVE VALVES CURRENT FEEDBACK (CRAWLER)
8 FAULT CABLE ORIENTATION OIL PRESSURE
TEMPERATURE
WHT 4-105 CRIBBING LOW FUEL CRIBBING ENABLE SYSTEM BROKEN 1000# MODE DRIVE AXLE SET ENGINE LOW
9 CRIBBING ENABLE SWITCH ENGINE HIGH
WHT 5-101 JUMP ENABLE
10 JUMP ENABLE
BLK 102 CNFG1 GND
11 GROUND Y G Y R G Y G R
12 Y
PREHEAT OVERLOAD
WHT 4-102 HEAD & TAIL LIGHTS

13
NO CHARGE GLOW PLUG CREEP ENGINE TILT 500# MODE PLATFORM GENERATOR FOOT SWITCH
WHT 5-101 JUMP ENABLE

G G Y R Y R G R D
BLK 102 CNFG1 GND
WHT 4-105 CRIBBING

G
BLK 000-40-44 CF

GROUND
PANEL DISPLAY
X513A
1
2
3
4
5
6
1
2
3
4
5
6
X513B
BLK 000-40-43 CF 16 AWG

WHT 4-105 CRIBBING

BLK 102 CNFG1 GND

C
Sheet_4-[1,H]

Sheet_9-[1,D]

Sheet_4-[3,F]

SHEET 5 1001165354-N
MAF01390

4 5 6 7 8

Figure 7-107. Electrical Schematic - Sheet 9 of 25

3121671 7-111
F

A
B
E

C
D
H

7-112
1
1

2
2

HARNESS
TO TURN TABLE
BLK 2/0 2/0 AWG GROUND STUD LOCATED
1
ON THE ENGINE BLOCK
X559

1
2
3
4
5
6
1
2
3
4
5
6
7
8
BLK 2/0 2/0 AWG

X183B
X181B
BLK 2/0 2/0 AWG GROUND STUD LOCATED ON THE
1
X558 PIVOT POINT OF AN ENGINE TRAY

WHT 6-16 18 AWG

BLK 2/0 2/0 AWG
BLK 2/0 2/0 AWG

SHIELD 6-50 18 AWG

3
3

WHT 6-18 GLOW 18 AWG

MS561- M

RED CABLE CAN HI 18 AWG

BLK CABLE CAN LO 18 AWG
RED 2/0 2/0 AWG
1

RED 6-51 ALT EXCITE 16 AWG

BLK 000-6-1 GROUND 16 AWG
AUX PUMP
MS561+

WHT 6-25 ENGINE START 14 AWG

BLK 2/0 2/0 AWG
1
BLK 16AWG 16 AWG
BT557-
BATTERY

RED 2/0 2/0 AWG

1
BT557+
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

RL560-87
RED 2/0 2/0 AWG 87
1
RED 2/0 2/0 AWG
RL560-30
RED 2/0 2/0 AWG 30
1
RL560-86
86
RELAY

1
AUX PUMP

RL560-85
BLK 16AWG 16 AWG 85
1

RL563-87
RED 2/0 2/0 AWG 87
1
RED 2/0 2/0 AWG

4
4

RL563-30
RED 14AWG 14 AWG 30
1

Figure 7-108. Electrical Schematic - Sheet 10 of 25

RL563-86
WHT 6-25 ENGINE START 86
RELAY
START

1
RL563-85
85
1

S240
RL564-87
RED 2/0 2/0 AWG 87
1
RED 10AWG
RL564-30
RED 6AWG 30
1
RL564-86
WHT 6-18 GLOW 18 AWG 86
RELAY

1
GLOW PLUGS

RL564-85
85
1

SHIELD 6-50 18 AWG RED 6AWG

3 C 1
BLK CABLE 18 AWG
2 B EC565
DEUTZ T4I ENGINE HARNESS SCHEMATIC

RED CABLE 18 AWG

1 A
GLOW PLUGS

S483
X485 X481
S484

CAN TERMINATOR
RED 10AWG 10 AWG

EC566-B+
- FUSE LINK 14 AWG
1 B+

5
5

S480 EC566-D+
RED 6-51 ALT EXCITE 16 AWG
1 D+
EC566-W
ALTERNATOR
ALTERNATOR

1 W
X239
WHT 6-17 DIAGNOSTIC 18 AWG
A
BLK 000-6-3 18 AWG
B
WHT 6-23 18 AWG
K
WHT 6-23 18 AWG
L

DIAGNOSTIC
CONNECTOR 1
EC562-B-
RED 14AWG
1
EC562
1 M
WHT 6-15 DIAGNOSTIC 18 AWG
ENGINE STARTER

EC562-B+

SHEET 6

3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

G
GLOW PLUGS ALTERNATOR ENGINE STARTER

ALTERNATOR
D+

M
B+

W
EC566-D+
EC566-B+

EC566-W
1

1
1
EC565

EC562-B+
EC562-B-
RED 6-51 ALT EXCITE 16 AWG

EC562
1

1
- FUSE LINK 14 AWG
RED 6AWG

RED 14AWG

DEUTZ TIER 4I
ENGINE CONNECTOR F
S480

RED 10AWG 10 AWG

4
3 GRD (TEMPA11) 8 2
COOLANT
17 ADC7 (TEMP3) 9 1 TEMPERATURE
25
24
SPEED 13 2 ENGINE
23
SPEED CAMSHAFT
ERM2 ENGINE CONTROL TO ENGINE

GRD (SPEED) 12 1
22
NTB TO ERM2 ENGINE CONTROL

21
20 GRD (ACD2) 23 1

16 ADC5 (TEMP1) 4 2 CHARGE AIR

+5V REF (ADC2) 25 3 PRESSURE

15
WHT 6-15 DIAGNOSTIC 18 AWG 4
14 14 ADC2 24

BLK 000-6-1 GROUND 16 AWG

18 E
+5V REF (ADC4) 22
1 1 1 ENGINE OIL
BLK CABLE CAN LO 18 AWG ADC4 21
13 13 2 PRESSURE
RED CABLE 18 AWG GND (ADC4) 20
12 12 3

9
8
ACTOR OUR 14 1
7
ACTOR OUT 15 2
S483 6 END
WHT 6-17 DIAGNOSTIC 18 AWG

RACK MEAS CAN 17 3

ACTUATOR
5
RACK MEAS SIGNAL 19 4
S484 2 2
RACK MEAS REF 18 5
11 11
BLK 000-6-3 18 AWG

10 10
WHT 6-23 18 AWG
WHT 6-23 18 AWG

X206
SHIELD 6-50 18 AWG
BLK CABLE 18 AWG
RED CABLE 18 AWG

D
X239
A
B
K
L

CONNECTOR
DIAGNOSTIC
X481
C
B
A
X485
3
2
1

CAN TERMINATOR

1001165354-N
SHEET 6 MAF01400

4 5 6 7 8

Figure 7-109. Electrical Schematic - Sheet 11 of 25

3121671 7-113
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

ECM-J2 BUSSMANN DIODE PACK FUEL PUMP 20A (SW), ECM 30A (CONT)
EIC
BLK 248-33 INJECTOR 1 1.5mm² YELLOW CONNECTOR
33 62 (BLUE)
BLK 248-16 INJECTOR 1 1.5mm² GENERIC
16 35
BLK 248-48 INJECTOR 4 1.5mm² RELAY, POWER MODULE
48 42
BLK 248-18 INJECTOR 4 1.5mm²
18 37
BLK 248-32 INJECTOR 3 1.5mm²
32 38
BLK 248-2 INJECTOR 3 1.5mm² 5A 10A
2 61
BLK 248-46 INJECTOR 2 1.5mm²
46 40
BLK 248-3 INJECTOR 2 1.5mm²
H 3
BLK 148-28 START RTN 0.75mm²
41
6 2

RL930-B+

RL930-1

RL930-2
BLK 248-5 MPROP ACTUATOR 1.5mm²

1
2

1
RL930
5 20

MS932

G
BLK 248-4 MPROP ACTUATOR 1.5mm²

C
D

H
B
A

E
F

RL931-87
4 19

1
BUSBAR
BLK 248-37 ENGINE SPEED CAMSHAFT
37 14
WHT 248-52 ENGINE SPEED CAMSHAFT

BLK 248-23 GLOW SENSE 0.75mm²

52 13

YEL 2-48-1 IGNITION 16AWG

YEL 2-1-99 IGNITION
ORG 248-23-1 GLOW SENSE
SHLD 248-53 ENGINE SPEED CAMSHAFT
53 9

BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

BLK 248-39 ENGINE SPEED CRANKSHAFT
39 15

ORG 248-23-1 GLOW SENSE

WHT 248-54 ENGINE SPEED CRANKSHAFT
54 21

WHT 48-96 FUEL PUMP 14AWG

SHLD 248-38 ENGINE SPEED CRANKSHAFT
38 1

RED 1-148-135 ECM PWR

YEL 2-48-4 IGNITION
BLK 248-7 RAIL PRESSURE FUEL 0.75mm²
7 32
8 57
BLK 148-73 START SIGNAL 0.75mm²
9 3
10 4
11 5
12 6
13 7
14 8
A [J2] 15 10
17 11
ECM CONNECTOR 19
BLK 248-19 EHXAUST GAS RECIRCULATION 1.5mm²
47
G 20
BLK 248-20 EHXAUST GAS RECIRCULATION 1.5mm²
48
21 12
22 59

S946
BLK 248-23 GLOW SENSE 0.75mm²
23 16
24
BLK 248-24 BOOST PRESSURE / TEMP 0.75mm²
22 EIC (ENGINE INTERFACE CONNECTION)
BLK 248-25 RAIL PRESSURE FUEL 0.75mm²
25 31
BLK 248-26 RAIL PRESSURE FUEL 0.75mm²
26 25
BLK 248-27 BOOST PRESSURE / TEMP 0.75mm²
27 29
BLK 248-28 COOLING TEMPERATURE 0.75mm²
28 24
BLK 248-29 OIL PRESSURE 0.75mm²
29 27
30 33
31 60
BLK 148-61 FUEL LOW PRESSURE 0.75mm²
34 17
BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²
35 18
36 58
1 30
BLK 248-40 AIR INLET TEMP 0.75mm² BLK 248-40 AIR INLET TEMP 0.75mm²
40 28
BLK 148-56 AIR INLET TEMP 0.75mm²
41 34
42 36
BLK 248-43 OIL PRESSURE 0.75mm²
43 23
BLK 248-44 OIL PRESSURE 0.75mm²
F 44 26
45 39
47 43
49 44
50 45
BLK 148-85 EHXAUST GAS RECIRCULATION 0.75mm²
51 46
BLK 148-72 THROTTLE FLAP 3 0.75mm²
55 49
BLK 148-44 EHXAUST GAS RECIRCULATION 0.75mm²
56 50
BLK 148-38 THROTTLE FLAP 4 0.75mm²
57 52
BLK 148-82 EHXAUST GAS RECIRCULATION 0.75mm²
58 51
59 53
60 54
55
56

ECM-J1
7
8
9
10
E 11
12
BLK 148-13 COOLANT LEVEL SIG 0.75mm²
13

S951
14
BLK 148-15-68 CLUTCH SWITCH 0.75mm²
15
16
17

S952
18
19
20
21
22
23
24
25
26 BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

27
BLK 148-28 START RTN 0.75mm²
28
29 BLK 148-29 COOLANT LEVEL PWR 0.75mm²

30
31
D 32
33
34
BLK 148-35-2 START 0.75mm²
35
36
37
BLK 148-38 THROTTLE FLAP 4 0.75mm²
38
39
40
41
42
43
BLK 148-44 EHXAUST GAS RECIRCULATION 0.75mm²
44
45
46
47
48
49
50
51
C 52
GRN CAN 2 LO DIAG CAN LOW 18AWG S968
53
YEL CAN 1 HI CUSTOMER CAN HIGH 18AWG
54
55 S953
BLK 148-56 AIR INLET TEMP 0.75mm²
56
BLK 148-57 WATER IN FUEL SW RTN 0.75mm²
57
K [J1] 58 X966
59 C C
ECM CONNECTOR 60
GRN CAN 2 LO DIAG CAN LOW
B B
BLK 148-61 FUEL LOW PRESSURE 0.75mm² YEL CAN 2 HI DIAG CAN HIGH
61 A A
120 OHM
62 X965
63
BLK 148-64 WATER IN FUEL SW 0.75mm²
64
65
66
67 X955
BLK 148-15-68 CLUTCH SWITCH 0.75mm² YEL CAN 1 HI CUSTOMER CAN HIGH 120 OHM
68 A A
GRN CAN 1 LO CUSTOMER CAN LOW
69 B B
70 C C
71 X956
BLK 148-72 THROTTLE FLAP 3 0.75mm²
72
B 73
BLK 148-73 START SIGNAL 0.75mm²

74
YEL CAN 2 HI DIAG CAN HIGH S969
75
GRN CAN 1 LO CUSTOMER CAN LOW
76
77 S954

78
79
80
81
BLK 148-82 EHXAUST GAS RECIRCULATION 0.75mm²
82
83
84
BLK 148-85 EHXAUST GAS RECIRCULATION 0.75mm²
85
86
87 BLK 148-87 COOLANT LEVEL GND 0.75mm²
BLK 148-88 IGNITION 0.75mm²
88
89
90
91
92

A 93
94
RED 148-5 ECM PWR 2.5mm²
5 S944
RED 148-3 ECM PWR 2.5mm²
3
RED 148-1 ECM PWR 2.5mm²
1
BLK 148-2 ECM GND 2.5mm²
2
BLK 148-4 ECM GND 2.5mm² S945

SHEET 7
4
BLK 148-6 ECM GND 2.5mm²
6
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
NC

NOTE: ALL WIRES ARE 18AWG UNLESS OTHERWISE SPECIFIED

1 2 3 4 5

Figure 7-110. Electrical Schematic - Sheet 12 of 25

7-114 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

FUEL PUMP 20A (SW), ECM 30A (CONT)

DEUTZ T4F ENGINE HARNESS SCHEMATIC
BUSSMANN DIODE PACK
(BLUE) YELLOW CONNECTOR

X547 PIVOT POINT OF AN ENGINE TRAY

GROUND STUD LOCATED ON THE
GENERIC
RELAY, POWER MODULE

GROUND STUD LOCATED

ON THE ENGINE BLOCK
AUX PUMP BATTERY AUX PUMP START GLOW PLUGS
5A ENGINE STARTER ALTERNATOR
10A RELAY RELAY RELAY GLOWPLUGS
ALTERNATOR

D+
B+
M
H

W
M

RL931-87
1
RL930-B+

EC555-D+
EC555-B+
BT545+

EC555-W
RL930-1

RL930-2

BT545-
1

1
2

1
RL930

1
1

1
MS932

G
C
D

H
B
A

MS550+

85
F

85
MS550-

85
RL931-87

1
1

X548
BUSBAR

RL549-85
RL549-87

RL549-30

RL549-86

RL552-85
RL552-87

RL552-30

RL552-86

RL553-85
RL553-87

RL553-30

RL553-86
BLK 248-23 GLOW SENSE 0.75mm²

1
YEL 2-48-1 IGNITION 16AWG

EC551-B+

1
2
EC551-B-
YEL 2-1-99 IGNITION

EC18
ORG 248-23-1 GLOW SENSE

BLK 16AWG 16 AWG

RED 47-8 ALT EXCITE 16AWG

EC551
1

1
RED 2/0 2/0 AWG
BLK 2/0 2/0 AWG

RED 48-14 GLOW 8AWG

BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

RED 2/0 2/0 AWG

BLK 2/0 2/0 AWG
BLK 2/0 2/0 AWG

BLK 2/0 2/0 AWG

RED 4AWG
BLK 16AWG 16 AWG
ORG 248-23-1 GLOW SENSE

RED 14AWG
BLK 2/0 2/0 AWG

RED 4AWG
RED 6AWG

RED 6AWG
RED 2/0 2/0 AWG

RED 2/0 2/0 AWG

RED 2/0 2/0 AWG
WHT 48-96 FUEL PUMP 14AWG

RED 2/0 2/0 AWG

RED 14AWG
RED 2/0

YEL 2-48-3 IGNITION

RED 1-148-135 ECM PWR
YEL 2-48-4 IGNITION
150A
IP556

G
S946

EIC (ENGINE INTERFACE CONNECTION)

BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²

X901
S1001 1 VSW
BLK 148-35-1 START
2 START
YEL CAN 1 HI CUSTOMER CAN HIGH
3 CAN + (HI)
GRN CAN 1 LO CUSTOMER CAN LO
4 CAN - (LOW) VEHICLE INTERFACE 1
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
5 ALT EXCITE
F
6 CAN SHIELD

X902
YEL 2-1-99 IGNITION
1 EMR4 IGNITION

2 GROUND

3 GENERATOR ENABLE

4 GLOW

5 GENERATOR POWER VEHICLE INTERFACE 2

X999 X1000 6 GENERATOR GROUND
BLK 148-35-3 1.5 k
1 1 7 PLUGGED
BLK 000-48-3 GND
2 2 8 PLUGGED

E
S951
S952

X950
YEL 2-48-2 IGNITION
A
BLK 000-48-2 ENG GND
B
C
D
E
GRN CAN 1 LO CUSTOMER CAN LO
F
D
GRN CAN 2 LO DIAG CAN LOW
S963 S964 YEL CAN 2 HI DIAG CAN HIGH
G DEUTZ DIAGNOSTIC
H
J
K
L
YEL CAN 1 HI CUSTOMER CAN HIGH
M

X960
YEL CAN 2 HI DIAG CAN HIGH 120 OHM
A A
GRN CAN 2 LO DIAG CAN LOW
B B
C C
X961

C
NORMALLY CLOSED

SN939
COOLANT LEVEL

PWR
BLK 148-29 COOLANT LEVEL PWR 0.75mm²
1
BLK 148-13 COOLANT LEVEL SIG 0.75mm²
3 SIG
BLK 148-87 COOLANT LEVEL GND 0.75mm²
2
4
GND
WIF SWITCH

X941 X942
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
WHT 48-96 FUEL PUMP 14AWG
2 2
WHT 48-96 FUEL PUMP 14AWG
2 WATER IN FUEL
3 3 SN959
BLK 000-48-1 ENG GND 14AWG BLK 000-48-1 ENG GND 14AWG
X955 4 4
YEL CAN 1 HI CUSTOMER CAN HIGH 120 OHM
FUEL PUMP

A A
GRN CAN 1 LO CUSTOMER CAN LOW
B B 1
M
C C 2 FUEL PUMP
X956 EC958
X958A EC958+
FUEL PUMP

1
WHT 48-96 FUEL PUMP
1 B
2
BLK 000-48-1 ENG GND
EC958- M
1
BLK 000-48-3 GND
BLK 000-48-2 ENG GND
BLK 000-48-1 ENG GND 14AWG T920 2 x 5mm 14 AWG RING
BLK 000-148-246 ECM GND 8AWG
1 GND
3/8" 6 AWG RING

1001165354-N
MAF01410
HEET 7
4 5 6 7 8

Figure 7-111. Electrical Schematic - Sheet 13 of 25

3121671 7-115
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

GM ENGINE HARNESS
H GASOLINE SENSOR INTERFACE EGO2
OIL PRESURE SWITCH EGO1
BLACK/LT GREEN 18 TWR BLACK/LT GREEN 18 SHD PED_12160825 CONNECTOR
A PED_12065287 CONNECTOR A SHD
LT GREEN/WHITE 18 PED_12052641 CONNECTOR DK GREEN/WHITE 18 PED_12177150 TERM (GOLD) BLACK/LT GREEN 18
B PED_12103881-L TERMINAL B A
LT GREEN/RED 18 PED_12048074 TERMINAL PINK/DK GREEN 18 PED_12089678 WIRE SEAL DK GREEN/ORANGE 18
C C B
GCP 90 WAY CONNECTOR WHITE/LT GREEN 18
D PED_12052634 LOCK BLACK/YELLOW 18
D
PED_12176368 LOCK PINK/DK GREEN 18
C
LT GREEN/RED 18 PED_12048086 SEAL PED_15427170 CLIP BLACK/WHITE 18
B TWR D
EGO1 1 DK GREEN/ORANGE 18 PED_12160482 CONNECTOR
FCI EGO2 2 DK GREEN/WHITE 18 PED_12048074 TERMINAL LT BLUE 18 WHITE/BLACK 18
C A LOCKOFF
211 PC 90 2S 0009 CONNECTOR EGO3 3 PED_12160480 LOCK PINK/TAN 18
B
211 A 90 0007 LOCKING CAM EGO4 4 BLACK/LT GREEN 18
A
211 A 90 0008 COVER TPS1 5 PURPLE/LT BLUE 18
211 CC 2S 1460 TERMINAL (GOLD) TPS2 6 LT BLUE/DK BLUE 18
MAP 7 LT GREEN 18
AUX ANA PD1 8 ORANGE/YELLOW 18
FPP1 9 DK BLUE/ORANGE 18
FPP2 IVS 10 PURPLE/YELLOW 18
AUX ANA PUD2 11
12 PED_12065287 CONNECTOR
AUX ANA PUD3
CAN TERM + 13 WHITE/ORANGE 18 PED_12103881-L TERMINAL
CAN1 + 14 BLUE/PINK 18
CAN1 - 15 BLUE/WHITE 18 BLACK/LT GREEN 18
B
CAN2 - 16 .
CAN2 + 17 UNUSED
C
CAN2 TERM + 18
5V EXT 1 19 LT GREEN/RED 18 TAN/WHITE 18
A
5V RTN 20 BLK/LT GREEN 18
CRANK + 21 PURPLE/WHITE 18
CRANK - 22 WHITE/PURPLE 18
23 GRAY/BROWN 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CAM +
24 PURPLE/ORANGE 18 RED/WHITE 18
CAM -
SPEED + 25 RED/WHITE 18
SPEED - 26 RED/BLACK 18 RED/BLACK 18
27
G KNOCK1 +
KNOCK1 - 28
KNOCK2 + 29
KNOCK2 - 30
SPARK COIL 1A 31 YELLOW 18
SPARK COIL 1B 32
SPARK COIL 2A 33
SPARK COIL 2B 34 BOSCH KOMPAKT 1 928 403 736 CONN
SPARK COIL 3A 35 1 928 498 060 TERMINAL
SPARK COIL 3B 36 1 928 300 599 SEAL
SPARK COIL 4A 37
SPARK COIL 4B 38 BLACK 12 LT GREEN 18
4
IAT 39 YELLOW/GRAY 18 BLACK 18 BLACK 16 LT GREEN/RED 18
3 BOSCH_TMAP
ECT 40 TAN/WHITE 18 YELLOW/GRAY 18
2
EGT 41 BLACK/LT GREEN 18
1
AUX DIG 1 42 DK GREEN/PURPLE 18
AUX DIG 2 43 TAN/RED 18
AUX DIG 3 44 TAN/DK GREEN 18
VSW 45 PINK/TAN 18
AUX ANA PU1 46 DK BLUE/YELLOW 18
AUX ANA PU2 47 YELLOW/DK BLUE 18
(FRT) AUX ANA PU3 48 LT GREEN/WHITE 18
(FPP2 ONLY) 5V EXT 2 49 LT GREEN/PURPLE 18
5V RTN 50 LT GREEN/BLACK 18
GOV1 51 GRAY/DK BLUE 18
GOV2 52 GRAY/RED 18
OIL PRESS 53 LT BLUE 18
(FRP) AUX ANA PUD1 54 WHITE/LT GREEN 18
PC TX 55 DK GREEN 18
PC RX 56 ORANGE 18
ALT EXCITE 57
TACH 58 GRAY 18
VBAT PROT 59
VBAT 60 RED/TAN 16
F INJ1 LS
INJ2 LS
61
62
BROWN/LT BLUE 18
BROWN/LT GREEN 18 PED_12146121 CONNECTOR
63 BROWN/YELLOW 18 PED_12048074 TERMINAL BLUE/PINK 18 BLUE/PINK 18
INJ3 LS
INJ4 LS 64 BROWN/WHITE 18 PED_12052845 LOCK
65 PINK/DK GREEN 16 A BLUE/WHITE 18 BLUE/WHITE 18
INJ5 LS
INJ6 LS 66 YELLOW/BLACK 18 B IGNITION COIL TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
INJ7 LS 67 PLUG C
68 PED_12162189 CONNECTOR
INJ8 LS PED_12124075 TERMINAL 10MM RING
GROUND 69 BLACK 16
STARTER 70 YELLOW/BLACK 18 BLACK 12
D
RELAY 71 WHITE/LT BLUE 18 GROUND
EGOH 1 72 BLACK/WHITE 18 BLACK 16
C PED_12089240 RING
EGOH 2 73 BLACK/YELLOW 18
EGOH 3 74 YELLOW 18 IGNITION MODULE PINK/DK GREEN 18
B
(LOCKOFF) EGOH 4 75 WHITE/BLACK 18
76 PINK/DK GREEN 16
BUZZER
77 BROWN/WHITE 16
A STARTER
PWM5
PWM5 RECIRC 78 WHITE/BROWN 16 SOLENOID
VBAT 79 RED/TAN 16 PINK/DK GREEN 16
80 GREEN/YELLOW 18 WHITE 16
MIL
GROUND 81 BLACK 16 PED_12162193 CONNECTOR
DBW + 82 PINK/WHITE 18 PED_12103881 TERMINAL
DBW - 83 TAN/ORANGE 18
FPUMP 84 TAN/BLACK 18 PURPLE/WHITE 18 A
85 PINK/YELLOW 16
AUX PWM3 RECIRC
86 BLACK/RED 16 WHITE/PURPLE 18 B CRANKSHAFT POSITION
AUX PWM3
AUX PWM1 87 TAN 18
AUX PWM2 88 DK BLUE 18
89 PINK/BLACK 18 JUNCTION MUST BE MADE 3-6 INCHES
(STARTER)AUX PWM4 FRON SENSOR CONNECTOR
AUX_PWM4_RECIRC 90
87A
BLK/LT GREEN 18 WHITE 16 30
87

E LT BLUE/PINK 18 86

PINK/BLACK 18 85
STARTER RELAY

PED_12110293 CONNECTOR
PED_12048074 TERMINAL
PED_12052845 LOCK

PURPLE/ORANGE 18 TWR
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH GRAY/BROWN 18 A CAM SENSOR
LT GREEN/RED 18 B
C
JUNCTION MUST BE MADE 3-6 INCHES
FROM SENSOR CONNECTOR

R2
MT CONNECTOR MASTER TRACK WHITE/LT BLUE 18 2
PINK/DK GREEN 14 3
CAP CONNECTOR RED 14 5
RED/TAN 18 1
CAN + A BLUE/PINK 18 4
CAN - B BLUE/WHITE 18
VSW C PINK/TAN 18 PURPLE/LT BLUE 18 POWER RELAY
6
GROUND D BLACK 18 LT BLUE/DK BLUE 18
RED/TAN 18 5
VBAT E PINK/WHITE 18
4
UNUSED F LT GREEN/RED 18
BLK/LT GREEN 18
3 BOSCH THROTTLE PINK/YELLOW 16
2
PED 12052848 CONNECTOR PED 12124107 CONNECTOR TAN/ORANGE 18
D PED 12059168 CAVITY PLUG PED 15324973 CABLE SEAL
1
PED 12059168 CAVITY PLUG AMP_1-967616-1 CONNECTOR
PED 12045773 TERMINAL AMP_965906-5 TERMINAL PINK/DK GREEN 18 DEPR
PED 12052850 TPA LOCK AMP_967067-1 SEAL BLUE/PINK 18 AMP_174262-2 CONNECTOR
PED 12020833 CPA LOCK WHITE 18 1 2 3 AMP_171662-1 TERMINAL
BLACK 18
BLUE/WHITE 18
4 5 6 AMP_174263-7 LOCK
RED/TAN 18 AMP_172888-2 SEAL

BROWN/YELLOW 18 BROWN/LT BLUE 18

BROWN/WHITE 18
BROWN/LT GREEN 18

PINK/DK GREEN 18 PINK/DK GREEN 18 PINK/DK GREEN 18 PINK/DK GREEN 16

PINK/DK GREEN 18
CAN TERMINATION
12010996 CONN 12015791 CONN
PED_15326181 CONN PED_15326181 CONN PED_15326181 CONN PED_15326181 CONN 12089305 TRM MALE 14/16 12124580 TRM FEMALE 14/16
PED_15305174 TERM PED_15305174 TERM PED_15305174 TERM PED_15305174 TERM 12089040 TRM MALE 18/20 12089188 TRM FEMALE 18/20
PED_12191226 SEAL PED_12191226 SEAL PED_12191226 SEAL PED_12191226 SEAL SHD TWR
WHITE 18 WHITE 18
PED_15305083 TPA PED_15305083 TPA PED_15305083 TPA PED_15305083 TPA
PED_15326096 CPA PED_15326096 CPA PED_15326096 CPA PED_15326096 CPA
INJ #4 INJ #3 INJ #2 INJ #1

C
PIVOT POINT OF AN ENGINE TRAY
GROUND STUD LOCATED ON THE

POWER
GROUND STUD LOCATED
ON THE ENGINE BLOCK

ENGINE STARTER FUEL PUMP

AUX PUMP BATTERY AUX PUMP START
RELAY
1

RELAY
X208

X207
M
M

BT256+
BT256-
1

BLK FUEL PUMP NEGATIVE 16 AWG

WHT FUEL PUMP POSITIVE 16 AWG

85
85

87
MS275+
MS275-
1

1
1

1
X273

X272

RL544-85
RL544-87

RL544-30

RL544-86
RL274-85

RL274-86

RL274-30

RL274-87

EC276-B+
EC276-B-
1

EC276
1

1
1

1
BLK 16AWG 16 AWG

RED 2/0 2/0 AWG

BLK 2/0 2/0 AWG
RED 2/0 2/0 AWG
BLK 2/0 2/0 AWG
BLK 2/0 2/0 AWG
BLK 2/0 2/0 AWG

BLK 2/0 2/0 AWG

RED 14AWG 14 AWG

BLK 16AWG 16 AWG

RED 2/0 2/0 AWG

RED 2/0 2/0 AWG
RED 2/0 2/0 AWG

RED 2/0 2/0 AWG

RED 14AWG

B
D
C
R
M
L
K
J
H TO GM ENGINE
G

WHT 6-53 ALTERNATOR EXCITATION

E CONNECTOR
X181B B
WHT 6-53 ALTERNATOR EXCITATION
5 S
WHT 6-14 IGNITION WHT 6-14 IGNITION
TO TURN TABLE 1 A
BLK CAN LO BLK CAN LO
4 P
RED CAN HI RED CAN HI
HARNESS 3 N
WHT 6-12 ENGINE START WHT 6-12 ENGINE START
2 F
6 X205

A X247
4 4
GRN 6-22 GRN 6-22
3 3 FUEL REGULATOR
FUEL REGULATOR RED 6-21 RED 6-21
2 2 TO GM HARNESS
WHT 6-20 WHT 6-20
1 1
BLK 6-19 BLK 6-19
X248

SHEET 8

1 2 3 4 5

Figure 7-112. Electrical Schematic - Sheet 14 of 25

7-116 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

GM ENGINE HARNESS
EGO2
H
EGO1
BLACK/LT GREEN 18 SHD PED_12160825 CONNECTOR
A SHD PED_12160825 CONNECTOR
PED_12052641 CONNECTOR DK GREEN/WHITE 18 PED_12177150 TERM (GOLD) BLACK/LT GREEN 18
B A
PED_12048074 TERMINAL PINK/DK GREEN 18 PED_12089678 WIRE SEAL DK GREEN/ORANGE 18 PED_12177150 TERM (GOLD)
C B
PED_12052634 LOCK BLACK/YELLOW 18 PED_12176368 LOCK PINK/DK GREEN 18 PED_12089678 WIRE SEAL
D C
PED_12048086 SEAL PED_15427170 CLIP BLACK/WHITE 18 PED_12176368 LOCK
TWR D
WHITE/BLACK 18
A LOCKOFF
PINK/TAN 18
B

PED_12065287 CONNECTOR
PED_12103881-L TERMINAL VEHICLE INTERFACE CONNECTORS
BLACK/LT GREEN 18
B CONNECTOR 2
. CAP
UNUSED PED_15326868 CONN
C
ECT PED_15304707 TERM PED_15326863 CONN
TAN/WHITE 18 PED_12191153 SEAL PED_15305171 PLUG
A
PED_15427170 CLIP PED_15358785 TPA
PED_15305171 CAVITY PLUG

RED/WHITE 18 RED/WHITE 18 PINK/DK GREEN 18 S 12V RELAYED POWER PLUG

ORANGE/YELLOW 18 R AUX ANA PD1 PLUG
RED/BLACK 18 RED/BLACK 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
RED/BLACK 18
RED/WHITE 18
P
N
VS -
VS +
PLUG
PLUG G
TAN/DK GREEN 18 M AUX DIG 3 PLUG
TAN/RED 18 L AUX DIG 2 PLUG
GRAY/DK BLUE 18 K GOV SELECT 1 PLUG
GRAY/RED 18 J GOV SELECT 2 PLUG
DK BLUE/YELLOW 18 H AUX ANA PU1 PLUG
YELLOW/DK BLUE 18 G AUX ANA PU2 PLUG
BOSCH KOMPAKT 1 928 403 736 CONN TAN 18 F AUX PWM 1 PLUG
1 928 498 060 TERMINAL BLACK 16 E GROUND PLUG
1 928 300 599 SEAL GRAY 18 D TACH PLUG
BROWN/WHITE 16 C AUX PWM 5 PLUG
LT GREEN 18 WHITE/BROWN 16 B AUX PWM 5 RECIRC PLUG
4
LT GREEN/RED 18 A UNUSED PLUG
3 BOSCH_TMAP
YELLOW/GRAY 18
2
BLACK/LT GREEN 18
1

LT GREEN/PURPLE 18 S 5V EXT 2 (FPP2 ONLY)

CONNECTOR 1
LT GREEN/BLACK 18 R 5V RTN 2 PED_15326863 CONN
BLUE/WHITE 18 P CAN1 - PED_12191819 TERM
BLUE/PINK 18 N CAN1 + PED_12191153 SEAL
LT GREEN/RED 18 M 5V EXT 1 PED_15305171 CAVITY PLUG
BLACK/LT GREEN 18 L 5V RTN 1
DK BLUE/ORANGE 18 K FPP1
PURPLE/YELLOW 18 J FPP2/IVS
DK GREEN/PURPLE 18 H FUEL SELECT (AUX DIG 1)
GREEN/YELLOW 18 G MIL
LT BLUE/PINK 18 F START COMMAND
DK BLUE 18
PINK/YELLOW 16
E
D
AUX PWM 2
FUEL PUMP +
F
BLACK/RED 16 C FUEL PUMP -
BLUE/PINK 18 BLUE/PINK 18 B UNUSED
PINK 18 A VSW
A BLUE/WHITE 18 BLUE/WHITE 18
B
IGNITION COIL TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
C
PED_12162189 CONNECTOR
PED_12124075 TERMINAL 10MM RING
YELLOW/BLACK 18 BLACK 12
D
GROUND
BLACK 16
C PED_12089240 RING
YELLOW 18 IGNITION MODULE PINK/DK GREEN 18
B
BLACK/LT GREEN 18 1 ANA RTN
PINK/DK GREEN 16
A STARTER LT GREEN/RED 18
DK GREEN 18
2
3
5V REF
PC TX
DIAGNOSTIC CONNECTOR
SOLENOID ORANGE 18 4 PC RX EPC_1F1T-14A624-AA-004 CONN
PINK/DK GREEN 16 RED/TAN 18 5 VBAT GTS_0330-930009 TERM (18-20)
WHITE 16 BLACK 18 6 GROUND EPC_E6DB-14A468-DA LOCK
EPC_F5AB-14A666-AA CAP
PED_12162193 CONNECTOR BLUE/PINK 18 7 CAN1 + TRW_647688-3801 CLIP
PED_12103881 TERMINAL BLUE/WHITE 18 8 CAN1 -

PURPLE/WHITE 18 A F2
RED/TAN 16 4 3 RED 16
WHITE/PURPLE 18 B CRANKSHAFT POSITION
20A
JUNCTION MUST BE MADE 3-6 INCHES
FRON SENSOR CONNECTOR
ECM
87A
WHITE 16 30 F6
87 RED/TAN 16 12 11 RED 16

LT BLUE/PINK 18 86
E
20A
R1 STARTER
PINK/BLACK 18 85
STARTER RELAY

PED_12110293 CONNECTOR
PED_12048074 TERMINAL
PED_12052845 LOCK F4 F1
PINK/DK GREEN 16 8 7 PINK/TAN 18 2 1 PINK 18

PURPLE/ORANGE 18 TWR
GRAY/BROWN 18 A
20A 5A
LT GREEN/RED 18 B
CAM SENSOR
C IGNITION VSW
JUNCTION MUST BE MADE 3-6 INCHES
FROM SENSOR CONNECTOR

PINK/DK GREEN 16
70A
R2 RED 8 2 1 RED 8
WHITE/LT BLUE 18 2
PINK/DK GREEN 14 3 F5
RED 14 5 PINK/DK GREEN 18 9 10 PINK/DK GREEN 18 M1
RED/TAN 18 1
4 5A MAXI-FUSE
POWER RELAY DEPR FUSE 8MM RING 6MM RING
RED 8
RED 14 RED 10 RED 8
BOSCH THROTTLE PINK/YELLOW 16
BATT + ALTERNATOR+ D
PINK/DK GREEN 18 DEPR
BLUE/PINK 18 AMP_174262-2 CONNECTOR
WHITE 18 1 2 3 AMP_171662-1 TERMINAL R3 PED_12162193 CONNECTOR
BLACK 18 TAN/BLACK 18 2 PED_12124075 TERMINAL
BLUE/WHITE 18
4 5 6 AMP_174263-7 LOCK PINK/YELLOW 16 3 6MM RING
RED/TAN 18 AMP_172888-2 SEAL RED 16 5 RED 16 A
PINK/TAN 18 1
ALTERNATOR ALTERNATOR -
4 PINK/DK GREEN 16 B
FUEL PUMP RELAY BLACK 8
10MM RING

PINK/DK GREEN 16
F3
CAN TERMINATION PINK/YELLOW 16 5 6 PINK/YELLOW 16
12010996 CONN 12015791 CONN
PED_15326181 CONN 12089305 TRM MALE 14/16 12124580 TRM FEMALE 14/16 10A
PED_15305174 TERM 12089040 TRM MALE 18/20 12089188 TRM FEMALE 18/20 FUEL PUMP
PED_12191226 SEAL SHD TWR
WHITE 18 WHITE 18
PED_15305083 TPA
PED_15326096 CPA

POWER
FUEL PUMP
1

1
X208

X207
M

BLK FUEL PUMP NEGATIVE 16 AWG

WHT FUEL PUMP POSITIVE 16 AWG

EC276-B+
EC276
1
RED 2/0 2/0 AWG

D
C
R
M
L
K
J
H TO GM ENGINE
G
E CONNECTOR
B
S
WHT 6-14 IGNITION
A
BLK CAN LO
P
RED CAN HI
N
F
X205

A
4
GRN 6-22
3 FUEL REGULATOR
RED 6-21
2 TO GM HARNESS
WHT 6-20

1001165354-N
1
BLK 6-19
X248

SHEET 8 MAF01420

4 5 6 7 8

Figure 7-113. Electrical Schematic - Sheet 15 of 25

3121671 7-117
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5 6 7 8

PLTFM SNSR PLTFM SNSR

RELAY #1 RELAY #2
H H
87a

87a
87
30

85
86

86
85

30
87
RL-502
RL-503

WHT 1-88 SG INPUT 2

WHT 1-87 SG INPUT1
WHT 1-90-1
WHT P9-1
WHT P5-1
WHT P4-1

WHT P4-1

WHT P5-1
WHT P9-1
WHT P4
WHT P5

G G

WHT 1-88 SG INPUT 2

Sheet_2-[3,G]

WHT 1-87 SG INPUT1

Sheet_2-[6,G]

BLK 1-86 SG GND

Sheet_2-[6,G]

WHT 1-90 SG POWER 18 OHM

Sheet_2-[6,F]
F R501 F
BLK 1-86 SG GND
WHT P10

WHT P4
WHT P5

X500
1
2
3
4

E E
1
2
3
4

SKYGUARD (OPTION)
PLTFM SNSR

D D

CRIBBING OPTION HARNESS

1001232714
C C
CRIBBING SWITCH

Sheet_4-[5,B] 1
YEL 4-85 IGN
OR 2
OPTION

WHT 4-105 CRIBBING

(FOR CRAWLER)-Sheet_11-[5,B] 3
4
Sheet_5-[4,C] 5
OR 6
(FOR CRAWLER)-Sheet_12-[4,C] SW396

B B

A A

1001165354-N
SHEET 9 MAF01430
1 2 3 4 5 6 7 8

Figure 7-114. Electrical Schematic - Sheet 16 of 25

7-118 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally

3121671 7-119
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

PLATFORM WORK LIGHTS (OPTION)

H
CHASSIS HEAD AND TAIL LIGHTS (OPTION)

FRONT LEFT
LED PLATFORM WORK LIGHT
LB495

FRONT RIGHT
LED PALTFORM WORK LIGHT BLK 000-60-11 GND 16AWG
2
WHT 6-11 12V+ 16AWG WHT 6-29 12V+ 16AWG
1 1
BLK 000-60-29 GND 16AWG
2
LB670
1
2
LB637

1
2
LB157

S671
WHT 6-1 12V+ 16AWG
BLK 000-60-1 GND 16AWG

S672
WHT 6-2 12V+ 16AWG
BLK 000-60-2 GND 16AWG
G

REAR RIGHT
X666 4
WHT 6-30 12V+ 16AWG

REAR LEFT
1 3
BLK 000-60-12 GND 16AWG BLK 000-60-30 GND 16AWG
2 2
WHT 6-13 12V+ 16AWG
3 1
4 X668
BLK 000-60-1 GND 16AWG

BLK 000-60-2 GND 16AWG

WHT 6-1 12V+ 16AWG

WHT 6-2 12V+ 16AWG

BLK 4-146 14AWG

HEAD AND TAIL LIGHTS

WHT 6-8 12V+ 14AWG 87
4
BLK 4-146 14AWG 30
1

RELE
87a
3
BLK 000-40-109 GND 16AWG 85
2
WHT 4-145 86
F 5
RL673
X532
4
3
2
1

10A
4
3
2
1
X664

IP629
IP648 WHT 12V+ 16AWG
IP649 WHT 12V+ 16AWG

BLK GND 16AWG

BLK 000-40-109 GND 16AWG

BLK 4-146 14AWG
BLK 4-122 14AWG

WHT 4-145
3A

BLK GND 16AWG BLK GND 16AWG

X674

X675

X676

X505
J8_1 J8
E CJ01-8 1
BLK GND 12AWG BLK GND 12AWG
1

1
YEL/RED 12V+ 12AWG YEL/RED 12V+ 12AWG
2 2

MOUNT ON AUX PUMP RELAY BOLT

TO SHEET 2

MOUNT ON AUX PUMP RELAY BOLT

WHT 12V+ 16AWG WHT 12V+ 16AWG

MOUNT ON AUX PUMP RELAY B+

PAGE 5 X513B PIN 2

PLUG HARNESS BETWEEN PLATFORM BOARD AND EXISTING HARNESS

RED 201-1 12V+ 16AWG

23
GRN 203-1 CAN LOW
22
21
20
19
18
17
BLK 200-1 GND 16AWG
16
YEL/RED 202-1 IGN
15
14
13
12
11
C 10
9
8
YEL 204-1 CAN HI
7
6
5
4
3
2
1
TCU

J J
YEL/RED 202-2 IGN YEL/RED 202-3 IGN
H H
S570
G G
F F
E E
B D
GRN 203-2 CAN LOW GRN 203-3 CAN LOW
D
YEL 204-2 CAN HI S569 YEL 204-3 CAN HI
C C
RED 201-2 12V+ 16AWG S20 RED 201-3 12V+ 16AWG
B B
BLK 200-2 GND 16AWG S568 BLK 200-3 GND 16AWG
A A
S567
X111-2 X111-1

CLEAR SKY (OPTION)

SHEET 10

1 2 3 4 5

Figure 7-115. Electrical Schematic - Sheet 17 of 25

7-120 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

CHASSIS HEAD AND TAIL LIGHTS (OPTION) CHASSIS WORK LIGHTS (OPTION)
H
FRONT LEFT

FRONT LEFT
LB495 LB638

FRONT RIGHT

FRONT RIGHT
BLK 000-60-11 GND 16AWG BLK 000-60-3 GND 16AWG
2 2
WHT 6-11 12V+ 16AWG WHT 6-29 12V+ 16AWG WHT 6-4 12V+ 16AWG WHT 6-6 12V+ 16AWG
1 1 1 1
BLK 000-60-29 GND 16AWG BLK 000-60-5 GND 16AWG
2 2
LB670 LB640

S671

S642
S672

S643

REAR RIGHT
REAR RIGHT
WHT 6-7 12V+ 16AWG

REAR LEFT
X666
WHT 6-30 12V+ 16AWG
4 LB639
BLK 000-60-4 GND 16AWG BLK 000-60-6 GND 16AWG
1 G
REAR LEFT

1 3 2 2
BLK 000-60-12 GND 16AWG BLK 000-60-30 GND 16AWG WHT 6-5 12V+ 16AWG
2 2 1 LB641
WHT 6-13 12V+ 16AWG
3 1
4 X668
BLK 4-146 14AWG

HEAD AND TAIL LIGHTS

WHT 6-8 12V+ 14AWG 87 WHT 6-8 12V+ 14AWG 87
4 4
BLK 4-146 14AWG 30 BLK 4-70 14AWG 30
1 1

RELE

RELE
87a 87a
3 3
BLK 000-40-109 GND 16AWG 85 BLK 000-40-9 GND 16AWG 85
2 2
WHT 4-145 86 WHT 4-28 16AWG 86
5 5
RL673 RL168

IP630FUSE 6
F

10A
10A
IP629

BLK 000-40-9 GND 16AWG

BLK 000-40-17 14AWG
BLK 000-40-109 GND 16AWG
BLK 4-146 14AWG

WHT 4-28 16AWG

BLK 4-122 14AWG

BLK 4-70 14AWG

WHT 4-145

X677

X678

X679

X680
X674

X675

X676

X505

1
MOUNT ON AUX PUMP RELAY BOLT
1

MOUNT ON AUX PUMP RELAY BOLT

MOUNT ON AUX PUMP RELAY B+

PAGE 5 X513B PIN 2

MOUNT ON AUX PUMP RELAY B+

PAGE 5 X513B PIN 2

J
YEL/RED 202-3 IGN
H
G
F
E
GRN 203-3 CAN LOW
D
YEL 204-3 CAN HI
C
RED 201-3 12V+ 16AWG
BLK 200-3 GND 16AWG
B B
A
X111-1

1001165354-N
SHEET 10 MAF01440

4 5 6 7 8

Figure 7-116. Electrical Schematic - Sheet 18 of 25

3121671 7-121
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5
F1 F2 F3 F4 F5 F6 F7 F8

15A
15A

5A
5A

5A
5A
ENGINE PIVOT POINT
TURNTABLE HARNESS FOR CRAWLER OPTION
WHT 4-1 BRAKE

28
37
33
38
34
39
35
40
36
45
41
46
42
47
43
32
BRAKE

1
S663

[4,B]
BLK 000-40-1 GND
2

[5,B]
1
X691
HV662

WHT 4-552 16AWG

RED 4-51 12AWG

RED 4-169 MODE SEL 12AWG

RED 4-71 12AWG

WHT 4-82 GEN IGN

RED 4-563 LIGHT OPT

WHT 4-66 IGN
YEL 4-36 MODL PWR 14AWG

YEL 4-81 GEN IGN

RED 4-550 12AWG

YEL 4-72 IGN

RED 4-350 12AWG

RED 4-169-1 MOD SEL

RED 4-35 IGN 12AWG

WHT 4-65
WHT 4-50
2 SPEED

HV661 BLK 000-40-2 GND

BLK 000-40-64 BATT GND 16AWG

[4,B] BLK 000-40-81 16AWG

BLK 000-40-8 MODL GND 10AWG

H 1
WHT 4-2 TWO SPEED
FORWARD

XHV95
WHT 4-3 LEFT TRACK DRIVE FORWARD 16AWG
TRACK
DRIVE

1
LEFT

BLK 000-40-40 CF 16AWG

2
WHT 4-4 LEFT TRACK DRIVE REVERSE 16AWG
3
REVERSE

BLK 000-40-41 CF 16AWG BLK CF 000-40-43

TRACK
DRIVE

4
LEFT

S690

BLK 000-40-12 PLATF GND 12AWG

[5,B]

[5,B]
[5,B]

[2,F]
[5,B]
BLK CF 000-40-43 CO658-J8
Sheet_12-[4,C]

1
2
3
4
CO658-J1
1

GROUND TO PLATFORM MODULE

MODULE POWER
MODULE GROUND

POWER TO PLATFORM MODULE

BLK 000-40-3 GND
5 BRAKE/2 SPEED VALVE GROUND
WHT 4-1 BRAKE
23 BRAKE VALVE
WHT 4-2 TWO SPEED 2 SPEED VALVE
20
WHT 4-3 LEFT TRACK DRIVE FORWARD 16AWG
3 LEFT TRACK DRIVE FORWARD VALVE GROUND MODE
WHT 4-4 LEFT TRACK DRIVE REVERSE 16AWG
G 6 LEFT TRACK DRIVE REVERSE VALVE
19 IGNITION RELAY GROUND
8 BOOM ANGLE SENSOR GROUND
2 CAN1 TERMINATOR
4 PLATFORM EMS
BLK 000-40-162 GND
1 7 FOOTSWITCH
MSSO

SW712-2 BLK 000-40-162 GND

9 MSSO GROUND GROUND MODE POWER TO PLATFORM
WHT 4-163 MSSO
1 [6,E] 16
SW712-1 WHT 4-78 AUX PUMP 16AWG
AUX PUMP RELAY 1 13 APU ENABLE RELAY TILT SENSOR GROUND
X702 14 TELESCOPE RETRACTED SWITCH #1
X719 15
WHT 4-94 EMR4 IGNITION WHT 4-94 EMR4 IGNITION
1 10 ECU POWER
BLK 000-40-557 GND WHT 4-80 GLOW PLUG 18AWG
2 12 ENGINE GLOW PLUG RELAY
3 17 CAN1 TERMINATOR
WHT 4-80 GLOW PLUG 18AWG
4 18 PLATFORM MODE
5 21 CAN1 HIGH
WHT 4-5 POWER
6 1 28 ANALYZER POWER CAN1 LOW
ANALYZER

WHT 4-6 RECEIVE

7 2 29 ANALYZER RS-232 RX CAN1 SHIELD
WHT 4-7 TRANSMIT
8 3 30 ANALYZER RS-232 TX BOOM ANGLE SENSOR POWER
BLK 000-40-4 GND
4 31 ANALYZER GROUND TILT SENSOR POWER
X686 24
F C
BLK 000-40-161 GEN GND
25
UNIVERSAL GROUND MODULE BOOM ANGLE SENSOR #1
GENERATOR WHT 4-74 GEN ON WHT 4-74 GEN ON
B 22 GENERATOR ENABLE RELAY BOOM ANGLE SENSOR #2
CONNECTOR WHT 4-82 GEN IGN
A [5,G] 26 TELESCOPE RETRACTED SWITCH POWER
X711 27 TELESCOPE RETRACTED SWITCH GROUND
WHT 4-67 START 16AWG
11 ENGINE START RELAY CAPACITY LENGTH SWITCH #1
RED 4-76 ALT EXCITE 16AWG
32 ALTERNATOR EXCITATION TRANSPORT SWITCHES POWER
BLK 102 CNFG1 GND
Sheet_12-[4,C] 33 GROUND DOS SWITCH
WHT 4-117 PROX 2
[7,E] 34 TELESCOPE RETRACTED SWITCH #2 GROUND DISPLAY GROUND
WHT 4-167 CAP PROX 2
[7,D] 35 CAPACITY LENGTH SWITCH #2 GROUND DISPLAY POWER
CRAWLER PLATFORM JOYSTICKS
CO658-J2
10 MSSO SWITCH
21 CAN2 TERMINATOR
14 CAN2 TERMINATOR
28 CAN2 SHIELD
30 CAN2 LOW
5 CAN2 HIGH
TO SHEET 5 7
GRAY 12
VIOLET
ELECTRONIC JOYSTICK

7 VIOLET 23
SWING

GREEN
DRIVE AND STEER

S731
3 13
E 8 ORANGE 20
WHITE S732
2 9
6 3
YELLOW
5 WHITE 15
RED
LIFT

1 BLUE 4
WHT/YEL WHT/RED
4 S727 16
RED 8
C001-J6
TO SHEET 5 19
31
8
WHITE
CO69-J2 11
6 22
S725 BLUE
ELECTRONIC JOYSTICK
SWING

5 35
BLUE
LIFT AND SWING

1 34
ORN/YEL BLU/YEL
4 1
BLU/YEL
7 2
BROWN
3 17
BLACK
2 33
LIFT

S726
C001-J5 24
RED
18
GREEN
26
D 32
25
6
29
27
CO658-J3

CO658-J4
10

11
12
13

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
1
5
6

4
7
3
9
2
8

1
2
3
4
5
6
7
8
9

TO SHEET 5 TO SHEET 5

CO69-J3 CO69-J4

C
[5,H]

Sheet_9-[1,E]
[5,H]

[5,G]
[5,G]

[5,G]
[5,H]
BLK 000-40-64 BATT GND 16AWG

BLK 000-40-14 STRB GND

S85
YEL 4-54 STRB LIGHT
RED 4-76 ALT EXCITE 16AWG

BLK 000-40-161 GEN GND

B
BLK 000-40-14 STRB GND

BLK 000-40-81 16AWG

BLK 000-40-11 NEGATIVE

WHT 4-65

BLK 000-40-11 NEGATIVE

YEL 4-36 MODL PWR 14AWG
WHT 4-67 START 16AWG

BLK 000-40-557 GND

BLK 0040-558 GND

YEL 4-54 STRB LIGHT

GRN CAN2 LO

YEL 4-81 GEN IGN

GRN CAN2 LO

WHT 4-66 IGN

YEL CAN2 HI

YEL CAN2 HI
YEL 4-84 IGN

YEL 4-84 IGN

YEL 4-85 IGN

YEL 4-72 IGN

RED 4-65 PWR

[5,G]
LB280
2
1
X720

MS717

X701
1
2
3
4
5
6

MS718
1
2
3
4
5
6
7
8
9
10
11
12

J
B
G
F
E
D
C
H
A
1
2
3
4
5
6
7
8
9
10
11
12

ENGINE CONNECTORS
DIAGNOSTIC
CONNECTOR

NEGATIVE BUS
4460836 STROBE
IGN POWER
LIGHT
4460836

SHEET 11

1 2 3 4 5

Figure 7-117. Electrical Schematic - Sheet 19 of 25

7-122 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

FUSE BOX
TO B+ AUX
MTB SELECT SWITCH
R4 R3 R2
F1 F2 F3 F4 F5 F6 F7 F8 F9 D1 D2 D3 R1 PUMP RELAY
MTB EMS

15A
15A

1
5A
5A

5A
5A

X692
ENGINE PIVOT POINT
85 86 87 30 87a 85 86 87 30 87a 85 86 87 30 87a 85 86 87 30 87a

RED 4-49 B+ AUX PMP

28
37
33
38
34
39
35
40
36
45
41
46
42
47
43
48
44
29
25
30
26
31
27
19
24
15
16
23
20
17
22
13
14
21
18

10
32

3
4

8
5

1
2
9
6
[4,B]

[5,B]
1
X691

WHT 4-170
WHT 4-552 16AWG
RED 4-51 12AWG

RED 4-37 EMS 12AWG

RED 4-169 MODE SEL 12AWG

RED 4-39
WHT 4-41
RED 4-71 12AWG

WHT 4-38
WHT 4-82 GEN IGN

RED 4-563 LIGHT OPT

BLK 000-40-13 GND

WHT 4-66 IGN
YEL 4-36 MODL PWR 14AWG

YEL 4-81 GEN IGN

RED 4-550 12AWG

YEL 4-72 IGN

RED 4-166 12AWG

RED 4-350 12AWG

RED 4-169-1 MOD SEL

SW683-1B
SW683-1A

SW683-2A
SW683-2B
RED 4-40 12AWG
RED 4-35 IGN 12AWG

WHT 4-65
WHT 4-50

1B
1A

2A
2B
BLK 000-40-64 BATT GND 16AWG

[4,B] BLK 000-40-81 16AWG

SW682-B1
SW682-B
SW104-1

SW104-3

SW104-2

SW104-4
BLK 000-40-8 MODL GND 10AWG

RED 4-169 MODE SEL 12AWG

RED 4-47 SW683-2B

RED 4-175 SW683-2A

30A
WHT 4-51 PLTFM ENABLE

RED 4-46 12AWG

RED 4-37 EMS 12AWG
S710

IP688
WHT 4-50
RED 4-40 12AWG

RED 4-46 12AWG

RED 4-51 12AWG

S715

S685
BLK 000-40-12 PLATF GND 12AWG RED 4-563 LIGHT OPT

[5,B]

[5,B]
[5,B]

[2,F]
[5,B]
CO658-J8
1
2
3
4

BLK 000-40-12 PLATF GND 12AWG X681 G

1 26 16
GROUND TO PLATFORM MODULE
MODULE POWER
MODULE GROUND

POWER TO PLATFORM MODULE

RED 4-71 12AWG

5 BRAKE/2 SPEED VALVE GROUND 12 12
23 BRAKE VALVE 31 5
WHT 4-552 16AWG
20 2 SPEED VALVE 27 9
RED 4-169-1 MOD SEL
3 LEFT TRACK DRIVE FORWARD VALVE GROUND MODE 3 7
6 LEFT TRACK DRIVE REVERSE VALVE 11 8

X43 BOOM CABLE

WHT 4-51 PLTFM ENABLE
BLK 000-40-13 GND
19 IGNITION RELAY GROUND 19 13
BLK 000-40-76 GND
8 BOOM ANGLE SENSOR GROUND 9 10

TO SHEET 3
WHT 4-133 CAN1 TERM
2 CAN1 TERMINATOR 17 14
WHT 4-42 PLTF EMS WHT 4-43 PLTF EMS
4 PLATFORM EMS 1 17
WHT 4-52 FOOT SW S684
7 FOOTSWITCH 15 18
WHT 4-53 GROUND MODE
9 MSSO GROUND GROUND MODE POWER TO PLATFORM 14 4
WHT 4-52 FOOT SW
16 20 6
WHT 4-123 GND WHT 4-53 GROUND MODE
13 APU ENABLE RELAY TILT SENSOR GROUND 10 11
WHT 4-110 PROX 1
14 TELESCOPE RETRACTED SWITCH #1 21 19
15 5 15

5A
YEL CAN 1 HI
10 30 3

IP105
ECU POWER
GRN CAN 1 LO
12 ENGINE GLOW PLUG RELAY 8 2
17 CAN1 TERMINATOR 6 WHT 4-51-1 PLTFM ENABLE 1
WHT 4-132 PLAT MODE
18 PLATFORM MODE 2
21 CAN1 HIGH 13
YEL CAN 1 HI
MS687
F
GRN CAN 1 LO YEL CAN 1 HI
28 ANALYZER POWER CAN1 LOW 24 1
29 ANALYZER RS-232 RX CAN1 SHIELD 18 2
WHT 4-118 PWR 5V YEL CAN 1 HI 20AWG
30 ANALYZER RS-232 TX BOOM ANGLE SENSOR POWER 16 11
WHT 4-108 VCC YEL CAN 1 HI

3 x 4 Buss Bar
31 ANALYZER GROUND TILT SENSOR POWER 34 12
GRN CAN 1 LO
24 22 3

CAN 1
25
UNIVERSAL GROUND MODULE BOOM ANGLE SENSOR #1 4
WHT 4-86 BM ANGLE SEN 1 GRN CAN 1 LO
4
WHT 4-87 BM ANGLE SEN 2
22 GENERATOR ENABLE RELAY BOOM ANGLE SENSOR #2 7 9
WHT 4-119 PWR 12V GRN CAN 1 LO 20AWG
26 TELESCOPE RETRACTED SWITCH POWER 33 10
BLK 000-40-75 GND
27 TELESCOPE RETRACTED SWITCH GROUND 28 5
WHT 4-115 CAPACITY 1
11 ENGINE START RELAY CAPACITY LENGTH SWITCH #1 23 6
WHT 4-116 POWER 12V
32 ALTERNATOR EXCITATION TRANSPORT SWITCHES POWER 32 SN706 7
WHT 4-92 DOS SW
33 GROUND DOS SWITCH 35 8

TILT SENSOR
WHT 4-108 VCC

CAN BASED
BLK 000-40-51 GND 1
34 TELESCOPE RETRACTED SWITCH #2 GROUND DISPLAY GROUND 25 WHT 4-123 GND GND
RED 4-97 PWR 2
35 CAPACITY LENGTH SWITCH #2 GROUND DISPLAY POWER 29 YEL CAN 1 HI 20AWG B+
CO658-J7 3
GRN CAN 1 LO 20AWG CAN-L
4
WHT 4-163 MSSO CAN-H
10 MSSO SWITCH 8 [2,G]
WHT 4-96 CAN2 TERM
21 CAN2 TERMINATOR 7 X84
RED 4-65 PWR
14 CAN2 TERMINATOR 6 1
BLK 0040-558 GND
28 CAN2 SHIELD 5
GRN CAN2 LO RED 4-97 IGN
2 UNIVERSAL E
30 CAN2 LOW 4
YEL CAN2 HI WHT 4-51-1 PLTFM ENABLE
3 TELEMATICS
5 CAN2 HIGH 3 4
7 2
12 1 X714
WHT 4-111 PWR 12V
23 CO658-J12 1
BLK 000-40-77 GND TELESCOPE RETRACTED
13 2 PROXIMITY SENSOR
WHT 4-110 PROX 1
20 3 SHEET #3
WHT 4-113 PWR 12V
9 4 ZONE C5/6
BLK 000-40-80 GND
3 5 X616B
S703 WHT 4-117 PROX 2
15 [3,F] 6
4
16 S704
8
19
SN705
31
BLK 000-40-78 GND

ANGLE SENSOR
11 A
WHT 4-106 PWR 5V

MAIN BOOM
S697
22 B
S696 WHT 4-86 BM ANGLE SEN 1
35 C
BLK 000-40-79 GND
34 E
WHT 4-112 PWR 5V
1 F
2
WHT 4-87 BM ANGLE SEN 2
D D
17
33
24
18 X713
26 WHT 4-168 PWR 12V
1
32 BLK 000-40-167 GND
2
25
WHT 4-115 CAPACITY 1 DUAL DRIVE DISABLE LENGTH
3
6
WHT 4-114 PWR 12V PROXIMITY SENSOR
4
BLK 000-40-98 GND SHEET #3
29 5
WHT 4-167 CAP PROX 2 ZONE C5
27 [3,F] 6
X615B
7
8

OSC AXLE #2
CABLE
X709 1
WHT 4-116 POWER 12V

DOS
1 2 2
WHT 4-92 DOS SW
2 1 3
CO658-J3

CO658-J4

X708 4
10

11
12
13

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
1
5
6

4
7
3
9
2
8

1
2
3
4
5
6
7
8
9

CABLE
SN693

RED 4-97 PWR

RED 4-97 PWR S87
C
TO SHEET 5 TO SHEET 5

CO69-J3 CO69-J4

TO ENGINE
BLK 000-40-51 GND

PIVOT GND STUD

RED 4-97 PWR

YEL CAN2 HI
[5,H]

GRN CAN2 LO
GD700
Sheet_9-[1,E]
[5,H]

6
5
4
3
2
1

B
[5,G]
[5,G]

[5,G]
[5,H]
BLK 000-40-64 BATT GND 16AWG

BLK 000-40-14 STRB GND

S85
YEL 4-54 STRB LIGHT
BLK 000-40-161 GEN GND
BLK 000-40-14 STRB GND

BLK 000-40-81 16AWG

BLK 000-40-11 NEGATIVE

WHT 4-65

BLK 000-40-11 NEGATIVE

YEL 4-36 MODL PWR 14AWG
BLK 000-40-557 GND

GRN CAN2 LO

GRN CAN2 LO
YEL CAN2 HI

GRN CAN2 LO
BLK 0040-558 GND

GRN CAN2 LO
YEL CAN2 HI

YEL CAN2 HI
YEL CAN2 HI
YEL 4-54 STRB LIGHT

YEL 4-81 GEN IGN

GRN CAN2 LO

WHT 4-66 IGN

YEL CAN2 HI
YEL 4-84 IGN

YEL 4-85 IGN

YEL 4-72 IGN

MDI/HOURMETER
RED 4-65 PWR
[5,G]
LB280

MS699
2
1

8
7
6
5
10
9
4
3
12
11
2
1
MS717

X701
MS718
1
2
3
4
5
6
7
8
9
10
11
12

J
B
G
F
E
D
C
H
A

A
1
2
3
4
5
6
7
8
9
10
11
12

DIAGNOSTIC
CONNECTOR 3 x 4 Buss Bar
NEGATIVE BUS CAN 2
4460836 STROBE
IGN POWER
LIGHT
4460836
1001165354-N
SHEET 11 MAF01450

4 5 6 7 8

Figure 7-118. Electrical Schematic - Sheet 20 of 25

3121671 7-123
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5 6 7 8

H H

CRAWLER MAIN VALVE HARENSS

PLTF ROT L

HV53
BLK 000-40-19 TO SHEET 4
2
WHT 4-9 ROTATE LEFT
1
CO69-J2
PLTF ROT R

HV52 CO69-J2
BLK 000-40-20 WHT 4-9 ROTATE LEFT
2 10 PLATFORM ROTATE LEFT VALVE
WHT 4-10 ROTATE RIGHT WHT 4-10 ROTATE RIGHT
1 21 PLATFORM ROTATE RIGHT VALVE
BLK 000-40-5 GND
G WHT 4-12 JIB UP
17 PLATFORM ROTATE / JIB LIFT VALVES GROUN
G
S54 12 JIB UP VALVE
WHT 4-13 JIB DOWN
HV33 23 JIB DOWN VALVE
JIB UP

BLK 000-40-23 BLK 000-40-25 GND

2 30 MAIN DUMP VALVE GROUND
WHT 4-12 JIB UP WHT 4-14 MAIN DUMP
1 13 MAIN DUMP VALVE
20
2
JIB DOWN

HV36 24
BLK 000-40-24 WHT 4-19 MAIN TELE IN
2 4 MAIN TELESCOPE IN VALVE
WHT 4-13 JIB DOWN BLK 000-40-7 GND 18 AWG
1 14 MAIN TELESCOPE / PLATFORM LEVEL VALVES GROUND
WHT 4-20 MAIN TELE OUT
16 MAIN TELESCOPE OUT VALVE
WHT 4-8 LEVEL UP
MAIN DUMP

5 PLATFORM LEVEL UP VALVE

HV37 WHT 4-11 LEVEL DOWN
BLK 000-40-25 GND 7
PLATFORM LEVEL DOWN VALVE
2 28 STEER VALVES GROUND
WHT 4-14 MAIN DUMP
1 3
15
MAIN TELE IN

WHT 4-21 RIGHT TRACK DRIVE REVERSE 16AWG

8 RIGHT TRACK DRIVE REVERSE VALVE
HV38 WHT 5-3 RIGHT TRACK DRIVE FORWARD 16AWG
BLK 000-40-31 19 RIGHT TRACK DRIVE FORWARD VALVE
2 WHT 4-23 FLOW CONTROL
WHT 4-19 MAIN TELE IN 31FLOW CONTROL GROUND
1 WHT 4-24 MAIN LIFT UP
11 MAIN LIFT UP VALVE
WHT 4-104 MAIN LIFT DOWN
22 MAIN LIFT DOWN VALVE
MAIN TELE OUT

S55
F WHT 4-26 SWING RIGHT
WHT 4-27 SWING LEFT
35 SWING RIGHT VALVE F
HV39 34 SWING LEFT VALVE
BLK 000-40-21
2 1
WHT 4-20 MAIN TELE OUT WHT 4-103 MAIN LIFT DOWN AUX
1 9 AUX POWER MAIN LIFT DOWN VALVE
MAIN VALVE BANK

33
PLTF LVL UP

18
HV51 26 HEAD/TAIL LIGHT ENABLE RELAY
BLK 000-40-22
2 32
WHT 4-8 LEVEL UP WHT 4-75 FUEL SENSOR
1 25 FUEL SENSOR SIGNAL
BLK 000-40-45
6 FUEL SENSOR GROUND
PLTF LVL DOWN

29GROUND ALARM GROUND

HV50 27GROUND ALARM
BLK 000-40-30
2
WHT 4-11 LEVEL DOWN
1
MAIN LIFT DOWN

HV46
BLK 000-40-63 CF
2
WHT 4-104 MAIN LIFT DOWN
1
MAIN LIFT DOWN

E TO SHEET 4 E
HV66
BLK 000-40-49 AUX DOWN CF C069-J3
AUX

2 CO69-J3
WHT 4-103 MAIN LIFT DOWN AUX
1 BLK 000-50-54 RIGHT TRACK CF 16AWG
2 RIGHT TRACK DRIVE VALVES CURRENT FEEDBACK (CRAWLER)
BLK 000-40-49 AUX DOWN CF
MAIN LIFT UP

5 AUXILIARY DOWN CURRENT FEEDBACK

BLK 000-40-33 CF
6 FLOW CONTROL VALVE CURRENT FEEDBACK
HV45 BLK 000-40-35 CF
BLK 000-40-34 CF S57 14 MAIN LIFT VALVES CURRENT FEEDBACK
2 BLK 000-40-38 CF
WHT 4-24 MAIN LIFT UP 4 SWING VALVES CURRENT FEEDBACK
1
3
WHT 4-30 ALRM
7GROUND ALARM POWER
STEER RIGHT

BLK 000-40-44 CF
1 LEFT TRACK DRIVE VALVES CURRENT FEEDBACK (CRAWLER)
HV40
8
2 WHT 4-105 CRIBBING
9 CRIBBING ENABLE SWITCH
1 WHT 5-101 JUMP ENABLE
10 JUMP ENABLE
BLK 102 CNFG1 GND
11 GROUND
STEER LEFT

12
HV42
WHT 4-102 HEAD & TAIL LIGHTS

13
2
1
WHT 5-101 JUMP ENABLE
FLOW CONTROL

D D
BLK 102 CNFG1 GND
WHT 4-105 CRIBBING

HV44
BLK 000-40-44 CF

BLK 000-40-33 CF
2
WHT 4-23 FLOW CONTROL
1
SWING RIGHT

HV47 S58
BLK 000-40-37 CF
2
WHT 4-26 SWING RIGHT
1
X513A
SWING LEFT

HV48
BLK 000-40-39 CF
1
2
3
4
5
6

2
WHT 4-27 SWING LEFT
1
2
3
4
5
6
X513B

1
WHT 4-105 CRIBBING

BLK 102 CNFG1 GND

BLK CF 000-40-43
RIGHT
TRACK
DRIVE
REVERSE

BLK 000-50-51 CF 16AWG

4
BLK 000-40-10 ALRM GND

WHT 4-21 RIGHT TRACK DRIVE REVERSE 16AWG

3
BLK 000-50-50 CF 16AWG S65
C 2 C
RIGHT
TRACK
DRIVE
FORWARD

WHT 5-3 RIGHT TRACK DRIVE FORWARD 16AWG

1
WHT 4-29 ALRM
WHT 4-30 ALRM

X80
SN67 X68

X70

Sheet_11-[1,G]

Sheet_9-[1,D]

Sheet_11-[3,F]
1
1

AH56
2
1

C
B
A

ALARM

FUEL
B SENSOR B

A A

1001165354-N
SHEET 12 MAF01460
1 2 3 4 5 6 7 8

Figure 7-119. Electrical Schematic - Sheet 21 of 25

7-124 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121671 7-125
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

H
HDGCP90

C
PIVOT POINT OF AN ENGINE TRAY
GROUND STUD LOCATED ON THE

POWER
GROUND STUD LOCATED
ON THE ENGINE BLOCK

ENGINE STARTER FUEL PUMP

AUX PUMP BATTERY AUX PUMP START
RELAY
1

RELAY
X208

X207
M
M

BT698+
BT698-
1

BLK FUEL PUMP NEGATIVE

WHT FUEL PUMP POSITIVE

85
85

87
MS115+
MS115-
1

1
1

1
X113

X112

RL117-85
RL117-87

RL117-30

RL117-86

EC116-B+
RL114-85

RL114-86

RL114-30

RL114-87

EC116-B-
RED 2/0AWG
BLK 2/0AWG
BLK 16AWG

EC116
1

1
1

1
RED 2/0AWG
BLK 2/0AWG
BLK 2/0AWG

BLK 2/0AWG
BLK 2/0AWG

BLK 2/0AWG

RED 2/0AWG
RED 2/0AWG

RED 2/0AWG
RED 2/0AWG
RED 2/0AWG

RED 2/0AWG

RED 14AWG

RED 14AWG
BLK 16AWG

D
RED 1-1 6AWG 40A RED 1-1
C 1
R X1 F1
M
L
K OPTION 2
J
H TO KUBOTA ENGINE
G
E CONNECTOR
X193 B
TO TURN TABLE
5 S
WHT 6-14 IGNITION WHT 6-14 IGNITION
1 A
HARNESS BLK CAN LO BLK CAN LO
4 P
RED CAN HI RED CAN HI
TO SHEET 4, A2 3
WHT 6-12 ENGINE START WHT 6-12 ENGINE START
N
2 F
X183 6 X205
A
X247
GRN 6-22 GRN 6-22
4 D
VIO 6-21 VIO 6-21
3 C FUEL REGULATOR
FUEL REGULATOR WHT 6-20 WHT 6-20
2 B TO KUBOTA HARNESS
RED 6-19 RED 6-19
1 A
X248
SHEET 13

1 2 3 4 5

Figure 7-120. Electrical Schematic - Sheet 22 of 25

7-126 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

OPTION 1
*
E

POWER

ENGINE STARTER FUEL PUMP

1
X208

X207
M

BLK FUEL PUMP NEGATIVE

WHT FUEL PUMP POSITIVE

EC116-B+
EC116-B-

EC116
1

1
RED 2/0AWG
RED 14AWG

*
X2
D
RED 1-2 10AWG
2
KUBOTA
RED 1-1 6AWG 40A RED 1-1 6AWG RED 1-3 10AWG
C 1 1
R X1 F1 S1 ENGINE
M
HARNESS
L
K OPTION 2
J
H TO KUBOTA ENGINE
G
NOTE
E CONNECTOR
B
S
REFER TO SERVICE MANUAL FOR OPTION ASSEMBLED
WHT 6-14 IGNITION
A
BLK CAN LO
P
OPTION 1 COMES ASSEMBLED ON KUBOTA HARNESS
RED CAN HI
N
WHT 6-12 ENGINE START
F
OPTION 2 JLG HARNESS ADDED TO KUBOTA HARNESS

GRN 6-22
VIO 6-21
X205

D
* CONNECTS TO FACTOR KUBOTA ENGINE HARNESS AT THIS POINT A

C FUEL REGULATOR
WHT 6-20
B TO KUBOTA HARNESS
RED 6-19
A
X248
1001165354-N
SHEET 13 MAF01470

4 5 6 7 8

Figure 7-121. Electrical Schematic - Sheet 23 of 25

3121671 7-127
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

2500W GENERATOR HARNESS

RED 4-557 GEN PWR 12AWG
1
X633
H RED 4-555 GEN PWR 12AWG
1 87
4

GEN RELAY
X632 30A RED 4-556 GEN PWR 30
TO SHEET 4 1
87a
A IP634 3
WHT 4-554 GEN ON 85
TO X530 B
BLK 000-40-553 GND
2
86
C 5
X631 RL630

TO PLATFORM BOX
4000W GENERATOR HARNESS
GENERATOR
G "ON"
GENERATOR LIGHT
SWITCH
BLU/ORN 52-4

BLU/ORN 52-3

GENERATOR CONTROL BOX

BLU/ORN 52-4

GENERATOR
3 C
B +12V ENABLE BLU/ORN 52-5
4

CR1
C BAT. NEGATIVE BLACK
F D
TO 15 POS. MATE-N-LOCK
J2-15
PIN 1

PIN 2

120V 120V
CONNECTOR
NOTE: CONNECT WIRE #90 TO TERMINAL 3T
90

20 AMP
PIN 1
PIN 2

TO 15 POS. MATE-N-LOCK CONNECTOR GENERATOR CASE

10/4 BOOM CABLE
1T 3T 2T
LINE 1
BLACK

BLU/ORN 52-4 LINE 2

BROWN

BLU/ORN 52-3 NEUTRAL

BLUE
E ENGINE GROUND
SUPPORT GREEN/YELLOW
2 1

SUPPLIED WITH GENERATOR

TO PLATFORM BOX 7500W GENERATOR HARNESS

D
GENERATOR GENERATOR AND AC WIRING OPTION
"ON" 240VOLT
GENERATOR LIGHT 30 AMP
RECEPT.
SWITCH PLUG AND CONNECTOR X Y G
TERMINANTION
BOOM CABLE
BLU/ORN 52-4

BLU/ORN 52-3

BLU/ORN 52-4

GENERATOR PLATFORM

GREEN
JUNCTION BLACK
WHITE
BOX

C
30 AMP
LINE 1 F
BLACK 1 Z BLACK 1 1 BLACK
TO 15 POS. MATE-N-LOCK
J2-15
PIN 1

PIN 2

CONNECTOR LINE 2 E
BLACK 2 Y BLACK 2 2 WHITE
LINE 3 D
BROWN X BROWN 3 RED
PIN 1

C
PIN 2

LINE 4 NEUTRAL
TO 15 POS. MATE-N-LOCK CONNECTOR BLUE WH BLUE 4
LINE 5 GROUND B
GRN/YEL GRD GRN/YEL 5 GREEN

A 15 AMP
BLU/ORN 52-4 C.B.

B BLU/ORN 52-3
GREEN

BLACK
WHITE

2 1

G W B
120VOLT
15 AMP
RECEPT.

SHEET 14

1 2 3 4 5

Figure 7-122. Electrical Schematic - Sheet 24 of 25

7-128 3121671
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4 5 6 7 8

2500W GENERATOR HARNESS H

RED 4-557 GEN PWR 12AWG

1
X633
RED 4-555 GEN PWR 12AWG
1 87
4

GEN RELAY
X632 30A RED 4-556 GEN PWR 30
TO SHEET 4 1
87a
A IP634 3
WHT 4-554 GEN ON 85
TO X530 B
BLK 000-40-553 GND
2
86
C 5
X631 RL630

4000W GENERATOR HARNESS G

GENERATOR CONTROL BOX 60 HZ 4000 WATT GENERATOR AND AC WIRING

3 C
B +12V ENABLE BLU/ORN 52-5 A BLU/ORN 52-5 14 BLU/ORN 52-5 J1-22
4
CR1

C BAT. NEGATIVE BLACK

NOTE: CONNECT WIRE #90 TO TERMINAL 3T PLATFORM BLACK X OPTIONAL

JUNCTION Y 240VOLT
WHITE
BOX 20 AMP
GREEN G RECEPT
TERMINAL
10/4 BOOM CABLE STRIP

LINE 1
BLACK 1 15 AMP
C.B.
LINE 2
BROWN 2 BLACK BRASS E
120VOLT
NEUTRAL 15 AMP
BLUE 3 WHITE SILVER GFCI
RECEPT
GROUND GREEN
GREEN/YELLOW 4 GREEN

7500W GENERATOR HARNESS

GENERATOR AND AC WIRING OPTION

240VOLT
30 AMP
RECEPT.
PLUG AND CONNECTOR X Y G
TERMINANTION
BOOM CABLE

PLUG AND CONNECTOR

TERMINATION
PLATFORM DOM. ONLY
GREEN

JUNCTION
BLACK
WHITE

BOX C

CONNECTOR PLUG

30 AMP
LINE 1 F
BLACK 1 Z BLACK 1 1 BLACK Z

LINE 2 E
BLACK 2 Y BLACK 2 2 WHITE Y
LINE 3 D 240 VOLT
BROWN X BROWN 3 RED X 3 PHASE
WELDER
LINE 4 NEUTRAL C
BLUE WH BLUE 4
LINE 5 GROUND B
GRN/YEL GRD GRN/YEL 5 GREEN GR B
A 15 AMP
C.B.
GREEN

BLACK
WHITE

G W B
120VOLT
15 AMP
RECEPT.

1001165354-N
SHEET 14 MAF01480

4 5 6 7 8

Figure 7-123. Electrical Schematic - Sheet 25 of 25

3121671 7-129
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

7-130 3121671
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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