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800A, 800AJ SN 0300183033 To Present

JLG 800aj manual

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589 views612 pages

800A, 800AJ SN 0300183033 To Present

JLG 800aj manual

Uploaded by

Brian Bobb

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Available Formats

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Service and Maintenance Manual

Model
800A
800AJ
S/N 0300183034 to Present

3121628

June 29, 2018 - Rev E

AS/NZS
INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL C MAINTENANCE
This section contains the general safety precautions which
must be observed during maintenance of the aerial platform.
It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
possible injury to themselves or others, or damage to the SAFETY VIOLATION.
equipment. A maintenance program must be followed to
ensure that the machine is safe to operate. • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER. TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during maintenance • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-
are inserted at the appropriate point in the manual. These pre- FORMING ANY MAINTENANCE.
cautions are, for the most part, those that apply when servic-
ing hydraulic and larger machine component parts. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
Your safety, and that of others, is the first consideration when CAUGHT ON OR ENTANGLED IN EQUIPMENT.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
the aid of a mechanical device. Do not allow heavy objects to MACHINE AND IN SERVICE MANUAL.
rest in an unstable position. When raising a portion of the • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
equipment, ensure that adequate support is provided. SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL-
ANT SYSTEM.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL-
BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
ITY OF THE OWNER/OPERATOR.
BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
HAS BEEN ENGAGED.
B HYDRAULIC SYSTEM SAFETY • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER-
FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
It should be noted that the machines hydraulic systems oper-
POWER CONTROLS.
ate at extremely high potentially dangerous pressures. Every
effort should be made to relieve any system pressure prior to • BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING
disconnecting or removing any portion of the system. REPLACEMENT OF ELECTRICAL COMPONENTS.

Do not use your hand to check for leaks. Use a piece of card- • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
board or paper to search for leaks. Wear gloves to help protect STOWED IN THEIR PROPER PLACE.
hands from spraying fluid. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-
VENTS.

5-15 O-ring Boss (ORB) - Table 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-16 O-ring Boss (ORB) - Table 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-17 O-ring Boss (ORB) - Table 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-18 Metric Flat Face Port (MFF) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-26 British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5-27 British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-29 British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5-30 British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5-31 Flange Code (FL61 & FL62) -Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-32 Flange Code (FL61 & FL62) - Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-33 Symbols Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
5-34 Gauge and Port information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
5-35 Excessive Noise and/ or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-136
5-36 Actuator Response Is Sluggish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-136
5-37 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
5-38 Low Pump Output Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
5-39 Pressure or Flow Instability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5-40 System Pressure Not Reaching Pressure Compensator Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5-41 High Inlet Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
6-1 Analyzer Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-3 800A Machine Configuration Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-4 800AJ Machine Configuration Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-5 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-6 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-7 ADJUSTMENTS - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6-8 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-9 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6-10 SkyGlazier Capacity Reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-11 Pipe Rack Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-12 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
6-13 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

3121628 xvii
LIST OF TABLES

TABLE NO. TITLE PAGE NO.

This page left blank intentionally.

xviii 3121628
SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.2 CAPACITIES
Table 1-1. Operating Specifications Table 1-2. Capacities

Travel Speed 3.0 MPH (4.83 Km/hr.) Fuel Tank Approx. 39 Gallons (147.6 L)
Gradeability Hydraulic Tank Approx. 40 Gallons (151.4 L)
2WD 30% Hydraulic System (Including Tank) 77 Gallons (291.4 L)
4WD 45%
Drive Hub 44 ounces (1.3 L)
Turning Radius (Outside)
Drive Brake 2.7 ounces (80 ml)
2WS 19 ft. 8 in. (6.02 m)
4WS 11 ft. 7 in. (3.53 m) Engine Crankcase
Deutz D2011L04 11 qt (10.5 L)
Turning Radius (Inside)
Deutz TD 2.9L 2.4 Gallons (8.9 L) w/Filter
2WS 12 ft. 6 in. (3.8 m)
GM 4.5 qt (4.25 L) w/Filter
4WS 6 ft. (1.83 m)
Deutz TD 2.9 L4 China III 2.11Gallons (8.0L)
Overall Width 8 ft. 2 in. (2.48 m) Ford 2.5 L MSG-425 7 qt (6.6 L)
Tailswing 8 ft. 4 in. (2.56 m)
Ground Clearance 11 in.(28 cm) 1.3 TIRES
Machine Height Stowed 9 ft. 9.5 in.(2.98 m)
Table 1-3. Tire Specifications
Machine Length (Stowed)
800A 36 ft. 9 in. (11.25 m) PLY LOAD
SIZE TYPE PRESSURE
800AJ 36 ft. 6 in. (11.13 m) RATING RANGE
Wheel base 10 ft. (3.05 m) 15-625 pneumatic 16 H 95 psi (6.5 bar)
Boom Elevation - 800A 15-625 foam-filled 16 H N/A
Above Grade +80 ft.(24.38 m) 18-625 foam-filled 16 H N/A
Below Grade -15 ft. 7 in. (4.75 m)
Boom Elevation - 800AJ
Above Grade +80 ft. (24.48 m) 1.4 ENGINE DATA
Below Grade -13 ft. 1 in. (3.99 m) Table 1-4. Deutz D2011L04 Specifications
Max. Ground Bearing Pressure 76 psi. (5.3 kg/cm2) Type Liquid Cooled (Oil)
Max. Tire Load 17,755 lbs. (8054 kg) Fuel Diesel
Machine Weight approximately* 35,500 lbs. (16,103 kg) Oil Capacity
* Certain options or country standards can increase weight. Cooling System 5 qt (4.5 L)
Crankcase 11 qt (10.5 L) w/Filter
Total Capacity 16 qt (15 L)
Idle RPM 1000
Low RPM 1800
High RPM 2600
Alternator 55 Amp, belt drive
Fuel Consumption 0.88 GPH (3.33 lph)
Battery 1000 Cold Cranking Amps, 210 minutes
Reserve Capacity, 12 VDC
Horsepower 61.6 @ 2600 RPM, full load

3121628 1-1
SECTION 1 - SPECIFICATIONS

Table 1-8. Ford 2.5L DF, MSG-425

Table 1-5. Deutz TD 2.9 Specifications
Fuel Gasoline/LP Gas
Fuel Ultra Low Sulfur Diesel (15 ppm)
Oil Capacity 7 qt (6.6 L)
Output 67 hp (50 kW)
Coolant Capacity 0.63 Gallons (2.4 L)
Torque 173 ft.lbs. (234 Nm) @ 1800rpm
Low RPM 1000 ±50 rpm
Oil Capacity (Crankcase) 2.4 Gallons (8.9 L) w/Filter
High RPM 3200 ±50 rpm
Cooling System 3.3 Gallons (12.5 L)
Alternator 150 AMP
Low RPM 1200 ± 50 rpm
Starter 64.4A @3574 RPM
High RPM 2600 ± 50 rpm
Fan Ratio 1:3
Alternator 95 Amp
Fuel Consumption
Fuel Consumption 0.65 GPH (2.48 lph) Gasoline 1 GPH (3.79 LPH)
LP 5.34 lb./h(2.42 Kg/h)
Max Output (Power)
Table 1-6. GM 3.0L Specifications Gasoline 84HP @3200
LP 80HP @3200
Fuel Gasoline or Gasoline/LP Gas
Max Output (Torque)
No. of Cylinders 4 Gasoline 142 ft. lbs. (192Nm) @2400 RPM
BHP LP 145 ft. lbs. (197Nm) @2400 RPM
Gasoline 83 hp @ 3000 rpm
LP 75 hp @ 3000 rpm
Bore 4.0 in. (101.6 mm)
Stroke 3.6 in. (91.44 mm)
Displacement 181 cu.in. (3.0 L, 2966 cc)
Oil Capacity w/filter 4.5 qt (4.25 L)
Minimum Oil Pressure
at idle 6 psi (0.4 Bar) @ 1000 rpm
Hot 18 psi (1.2 Bar) @ 2000 rpm
Compression Ratio 9.2:1
Firing Order 1-3-4-2
Max. RPM 2800
Fuel Consumption 2.55 GPH (9.65 lph)

Table 1-7. Deutz TD 2.9 L4 China III Specifications

Fuel Low Sulfur Diesel (500 ppm)

No. of Cylinders 4
Output 67 hp (50 kW)
Torque 173 ft.lbs. (234 Nm) @ 1800rpm
Displacement 177 cu.in. (2.9 L, 2900cc)
Oil Capacity (Crankcase) 2.11 Gallons (8.0 L) w/Filter
Cooling System TBD
Low RPM 1200 ± 50 rpm
High RPM 2600 ± 50 rpm
Alternator 95 Amp
Fuel Consumption TBD

1-2 3121628
SECTION 1 - SPECIFICATIONS

1.5 COMPONENT DATA 1.6 TORQUE REQUIREMENTS

Table 1-12. Torque Requirements
Drive System
Table 1-9. Drive System Specifications DESCRIPTION TORQUE VALUE (DRY) INTERVAL HOURS

Drive Motor Displacement Wheel Bolts 300 ft. lbs. 150

2WD 2.439 cu. in. max. 1.347 cu. in. min. (407 Nm)
(40 cc max. 22.09 cc min.)
4WD 2.13 cu. in. max. 0.63 cu. in. min. Support to Rotator Bolts 50 ft. lbs. 150
(35 cc max. 10.3 cc min.) (68 Nm)
Drive Hub Ratio Rotator Center Bolt 480 ft.lbs. 150
2WD 87:1 (651 Nm)
4WD 87:1
Drive Brake Automatic spring applied, hydraulically released Swing Bearing Bolts 190 ft. lbs. 50/600*
disc brakes. (260 Nm)

Starter or Aux Pump

Swing System Solenoid
Contacts 95 in. lbs. (10.5 Nm) As required
Table 1-10. Swing System Specifications
Coil 40 in. lbs. (4.5 Nm)
Swing Motor Displacement 4.9 cu. in. (80 cm3) *Check swing bearing bolts for security after first 50 hours of operation and every 600
Swing Brake Automatic spring applied hydraulically hours thereafter. (See Swing Bearing in Section 3.)
released disc brakes
NOTE: When maintenance becomes necessary or a fastener has
Swing Hub Ratio 36.13:1
loosened, refer to the Torque Chart to determine proper
torque value.
Auxiliary Power Pump
Table 1-11. Auxiliary Power Pump Specifications

Pump Output 1.43 GPM (5.6 lpm) @ 1800 psi. (124 bar)
Pump Displacement 0.273 cu. in. (4.48 cm3)
Valving Non-Adj. Unloader Preset to 230 psi
Adjustable Relief Set at 1800 psi.
Motor 12 V.D.C. 2T Extended EMC Protected Intermittent
Duty
Rotation Counterclockwise

3121628 1-3
SECTION 1 - SPECIFICATIONS

1.7 HYDRAULIC OIL Table 1-15. Mobil DTE 10 Excel 32 Specs

Table 1-13. Hydraulic Oil ISO Viscosity Grade #32

Pour Point, Max -65°F (-54°C)
HYDRAULIC SYSTEM
S.A.E. VISCOSITY Flash Point, Min. 482°F (250°C)
OPERATING
GRADE VISCOSITY
TEMPERATURE RANGE
+0° to + 180° F (-18° to +83° C) 10W at 40° C 32.7cSt

+0° to + 210° F (-18° to +99° C) 10W-20, 10W-30 at 100° C 6.63 cSt

+50° to + 210° F (+10° to +99° C 20W-20 at 100° F 32.7cSt

at 212° F 6.63 cSt
NOTE: Hydraulic oils must have anti-wear qualities at least to API Viscosity Index 164
Service Classification GL-3, and sufficient chemical stabil- Density (Kg/l) @ 15°C 0.8468
ity for mobile hydraulic system service. JLG Industries
Density (lb/in³) @ 60°F 0.0305
recommends Mobilfluid 424 hydraulic oil, which has an
SAE viscosity index of 152.
Table 1-16. Mobil EAL 224H Specs
NOTE: Aside from JLG recommendations, it is not advisable to mix
oils of different brands or types, as they may not contain Type Synthetic Biodegradable
the same required additives or be of comparable viscosi- ISO Viscosity Grade 32/46
ties. If use of hydraulic oil other than Mobilfluid 424 is Specific Gravity .922
desired, contact JLG Industries for proper recommenda-
Pour Point, Max -25°F (-32°C)
tions.
Flash Point, Min. 428°F (220°C)
Table 1-14. Mobilfluid 424 Specs Operating Temp. 0 to 180°F (-17 to 162°C)
Weight 7.64 lb. per gal.
SAE Grade 10W-30 (0.9 kg per liter)
Gravity, API 29.0 VISCOSITY
Density, Lb/Gal. 60°F 7.35 at 40° C 37 cSt
Pour Point, Max -46°F (-43°C) at 100° C 8.4 cSt
Viscosity Index 213
Flash Point, Min. 442°F (228°C)
NOTE: Must be stored above 32°F (14°C)
VISCOSITY
Brookfield, cP at -18°C 2700
Table 1-17. UCon Hydrolube HP-5046
at 40° C 55 cSt
at 100° C 9.3 cSt Type Synthetic Biodegradable
Viscosity Index 152 Specific Gravity 1.082
Pour Point, Max -58°F (-50°C)
pH 9.1
VISCOSITY
at 0° C (32° F) 340 cSt (1600SUS)
at 40° C (104° F) 46 cSt (215SUS)
at 65° C (150° F) 22 cSt (106SUS)
Viscosity Index 170

1-4 3121628
SECTION 1 - SPECIFICATIONS

Table 1-18. Exxon Univis HVI 26 Specs 1.8 MAJOR COMPONENT WEIGHTS
Specific Gravity 32.1 Table 1-19. Major Component Weights
Pour Point -76°F (-60°C)
Flash Point 217°F (103°C) MAJOR COMPONENTS LBS. KG.

VISCOSITY Platform & Control Console 250 113

at 40° C 25.8 cSt Main Boom (Inc. Slave Cylinder Rotator, Support) 3185 1445
at 100° C 9.3 cSt
Main Lift Cylinder 444.7 202
Viscosity Index 376
Main Telescope Cylinder 522 237
NOTE: Mobil/Exxon recommends that this oil be checked on a
yearly basis for viscosity. Upright 1175 535
Upright Level Cylinder 529.5 240
Tower Boom Complete 3450 1565
Tower Lift Cylinder 625 284
Tower Telescope Cylinder 232.5 105
Turntable Counterweight 4805 2180
Turntable Complete (Including Engine) 10625 4820
Chassis Complete (Pneumatic Tires) 13350 6060
Chassis Complete (Foam Filled Tires) 12220 5545
Machine Complete (GVW) w/ Pneumatic Tires 34200 15513
Machine Complete (GVW) w/ Foam Filled Tires 33100 15014
NOTE: The above components are separate assemblies.
Example: "TURNTABLE COMPLETE" does not include booms,
upright, lift cylinders or platform. The weights of these compo-
nents must be added for the total weight.

3121628 1-5
SECTION 1 - SPECIFICATIONS

Critical Stability Weights

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT

WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUN-
TER WEIGHT, ENGINE, AND PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO
EFFECT STABILITY.

Table 1-20. Critical Stability Weights

COMPONENTS LBS. KG.

Tire & Wheel Size 15-625 544 247
(Foam Filled Only)
18-625 601 273
Engine Deutz 534 242
GM w/pumps 1030 468
Ford 2.5L MSG-425 358.5 162.6
Counterweight 4805 2180
Wheel Hubs Rear 218 99
Front 2WD 210 95
Front 4WD 218 99
Platform 6 ft. (1.83 m) 205 93
8 ft. (2.44 m) 230 105

1-6 3121628
SECTION 1 - SPECIFICATIONS

2,3 2,3

1
8,9,10,12
11

4
6

3 3

Figure 1-1. Maintenance and Lubrication Diagram

3121628 1-7
SECTION 1 - SPECIFICATIONS

1.9 OPERATOR MAINTENANCE 2. Wheel Bearings

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

Maintenance and Lubrication Diagram.

Table 1-21. Lubrication Specifications.

KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MIL-Spec MIL-L-2105
HO Hydraulic Oil. Refer Section 1.7, Hydraulic Oil.
Lube Point(s) - Repack
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API
Capacity - A/R
CC/CD class, MIL-L-2104B/MIL-L-2104C
Lube - MPG
Super Synthetic-Based Oil, Non-Flammable. Withstands temperatures within - Interval - Every 2 years or 1200 hours of operation
Lube® 45° to 450°F (-43° to 232° C). JLG P/N 3020042. 3. Wheel Drive Hub

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-

MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
FREQUENCIES MUST BE INCREASED ACCORDINGLY.

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) - Level/Fill Plug

Capacity - 17 oz. (0.5 L) - 1/2 Full
Lube - EPGL
Interval - Check level every 3 months or 150 hours of
operation; change every 2 years or 1200 hours of
operation.
Comments - Place Fill port at 12 o’clock position and
Check port at 3 o’clock position. Pour lubricant into fill
port until it just starts to flow out of check port.

Lube Point(s) - 2 Grease Fittings

Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hours of operation
Comments - Remote Access

1-8 3121628
SECTION 1 - SPECIFICATIONS

4. Swing Drive Hub 7. Hydraulic Tank

Lube Point(s) - Level/Fill Plug Lube Point(s) - Fill Cap

Capacity - 43 oz. (1.3 L) Capacity - 40 gallons (151 L) Tank; 77 gallons (291.4 L)
Lube - 90w80 Gear oil System
Interval - Check level every 3 months or 150 hours of Lube - HO
operation; change every 2 years or 1200 hours of Interval - Check Level daily; Change every 2 years or
operation. 1200 hours of operation.
8. Oil Change w/Filter - Deutz D2011
5. Hydraulic Return Filter

Interval - Change after first 50 hours and every 6 Lube Point(s) - Fill Cap/Spin-on Element
months or 300 hours thereafter or as indicated by Capacity - 11 Quarts (10.5 L) Crankcase
Condition Indicator. Lube - EO
Interval - Every Year or 1200 hours of operation
6. Hydraulic Charge Filter Comments - Check level daily/Change in accordance
with engine manual. Refer to Figure 1-2., Deutz 2011
Engine Dipstick.

Interval - Change after first 50 hours and every 6

months or 300 hours thereafter or as indicated by
Condition Indicator.

3121628 1-9
SECTION 1 - SPECIFICATIONS

B. Oil Change w/Filter - Deutz TD2.9 C. Oil Change w/Filter - Deutz TD 2.9 L4 China III

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

Capacity - 9.6 Quarts (9.0 L)
Lube - EO
MAE19140
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance Lube Point(s) - Fill Cap/Spin-on Element
with engine manual. Capacity - 8.5 Quarts (8.0 L)
Lube - EO
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.
9. Oil Change w/Filter - GM

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

(JLG P/N 7027965)
Capacity - 4.5 qt. (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.

Figure 1-2. Deutz 2011 Engine Dipstick

1-10 3121628
SECTION 1 - SPECIFICATIONS

10. A. Fuel Filter - Deutz D2011 D. Fuel Filter - Deutz TD 2.9 L4 China III

Lube Point(s) - Replaceable Element

Interval - Every Year or 600 hours of operation
B. Fuel Filter - Deutz TD2.9 (On Hydraulic Tank)
Lube Point(s) - Replaceable Element
Interval - Change in accordance with engine manual

11. Fuel/Water Separator - Deutz TD 2.9 L4 China III

Lube Point(s) - Replaceable Element

Interval - Change in accordance with engine manual
C. Fuel Filter - Deutz TD2.9 (On Engine)

MAE25900

Lube Point(s) - Replaceable Element

Interval - Drain water daily; Change every year or
600hours of operation.

12. Fuel Filter (Gasoline) - GM

Lube Point(s) - Replaceable Element
Interval - Change in accordance with engine manual Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation

3121628 1-11
SECTION 1 - SPECIFICATIONS

13. Air Filter 14. Fuel Filter (Propane) - GM Engine

Interval - 3 Months or 150 hours of operation

Lube Point(s) - Replaceable Element Comments - Replace filter. Refer to Propane Fuel Filter
Replacement.
Interval - Every 6 months or 300 hours of operation
or as indicated by the condition indicator

B. Air Filter (Deutz TD 2.9)

Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation
or as indicated by the condition indicator

C. Air Filter (Deutz TD 2.9 L4 China III)

Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation
or as indicated by the condition indicator

1-12 3121628
SECTION 1 - SPECIFICATIONS

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

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

3121628 1-13
SECTION 1 - SPECIFICATIONS

To rqu e
Torqu e
Torq ue
Tor que
Torq ue

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 5)

1-14 3121628
SECTION 1 - SPECIFICATIONS

Torq ue
Tor que
Torqu e
Torq ue
Cl amp Load
To rque
Torque

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

3121628 1-15
SECTION 1 - SPECIFICATIONS

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

Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 4 of 5)

1-16 3121628
SECTION 1 - SPECIFICATIONS

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

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

3121628 1-17
SECTION 1 - SPECIFICATIONS

NOTES:

1-18 3121628
SECTION 2 - GENERAL

SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form
and the Inspection and Preventive Maintenance Schedule for
MAINTENANCE items requiring inspection during the performance of these
inspections. Reference the appropriate areas of this manual for
General servicing and maintenance procedures.
This section provides the necessary information needed by
those personnel that are responsible to place the machine in
Annual Machine Inspection
operation readiness and maintain its safe operating condition. The Annual Machine Inspection must be performed on an
For maximum service life and safe operation, ensure that all annual basis, no later than thirteen (13) months from the date
the necessary inspections and maintenance have been com- of the prior Annual Machine Inspection. JLG Industries recom-
pleted before placing the machine into service. With proper mends this task be performed by a Factory-Trained Service
care, maintenance, and inspections performed per JLG's rec- Technician. JLG Industries, Inc. recognizes a Factory-Trained
ommendations, and with any and all discrepancies corrected, Service Technician as a person who has successfully com-
this product will be fit for continued use. pleted the JLG Service Training School for the subject JLG
product model. Reference the machine Service and Mainte-
Preparation, Inspection, and Maintenance nance Manual and appropriate JLG inspection form for perfor-
It is important to establish and conform to a comprehensive mance of this inspection.
inspection and preventive maintenance program. The follow- Reference the JLG Annual Machine Inspection Form and the
ing table outlines the periodic machine inspections and main- Inspection and Preventive Maintenance Schedule for items
tenance recommended by JLG Industries, Inc. Consult your requiring inspection during the performance of this inspec-
national, regional, or local regulations for further requirements tion. Reference the appropriate areas of this manual for servic-
for aerial work platforms. The frequency of inspections and ing and maintenance procedures.
maintenance must be increased as environment, severity and
frequency of usage requires. For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
Pre-Start Inspection information for each machine. When performing each Annual
Machine Inspection, notify JLG Industries, Inc. of the current
It is the User’s or Operator’s primary responsibility to perform a machine ownership.
Pre-Start Inspection of the machine prior to use daily or at
each change of operator. Reference the Operator’s and Safety Preventative Maintenance
Manual for completion procedures for the Pre-Start Inspec-
tion. The Operator and Safety Manual must be read in its In conjunction with the specified inspections, maintenance
entirety and understood prior to performing the Pre-Start shall be performed by a qualified JLG equipment mechanic.
Inspection. JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized
Pre-Delivery Inspection and Frequent Inspection degree, certificate, extensive knowledge, training, or experi-
ence, has successfully demonstrated the ability and profi-
The Pre-Delivery Inspection and Frequent Inspection shall be ciency to service, repair, and maintain the subject JLG product
performed by a qualified JLG equipment mechanic. JLG Indus- model.
tries, Inc. recognizes a qualified JLG equipment mechanic as a
person who, by possession of a recognized degree, certificate, Reference the Preventive Maintenance Schedule and the
extensive knowledge, training, or experience, has successfully appropriate areas of this manual for servicing and mainte-
demonstrated the ability and proficiency to service, repair, and nance procedures. The frequency of service and maintenance
maintain the subject JLG product model. must be increased as environment, severity and frequency of
usage requires.
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.

3121628 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 Operator and Safety Manual
At each Operator change.

Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
rental delivery. and applicable JLG inspection form.

Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
purchased used.

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

Preventative At intervals as specified in the Service and Mainte- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance nance Manual.

2.2 SERVICE AND GUIDELINES sure all parts are clean before they are installed. New
parts should remain in their containers until they are
General ready to be used.

The following information is provided to assist you in the use Components Removal and Installation
and application of servicing and maintenance procedures
contained in this book. 1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as near
Safety and Workmanship perpendicular as possible to top of part being lifted.
Your safety, and that of others, is the first consideration when
2. Should it be necessary to remove a component on an
engaging in the maintenance of equipment. Always be con-
angle, keep in mind that the capacity of an eyebolt or
scious of weight. Never attempt to move heavy parts without
similar bracket lessens, as the angle between the
the aid of a mechanical device. Do not allow heavy objects to
supporting structure and the component becomes less
rest in an unstable position. When raising a portion of the
than 90 degrees.
equipment, ensure that adequate support is provided.
3. If a part resists removal, check to see whether all nuts,
Cleanliness bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.
1. The most important single item in preserving the long
service life of a machine is to keep dirt and foreign mate-
rials out of the vital components. Precautions have been Component Disassembly and Reassembly
taken to safeguard against this. Shields, covers, seals,
When disassembling or reassembling a component, complete
and filters are provided to keep air, fuel, and oil supplies
the procedural steps in sequence. Do not partially disassemble
clean; however, these items must be maintained on a
or assemble one part, then start on another. Always recheck
scheduled basis in order to function properly.
your work to assure that nothing has been overlooked. Do not
2. At any time when air, fuel, or oil lines are disconnected, make any adjustments, other than those recommended, with-
clear adjacent areas as well as the openings and fittings out obtaining proper approval.
themselves. As soon as a line or component is
disconnected, cap or cover all openings to prevent entry Pressure-Fit Parts
of foreign matter.
When assembling pressure-fit parts, use a molybdenum disul-
3. Clean and inspect all parts during servicing or mainte- fide base compound or equivalent to lubricate the mating sur-
nance, and assure that all passages and openings are face.
unobstructed. Cover all parts to keep them clean. Be

2-2 3121628
SECTION 2 - GENERAL

Bearings 2. Disassemble and reassemble parts on clean work sur-

face. Clean all metal parts with non-flammable cleaning
1. When a bearing is removed, cover it to keep out dirt and solvent. Lubricate components, as required, to aid
abrasives. Clean bearings in nonflammable cleaning sol- assembly.
vent and allow to drip dry. Compressed air can be used
but do not spin the bearing. Lubrication
2. Discard bearings if the races and balls (or rollers) are Service applicable components with the amount, type, and
pitted, scored, or burned. grade of lubricant recommended in this manual, at the
specified intervals. When recommended lubricants are not
3. If bearing is found to be serviceable, apply a light coat of available, consult your local supplier for an equivalent that
oil and wrap it in clean (waxed) paper. Do not unwrap meets or exceeds the specifications listed.
reusable or new bearings until they are ready to install.
4. Lubricate new or used serviceable bearings before Battery
installation. When pressing a bearing into a retainer or Clean battery using a non-metallic brush and a solution of
bore, apply pressure to the outer race. If the bearing is to baking soda and water. Rinse with clean water. After cleaning,
be installed on a shaft, apply pressure to the inner race. thoroughly dry battery and coat terminals with an anti corro-
sion compound.
Gaskets
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 Components and assemblies requiring lubrication and servic-
gasket material or stock of equivalent material and thickness. ing are shown in the Lubrication Chart in Section 1.
Be sure to cut holes in the right location, as blank gaskets can
cause serious system damage. 2.3 LUBRICATION AND INFORMATION
Bolt Usage and Torque Application Hydraulic System
1. The primary enemy of a hydraulic system is contamina-
tion. Contaminants enter the system by various means,
SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
e.g., using inadequate hydraulic oil, allowing moisture,
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
grease, filings, sealing components, sand, etc., to enter
when performing maintenance, or by permitting the
1. Always use new replacement hardware when installing
pump to cavitate due to insufficient system warm-up or
locking fasteners. Use bolts of proper length. A bolt
leaks in the pump supply (suction) lines..
which is too long will bottom before the head is tight
against its related part. If a bolt is too short, there will 2. The design and manufacturing tolerances of the
not be enough thread area to engage and hold the part component working parts are very close, therefore, even
properly. When replacing bolts, use only those having the smallest amount of dirt or foreign matter entering a
the same specifications of the original, or one which is system can cause wear or damage to the components
equivalent. and generally results in faulty operation. Every
precaution must be taken to keep hydraulic oil clean,
2. Unless specific torque requirements are given within the
including reserve oil in storage. Hydraulic system filters
text, standard torque values should be used on heat-
should be checked, cleaned, and/or replaced as
treated bolts, studs, and steel nuts, in accordance with
necessary, at the specified intervals required in the
recommended shop practices. (See Torque Chart Sec-
Lubrication Chart in Section 1. Always examine filters for
tion 1).
evidence of metal particles.
Hydraulic Lines and Electrical Wiring 3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or
Clearly mark or tag hydraulic lines and electrical wiring, as well
corrosion. If this condition occurs, the system must be
as their receptacles, when disconnecting or removing them
drained, flushed, and refilled with clean oil.
from the unit. This will assure that they are correctly rein-
stalled.

Hydraulic System
1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
flush the entire system.

3121628 2-3
SECTION 2 - GENERAL

4. It is not advisable to mix oils of different brands or types, Changing Hydraulic Oil
as they may not contain the same required additives or
be of comparable viscosities. Good grade mineral oils, 1. Filter elements must be changed after the first 50 hours
with viscosities suited to the ambient temperatures in of operation and every 300 hours (unless specified
which the machine is operating, are recommended for otherwise) thereafter. If it is necessary to change the oil,
use. use only those oils meeting or exceeding the
specifications appearing in this manual. If unable to
NOTE: Metal particles may appear in the oil or filters of new obtain the same type of oil supplied with the machine,
machines due to the wear-in of meshing components. consult local supplier for assistance in selecting the
proper equivalent. Avoid mixing petroleum and
Hydraulic Oil synthetic base oils.
1. Refer to Section 1 for recommendations for viscosity 2. Use every precaution to keep the hydraulic oil clean. If
ranges. the oil must be poured from the original container into
another, be sure to clean all possible contaminants from
2. JLG recommends Mobilfluid 424 hydraulic oil, which has the service container. Always clean the mesh element of
an SAE viscosity of 10W-30 and a viscosity index of 152. the filter and replace the cartridge any time the system
NOTE: Start-up of hydraulic system with oil temperatures below - oil is changed.
15 degrees F (-26 degrees C) is not recommended. If it is 3. While the unit is shut down, a good preventive mainte-
necessary to start the system in a sub-zero environment, it nance measure is to make a thorough inspection of all
will be necessary to heat the oil with a low density, 100VAC hydraulic components, lines, fittings, etc., as well as a
heater to a minimum temperature of -15 degrees F (-26 functional check of each system, before placing the
degrees C). machine back in service.

3. The only exception to the above is to drain and fill the Lubrication Specifications
system with Mobil DTE 13 oil or its equivalent. This will
allow start up at temperatures down to -20 degrees F (- Specified lubricants, as recommended by the component
29 degrees C). However, use of this oil will give poor per- manufacturers, are always the best choice, however, multi-pur-
formance at temperatures above 120 degrees F (49 pose greases usually have the qualities which meet a variety of
degrees C). Systems using DTE 13 oil should not be oper- single purpose grease requirements. Should any question
ated at temperatures above 200 degrees F (94 degrees arise, regarding the use of greases in maintenance stock, con-
C) under any condition. sult your local supplier for evaluation. Refer to Section 1 for an
explanation of the lubricant key designations appearing in the
Lubrication Chart.

2-4 3121628
SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST Table 2-2. Cylinder Drift

Theory Max. Acceptable Drift

Cylinder Bore Diameter
in 10 Minutes
When a hydraulic cylinder is supporting a load, cylinder drift
inches mm inches mm
may occur as a result of any of the circumstances below:
3 76.2 0.026 0.66
• Normal leakage of load holding valves or malfunction of 3.5 89 0.019 0.48
load holding valves. See Cylinder Leakage Test and 4 101.6 0.015 0.38
“Cylinder Drift” below for evaluation.
5 127 0.009 0.22
• Damaged or worn piston seals.
6 152.4 0.006 0.15
• Normal thermal expansion or contraction of the hydraulic 7 177.8 0.005 0.13
oil within cylinders (See Cylinder Thermal Drift below).
8 203.2 0.004 0.10
The first two circumstances may result in cylinder movement 9 228.6 0.003 0.08
due to oil leaking out of the cylinder externally or by leaking
back to tank or due to oil leaking internally from one cylinder NOTE: The information is based on 6 drops per minute cylinder
chamber to the other. leakage.

Thermal expansion or contraction of oil in hydraulic cylinders Cylinder Thermal Drift

is a normal occurrence and does not result in oil leaking out of
the cylinder or leaking internally from one cylinder chamber The oil in all hydraulic cylinders will expand or contract due to
to the other. Thermal expansion or contraction is the tendency thermal effects over time and may result in changes to the
for materials to change size in response to a change in boom and/or platform position while the machine is
temperature. stationary. These effects occur as the cylinder oil changes
temperature, usually from a higher oil temperature as it cools
and approaches the ambient air temperature. Results of these
Cylinder Leakage Test effects are related to several factors including cylinder length
Cylinder oil must be at stabilized ambient temperature and change in temperature over the time the cylinder remains
before beginning this test. stationary.

Measure drift at cylinder rod with a calibrated dial indicator.

In an area free of obstructions, cylinder must have load

applied and appropriately positioned to detect drift.

Cylinder leakage is acceptable if it passes this test.

3121628 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
• Ground only to structure being welded.
the following is observed:
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.

or Frequent2 (Yearly) Years
Inspection Inspection

Annual Machine Inspection Due 21 21

No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to each sale, lease, or delivery
2 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
3Annually, no later than 13 months from the date of the prior inspection

Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill

3121628 2-9
SECTION 2 - GENERAL

AMBIENT AIR
TEMPERATURE

120°F(49°C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE. 110°F(43°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
SUMMER
GRADE 70°F(21°C)
ENGINE FUEL
60°F(16°C)
SPECIFICATIONS 50°F(10°C)
40°F(4°C)
30° F(-1°C)

ENGINE WILL START AND OPERATE UNAIDED AT THIS

WINTER 20° F(-7°C)
GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10°F(-12°C)
FUEL
FULLY CHARGED BATTERY.
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THS TEMPERATUREI WINTER
GRADE -10°F(-23°C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER
FUEL -20°F(-29°C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR
KEROSENE -30°F(-34° C)
GLOW PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER). ADDED
-40°F(-40° C)
NO OPERATION BELOWTHIS
AMBIENT TEMPERATURE.

EXTENDED DRIVING WITH

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

120° F (49° C)
NO OPERATION ABOVE THIS PROLONGED OPERATION IN NOTE:
110° F (43° C) AMBIENT TEMPERATURE. AMBIENT AIR TEMPERATURES
OF 100°F (38° C) OR ABOVE. 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
100° F (38° C)
CONSISTENTLY WITHIN SHOWN LIMITS.
MOBIL 424 10W-30

90° F (32° C)
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
50° F (10° C)
HYDRAULIC SUMMER-GRADE
WINTER-GRADE
MOBIL DTE 13

SPECIFICATIONS FUEL
FUEL
40° F (4° C) F C
30° F (-1° C) +32 0
AMBIENT TEMPERATURE

20° F (-7° C)
10° F (-12° C)
+23 -5

0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM

WITHOUT HEATING AIDS WITH MOBIL 424 +14 -10
-10° F (-23° C) HYDRAULIC OIL BELOWTHIS TEMPERATURE.
-20° F (-29° C) +5 -15
DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS
-30° F (-34° C) AND COLD WEATHER HYDRAULIC OIL BELOWTHIS TEMPERATURE.
-4 -20
-40° F (-40° C)
NO OPERATION BELOWTHIS
AMBIENT TEMPERATURE. -13 -25

-22 -30
0 10 20 30 40 50 60
% OF ADDED KEROSENE
4150548 E

Figure 2-1. Engine and Hydraulic Operating Temperature Specifications - Deutz

2-10 3121628
SECTION 2 - GENERAL

AMBIENT AIR
TEMPERATURE

120 F(49 C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE. 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)

ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS,
-10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER).
-30 F(-34 C)
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE.

EXTENDED DRIVING WITH

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

120° F (49° C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE. PROLONGED OPERATION IN
110° F (43° C) AMBIENT AIR TEMPERATURES
OF 100° F (38° C) OR ABOVE.
100° F (38° C)
90° F (32° C)
MOBIL 424 10W-30

80° F (27° C)
70° F (21° C)
EXXON UNIVIS HVI 26

60° F (16° C)
50° F (10° C) HYDRAULIC
SPECIFICATIONS
MOBIL DTE 13

40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE.

-20° F (-29° C)
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE.
-40° F (-40° C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE.

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES

CONSISTENTLY WITHIN SHOWN LIMITS.

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL. 4150548 E

Figure 2-2. Engine and Hydraulic Operating Temperature Specifications - GM

3121628 2-11
SECTION 2 - GENERAL

-40

4150548 E

Figure 2-3. Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425

2-12 3121628
SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & 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
The air pressure for pneumatic tires must be equal to the air by JLG. Due to size variations between tire brands, both tires
pressure that is stenciled on the side of the JLG product or rim on the same axle should be the same.
decal for safe and proper operational characteristics.
Wheel Replacement
Tire Damage
The rims installed on each product model have been designed
For pneumatic tires, JLG Industries, Inc. recommends that for stability requirements which consist of track width, tire
when any cut, rip, or tear is discovered that exposes sidewall or pressure, and load capacity. Size changes such as rim width,
tread area cords in the tire, measures must be taken to remove center piece location, larger or smaller diameter, etc., without
the JLG product from service immediately. Arrangements written factory recommendations, may result in an unsafe
must be made for replacement of the tire or tire assembly. condition regarding stability.

For polyurethane foam filled tires, JLG Industries, Inc. recom- Wheel Installation
mends that when any of the following are discovered, mea-
It is extremely important to apply and maintain proper wheel
sures must be taken to remove the JLG product from service
mounting torque.
immediately and arrangements must be made for replace-
ment of the tire or tire assembly.

• a smooth, even cut through the cord plies which WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE
exceeds 3 inches (7.5 cm) in total length TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
• any tears or rips (ragged edges) in the cord plies SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS
which exceeds 1 inch (2.5 cm) in any direction MATCHED TO THE CONE ANGLE OF THE WHEEL.

• any punctures which exceed 1 inch in diameter Tighten the lug nuts to the proper torque to prevent wheels
• any damage to the bead area cords of the tire from coming loose. Use a torque wrench to tighten the fasten-
ers. If you do not have a torque wrench, tighten the fasteners
If a tire is damaged but is within the above noted criteria, the with a lug wrench, then immediately have a service garage or
tire must be inspected on a daily basis to insure the damage dealer tighten the lug nuts to the proper torque. Over-tighten-
has not propagated beyond the allowable criteria. ing will result in breaking the studs or permanently deforming
the mounting stud holes in the wheels. The proper procedure
Tire Replacement for attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO
JLG recommends a replacement tire be the same size, ply and
NOT use a lubricant on threads or nuts.
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
the following characteristics:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than origi-
nal
• Wheel diameter, width, and offset dimensions equal
to the original

3121628 3-1
SECTION 3 - CHASSIS & TURNTABLE

2. Tighten nuts in the following sequence: 3.2 LOCKOUT CYLINDER BLEEDING

1. Start the engine.
2. Position the turntable to the normal stowed position.
3. Attach clear tubing to bleeder valve nipple.
4. Position a small bucket/bottle in front of the lockout cyl-
inder bleeder valve and insert clear tubing.
5. Using a 3/8” wrench, loosen the bleeder valve, turning
counterclockwise slowly. Bleed air from the top of lock-
out cylinder. Capture hydraulic oil until a steady unbro-
ken stream of hydraulic oil is viewed. Tighten/close the
bleeder valve while stream of hydraulic oil is running.
6. Locate the bleeder valve on the opposite side lockout
cylinder. Repeat the process.

3. The tightening of the nuts should be done in stages. Fol-

lowing the recommended sequence, tighten nuts per
wheel torque chart. Bleeder Valve

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
70 ft. lbs. 170 ft. lbs. 300 ft. lbs.
(95 Nm) (225 Nm) (405 Nm)

4. Wheel nuts should be torqued after first 50 hours of

operation and after each wheel removal. Check torque
every 3 months or 150 hours of operation.

3-2 3121628
SECTION 3 - CHASSIS & TURNTABLE

3
1 9

10, A

4 11
10, A 9
8
5
10, A
7

6
9

2 11 10, A

4
10, A 9
8
A. Apply JLG Threadlocker P/N 0100011
5

1001151037 C
1001154584 D

1. Oscillating Axle 4. Keeper Pin 7. Stop Plate 10. Bolt

2. Fixed Axle 5. Axle Pivot Pin 8. Washer 11. Shim
3. Axle Lockout Cylinder 6. Shim 9. Bushing

Figure 3-1. Axle Installation

3121628 3-3
SECTION 3 - CHASSIS & TURNTABLE

6 5, A

2 7 9

4
5, A 8

10
11 5, A
2
10 7 1
12
6
3

A. Apply JLG Threadlocker P/N 0100011 5, A

1001151034 F
1001151035 E

1. Drive Spindle 4. Kingpin 7. Composite Bearing 10. Keeper PIN

2. Steer Cylinder 5. Bolt 8. Thrust Washer 11. Cylinder Pivot Pin
3. Tie Rod 6. Thrust Washer 9. Retaining Plate 12. Cylinder Pivot Pin

Figure 3-2. Steering Installation

3-4 3121628
SECTION 3 - CHASSIS & TURNTABLE

3.3 OSCILLATING AXLE LOCKOUT TEST 9. Place the 6 inch (15.2 cm) high block with ascension
ramp in front of right front wheel.
10. Place DRIVE control lever to FORWARD and carefully
drive machine up ascension ramp until right front wheel
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS-
is on top of block.
TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
SUSPECTED. 11. Carefully activate SWING control lever and position
boom over left side of machine.
NOTE: Ensure boom is fully retracted, lowered, and centered 12. With boom over left side of machine, place DRIVE con-
between drive wheels prior to beginning lockout cylinder trol lever to REVERSE and drive machine off of block and
test. ramp.
13. Have an assistant check to see that right front wheel
1. Place a 6 inch (15.2 cm) high block with ascension ramp
remains locked in position off of ground.
in front of left front wheel.
14. Carefully activate SWING control lever and return boom
2. From platform control station, activate machine hydrau- to stowed position (centered between drive wheels).
lic system. When boom reaches center, stowed position, lockout
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/ cylinders should release and allow wheel to rest on
TORQUE SELECT control switches to their respective ground, it may be necessary activate DRIVE to release
LOW positions. cylinders.
4. Place DRIVE control lever to FORWARD position and 15. If lockout cylinders do not function properly, have
carefully drive machine up ascension ramp until left trained personnel correct the malfunction prior to any
front wheel is on top of block. further operation
5. Carefully activate SWING control lever and position
boom over right side of machine.
6. With boom over right side of machine, place DRIVE con-
trol lever to REVERSE and drive machine off of block and
ramp.
7. Have an assistant check to see that left front wheel
remains locked in position off of ground.
8. Carefully activate SWING control lever and return boom
to stowed position (centered between drive wheels).
When boom reaches center, stowed position, lockout
cylinders should release and allow wheel to rest on
ground, it may be necessary activate DRIVE to release
cylinders.

3121628 3-5
SECTION 3 - CHASSIS & TURNTABLE

4 4

5
5

1 1

1. Axle Lockout Cylinder 4. Drive Motor

2. Flow Drive Valve 5. Drive Hub
3. Swivel

Figure 3-3. Chassis Component Location

3-6 3121628
SECTION 3 - CHASSIS & TURNTABLE

12 12 2
2

1
11

9 14

7
16

8 3

6 5

1. Ground Control Box 5. Auxiliary Power Pump 9. Generator 13. Fuel Tank
2. Headlight 6. Swivel 10. Deutz Module & Diagnostic Connector 14. Hydraulic Oil Tank
3. Auxiliary Power Relay 7. Drive Pumps 11. Fuel Level Sensor 15. Swing Drive
4. Main Control Valve 8. Function Pump 12. Strobe 16. Battery

Figure 3-4. Turntable Component Location

3121628 3-7
SECTION 3 - CHASSIS & TURNTABLE

3.4 DRIVE HUB (TORQUE) 3. Inspect bearing mounting surfaces on spindle, hub,
input shaft and carrier. Replace components as neces-
sary.
Disassembly
4. Inspect all geared components for chipped or broken
1. Position hub over suitable container and remove drain teeth and for excessive or uneven wear patterns.
plugs (10) from unit. Allow oil to completely drain, then 5. Inspect carrier for damage, especially in anti-roll pin and
replace drain plugs. planet shaft hole areas.
2. Remove bolts (41) securing cover assembly to hub (7). 6. Inspect all planet shafts for scoring or other damage.
Remove cover assembly (23) and discard o-ring seal (22).
7. Inspect all threaded components for damage including
3. Lift carrier assembly and top thrust washer and thrust stretching, thread deformation, or twisting.
bearing(39, 40) from hub. Thrust washer may stick inside 8. Inspect seal mounting area in hub for burrs or sharp
cover. edges. Dress applicable surfaces or replace components
4. Pry ring gear (21) loose from hub and remove it. Remove as necessary.
o-ring seal (22) from hub counterbore and discard it. 9. Inspect cover for cracks or other damage, and o-ring
sealing area for burrs or sharp edges. Dress applicable
5. Remove input gear (37) and thrust spacer (36) from
surfaces or replace cover as necessary.
input shaft assembly and remove input shaft assembly
from hub.
Repair
6. Lift internal gear (12) and thrust washer and thrust bear-
ing (39, 40) from hub. Thrust washer may stick to bottom 1. Cover Assembly.
of carrier. a. Remove two bolts (25) securing disconnect cap (26)
7. Remove retaining ring (9) from spindle (1) and discard; to cover (23) and remove cap.
lift hub from spindle. b. Remove two bolts (25) securing cover cap (24) to
cover and remove cap.
c. Remove disconnect rod (27) from cap and remove
EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL. o-rings (28, 29) from cover cap. Discard o-rings.
d. If necessary, remove pipe plug (30) from cover.
8. Remove inside bearing cone (6) and bearing shim (8). e. Clean and inspect parts in accordance with Clean-
ing and Inspection procedures. Replace parts as
9. If necessary, pry seal (2) out of hub using screwdriver or
necessary.
pry bar. With seal removed, outside bearing cone (4) can
be removed. f. If removed, screw pipe plug into cover.

10. If necessary, remove inner and outer bearing cups (3, 5) g. Slip o-ring (29) over cover cap and against face.
using a suitable slide hammer puller or driven out with a h. Place o-ring (28) into cover cap internal groove. Dis-
punch. connect rod may be used to push o-ring into
groove.
11. To remove the cluster gears from the carrier, drive the
anti-roll pin into the planet shaft of the cluster gear. i. Place cover cap into cover with large hole located
After the planet shaft is removed, the roll pin should be over pipe plug. Secure cover cap to cover with two
driven out of the planet shaft. bolts. Torque bolts to 70-80 in. lbs. (7.9-9.0 Nm).
j. Place disconnect cap over cover cap with nipple fac-
ing out and secure with two bolts. Torque bolts to
70-80 in. lbs. (7.9-9.0 Nm).
WHEN REBUILDING TORQUE HUB, REMOVE AND REPLACE ALL O-RINGS AND
RETAINING RINGS. k. Turn cover over and push disconnect rod into cover
cap. Rod will be held in place by friction from o-ring.

Cleaning and Inspection 2. Carrier Assembly.

a. Drive anti-roll pin (19) into planet shaft (17) using a
1. Thoroughly clean all parts in an approved cleaning sol- suitable punch.
vent.
b. Using a suitable press, press planet shaft from car-
2. Inspect bearing cups and cones for damage, pitting, cor- rier (13). After planet shaft is removed, drive anti-roll
rosion, or excessive wear. If necessary, replace bearings pin from shaft.
as a complete set ensuring that they remain covered c. Remove cluster gear (18) and thrust washers (14)
until use. from carriers.

3-8 3121628
SECTION 3 - CHASSIS & TURNTABLE

d. Remove needle rollers (15) from cluster gear bore. k. Place second set of needle rollers into cluster gear.
e. Remove spacer (16) from cluster gear bore and l. Apply grease or petroleum jelly to tang side of two
remove second set of needle rollers (15). thrust washers. Place thrust washers against bosses
f. Repeat steps (a) through (e) for remaining two clus- in carrier with washer tang fitting into slot in carrier
ter gears. outside diameter.
g. Clean and inspect all parts in accordance with
Cleaning and Inspection procedures. Replace parts
as necessary.
h. Apply a coat of grease or petroleum jelly to cluster
gear bore.

m. While keeping thrust washers in place, slide cluster

gear into carrier with larger gear on side with small
pin hole.

i. Place needle rollers into cluster gear bore.

n. Line up cluster gear and thrust washers with hole in

carrier and slide planet shaft through. Ensure cham-
fered side of hole in planet shaft is lined up with pin
hole in carrier.
j. Place spacer into opposite side of cluster gear and
against needle rollers.

3121628 3-9
SECTION 3 - CHASSIS & TURNTABLE

o. Drive anti-roll pin flush into carrier hole, locking 2. Place bearing cone (4) into bearing cup (3) in small end
planet shaft into place. of hub.

p. Repeat steps (h) through (o) for remaining two clus-

ter gears. 3. Press new seal (2) into hub counterbore with flat metal
side facing in. Use a flat object to ensure that seal is
3. Input Shaft Assembly. pressed evenly and is flush with hub face.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL AND

INSTALLATION

a. Carefully remove retaining ring (33) from counter-

bore in the spindle (1) and discard retaining ring.
b. Remove two washers (31) and spring (32) from
input shaft.
c. Clean and inspect all parts in accordance with
Cleaning and Inspection procedures. Replace parts
as necessary.
d. Place washer (31), spring (32), and washer (31), in
that order, onto input shaft. 4. Lower hub onto spindle (1) with large open end up.

Assembly
1. Using a suitable press, press new bearing cups (3, 5),
with large inside diameters facing out, into hub (7)
counterbores.

3-10 3121628
SECTION 3 - CHASSIS & TURNTABLE

5. Place bearing cone (6) over end of spindle and into 8. The disengage spacer and spring are installed into the
bearing cup. counterbore of the spindle.

6. Place bearing shim (8) over end of spindle and against 9. Install retaining ring into input shaft groove to secure
bearing cone. spacers and spring to shaft.

10. Place the internal gear (12) onto end of spindle by

matching the bore spline, the spindle spline.
EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

7. Install retaining ring (9) completely into spindle groove

and against bearing shim. Ensure retaining ring is
entirely in groove.

3121628 3-11
SECTION 3 - CHASSIS & TURNTABLE

11. Install thrust washers and thrust bearing (39, 40) on the 14. Place input shaft assembly (35) into spindle bore with
portion of the spindle which extends into the internal unsplined end facing out.
gear. The action of the spring should be checked at this point.

15. Place thrust spacer (36) over input shaft (35) with coun-
12. The o-ring is placed into the counterbore provided in terbore side facing spindle.
the hub. Slight stretching may be necessary. Use suffi-
cient grease or petroleum jelly to hold in place.

16. Locate the four counter reamed holes in the face of the
hub, mark them for later identification.

13. Install retaining ring (34) into input shaft retaining ring
groove.

3-12 3121628
SECTION 3 - CHASSIS & TURNTABLE

17. Place o-ring (22) into cover assembly counterbore. Use 20. While holding ring gear, and cluster gears in mesh, place
petroleum jelly or grease to hold o-ring in place. Slight small side of cluster gears into mesh with internal gear.
stretching of o-ring may be necessary to insure proper On ring gear, locate hole marked ‘X’ over one of the
seating. marked counterbored holes in hub.

NOTE: If gears do not mesh easily or carrier assembly does not

18. Place carrier assembly on a flat surface with large gears rotate freely, then remove carrier and ring gear and check
up and positioned as shown. Find punch marked tooth cluster gear timing.
on each large gear and locate at 12 o’clock (straight up)
from each planet pin. Marked tooth will be located just 21. Install input gear (37) into the carrier assembly, meshing
under carrier on upper two gears. with large diameter cluster gears (18). Counterbore in
bore of input gear must be to outside of carrier assem-
bly.

19. With shoulder side of ring gear (21) facing down, place
ring gear over (into mesh with) large gears. Ensure
punch marks remain in correct location during ring gear 22. After inserting at least one bolt in the proper location,
installation. The side of the ring gear with ’X’ stamped rotate the carrier. Check freedom of rotation and timing.
on it should be up.

3121628 3-13
SECTION 3 - CHASSIS & TURNTABLE

23. Install thrust washers and thrust bearing (39, 40) into 27. Install bolts (41) in remaining holes. Torque bolts to
carrier counterbore. 47 ft. lbs. (64 Nm).

24. Place o-ring (22) into cover assembly counterbore. Use

28. Place coupling (1) into spindle and onto input shaft.
petroleum jelly or grease to hold o-ring in place.

25. Place cover assembly over ring gear with oil level check 29. Fill hub one-half full of EPGL 90 lubricant before
plug in cover located approximately 90 degrees from oil operation.
fill plug in hub.
26. Locate four bolts (42), 90 degrees apart into counter-
bored holes in hub marked in step (16). Torque bolts to
47 ft. lbs. (64 Nm).

3-14 3121628
SECTION 3 - CHASSIS & TURNTABLE

1. Spindle
1.
2. Spindle
Seal
2.
3. Seal
Bearing Cup
3.
4. Bearing Cone
Bearing Cup
4.
5. Bearing Cup
Bearing Cone
5.
6. Bearing
Bearing Cup
Cone
6.
7. Bearing
Hub Cone
7.
8. Hub
Spacer
8.
9. Spacer Ring
Retaining
9.
10. Retaining
Plug Ring
10.
11. Plug
Wheel Bolt
11.
12. Wheel Bolt
Internal Gear
12.
13. Internal
Carrier Gear
13.
14. Carrier
Thrust Washer
14.
15. Thrust Washer
Needle Roller
15.
16. Needle
Spacer Roller
16.
17. Spacer
Planet Shaft
17.
18. Planet
ClusterShaft
Gear
18.
19. Cluster
Roll PinGear
19.
20. RollUsed
Not Pin
20.
21. Not UsedGear
Cluster
21.
22. Cluster Gear
O-ring
22.
23. O-ring
Cover
23.
24. Cover Cap
Cover
24.
25. Cover
Bolt Cap
25.
26. Bolt
Disconnect Cap
26.
27. Disconnect
Disconnect Cap
Rod
27.
28. Disconnect Rod
O-ring
28.
29. O-ring
O-ring
29.
30. O-ring
Pipe Plug
30.
31. Pipe Plug
Washer
31.
32. Washer
Spring
32.
33. Spring
Retaining Ring
33.
34. Retaining
Retaining Ring
Ring
34.
35. Retaining
Input ShaftRing
35.
36. Input
ThrustShaft
Spacer
36.
37. ThrustGear
Input Spacer
37.
38. InputUsed
Not Gear
38.
39. Not Used
Thrust Washer
39.
40. Thrust Washer
Thrust Bearing
40.
41. Thrust Bearing
Bolt
41.
42. Bolt
Coupling
42. Coupling

Figure 3-5. Drive Hub (Torque)

3121628 3-15
SECTION 3 - CHASSIS & TURNTABLE

3.5 DRIVE BRAKE Assembly

Disassembly 1. Lightly lubricate rotary shaft seal (12) and assemble to
housing (2) taking care not to damage seal lip.
1. Supporting brake:, remove the six socket head cap-
2. Apply ring of Loctite 641 or equivalent adhesive to full
screws and washers (13 & 14) in equal increments to
circumference of housing (2) bearing recess adjacent to
ensure the spring pressure within the brake is reduced
shoulder.
gradually and evenly.
Apply complete coverage of Loctite 641 to outside
If a press is available, the cylinder housing (8) can be
diameter of bearing (10) and assemble fully In housing
restrained while removing the six capscrews and wash-
(2), retaining with internal retaining ring (11). Remove
ers (13 & 14).
excess adhesive with a clean cloth.
The brake assembly can now be fully dismantled and
Press shaft (1) through bearing (10), ensuring bearing
the parts examined.
inner ring Is adequately supported.
2. Remove cylinder housing (8) and piston (9) subassembly 3. Assemble correct quantity of springs (22 & 23) in orien-
and dismantle if required, removing O-ring seals (15 & tation required.
17) and backing rings (16 & 18) as necessary.
4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or
3. Remove gasket (7) from housing (2). equivalent) silicon grease and assemble together with
4. Remove friction plates (3 & 6) and pressure plate (4). backing rings (16 & 18) to piston (9). To ensure correct
brake operation. It is important that the backing rings
5. Remove two dowel pins (19).
are assembled opposite to the pressurized side of pis-
6. Remove springs (22 & 23). ton.
7. Should it be necessary to replace ball bearing (10) or 5. Correctly orientate piston (9) aligning spaces with the
shaft seal (12), reverse remainder of brake subassembly, two dowel pin holes and, assemble into cylinder hous-
supporting on face C of housing (2). ing (8) taking care not to damage seals and carefully lay
8. Remove internal retaining ring (11). aside.
9. Using arbor press or similar to break Loctite seal, remove 6. Locate 2-off pins (19) in housing (2) followed by pressure
brake shaft (1) from housing (2) and lay aside. plate (4) and friction plates i.e. an inner (3) followed by
an outer (6) in correct sequence.
10. Reverse housing (2) and press out ball bearing (10).
Shaft seal (12) can also be removed if necessary. 7. Position gasket (7) in correct orientation.
8. Align two holes in cylinder with dowel pins (19) and
Inspection assemble piston & cylinder sub-assembly to remainder
of brake securing with 6 capscrews and washers (13 &
1. Inspect friction plates (3 & 6) and friction surface on
14). Torque to 55 ft.Ibs. (75 Nm).
pressure plate (4) for wear or damage.
NOTE: The use of a suitable press (hydraulic or arbor) pressing
2. Examine friction plates (3) and brake shaft (1) for wear or
down on cylinder end face B will ease assembly of the cap-
damage to the splines.
screws (13).
3. Examine input and output splines of brake shaft (1) for
wear or damage.
4. Examine compression springs (22 & 23) for damage or
fatigue.
5. Check ball bearing (10) for axial float or wear.
6. Examine O-ring seals (15 & 17) and backing rings (16 &
18) for damage.

3-16 3121628
SECTION 3 - CHASSIS & TURNTABLE

13
14

7
17
18
9
15
16

6
3 21
6

3
4
19
22
23
2

12
10
11

1. Shaft 6. Outer Plate 11. Retaining Ring 16. Backup Ring 21. Plug
2. Housing 7. Gasket 12. Shaft Seal 17. O-ring 22. Spring (Natural)
3. Friction Plate 8. Cylinder 13. Capscrew 18. Backup Ring 23. Spring (Blue)
4. Pressure Plate 9. Piston 14. Lockwasher 19. Dowel Pin
5. Gasket 10. Ball Bearing 15. O-ring 20. Plug

Figure 3-6. Drive Brake

3121628 3-17
SECTION 3 - CHASSIS & TURNTABLE

3.6 DRIVE MOTOR Shaft Seal Replacement

Description REMOVAL
The drive motors are low to medium power, two-position axial 1. Remove the snap ring (1) retaining the shaft seal and
piston motors incorporating an integral servo piston. They are support washer.
designed for operation in both open and closed circuit appli-
cations. The standard control is a direct acting single line 1
hydraulic control. The integral servo piston controls motor dis-
placement.
2
The motors are spring biased to maximum displacement and
hydraulically shifted to minimum displacement. Minimum and
3
maximum displacement can be set with fixed internal stops.
The large diameter servo piston allows smooth acceleration
and deceleration with relatively large circuit orificing.

Bias spring
Servo piston
Minimum
Angle Swashplate
Stop
1. Snap Ring
2. Support Washer
Output 3. Shaft Seal
Cylinder Shaft
Block Figure 3-8. Removing the Shaft Seal

2. Remove the support washer (2).

Shaft 3. Carefully pry out the shaft seal (3).
Seal
Piston To avoid damaging the shaft during removal, install a
Endcap Slipper Bearing large sheet metal screw into the chuck of a slide ham-
Valve plate
mer. Drive the screw into the seal surface and use the
Figure 3-7. Drive Motor Cross Section slide hammer to pull the seal.
4. Discard the seal.

INSPECT THE COMPONENTS

Inspect the new seal, the motor housing seal bore, and the
sealing area on the shaft for rust, wear, and contamination.
Polish the shaft and clean the housing if necessary.

INSTALLATION
1. Cover the shaft splines with an installation sleeve to pro-
tect the shaft seal during installation.
2. Install a new shaft seal with the cupped side facing the
motor. Press seal into housing until it bottoms out. Press
evenly to avoid binding and damaging the seal.
3. Install seal support washer.
4. Install snap ring.
5. Remove the installation sleeve.

3-18 3121628
SECTION 3 - CHASSIS & TURNTABLE

Loop Flushing Valve 2. Using a 1/4 in hex wrench remove plug (3).
3. Remove O-rings (4, 5, and 6).
REMOVAL 4. Using pliers, remove centering springs (7, 8, and 9).
1. Using a 11/16 in internal hex wrench remove plug (1) 5. Remove spring retaining washers (10 and 11).
and (2).
6. Remove shift spool (12).
6 7. Remove orifice poppet (13).
9
11 INSPECT THE COMPONENTS
2
Inspect new O-rings and the sealing area for rust, wear, or con-
11/16 in
tamination. Also check springs and poppet for wear.
27 ft.lbs.
(37 Nm)
INSTALLATION
1. Install orifice poppet (13).
2. Install shift spool (12).
3. Install spring retaining washers onto springs (10 and 11).
10 12
4. Carefully install centering springs (7, 8, and 9).
8
4 5. Install new O-rings (6, 4, and 5).
6. Using a 1/4 in hex wrench torque plug (3) to 20 ft. lbs.
1 13 (27 Nm).
11/16 in
27 ft.lbs. 7. Using a 11/16 in internal hex, torque plugs (2 and 1) to
(37 Nm) 7 27 ft.lbs. (37 Nm).
5/8 in
5 3 20 ft.lbs.
(27 Nm)

1. Plug 6. O-ring 11. Washer

2. Plug 7. Spring 12. Shift Spool
3. Plug 8. Spring 13. Orifice Poppet
4. O-ring 9. Spring
5. O-ring 10. Washer

Figure 3-9. Loop Flushing Spool

3121628 3-19
SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting

During assembly, coat all moving parts with a film of clean

hydraulic oil. This assures that these parts will be lubricated
during start-up.
15
Replace all O-Rings and gaskets.

It is recommended that all O-rings be replaced. Lightly 14

lubricate all O-rings with clean petroleum jelly prior to
assembly.

6 21
9
5 11
2
7
13 18
3

10 12
16
8
4 16

1
20

14. Lock Nut 18. Cavity Plug

15. O-ring Plug 19. Drain Plug
16. Control Line Plug 20. Drain Plug
17. Control Line Plug 21. Work Port Plug

Figure 3-11. Plugs, Fittings, and Speed Sensor

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

12. Using a 9/16 inch internal hex wrench, remove work

port plugs (21, if equipped with axial ports). Discard O-
rings.

3121628 3-21
SECTION 3 - CHASSIS & TURNTABLE

22 25

30 27

23 29

26
24
28

22. Screw
23. End Cap 25. Valve Plate
24. O-ring 26. End Cap
27. O-ring
Figure 3-12. End Cap
28. O-ring
29. Angle Stop
13. Using an 8 mm internal hex wrench, remove the endcap 30. Servo Spring
screws (22).
14. Remove the endcap (23). Remove O-ring (24) from the Figure 3-13. Valve Plate & Rear Shaft Bearing
housing or endcap.

When the endcap screws are removed, pressure from

the servo spring will cause the endcap to bind on the TAKE CARE NOT TO SCRATCH THE SURFACE OF THE VALVE PLATE.
shaft. Press down on the portion of the endcap covering
the servo piston and hold the endcap level while remov- 15. Remove the valve plate (25) and timing pin (26) from the
ing. endcap.

Each displacement has a unique valve plate. For identifi-

cation, the last two digits of the valve plate part number
are stamped on its surface.
16. Remove and discard the O-rings (27 and 28).
17. Remove the rear shaft bearing (29) from the endcap
with a bearing puller.

The bearing may be difficult to remove with a puller. Try

this as an alternative: Pack the bearing cavity with heavy
grease. After the shaft is removed, insert it into the bear-
ing cavity and tap lightly with a soft mallet on the
splined end. The grease will force the bearing out. Use
caution not to drive the bearing past the rear shaft jour-
nal as the bearing may become trapped on the shaft
and damaged.

3-22 3121628
SECTION 3 - CHASSIS & TURNTABLE

18. Remove minimum angle stop (29) and servo spring (30) 20. Turn the housing over and remove the snap ring (32)
from the housing. retaining the shaft seal and support washer. Remove the
support washer (33) and carefully pry out the shaft seal
(34). Discard the seal.

To avoid damaging the shaft during seal removal. Install

a large sheet metal screw into the chuck of a slide ham-
mer. Drive the screw into the seal surface and use the
31
slide hammer to pull the seal.

36
35
31. Cylinder Kit Assembly 37

Figure 3-14. Cylinder Kit

19. Turn the housing on its side and remove the cylinder kit
assembly (31). Set the assembly aside, being careful not
to scratch the running surface.

NOTE: Grooves on the surface of the cylinder kit identify its dis-
placement: 35. Inner Snap Ring
36. Snap Ring
Table 3-5. Displacement Identifiers
37. Bearing
# of Grooves Frame L Frame K 38. Shaft
1 25 38 Figure 3-16. Shaft & Front Bearing
2 30 45
3 35 -- 21. Remove the inner snap ring (35) and the shaft / bearing
assembly.
22. Remove the snap-ring (36) retaining the shaft front
bearing. Pull the bearing (37) off of the shaft (38).
32

32. Snap Ring

33. Support Washer
34. Shaft Seal

Figure 3-15. Shaft Seal

3121628 3-23
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 3-17. Swash Plate & Servo Piston

44. Piston 49. Retaining Ring
45. Slipper Retainer 50. Block Spring Washer
23. Turn housing over and remove the swashplate (39) by
46. Cylinder Block 51. Spiral Retaining Ring
lifting on the end opposite the servo lever.
47. Ball Guide 52. Block Spring
24. Remove the servo piston (40). Remove the piston seal 48. Holddown Pins 53. Inner Block Spring Washer
(41) and O-ring (42) from the servo piston. Discard the
seal and O-ring. Figure 3-18. Cylinder Kit Disassembly
25. Remove the journal bearings (43) from the housing. If 26. Remove pistons (44) and slipper retainer (45) from the
the bearings are to be reused, note the location and ori- cylinder block (46).
entation of each bearing for reassembly.
The pistons are not selectively fitted, however units with
high hourly usage may develop wear patterns. Number
the pistons and bores for reassembly if they are to be
reused.
27. Remove the ball guide (47), hold-down pins (48), and
retaining ring (49) from the cylinder block.

NOTE: Most repairs do not require block spring removal. Perform

this procedure only if you suspect problems with the block
spring.

3-24 3121628
SECTION 3 - CHASSIS & TURNTABLE

SLIPPERS
Inspect the running surface of the slippers. Replace any piston
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES assemblies with scored or excessively rounded slipper edges.
FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO Measure the slipper foot thickness. Replace any piston assem-
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS blies with excessively worn slippers. Check the slipper axial
SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. end-play. Replace any piston assemblies with excessive end-
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED. play.
Minimum slipper foot thickness and maximum axial end-play
28. Turn the block over. Using a press, apply pressure on the
are given in the table below.
block spring washer (50) to compress the block spring.
Compress the spring enough to safely remove the spiral
Table 3-6. Slipper Foot Thickness & End Play
retaining ring (51). While maintaining pressure, unwind
the spiral retaining ring (51). Carefully release the pres- L Frame K Frame
sure and remove the outer block spring washer (50), Measurement
mm (in.) mm (in.)
block spring (52), and inner block spring washer (53)
Slipper Foot Thickness 2.71 4.07
from the cylinder block.
(0.11) (0.16)
Inspection Piston/Slipper End Play 0.15
(0.006)
After disassembly, wash all parts (including the end-cap and
housing) thoroughly with clean solvent and allow to air dry.
Blow out oil passages in the housing and endcap with com- CYLINDER BLOCK
pressed air. Conduct inspection in a clean area and keep all Measure the cylinder block height. Replace blocks worn
parts free from contamination. Clean and dry parts again after beyond the minimum height specification. Inspect the run-
any rework or resurfacing. ning surface of the cylinder block. Replace or resurface worn
or scratched blocks. Blocks may be resurfaced to the specifica-
PISTON tions shown in the drawing, provided resurfacing will not
Inspect the pistons for damage and discoloration. Discolored reduce the block height below the minimum specification.
pistons may indicate excessive heat; do not reuse. Table 3-7, Cylinder Block Measurements.

Maximum end play

Minimum Slipper
slipper fo ot
thickness

3121628 3-25
SECTION 3 - CHASSIS & TURNTABLE

Table 3-7. Cylinder Block Measurements

Measurement L25 mm (in.) L30 mm (in.) L35 mm (in.) K38 mm (in.) K45 mm (in.)
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)

BALL GUIDE AND SLIPPER RETAINER SWASHPLATE AND JOURNAL BEARINGS

Inspect the ball guide and slipper retainer for damage, discol- Inspect the running face, servo ball-joint, and swashplate jour-
oration, or excessive wear. A discolored ball guide or slipper nal surfaces for damage or excessive wear. Some material
retainer indicates excessive heat. Do not reuse. transfer may appear on these surfaces and is acceptable pro-
viding the surface condition meets specifications shown. Mea-
Slipper retainer sure the swashplate thickness from the journals to the running
face. Replace swashplate if damaged or worn beyond mini-
mum specification. Replace swashplate if the difference in
thickness from one side to the other exceeds specification.
Ball guide

0.0025 mm
[0.0001 in]
VALVE PLATE
The condition of the valve plate is critical to the efficiency of 25.8 mm
LV [1.015 in]
the motor. Inspect the valve plate surfaces carefully for exces-
sive wear, grooves, or scratches. Replace or resurface grooved KV24.6 mm
[0.969 in]
or scratched valve plates. Measure the valve plate thickness Thickness equality
and replace if worn beyond the minimum specification. Valve side to side:
0.05 mm [0.002 in]
plates may be resurfaced to the specifications shown in the
drawing, provided resurfacing will not reduce the thickness
below the minimum specification.
3.83 mm [0.151 in] min.

0.025 mm
[0.001 in]

Inspect the journal bearings for damage or excessive wear.

Replace journal bearings if scratched, warped, or excessively
worn. The polymer wear layer must be smooth and intact.
0.0076 mm
[0.00030 in]
convex max

3-26 3121628
SECTION 3 - CHASSIS & TURNTABLE

SHAFT BEARINGS Assembly

Inspect bearings for excessive wear or contamination. Rotate
the bearings while feeling for uneven movement. Bearings 1. Install new O-ring (1) and piston seal (2) to the servo pis-
should spin smoothly and freely. Replace bearings that appear ton (3). Install the piston seal over the O-ring.
worn or do not rotate smoothly.
Installing the piston seal stretches it, making it difficult
to install the servo piston in its bore. Allow 30 minutes
for the seal to relax after installation. To speed up seal
relaxation, compress the seal by installing the piston
head into the servo cavity in the end-cap and let it stand
for at least five minutes.

2
3

SHAFT
Inspect the motor shaft. Look for damage or excessive wear on
the output and block splines. Inspect the bearing surfaces and
sealing surface. Replace shafts with damaged or excessively
worn splines, bearing surfaces, or sealing surfaces.
1
SERVO PISTON AND MINIMUM ANGLE STOP
Inspect the minimum angle stop, servo piston head, and servo
piston ball-socket for damage or excessive wear. Replace if
necessary.
3

LOOP FLUSHING SPOOL 1. O-ring

Inspect the loop flushing spool. Check for cracks or damage. 2. Piston Seal
Replace if necessary. 3. Servo Piston

Figure 3-19. Servo Piston

2. After piston seal has relaxed, lubricate and install servo

piston into the housing bore. Align the piston with the
ball socket facing the inside of the housing.

3121628 3-27
SECTION 3 - CHASSIS & TURNTABLE

4. Turn the block over and install the retaining ring (8),
hold-down pins (9), and ball guide (10) to the cylinder
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES block.
ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO 5. Install the pistons (11) to the slipper retainer (12). Install
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS the piston/retainer assembly into the cylinder block.
SECURE BEFORE ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING. Ensure the concave surface of the retainer seats on the
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED. ball guide. If you're reusing the pistons, install them to
the original block bores. Lubricate the pistons, slippers,
3. Install the inner block spring washer (4), block spring (5), retainer, and ball guide before assembly. Set the cylinder
and outer washer (6) into the cylinder block. Using a kit aside on a clean surface until needed.
press, compress the block spring enough to expose the
retaining ring groove. Wind the spiral retaining ring (7) 6. Install the journal bearings (13) into the housing seats.
into the groove in the cylinder block. Use assembly grease to keep the bearings seated during
assembly. Ensure the locating nubs drop into the cavi-
ties in the seats. If you're reusing the bearings, install
11 them in the original location and orientation. Lubricate
the journal bearings.
12

14
10 13

9
8

7 13. Journal Bearings

14. Swashplate

Figure 3-21. Swashplate and Journal Bearing

4. Block Spring Washer 9. Holddown Pins
5. Block Spring 10. Ball Guide 7. Install the swashplate (14) into the housing. Tilt the
6. Outer Washer 11. Piston swashplate and guide the servo lever ball into its socket
7. Spiral Retaining Ring 12. Slipper Retainer in the servo piston rod. Ensure the swashplate seats into
8. Retaining Ring the journal bearings and moves freely. Lubricate the
running surface of the swashplate.
Figure 3-20. Cylinder Kit Assembly

3-28 3121628
SECTION 3 - CHASSIS & TURNTABLE

8. Press front shaft bearing (15) onto shaft (16). Press bear- 10. Verify swashplate and bearings are properly seated.
ing onto shaft with lettering facing out. Lubricate bear- Install the cylinder kit (19) onto the shaft. Install with the
ing rollers. Install snap-ring (17) onto shaft. slippers facing the swashplate. Rock the shaft to align
the block splines and slide the cylinder kit into place.
Orient the motor with the shaft pointing downward and
verify the cylinder kit, swashplate, journal bearings, and
servo piston are all secure and properly installed.

15
16
19. Cylinder Kit

Figure 3-23. Cylinder Kit Installation

17
11. Lubricate and install the servo spring (20), and minimum
18 angle stop (21) into the housing bore.

15. Front Shaft Bearing

16. Shaft
17. Snap Ring
18. Snap Ring
21
Figure 3-22. Shaft and Front Bearing

9. While holding the swashplate in place, turn the housing 20

on its side. Install the install shaft/bearing assembly into
housing from the flange end. Install the snap-ring (18).

20. Servo Spring

21. Minimum Angle Stop

Figure 3-24. Servo Spring and Minimum Angle

Stop

3121628 3-29
SECTION 3 - CHASSIS & TURNTABLE

12. Press the rear shaft bearing (22) into the endcap. Install 15. Install the endcap (25) onto the housing with the end-
the bearing with letters facing out. Press until bearing cap screws (26). Check to ensure the endcap will prop-
surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap sur- erly seat onto the housing without interference.
face. Improper assembly of the internal components may
prevent the endcap from seating properly. Ensure the O-
22 3 mm
23 [0.12 in]
rings seat properly when installing the endcap.
2 mm
[0.08 in]
26
8 mm
35-45 ft.lbs.
23 (47-61 Nm)

24
25

25. End Cap

22. Rear Shaft Bearing 26. Screw
23. Timing Pin
24. Valve Plate Figure 3-26. End Cap

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

3-30 3121628
SECTION 3 - CHASSIS & TURNTABLE

18. Cover shaft splines with an installation sleeve. Install a 19. Install remaining plugs and fittings to the housing. Refer
new shaft seal (27) with the cup side facing the motor. to the drawing below for wrench sizes and installation
Press seal into housing until it bottoms out. Press evenly torques.
to avoid binding and damaging the seal. Install seal sup- 1/4 in
5/16 in
port washer (28) and snap ring (29). 63 ft.lbs. 33 ft.lbs.
(85 Nm) (45 Nm)

9/16 in
125 ft.lbs.
(170 Nm)

3 mm
27. Shaft Seal 1.5 to 2.5 ft.lbs.
28. Seal Support Washer (2.03 to 3.39 Nm)
29. Snap Ring

Figure 3-27. Shaft Seal

1/4 in
33 ft.lbs.
(45 Nm)

5/16in
63 ft.lbs.
(85 Nm)

Figure 3-28. Plugs and Fittings Installation

3121628 3-31
SECTION 3 - CHASSIS & TURNTABLE

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

37 Follow this procedure when starting-up a new motor or when
36 installing a motor that has been removed.
39 33
41 Prior to installing the motor, inspect for damage incurred dur-
34
30 11/16 in ing shipping. Make certain all system components (reservoir,
40 27 ft.lbs. hoses, valves, fittings, heat exchanger, etc.) are clean prior to
(37 Nm) filling with fluid.
5/8 in
20 ft.lbs. 1. Fill the reservoir with recommended hydraulic fluid.
(27 Nm) Always filter fluid through a 10 micron filter when pour-
ing into the reservoir. Never reuse hydraulic fluid.
31
32
35 2. Fill the inlet line leading from the pump to the reservoir.
38 Check the inlet line for properly tightened fittings and
be certain it is free of restrictions and air leaks.
42 3. Fill the pump and motor housing with clean hydraulic
11/16 in
fluid. Pour filtered oil directly into the upper most case
27 ft.lbs.
(37 Nm) drain port.
4. To ensure the pump and motor stay filled with oil, install
case drain lines into the upper most case drain ports.
5. Install a 0 to 500 psi (0 to 35 bar) gauge in the charge
pressure gauge port of the pump to monitor system
30. Orifice Poppet 34. Spring 37. O-ring 40. Plug pressure during start up.
31. Shift Spool 35. Spring 38. O-ring 41. Plug 6. While watching the pressure gauge, run the engine at
32. Spring 36. Spring 39. O-ring 42. Plug the lowest possible speed until system pressure builds
33. Spring to normal levels (minimum 160 psi [11 bar]). Once sys-
Figure 3-29. Loop Flushing Spool tem pressure is established, increase to full operating
speed. If system pressure is not maintained, shut down
the prime mover, determine cause, and take corrective
21. Install shift spool (31).
action.
22. Install spring retaining washers onto springs (32 and 33).
7. Operate the hydraulic system for at least fifteen minutes
23. Carefully install centering springs (34, 35, and 36). under light load conditions.
24. Install new O-rings (37, 38, and 39). 8. Check and adjust control settings as necessary after
25. Using a 5/8 in wrench torque plug (40) to 20 ft.lbs. (27 installation.
Nm). 9. Shut down the prime mover and remove the pressure
26. Using a 11/16 in wrench, torque plugs (41 and 42) to 27 gauge. Replace plug at the charge pressure gauge port.
ft.lbs. (37 Nm). 10. Check the fluid level in the reservoir; add clean filtered
fluid if necessary. The motor is now ready for operation.

3-32 3121628
SECTION 3 - CHASSIS & TURNTABLE

FRAME REF.

4
2

3
7

9
8 5
1001156136 A

1. Swing Drive 4. Swing Bearing 7. Grease Line

2. Swing Motor 5. Outer Race Bearing Bolt 8. Bolt
3. Inner Race Bearing Bolt 6. Turntable Lock Pin 9. Jam Nut

Figure 3-30. Swing System

3121628 3-33
SECTION 3 - CHASSIS & TURNTABLE

3.7 SWING DRIVE Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
Roll, Leak And Brake Testing should be taken to ensure that the bolts are not tightened
beyond their specified torque.
Torque-Hub units should always be roll and leak tested before
disassembly and after assembly to make sure that the unit's The following steps describe how to tighten and torque bolts
gears, bearings and seals are working properly. The following or socket head cap screws in a bolt circle.
information briefly outlines what to look for when performing
these tests.

NOTE: The brake must be released before performing the roll test.
This can be accomplished by either pressure testing using
the Brake Leak Test procedure below or by tightening the
12 bolts into the piston through the end plate (See Brake
Disassembly Procedure).

NOTE: Bolts must be removed while performing brake release test.

Roll Test

The purpose of the roll test is to determine if the unit's gears

are rotating freely and properly. You should be able to rotate
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
1. Tighten (but do not torque) bolt “A" until snug.
packages roll with more difficulty than others. Do not be con-
cerned if the gears in your unit seem to roll hard as long as 2. Go to the opposite side of the bolt circle and tighten
they roll with consistency. Release the pressure at the Brake bolt “B” until equally snug.
Housing (6) and remove the test fixtures.
3. Crisscross around the bolt circle and tighten remaining
Leak Test (Main Unit) bolts.
4. Now use a torque wrench to apply the specified torque
The purpose of a leak test is to make sure the unit is air tight.
to bolt “A”.
You can tell if your unit has a leak if the pressure gauge read-
ing on your air checker starts to fall after the unit has been 5. Using the same sequence, crisscross around the bolt cir-
pressurized and allowed to equalize. Leaks will most likely cle and apply an equal torque to the remaining bolts.
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 exte-
rior of the unit, then checking for air bubbles. If a leak is
detected in a seal, o-ring or gasket, the part must be replaced,
and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20 min-
utes.

Brake Test

The brake test must be performed with the Motor removed

and the Brake Test Plate (T-214404) installed. Install the Hex
Bolts through Brake Test Plate and torque to 80 - 100 ft. lbs.
(108-135 Nm). Install Roll Checking Tool (T-212731) and apply
210 psi (14 bar) to the o-ring port in the side of the Brake
Housing. The roll checking fixture should roll freely. Increase
the pressure to 3000 psi (207 bar) and perform the Roll Test.

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

fective brake parts.

3-34 3121628
SECTION 3 - CHASSIS & TURNTABLE

Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (30)
and remove fittings from Brake (6) and Motor Control
NOTE: Refer to Figure 3-31. Valve (32).
5. Remove O-ring Plugs (23) from Motor Control Valve (32).
1. Place unit on bench with the motor end up.
6. Remove Motor Control Valve (32) from Motor (31) by
2. Remove O-ring Plug (1P) and drain the oil from the gear-
removing the four Bolts (21) and washers (22).
box.
3. Remove Hydraulic Tubing Assembly (35) by loosening
fittings on both ends of tube with a wrench.

3121628 3-35
SECTION 3 - CHASSIS & TURNTABLE

32
31
23
22
21
6

1P. O-ring Plug 30. Elbow Fitting

6. Hydraulic Brake 31. Hydraulic Motor
21. Hex Bolt 32. Motor Control Valve
22. Lockwasher 35. Hydraulic Tubing
23. Plug

Figure 3-31. Motor Control Valve

3-36 3121628
SECTION 3 - CHASSIS & TURNTABLE

Motor and Brake Disassembly 4. Remove the Springs (8L) from the piston.
5. Apply less than 50 psi (3.45 bar) air to the “brake port” to
NOTE: Refer to Figure 3-32.
remove Brake Piston (8A).
1. With unit resting on bench with Motor (31) end up,
loosen Hex Bolts (29) and remove Lift Lugs (28) from the
Motor (31). THE PISTON MAY MOVE QUICKLY. EYE PROTECTION SHOULD BE WORN DUR-
ING THIS PROCEDURE.
2. Pull Motor (31) straight up and remove Motor (31) from
Brake Housing (6).
6. Remove Rotors (8J) and Stators (8K) from Brake Housing
3. Remove O-ring (26) from between Motor (31) and Brake (6).
Housing (6).

6
8K
8J 8K
8J 8K
8J
8K 8J
8K

8A 28
8L 29
26
31

6. Brake Housing 26. O-ring

8A. Brake Piston 28. Lift Lug
8L. Spring 29. Hex Bolt
8J. Rotors 31. Motor
8K. Stator

Figure 3-32. Motor and Brake

3121628 3-37
SECTION 3 - CHASSIS & TURNTABLE

Main Drive Disassembly 5. Remove Thrust Washer (11) from between Brake Hous-
ing (6) and Carrier Subassembly.
NOTE: Refer to Figure 3-33. 6. Remove Ring Gear (4) from Housing (1G).

1. Remove Sun Gear (8) with Retaining Ring (44) inside. 7. Remove O-ring (5) from between Ring Gear (4) and
Housing (1G).
2. With the unit resting on the Output Shaft (Pinion) (1A),
remove the Bolts (12) from the Brake Housing (6). 8. Remove Carrier Sub-Assembly.

3. Remove the Brake Housing (6) from the main assembly. 9. Remove Thrust Washer (11) from between Carrier Sub-
Assembly and Internal Gear (2).
4. Remove O-ring (5A) from between Brake Housing (6)
and Ring Gear (4). 10. Remove Internal Gear (2).

13
Carrier
Subassembly
11
5

5A
6

1G Hub-Shaft 20
2
Subassembly
3F
44

4 11

8
12

1A. Output Shaft (Pinion) 5. O-ring 12. Bolt

1G. Housing 5A. O-ring 13. Dowel Pin
2. Internal Gear 6. Brake Housing 20. Pipe Plug
3F. Carrier subassembly 8. Sun Gear 44. Ring
4. Ring Gear 11. Thrust Washer

Figure 3-33. Main Drive Assembly

3-38 3121628
SECTION 3 - CHASSIS & TURNTABLE

Hub-Shaft Disassembly 3. While supporting the Housing (1G) on the Output Shaft
(1A) end, press the Output Shaft (1A) out of the Housing
NOTE: Refer to Figure 3-34. (1G).

NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by
1. Using retaining ring pliers remove Retaining Ring (1I) the Bearing Cone (1D) during this step.
from groove in Output Shaft (1A) and discard.
4. Remove the Bearing Cone (1E) from the Housing (1G).
5. Use a bearing puller to remove the Bearing Cone (1D)
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. from the Shaft (1A).
6. Bearing Cups (1C & 1F) will remain in Housing (1G).
2. Remove Thrust Washer (1H).

1B
1C

1A 1H

1G
1E
1I

1A. Output Shaft 1F. Bearing Cup

1B. Lip Seal 1G. Housing
1C. Bearing Cup 1H. Thrust Washer
1D. Bearing Cone 1I. Retaining Ring
1E. Bearing Cone

Figure 3-34. Hub-Shaft

3121628 3-39
SECTION 3 - CHASSIS & TURNTABLE

Carrier Disassembly 2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a
small punch to remove the Roll Pin (3D) from the Planet
Shaft (3E).
NOTE: Refer to Figure 3-35.
3. Slide the Planet Gear (3F), the two Thrust Washers (3B)
1. Using a 3/16” punch drive the Roll Pin (3G) which holds out of the Carrier (3A).
the Planet Shaft (3E) in the Carrier (3A) down into the 4. Remove both rows of Needle Bearings (3C) and the
Planet Shaft (3E) until it bottoms. Spacer (3D) from the bore of the Planet Gear (3F).

NOTE: Make sure that the Roll Pin has bottomed. Otherwise, dam- 5. Repeat Steps 1 thru 4 for the remaining two Cluster
age to the carrier could occur when the Planet Shaft is Gears (3F).
removed.

3B 3F 3G

3C
3D
3C 3B

3A. Carrier 3E. Planet Shaft

3B. Thrust Washers 3F. Cluster Gear
3C. Needle Bearing 3G. Roll Pin
3D. Spacer

Figure 3-35. Carrier

3-40 3121628
SECTION 3 - CHASSIS & TURNTABLE

Hub-Shaft Assembly Carrier Assembly

NOTE: Refer to Figure 3-34. NOTE: Refer to Figure 3-35.

1. Press Bearing Cup (1C) into Housing (1G) taking care to 1. Apply a liberal Coat of grease to the bore of Cluster Gear
insure cup starts square with the bore of Hub (1G). (3F). This will enable the Needle Rollers (3C) to be held in
place during assembly.
2. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing
(1G). 2. Install the first row of Needle Rollers (3C) into the bore of
Cluster Gear (3F).
3. Press or tap Seal (1B) Into the counterbore of Housing
(1G) to the point where it becomes flush with the Hous- 3. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of
ing (1G) face. Care should be taken to insure Seal (1B) is the Needle Rollers (3C).
being correctly installed (smooth face up). Apply grease
4. Place second row of Needle Rollers (3C) into bore of
to the rubber portion of the seal bore.
Cluster Gear (3F) against Spacer (3D).
4. Invert Hub (1G) and press Bearing Cup (1E) into counter-
5. Place Carrier (3A) so that one of the roll pin holes is
bore of Housing (1G).
straight up.
5. Carefully lower Housing (1G) onto the Output Shaft (1A) 6. Start Planet Shaft (3E) through the hole in Carrier (3A).
until Bearing Cone (1D) contacts the Output Shaft (1A). Using ample grease to hold it in position, slide one
6. Press on the small end of the Bearing Cone (1D), being Thrust Washer (3B) over the Planet Shaft (3E) with the
careful not to contact the bearing cage, until the Bearing tang resting in the cast slot of the Carrier (3A).
Cone (1D) seats on the shoulder of the Output Shaft 7. With large end of Cluster Gear (3F) facing the roll pin
(1A). hole in the Carrier, place the Cluster Gear into position in
7. Start the Bearing Cone (1F) onto the Output Shaft (1A). carrier (3A) and push Planet Shaft (3E) through the Clus-
ter Gear (3F) without going all the way through.
8. Press or tap the Bearing Cone (1F) onto the Output Shaft
(1A) until it is just seated in the Bearing Cup (1E). while 8. Slide the second Thrust Washer (3B) between the Cluster
rotating the Housing (G). Gear (3F) and the Carrier (3A) with the tang of the
washer located in the cast slot of the Carrier (3A). Finish
9. Install Bearing Spacer (1H) onto Output Shaft (1A) and sliding the Planet Shaft (3E) through the Thrust Washer
against Bearing Cone (1F). (3B) and into the Carrier (3A).
10. Install Retaining Ring (1I) into the groove in the Output 9. Position the non-chamfered side on the Planet Shaft (3E)
Shaft (1A). This Retaining Ring (1I) should never be roll pin hole so that it is in line with the hole in the Car-
reused in a repair or rebuild. rier (3A) using a 1/8” (3 mm) diameter punch.
10. After using a 3/16” (5 mm) punch to align the two roll
pin holes. Drive the Roll Pin (3G) through Carrier (3A)
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. and into the Planet Shaft (3E) until the Roll Pin (3G) is
flush with the bottom of the cast slot in the Carrier (3A)
11. Tap the Retaining Ring (1I) with a soft metal punch to
outside diameter at the thrust washer (3B) tang. Use a 1/
ensure that the Retaining Ring (1I) is completely seated
4” (6 mm) pin punch to make sure the Roll Pin (3G) is
in the groove of the Output Shaft (IA).
flush in the slot.
11. Repeat Steps 1 thru 10 for the remaining two Cluster
Gears(3F).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
12. Install O-ring Plug (1P) and torque to 23 to 24 ft.lbs. (31
to 32 Nm).

3121628 3-41
SECTION 3 - CHASSIS & TURNTABLE

Main Drive Assembly NOTE: If gears do not mesh easily or Carrier Assembly does not
rotate freely, then remove the Carrier and Ring Gear and
NOTE: Refer to Figure 3-33. check the Cluster Gear timing.

1. With the Hub Shaft Sub-Assembly resting on the Shaft 9. Install Thrust Washer (11) into the counter-bore on the
(1A) install Internal Gear (2). The spline of the Internal face of the carrier. Use grease to hold in place.
Gear (2) bore will mesh with the spline of the Output
10. Place O-ring (5A) into counter-bore or Brake Housing (6).
Shaft (1A). This will be a tight fit.
Use grease to hold O-Ring in place.
2. Inspect the location of the Internal Gear (2) on the Out-
put Shaft (1A). The portion of the Output Shaft (1A)
should protrude through the Internal Gear (2) bore.
BEWARE OF SHARP EDGES OF THE COUNTER-BORE WHILE SEATING THIS O-
3. Install 4 Dowel Pins (13) into counter bore holes in Hub RING.
(IG).
11. Install the Brake Housing (6), taking care to correctly
4. Install Thrust Washer (11) in counter bore of Carrier Sub- align Pipe Plug (20) with those in the Hub (I G).
Assembly (Small Cluster-Gear end) Use grease to hold in
place. 12. Install Bolts (12) through the Brake Housing (6) into the
Hub (1G) and torque to 23-27 ft.lbs. (31-37 Nm).
5. Place O-ring (5) into Hub counter-bore. Use grease to
hold O-ring in place. 13. With gearbox standing on the pinion end fill gearbox
with 43 oz. of ISO VG150/VG220 gear Oil.
14. Install Retaining Ring (44) into the groove in the Sun
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE SEATING THIS Gear (8).
ORING.
15. Install the Sun Gear (8) into mesh with the Planet Gears
6. Place Carrier Sub-Assembly on bench with the large end (3F).
of Cluster Gears (3F) facing up with one at the 12 o'clock
16. Install Pipe Plug (20) into Cover (6) torque to 23 to 24
position. Find the punch marked tooth on each gear at
ft·lbs. (31-32 Nm).
the large end and locate at 12 o'clock (straight up) from
each planet pin. Marked tooth will be located just under
the Carrier on upper two gears. Check the timing
through the slots in the carrier (See Carrier Sub-Assem-
bly).
7. With large shoulder side of Ring Gear (4) facing down,
place Ring Gear (4) over (into mesh with) cluster gears
(3F). Be sure that cluster gear timing marks (punch
marks) remain in correct location during Ring Gear (4)
installation. The side of the Ring Gear (4) with an "X" or
punch mark stamped on it should be up.
8. While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
with the Internal Gear (2). On the Ring Gear (4) locate
the hole marked "X", or punch marked, over one of the
marked counter-bored holes (Step 5) in Hub (1G). Check
timing through the slots in the carrier. Rotate carrier in
assembly to check for freedom of rotation.

3-42 3121628
SECTION 3 - CHASSIS & TURNTABLE

Motor and Brake Assembly Motor Control Valve Assembly

NOTE: Refer to Figure 3-32. NOTE: Refer to Figure 3-31.

1. Alternate Stators (8K) (O.D. lobes) with Rotors (8J) (I.D. 1. Lay assembly down with motor ports facing up. Remove
splines) into bore of Brake Housing (6). starting with a the two plastic plugs in the motor ports, being careful
Stator (8K) and ending with a Stator (8K). not to lose the O-ring in each port. Assemble the Motor
control Valve (32) onto the Motor (31) with Bolt (21) and
2. Grease the O-rings (8F) & (8D) and Back-up rings (8H) &
Lock Washers (22). Torque Bolts (21) to 23-27 ft.lbs. (31-
(8E). and place them in their respective grooves in the
37 Nm).
Brake Housing (6) and Piston (8A). Make sure the Back-
up rings are correctly positioned. NOTE: Be sure to align the holes in the control valve with the
motor ports.
3. Apply grease sparingly to the Piston O.D. (8A) and the
bore of the Brake Housing (6). Insert Piston (8A) into
2. Install Elbow Fittings (30) into Brake (6). Do not tighten
Brake Housing (6) be sure not to damage the O-rings.
jam nuts.
4. Install Springs (8L) into the spring pockets of the Piston
3. Install Elbow Fittings (30) into Motor Control Valve (32).
(8A).
Do not tighten jam nuts.
5. Test the brake and perform the roll test. Remove the
4. Assemble Tube (35) into Elbow Fittings (30) and torque
Brake Test Plate.
to 13-15 ft.lbs (18-20 Nm). Tighten the jam nuts on the
6. Install the O-ring (26) onto the pilot of the Motor (31), Elbow Fittings (30) and torque to 13-15 ft.lbs. (18-20
use grease to keep the O-ring in place. Nm).
7. Place Motor (31) into Brake pilot, and line up holes. 5. Install one O-ring Plug (23) into Motor Control Valve (32)
and torque to 30-31 fI.lbs. (41-42 Nm).
8. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble
Hex Bolts (29) with Lift Lugs (28) through the Motor (31) 6. Pressure test brake, tube and control valve connections
and Brake (6) against Motor flange. Torque to 80-100 by applying 3000 psi (207 bar) pressure to the open port
ft.lbs. (108-136 Nm). in the Motor Control Valve (32) and holding lor 1 minute.
Check lor leaks al the control-valve-motor interface and
the tube connections. Release pressure and install the
remaining O-ring Plug (23) into Motor Control Valve (32)
and torque to 30-31 ft.lbs. (41-42 Nm).

3121628 3-43
SECTION 3 - CHASSIS & TURNTABLE

1H
5A

1E
4

1G
11

1C 11
44

1A. Output Shaft 1G. Housing 2. Internal Gear 5A. O-Ring 12. Bolt
1B. Lip Seal 1H. Thrust Washer 3. Carrier Assembly 6. Brake Housing 13. Dowel Pin
1C. Bearing 1I. Retaining Ring 4. Ring Gear 8. Sun Gear 20. Pipe Plug
1D. Bearing 1J. Pipe Plug 5. 0-Ring 11. Thrust washer 44. Internal Retaining Ring

Figure 3-36. Swing Drive Assembly

3-44 3121628
SECTION 3 - CHASSIS & TURNTABLE

101

102

104

105 103
106
104

107

104

108

104
8K
109

110 8K

104
8K
112

113 8K
29
115
114
28 118
116 8K
125
117 29
32
23
28 6

22
21
30

6. Brake Housing 8L. Spring 35. Tube 108. Rotor Set 117. Back-up Washer
8A. Piston 21. Thrust Washer 101. Bolt 109. Wear Plate 118. Housing
8D. 0-Ring 22. Lock washer 102. End Cover 110. Drive Link 119. Outer Bearing
8E. Back-Up Ring 23. Pipe Plug 103. Commutator Seal 112. Coupling Shaft 120. Seal
8F. O-Ring 26. 0-Ring 104. Ring Seal 113. Inner Bearing 125. Back-up Washer
8H. Back-up Ring 28. Lifting lug 105. Commutator and Ring Assy 114. Thrust Washer
8J. Rotor Disc 29. Bolt 106. Ring 115. Thrust Bearing
8K. Stator Disc 30. Elbow 107. Manifold 116. Inner Seal

Figure 3-37. Swing Motor and Brake Assembly

3121628 3-45
SECTION 3 - CHASSIS & TURNTABLE

3.8 SWING MOTOR

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

3. Remove the five, six, or seven special ring head bolts (1)
using an appropriate 1/2 or 9/16 inch size socket.
Inspect bolts for damaged threads, or sealing rings,
under the bolt head. Replace damaged bolts.

IF THE TORQMOTOR™ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DIS-

LODGED DURINGTHE SERVICE PROCEDURES, CAUSING INJURY.
2. Scribe an alignment mark down and across the Torqmo-
tor™ components from end cover (2) to housing (18) to
facilitate reassembly orientation where required. Loosen
two shuttle or relief valve plugs (21) for disassembly
later if included in end cover. 3/16 or 3/8 inch Allen
wrench or 1 inch hex socket required.

4. Remove end cover assembly (2) and seal ring (4). Discard
seal ring.

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

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

3-46 3121628
SECTION 3 - CHASSIS & TURNTABLE

1. Special Bolts 8. Rotor Set 12. Coupling Shaft 18A. O-Ring

2. End Cover 8A. Rotor 13. Bearing/Bushing, Inner 19. Bearing/Bushing, Outer
3. Seal Ring-Commutator 8B. Stator or Stator Vane 14. Thrust Washer 20. Dirt & Water Seal
4. Seal Ring 8D. Stator Half 15. Thrust Bearing 21. Plug
5. Commutator Ring 9. Wear Plate 16. Seal
6. Commutator Ring 10. Drive Link 17. Back-up Washer
7. Manifold 11. Not Used 18. Housing

Figure 3-38. Swing Drive Motor

3121628 3-47
SECTION 3 - CHASSIS & TURNTABLE

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

BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS

THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE 8. Remove commutator (5) and seal ring (3) Remove seal
REMOVED. ring from commutator, using an air hose to blow air into
ring groove until seal ring is lifted out and discard seal
NOTE: O- ring is not included in seal kit but serviced separately, if ring. Inspect commutator for cracks or burrs, wear, scor-
required. ing, spalling or brinelling. If any of these conditions exist,
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

3-48 3121628
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 Torqmotor™ will ensure correct
Remove and discard the seal rings (4) that are on both reassembly of rotor into stator and rotor set intoTorqmo-
sides of the manifold. tor™.Marking all rotor components and mating spline
components for exact repositioning at assembly will
ensure maximum wear life and performance of rotor set
and Torqmotor™.

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 and TH may have a rotor set with two stator
halves (8B & 8D) with a seal ring (4) between them and two
sets of seven vanes (8C & 8E). Discard seal ring only if stator
10. Remove rotor set (8) and warplane (9), together to retain halves become disassembled during the service proce-
the rotor set in its assembled form, maintaining the dures.
same rotor vane (8C) to stator (8B) contact surfaces. The
drive link (10) may come away from the coupling shaft
NOTE: A polished pattern on the wear plate from rotor rotation is
(12) with the rotor set, and wear plate.You may have to
normal.
shift the rotor set on the warplane to work the drive link
out of the rotor (8A) and warplane. Inspect the rotor set
in its assembled form for nicks, scoring, or spalling on 11. Place rotor set (8) and wear plate (9) on a flat surface
any surface and for broken or worn splines. If the rotor and center rotor (8A) in stator (8B) such that two rotor
set component requires replacement, the complete lobes (180 degrees apart) and a roller vane (8C) center-
line are on the same stator centerline. Check the rotor
rotor set must be replaced as it is a matched set. Inspect
lobe to roller vane clearance with a feeler gage at this
the warplane for cracks, brinelling, or scoring. Discard
common centerline. If there is more than 0.005 inches
seal ring (4) that is between the rotor set and wear plate.
(0.13 mm) of clearance, replace rotor set.

3121628 3-49
SECTION 3 - CHASSIS & TURNTABLE

NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets 14. Check exposed portion of coupling shaft (12) to be sure
of seven vanes (8C & 8E) as shown in the alternate con- you have removed all signs of rust and corrosion which
struction TG rotor set assembly view, check the rotor lobe might prevent its withdrawal through the seal and bear-
to roller vane clearance at both ends of rotor. ing. Crocus cloth or fine emery paper may be used.
Remove any key (12A), nut (12B), washer (12C), bolt
12. Remove drive link (10) from coupling shaft (12) if it was (12D), lock washer (12E), or retaining ring (12F).
not removed with rotor set and wear plate. Inspect drive
link for cracks and worn or damaged splines. No percep-
tible lash (play) should be noted between mating spline
parts. Remove and discard seal ring (4) from housing
(18).

15. Remove coupling shaft (12), by pushing on the output

end of shaft. Inspect coupling shaft bearing and seal sur-
faces for spalling, nicks, grooves, severe wear or corro-
sion and discoloration. Inspect for damaged or worn
internal and external splines or keyway. Replace cou-
pling shaft if any of these conditions exist.
13. Remove thrust bearing (11) from top of coupling shaft
(12). Inspect for wear, brinelling, corrosion and a full
complement of retained rollers.

Inspection Areas

3-50 3121628
SECTION 3 - CHASSIS & TURNTABLE

NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 19. Remove housing (18) from vise, invert it and remove and
0.020 inches (0.51 mm) diametrically, replace coupling discard seal
shaft.
20. A blind hole bearing or seal puller is required.
NOTE: A slight “polish” is permissible in the shaft bearing areas.
Anything more would require coupling shaft replacement.

16. Remove and discard seal ring (4) from housing (18).
17. Remove thrust bearing (15) and thrust washer (14)
Inspect for wear, brinelling, corrosion and a full comple-
ment of retained rollers.

21. Inspect housing (18) assembly for cracks, the machined

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.

18. Remove seal (16) and back up washer (17) from Small
Frame, housing (18). Discard both.

3121628 3-51
SECTION 3 - CHASSIS & TURNTABLE

22. If the housing (18) assembly has passed inspection to NOTE: The depth or location of bearing/bushing (13) in relation to
this point, inspect the housing bearings/bushings (19) the housing wear plate surface and the depth or location
and (13) and if they are captured in the housing cavity of bearing/bushing (19) in relation to the beginning of
the two thrust washers (14) and thrust bearing (15). The bearing/bushing counter bore should be measured and
bearing rollers must be firmly retained in the bearing noted before removing the bearings/ bushings. This will
cages, but must rotate and orbit freely. All rollers and facilitate the correct reassembly of new bearings/bushings.
thrust washers must be free of brinelling and corrosion.
The bushing (19) or (13) to coupling shaft diameter
clearance must not exceed 0.010 inch (0.025 mm). A
bearing, bushing, or thrust washer that does not pass
inspection must be replaced. If the housing has passed
this inspection the disassembly of the Torqmotor™ is
completed.

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

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

3-52 3121628
SECTION 3 - CHASSIS & TURNTABLE

Assembly
Replace all seals and seal rings with new ones each time you
reassemble the Torqmotor™ 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 Torqmotor™
distributors. (Contact your local dealer for availability).

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

before assembly.

Wash all parts in clean petroleum-based solvents before

assembly. Blow them dry with compressed air. Remove any
paint chips from mating surfaces of the end cover, commuta-
tor set, manifold rotor set, wear plate and housing and from
port and sealing areas. NOTE: Bearing mandrel must be pressed against the lettered end
of bearing shell. Take care that the housing bore is square
with the press base and the bearing/bushing is not cocked
when pressing a bearing/bushing into the housing.
SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY
SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR
DEATH.
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
BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADE-
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX- QUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COM-
IMUM AIR PRESSURE REQUIREMENTS. PONENTS WHEN ASSEMBLED.
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 BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE
new bearing/bushing into the counterbore at the HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE
mounting flange end of the housing, using the appro- REUSED.
priate sized bearing mandrel, which will control the
bearing/ bushing depth.
Torqmotor™ housings require the use of bearing man-
drel to press bearing/ bushing (19) into the housing to a
required depth of 0.151/0.161 inches (3.84/4.09 mm)
from the end of the bearing counterbore.

3121628 3-53
SECTION 3 - CHASSIS & TURNTABLE

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

can now be pressed into its counterbore in housing (18)
flush to 0.03 inch (.76 mm) below the housing wear
plate contact face. Use the opposite end of the bearing
mandrel that was used to press in the outer bearing/
bushing (19).

3. Press a new dirt and water seal (20) into the housing (18)
outer bearing counterbore.
The Torqmotor™ dirt and water seal (20) must be
pressed in until its flange is flush against the housing.

3-54 3121628
SECTION 3 - CHASSIS & TURNTABLE

4. Place housing (18) assembly into a soft jawed vise with

the coupling shaft bore down, clamping against the
mounting flange. ORIGINAL DESIGN LARGE FRAME, TF & TG TORQMOTORS™ 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).

6. Assemble thrust washer (14) then thrust bearing (15)

that was removed from the Torqmotor™.

5. On the Torqmotor™ assemble a new backup washer (17)

and new seal (16) with the seal lip facing toward the
inside of Torqmotor™, into their respective counterbores
in housing (18) if they were not assembled in procedure
2.
NOTE: Torqmotors™ require one thrust washer (14) with thrust
bearing (15).The coupling shaft will be seated directly
against the thrust.

7. Apply masking tape around splines or keyway on shaft

(12) to prevent damage to seal.

3121628 3-55
SECTION 3 - CHASSIS & TURNTABLE

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.

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

(4) and insert it into the housing (18) seal ring groove.

THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC

FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED
GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT #K-
70M.

NOTE: Mobil Mobilith SHC ® 460

NOTE: A 102Tube (P/N 406010) is included in each seal kit.

NOTE: The coupling shaft (12) will be flush or just below the hous-
ing wear plate surface on Torqmotors™ when properly
seated. The coupling shaft must rotate smoothly on the NOTE: One or two alignment studs screwed finger tight into hous-
thrust bearing package. ing (18) bolt holes, approximately 180 degrees apart, will
facilitate the assembly and alignment of components as
required in the following procedures.The studs can be
made by cutting off the heads of either 3/8-24 UNF 2A or 5/
16-24 UNF 2A bolts as required that are over 0.5 inch (12.7
mm) longer than the bolts (1) used in the Torqmotor™.

3-56 3121628
SECTION 3 - CHASSIS & TURNTABLE

10. Install drive link (10) the long splined end down into the 12. Apply a small amount of clean grease to a new seal ring
coupling shaft (12) and engage the drive link splines (4) and assemble it into the seal ring groove on the wear
into mesh with the coupling shaft splines. plate side of the rotor set stator (8B).

13. Install the assembled rotor set (8) onto wear plate (9)
NOTE: Use any alignment marks put on the coupling shaft and
with rotor (8A) counterbore and seal ring side down and
drive link before disassembly to assemble the drive link
the splines into mesh with the drive link splines.
splines in their original position in the mating coupling
shaft splines.

11. Assemble wear plate (9) over the drive link (10) and
alignment studs onto the housing (18).

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

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

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

Assembly Procedure.”

NOTE: The rotor set rotor counterbore side must be down against
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).

3121628 3-57
SECTION 3 - CHASSIS & TURNTABLE

14. Apply clean grease to a new seal ring (4) and assemble it 16. Apply grease to a new seal ring (4) and insert it in the
in the seal ring groove in the rotor set contact side of seal ring groove exposed on the manifold.
manifold (7).

17. Assemble the commutator ring (6) over alignment studs

onto the manifold.
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.

15. Assemble the manifold (7) over the alignment studs and
drive link (10) and onto the rotor set. Be sure the correct
manifold surface is against the rotor set.

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

3-58 3121628
SECTION 3 - CHASSIS & TURNTABLE

19. 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.

3121628 3-59
SECTION 3 - CHASSIS & TURNTABLE

20. Assemble the 5 or 7 special bolts (1) and screw in finger NOTE: The special bolts required for use with the relief or shuttle
tight. Remove and replace the two alignment studs with valve (24) end cover assembly (2) are longer than the bolts
bolts after the other bolts are in place. Alternately and required with standard and cover assembly. Refer to the
progressively tighten the bolts to pull the end cover and individual service parts lists or parts list charts for correct
other components into place with a final torque of 50-55 service part number if replacement is required.
ft. lbs.(68-75 N m) for the seven 3/8-24 threaded bolts.
21. 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.

Thrust
Washers Housing

Steel
Washer
Seal

Thrust Backup
Bearing Washer

Not To Scale
Shaft

3-60 3121628
SECTION 3 - CHASSIS & TURNTABLE

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

5. Grasp the output end of coupling shaft (12) with locking

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

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

NOTE: If the manifold side of the rotor was etched during Torqmo- tor and wear plate.
tor 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.

3121628 3-61
SECTION 3 - CHASSIS & TURNTABLE

3.9 SWING HUB INSTALLATION 4. Remove turntable lock pin.

5. Apply JLG Threadlocker P/N 0100019 and pre-torque
Ensure mounting plate and mounting location of the base
swing drive mounting bolts to 30 ft. lbs. (40 Nm).
plate are clean and painted with a uniform coating of mini-
mum thickness (no runs, drips, etc.).

Procedure For Setting Swing Gear Backlash

Set backlash to 0.010 in. to 0.015 in. (0.254 mm - 0.381 mm)
using the following procedure:

1. Place the machine on firm, level ground.

2. Place shim between pinion and bearing at bearing high

spot (shown below).
HIGH SPOT in this area with
two x's and yellow paint in
tooth space.

6. Tighten jack bolt until pinion is completely snug against

shim and bearing then loosen jack bolt.

HIGH SPOT
marked with yellow paint

Jam Nut
Jack Bolt

3. Apply JLG Threadlocker P/N 0100019 and torque pivot

bolt to 205 ft. lbs. (280 Nm) (shown below).

7. Apply JLG Threadlocker P/N 0100019 and torque jack

bolt 50 ft. lbs. (68 Nm).
8. Apply JLG Threadlocker P/N 0100019 and tighten jam
nut.

Pivot Bolt

NOTE: Make sure the turntable is properly supported during the

following step. The turntable can swing a few degrees
when the turntable lock is removed if the turntable is not
balanced properly.

3-62 3121628
SECTION 3 - CHASSIS & TURNTABLE

9. Torque mounting bolts to 340 ft. lbs. (Nm). 3.10 SWING HUB REMOVAL
1. Disconnect all wiring harness terminals connected to
the swing motor.
2. Gently loosen the set screw. Do not remove.
3. Remove the pivot bolt using Allen Wrench.

Jam Nut
Jack Bolt

10. Remove shim and discard..

Pivot Bolt Mounting Bolt

4. Remove the mounting bolts securing swing drive hub to

the turntable.
5. Using the suitable lifting device, remove the swing drive
hub from mounting plate without damaging the swing
gear.
6. Place swing drive hub in the clean area.
7. Refer to Section 3.7, Swing Drive for swing drive mainte-
nance.
Swing Drive Lubrication
Fill Swing Drive Gearbox with 43 oz (1.27 L) 90w80gear oil with
EP additives. Oil should cover the ring gear. Torque pipe plug
to 23-25 ft.lbs (31- 33 Nm).

Fill Plug

Drain Plug

3121628 3-63
SECTION 3 - CHASSIS & TURNTABLE

3.11 SWING BEARING 2. Check the turntable to bearing Attach bolts as follows:
a. Elevate the fully retracted main boom to full eleva-
Turntable Bearing Mounting Bolt Condition Check tion.
b. At the position indicated on Figure 3-39. try to insert
the 0.0015” feeler gauge between the bolt head and
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL hardened washer at the arrow indicated position.
LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE c. Lower the boom to horizontal and fully extend the
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE boom.
SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. d. At the position indicated on Figure 3-41., try and
insert the 0.0015” feeler gauge between the bolt
NOTE: This check is designed to replace the existing bearing bolt head and hardened washer at the arrow indicated
torque checks on JLG Lifts in service. This check must be position.
performed after the first 50 hours of machine operation
and every 600 hours of machine operation thereafter. If
during this check any bolts are found to be missing or
loose, replace missing or loose bolts with new bolts and
torque to the value specified in the torque chart, after 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.
(See Figure 3-40.)
b. At the positions indicated on Figure 3-41. try to
insert a.0015 feeler gauge between the bolt and
hardened washer at the arrow indicated position.
c. Ensure that the 0.0015” feeler gauge will not pene-
trate under the bolt head to the bolt shank.
d. Swing the turntable 90 degrees, and check some
selected bolts at the new position.
e. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in
all quadrants.

3-64 3121628
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-39. Swing Bearing Tolerance Boom Placement (Sheet 1 of 2)

3121628 3-65
3-66
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-40. Swing Bearing Tolerance Boom Placement (Sheet 2 of 2)

3121628
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-42. Swing Bearing Tolerance Measuring Point

Figure 3-41. Swing Bolt Feeler Gauge Check
Swing Bearing Replacement
Wear Tolerance
REMOVAL
1. From the underside of the machine, at rear center, with
the main boom fully elevated and fully retracted, and 1. From Ground Control station, operate the boom ade-
tower boom stowed, as shown in Figure 3-39., Swing quately to provide access to frame opening to rotary
Bearing Tolerance Boom Placement (Sheet 1 of 2), using coupling.
a magnetic base dial indicator, measure and record the
distance between the swing bearing and turntable. See
Figure 3-42., Swing Bearing Tolerance Measuring Point
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
2. At the same point, with the main boom at horizontal PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCK-
and fully extended, and the tower boom fully elevated ING.
and fully retracted as shown in Figure 3-40., Swing Bear-
ing Tolerance Boom Placement (Sheet 2 of 2). Using a
2. Attach an adequate support sling to the boom and draw
magnetic base dial indicator, measure and record the
all slack from sling. Prop or block the boom if feasible.
distance between the swing bearing and turntable. See
Figure 3-42., Swing Bearing Tolerance Measuring Point 3. From inside turntable, remove mounting hardware
3. If a difference greater than 0.079 in. (2.00 mm) is deter- which attach rotary coupling retaining yoke brackets to
mined, the swing bearing should be replaced. turntable.
4. If a difference less than 0.079 in. (2.00 mm) is deter-
mined, and any of the following conditions exist, the
bearing should be removed, disassembled, and HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-
inspected for the following: CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS-
a. Metal particles in the grease. TEM.
b. Increased drive power required.
4. Tag and disconnect the hydraulic lines from the fittings
c. Noise. on the top of the rotary coupling. Use a suitable con-
d. Rough rotation. tainer to retain any residual hydraulic fluid. Immediately
cap lines and ports.
5. If bearing inspection shows no defects, reassemble and
return to service. 5. Attach suitable overhead lifting equipment to the base
of the turntable weldment.

6. Use a suitable tool to scribe a line on the inner race of

the swing bearing and on the underside of the turnta-
ble. This will aid in aligning the bearing upon installa-
tion. Remove the bolts and washers which attach the
turntable to the bearing inner race. Discard the bolts.

7. Use the lifting equipment to carefully lift the complete

turntable assembly from the bearing. Ensure that no
damage occurs to the turntable, bearing or frame-
mounted components.

3121628 3-67
SECTION 3 - CHASSIS & TURNTABLE

8. Carefully place the turntable on a suitably supported 7. Clean any residue off the new bearing bolts, then apply
trestle. a light coating of JLG Threadlocker P/N 0100019 and
install the bolts and washers through the turntable and
9. Use a suitable tool to scribe a line on the outer race of inner race of the bearing.
the swing bearing and the frame. This line will aid in
aligning the bearing upon installation. Remove the bolts 8. Following the Torque Sequence diagram shown in Fig-
and washers which attach the outer race of the bearing ure 3-45., Swing Bearing Torque Sequence, tighten the
to the frame. Discard the bolts. Use suitable lifting bolts to a torque of 190 ft. lbs. (260 Nm) w/Loctite.
equipment to remove the bearing from the frame, then 9. Remove the lifting equipment.
move the bearing to a clean, suitably supported work
area. 10. Install the rotary coupling retaining yoke brackets, apply
a light coating of JLG Threadlocker P/N 0100011 to the
attaching bolts and secure the yoke to the turntable
INSTALLATION with the mounting hardware.

1. Using suitable lifting equipment, carefully lower the 11. Connect the hydraulic lines to the rotary coupling as
swing bearing into position on the frame. Ensure the tagged prior to removal.
scribed line of the outer race of the bearing aligns with 12. At ground control station, use boom lift control to lower
the scribed line on the frame. If a new swing bearing is boom to stowed position.
used, ensure that the filler plug fitting is at 90 degrees
from the fore and aft center line of the frame. 13. Using all applicable safety precautions, activate the
hydraulic system and check the swing system for proper
and safe operation.

JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS- Swing Bearing Torque Values
CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE
ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPER- 1. Outer Race - 190 ft. lbs. (260 Nm) w/JLG Threadlocker
ATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. P/N 0100019.
USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED. 2. Inner Race - 190 ft. lbs. (260 Nm) w/JLG Threadlocker P/N
0100019.
2. Apply a light coating of JLG Threadlocker P/N 0100019
3. See Swing Bearing Torquing Sequence.
to the new bearing bolts, and loosely install the bolts
and washers through the frame and outer race of bear-
ing.
CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR
LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS
THEREAFTER.
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED
FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING
ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.

3. Refer to the Torque Sequence diagram as shown in Fig-

ure 3-45., Swing Bearing Torque Sequence. Clean any
residue off the new bearing bolts, then apply a light
coating of JLG Threadlocker P/N 0100019 and install the
bolts and washers through the frame and outer race of
the bearing. Tighten the bolts to an initial torque of 190
Ft. lbs. (260 Nm) w/JLG Threadlocker P/N 0100019.

4. Remove the lifting equipment from the bearing.

5. Using suitable lifting equipment, carefully position the

turntable assembly above the machine frame.

6. Carefully lower the turntable onto the swing bearing,

ensuring that the scribed line of the inner race of the
bearing aligns with scribed line on the turntable. If a
new swing bearing is used, ensure that the filler plug fit-
ting is at 90 degrees from the fore and aft center line of
the turntable.

3-68 3121628
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-43. Swing Bearing Removal (800A)

3121628 3-69
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-44. Swing Bearing Removal (800AJ)

3-70 3121628
SECTION 3 - CHASSIS & TURNTABLE

FRONT

NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races.

Figure 3-45. Swing Bearing Torque Sequence

3.12 TILT INDICATOR SYSTEM 3.13 SPARK ARRESTER CLEANING INSTRUCTIONS

1. The tilt indicator system measures the turntable angle 1. Remove the cleanout plug in the bottom of spark
arrester (muffler).
with respect to level ground. The tilt switch itself has
two settings; 5 (or 4 degree dependent upon market) 2. Without causing deformation (or any type of damage to
and 8.5 degrees. the spark arrester) repeatedly tap on the arrester near
the cleanout plug. This may be enough to begin drain-
2. The smaller angle is used for the purpose of warning the age of the spark trap.
operator by means of the tilt light in the platform dis- 3. An industrial vacuum cleaner can do a complete job at
play panel. this point.
a. Or, IN A SAFE AREA, start the engine. Then alternate
3. Additionally when used in conjunction with the "above
between low idle and high idle for two to three min-
elevation cutout system" or the "transport position utes.
interlock system", the tilt switch will cause an alarm to
b. Or, operate the engine as required by the applica-
sound, and automatically put the machine in the creep
tion for two to three minutes.
speed mode. With the exception of the speed cutback,
c. Install the cleanout plug.
this is a warning system only.

4. The machine will continue to function. The operator is

responsible to prevent the machine from attaining an
unstable position. The 8.5 degree angle is used exclu-
sively for the purpose of automatically shifting the drive
motors to the maximum displacement position (slow
speed).

3121628 3-71
SECTION 3 - CHASSIS & TURNTABLE

3.14 ROTARY COUPLING 7. Assemble lip seals (2) in direction shown in Figure 3-46.,
Rotary Coupling Seal Installation.
Use the following procedure to install the seal kit.
8. Reassemble O-ring (4).
1. If not already removed, remove the axle oscillation valve
from the cylinder barrel. The spool of the valve pro- 9. Heat cap seals (5) in hydraulic oil for 5 minutes at 300° F
trudes into the barrel and will damage the spool and (149° C).
seals if left in place. 10. Assemble cap seals over O-rings.
2. Remove snap ring (7) from end. 11. Reinsert center body into housing (lube with hydraulic
3. Remove thrust ring (3) from the same end. oil).
4. Remove center body (1) from housing (3). 12. Replace thrust ring and snap ring.
5. Cut off old seals (2, 4, 5). 13. Install proximity switch as shown in Figure 3-50.
6. Remove proximity switch.

Figure 3-46. Rotary Coupling Seal Installation

3-72 3121628
SECTION 3 - CHASSIS & TURNTABLE

1. Center Body 6. Thrust Ring
2. Seal 7. Snap Ring
3. Housing 8. Valve Block (Axle Oscillation)
4. O-ring 9. O-ring
5. Seal 10. Proximity Switch

Figure 3-47. Rotary Coupling Cutaway

3121628 3-73
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-48. Rotary Coupling Port Location (7 Port)

3-74 3121628
SECTION 3 - CHASSIS & TURNTABLE

4 9 8 3

1
2 2
3
4

7 7
8
9

5 6
1 2
7

1
2 2
3

7 7
8
9

Figure 3-49. Rotary Coupling Port Location (9 Port)

3121628 3-75
SECTION 3 - CHASSIS & TURNTABLE

1. JLG Threadlocker 6. Rotary Coupling 11. Ring 16. O-ring 21. Bolt
2. Bolt 7. Spool 12. Seal 17. Valve 22. Nut
3. Bolt 8. Retaining Ring 13. O-ring 18. Check Valve 23. Washer
4. Bolt 9. Plug 14. Bearing 19. Case 24. Bracket
5. Bracket 10. Torque Lug 15. Cap Seal 20. Plunger Valve 25. Proximity Switch

Figure 3-50. Rotary Coupling Installation

3-76 3121628
SECTION 3 - CHASSIS & TURNTABLE

Table 3-8. Coupling Port Information Table (7 port) Table 3-9. Coupling Port Information Table (9 port)

Operating Proof Operating Proof

Port Port
Outlets Port Size Description Pressure Pressure Outlets Port Size Description Pressure Pressure
No. No.
PSI (Bar) PSI (Bar) PSI (Bar) PSI (Bar)
1 1 -8 Brake 450 (31) 675 (46.5) 1 1 -8 Brake 450 (31) 675 (46.5)
2 2 -6 2 Speed 4500 (310) 6750 (465) 2 2 -6 2 Speed 4500 (310) 6750 (465)
3 1 -6 Steer 2500 (172) 3750 (258.5) 3 1 -6 Steer 2500 (172) 3750 (258.5)
4 1 -6 Steer 2500 (172) 3750 (258.5) 4 1 -6 Steer 2500 (172) 3750 (258.5)
5 2 1-6, 1-16 Drive Reverse 4500 (310) 6750 (465) 5 2 1-6, 1-16 Drive Reverse 4500(310) 6750(465)
6 1 -16 Drive Forward 4500 (310) 6750 (465) 6 1 -16 Drive Forward 4500 (310) 6750 (465)
7 3 2-8, 1-6 Drain 250 (17) 375 (26) 7 3 2-8, 1-6 Drain 250 (17) 375 (26)
8 1 -6 Steer 2500 (172) 3750 (258.5)
9 1 -6 Steer 2500(172) 3750 (258.5)

3121628 3-77
SECTION 3 - CHASSIS & TURNTABLE

3.15 GENERATOR Overload Protection

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

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-
quent service.

Inspecting Brushes, Replacing Brushes, and

Cleaning Slip Rings
Refer to Figure 3-51., Inspecting Generator Brushes, Replacing
Brushes, and Cleaning Slip Rings.
Every 500 hours of service, blow out the inside of the genera-
tor. If operating in a hostile environment, clean monthly. INSPECTING BRUSH POSITION
Inspect brush alignment with slip rings. View alignment
through the air vents in the stator barrel. The brushes must
ride completely on the slip rings.

INSPECTING BRUSHES
Remove the end panel. Inspect the wires. Remove the brush
holder assembly. Pull the brushes from the holders.

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

minimum length.

CLEANING SLIP RINGS

Visually inspect the slip rings. Under normal use, the rings turn
dark brown.
If the slip rings are corroded or their surface is uneven, remove
the belt to turn the shaft by hand for cleaning.
Clean the rings with 220 grit emery paper. Remove as little
material as possible. If the rings are deeply pitted and do not
clean up, consult generator factory service.
Reinstall the belt, brush holder assembly, and end panel.

3-78 3121628
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

1. Brush Holder Assembly

2. Brushes
3. Slip Rings

Figure 3-51. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings

3121628 3-79
SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting
Table 3-10. Troubleshooting

Trouble Remedy

No generator output at platform AC receptacles. Be sure generator control switch is turned on at platform.

Check and secure electrical connections at platform, generator, and control box.

Be sure all equipment is turned off when starting unit.

Reset circuit breaker CB1.

Check plug PLG3 connection and/or connections at receptacles RC3 and RC5.

Be sure + 12 volts DC input voltage is being supplied to control box.

Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes if necessary.

Disconnect leads 12 and 13 from brushes, and check continuity across slip rings (nominal reading is 26 ohms).
Replace generator if rotor is open.

Disconnect stator weld leads 1, 2, and 3 from circuit breaker CB1 , and check continuity between leads. Replace
generator if necessary.

Disconnect plug PLG4 and check continuity between exciter leads 5 and 6. Replace generator if necessary.

Check power board PC1 and connections, and replace if necessary.

Check control board PC2 and connections, and replace if necessary.

Low generator output at platform AC recepta- Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
cles. Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes if necessary.
Disconnect leads 12 and 13 from brushes, and check continuity across slip rings nominal reading is 26 ohms).
Replace generator if rotor is open.

Disconnect stator weld leads 1, 2, and 3 from circuit breaker CB1, and check continuity between leads. Replace
generator if necessary.

Disconnect plug PLG4 and check continuity between exciter leads 5 and 6. Replace generator if necessary.

Check power board PC1 and connections, and replace if necessary.

Check control board PC2 and connections, and replace if necessary.

High generator output at platform AC recepta- Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
cles. Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes if necessary.
Check power board PC1 and connections, and replace if necessary.

Check control board PC2 and connections, and replace if necessary.

Erratic generator output at platform AC recepta- Check and secure electrical connections at platform, generator, and control box.
cles. Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).

Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes n necessary.

Disconnect leads 12 and 13 from brushes, and check continuity across slip rings nominal reading is 26 ohms).
Replace generator if rotor is open.

Check power board PC1 and connections, and replace if necessary

Check control board PC2 and connections, and replace if necessary

3-80 3121628
SECTION 3 - CHASSIS & TURNTABLE

Generator Disassembly and Assembly 2. Remove brush holder assembly.

3. Disassemble generator parts shown in Figure 3-52.
Refer to Figure 3-53. and Figure 3-54. 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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Figure 3-52. Generator Disassembly and Assembly

3121628 3-81
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-53. Generator Troubleshooting Circuit Diagram (Sheet 1 of 2)

3-82 3121628
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-54. Generator Troubleshooting Circuit Diagram (Sheet 2 of 2)

3121628 3-83
3-84
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-55. Generator Electrical Circuit Diagram

3121628
3121628
Figure 3-56. Power Board PC1 Electrical Circuit Diagram

3-85
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-57. Power Board PC2 Electrical Circuit Diagram (Sheet 1 of 2)

3-86 3121628
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-58. Power Board PC2 Electrical Circuit Diagram (Sheet 2 of 2)

3121628 3-87
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 3-11. 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

3-88 3121628
SECTION 3 - CHASSIS & TURNTABLE

3.16 AUXILIARY POWER SYSTEM The auxiliary pump functions to provide sufficient oil flow to
operate the basic machine functions should the main pump or
The auxiliary power system is intended as a secondary means engine fail. The auxiliary pump will operate tower boom lift,
of moving the boom in the event of primary power loss. This tower telescope, main boom lift, main telescope and swing.
system uses an electric motor/pump unit powered by a 12V The Auxiliary Power control switch energizes the electrically
(extended upto 24V DC) battery. operated hydraulic pump.

1. Auxiliary Pump
2. Battery

Figure 3-59. Auxiliary Power System

3121628 3-89
SECTION 3 - CHASSIS & TURNTABLE

3.17 DEUTZ ENGINE

1. Fan 9. Turbocharger 17. Rear Engine Mount 25. Flywheel 33. Oil Filter
2. Adapter 10. Exhaust Pipe 18. Coupling 26. Fuel Filter 34. Belt Tensioner
3. Drive Belt 11. Spark Arrester 19. Pump Adapter Plate 27. Pressure Sensor 35. Plug
4. Water Pump 12. Pressure Sensor 20. Pump Assembly 28. Rear Engine Mount 36. Alternator
5. Fuel Injector 13. Front Engine Mount 21. Gear Pump Assembly 29. Oil Pan Drain Plug 37. Adapter
6. Thermostat 14. Motor Mount 22. Oil Drain Hose 30. Front Engine/Generator Mount 38. Pulley
7. Oil Fill Cap 15. Shuttle Valve 23. Oil Drain Valve 31. Oil Fill Cap
8. Temperature Sender 16. Catalytic Converter/Muffler 24. Pump Coupler 32. Oil Cooler

Figure 3-60. Deutz D2.9 L4 Engine Components - Sheet 1 of 2

3-90 3121628
SECTION 3 - CHASSIS & TURNTABLE

NOTE:
HOITCH PIN
SHOWN HERE
FOR CLARITY

1. Radiator Assembly 5. Coolant Level Sensor 9. Battery Relay 13. Hitch Pin
2. Coolant Recovery Tank 6. Fuel Pump 10. Power Module Relay 14. Engine Tray
3. Air Filter Service Indicator 7. Fuel Pre-Filter 11. Relay 15. Air Filter Assembly
4. Coolant Overflow Hose 8. Battery 12. Lanyard 16. Engine Control Unit (ECU)

Figure 3-61. Deutz D2.9 L4 Engine Components - Sheet 2 of 2

3121628 3-91
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-62. Deutz 2.9 L4 Engine Installation (800A) - Sheet 1 of 7

3-92 3121628
SECTION 3 - CHASSIS & TURNTABLE

SEE

Figure 3-63. Deutz 2.9 L4 Engine Installation (800AJ) - Sheet 2 of 7

3121628 3-93
SECTION 3 - CHASSIS & TURNTABLE

ROUTE SUPPLY FUEL

Figure 3-64. Deutz 2.9 L4 Engine Installation - Sheet 3 of 7

3-94 3121628
SECTION 3 - CHASSIS & TURNTABLE

ROUTE SUPPLY FUEL LINE THRU

Figure 3-65. Deutz 2.9 L4 Engine Installation - Sheet 4 of 7

3121628 3-95
SECTION 3 - CHASSIS & TURNTABLE

PLUG THE BATTERY HEATER CORD,

Figure 3-66. Deutz 2.9 L4 Engine Installation (800AJ) - Sheet 5 of 7

3-96 3121628
SECTION 3 - CHASSIS & TURNTABLE

SUPPLY LINE

Figure 3-67. Deutz 2.9 L4 Engine Installation- Sheet 6 of 7

3121628 3-97
3-98
SECTION 3 - CHASSIS & TURNTABLE

BATTERY CABLE SCHEMATIC

Figure 3-68. Deutz 2.9 L4 Engine Installation -Sheet 7 of 7

3121628
SECTION 3 - CHASSIS & TURNTABLE

3.18 DEUTZ TD 2.9 L4 CHINA III ENGINE

PLUG INTO FUEL PUMP AND FILTER

VENT LINE ASSEMBLY MOUNTED ON SIDE SHEET

SUPPLY LINE
FUEL RETURN LINE

A
EW
VI

VIEW A

MAE19170B

Figure 3-69. Deutz TD 2.9 L4 China III Engine Installation - Sheet 1 of 7

3121628 3-99
SECTION 3 - CHASSIS & TURNTABLE

ECM
SHIPPED WITH BASE ENGINE ( 29 )

INSTALL ON TURNTABLE SIDE SHEET

9 1
1 A/R

SEE DETAIL B

DETAIL B
MAE19180B

Figure 3-70. Deutz TD 2.9 L4 China III Engine Installation - Sheet 2 of 7

3-100 3121628
SECTION 3 - CHASSIS & TURNTABLE

RETURN FUEL LINE

FUEL FILTER SHOWN

TRANPARENT FOR CLARITY
SUPPLY FUEL LINE
TO FINE FUEL FILTER

REFERENCE FOR HOSE ROUTING

MAE19190B

Figure 3-71. Deutz TD 2.9 L4 China III Engine Installation - Sheet 3 of 7

3121628 3-101
SECTION 3 - CHASSIS & TURNTABLE

SUPPLY LINE
TO FINE FUEL FILTER

SUPPLY LINE
FROM TANK

MAE19200B

Figure 3-72. Deutz TD 2.9 L4 China III Engine Installation - Sheet 4 of 7

3-102 3121628
SECTION 3 - CHASSIS & TURNTABLE

SEE DETAIL E

1/2" FUEL LINE

FROM TANK TO PRE-FILTER

ROUTE FUEL LINE

FROM TANK AND
PUMP THRU SIDE
SHEET HANGER

3/8" FUEL LINE

FROM PUMP TO
FINE FILTER ON
ENGINE

DETAIL E MAE19210B

Figure 3-73. Deutz TD 2.9 L4 China III Engine Installation - Sheet 5 of 7

3121628 3-103
SECTION 3 - CHASSIS & TURNTABLE

SEE DETAIL F

ROUTE SUPPLY FUEL

LINE AS SHOWN

ROUTE RETURN FUEL

LINE AS SHOWN DETAIL F

MAE19220B

Figure 3-74. Deutz TD 2.9 L4 China III Engine Installation - Sheet 6 of 7

3-104 3121628
SECTION 3 - CHASSIS & TURNTABLE

SEE DETAIL G
SEE DETAIL D

ROUTE RETURN FUEL LINE THRU SIDE OPENING AND

AROUND PIVOT PIN THRU SIDE SHEET HANGER AND
THEN RUN THRU P-CLAMP AT ENGINE MOUNT TO ENGINE

DETAIL D

ROUTE SUPPLY FUEL LINE THRU

SIDE SHEET OPENING AND AROUND
PIVOT PIN, UP OVER THE ENGINE
TRAY AND UNDER HYD PUMPS TO
THE FINE FUEL FILTER INLET DETAIL G MAE19230B

Figure 3-75. Deutz TD 2.9 L4 China III Engine Installation - Sheet 7 of 7

3121628 3-105
SECTION 3 - CHASSIS & TURNTABLE

NOTE: Refer to engine manufacturer’s manual for detailed oper- Change Engine Oil
ating and maintenance instructions.
1. Allow engine to warm up. Engine oil should reach
Check Oil Level approximately 176° F (80° C).
2. Make sure machine and engine are level and switch off
1. Make sure machine and engine are level and switch
engine.
engine OFF before checking oil level.
3. Place oil tray under engine.
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 HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
with an approved grade and type of oil outlined in DRAINING.
engine manufacturer’s operator’s manual.

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

MINIMUM OIL DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU-
LEVEL LATIONS.
4. Open oil drain valve and drain oil.
5. Close oil drain valve.

MAXIMUM OIL
6. Pour in new engine oil. Refer to Section 1 for capacity
LEVEL and Figure 3-77., Engine Oil Viscosity.

Figure 3-76. Deutz 2.9 T4F Dipstick Markings

5. Replace dipstick until fully seated.

Figure 3-77. Engine Oil Viscosity

3-106 3121628
SECTION 3 - CHASSIS & TURNTABLE

Change Oil Filter Change Fuel Filters

1. Wipe area around filter to clean any dirt from area.
2. Using a suitable oil filter removal tool, loosen lube oil fil- FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
ter cartridge and spin off.
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON THE FUEL SYSTEMS.
1. Wipe area around filter to clean any dirt from area.
2. Disconnect water sensor connector (Pre-filter Only).
3. Remove fuel filter cartridge. Catch any escaping fuel.

3. Catch any escaping oil.

4. Clean any dirt from filter carrier sealing surface.
5. Lightly coat new oil filter rubber gasket with clean oil
6. Screw in new filter by hand until gasket is flush.
7. Hand-tighten filter another half-turn.

4. Clean dirt from filter carrier sealing surface.

5. Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.
6. Screw in new filter by hand until gasket is flush. Hand-
tighten filter another half-turn.

8. Check oil level.

9. Check oil pressure.
10. Check oil filter cartridge for leaks.

7. Connect water sensor connector (Pre-filter Only).

8. Open fuel shut-off valve.
9. Check for leaks.

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SECTION 3 - CHASSIS & TURNTABLE

3.19 DUAL FUEL SYSTEM 3.20 DEUTZ EMR 2

The EMR2 consists of the sensors, the control unit and the
actuator. Engine-side controls as well as the JLG Control Sys-
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT tem are connected by means of separate cable harnesses to
ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE the EMR control unit.
FOLLOWING INSTRUCTIONS MUST BE FOLLOWED.
The sensors attached to the engine provide the electronics in
the control unit with all the relevant physical parameters In
Changing from Gasoline to LP Gas accordance with the information of the current condition of
the engine and the preconditions (throttle position etc.), the
1. Start the engine from the ground control station.
EMR2 controls an actuator that operates the control rod of the
2. Open the hand valve on the LP gas supply tank by turn- injection pump and thus doses the fuel quantity in accordance
ing counterclockwise. with the performance requirements.
The exact position of the regulating rod is reported back and,
if necessary, is corrected, by means of the control rod travel
BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO LP GAS. sensor, situated together with the rotation magnets in a hous-
ing of the actuator.
3. While the engine is operating, place the two position
The EMR2 is equipped with safety devices and measures in the
LPG/Gasoline switch at the platform control station to
hardware and software in order to ensure emergency running
the LP position. Allow the engine to operate without
(Limp home) functions.
load until the engine regains smoothness.
In order to switch the engine off, the EMR2 is switched in a de-
Changing from LP Gas to Gasoline energized fashion over the ignition switch. A strong spring in
the actuator presses the control rod in the de-energized con-
1. With engine operating on LP under a no load condition,
dition into the zero position. As a redundancy measure, an
throw the LPG/Gasoline switch at the platform control
additional solenoid serves for switching off and this, indepen-
station to the “Gasoline” position. Allow the engine to
dently of the actuator, also moves the control rod in the de-
operate with no load until the engine regains smooth-
energized condition into the zero position.
ness.
After the programming, that is carried out over the ISO9141
2. Close the hand valve on the LP gas supply tank by turn.
interface, the EMR2 possesses a motor-specific data set and
this is then fixedly assigned to the engine. Included in this are
the various application cases as well as the customer’s wishes
regarding a particular scope of function.
Each EMR2 module is matched by serial number to the engine.
Modules cannot be swapped between engines.

3-108 3121628
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-78. EMR 2 Engine Side Equipment

3121628 3-109
3-110
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-79. Deutz EMR 2 Troubleshooting Flow Chart

3121628
3121628
Figure 3-80. Deutz EMR 2 Vehicle Side Connection Diagram

3-111
SECTION 3 - CHASSIS & TURNTABLE
3-112
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-81. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

3121628
3121628
Figure 3-82. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

3-113
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-83. EMR 2 Engine Plug Pin Identification

3-114 3121628
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-84. EMR 2 Vehicle Plug Pin Identification

3121628 3-115
3-116
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-85. EMR2 Fault Codes - Sheet 1 of 5

3121628
3121628
Figure 3-86. EMR2 Fault Codes - Sheet 2 of 5

3-117
SECTION 3 - CHASSIS & TURNTABLE
3-118
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-87. EMR2 Fault Codes - Sheet 3 of 5

3121628
3121628
Figure 3-88. EMR2 Fault Codes - Sheet 4 of 5

3-119
SECTION 3 - CHASSIS & TURNTABLE
3-120
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-89. EMR2 Fault Codes - Sheet 5 of 5

3121628
SECTION 3 - CHASSIS & TURNTABLE

3.21 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 inch (13mm). 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 3-90. 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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SECTION 3 - CHASSIS & TURNTABLE

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
7. Fill the crankcase with oil. the EPR and continue to fill radiator with coolant.
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-
ATION. A WARM EPR IS AN INDICATION THAT THE COOLING SYSTEM IS 3. With the radiator cap still removed, start the engine and
PROPERLY FILLED AND FUNCTIONING. run until the thermostat opens. The thermostat opens at
170° F (77° C), which can be checked using the JLG
handheld analyzer.
MAKE SURE ENGINE IS COOL BEFORE PERFORMING ANY MAINTENANCE
WORK.
WHILE ENGINE IS RUNNING, AIR AND/OR STEAM MAY BE PRESENT COMING
FROM THE RADIATOR. THIS IS NORMAL.

4. After running the engine for 5 minutes after it has

reached operating temperature, shut the engine off and
continue to step 5.

3-122 3121628
SECTION 3 - CHASSIS & TURNTABLE

this mode the gasoline fuel pump is isolated and will not be
activated. The primary components of the gasoline dual fuel
WITH THE ENGINE RUNNING OR WHEN SHUTTING OFF THE ENGINE, SOME system are the gasoline tank, electric fuel pump and filter, fuel
HEATED COOLANT MAY SPILL OUT DUE TO AIR "BURPING" OUT OF THE SYS- supply line, injector rail and injectors and the fuel pressure
TEM WITH THE RADIATOR CAP OFF. regulator. The primary components of the LPG dual fuel sys-
tem are the LPG fuel tank, in-fuel filter, LPG Low Pressure lock-
5. Next, verify that the 2 coolant hoses on the EPR are off, Electronic Pressure Regulator (EPR) and the fuel mixer
warm. If they are not warm repeat step 3 and 4, other- module. The LPG fuel system operates at pressures which
wise continue to step 6. range from 14.0 inches (355.60 mm) of water column up to
312 psi (21.5 BAR).
Components which are shared by both systems include the
A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM UPPER RADIA- Electronic Throttle Control and the ECM. The ECM contains a
TOR HOSE AND A WARM EPR HOSE. IF THE UPPER RADIATOR HOSE AND/OR dual calibration; one controls the gasoline fuel system during
EPR HOSE ARE NOT WARM TO THE TOUCH AFTER THE ENGINE HAS RUN FOR 5- gasoline operation and one controls the LPG fuel system dur-
8 MINUTES AFTER REACHING OPERATING TEMPERATURE, THE SYSTEM MAY ing LPG operation.
STILL CONTAIN AIR. IT MAY BE NECESSARY TO REPEAT THE ABOVE STEPS.
Fuel Filter
6. Fill radiator with coolant as needed and install the radia-
tor cap. Next, remove the cap off the coolant recovery Propane fuel like all other motor fuels is subject to contamina-
bottle and fill just below the HOT FULL line and reinstall tion from outside sources. Refueling of the equipment’s tank
the caps. 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.

Electric Lock Off

The Electric Lock Off device is an integrated assembly. When
energized the solenoid opens the valve and allows the Pro-
pane fuel to flow through the device. The valve opens during
cranking and run cycles of the engine. The lock off supply volt-
age is controlled by the engine control module (ECM).
3.22 GM ENGINE DUAL FUEL SYSTEM
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.

The Dual Fuel system allows the operator to operate the vehi-
cle on either gasoline or LPG by positioning a selector switch
in the operator's platform. When the operator places the selec-
tor switch in the gasoline mode the gasoline fuel pump is
energized. While in the gasoline mode the LPG fuel lock-off is Figure 3-91. Electric Fuel Lock Off
isolated and will not energize. In addition the gasoline injector
circuit is enabled and injector pulses are provided to each
injector and the ECM calibration for gasoline is also enabled.
When the operator selects the LPG mode the Low Pressure
LPG lock-off is energized and fuel from the LPG tank flows to
the Electronic Pressure Regulator (EPR). The EPR receives an
electronic signal to position the secondary lever for the start or
run positions and when the engine begins to crank the mixer
air valve will rise and fuel will begin flowing to engine. During

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EPR Assembly When the engine is cranking, sufficient vacuum will be intro-
duced into the secondary chamber from the mixer drawing
The EPR assembly is a combination Low Pressure Regulator the secondary diaphragm down onto the spring loaded lever
and a Voice Coil Assembly. The Voice coil is an electronic actu- and opening the secondary valve allowing vaporized fuel to
ator which is controlled by an internal microprocessor. The pass to the mixer. This mechanical action in conjunction with
microprocessor provides output data to the ECM and receives the EPR reactions causes the downward action on the second-
input data over a CAN BUS connection. The internal micropro- ary lever causing it to open wider allowing more fuel to flow to
cessor receives electrical signals from the Fuel Pressure Sensor the mixer.
FPS and the Fuel Temperature Pressure FTP and communi-
cates the data to the ECM. The ECM uses the FPS and FTP data
to calculate the location of the secondary lever in the LPR and THE VOICE COIL SECTION OF THE EPR ASSEMBLY IS AN EMISSIONS CONTROL
sends that data back to the EPR via the CAN BUS. The internal DEVICE AND CANNOT BE REBUILT. IF THE COIL ASSEMBLY FAILS TO OPERATE
microprocessor in the EPR will then output a signal, which PROPERLY, REPLACE IT WITH AN OEM REPLACEMENT PART ONLY.
causes the voice coil to move and position the secondary lever
to the correct location.

Figure 3-93. 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 3-92. EPR Assembly

Low Pressure Regulator (LPR)

The LPR is a combination vaporizer, pressure regulating
device. The LPR is a negative pressure, two stage regulator that
is normally closed when the engine is not running. When the
engine is cranking or running, a partial vacuum is created in
the fuel line which connects the regulator to the mixer. This
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
fuel. This action causes the flow of fuel into the regulator to be
regulated.

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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 increasing or decreasing the air/fuel flow to the engine.
inches (101.6 mm) of water column at start to as high as 14.0
inches (355.60 mm) of water column at full throttle. The vac- The electronic throttle control device also incorporates two
uum being created is referred to as Air Valve Vacuum (AVV). As internal Throttle Position Sensors (TPS) which provide output
the air valve vacuum reaches 4.0 inches (101.6mm) of water signals to the ECM as to the location of the throttle shaft and
column, the air valve begins to lift against the air valve spring. blade. The TPS information is used by the ECM to correct
The amount of AVV generated is a direct result of the throttle speed and load control as well as emission control.
position. 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 second-
ary chamber the secondary diaphragm is drawn further down
forcing the secondary valve lever to open wider.

Figure 3-95. ETC throttle control device

Figure 3-94. 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 3-96. LPG Engine Control Unit (ECM)

Figure 3-98. Heated Exhaust Gas Oxygen Sensor (HEGO)

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 3-97. 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 3-99. Gasoline Fuel Pressure and Temperature

Manifold Assembly

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3.23 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 3-100. 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 3-101. 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.
5. Remove the Electric Lock Off from the regulator.
6. Remove the lock pin from the vapor fitting on the regu-
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.
10. Disconnect the EPR electrical connector.

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SECTION 3 - CHASSIS & TURNTABLE

10. Start the vehicle and leak check the propane fuel system REMOVAL
at each serviced fitting Refer to Propane Fuel System
1. Disconnect the TMAP electrical connector.
Leak Test.
2. Remove the two retaining bolts.
3. Remove the TMAP.
INSTALLATION

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

installation.

1. Install in the TMAP.

2. Tighten retaining bolts to 62 lb-in (7 Nm).
Start the vehicle and check for proper operation.

Figure 3-102. Pressure Regulator Section

Electronic Throttle Control Replacement
PRESSURE REGULATOR SECTION REMOVAL See Figure 3-103.

1. Remove the EPR refer to EPR Removal Procedure. REMOVAL

1. Disconnect the negative battery cable.
2. Remove the six (6) regulator to voice coil screws using
the special tool and separate the regulator from the 2. Remove the air intake duct.
actuator. 3. Release the hose clamp on the vapor fuel line and
remove the vapor hose.
4. Disconnect the TMAP electrical connector.
DO NOT REMOVE THE SECONDARY DIAPHRAGM RETAINING PLATE AND DIA- 5. Disconnect the electronic throttle control connector.
PHRAGM THIS WILL VOID THE WARRANTY OF THE ACTUATOR SECTION. 6. Remove the manifold to throttle body adapter bolts and
remove the throttle body mixer assembly.
PRESSURE REGULATOR SECTION INSTALLATION 7. Pull the throttle body assembly from the adapter.
1. Install the regulator to the actuator section using the six 8. Remove electronic throttle control device.
(6) retaining screws and tighten 70 in lbs (8 Nm). 9. Remove the O-rings gasket and discard.

2. Install the EPR refer to EPR Installation.

Temperature Manifold Absolute Pressure (TMAP)

Sensor

Figure 3-103. (TMAP) Sensor & Electronic Throttle

Control (ETC)

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SECTION 3 - CHASSIS & TURNTABLE

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 3-104. Mixer Assembly

Mixer Replacement
See Figure 3-104.

REMOVAL
1. Remove the Throttle control device Refer to Electronic
Throttle Body Replacement.
2. Remove the four (4) bolts to the throttle control device
to mixer adapter bolts.
3. Remove and discard the mixer to adapter gasket.

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SECTION 3 - CHASSIS & TURNTABLE

INSTALLATION Engine Control Module Replacement

REMOVAL
COVER THROTTLE BODY ADAPTER OPENING TO PREVENT DEBRIS FROM
1. Disconnect Negative battery cable.
ENTERING ENGINE UNTIL REASSEMBLY.
2. Remove controller from mounting bracket.
1. Install Mixer to adapter gasket onto the mixer.
3. Push connector lock back to unlock connector.
2. Install the mixer to the throttle control device to mixer
adapter and secure with the 4 retaining screws. Tighten 4. Unplug controller and remove.
80 lb-in (9 Nm).
INSTALLATION
3. Install Throttle body. Refer to Electronic Throttle Control
Device Replacement.
4. Start the engine and leak check all fittings and connec-
THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY YOU HAVE THE
tions.
CORRECT CONTROLLER

Coolant Hose Replacement 1. Plug connector into controller.

REMOVAL
2. Push lock into place.
1. Drain the coolant.
3. Mount controller into mounting bracket.
2. Using hose clamp pliers, disconnect both hose clamps
4. Reconnect the battery cable.
on each hose.
3. Remove the hose from each of the fittings. 5. Start engine.

INSTALLATION 6. Check for any DTC codes and clear.

NOTE: Use hose material and lengths specified by JLG. 7. Verify engine is in closed loop and no warning lights are
illuminated.
1. Install the hose clamps to each hose and set the clamp
back on each hose to make installation easier. Heated Exhaust Gas Oxygen Sensor Replacement
2. Fit the hose to the fittings.
REMOVAL
3. Secure by positioning each of the clamps.
1. Disconnect Negative battery cable.
Vapor Hose Replacement 2. Disconnect the O2 sensor electrical connector.
REMOVAL 3. Using an O2 Sensor socket, remove the O2 Sensor and
discard.
1. Using hose clamp pliers disconnect both hose clamps.
INSTALLATION
2. Remove the vapor hose from each fitting.
INSTALLATION

BEFORE INSTALL THE O2 SENSOR LUBRICATE THREADS WITH ANTI-SEIZE

COMPOUND GM P/N 5613695 OR EQUIVALENT. AVOID GETTING COMPOUND
THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED, DO NOT USE HOSE ON THE SENSOR TIP.
MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED PARTS.
1. Install O2 sensor. Tighten to 30 ft.lb. (41 Nm).
1. Install hose clamps and set back on each hose.

2. Reinstall the vapor hose to each fitting. 2. Start engine.

3. Reset clamps. 3. Check for any DTC codes and clear.

4. Start engine and check for leaks. 4. Verify engine is in closed loop and no warning lights are
illuminated.

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3.24 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 3-105. EPR Assembly • Diagnostic Display tool.

Pressure Gauges
To maintain fuel and emission control on the LPG fuel system • IMPCO ITK-2 Test kit
the Engine Control Units (ECM) relies on numerous engine
sensor and output data from the Electronic Pressure Regulator • Water Column Gauge / Manometer (GM 7333-6 or equiva-
(EPR). The ECM will then determine the target fuel calibration lent).
and command the EPR to reposition the voice coil to the • 0-10 PSI Gauge
proper position which, subsequently reposition the secondary
lever in the pressure regulator to maintain proper control. The Test Description
EPR and ECM will continue to communicate back and forth The numbers below refer to step numbers on the diagnostic
during normal operation. table.
In the event that the EPR fails to communicate or the Commu- 5. This step determines if the LPR requires replacement
nications Area Network (CAN) cable fails to transmit data the
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 10. This step determines if the Mixer requires replacement
will be drawn in a downwards motion. This downward motion
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" 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 3-12. 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 3-12. 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 3-13. 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, pinches 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 3-13. 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.

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 3-14. DTC to SPN/FMI Cross Reference Chart

DTC Description SPN Code FMI Code

16 Crank Never Synced at Start 636 8
91 Fuel Pump Low Voltage 5294 4
92 Fuel Pump High Voltage 94 3
107 MAP Low Voltage 106 4
108 MAP High Pressure 106 16
111 IAT Higher Than Expected 1 105 15
112 IAT Low Voltage 105 4
113 IAT High Voltage 105 3
116 ECT Higher Than Expected 1 110 15
117 ECT Low Voltage 110 4
118 ECT High Voltage 110 3
121 TPS 1 Lower Than TPS 2 51 1
122 TPS 1 Signal Voltage Low 51 4
123 TPS 1 Signal Voltage High 51 3
127 IAT Higher Than Expected 2 105 0
129 BP Low Pressure 108 1
134 EGO 1 Open/Inactive 724 10
154 EGO 2 Open/Inactive 520208 10
171 Adaptive Learn High Gasoline 520200 0
172 Adaptive Learn Low Gasoline 520200 1
182 Fuel Temp Gasoline Low Voltage 174 4
183 Fuel Temp Gasoline High Voltage 174 3
187 Fuel Temp LPG Low Voltage 520240 4
188 Fuel Temp LPG High Voltage 520240 3
217 ECT Higher Than Expected 2 110 0
219 Max Govern Speed Override 515 15
221 TPS 2 Signal Voltage Low 51 0
222 TPS 2 Signal Low Voltage 520251 4
223 TPS 2 Signal High Voltage 520251 3
261 Injector Driver 1 Open 651 5
262 Injector Driver 1 Shorted 651 6
264 Injector Driver 2 Open 652 5
265 Injector Driver 2 Shorted 652 6
267 Injector Driver 3 Open 653 5
268 Injector Driver 3 Shorted 653 6
270 Injector Driver 4 Open 654 5
271 Injector Driver 4 Shorted 654 6
336 Crank Sync Noise 636 2
337 Crank Loss 636 4
341 Cam Sync Noise 723 2
342 Cam Sensor Loss 723 4
420 Gasoline Cat Monitor 520211 10
524 Oil Pressure Low 100 1

FUEL REGUALTOR
SUPPLIED WITH ENGINE
QTY: 3 QUICK CONNECT
HOSE CLAMP TORQUE RETURN PORT BARBS SUPPLIED
TO BE 1-1.4 Nm WITH REGULATOR
[9-13 IN-LBS]

ROUTE TO LP REGULATOR
VALVE ON ENGINE

ROUTE SUPPLY FUEL

LINE FROM FUEL
REGULATOR OVER TO
ENGINE THRU TT CUTOUT

ROUTE RETURN FUEL

LINE ALONG TT SIDE
SHEET AND BEHIND
FUEL AND HYDRAULIC
TANK AS SHOWN

SECURE DUAL FUEL SWITCH

ENGINE HARNESS LOCATION
TO STANDOFF

CONSOLE BOX ASSY

MAE19390D

Figure 3-106. Ford Engine Installation - Sheet 1 of 4

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SECTION 3 - CHASSIS & TURNTABLE

1 SEE DETAIL A
2 4
3
5

DETAIL A

SOME COMPONENTS ARE BLANKED FOR CLARITY MAE19400D

Figure 3-107. Ford Engine Installation - Sheet 2 of 4

3-196 3121628
SECTION 3 - CHASSIS & TURNTABLE

ROUTE LP HOSE THRU SECURE FUEL LINE AWAY

TT CUTOUT FROM COOLANT HOSE
AND ALONG OTHER USING SEQ #70
FUEL LINE FOR TAIL PIPE

9 SEE DETAIL B

TO ATTACH LANYARD
TO TURNTABLE
10

11
DETAIL B
SOME COMPONENTS ARE BLANKED FOR CLRITY

MAE19410D

Figure 3-108. Ford Engine Installation - Sheet 3 of 4

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SECTION 3 - CHASSIS & TURNTABLE

16
15
14
FUEL SHUTOFF 13
13
VALVE IN BOTTOM FUEL FILTER
OF FUEL TANK SUPPLIED WITH WITH PUMP
FUEL
ENGINE
SUPPLIED
ENGINE
QTY: 1 QUICK CONNECT BARB
HOSE CLAMP TORQUE SUPPLIED W/PUMPS
TO BE 1-1.4 Nm
[9-13 IN-LBS]

CONNECT TO THE POSTIVE TERMINAL CONNECT TO THE NEGATIVE TERMINAL

AND TORQUE NUT TO BE AND TORQUE NUT TO BE
1.2 0.4 Nm [10.6 10 IN-LBS] 1.6 0.4 Nm [14 10 IN-LBS]
MAE19420D

1. High Pressure Fuel Hose 5. J-Bolt 9. Clamp 13. P-Clamp

2. Battery Cable Kit 6. Battery 10. LP Gas Hose 14. High Pressure Fuel Hose
3. Solenoid Assembly Relay 7. Battery Bracket 11. High Pressure Fuel Hose 15. Fuel Pump Filter Bracket
4. Battery Hold Down Bracket 8. Battery Cable Kit 12. Engine Tray Mount 16. High Pressure Fuel Hose

Fault Name
Number DTC (Current)
744 PWM5 short to power 1640
761 MIL control ground short 1644
762 MIL open 650
763 MIL control short to power 1645
771 Tach output ground short 2618
772 Tach output short to power 2619
1182 Fuel impurity level high 1182
1183 Megajector autozero / lockoff failed 1183
1311 Misfire detected 1311
1312 Misfire detected 1312
1313 Misfire detected 1313
1314 Misfire detected 1314
1315 Misfire detected 1315
1316 Misfire detected 1316
1317 Misfire detected 1317
1318 Misfire detected 1318
1547 AUX analog PUD4 high 1547
1548 AUX analog PUD4 low 1548
1561 AUX analog PD2 high 1561
1562 AUX analog PD2 low 1562
1563 AUX analog PD3 high 1563
1564 AUX analog PD3 low 1564
1629 J1939 TSC1 message receipt lost 1629
1630 J1939 ETC message receipt lost 1630
1661 PWM6 open / ground short 1661
1662 PWM6 short to power 1662
1663 PWM7 open / ground short 1663
1664 PWM7 short to power 1664
1665 PWM8 open / ground short 1665
1666 PWM8 short to power 1666
1669 PWM9 open / ground short 1669
1670 PWM9 short to power 1670

3-204 3121628
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Table 3-17. CAN to DTC Cross Reference (Ford Engine)

DTC DTC and Description SPN FMI

108 MAP pressure high 106 16
107 MAP voltage low 106 4
118 ECT voltage high 110 3
117 ECT voltage low 110 4
116 ECT higher than expected stage 1 110 15
113 IAT voltage high 105 3
112 IAT voltage low 105 4
2229 BP pressure high 108 0
129 BP pressure low 108 1
563 Vbat voltage high 168 15
562 Vbat voltage low 168 17
643 Sensor supply voltage 1 high 1079 3
642 Sensor supply voltage 1 low 1079 4
123 TPS1 voltage high 51 3
122 TPS1 voltage low 51 4
223 TPS2 voltage high 3673 3
222 TPS2 voltage low 3673 4
221 TPS1-2 higher than expected 51 0
121 TPS1-2 lower than expected 51 1
2122 FPP1 voltage high 91 3
2123 FPP1 voltage low 91 4
2128 FPP2 voltage high 29 3
2127 FPP2 voltage low 29 4
2115 FPP1 higher than IVS 91 0
2139 FPP1 lower than IVS 91 1
2116 FPP2 higher than IVS 29 0
2140 FPP2 lower than IVS 29 1
2126 FPP1-2 higher than expected 91 16
2121 FPP1-2 lower than expected 91 18
524 Oil pressure low 100 1
171 Adaptive-learn gasoline bank1 high 4237 0
172 Adaptive-learn gasoline bank1 low 4237 1
1155 Closed-loop gasoline bank1 high 4236 0
1156 Closed-loop gasoline bank1 low 4236 1
1157 Closed-loop gasoline bank2 high 4238 0
1158 Closed-loop gasoline bank2 low 4238 1
1151 Closed-loop LPG high 4236 0
1152 Closed-loop LPG low 4236 1
1153 Closed-loop NG high 4236 0
1154 Closed-loop NG low 4236 1
174 Adaptive-learn gasoline bank2 high 4239 0
175 Adaptive-learn gasoline bank2 low 4239 1

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SECTION 3 - CHASSIS & TURNTABLE

Table 3-17. CAN to DTC Cross Reference (Ford Engine)

DTC DTC and Description SPN FMI
1161 Adaptive-learn LPG high 4237 0
1162 Adaptive-learn LPG low 4237 1
1163 Adaptive-learn NG high 4237 0
1164 Adaptive-learn NG low 4237 1
261 Injector 1 open or short to ground 651 5
264 Injector 2 open or short to ground 652 5
267 Injector 3 open or short to ground 653 5
270 Injector 4 open or short to ground 654 5
273 Injector 5 open or short to ground 655 5
276 Injector 6 open or short to ground 656 5
279 Injector 7 open or short to ground 657 5
282 Injector 8 open or short to ground 658 5
285 Injector 9 open or short to ground 659 5
288 Injector 10 open or short to ground 660 5
262 Injector 1 coil shorted 651 6
265 Injector 2 coil shorted 652 6
268 Injector 3 coil shorted 653 6
271 Injector 4 coil shorted 654 6
274 Injector 5 coil shorted 655 6
277 Injector 6 coil shorted 656 6
280 Injector 7 coil shorted 657 6
283 Injector 8 coil shorted 658 6
286 Injector 9 coil shorted 659 6
289 Injector 10 coil shorted 660 6
2300 Spark coil 1 primary open or short to ground 1268 5
2303 Spark coil 2 primary open or short to ground 1269 5
2306 Spark coil 3 primary open or short to ground 1270 5
2309 Spark coil 4 primary open or short to ground 1271 5
2312 Spark coil 5 primary open or short to ground 1272 5
2315 Spark coil 6 primary open or short to ground 1273 5
2318 Spark coil 7 primary open or short to ground 1274 5
2321 Spark coil 8 primary open or short to ground 1275 5
2324 Spark coil 9 primary open or short to ground 1276 5
2327 Spark coil 10 primary open or short to ground 1277 5
2301 Spark coil 1 primary shorted 1268 6
2304 Spark coil 2 primary shorted 1269 6
2307 Spark coil 3 primary shorted 1270 6
2310 Spark coil 4 primary shorted 1271 6
2313 Spark coil 5 primary shorted 1272 6
2316 Spark coil 6 primary shorted 1273 6
2319 Spark coil 7 primary shorted 1274 6
2322 Spark coil 8 primary shorted 1275 6
2325 Spark coil 9 primary shorted 1276 6

3-206 3121628
SECTION 3 - CHASSIS & TURNTABLE

Table 3-17. CAN to DTC Cross Reference (Ford Engine)

DTC DTC and Description SPN FMI
2328 Spark coil 10 primary shorted 1277 6
217 ECT higher than expected stage 2 110 0
111 IAT higher than expected stage 1 105 15
127 IAT higher than expected stage 2 105 0
327 Knock1 sensor open or not present 731 4
2112 Unable to reach higher TPS 51 7
2111 Unable to reach lower TPS 51 7
1531 Gov1/2/3 interlock failure 0 31
628 Fuel-pump high-side open or short to ground 1347 5
629 Fuel-pump high-side short to power 1347 6
342 Loss of CAM input signal 723 4
341 CAM input signal noise 723 2
336 CRANK input signal noise 636 2
16 Crank and/or cam could not synchronize during start 636 8
606 Microprocessor failure - COP 629 31
1612 Microprocessor failure - RTI 1 629 31
1613 Microprocessor failure - RTI 2 629 31
1614 Microprocessor failure - RTI 3 629 31
1615 Microprocessor failure - A/D 629 31
1616 Microprocessor failure - Interrupt 629 31
601 Microprocessor failure - FLASH 628 13
604 Microprocessor failure - RAM 630 12
326 Knock1 excessive or erratic signal 731 2
219 RPM higher than max allowed govern speed 515 15
1111 RPM above fuel rev limit level 515 16
1112 RPM above spark rev limit level 515 0
134 EGO1 open / lazy 3217 5
154 EGO2 open / lazy 3227 5
140 EGO3 open / lazy 3256 5
1521 CHT higher than expected stage 1 110 16
1522 CHT higher than expected stage 2 110 0
1515 AUX analog Pull-Down 1 high voltage 710 3
1516 AUX analog Pull-Down 1 low voltage 710 4
1511 AUX analog Pull-Up 1 high voltage 701 3
1512 AUX analog Pull-Up 1 low voltage 701 4
1513 AUX analog Pull-Up 2 high voltage 702 3
1514 AUX analog Pull-Up 2 low voltage 702 4
1621 RS-485 Rx inactive 0 31
1622 RS-485 Rx noise 0 31
1623 RS-485 Rx bad packet format 0 31
1624 RS-485 remote shutdown request 0 31
238 TIP high voltage 102 3
237 TIP low voltage 102 4

3121628 3-207
SECTION 3 - CHASSIS & TURNTABLE

Table 3-17. CAN to DTC Cross Reference (Ford Engine)

DTC DTC and Description SPN FMI
92 FP high voltage 94 3
91 FP low voltage 94 4
420 Catalyst inactive on gasoline (Bank 1) 3050 11
1165 Catalyst inactive on LPG 3050 11
1166 Catalyst inactive on NG 3050 11
1171 MegaJector delivery pressure higher than expected 520260 0
1172 MegaJector delivery pressure lower than expected 520260 1
1173 MegaJector comm lost 520260 31
1174 MegaJector voltage supply high 520260 3
1175 MegaJector voltage supply low 520260 4
1176 MegaJector internal actuator fault detection 520260 12
1177 MegaJector internal circuitry fault detection 520260 12
1178 MegaJector internal comm fault detection 520260 12
1131 WGP voltage high 1192 3
1132 WGP voltage low 1192 4
234 Boost control overboost failure 102 0
299 Boost control underboost failure 102 1
236 TIP active 102 2
183 FT high voltage 174 3
182 FT low voltage 174 4
524 Oil pressure sender low pressure 100 1
521 Oil pressure sender high pressure 100 0
523 Oil pressure sender high voltage 100 3
522 Oil pressure sender low voltage 100 4
337 Crank signal loss 636 4
1625 J1939 shutdown request 1110 31
1626 CAN-J1939 Tx fault 639 12
1627 CAN-J1939 Rx fault 639 12
508 IAC ground short 520201 6
509 IAC coil open/short 520201 5
686 Power relay ground short 1485 4
685 Power relay coil open 1485 5
687 Power relay coil short to power 1485 3
616 Start relay ground short 1321 4
615 Start relay coil open 1321 5
617 Start relay coil short to power 1321 3
1641 Buzzer control ground short 920 4
1642 Buzzer open 920 5
1643 Buzzer control short to power 920 3
628 Fuel pump relay control ground short 1348 4
627 Fuel pump relay coil open 1348 5
629 Fuel pump relay coil short to power 1348 3
1644 MIL control ground short 1213 4

3-208 3121628
SECTION 3 - CHASSIS & TURNTABLE

Table 3-17. CAN to DTC Cross Reference (Ford Engine)

DTC DTC and Description SPN FMI
650 MIL open 1213 5
1645 MIL control short to power 1213 3
2618 Tach output ground short 645 4
2619 Tach output short to power 645 3
2130 IVS stuck at-idle, FPP1/2 match 558 5
2131 IVS stuck off-idle, FPP1/2 match 558 6
1121 FPP1/2 simultaneous voltages out-of-range (redundancy lost) 91 31
2120 FPP1 invalid voltage and FPP2 disagrees with IVS (redundancy lost) 520199 11
2125 FPP1/2 do not match each other or IVS (redundancy lost) 520199 11
1122 FPP1/2 do not match each other or IVS (redundancy lost) 520199 11
653 Sensor supply voltage 2 high 1080 3
652 Sensor supply voltage 2 low 1080 4
1611 Sensor supply voltage 1 and 2 out-of-range 1079 31
332 Knock2 sensor open or not present 520197 4
331 Knock2 excessive or erratic signal 520197 2
2135 TPS1/2 simultaneous voltages out-of-range 51 31
2428 EGT temperature high 173 0
1628 J1939 CAN address / engine-number conflict 639 13
1631 PWM1-Gauge1 open / ground short 697 5
1632 PWM1-Gauge1 short to power 697 3
1633 PWM2-Gauge2 open / ground short 698 5
1634 PWM2-Gauge2 short to power 698 3
1635 PWM3-Gauge3 open / ground short 699 5
1636 PWM3-Gauge3 short to power 699 3
1637 PWM4 open / ground short 700 5
1638 PWM4 short to power 700 3
1639 PWM5 open / ground short 924 5
1640 PWM5 short to power 924 3
430 Catalyst inactive on gasoline (Bank 2) 3051 11
160 EGO4 open / lazy 3266 5
1517 AUX analog Pull-Up 3 high voltage 703 3
1518 AUX analog Pull-Up 3 low voltage 703 4
1541 AUX analog Pull-Up/Down 1 high voltage 704 3
1542 AUX analog Pull-Up/Down 1 low voltage 704 4
1543 AUX analog Pull-Up/Down 2 high voltage 705 3
1544 AUX analog Pull-Up/Down 2 low voltage 705 4
1545 AUX analog Pull-Up/Down 3 high voltage 706 3
1546 AUX analog Pull-Up/Down 3 low voltage 706 4
1551 AUX digital 1 high voltage 707 3
1552 AUX digital 1 low voltage 707 4
1553 AUX digital 2 high voltage 708 3
1554 AUX digital 2 low voltage 708 4
1555 AUX digital 3 high voltage 709 3

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SECTION 3 - CHASSIS & TURNTABLE

Table 3-17. CAN to DTC Cross Reference (Ford Engine)

DTC DTC and Description SPN FMI
1556 AUX digital 3 low voltage 709 4
188 Gaseous fuel temperature sender high voltage 3468 3
187 Gaseous fuel temperature sender low voltage 3468 4
1629 J1939 TSC1 message receipt loss 695 9
359 Fuel run-out longer than expected 632 31
1630 J1939 ETC message receipt loss 91 19
502 Roadspeed input loss of signal 84 8
1411 EMWT1 voltage high 441 3
1412 EMWT2 voltage high 442 3
1413 EMWT1 voltage low 441 4
1414 EMWT2 voltage low 442 4
1415 EMWT1 higher than expected stage 1 441 15
1416 EMWT2 higher than expected stage 1 442 15
1417 EMWT1 higher than expected stage 2 441 0
1418 EMWT2 higher than expected stage 2 442 0
1561 AUX analog Pull-Down 2 high voltage 711 3
1561 AUX analog Pull-Down 2 low voltage 711 4
1561 AUX analog Pull-Down 3 high voltage 712 3
1561 AUX analog Pull-Down 3 low voltage 712 4
1419 ERWT1 voltage high 1385 3
1420 ERWT2 voltage high 1386 3
1421 ERWT1 voltage low 1385 4
1422 ERWT2 voltage low 1386 4
1423 ERWT1 higher than expected stage 1 1385 15
1424 ERWT2 higher than expected stage 1 1386 15
1425 ERWT1 higher than expected stage 2 1385 0
1426 ERWT2 higher than expected stage 2 1386 0
8901 UEGO microprocessor internal fault 3221 31
8902 UEGO heater supply high voltage 3222 3
8903 UEGO heater supply low voltage 3222 4
8904 UEGO cal resistor voltage high 3221 3
8905 UEGO cal resistor voltage low 3221 4
8906 UEGO return voltage shorted high 3056 3
8907 UEGO return voltage shorted low 3056 4
8908 UEGO pump voltage shorted high 3218 3
8909 UEGO pump voltage shorted low 3218 4
8910 UEGO sense cell voltage high 3217 3
8911 UEGO sense cell voltage low 3217 4
8912 UEGO pump voltage at high drive limit 3225 3
8913 UEGO pump voltage at low drive limit 3225 4
8914 UEGO sense cell slow to warm up 3222 10
8915 UEGO pump cell slow to warm up 3225 10
8916 UEGO sense cell impedance high 3222 0

3-210 3121628
SECTION 3 - CHASSIS & TURNTABLE

Table 3-17. CAN to DTC Cross Reference (Ford Engine)

DTC DTC and Description SPN FMI

8917 UEGO pump cell impedance high 3225 0
8918 UEGO pump cell impedance low 3225 1
1311 Cylinder 1 misfire detected 1323 11
1312 Cylinder 2 misfire detected 1324 11
1313 Cylinder 3 misfire detected 1325 11
1314 Cylinder 4 misfire detected 1326 11
1315 Cylinder 5 misfire detected 1327 11
1316 Cylinder 6 misfire detected 1328 11
1317 Cylinder 7 misfire detected 1329 11
1318 Cylinder 8 misfire detected 1330 11
301 Cylinder 1 emissions/catalyst damaging misfire 1323 31
302 Cylinder 2 emissions/catalyst damaging misfire 1324 31
303 Cylinder 3 emissions/catalyst damaging misfire 1325 31
304 Cylinder 4 emissions/catalyst damaging misfire 1326 31
305 Cylinder 5 emissions/catalyst damaging misfire 1327 31
306 Cylinder 6 emissions/catalyst damaging misfire 1328 31
307 Cylinder 7 emissions/catalyst damaging misfire 1329 31
308 Cylinder 8 emissions/catalyst damaging misfire 1330 31
1651 J1939 ETC message receipt loss while in-gear 91 9
1661 PWM6 open / ground short 925 5
1662 PWM6 short to power 925 3
1663 PWM7 open / ground short 926 5
1664 PWM7 short to power 926 3
1547 AUX analog Pull-Up/Down 4 high voltage 713 3
1548 AUX analog Pull-Up/Down 4 low voltage 713 4
1182 Fuel impurity level high 520401 0
1665 PWM8 open / ground short 2646 5
1666 PWM8 short to power 2646 3
1669 PWM9 open / ground short 2647 5
1670 PWM9 short to power 2647 3

3121628 3-211
SECTION 3 - CHASSIS & TURNTABLE

3.26 COUNTERWEIGHT Machines originally equipped with foam filled tires cannot be
converted to pneumatic tires and 4 wheel drives cannot be
Both the 800A and the 800AJ share the same tail and frame converted to 2 wheel drives without adding counterweight.
counterweights regardless of market. However, there is a dif- No counterweight difference is required between the narrow
ference in frame counterweights depending on the equipped and wide pneumatic tire options. Similarly, no counterweight
tires and wheel drive options. Pneumatic tire machines require difference is required between the narrow and wide foam
filled tires.
more frame counterweight than is required with foam filled
tires and 2 wheel drive machines require more counterweight If the counterweight has been removed, ensure the retaining
than 4 wheel drives. bolts are torqued to the proper value as shown inFigure 3-110.

B,C B,C

B,C

A. Actual Weight Stamping

B. Apply JLG Threadlocker P/N 0100011 to Bolt Threads and to Threads in Counterweight.

C. Torque to 285 ft. lbs. (386 Nm). Typical Four Places.

Figure 3-110. Counterweight

3-212 3121628
SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM

4.1 PLATFORM Platform Valve Installation

Platform Valve Removal 1. Install platform control valve onto the mounting bracket
and secure using hardware.
1. Tag and disconnect the hydraulic lines from the plat-
form control valve. Use suitable container to retain any 2. Install the mounting bracket onto the platform support
residual hydraulic fluid. Cap hydraulic lines and ports. and secure using hardware.
2. Remove hardware securing cover from the platform
support. Remove cover.

3. Install cover onto the platform support securing the

hardware.
3. Remove hardware securing the mounting bracket to the
platform support. Take out the mounting bracket along
with platform control valve.
4. Remove hardware securing the platform control valve to
the mounting bracket. Remove platform control valve.

4. Remove tag and reconnect the hydraulic lines to the

platform control valve.

3121628 4-1
SECTION 4 - BOOM & PLATFORM

Support Removal 4. Remove the bolts and locknuts securing the support to
the rotator.

Figure 4-1. Location of Components Platform Support

1. Disconnect electrical cables from control console.

2. Remove the bolts securing the platform to the platform 5. Using a suitable brass drift and hammer, remove the
support, then remove the platform. rotator shaft, then remove the support from the rotator.
NOTE: The Platform Weighs approximately 220 lbs (100 kg).

3. Using a suitable device, support the platform support.

NOTE: The platform support weighs approximately 77 lbs. (35 kg).

4-2 3121628
SECTION 4 - BOOM & PLATFORM

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

install the bolts securing the platform to the platform
1. Using a suitable device, support the platform support support. Torque the bolts to 75 ft. lbs. (102 Nm).
and position it on the rotator.

NOTE: The platform support weighs approximately 77 lbs. (35 kg).

2. Install the rotator center bolt.

6. Connect the electrical cables to the platform control

console.

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

and locknuts securing the support to the rotator and
install the bolts and locknuts.

4. Torque the nut on the rotator center bolt to 480 ft. lbs.
(651 Nm). Torque the retaining bolts to 40 ft. lbs. (55
Nm).

3121628 4-3
SECTION 4 - BOOM & PLATFORM

A,B,D
NOTE: If any rotator bolts are replaced, replace all
bolts on the rotator and torque them.

C,D

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

B JLG Thread locker (#0100011)
C Torque to 480 ft. lbs. (650 Nm)
D Check torque every 150 hours of operation
E Torque to 75 ft. lbs. (102 Nm)

Figure 4-2. Platform Support Torque Values

4.2 ROTATOR AND PLATFORM (SLAVE) CYLINDER

Removal
1. Tag and disconnect hydraulic lines to rotator. Use suit-
able container to retain any residual hydraulic fluid. Cap
hydraulic lines and ports.
2. Supporting the rotator, remove hardware from pin #1.
Using a suitable brass drift and hammer remove pin #1
from the fly boom.
3. Remove the hardware from pin #2. Using a suitable
brass drift and hammer, remove pin #2 from the fly
boom and remove the rotator.
3
4. Telescope the fly section out approximately 20 inches
(50 cm) to gain access to the platform (slave) leveling
cylinder. (800 AJ only)
5. Supporting the platform (slave) cylinder, remove the
hardware from pin #3. Using a suitable brass drift and 2
hammer remove pin #3 from the fly boom.
1
6. Tag and disconnect hydraulic lines to the platform
(slave) leveling cylinder. Use a suitable container to Figure 4-3. Reassembly of Components-Rotator and
retain any residual hydraulic fluid. Cap hydraulic lines Leveling Cylinder
and ports. Remove the platform (slave) cylinder.

4-4 3121628
SECTION 4 - BOOM & PLATFORM

4.3 BOOM SYSTEM Transport Position Interlock System (CE only)

The transport position interlock system uses the "above eleva-
Switch Systems tion cutout system" switches with the addition of a main
boom telescope switch to sense when the boom is out of the
The Capacity Indicator, Transport Position Interlock, and
transport (nearly stowed) position. The articulated jib of the
Above Elevation Systems use normally closed electrical
800AJ may be in any position All controls are simultaneously
switches with "positive opening" contacts.
functional when the booms are within the transport position
as on the standard machine. When the booms are outside of
Capacity Indicator System (800A only) the transport position, the control functions are interlocked to
The capacity indicator system uses a main boom length switch prevent simultaneous operation of any boom function with
and a main boom angle switch to activate the 500 lbs. (230 kg) drive/steer. The first function set to be operated in this mode,
or the 1000 lbs. (450 kg) lights in the platform display panel. becomes the master function set. In other words, while oper-
This is an indicator system only. The operator is responsible to ating drive/steer functions the boom functions are inoperable.
maintain the safe working envelope indicated by the system Likewise, while operating boom functions drive/steer func-
for the load in the platform. As described in the Positive Open- tions are inoperable. In addition to being an interlock, this sys-
ing Switch System, the "safe" condition of the machine is when tem also disallows high speed operation while the booms are
500 lbs. (230 kg) is allowed to be unrestricted (at low boom beyond the transport position. While in this position, the
angles and extended boom lengths). machine will respond in the same way as described in the
Above Elevation Cutout System. As described in the Positive
Above Elevation (Above Horizontal) Cutout Opening Switch System, the "safe" condition of the machine is
when the use of multiple function operation is allowed (at low
System boom angles and short boom lengths).
The above elevation cutout system uses a main boom angle
switch and a tower boom angle switch to sense when the
boom is raised substantially above horizontal. The articulated
Platform Control Enable System
jib of the 800AJ may be in any position. When "above eleva- The platform controls make use of a time dependent enable
tion", the drive motors are automatically restricted to their circuit to limit the time availability of "live" or enabled controls.
maximum displacement position (slow speed). Additionally When the footswitch is depressed, the controls are enabled
when used in conjunction with the "tilt indicator system", the and the operator has 7 seconds to operate any control. The
elevation switches will cause an alarm to sound and automati- controls will remain enabled as long as the operator continues
cally put the machine in the creep speed mode. With the to use any function and will remain enabled 7 seconds after
exception of the speed cutback, this is a warning system only. the last function has been used. While the controls are "live"
The machine will continue to function. The operator is respon- the enabled light will be illuminated in the platform display
sible to prevent the machine from attaining an unstable posi- panel. When the time limit has been reached, the enabled
tion. As described in the Positive Opening Switch System, the light will turn off and the controls will be "dead" or disabled. To
"safe" condition of the machine is when high engine and high continue use of the machine the controls must be re-enabled
speed is allowed (at low boom angles). to start the timer system over again. This is done be cycling the
footswitch by releasing and redepressed the footswitch.

Function Speed Control System

The platform controls for the rotate, tower lift, tower tele-
scope, jib lift, and main telescope functions are controlled
through a common infinitely variable speed control knob. This
knob feeds a common valve driver control circuit allowing a
smooth ramp up and controlled maximum output speed. No
ramp down is provided. These functions are controlled
through common settings in which compromises must be
made from function to function due to differences in flow and
pressure. Not all functions will respond the same to the
changes in the function speed knob position.

3121628 4-5
SECTION 4 - BOOM & PLATFORM

Platform Upright Level Override System

The standard platform utilizes a hinged swing gate for ease of As the tower boom is raised the upright is leveled by a master-
entry and 3/4" expanded metal floor mesh. The optional drop slave cylinder arrangement between the tower lift cylinder
bar gate platform utilizes 1/2" expanded metal floor mesh. and the upright level cylinder. The upright can become out of
level in two directions, towards the platform or away from the
Main Lift End Stroke Dampening System platform. If the upright is out of level towards the platform, it
will automatically correct itself when the tower is lowered by
The main boom lift cylinder is constructed in a way that causes
dumping oil from the upright level cylinder over a relief valve
the lift cylinder oil flow to be restricted by an orifice while rais-
mounted in the upright until the tower lift cylinder reaches
ing the boom within 5 degrees of maximum elevation. This
the end of its stroke. If the upright is out of level away from the
restriction slows the boom lift speed while raising the boom.
platform, the tower lift cylinder is fully retracted with stroke
The oil flow is not restricted while lowering the boom and
remaining in the upright level cylinder. To correct this condi-
therefor the speed is not altered.
tion a re-leveling valve (with a red pull knob) allows the tower
to be raised (from ground control) without extending the
QuikStick Lift System upright level cylinder. The upright will then correct itself when
The main boom lift cylinder is pinned between the main boom the tower is lowered to the stowed position.
and the nose of the tower fly boom. This causes an interde-
pendency between the tower and main boom. The main Ground Control Keyswitch System
boom changes angle when the tower is raised or lowered. In
The ground control keyswitch is used for selecting the active
addition, the maximum angle achieved by the main boom is
control of the machine between the platform or ground con-
dependent on the position of the tower boom. When the
trol stations and as another shut off switch for machine power.
tower boom is stowed, the main boom's maximum angle is 25
On the standard keyswitch, the key is removable only in the off
degrees. When the tower boom is fully raised, the main
position. This allows the ground control station to have ulti-
boom's maximum angle is 70 degrees. The main boom can be
mate priority over the platform control.
also be raised or lowered independent of the tower boom
within the limits of the boom rests and main boom lift cylinder
stroke to a minimum angle of -35 degrees. This allows the plat-
form to reach the ground at any position of the tower boom.

Tower Boom Sequence Valve System

The two section tower boom uses two hydraulic lockout valves
to prevent the boom from being telescoped until the boom is
fully raised and to prevent the tower boom from being low-
ered until it is fully retracted. Until the valve mounted in the
turntable is actuated by the cam on the tower lift cylinder bar-
rel (at max tower angle), the tower telescope oil flow is
blocked preventing the tower from telescoping out. Similarly,
until the valve mounted on the tower fly boom is actuated by
the tower base boom, the tower lift cylinder oil flow is blocked
preventing the tower from lifting down. This is an automatic
system.

4-6 3121628
SECTION 4 - BOOM & PLATFORM

1. UMS Sensor 3. Tower Boom Angle Switch 5. Tower Lift Plunger Valve 7. Rotator Valve
2. Main Boom Angle Switch 4. Tower Telescope Plunger Valve 6. Proximity Switch 8. Platform Control Valve

Figure 4-4. Boom Component Location

3121628 4-7
SECTION 4 - BOOM & PLATFORM

4.4 MAIN BOOM POWERTRACK 6. Remove bolt #1 securing the push tube on the fly boom
section.
Removal
1. Disconnect wiring harness connectors located in tower
upright.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

2. Tag and disconnect hydraulic lines from connectors at

boom assembly. Use suitable container to retain any
residual hydraulic fluid. Cap hydraulic lines and ports.
3. Disconnect dual capacity indicator limit switch from side
of boom section. (800A only)
Figure 4-5. Main Boom Powertrack Components
4. Remove hydraulic lines and electrical cables from Pow-
ertrack. 7. Remove bolt #2 securing the push tube on the mid
boom section.
5. Using suitable lifting equipment, adequately support
Powertrack weight along entire length. 8. With Powertrack supported and using all applicable
safety precautions, remove bolts #3, #4 and #5 securing
rail to the base boom section. Remove Powertrack from
boom section.

4-8 3121628
3121628
HOSE AND CABLE CARRIER

POWERTRACK
PROTECTION PAD

POWERTRACK SUPPOR T

NOTE: MAINTAIN AN EVEN DISTRIBUTION OF HOSES AND CABLES ACROSS THE BAR
CLAMP. TIGHTEN THE BAR CLAMP UNTIL ALL HOSES AND CABLES ARE SECURE.

0258076 J
0258077 I

Figure 4-6. Powertrack Installation Main Boom (Sheet 1 of 2)

4-9
SECTION 4 - BOOM & PLATFORM
4-10
HOSES AND CABLES SHOULD NOT BE
PULLED TIGHT AGAINST THE INSIDE
RADIUS OF THE POWERTRACK

HOSES AND CABLES SHOULD BE AGAINST

SECTION 4 - BOOM & PLATFORM

THE OUTSIDE RADIUS OF THE POWERTRACK

PLATE
PUSH TUBE

INCORRECT CORRECT

Figure 4-7. Powertrack Installation Main Boom (Sheet 2 of 2)

0258076 J
0258077 I

3121628
3121628
POWERTRACK SIDE

SEE DETAIL B ON
FOR HOSING INSTALLATION

SEE DETAIL A

MASTER CYLINDER SIDE

RH END VIEW

POWERTRACK

1001171202 B
1001171203 C

Figure 4-8. Powertrack Installation Tower Boom (Sheet 1 of 3)

4-11
SECTION 4 - BOOM & PLATFORM
4-12
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+26(
SECTION 4 - BOOM & PLATFORM

833(57(/(9 &$%/(
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1001171202 B
1001171203 C

Figure 4-9. Powertrack Installation Tower Boom (Sheet 2 of 3)

3121628
3121628
+26(6$1'&$%/(6(;,7,1*7+,6(1'
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1001171202 B
1001171203 C

Figure 4-10. Powertrack Installation Tower Boom (Sheet 3 of 3)

4-13
SECTION 4 - BOOM & PLATFORM
SECTION 4 - BOOM & PLATFORM

4.5 POWERTRACK MAINTENANCE Round Bar/Poly Bar Removal

Flat Bar Removal 1. Use a small ¼” ratchet with a T-25 Torx bit. Remove the
10-24 x 0.812 screw. (If the bar spins then grip the bar
NOTE: Hoses shown in the Powertrack are for example only. and poly tightly with a vise-grip).
Actual hose and cable arrangements will be different.

2. Lift up one end of the bar and slide the poly roller off.

1. Use a small ¼” ratchet and a T-20 Torx bit. Remove the 8-

32 x 0.500 screws from both sides. (If the track also has a
flat bar on the inside of the track instead of round bar/
poly, perform the same step to remove it.)

4-14 3121628
SECTION 4 - BOOM & PLATFORM

3. While gripping the bar tightly, remove the other 10-24 x Removing and Installing Links
0.812 screw.
1. To remove the links, the rivets holding the links together
must be removed. The following will show one way this
can be done. Use a right angle die grinder with a ¼” ball
double cut bur.

2. Insert the tool into the rolled over end of the rivet as
shown. Grind out the middle of the rivet until the rolled
over part of the rivet falls off. Repeat this step for all riv-
ets that must be removed.

3121628 4-15
SECTION 4 - BOOM & PLATFORM

3. After grinding, it is sometimes necessary to use a center 4. To install new links, extend the main moving end over
punch to punch out the rivet from the link. the lower part of the track so the new connection point
is in the curved part of the track. This will allow the
round half-shears to be rotated in a way they will fit into
the peanut-shaped cut-outs.

4-16 3121628
SECTION 4 - BOOM & PLATFORM

5. Install the pin into the center hole, then slide the washer NOTE: When installing snap rings make sure they are seated in
over the pin. Install the snap ring into the groove in the the pin groove and closed properly.
pin.

CLOSED SNAP RING

SNAP RING NOT

CLOSED PROPERLY

3121628 4-17
SECTION 4 - BOOM & PLATFORM

6. Install more pins, washers, and snap rings into all the Installing a New Flat Bar
links where a rivet was removed.
1. While holding the flat bar, install new 8-32 x 0.500 self
threading torx screws into both holes on each side of
track.

NOTE: Maximum tightening torque for the 8-32 screw is 18-20 in-
lbs (2-2.2 Nm).

4-18 3121628
SECTION 4 - BOOM & PLATFORM

Installing a New Round Bar/Poly Roller NOTE: Maximum tightening torque for the 10-24 screw is 45-50
in-lbs (5-5.6 Nm).
1. While tightly holding the round bar, install the new 10-
24 x 0.812 self threading torx screw. Next lift up the Replacing a Fixed End Bracket
other end and slide a new poly roller on. Install another
10-24 x 0.812 screw on the other side. 1. Remove the bracket by removing the center pin, washer,
and snap ring. Install a new bracket then reinstall the
pin, washer, and new snap ring. After installing the new
bracket make sure that it rotates correctly.

3121628 4-19
SECTION 4 - BOOM & PLATFORM

Replacing a Moving End Bracket Replacing a One Piece Bracket

1. Remove bracket by removing all pins, washers, and snap 1. Remove all pins, washers, and snap rings and slide the
rings. Replace with a new bracket and reinstall the pins, bracket off of the links.
washers, and new snap rings. After installing a new
bracket make sure that it rotates correctly.

4-20 3121628
SECTION 4 - BOOM & PLATFORM

2. To install a new bracket, slide the bracket over the links 4.6 BOOM CLEANLINESS GUIDELINES
and reinstall the pins, washers, and new snap rings. After
installing the new bracket make sure that it rotates cor- The following are guidelines for internal boom cleanliness for
rectly. machines that are used in excessively dirty environments.
1. JLG recommends the use of the JLG Hostile Environment
Package if available to keep the internal portions of a
boom cleaner and to help prevent dirt and debris from
entering the boom. This package reduces the amount of
contamination which can enter the boom but does not
eliminate the need for more frequent inspections and
maintenance when used in these types of environ-
ments.
2. JLG recommends that you follow all guidelines for ser-
vicing your equipment in accordance with the instruc-
tions outlined in the JLG Service & Maintenance Manual
for your machine. Periodic maintenance and inspection
is vital to the proper operation of the machine. The fre-
quency of service and maintenance must be increased
as environment, severity and frequency of usage
requires.
3. Debris and foreign matter inside of the boom can cause
premature failure of components and should be
removed. Methods to remove debris should always be
done using all applicable safety precautions outlined in
the JLG Service & Maintenance Manuals.
4. The first attempt to remove debris from inside the boom
must be to utilize pressurized air to blow the debris
toward the nearest exiting point from the boom. Make
sure that all debris is removed before operating the
machine.
5. If pressurized air cannot dislodge the debris, then water
with mild solvents applied via a pressure washer can be
used. Again the method is to wash the debris toward the
nearest exiting point from the boom. Make sure that all
debris is removed, that no “puddling” of water has
occurred, and that the boom internal components are
dry prior to operating the machine. Make sure you com-
ply with all federal and local laws for disposing of the
wash water and debris.
6. If neither pressurized air nor washing of the boom dis-
lodges and removes the debris, then disassemble the
boom in accordance to the instructions outlined in the
JLG Service & Maintenance Manual to remove the
debris.

3121628 4-21
SECTION 4 - BOOM & PLATFORM

4.7 MAIN BOOM ASSEMBLY tion. Next, install a 3/8-16 UNC threaded lifting eye
into the threaded hole of the pin and pull pin out.

Removal
1. Using a suitable lifting equipment, adequately support
boom assembly weight along entire length.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

2. Tag and disconnect hydraulic lines from telescope cylin-

der. Use suitable container to retain any residual hydrau-
lic fluid. Cap hydraulic lines and ports.

3. Using a suitable brass drift and hammer, remove

d. Remove the bolt and keeper pin securing the mas-
hardware securing the main boom lift cylinder rod end
ter cylinder rod end pin to the upright. Remove the
pin to the base boom section. Remove the main boom
pin.
lift cylinder pin from base boom. Retract the main boom
lift cylinder by using the auxiliary power switch.

NOTE: When installing the master cylinder rod end pin, insert the
keeper hardware pin to prevent the pin from inserting too
far.

5. Remove the bolt and keeper pin securing the boom

pivot pin to the upright. Using a suitable brass drift and
4. Remove the Master Cylinder as follows: hammer, remove the pivot pin from upright.

a. Using an adequate supporting device, support the

master cylinder so it doesn’t fall when the retaining
pins are removed.

NOTE: The master cylinder weighs approximately 58.5 lbs. (26.5

kg).

b. Tag and disconnect hydraulic lines from Master Cyl-

inder. Use a suitable container to collect any residual
hydraulic fluid. Cap hydraulic lines and ports.

c. Remove the bolt and keeper pin securing the mas-

ter cylinder barrel end pin to the base boom sec-

4-22 3121628
SECTION 4 - BOOM & PLATFORM

6. Using all applicable safety precautions, carefully lift 4. Inspect inner diameter of boom pivot bearing for scor-
boom assembly clear of upright and lower to ground or ing, distortion, wear, or other damage. Replace bearing
suitably supported work surface. as necessary.

NOTE: The main boom alone weighs approximately 2226 lbs. 5. Inspect all wear pads for excessive wear, or other dam-
(1010 kg). Including the platform (slave) cylinder, rotator, age.
and platform support the assembly weighs approximately
3185 lbs. (1445 kg). 6. Inspect all threaded components for damage such as
stretching, thread deformation, or twisting. Replace as
necessary.
Disassembly
7. Inspect structural units of boom assembly for bending,
1. Remove hardware securing telescope cylinder to back
cracking, separation of welds, or other damage. Replace
end of the base boom section.
boom sections as necessary.
2. Remove hardware which secures the wear pads to the
base boom section; remove the wear pads from the top, Assembly
sides and bottom of the base boom section.
NOTE: When installing fly section wear pads, install same number
3. Using overhead crane or suitable lifting device, remove and thickness of shims as were removed during disassem-
fly boom assembly from base section. bly.
4. Remove hardware from the telescope cylinder pin.
Using a suitable brass drift and hammer remove the cyl- 1. Measure inside dimensions of the base section to deter-
inder pin from fly boom section. mine the number of shims required for proper fit.

5. Pull the telescope cylinder partially from aft end of the 2. Install side, top and bottom wear pads to the aft end of
fly boom section; secure the cylinder with a suitable fly section; shim evenly to the measurements of the
sling and lifting device at approximately the center of inside of base boom section.
gravity.

6. Carefully remove the telescope cylinder and place tele-

scope cylinder on a suitable trestle. WHEN ASSEMBLING BOOM SECTIONS, ENSURE THAT THE BOOM SLIDING TRA-
JECTORIES HAVE BEEN CLEARED OF CHAINS, TOOLS, AND OTHER OBSTRUC-
NOTE: The Main Boom Telescope Cylinder can be removed with- TIONS.
out disassembling the main boom by disconnecting
hydraulic lines, top attaching pin of main boom lift cylin-
der and telescope cylinders as directed above, and pulling 3. Secure the sling and lifting device at the telescope cylin-
out the telescope cylinder from the rear, thru the access der’s approximate center of gravity, and lift the cylinder
plate opening of the upright. to the aft end of the fly boom section.

4. Slide telescope cylinder into the aft end of fly boom sec-
7. Remove hardware which secures the wear pads to the tion. Align attachment holes in fly boom section with
aft end of fly boom section; remove the wear pads from hole in rod end of telescope cylinder.
the top, sides and bottom of the fly boom section.
5. Install telescope cylinder pin and secure with mounting
Inspection hardware.

NOTE: When inspecting pins and bearings, refer to Section 2, Pins 6. Secure the sling and lifting device at the fly boom
and Composite Bearing Repair Guidelines. assembly approximate center of gravity.

1. Inspect main boom pivot pin for wear, scoring, tapering 7. Slide fly boom assembly into the base boom section.
and ovality, or other damage. Replace pins as necessary. Shim boom, if necessary, for a total of 1/32 inch (metric
equivalent) clearance.
2. Inspect telescope cylinder attach point for scoring,
tapering and ovality. Replace pins as necessary. 8. Install wear pads into the forward position of the base
boom section. Shim boom, if necessary, for a total of 1/
3. Inspect main boom lift cylinder attach pin for wear, scor- 32 inch (metric equivalent) clearance.
ing, tapering and ovality, or other damage. Ensure pin
surfaces are protected prior to installation. Replace pins 9. Align the cylinder with the slots at aft end of base boom
as necessary. section, then secure cylinder with mounting hardware.

3121628 4-23
SECTION 4 - BOOM & PLATFORM

Installation b. Install the master cylinder rod end pin. Install the
bolt and keeper pin securing the master cylinder
1. Using all applicable safety precautions, carefully lift rod end pin to the upright.
boom assembly to align the pivot holes in the boom
with those of the upright.

NOTE: The main boom alone weighs approximately 2226 lbs.

(1010 kg). Including the platform (slave) cylinder, rotator,
and platform support the assembly weighs approximately
3185 lbs. (1445 kg).

2. Using a suitable brass drift and hammer, install the pivot

pin into the upright. Install the bolt and keeper pin
securing the boom pivot pin to the upright.

NOTE: When installing the master cylinder rod end pin, insert the
keeper hardware pin to prevent the pin from inserting too
far.

c. Install the barrel end retaining pin. Install the bolt

and keeper pin securing the master cylinder barrel
end pin to the base boom section.

3. Install the Master Cylinder as follows:

a. Using an adequate supporting device, align the
master cylinder with the mounting holes on the
boom and upright.

NOTE: The master cylinder weighs approximately 58.5 lbs. (26.5

kg).

d. Connect hydraulic lines to the master cylinder as

tagged during removal.

4-24 3121628
SECTION 4 - BOOM & PLATFORM

4.8 UPRIGHT NOTE: Steps 7 thru 10 are only necessary if the upright level cylin-
der is to be removed.
Removal
7. With upright removed, override tower telescope limit
switch and extend the tower boom to gain access to the
upright level cylinder rod end attach pin.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-
CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. 8. Tag and disconnect hydraulic lines to the upright lift cyl-
inder. Use a suitable container to collect any residual
hydraulic fluid. Cap hydraulic lines and ports.
1. Remove the main boom assembly. Refer to Section 4.7,
Main Boom Assembly. 9. Using an overhead crane or suitable lifting device, sup-
2. Tag and disconnect hydraulic lines to the main boom lift port the upright lift cylinder, remove mounting hard-
cylinder. Use a suitable container to collect any residual ware from the barrel end of the upright lift cylinder and
hydraulic fluid. Cap hydraulic lines and ports. remove the pin.

3. Remove mounting hardware from main boom lift Cylin- 10. Carefully remove the upright lift cylinder and place on a
der barrel end. Using a suitable brass drift and hammer, suitable work surface.
remove pin #1 from Upright and remove Main Boom Lift
Cylinder. Installation
NOTE: Steps 1 thru 4 are only necessary if the upright level cylin-
MAIN BOOM der is to be removed.
TELESCOPE CYLINDER
1. Using a suitable lifting device, carefully install the
upright lift cylinder into place in the tower boom.

2. Install the pin and mounting hardware at the barrel end

UPRIGHT of the upright lift cylinder.

3. Connect the hydraulic lines to the upright lift cylinder as

tagged during removal.

4. Override the tower telescope limit switch and retract the

tower boom.
MAIN BOOM UPRIGHT LEVEL 5. Using an adequate lifting device, install the upright into
LIFT CYLINDER CYLINDER position. Install pin # 4 into the tower boom assembly
and secure it in place with the mounting hardware.

6. Connect the Upright Level Cylinder as follows:

Figure 4-11. Location of Components - Upright a. Align the holes in the cylinder and upright for pin
#3, and install the pin into the upright and connect
4. Disconnect wiring harness to horizontal limit switch. the upright level cylinder to the upright. Install the
5. Disconnect the Upright Level Cylinder as follows: mounting hardware securing the pin.
b. Install the hose bracket and secure in place with the
a. Using a suitable lifting device, support the Upright.
mounting hardware.
b. Remove mounting hardware securing hose bracket
in upright, and remove the hose bracket. 7. Connect the wiring harness to horizontal limit switch.
c. Remove mounting hardware securing the upright 8. Align the holes in the main boom lift cylinder and
level cylinder to the upright. Using a suitable brass upright for pin #1 and install the pin. Secure the pin in
drift and hammer, remove pin #3 from upright and place with the mounting hardware.
disconnect the upright level cylinder from the
upright. 9. Connect the hydraulic lines to the main boom lift cylin-
der as tagged during removal.
6. Remove mounting hardware from the Upright Pivot Pin
using a suitable brass drift and hammer. Remove pin # 4 10. Install the main boom. Refer to Section 4.7, Main Boom
from tower boom assembly and remove the upright Assembly.
from the machine.

3121628 4-25
SECTION 4 - BOOM & PLATFORM

4.9 TOWER BOOM ASSEMBLY 7. Remove the Tower Fly as follows:

a. Mark all hoses and wiring harnesses at bracket on

Removal rear end of tower base boom for future assembly.
Remove hoses and wiring from tower boom Pow-
ertrack.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- b. Remove mounting hardware that secures the Pow-
CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. ertrack to tower base boom and remove the Pow-
ertrack.

1. Remove the main boom assembly. Refer to Section 4.7, c. Remove mounting hardware from tower boom tele-
Main Boom Assembly. scope cylinder barrel and rod end.
d. Slide the telescope cylinder out of the base boom,
2. Using an overhead crane or suitable lifting device, sup- support with an overhead crane or suitable lifting
port the entire Tower Boom Assembly and separately device.
support the tower lift cylinder.
e. Remove mounting hardware that secures the wear
3. Remove mounting hardware from tower lift cylinder rod pads to the front of tower base boom section;
end. with a brass drift and hammer, remove the tower Remove the wear pads from the top sides and bot-
Lift cylinder Pin disconnecting the tower lift cylinder. tom of the tower base boom.

4. Remove mounting hardware from the tower boom pivot f. Using an overhead crane or suitable lifting device,
pin. Using a suitable brass drift and hammer, remove pin remove the fly section.
#2 from turntable assembly.
Inspection
5. Using all applicable safety precautions, carefully lift the
Tower Boom Assembly clear of turntable and lower to NOTE: Refer to Section 2, Pins and Composite Bearing Repair
ground or a suitable supported work surface. Guidelines.

6. Remove mounting hardware from the upright leveling 1. Inspect tower boom pivot pin for wear scoring, tapering,
cylinder rod end. with a brass drift and hammer, remove and ovality, or other damage. Replace pins as necessary.
the pin, disconnecting the upright cylinder. Remove
with suitable lifting device. 2. Inspect tower boom pivot attach points for scoring,
tapering, and ovality, or other damage. Replace pins as
NOTE: Using a suitable lifting device, support the upright. necessary.

Figure 4-12. Location of Components - Tower Boom Powertrack

4-26 3121628
SECTION 4 - BOOM & PLATFORM

3. Inspect inner diameter of tower boom pivot bearings for 8. Attach internal Powertrack to tower base boom at bot-
scoring, distortion, wear, or other damage. tom only and extended out of boom that the Pow-
ertrack links are opened at top.
4. Inspect lift cylinder attach pin for wear, scoring, taper-
ing, and ovality, or other damage. Ensure pin surfaces 9. Attach hoses and wiring harnesses at front end of base
are protected prior to installation. Replace pins as neces- boom and route thru the Powertrack. Secure hoses and
sary. wiring harnesses with hose brackets.

5. Inspect inner diameter of upright attach point bearings 10. Roll the Powertrack back into the base boom section
for scoring, distortion, wear, or other damage. Replace and attach loose end of the Powertrack to the inside top
bearing as necessary. of the fly boom section.

6. Inspect all threaded components for damage such as Installation

stretching, thread deformation, or twisting. Replace as
necessary. 1. Using a suitable lifting device, position boom assembly
on turntable so that the pivot holes in both boom and
7. Inspect structural units of tower boom assembly for turntable are aligned.
bending, cracking, separation of welds, or other dam-
age. Replace boom sections as necessary. 2. Install boom pivot pin, ensuring that location of hole in
pin is aligned with attach point on turntable.
8. Inspect Powertrack for damage such as cracking, wear,
3. If necessary, gently tap pin into position with soft
or other damage. Replace links or assembly, as neces-
headed mallet. Secure pin mounting hardware.
sary.
4. Connect all wiring connectors to the correct connectors.
Assembly
5. Connect all hydraulic lines of boom assembly.
NOTE: When installing fly section wear pads, install same number 6. Using all applicable safety precautions, operate lifting
and thickness of shims as were removed during disassem- device in order to position boom lift cylinder so that
bly. holes in the cylinder rod end and boom structure are
aligned. Insert the lift cylinder pin, ensuring that loca-
1. Measure inside dimensions of the tower base section to tion of hole in pin is aligned with attach point on boom.
determine the number of shims required for proper fit.
7. Using all applicable safety precautions, operate from the
2. Install side, top, bottom wear pads to the aft end of lower controls and raise and extend boom fully, noting
tower fly section; shim evenly to the measurements of the performance of the extension cycle.
the inside of the base boom section.
8. Retract and lower boom, noting the performance of the
retraction cycle.

WHEN ASSEMBLING TOWER BOOM SECTIONS, ENSURE THAT THE BOOM SLID-
ING TRAJECTORIES HAVE BEEN CLEARED OF CHAINS, TOOLS, AND OTHER
OBSTRUCTIONS.

3. Align upright leveling cylinder with attach holes in

tower fly boom. Using a soft head mallet, install the cyl-
inder pin into tower fly boom and secure with mounting
hardware.

4. Secure the sling and lifting device at the tower fly boom
assembly’s approximate center of gravity.

5. Slide tower fly boom assembly into the tower base

boom section, for a total of 1/32 inch (metric equivalent)
clearance.

6. Install wear pads into the forward position of the tower

base boom section. Shim boom, if necessary, for a total
of 1/32 inch (metric equivalent) clearance.

7. Align the telescope cylinder with the slots at the aft end
of tower base boom section, then secure cylinder with
mounting hardware.

3121628 4-27
SECTION 4 - BOOM & PLATFORM

Tower Out of Sync 3. The counter/balance valve in the piston end of the
upright level cylinder. There could be a leak path from
Tower is out of sync backwards, upright leaning toward the the valve port to the pilot port.
platform. Replace the counter/balance valve.

When towering down the upright cylinder bottoms out before

the lower lift. Problems that could cause this are:
1. The releveling valve (red knob on the oil tank P/N:
4640866), this is a poppet valve that could be leaking
fluid out of the closed loop. Manually opening the valve
and flushing it can eliminate any contaminate on the
seat. The seat could also be damaged, so replacing the
cartridge might be necessary.

4. The counter/balance valve in the rod end of the lower

lift cylinder. There could be a leak path from the valve
port to the pilot port. Replace the counter/balance
valve.

2. A relief valve is located in the upright. This relief valve

could be leaking backwards out of the loop. Replace the
cartridge. They are pre-set.

5. The packing on either the upright or lower cylinder can

cause this. Do cylinder tests to determine if either cylin-
der needs new packing.

4-28 3121628
SECTION 4 - BOOM & PLATFORM

Tower is out of sync forwards, upright leaning toward the the pilot port to the valve port. Replace the counterbal-
steer axle. ance valve.

When towering down, the lower lift cylinder bottoms out

before the upright level cylinder. This is caused by too much
oil between the two cylinders. Problems that could cause this
are:
1. The relief valve located in the upright (P/N: 4640929). If
this valve is set too low or has contaminate in it causing
it to leak prematurely, when lifting down oil can pass
through it causing the volume to grow between the cyl-
inders. Flush the valve out and reinstall it, or replace the
cartridge. The cartridge pressure is pre-set so no adjust-
ment can be made.

3. The counterbalance valve in the rod end of the lower lift

cylinder. There could be a leak path from the pilot port
to the valve port. Replace the counterbalance valve.

2. The counterbalance valve in the piston end of the

upright level cylinder. There could be a leak path from

4. The packing on the lower lift cylinder can cause this. Do

a cylinder test to check this out. Refer to Section 2.4, Cyl-
inder Drift Test.

3121628 4-29
SECTION 4 - BOOM & PLATFORM

4.10 UPRIGHT MONITORING SYSTEM 7. Repeat steps 3 thru 6 as necessary until the upright is
90° (vertical) relative to the chassis.
The UMS provides a visual and audible warning to the opera-
tor when the limits of the upright assembly alignment have
been reached. In addition, the UMS will not allow the tower
boom to be lowered when the upright assembly is misaligned
in a direction oriented away from the work platform.

Re-Synchronizing Upright
A pull type control valve allows the operator to adjust the
upright level cylinder if the upright is not 90° (vertical) relative
to the chassis (Refer to Figure 4-13.). This valve is located in the
tank compartment area.
Perform the following steps with the aid of an assistant:
1. Turn the key switch to the ground control position.
2. Start the engine.
3. Pull and hold the red relevel knob located next to the
main control valve. Refer to Figure 4-13.
4. Raise the tower boom 6 feet (1.8 m).
5. Release the red relevel knob. Figure 4-13. Releveling Valve
6. Lower the tower boom fully and continue to hold down
the switch to Tower Down for an additional 20 seconds.

4-30 3121628
3121628
TO AVOID TIPPING IF THIS OCCURS:
-LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT
AND TELESCOPE FUNCTIONS. HAVE CONDITION COR-
UPRIGHT MUST BE 90° (VERTICAL) RELATIVE TO THE RECTED BY A TRAINED JLG SERVICE TECHNICIAN BEFORE
CHASSIS. CONTINUING USE OF MACHINE.

INCORRECT
CORRECT

90° 90°
90° 90°

Figure 4-14. Boom Upright Positioning

4-31
SECTION 4 - BOOM & PLATFORM
SECTION 4 - BOOM & PLATFORM

Calibration b. After pressing 'ENTER" one of the following screens

will be displayed:
1. Connect the JLG Hand-held analyzer to the original ana-
lyzer connection in the ground box.

DO NOT CONNECT TO THE ANALYZER CONNECTION PORT INSTALLED WITH THE

UPRIGHT MONITORING SYSTEM MODULE.

2. Pull out the emergency stop button at the ground con-

trol station and start the engine from the ground con-
trols.
3. To calibrate the Upright Monitoring System through the
hand-held analyzer, you must be in access level 1. To
advance to access level 1, scroll to the ACCESS LEVEL

menu and press "ENTER" . Using the arrows on the

keypad, enter the password "33271" and press

"ENTER" .
4. Calibrate the upright monitoring system sensor by the
following procedure:
Or
a. In access level 1, scroll through the menu items until
"CALIBRATIONS" is displayed on the second line of
the analyzer screen. The screen will display the fol-
lowing:

c. Scroll left to right through the above menu items

until "UMS SENSOR" sub menu appears on the bot-
t om l i n e o f t h e a n a l y ze r d i s pl ay. Pre ss t h e

"ENTER" key.

4-32 3121628
SECTION 4 - BOOM & PLATFORM

e. Press "ENTER" and the next screen will display

IT IS NOT NECESSARY TO CALIBRATE THE TILT SENSOR IN THE GROUND CON-
TROL MODULE AT THIS TIME. HOWEVER, WHEN THE TILT SENSOR IN THE the following, asking if the machine is on a level sur-
GROUND CONTROL MODULE IS RECALIBRATED, THE UPRIGHT MONITORING face:
SYSTEM TILT SENSOR MUST BE RECALIBRATED AS WELL.

d. After selecting "UMS SENSOR", the following screen

will appear:

THE MACHINE MUST BE LEVEL FOR PROPER CALIBRATION.

NOTE: By pressing the left or right arrow keys in this screen, you
may view the output of the sensor.
f. Verify the machine is level and press "ENTER" .
The screen will display the following, asking you to
fully elevate the main boom:

3121628 4-33
SECTION 4 - BOOM & PLATFORM

g. After the main boom has been fully elevated, press

"ENTER" . The analyzer will display the follow-

ing:

Should you get the above message, verify that the

sensor is installed correctly and verify the sensor
connection to the sensor harness is secure. Also,
NOTE: By pressing the left or right arrows in this screen, you may ensure the red knob is held fully open for the
view the output of each sensor. required time.

h. With the aid of an assistant, pull and hold the red re-
leveling knob on the hydraulic tank while lifting the If the calibration is executing properly, you shall see
tower boom. Raise the tower boom six (6) feet or the following display:
two (2) meters. After elevating the tower the

required distance, press “ENTER” .

If the upright monitoring system did not detect ade-

quate sensor activity, the screen will display:

4-34 3121628
SECTION 4 - BOOM & PLATFORM

i. When viewing the above display, press After the required activation time has passed,
release the function switch and press
“ENTER” . The screen will display the following:
“ENTER” . The analyzer will display the follow-
ing message:

j. Lower the tower boom onto the boom stop. Con-

tinue to hold the tower boom down function for at
If the calibration has been completed successfully,
least twenty (20) seconds WITHOUT RELEASING
THE FUNCTION SWITCH. The calibration must rec- the screen will automatically change to:
ognize continuous activation of the tower down
function switch for the required time.

3121628 4-35
SECTION 4 - BOOM & PLATFORM

If the calibration has not been completed success- Calibration Faults

fully, the display will automatically change to:
CAL Failed-Chassis Not Level
In the event the turntable tilt switch input is logic low indicat-
ing that the machine is not level the UMS calibration screens
shall display this fault.
CAL Failed-UMS Sensor Raw Output Out Of Range
The control system shall display a fault in the event the raw
sensor output is greater then ±5° for the UMS sensor.
CAL Failed-Turntable Sensor Raw Output Out Of Range
The control system shall display a fault in the event the raw
sensor output is greater then ±5° for the turntable sensor.
CAL Failed-Calibration Disrupted
If calibration is disrupted, the control system shall display this
fault.
CAL Failed- UMS Sensor Movement Not Detected
The UMS angle has not detected the required amount of
movement during calibration.

Repeat step j until the calibration time requirement

has been satisfied.

DO NOT RAISE THE TOWER BOOM AGAIN DURING CALIBRATION.

k. To correctly complete the calibration process, fully

retract and fully lower the main boom. Once the
machine is in the stowed position, turn off the
machine and disconnect the analyzer.

4-36 3121628
SECTION 4 - BOOM & PLATFORM

Function Check 4. Scroll through the top level menu until SERVICE MODE

appears. Press "ENTER" to select this menu item.

After pressing "ENTER" one of the following screens will
ON ADE EQUIPPED MACHINES, DO NOT CONNECT TO THE ANALYZER CONNEC-
be displayed:
TION PORT INSTALLED WITH THE UPRIGHT MONITORING SYSTEM MODULE.

1. Connect the hand-held analyzer at the ground control

station using the four-pin connector.

2. Pull out the emergency stop button at the ground con-

trol station and turn the key switch to ground controls.
Start the engine.
3. Advance to access level 1 by scrolling to the ACCESS

LEVEL menu and press "ENTER" . Using the arrows Or

on the keypad, enter the password "33271" and press

"ENTER" .

5. Scroll left to right through the above menu items until

"TEST UMS?" sub menu appears on the bottom line of

the analyzer display. Press the "ENTER" key.

3121628 4-37
SECTION 4 - BOOM & PLATFORM

6. The controller will now display the following: 8. From the ground controls, raise the tower boom several
feet. Verify that the tower boom will not lower.
9. To end the system test, press the Emergency Stop
Switch (EMS) at the ground controls. Upon loss of power
(pressing the EMS) to the system, the upright monitor-
ing system will reset and all functionality will be restored
to the machine.

Service Mode/Tower Boom Retrieval

The UMS software incorporates a service mode to temporarily
disengage the UMS and allow a tower lift down operation
when the UMS has detected a backward stability concern.

ON ADE EQUIPPED MACHINES, DO NOT CONNECT TO THE ANALYZER CONNEC-

TION PORT INSTALLED WITH THE UPRIGHT MONITORING SYSTEM MODULE.

1. Connect the hand-held analyzer at the ground control

station using the four-pin connector.

or, by pressing the up and down arrow keys:

2. Pull out the emergency stop button at the ground con-

trol station and turn the key switch to ground controls.
Start the engine.
3. Advance to access level 1 by scrolling to the ACCESS

LEVEL menu and press "ENTER" . Using the arrows

on the keypad, enter the password "33271" and press

"ENTER" .

7. When the "YES" message is displayed, press the "ENTER"

key to automatically perform a function test.

Upon the function test, the system will activate the
Upright Monitoring System, warning lights, and alarm.
Verify that the alarm sounds, the boom malfunction
indicator lights (platform and ground) are illuminated.

4-38 3121628
SECTION 4 - BOOM & PLATFORM

4. Scroll through the top level menu until SERVICE MODE 5. Scroll left to right through the above menu items until
"TOWER LIFT DOWN?" sub menu appears on the bottom
appears. Press "ENTER" to select this menu item.
After pressing "ENTER" one of the following screens will line of the analyzer display. Press the "ENTER" key.
be displayed:
6. The controller will now display the following:

3121628 4-39
SECTION 4 - BOOM & PLATFORM

7. Enter the service code "81075" and press the "ENTER" The flashing and scrolling messages will repeat until the

key. The controller display will now display the "ENTER" key is pressed.
following,

8. When the "ENTER" key is pressed, the UMS will be

disabled and the display will read:

followed by:

9. Before using tower lift down adhere to the following:

• Make sure the main boom is fully retracted.
• Make sure the tower boom is fully retracted.
• Slowly lower the tower boom.
10. When the platform has been safely lowered to the
ground, exit the service mode by pressing the Emer-
gency Stop Switch (EMS) at the ground controls. Upon
loss of power (pressing the EMS) to the system, the
upright monitoring system will reset and all functional-
ity will be restored to the machine.

4-40 3121628
SECTION 4 - BOOM & PLATFORM

Figure 4-15. UMS Sensor Location

3121628 4-41
SECTION 4 - BOOM & PLATFORM

Figure 4-16. UMS Module Location

4-42 3121628
SECTION 4 - BOOM & PLATFORM

J1 J2
1 IGN POWER (7-33V) 1 +5V ANALOG EXCITATION
2 GROUND 2 ANALOG INPUT 0
3 DIGITAL INPUT 0 3 ANALOG GROUND
4 DIGITAL INPUT 1 4 +5V ANALOG EXCITATION
5 DIGITAL INPUT 2 5 ANALOG INPUT 1
6 DIGITAL INPUT 3 6 ANALOG GROUND
7 DIGITAL OUTPUT 0 (PWM, IF) 7 ANALOG INPUT 2
8 DIGITAL OUTPUT 1 (PWM, IF) 8 ANALOG INPUT 3 (NOT POPULATED)
9 DIGITAL OUTPUT 2 (PWM, IF) 9 CANBUS HIGH
10 DIGITAL OUTPUT 3 (PWM, IF) 10 CANBUS LOW
11 DIGITAL OUTPUT 4 (PWM) 11 ANALYZER TRANSMIT
12 DIGITAL OUTPUT 5 (PWM) 12 ANALYZER RECEIVE

J2 J1
GRAY BLACK

Figure 4-17. UMS Module Pin Identification

3121628 4-43
SECTION 4 - BOOM & PLATFORM

4.11 UMS TROUBLESHOOTING AND FAULT Auto Detection Input Low Message
MESSAGES 2/5 AUTO DETECTION INPUT LOW
If the UMS detects a valid ground module software version but
Backward Stability Concern Message digital input 2 is not tied high the UMS module shall report a
2/5 UMS SENSOR BACKWARD LIMIT REACHED fault.
When the upright angle relative to the turntable is higher than Solution:
+2.5° (away from the work platform), tower lift down will be
• Inspect wire harness, there should be 12 volts going into
disallowed immediately. Tower Lift Down will be re-allowed
pin J1-5 (black connector) of UMS module.
when the upright angle relative to the turntable is less than
2.0°. If Tower Lift Down is disabled for more than 1.5 seconds,
the ground boom malfunction indicator lamp, upright tilted
UMS Sensor Communications lost
lamp and platform alarm will light/sound continually and a 6/6 UMS SENSOR COMMUNICATIONS LOST
fault shall be raised. These conditions will be latched along
If the UMS detects a valid ground module software version but
with Tower Lift Down until the upright angle is less than 2.0°
digital input 2 is not tied high the UMS module shall report a
for 2 seconds and the Tower Lift Down command is returned
fault.
to neutral.
Solution:
Solution:
• Inspect wire harness; CANbus communications are on pins
• Inspect sensor mounting.
J2-9 & J2-10 (gray connector) of the UMS module.
• Verify sensor calibration on level pad.
• Using access level 1 of the UMS module, under “DIAGNOS-
• Follow the corrective action listed on decal 1702265 TICS” CAN, EX/SEC and TX/SEC should be values greater
located near the red knob of the machine. than 0. Also “BUS OFF:” and “BUS ERR:” should be 0 and
• Inspect machine hydraulics. Refer to Holding Valve Checks “PASSIVE:” should be a low value.
in Section 5 - Hydraulics.
Out of Usable Range Message
Forward Stability Concern Message 8/1 UMS SENSOR OUT OF USABLE RANGE
2/5 UMS SENSOR FORWARD LIMIT REACHED When both the Chassis tilt sensor and the UMS sensor read
When the upright angle relative to the turntable is less than – greater than 10° in the same direction the UMS will be disen-
4.0° for longer than 1.5 seconds, the ground control boom gaged until the condition no longer exists and a fault shall be
malfunction indicator lamp, the platform malfunction indica- raised.
tor lamp, and platform alarm will light/sound continually and a Solution:
fault will be raised. The light/alarm signal will stop only when
the upright angle reaches values greater than –3.0° for 2 sec- • Verify the message clears when operating the machine on
onds. grade less than 10°.

Solution: • Inspect sensor mounting.

• Verify sensor calibration on level pad.
• Inspect sensor mounting.
• Verify sensor calibration on level pad.
• Tower lift down.
• Inspect machine hydraulics. Refer to Holding Valve Checks
in Section 5 - Hydraulics.

4-44 3121628
SECTION 4 - BOOM & PLATFORM

UMS Sensor Not Calibrated Message Incompatible Software Detected Message

8/1 UMS SENSOR NOT CALIBRATED 9/9 INCOMPATIBLE SOFTWARE DETECTED
If the control system detects a sensor out of range condition or If the control system detects that the ground module software
a not calibrated fault with the UMS angle sensor, the control is incompatible with the UMS module, the UMS module shall
system shall report a fault and disable Tower Lift Down and report a fault and disable the footswitch signal to the ground
activate the ground boom malfunction indicator lamp, upright module.
tilted lamp and platform alarm continually
Solution:
If the control system detects that the UMS angle sensor has
• Update ground module software.
not been calibrated, the ground boom malfunction lamp will
flash at a 3 Hz rate until the system is calibrated or disabled.
Calibration Faults
Solution:
CAL FAILED-CHASSIS NOT LEVEL
• Calibrate sensor.
The control system shall display a fault in the event the raw
sensor output is greater than ±5° for the chassis sensor.
UMS Sensor Faulted Message
CAL FAILED-UMS SENSOR RAW OUTPUT OUT OF RANGE
8/1 UMS SENSOR FAULTED
The control system shall display a fault in the event the raw
If the system detects that the UMS sensor frequency outside
sensor output is greater then ±5° for the UMS sensor.
the 100Hz +/- 5Hz range or the duty cycle is outside 50% +/-
21% range the control system shall report a fault. CAL FAILED-CALIBRATION DISRUPTED
Solution: If calibration is disrupted, the control system shall display this
fault.
• Inspect wire harness going to the sensor and UMS module.
• Inspect sensor mounting. CAL FAILED- UMS SENSOR MOVEMENT NOT DETECTED

• Replace sensor. The UMS angle has not detected the required amount of
movement during calibration.

3121628 4-45
SECTION 4 - BOOM & PLATFORM

4.12 ARTICULATING JIB 3. Remove mounting hardware from lift cylinder pin #7.
Using a suitable brass drift and hammer, remove the cyl-
NOTE: Pin numbers listed in the following procedures are refer- inder pin from articulating jib boom.
enced in Figure 4-18., Location of Components-Articulat-
ing Jib. Inspection
NOTE: Using a suitable lifting device, support the jib. NOTE: When inspecting pins and bearings Refer to Section 2.5,
Pins and Composite Bearing Repair Guidelines.
Removal
1. Inspect articulating fly boom pivot pin for wear, scoring,
1. For platform/support removal see platform/support tapering and ovality, or other damage. Replace pins as
removal diagram. (See Section 4.1, Platform). necessary.
2. Position the articulating jib boom level with the ground. 2. Inspect articulating fly boom pivot attach points for
3. Remove mounting hardware from platform (slave) cylin- scoring, tapering and ovality, or other damage. Replace
der pin #1. Using a suitable brass drift and hammer, pins as necessary.
remove the cylinder pin from articulating jib boom.
3. Inspect inner diameter of articulating fly boom pivot
4. Remove mounting hardware from articulating jib boom bearings for scoring, distortion, wear, or other damage.
pivot pin #2. Using a suitable brass drift and hammer, Replace bearings as necessary.
remove the pivot pin from boom assembly.
4. Inspect lift cylinder attach pin for wear, scoring, tapering
Disassembly and ovality, or other damage. Ensure pin surfaces are
protected prior to installation. Replace pins as neces-
1. Remove mounting hardware from articulating jib boom sary.
pivot pins #3 and #4. Using a suitable brass drift and
hammer, remove the pins from articulating jib boom 5. Inspect inner diameter of rotator attach point bearings
pivot weldment. for scoring, distortion, wear, or other damage.

2. Remove mounting hardware from rotator support pins 6. Inspect all threaded components for damage such as
#5 and #6. Using a suitable brass drift and hammer, stretching, thread deformation, or twisting. Replace as
remove the pins from rotator support. necessary.

PLATFORM (SLAVE) LEVELING CYLINDER

ARTICULATING JIB

JIB LIFT CYLINDER

Figure 4-18. Location of Components-Articulating Jib

4-46 3121628
SECTION 4 - BOOM & PLATFORM

7. Inspect structural units of articulating jib boom assem- 7. Disconnect hose that is to be replaced, and cap the male
bly for bending, cracking, separation of welds, or other fitting.
damage. Replace boom sections as necessary.
8. Attach the new hose to the end of the hose to be
Assembly replaced.

1. Align lift cylinder with attach holes in articulating jib 9. Pull these lines thru the upright and out the bottom,
boom. Using a soft head mallet, install cylinder pin #7 then feed back into the fly boom.
into articulating jib boom and secure with mounting
10. At the Powertrack, in front of the tower boom, open the
hardware.
Powertrack links to expose the hose to be replaced.
2. Align rotator support with attach hole in articulating jib
11. Pull hose to be replaced, attached to the new hose, thru
boom. Using a soft head mallet, install rotator support
the fly boom and thru the Powertrack links.
pin #6 into articulating jib boom and secure with
mounting hardware. 12. Disconnect new hose from the replaced hose and con-
3. Align bottom tubes with attach holes in rotator support. nect to fitting where the damaged hose was connected.
Using a soft head mallet, install rotator support pin #5
13. Roll Powertrack back into base, and attach the top bar of
into articulating jib boom and secure with mounting
the Powertrack (2) bolts to the inside top of the fly boom
hardware.
section.
4. Align articulating jib boom with attach hole in articulat-
14. Check for leaks and hardware tightened securely.
ing jib boom pivot weldment. Using a soft head mallet,
install rotator support pin #4 into articulating jib boom 15. Replace access cover plates and front cover.
and secure with mounting hardware.
5. Align bottom tubes with attach holes in articulating jib 4.14 LIMIT SWITCHES ADJUSTMENT
boom pivot weldment. Using a soft head mallet, install
rotator support pin #3 into articulating jib boom pivot Main Boom Horizontal Limit Switch
weldment and secure with mounting hardware.
1. Place machine on level surface.
6. Align articulating jib boom pivot weldment with attach
holes in fly boom assembly. Using a soft head mallet, 2. Raise main boom 5 to 10 degrees above horizontal. limit
install pivot pin #2 into fly boom assembly and secure switch should activate before this point.
with mounting hardware.
3. Lower main boom until limit switch resets. This should
7. Align the platform (slave) leveling cylinder with attach be 1 degree above to 4 degrees below horizontal. (See
holes in articulating jib boom pivot weldment. Using a Figure 4-22. for adjustments)
soft head mallet, install platform (slave) leveling cylinder
pin #1 into articulating jib boom pivot weldment and NOTE: Angle indicator should be placed approx. 2 ft. from the
secure with mounting hardware. main boom pivot pin and the attach point on the main
boom. Tower angle switch must be reset before main boom
4.13 SEQUENCE FOR HOSE REPLACEMENT IN THE angle switch can be activated.
TOWER BOOM
Tower Boom Horizontal Limit Switch
1. Remove the tower boom front cover bolts, exposing the
Powertrack. 1. Place machine on level surface.
2. Remove bolts to disconnect the top bar of the Pow- 2. Raise Tower Boom 8 to 13 degrees above horizontal. The
ertrack tower angle limit switch should activate at this point.
3. Pull the Powertrack out of base boom. (as far as hoses
3. Lower the tower boom until the limit switch resets. This
will allow)
should be 2 to 7 degrees below where the switch was
4. At left side rear of upright, remove access cover plate (4) activated. (See Figure 4-19. and Figure 4-20. for adjust-
bolts. (others if necessary) ments).

5. Remove access cover plate, (4) bolts, from bottom front

of fly boom.
6. Cut cable ties that attach hose to be replaced.

3121628 4-47
SECTION 4 - BOOM & PLATFORM

main SWITCH (DUAL CAPACITY BOOM ANGLE SWITCH) SHOWN FOR

REFERENCE ONLY.

SWITCH TO ACTIVATE WHEN MAIN BOOM IS RAISED 5° TO 10° ABOVE HORIZONTAL.

SWITCH TO RESET WHEN MAIN BOOM IS LOWERED 1° BELOW TO 4° ABOVE HORIZONTAL.

PLUNGER VALVE TO ACTUATE WHEN

BOOM IS RAISED BEYOND 76° FROM
SWITCH TO ACTIVATE WHEN TOWER BOOM IS RAISED
HORIZONTAL.
TO 8° TO 13° FROM HORIZONTAL SWITCH TO RESET
WHEN TOWER BOOM IS LOWERED TO 2° TO 7° FROM
HORIZONTAL.

SUGGESTED
INITIAL ARM SUGGESTED
POSITION INITIAL ARM
MOUNTING SETTING POSITION
SURFACE SETTING

MOUNTING
SURFACE

SWITCH ORIENTATION SWITCH ORIENTATION

0258217 R

Figure 4-19. Boom Valve and Limit Switches Location (Sheet 1 of 3)

4-48 3121628
SECTION 4 - BOOM & PLATFORM

See Section 4.15, Boom Valve

Adjustment

ADJUST GAP TO WITHIN 0.20 in. (5 mm) (PREFERRED GAP 0.125 in. LEDS WILL LIGHT WHEN POWER IS
(3.175 mm) WHEN LOWER BOOM IS FULLY RETRACTED AND AFTER ON AND TARGET IS WITHIN SENSING
VALVE IS ADJUSTED ADJUST SWITCH BY LOOSENING CLAMP ON DISTANCE
TELE ROD AND SLIDING TO APPROXIMATE 0.125 in. (3.175 mm) GAP

1.0 in. (25.4 mm) CEN-

TER PROXIMITY SWITCH
IN MOUNT

0258217 R

Figure 4-20. Boom Valve and Limit Switches Location (Sheet 2 of 3)

3121628 4-49
SECTION 4 - BOOM & PLATFORM

See Section 4.15, Boom Valve

Adjustment

0258217 R

Figure 4-21. Boom Valve and Limit Switches Location (Sheet 3 of 3)

4-50 3121628
3121628
SWITCH TO ACTIVATE WHEN BOOM
IS RAISED 56 TO 61 FROM HORIZONTAL
SWITCH TO RESET WHEN BOOM
IS LOWERED TO 55 TO 50FROM HORIZONTAL

SEE VIEW -A- FOR

SWITCH ORIENTATION

LOWER SWITCH (ELEVATION

SWITCH) SHOWN FOR
REFERENCE ONLY

SWITCH TO ACTIVATE WHEN BOOM

IS 168" 1" FROM FULLY EXTENDED
SEE VIEW -B- FOR SWITCH ORIENTATION

MOUNTING SURFACEREF
MOUNTING SURFACE
REF

90 REF SUGGESTED
90 REF INITAL ARM
POSITION
SETTING
SUGESTED
INITAL ARM
POSTION
SETTING

VIEW -B- VIEW -A-

0258338 H

Figure 4-22. Dual Capacity Switches Installation (800 Only if equipped)

4-51
SECTION 4 - BOOM & PLATFORM
4-52
685)$&(60867%(&/($1('
SECTION 4 - BOOM & PLATFORM

/,0,76:,7&+ %()25($33/<,1*7$3(
675$,15(/,()&211(&7256

6:,7&+72$&7,9$7(:+(1%220
,6(;7(1'('
02817,1* 6((9,(:$)256:,7&+25,(17$7,21
685)$&(
5()

5()

68**(67('
,1,7,$/$50
326,7,216(77,1*

0258384 F

Figure 4-23. Transportation Switch Installation (CE only)

3121628
SECTION 4 - BOOM & PLATFORM

Dual Capacity Angle Limit Switch (800A only) Main Boom Length Switch (800A only)
1. Lift main boom to approximately horizontal.
NOTE: The boom position and location of the Main Boom Dual
Capacity Switch requires a working surface 20 ft. (6m) high 2. Telescope boom out until 500 lb. light comes on (may
to safely check and adjust the switch. need to use auxiliary power to position boom correctly).
3. Mark the wear pad location on the main fly boom.
1. Place machine on level surface.
4. Telescope the main boom to full extension.
2. From platform control, with less than 500 lbs. (227 kg) in 5. Measure from the mark on the fly boom to the wear pad.
platform, raise tower boom to maximum angle. Extend The dimension should be 167" to 169".
main boom until the capacity indicator lights change
from 1000 lbs. (454 kg) to 500 lbs. (227 kg). 6. Lower the tower boom until limit switch resets. This
should be 2 to 7 degrees below where the switch
3. With main boom length in this position, raise the main
boom until the indicator lights change back to the 1000
lbs. (454 kg) indicator.

4. The Dual Capacity Limit Switch, located at the telescope

cylinder of the Main Boom, Figure 4-22., will activate the
1000 lb. light when the main boom is at 56 to 61
degrees.

NOTE: Place angle indicator on main base boom at least 2 ft.

(0.6m) from pivot pin.

5. Lower main boom until 500 lb. light comes on. The
boom angle at this point should be 50 to 55 degrees.

NOTE: If limit switch settings need to be changed, you will need to

recheck that the 500 lb. light comes on at 50 degrees to 55
degrees when lifting down.

6. Raise, extend, retract, and lower main boom. Check for

smooth operation.

3121628 4-53
SECTION 4 - BOOM & PLATFORM

4.15 BOOM VALVE ADJUSTMENT Main Boom

1. Adjust the screws so the plunger on the valves has 0.250 1. Shim up wear pads to within 1/32 inch (0.8 mm) clear-
in. (6.35 mm) travel remaining when the lower boom is ance between wear pad and adjacent surface.
fully raised and retracted.
2. Adjusting wear pads, removing or adding shims, bolt
2. After the valves are adjusted, adjust the proximity length must also be changed.
switches to within 0.20 in. (5 mm) of their target. The
a. When adding shims, longer bolts must be used to
LED’s on the proximity switches will light when the
ensure proper thread engagement in insert.
power is on and the switch is within 0.20 in. (5 mm) of
the target. There is a proximity switch to back up both b. When shims are removed, shorter bolts must be
valves. used so bolt does not protrude from insert and
Sheaves and wire rope must be replaced as sets.
NOTE: The cam valve under the boom requires the tower boom to
be completely lowered and the cam valve mounted on T/T
requires the tower boom to be fully elevated prior to
adjustment.

Tower Boom
1. Shim up wear pads until 1/32 inch (0.8 mm) clearance to
adjacent surface.
2. When adjusting wear pads, removing or adding shims,
bolt length must also be changed.
a. When adding shims, longer bolts must be used to
ensure proper thread engagement in insert.
b. When shims are removed, shorter bolts must be
used so bolt does not protrude from insert and
come into contact with boom surface.

4-54 3121628
SECTION 4 - BOOM & PLATFORM

4.16 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
The L20 Series rotary actuator is a simple mechanism that uses by set screws or pins.
the sliding spline operating concept to convert linear piston
motion into powerful shaft rotation. Each actuator is com- Required Tools
posed of a housing with integrated gear teeth (01) and only
Upon assembly and disassembly of the actuator there are
two moving parts: the central shaft with integrated bearing
basic tools required. The tools and their intended functions are
tube and mounting flange (02), and the annular piston sleeve
as follows:
(03). Helical spline teeth machined on the shaft engage
matching splines on the inside diameter of the piston. The
outside diameter of the piston carries a second set of splines,
of opposite hand, which engage with matching splines in the
housing. As hydraulic pressure is applied, the piston is dis-
placed axially within the housing - similar to the operation of a
hydraulic cylinder - while the splines cause the shaft to rotate.
When the control valve is closed, oil is trapped inside the actu-
ator, preventing piston movement and locking the shaft in
position.

1. Flashlight - helps examine timing marks, component

failure and overall condition.

2. Felt Marker - match mark the timing marks and outline

troubled areas.

3. Allen wrench - removal of port plugs and set screws.

4. Box knife - removal of seals.

5. Seal tool - assembly and disassembly of seals and wear

guides.

6. Pry bar - removal of end cap and manual rotation of

shaft.
Bars indicate starting positions As fluid pressure is applied, the 7. Rubber mallet- removal and installation of shaft and pis-
of piston and shaft. Arrows indi- piston is displaced axially while ton sleeve assembly.
cate direction they will rotate. the helical gearing causes the
The housing with integral ring piston and shaft to rotate simul- 8. Nylon drift - installation of piston sleeve
gear remains stationary. taneously. The double helix
design compounds rotation: 9. End cap dowel pins - removal and installation of end cap
shaft rotation is about twice that (sold with Helac seal kit).
of the piston.

3121628 4-55
SECTION 4 - BOOM & PLATFORM

The seal tool is merely a customized standard flat head screw-

driver. To make this tool you will need to heat the flat end with
a torch. Secure the heated end of the screwdriver in a vice and
physically bend the heated end to a slight radius. Once the
radius is achieved round off all sharp edges of the heated end
by using a grinder. There may be some slight modifications for
your own personal preference.

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

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

Figure 4-24. Rotator - Exploded View

4-56 3121628
SECTION 4 - BOOM & PLATFORM

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

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

Figure 4-25. Rotator- Assembly Drawing

3121628 4-57
SECTION 4 - BOOM & PLATFORM

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

shown).

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).
If the pin will not come out with the ”Easy Out”, use 5/1
6” drill bit to a depth of 1/2” (12.7mm) to drill out the
entire pin.
4. Install the end cap (4) removal tools provided with the
Helac seal kit.

2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center

of each lock pin to a depth of approximately 3/16”
(4.76mm).

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

(4) by turning it counter clockwise.

4-58 3121628
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.

3121628 4-59
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.

4-60 3121628
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).

3121628 4-61
SECTION 4 - BOOM & PLATFORM

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

ness (not less than 0.123” 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” or 2.34
mm).

4-62 3121628
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 0-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).

3121628 4-63
SECTION 4 - BOOM & PLATFORM

6. Install the O-ring (204) and back-up ring (207) into the Repeat this step for the outer seal (202).
inner seal groove on the end cap (4).

8. Insert the piston (3) into the housing (1) as shown, until
7. Install the inner T-seal (200) into the piston (3) using a the outer piston seal (202) is touching inside the hous-
circular motion. ing bore.

Install the outer T-seal (202) by stretching it around the

groove in a circular motion.

Each T-seal has 2 back-up rings (see drawing for orienta-

tion).

Beginning with the inner seal (200) insert one end of b/u
ring in the lower groove and feed the rest in using a cir-
cular motion. Make sure the wedged ends overlap cor-
rectly.

4-64 3121628
SECTION 4 - BOOM & PLATFORM

9. Looking from the angle shown, rotate the piston (3) until 11. 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.

12. Looking from the view shown, use the existing timing
10. 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.

3121628 4-65
SECTION 4 - BOOM & PLATFORM

13. Install 2 bolts in the threaded holes in the flange. Using a 16. 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.

17. 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).

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

4-66 3121628
SECTION 4 - BOOM & PLATFORM

18. Tighten the end cap (4). In most cases the original holes 20. 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).

19. 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.

3121628 4-67
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 4-26., Rotator Counterbalance Valve.
4. Torque the 1/4-inch bolts 110 to 120 in.lbs. (12.4 to 13.5
1. Make sure the surface of the actuator is clean, free of any Nm). Do not torque over 125 in.lbs. (14.1 Nm). Torque
contamination and foreign debris including old JLG the 5/16-inch bolts 140 in.lbs. (15.8 Nm). Do not torque
Threadlocker P/N 0100011. 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 4-26. Rotator Counterbalance Valve

4-68 3121628
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).

3121628 4-69
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 4.17 FOOT SWITCH ADJUSTMENT
gallons (8 liters) is purged.
Adjust so that functions will operate when pedal is at center of
1. Connect a 3/16" inside diameter x 5/16" outside diame- travel. If switch operates within last 1/4 in. (6.35 mm) of travel,
ter x 5 foot clear, vinyl drain tube to each of the two top or bottom, it should be adjusted.
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.

4-70 3121628
SECTION 4 - BOOM & PLATFORM

Troubleshooting
Table 4-1. Troubleshooting

Problem Cause Solution

1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s
pressure specifications. Load may be above maximum
capacity of the actuator.

b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic lines for
restrictions and leaks.

c. Control or counterbalance valve has internal leak c. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate the actuator through housing ports
(do not exceed OEM’s operating pressure). The valve must
be replaced if a steady flow of fluid is seen coming from the
valve ports.

d. Piston and/or shaft seal leak d. Remove the plug and the housing’s valve ports. Operate
the actuator through the housing ports. Conduct the inter-
nal leakage test.

e. Re-build the actuator. Remove all rust then polish.

e. Corrosion build-up on the thrust surfaces Replacement parts may be needed.

f. Re-build the actuator. Use fluid that is compatible with

f. Swollen seals and composite bearings caused by incom- seals and bearings.
patible hydraulic fluid
2. Operation is erratic or not responsive a. Air in actuator a. Purge air from actuator. See bleeding procedures.
3. Shaft will not fully rotate a. Twisted or chipped gear teeth a. Check for gear binding. Actuator may not be able to be re-
built and may need to be replaced. Damage could be a result
of overload or shock.

b. Port fittings are obstructing the piston b. Check thread length of port fittings. Fittings should dur-
ing stroke not reach inside the housing bore.
4. Selected position cannot be maintained a. Control or counterbalance valve has internal leak a. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate the actuator through housing ports
(do not exceed OEM’s operating pressure). The valve must
be replaced if a steady flow of fluid is seen coming from the
valve ports.

b. Piston and/or shaft seal leak b. Remove the plug and the housing’s valve ports. Operate
the actuator through the housing ports. Conduct the inter-
nal leakage test.

c. Purge air from actuator. See bleeding procedures

c. Air in actuator

3121628 4-71
SECTION 4 - BOOM & PLATFORM

4.18 SKYGUARD IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE &

“BOTH” IS SELECTED.
In Platform Mode:
Operation
NOTE: Machine will treat Soft Touch/SkyGuard override switch as
Skyguard is used to provide enhanced control panel protec- if it is a Soft Touch and SkyGuard switch.
tion. When the SkyGuard sensor is activated, functions that
were in use at the time of actuation will reverse or cutout. The 1. In an area free of obstructions, from platform controls
table below outlines these functions. test the SkyGuard feature by operating the telescopic
out functions and engaging the SkyGuard sensor, tele-
scopic out function will be stopped, soft touch indicator
light will flash at 3HZ, the horn will be turned on until
the SkyGuard sensor and footswitch is disengaged.
2. With SkyGuard sensor engaged, press and hold the yel-
low “Override Soft Touch” button and then operate a
function switch or joystick to check if the operation can
be resumed.
3. Disengage the SkyGuard sensor, release controls, recycle
the foot switch, make sure normal operation is available.

In Ground Mode:
Operation will be allowed regardless of SkyGuard switch acti-
vation.

Figure 4-27. Skyguard

IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE &

“SOFT TOUCH” IS SELECTED.
Functional Test Machine will treat the Soft Touch/SkyGuard override switch as
if it is a Soft Touch switch
IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE &
“SKYGUARD” IS SELECTED IN MACHINE SET UP.
In Platform Mode: IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE &
“NONE” IS SELECTED.
1. In an area free of obstructions, from the platform con- Skyguard sensor status will be ignored. No function cutout or
trols test the SkyGuard feature by operating the tele- reversal will be implemented.
scope out functions and engaging (and holding) the
SkyGuard sensor. Telescope function will be stopped
and telescope in function will be activated for a short
duration. Soft touch indicator light will flash at 3HZ,
horn will be turned on, until the SkyGuard sensor and
footswitch is disengaged.

2. With SkyGuard sensor engaged, press and hold

the yellow “Override Soft Touch” button and then oper-
ate a function switch or joystick to check if the operation
can be resumed.

3. Disengage the SkyGuard sensor, release controls, recycle

the foot switch, make sure normal operation available.

In Ground Mode:

Operation will be allowed regardless of SkyGuard sensor acti-

vation.

4-72 3121628
SECTION 4 - BOOM & PLATFORM

Diagnostic & Troubleshooting 2. If machine operation is not available:

If you are experiencing a problem that is not described here, Help menu or diagnostics menu is to be used to collect
see your authorized dealer for service. the fault information.
Depending on configuration, diagnostics menu
will read:
1. Check the configuration under the menu “MACHINE
SETUP  STOUCH/SKYGUARD” according to the actual Diagnostics->System->Skyguard switch
system installed on machine. Make sure recommended
Diagnostics->System->STOUCH OR SG
configuration described is selected.
Pressing to engage the SkyGuard sensor will change the
switch or relay to open/close status.
If SkyGuard Does Not Function with sensor engaged.
If the switch status states “Closed” regardless of sensor
activation status:
AUTHORIZED TECHNICIAN OR OPERATOR IS REQUIRED TO CONDUCT AN OPER-
Power or ground wire is not making good contact and/
ATION CHECK OF SKYGUARD SENSOR DAILY.
or may be loose or broken.

Help menu or diagnostics menu is to be used to collect Both relays failed (low probability)
the fault information.
If the switch status is in disagreement, then one relay
Depending on configurations, diagnostics menu may have failed or one relay isn't inserted into the
will read: holder correctly. This may also be noticed since machine
will not be able to be operated.
Diagnostics->System->Skyguard switch

Diagnostics->System->STOUCH OR SG Switch disagreement fault (2563) and SkyGuard switch

activation fault (0039) will be shown under
Pressing to engage the SkyGuard sensor will change the Help menu.
switch or relay to open/close status.
Refer to the following table per Figure 4-28. for Sky-
If the switch status stays in “Open” while the actual Sky- Guard function.
Guard sensor is pressed, then the SkyGuard sensor may Refer Figure 4-28. and Figure 4-29. for SkyGuard harness.
have failed, it needs to be changed immediately.

Table 4-2. SkyGuard Function Table

DRIVE
MAIN MAIN REVERSE TOWER TOWER
MAIN MAIN BASKET BASKET JIB JIB
TELE TELE LIFT LIFT
LIFT DOS DOS LEVEL ROTATE LIFT ROTATE
IN OUT DOS DOS UP DOWN
NOT NOT
ENABLED ENABLED
ENABLED

R C R R R C* R R R C C C C N/A N/A

R = Indicates reversal is activated

C = Indicates cutout is activated
NA = Indicates the function does not exist for the model
* = Disregard when boom is in line and driving forward with or without steering and no other functions active
Note ‐ When SoftTouch is enable w ith SkyGuard allfuncti ons are cutout only

3121628 4-73
SECTION 4 - BOOM & PLATFORM

X508
X504

R501

XICON 280-CR25-18-RC OR EQUIVALENT

18 25W WIREWOUND RESISTOR

Jumper Harness
X506
X505

X510
X500

X509
X507

Figure 4-28. SkyGuard Harness

4-74 3121628
SECTION 4 - BOOM & PLATFORM

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Figure 4-29. SkyGuard Harness Wiring Diagram

3121628 4-75
SECTION 4 - BOOM & PLATFORM

4.19 BOLT ON FALL ARREST • Cable: Inspect cable for proper tension, broken strands,
kinks, or any signs of corrosion.
The bolt on fall arrest system is designed to provide a lanyard
attach point while allowing the operator to access areas out- GAP
GAPSHOWING:
SHOWING:
side the platform. Exit/Enter the platform through the gate INCORRECT
INCORRECT
area only. The system is designed for use by one person.

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:
External Fall Arrest System capacity is 310 lb (140 kg) - one (1) NO GAP: CORRECT
CORRECT
person maximum.

Do not move the platform during use of the external fall arrest
system.

DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM.

BE CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.
Figure 4-30. Bolt On Fall Arrest Cable Tension

• Fittings & Brackets: Ensure all fittings are tight and there are
IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTH- no signs of fractures. Inspect brackets for any damage.
ERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLAT-
FORM FULLY INSPECTED BEFORE RETURNING TO SERVICE. REFER TO THE • Attachment Ring: No cracks or signs of wear are accept-
SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES. able. Any signs of corrosion requires replacement.
THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND • Attaching Hardware: Inspect all attaching hardware to
CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICATION MUST BE ensure there are no missing components and hardware is
PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER.
properly tightened.

Inspection Before Use • Platform Rails: No visible damage is acceptable.

The external fall arrest system must be inspected before each

use of the aerial work platform. Replace components if there Installation
are any signs of wear or damage.
1. Install the retaining hardware (bolts, nuts, and washers)
Before each use, perform a visual inspection of the following and secure the brackets to the platform rail. Tighten the
components: nuts but do not torque them yet.

BOLT

WASHER

NUT

4-76 3121628
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 15
4. Without twisting the fall arrest cable, pull it thru the left
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

3121628 4-77
SECTION 4 - BOOM & PLATFORM

7
1,2,3,4

5
1. Belleville Washer
2. Washer
6 3. Hex Nut
4. Jam Nut
5. LH Bracket
6. Attachment Ring
7. Cable
8. RH Bracket
9. Decal

Figure 4-31. Bolt On Fall Arrest System

4-78 3121628
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-
When assembling connectors in the hydraulic that use o-ring rated.
fittings, it is necessary to lubricate all fittings with hydraulic oil
prior to assembly. To lubricate the fittings, use one of the fol-
lowing procedures.

NOTE: All O-ring fittings must be pre-lubricated with hydraulic oil

prior to assembly.

Cup and Brush

The following is needed to correctly oil the o-ring in this man-
ner:

• A small container for hydraulic oil

• Small paint brush 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring is
coated with hydraulic oil.

1. Hold the fitting in one hand while using the brush with
the other hand to dip into the container. Remove excess
hydraulic oil from the brush so an even film of oil is
applied on the o-ring.

3121628 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 3121628
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

3121628 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 5-10. ORB-MPP Thread

Tightening Methods
Torque = Application of a twisting force to the applicable con-
Figure 5-8. ORB-MPP Thread nection by use of a precise measurement instrument (i.e.
torque wrench).
MFF = metric flat face port per ISO 9974-1
Finger Tight = The point where the connector will no longer
BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852- thread onto the mating part when tightened by hand or fin-
2 gers. Finger Tight is relative to user strength and will have
some variance. The average torque applied by this method is 3
ft-lbs [4 N-m] Also referred to as ‘Hand Tight.’
TFFT = Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by hand (fin-
gers) and applying an additional rotation counted by a
defined number of turns by use of a tool.
FFWR = Flats from Wrench Resistance; Application of a pre-
load to a connection by tightening to the point of initial
wrench resistance and turning the nut a described number of
‘flats’. A ‘flat’ is one side of the hexagonal tube nut and
equates to 1/6 of a turn. Also referred to as the ‘Flats Method.’

Figure 5-9. MFF-BSPP Thread

5-4 3121628
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 main limit for
steel.
1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling 5. To achieve the specified torque, the torque wrench is to
or assembly. Nicks and scratches in sealing surfaces can be held perpendicular to the axis of rotation.
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting attach-
ment to ensure that the tube has not been damaged.
3. The assembly process is one of the leading causes for
contamination in air and hydraulic systems. Contamina-
tion can prevent proper tightening of fittings and adapt-
ers from occurring.
a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as nec-
essary before re-installing.
c. Sealing compounds should be applied where speci- Figure 5-11. Torque Wrench Angle
fied; however, care should be taken not to introduce
sealant into the system. 6. Refer to the appropriate section in this manual for more
d. Avoid applying sealant to the area of the threads specific instructions and procedures for each type of fit-
where the sealant will be forced into the system. ting connection
This is generally the first two threads of a fitting.
e. Sealant should only be applied to the male threads.
f. Straight thread fittings do not require sealants. O-
rings or washers are provided for sealing.
g. When replacing or installing an O-ring, care is to be
taken while transferring the O-ring over the threads
as it may become nicked or torn. When replacing an
O-ring on a fitting, the use of a thread protector is
recommended.
h. When installing fittings with O-rings, lubrication
shall be used to prevent scuffing or tearing of the O-
ring. See O-ring Installation (Replacement) in this
section.

3121628 5-5
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS
TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED
Thread Tapered (NPTF) Connections. TURNS AND USE THE LAST TURN FOR ALIGNMENT.
1. Inspect components to ensure male and female port
threads are free of rust, splits, dirt, foreign matter, or 5. Rotate male fitting the number of turns per Table 5-1,
burrs. NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT
procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to
the male pipe threads if not already applied. Ensure the NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
first 1 to 2 threads are uncovered to prevent system con- applicable for the following material configurations:
tamination.
• STEEL fittings with STEEL mating components
3. Assemble connection hand tight.
• STEEL fittings with ALUMINUM or BRASS mating compo-
4. Mark fittings, male and female. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE
PIPE FITTING AND DAMAGE TO THE JOINING FITTING, • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
FLANGE OR COMPONENT MAY OCCUR. mating components.

Table 5-1. NPTF Pipe Thread

TYPE/FITTING IDENTIFICATION
Turns From Finger
Thread Size ØA*
Material Dash Size Tight (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
STEEL, ALUMINUM, OR BRASS MATING C

4 1/4 - 18 0.54 13.61 2 to 3

6 3/8 - 18 0.67 17.05 2 to 3
8 1/2 - 14 0.84 21.22 2 to 3
12 3/4 - 14 1.05 26.56 2 to 3
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
OMPONENTS

24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5

32 2 - 11 1/2 2.37 60.09 1.5 to 2.5

* ØA thread dimension for reference only.

** See FFWR and TFFT Methods subsection for TFFT procedure requirements.

5-6 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Assembly Instructions for British Standard Pipe TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED
TURNS AND USE THE LAST TURN FOR ALIGNMENT.
Thread Tapered (BSPT) Connections
1. Inspect components to ensure male and female port 5. Rotate male fitting the number of turns per Table 5-2,
threads are free of rust, splits, dirt, foreign matter, or BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT
burrs. procedure requirements.

2. Apply a suitable thread sealant, such as Loctite 567, to NOTE: TFFT values provided in Table 5-2, BSPT Pipe Thread are
the male pipe threads if not already applied. Ensure the applicable for the following material configurations:
first 1 to 2 threads are uncovered to prevent system con-
tamination. • STEEL fittings with STEEL mating components

3. Assemble connection hand tight. • STEEL fittings with ALUMINUM or BRASS mating compo-
nents
4. Mark fittings, male and female.
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents

OVER TIGHTENING MAY CAUSE DEFORMATION OF THE • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
PIPE FITTING AND DAMAGE TO THE JOINING FITTING, mating components.
FLANGE OR COMPONENT MAY OCCUR.

NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS

Table 5-2. BSPT Pipe Thread

TYPE/FITTING IDENTIFICATION
Turns From
Thread Size ØA* Finger Tight
MATERIAL Dash Size (TFFT)**
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH

4 1/4 - 19 0.52 13.16 2 to 3

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

8 1/2 - 14 0.83 20.96 2 to 3

12 3/4 - 14 1.04 26.44 2 to 3
MATING COMPONENTS

16 1 - 11 1.31 33.25 1.5 to 2.5

20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5

* ØA thread dimension for reference only.

** See Appendix B for TFFT procedure requirements.

3121628 5-7
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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

5-8 3121628
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 --
STEEL FITTINGS WITH STEEL MATING COMPONENTS;

3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --

4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
UN-LUBRICATED THREADS

6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2

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

3121628 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 --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --

4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methodsfor FFWR procedure requirements.

5-10 3121628
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 ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
THE JOINT EVENTUALLY LEADING TO LEAKAGE. COMPONENTS’ indicate either the following material configu-
rations:
2. Align tube to fitting.
• 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 LUBRI-
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
CATED OR OILY FITTINGS. NO LUBRICATION OR SEALANT
IS REQUIRED. THE LUBRICATION WOULD CAUSE mating components.
INCREASED CLAMPING FORCE AND CAUSE FITTING DAM-
AGE.

3121628 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 3121628
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-
replace fitting or adapter. uration of the connection.

ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING

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

Flats from Wrench

TYPE/FITTING IDENTIFICATION Torque Resistance
(F.F.W.R)**
MATERIAL

Thread Size ØA* ØB* [Ft-Lb] [N-m] Swivel &

Tube
Dash Size Hose
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Nuts
Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
STEEL MATING COMPONENTS;

8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4

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 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methodsfor FFWR procedure requirements.

3121628 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)**
Thread Swivel &
MATERIAL

Dash ØA* ØB* [Ft-Lb] [N-m] Tube

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

6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

UN-LUBRICATED THREADS
MATING COMPONENTS;

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

ALUMINUM/BRASS

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

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

5-14 3121628
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 Table 5-9, DIN
24°Cone (MBTL & MBTS) while using the Double Wrench
Method. The tube must not turn with the nut.

3121628 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)

Tube Thread M Torque Flats from

MATERIAL

ØA* ØB* C* ØD* Wrench

TYPE

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

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

8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75

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

28 M36 x 2 33.90 36.00 7.50 28.20 characteristics of the connection. 1.5 to 1.75
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
Refer to the specific procedure
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
in the
Tube Thread M Torque Flats from
ØA* ØB* C* ØD* Wrench
TYPE

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

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

8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75

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

5-16 3121628
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.

3121628 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 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-11. Bulkhead Fittings (BH) - METRIC

FASTENING JAM NUT

TYPE/FITTING IDENTIFICATION
for Bulkhead Connectors

Connecting Torque
Thread M Size
MATERIAL TYPE Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
DIN 24° CONE FLARELESS BITE
(MBTL) BULKHEAD FITTING

10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
STEEL FITTINGS

Connecting Torque
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING

Thread M Size
Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
14 M22 x 1.5 44 47 50 60 64 68
16 M24 x 1.5 70 75 80 95 102 108
20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325

3121628 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 thru
Table 5-17 while using the Double Wrench Method.
Fittings
a. The table headings identify the straight thread O-
1. Inspect components to ensure that male and female ring port and the type on the other side of the fit-
port threads are free of rust, splits, dirt, foreign matter, or ting. The torque will be applied to the straight
burrs. thread O-ring port.

2. Ensure proper O-ring is installed. If O-ring is missing b. Torque values provided in Table 5-12 thru Table 5-17
install per O-ring Installation (Replacement). are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID • STEEL fittings with ALUMINUM or BRASS mating compo-
ADDING OIL TO THE THREADED CONNECTION OF THE FIT- nents
TING. THE LUBRICATION WOULD CAUSE INCREASED
CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
4. For Non-Adjustable and Plugs, thread the fitting by
hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
Assembly for proper assembly.

5-20 3121628
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
STEEL FITTINGS WITH STEEL MATING

5 1/2-20 0.50 12.70 23 25 26 32 34 35

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

4 7/16-20 0.44 11.11 14 15 16 19 20 22

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

3121628 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
STEEL FITTINGS WITH STEEL MATING

5 1/2-20 0.50 12.70 30 32 33 40 43 45

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

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

5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* 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 3121628
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
STEEL FITTINGS WITH STEEL MATING

5 1/2-20 0.50 12.70 21 22 23 28 30 31

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

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

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

3121628 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
STEEL FITTINGS WITH STEEL MATING

5 1/2-20 0.50 12.70 30 32 33 40 43 45

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

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

5-24 3121628
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
STEEL FITTINGS WITH STEEL MATING

5 1/2-20 0.50 12.70 14 15 16 19 20 22

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

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

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

3121628 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
STEEL FITTINGS WITH STEEL MATING

5 1/2-20 0.50 12.70 9 10 11 12 14 15

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

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

5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
* 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 3121628
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
ment) for instructions. are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID • STEEL fittings with ALUMINUM or BRASS mating compo-
ADDING OIL TO THE THREADED CONNECTION OF THE FIT- nents
TING. THE LUBRICATION WOULD CAUSE INCREASED
CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
by hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
Assembly for proper assembly.

3121628 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
COMPONENTS; UN-LUBRICATED THREADS

M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
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 3121628
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
COMPONENTS; UN-LUBRICATED THREADS

M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
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

3121628 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 Connecting Torque Torque Torque

MATERIAL M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
COMPONENTS; UN-LUBRICATED THREADS

M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
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 Connecting Torque Torque Torque
MATERIAL M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 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 3121628
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
COMPONENTS; UN-LUBRICATED THREADS

M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
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

3121628 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
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS
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
M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
COMPONENTS; UN-LUBRICATED THREADS

M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
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 3121628
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 Connecting Torque Torque Torque

MATERIAL M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
COMPONENTS; UN-LUBRICATED THREADS

M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
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 Connecting Torque Torque Torque
MATERIAL M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 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 -- -- -- -- -- --

3121628 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 preinstalled, install proper size, taking based on the material configuration of the connec-
care not to damage it. See O-ring Installation (Replace- tion. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/
ment) for instructions. BRASS MATING COMPONENTS’ indicate either the
following material configurations:
• 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 FIT- • ALUMINUM or BRASS fittings with STEEL mating compo-
TING. THE LUBRICATION WOULD CAUSE INCREASED nents
CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
3. Pre-lubricate the O-ring with Hydraulic Oil.
7. Inspect to ensure the O-ring is not pinched and the
4. For Non-Adjustable Fittings and Plugs, thread the fitting washer is seated flat on the counter bore of the port.
by hand until contact.

5. For Adjustable fittings, refer to Adjustable Stud End

Assembly for proper assembly.

5-34 3121628
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 Connecting Torque Torque

MATERIAL

M 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
M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
STEEL FITTINGS WITH STEEL MATING COMPONENTS;

M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
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

3121628 5-35
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 Connecting Torque Torque

MATERIAL

M 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
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING

M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
COMPONENTS; UN-LUBRICATED THREADS

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

5-36 3121628
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 • STEEL fittings with ALUMINUM or BRASS mating compo-
ADDING OIL TO THE THREADED CONNECTION OF THE FIT- nents
TING. THE LUBRICATION WOULD CAUSE INCREASED
CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
by hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
Assembly for proper assembly.

3121628 5-37
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 Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(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
COMPONENTS; UN-LUBRICATED THREADS

G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
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 Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(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

5-38 3121628
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
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 Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(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
COMPONENTS; UN-LUBRICATED THREADS

G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
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 Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(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

3121628 5-39
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
COMPONENTS; UN-LUBRICATED THREADS

G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
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

5-40 3121628
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 Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(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
COMPONENTS; UN-LUBRICATED THREADS

G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
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 Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(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

3121628 5-41
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
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end
BSPP Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(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
COMPONENTS; UN-LUBRICATED THREADS

G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
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 Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(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

5-42 3121628
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
COMPONENTS; UN-LUBRICATED THREADS

G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
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

3121628 5-43
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. See Figure for O-ring installation instructions.
3. Pre-lubricate the O-ring with Hydraulic Oil.
4. Position flange and clamp halves.
5. Place lock washers on bolt and bolt through clamp
halves.
6. Tighten all bolts by hand.
7. Torque bolts in diagonal sequence in two or more incre-
ments to the torque listed on Table Table 5-31and Table
5-32.

5-44 3121628
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 Fastener Torque for Flanges Equipped with
Inch
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws
Flange
TYPE Size
SAE Dash [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
CODE 61 SPLIT FLANGE (FL61)

20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101

24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Bolt Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with
Inch
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws
Flange
TYPE Size
SAE Dash [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 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.

3121628 5-45
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 Fastener Torque for Flanges Equipped with
Inch
Flange Size A* Thread CLASS 8.8 Screws CLASS 10.9 Screws
Flange
TYPE Size
SAE Dash [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 Fastener Torque for Flanges Equipped with
Inch
Flange Size A* Thread CLASS 8.8 Screws CLASS 10.9 Screws
Flange
TYPE Size
SAE Dash [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.

5-46 3121628
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 5-12. for double wrench method require-
wrenches must be used; one torque wrench and one backup ments.
wrench. If two wrenches are not used, inadvertent component
rotation may occur which absorbs torque and causes
improper joint load and leads to leaks. For hose connections,

Figure 5-12. Double Wrench Method

3121628 5-47
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 back-up washer. The washer
and o-ring should be positioned at the extreme top end
2. Mark a dot on one of the swivel hex nut flats and of the groove as shown.
another dot in line on the connecting tube adapter. See
Figure B.1. 3. Position #2 – Position the locknut to just touch the back-
up washer as shown. The locknut in this position will
3. Use the double wrench method per Appendix A, turn eliminate potential back up washer damage during the
the swivel nut to tighten as shown in Figure B.1. The nut next step.
is to be rotated clockwise the number of hex flats as
4. Position #3 – Install the connector into the straight
defined by the applicable Table in Section 5.0.
thread box port until the metal back-up washer contacts
the face of the port as shown.
4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering 5. Position #4 – Adjust the connector to the proper posi-
the dots, to indicate the connection has been properly tion by turning out (counterclockwise) up to a maxi-
tightened. See Figure 5-13. mum of one turn as shown to provide proper alignment
with the mating connector, tube assembly, or hose
assembly.
6. Position #5 – Using two wrenches, use the backup
wrench to hold the connector in the desired position
and then use the torque wrench to tighten the locknut
to the appropriate torque.
7. Visually inspect, where possible, the joint to ensure the
o-ring is not pinched or bulging out from under the
washer and that the backup washer is properly seated
flat against the face of the port.

Figure 5-13. FFWR Method

TFFT (TURNS FROM FINGER TIGHT METHOD)

1. Tighten the swivel nut to the mating fitting until no lat-

eral movement of the swivel nut can be detected; finger
tight condition.

2. Mark a dot on one of the swivel hex nut flats and

another dot in line on the connecting tube adapter.

3. Use the double wrench method per Appendix A, turn

the swivel nut to tighten. The nut is to be rotated clock-
wise the number of turns as defined by the applicable
Table in Section 5.0.

4. After the connection has been properly tightened, mark

a straight line across the connecting parts, not covering
the dots, to indicate the connection has been properly
tightened.

5-48 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Figure 5-14. Adjustable Stud End Assembly

O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On

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

1. Inspect O-ring for tears or nicks. If any are found replace

O-ring.

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

the same but are of different material, different hard-
ness, or are slightly different diameters or widths.

3. Use a thread protector when replacing O-rings on fit-

tings.

3121628 5-49
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 and rod seal in rod bore
grooves. Make sure they are not twisted.
VALVE CAN CAUSE ROD TO FALL OUT OF BARREL.
2. Install new wiper in barrel.
1. Open bleeder valve. Rotate rod and remove from barrel.
3. Lubricate rod bore with clean hydraulic fluid.
2. Remove wiper. Do not scratch barrel bore.
3. Remove two wear rings and rod seal from grooves of rod
bore. Do not scratch barrel bore. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE ROD. AVOID PULL-
ING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE ROD AND
4. Remove counterbalance valve.
CYLINDER BARREL SURFACES.
CLEANING AND INSPECTION
4. Install rod in bore and push to top of the bore.
1. Inspect bore and rod for scoring, pitting, or excessive
wear. 5. Install counterbalance valve. Torque to 22 ft.lbs. (30 Nm).

2. Remove minor surface blemishes with wet sandpaper. 6. Bleed system.

Pitting requires replacement of barrel and rod.
3. Clean all parts with approved solvent and dry with com-
pressed air.

5-50 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1001204560 A

1. Barrel 6. Counterbalance Valve

2. Rod 7. O-ring Plug
3. Wiper 8. O-ring Plug
4. Rod Seal 9. Bleeder Valve
5. Wear Ring

Figure 5-15. Axle Lockout Cylinder

3121628 5-51
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Platform (Slave) Cylinder 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.

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.

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.
Figure 5-17. Capscrew Removal
3. Remove cartridge valve and fittings 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.

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.

Figure 5-16. Cylinder Barrel Support

Figure 5-18. Cylinder Rod Support

5-52 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1684408 E
1684228 E
1001138791 A

1. Capscrew 6. Rod 11. Backup Ring 16. O-ring 21. Tube Spacer
2. Tapered Bushing 7. Plug 12. Wear Ring 17. Capscrew 22. Cartridge Valve
3. Bushing 8. Plug 13. Washer Ring 18. Seal 23. Cartridge Valve
4. Head 9. Piston 14. Backup Ring 19. Wiper
5. Barrel 10. Lock Ring 15. O-ring 20. Seal

Figure 5-19. Platform (Slave) Cylinder

3121628 5-53
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 loosen 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.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-20. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

14. Remove the rod from the holding fixture. Remove the 10. Inspect cylinder head outside diameter for scoring or
cylinder head gland. Discard the o-rings, back-up rings, other damage and ovality and tapering. Replace as nec-
rod seals, and wiper seals. essary.

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 inside of steel bushing prior to bearing
installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.

5-54 3121628
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 gland groove.

Figure 5-21. 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 5-22. Rod Seal Installation

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

BACKUP WASHER
O-R ING RING POLY RING
SEAL
WEAR RING WIPER
SEAL

Figure 5-23. Cylinder Head Seal Installation

3121628 5-55
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

2. Use a soft mallet to tap a new wiper seal into the appli- 9. Assemble the tapered bushing loosely into the piston
cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the
ring into the applicable cylinder head gland groove. bushing and into the tapped holes in the piston.

PISTON

TAPERED
BUSHING
ROD
CAPSCREW

Figure 5-24. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head. Figure 5-26. Tapered Bushing Installation

10. Tighten the capscrews evenly and progressively in rota-

tion to 9 ft.lbs. (12 Nm).
11. 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 5-25. Installation of Head Seal Kit

PISTON
4. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the TAPERED
rod to the rod end, as applicable. BUSHING
ROD
5. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to piston as possi-
ble.
CAPSCREW
6. Place a new o-ring and back-up rings in the inner piston
diameter groove. BRASS SHAFT
7. Carefully thread the piston on the cylinder rod hand Figure 5-27. Seating the Tapered Bearing
tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.

8. Thread piston onto rod until it abuts the spacer end and
install the tapered bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

5-56 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

12. Rotate the capscrews evenly and progressively in 16. With barrel clamped securely, and while adequately sup-
rotation 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
13. Remove the cylinder rod from the holding fixture. are not damaged or dislodged.
17. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

Figure 5-28. Hydrolock Piston Seal Installation

14. Place new hydrolock seal and guidelock rings in the

outer piston diameter groove. (A tube, with I.D. slightly Figure 5-30. Rod Assembly Installation
larger than the O.D. of the piston is recommended to
install the solid seal). 18. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 35 ft.lbs. (50 Nm).
GUIDELOCK
RING HYDROLOCK 19. After the cylinder has been reassembled, the rod should
BACKUP
SEAL O-RING RING
be pushed all the way in (fully retracted) prior to the re-
installation of any holding valve or valves.
20. If applicable, install the cartridge-type holding valve and
fittings in the rod port block, using new o-rings as appli-
cable. Torque valve to 50-55 ft.lbs. (68-75 Nm).

Figure 5-29. Piston Seal Kit Installation

15. 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.

3121628 5-57
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Upright Level Cylinder 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.

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.

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. Figure 5-32. Capscrew Removal
3. Remove the cartridge valve and fittings from the cylin-
der 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.

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.

Figure 5-31. Cylinder Barrel Support

Figure 5-33. Cylinder Rod Support

5-58 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1684497 C

1. Rod 6. Piston 11. O-ring Plug 15. Washer Ring 19. Wear Ring
2. Barrel 7. Tapered Bushing 12. Bushing 16. Backup Ring 20. O-ring
3. Head 8. Cartridge Valve 13. Lock Ring 17. Wiper 21. Backup Ring
4. Washer Ring 9. Cartridge Valve 14. Seal 18. Rod Seal 22. Bolt
5. Bolt 10. O-ring Plug

Figure 5-34. Upright Level Cylinder

3121628 5-59
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. Inspect threaded portion of rod for excessive damage.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-35. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

11. Screw the piston counterclockwise, by hand, and 8. Inspect cylinder head inside diameter for scoring or
remove the piston from cylinder rod. other damage and for ovality and tapering. Replace as
necessary.
12. Remove and discard the piston o-rings, seal rings, and
backup rings. 9. Inspect seal and o-ring grooves in head for burrs and
13. Remove the rod from the holding fixture. Remove the sharp edges. Dress applicable surfaces as necessary.
cylinder head gland. Discard the o-rings, back-up rings,
10. Inspect cylinder head outside diameter for scoring or
rod seals, and wiper seals.
other damage and ovality and tapering. Replace as nec-
essary.

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

5-60 3121628
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 gland groove.

Figure 5-36. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

BACKUP
O-RING RING
ROD SEAL
WEAR RING
WIPER
SEAL

Figure 5-38. Cylinder Head Seal Installation

3121628 5-61
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston
cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the
ring into the applicable cylinder head gland groove. bushing and into the tapped holes in the piston.

PISTON

TAPERED
BUSHING
ROD
CAPSCREW

Figure 5-39. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head. Figure 5-41. Tapered Bushing Installation

11. Tighten the capscrews evenly and progressively in rota-

tion to 60 ft.lbs. (81 Nm).
12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4" in diameter) as follows;
a. Place the shaft against the cylinder rod and in
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 5-40. Installation of Head Seal Kit

4. Install washer ring onto rod, carefully install the head PISTON
gland on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the TAPERED
rod to the rod end, as applicable.
BUSHING
ROD
5. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to piston as possi-
ble.
CAPSCREW
6. Place a new o-ring and back-up rings in the inner piston
diameter groove.
BRASS SHAFT
7. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are not Figure 5-42. Seating the Tapered Bearing
damaged or dislodged.

8. Thread piston onto rod and install the tapered bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

9. Install the bolt in tapered bushing.

5-62 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

13. Rotate the capscrews evenly and progressively in 17. With barrel clamped securely, and while adequately sup-
rotation to 60 ft.lbs. (81 Nm). porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston loading o-ring and seal ring
14. Remove the cylinder rod from the holding fixture. are not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

Figure 5-43. Hydrolock Piston Seal Installation

15. Place new hydrolock seal and guidelock rings in the

outer piston diameter groove. (A tube, with I.D. slightly Figure 5-45. Rod Assembly Installation
larger than the O.D. of the piston is recommended to
install the solid seal). 19. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 300 ft.lbs. (407
GUIDELOCK Nm).
HYDROLOCK RING
SEAL RING WASHER
20. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the re-
BACKUP
RING installation of any holding valve or valves.
21. If applicable, install the cartridge-type holding valve and
fittings in the rod port block, using new o-rings as appli-
cable. Torque valves to 50-55 ft.lbs. (68-75 Nm).

Figure 5-44. Piston Seal Kit Installation

16. 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.

3121628 5-63
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Jib Lift Cylinder (800AJ 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.

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.

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.
Figure 5-47. Capscrew Removal
3. Remove the counterbalance holding valve and fittings
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.

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.

Figure 5-46. Cylinder Barrel Support

Figure 5-48. Cylinder Rod Support

5-64 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1683609 K
1001138792 A

1. Barrel 5. Rod 9. Piston 14. Piston Seal 19. Rod Seal

1A. Bushing 5A. Bushing 10. Tapered Bushing 15. O-ring 20. Wiper Seal
2. Head 6. Counterbalance Valve 11. Tube Spacer 16. Backup Ring 21. Wear Ring
3. Ring Washer 7. O-ring Plug 12. Setscrew 17. O-ring 22. Capscrew
4. Bolt 8. O-ring Plug 13. Lock Ring 18. Backup Ring

Figure 5-49. Jib Lift Cylinder (800AJ Only)

3121628 5-65
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. Inspect threaded portion of rod for excessive damage.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-50. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

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

5-66 3121628
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 gland groove.

Figure 5-51. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

O-RING BACKUP
WEAR RING RING
WIPER SEAL

ROD
SEAL

Figure 5-53. Cylinder Head Seal Installation

3121628 5-67
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 gland groove. Install a new wear
11. Assemble the tapered bushing loosely into the piston
ring into the applicable cylinder head gland 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 5-54. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head. Figure 5-56. 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 5-55. Installation of Head Seal Kit

6. Using suitable protection, clamp the cylinder rod in a

vise or similar holding fixture as close to piston as possi- CAPSCREW
ble.

7. Place a new o-ring and back-up rings in the inner piston BRASS SHAFT
diameter groove.
Figure 5-57. Seating the Tapered Bearing
8. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.

9. Thread piston onto rod until it abuts the spacer end and
install the tapered bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

5-68 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

14. Rotate the capscrews evenly and progressively in 18. With barrel clamped securely, and while adequately sup-
rotation to 5 ft.lbs. (7 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.
19. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

Figure 5-58. Hydrolock Piston Seal Installation

16. Place new hydrolock seal and guidelock rings in the

outer piston diameter groove. (A tube, with I.D. slightly Figure 5-60. Rod Assembly Installation
larger than the O.D. of the piston is recommended to
install the solid seal). 20. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 20 ft.lbs. (27 Nm).
HYDROLOCK
GUIDELOCK 21. After the cylinder has been reassembled, the rod should
RING SEAL O-RING BACKUP be pushed all the way in (fully retracted) prior to the re-
RING installation of any holding valve or valves.
22. If applicable, install the cartridge-type holding valve and
fittings in the rod port block, using new o-rings as appli-
cable. Torque valves to 50-55 ft.lbs. (68-75 Nm).

Figure 5-59. Piston Seal Kit Installation

17. 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.

3121628 5-69
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Main Boom Lift Cylinder 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.

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.

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.
Figure 5-62. Capscrew Removal
3. Remove the cartridge valve and fittings from the cylin-
der 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.

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.

Figure 5-61. Cylinder Barrel Support

Figure 5-63. Cylinder Rod Support

5-70 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1683547 L

1. Barrel 6. Head 11. Wiper 16. T-Seal 21. Check Valve

2. Rod 7. Washer Ring 12. Rod Seal 17. Seal 22. Plug
3. Piston 8. Bolt 13. O-ring 18. Bushing 23. Wear Ring
4. Tapered Bushing 9. O-ring 14. Backup Ring 19. Cartridge Valve 24. Bolt
5. O-ring Plug 10. Backup Ring 15. Wear Ring 20. Orifice

Figure 5-64. Main Boom Lift Cylinder

3121628 5-71
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. Inspect threaded portion of rod for excessive damage.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-65. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

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

5-72 3121628
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 gland groove.

Figure 5-66. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

BACKUP
RING ROD
O-RING SEAL
WEAR RING WIPER
SEAL

Figure 5-68. Cylinder Head Seal Installation

3121628 5-73
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

TAPERED
BUSHING
ROD
CAPSCREW

Figure 5-69. Wiper Seal Installation

Figure 5-71. Tapered Bushing Installation

3. Place a new o-ring and back-up seal in the applicable
outside diameter groove of the cylinder head.
10. Tighten the capscrews evenly and progressively in rota-
tion to 60 ft.lbs. (81 Nm).
11. 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 5-70. Installation of Head Seal Kit

PISTON
4. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod seals TAPERED
are not damaged or dislodged. Push the head along the BUSHING
rod to the rod end, as applicable. ROD

5. Using suitable protection, clamp the cylinder rod in a

vise or similar holding fixture as close to piston as possi-
ble. CAPSCREW

6. Place a new o-ring and back-up rings in the inner piston BRASS SHAFT
diameter groove.
Figure 5-72. Seating the Tapered Bearing
7. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.

8. Thread piston onto rod hand tight and install the

tapered bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

5-74 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

12. Rotate the capscrews evenly and progressively in

rotation to 60 ft.lbs. (81 Nm).
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
13. Remove the cylinder rod from the holding fixture. HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
14. Place new T-seal and wear rings in the outer piston CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
diameter groove. (A tube, with I.D. slightly larger than
the O.D. of the piston is recommended to install the 16. With barrel clamped securely, and while adequately sup-
solid seal). porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston loading o-ring and seal ring
are not damaged or dislodged.
WEAR RING T-SEAL BACKUP
SEAL 17. Continue pushing the rod into the barrel until the cylin-
RING
der head gland can be inserted into the barrel cylinder.

RING
WASHER

Figure 5-73. Piston Seal Kit Installation Figure 5-74. Rod Assembly Installation

15. Position the cylinder barrel in a suitable holding fixture. 18. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 300 ft.lbs. (407
Nm).
19. 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.
20. If applicable, install the cartridge-type holding valve and
fittings in the rod port block, using new o-rings as appli-
cable. Torque valves to 50-55 ft.lbs. (68-75 Nm).

3121628 5-75
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Tower Boom Lift Cylinder 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.

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.

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.
Figure 5-76. Capscrew Removal
3. Remove the cartridge valve and fittings from the cylin-
der 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.

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.

Figure 5-75. Cylinder Barrel Support

Figure 5-77. Cylinder Rod Support

5-76 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1683537 I

1. Barrel 6. O-ring Plug 10. O-ring 14. O-ring 18. Wiper

2. Head 7. Cartridge Valve 11. Lock Ring 15. Backup Ring 19. Tapered Bushing
3. Rod 8. Cartridge Valve 12. Seal 16. Wear Ring 20. Capscrew
4. Piston 9. Bushing 13. Lock Ring 17. Seal 21. Bolt
5. O-ring Plug

Figure 5-78. Tower Boom Lift Cylinder

3121628 5-77
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. Inspect threaded portion of rod for excessive damage.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-79. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

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

5-78 3121628
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 gland groove.

Figure 5-80. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

BACKUP
O-RING RING ROD SEAL
WEAR RING
WIPER SEAL

Figure 5-82. Cylinder Head Seal Installation

3121628 5-79
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

PISTON

TAPERED
BUSHING
ROD
CAPSCREW

Figure 5-83. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head. Figure 5-85. Tapered Bushing Installation

10. Tighten the capscrews evenly and progressively in rota-

tion to 30 ft.lbs. (41 Nm).
11. 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 5-84. Installation of Head Seal Kit

PISTON
4. Carefully install the head gland on the rod, ensuring that
the wiper and rod seals are not damaged or dislodged.
Push the head along the rod to the rod end, as applica- TAPERED
ble. BUSHING
ROD
5. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to piston as possi-
ble.
CAPSCREW
6. Place a new o-ring and back-up rings in the inner piston
diameter groove. BRASS SHAFT
7. Carefully thread the piston on the cylinder rod hand Figure 5-86. Seating the Tapered Bearing
tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.

8. Thread piston onto rod hand tight and install the

tapered bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

5-80 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

12. Rotate the capscrews evenly and progressively in 16. With barrel clamped securely, and while adequately sup-
rotation to 30 ft.lbs. (41 Nm). porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston loading o-ring and seal ring
13. Remove the cylinder rod from the holding fixture. are not damaged or dislodged.
17. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

Figure 5-87. Hydrolock Piston Seal Installation

14. Place new hydrolock seal and guidelock rings in the

outer piston diameter groove. (A tube, with I.D. slightly Figure 5-89. Rod Assembly Installation
larger than the O.D. of the piston is recommended to
install the solid seal). 18. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 300 ft.lbs. (407
GUIDELOCK HYDROLOCK Nm).
RING SEAL BACKUP 19. After the cylinder has been reassembled, the rod should
O-RING RING be pushed all the way in (fully retracted) prior to the re-
installation of any holding valve or valves.
20. If applicable, install the cartridge-type holding valve and
fittings in the rod port block, using new o-rings as appli-
cable. Torque valves to 50-55 ft.lbs. (68-75 Nm).

Figure 5-88. Piston Seal Kit Installation

15. 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.

3121628 5-81
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Master Cylinder (800A) 4. 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.

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.

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.
Figure 5-91. Capscrew Removal
3. Place the cylinder barrel into a suitable holding fixture.
5. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.

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.

6. With the barrel clamped securely, apply pressure to the

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

Figure 5-90. Cylinder Barrel Support

Figure 5-92. Cylinder Rod Support

5-82 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

* Torque 5 ft.lbs (7 Nm)

** Torque 20 ft.lbs (27 Nm)

1683608 I

1. Tapered Bushing 6. Barrel 10. Backup Ring 14. O-ring 18. Wiper
2. Bushing 7. Rod 11. O-ring 15. Washer Ring 19. Seal
3. Bushing 8. Piston 12. Wear Ring 16. Setscrew 20. T-Seal
4. Tube Spacer 9. Wear Ring 13. Backup Ring 17. Capscrew 21. Capscrew
5. Head

Figure 5-93. Master Cylinder (800A)

3121628 5-83
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

7. 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.
8. 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 loosen on the piston. other damage. If necessary, dress rod with Scotch Brite
9. Remove the bushing from the piston. or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive damage.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-94. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

10. Screw the piston counterclockwise, by hand, and 8. Inspect cylinder head inside diameter for scoring or
remove the piston from cylinder rod. other damage and for ovality and tapering. Replace as
necessary.
11. Remove and discard the piston o-rings, seal rings, and
backup rings. 9. Inspect seal and o-ring grooves in head for burrs and
12. Remove the setscrew from the piston spacer. Remove sharp edges. Dress applicable surfaces as necessary.
spacer from the rod.
10. Inspect cylinder head outside diameter for scoring or
13. Remove the rod from the holding fixture. Remove cap- other damage and ovality and tapering. Replace as nec-
screws and washer ring. Remove the cylinder head essary.
gland. Discard the o-rings, back-up rings, rod seals, and
wiper seals. 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

5-84 3121628
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 gland groove.

Figure 5-95. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

BACKUP ROD
O-RING RING SEAL WIPER
SEAL

Figure 5-97. Cylinder Head Seal Installation

3121628 5-85
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

PISTON

TAPERED
BUSHING
ROD
CAPSCREW

Figure 5-98. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head. Figure 5-100. Tapered Bushing Installation

11. Tighten the capscrews evenly and progressively in rota-

tion to 5 ft.lbs. (7 Nm).
12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4" in diameter) as follows;
a. Place the shaft against the cylinder rod and in
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 5-99. Installation of Head Seal Kit

4. Install washer ring onto rod, carefully install the head PISTON
gland on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the
rod to the rod end, as applicable. TAPERED
BUSHING
5. Using suitable protection, clamp the cylinder rod in a ROD
vise or similar holding fixture as close to piston as possi-
ble.
6. Place a new o-ring and back-up rings in the inner piston CAPSCREW
diameter groove.
7. Carefully slide piston spacer onto the cylinder rod. Install BRASS SHAFT
setscrew on the spacer.
Figure 5-101. Seating the Tapered Bearing
8. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.
9. Thread piston onto rod until it abuts the spacer end and
install the tapered bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

5-86 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

13. Rotate the capscrews evenly and progressively in

rotation to 5 ft.lbs. (7 Nm).
14. Remove the cylinder rod from the holding fixture.
15. Place new T-seal and wear 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).

WEAR O-RING
RING
BACKUP
T-SEAL RING
SPACER

Figure 5-103. Rod Assembly Installation

19. Apply JLG Threadlocker P/N 0100011 to the socket head

bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 20 ft.lbs. (27 Nm).
20. 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, If applicable.

Figure 5-102. Piston Seal Kit Installation

16. 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.

17. 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 o-ring and seal ring
are not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.

3121628 5-87
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Master Cylinder (800AJ) 4. 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.

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.

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. Figure 5-105. Capscrew Removal
3. Place the cylinder barrel into a suitable holding fixture.
5. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.

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.

6. With the barrel clamped securely, apply pressure to the

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

Figure 5-104. Cylinder Barrel Support

Figure 5-106. Cylinder Rod Support

5-88 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1683682 G
1001138793 A

1. Capscrew 5. Head 9. Wear Ring 13. Washer Ring 17. Rod Seal
2. Tapered Bushing 6. Barrel 10. Lock Ring 14. O-ring 18. Wiper
3. Bushing 7. Rod 11. Backup Ring 15. O-ring 19. Seal
4. Bushing 8. Piston 12. Backup Ring 16. Capscrew 20. Tube Spacer

Figure 5-107. Master Cylinder (800AJ)

3121628 5-89
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. Inspect threaded portion of rod for excessive damage.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-108. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

13. Remove the rod from the holding fixture. Remove the 10. Inspect cylinder head outside diameter for scoring or
cylinder head gland. Discard the o-rings, back-up rings, other damage and ovality and tapering. Replace as nec-
rod seals, and wiper seals. essary.

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

5-90 3121628
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 gland groove.

Figure 5-109. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

BACKUP
O-RING RING RED
SEAL

WEAR RING WIPER

SEAL

Figure 5-111. Cylinder Head Seal Installation

3121628 5-91
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

PISTON

TAPERED
BUSHING
ROD
CAPSCREW

Figure 5-112. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head. Figure 5-114. Tapered Bushing Installation

11. Tighten the capscrews evenly and progressively in rota-

tion to 9 ft.lbs. (12 Nm).
12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4" in diameter) as follows;
a. Place the shaft against the cylinder rod and in
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 5-113. Installation of Head Seal Kit

6. Place a new o-ring and back-up rings in the inner piston CAPSCREW
diameter groove.

7. Install piston spacer onto the cylinder rod.

BRASS SHAFT
Figure 5-115. Seating the Tapered Bearing
8. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.

9. Thread piston onto rod until it abuts the spacer end and
install the tapered bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

5-92 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

13. Rotate the capscrews evenly and progressively in 17. With barrel clamped securely, and while adequately sup-
rotation 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
14. Remove the cylinder rod from the holding fixture. are not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

Figure 5-116. Hydrolock Piston Seal Installation

15. Place new hydrolock seal and guidelock rings in the

outer piston diameter groove. (A tube, with I.D. slightly Figure 5-118. Rod Assembly Installation
larger than the O.D. of the piston is recommended to
install the solid seal). 19. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 35 ft.lbs. (50 Nm).
HYDROLOCK GUIDELOCK
SEAL RING BACKUP
O-RING RING

Figure 5-117. Piston Seal Kit Installation

16. 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.

3121628 5-93
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Steer Cylinder 4. Using a hook spanner, loosen the spanner nut retainer
and remove spanner nut from cylinder barrel.
DISASSEMBLY

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK

SURFACE IN A DIRT FREE WORK AREA. SPANNER NUT

1. Connect a suitable auxiliary hydraulic power source to

the cylinder port block fitting.
HOOK SPANNER

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

SLIGHTLY TO AVOID TRAPPING PRESSURE.
CYLINDER
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. Figure 5-120. Spanner Nut Removal
3. Place the cylinder barrel into a suitable holding fixture.
5. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.

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.

6. With the barrel clamped securely, apply pressure to the

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

Figure 5-119. Cylinder Barrel Support

Figure 5-121. Cylinder Rod Support

5-94 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1001150539 F

1. Piston 6. Barrel 11. Spanner Nut

2. Wear Ring 7. Head 12. Wiper Seal
3. Seal 8. O-ring 13. Rod Seal
4. Setscrew 9. Backup Ring 14. Bushing
5. Rod 10. C- Ring

Figure 5-122. Steer Cylinder

3121628 5-95
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

7. Using suitable protection, clamp the cylinder rod in a 11. If applicable, inspect rod and barrel bearings for signs of
vise or similar holding fixture as close to the piston as correct excessive wear or damage. Replace as necessary.
possible.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
8. Remove the setscrews from the piston. etc. to facilitate bearing installation.
9. Screw the piston counterclockwise, by hand, and b. Inspect steel bushing for wear or other damage. If
remove the piston from cylinder rod. steel bushing is worn or damaged, rod/barrel must
be replaced.
10. Remove and discard the piston seal and wear rings.
c. Lubricate inside of steel bushing prior to bearing
11. Remove the rod from the holding fixture. Remove the installation.
cylinder head gland. Discard the o-ring, back-up ring, c- d. Using an arbor of the correct size, carefully press the
ring, rod seal, and wiper seal. bearing into steel bushing.

Cleaning and Inspection NOTE: Install pin into the composite bearing dry. Lubrication is
not required with nickel plated pins and bearings.
1. Clean all parts thoroughly in an approved cleaning sol-
vent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
Figure 5-123. Composite Bearing Installation
5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
essary. 12. Inspect spacer for burrs and sharp edges. If necessary,
dress inside diameter surface with Scotch Brite or equiv-
6. Inspect threaded portion of barrel for damage. Dress alent.
threads as necessary.
13. If applicable, inspect port block fittings and holding
7. Inspect seal and o-ring grooves in piston for burrs and valve. Replace as necessary.
sharp edges. Dress applicable surfaces as necessary.
14. Inspect the oil ports for blockage or the presence of dirt
8. Inspect cylinder head inside diameter for scoring or or other foreign material. Repair as necessary.
other damage and for ovality and tapering. Replace as
necessary. 15. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
9. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
10. Inspect cylinder head outside diameter for scoring or
other damage and ovality and tapering. Replace as nec-
essary.

5-96 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli-
cable cylinder head gland groove. Install a new wear
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
ring into the applicable cylinder head gland groove.
seal kit is used. See your JLG Parts Manual.

NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.

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

applicable cylinder head gland groove.

Figure 5-126. Wiper Seal Installation

3. Place a new o-ring, back-up ring and c-ring in the appli-

cable outside diameter groove of the cylinder head.

CYLINDER
Figure 5-124. Rod Seal Installation HEAD
O-RING

RETAINER
WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. RING
IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

BACKUP BACKUP
RING O-R ING RING
C-R ING

ROD SEAL Figure 5-127. Installation of Head Seal Kit

WIPER
SEAL 4. Install spanner nut onto rod. Carefully install the head
gland on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the
rod to the rod end, as applicable.

5. Using suitable protection, clamp the cylinder rod in a

vise or similar holding fixture as close to piston as possi-
ble.

6. Carefully thread the piston on the cylinder rod hand

tight, ensuring that the o-ring and back-up rings are not
Figure 5-125. Cylinder Head Seal Installation damaged or dislodged.

7. Install the setscrews on the piston.

8. Remove the cylinder rod from the holding fixture.

3121628 5-97
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

9. Place new seal and wear ring in the outer piston diame-
ter grooves. (A tube, with I.D. slightly larger than the O.D.
of the piston is recommended to install the solid seal). 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.
WEAR
RING SEAL 11. With barrel clamped securely, and while adequately sup-
WEAR porting the rod, insert the piston end into the barrel cyl-
RING inder. Ensure that the piston loading o-ring and seal ring
are not damaged or dislodged.
12. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
13. Secure spanner nut into the cylinder barrel. Torque nut
to 325-390 ft.lbs. (441-529 Nm).
14. 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, if applica-
ble.

Figure 5-128. Piston Seal Kit Installation

10. Position the cylinder barrel in a suitable holding fixture.

5-98 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Main Boom Telescope Cylinder 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.

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.

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.
Figure 5-130. Capscrew Removal
3. Remove capscrews and valve assembly from the barrel
end. 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.

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.

Figure 5-129. Cylinder Barrel Support

Figure 5-131. Cylinder Rod Support

3121628 5-99
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1001188968 A
1001149284 A

1. Bolt 6. Head 11. Wear Ring 16. Capscrew 21. Wear Ring
2. Tapered Bushing 7. O-ring Plug 12. Backup Ring 17. Capscrew 22. Wiper
3. Tube Spacer 8. Wear Pad 13. Wear Ring 18. Bolt 23. T-Seal
4. Barrel 9. Piston 14. O-ring 19. Backup Ring 24. Valve Assembly
5. Rod 10. Plate 15. O-ring 20. Rod Seal

Figure 5-132. Main Boom Telescopic Cylinder

5-100 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. Inspect threaded portion of rod for excessive damage.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-133. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

11. Screw the piston counterclockwise, by hand, and 8. Inspect cylinder head inside diameter for scoring or
remove the piston from cylinder rod. other damage and for ovality and tapering. Replace as
necessary.
12. Remove and discard the piston o-rings, seal rings, and
backup rings. 9. Inspect seal and o-ring grooves in head for burrs and
13. Remove o-rings from piston spacer. Remove piston sharp edges. Dress applicable surfaces as necessary.
spacer from the rod.
10. Inspect cylinder head outside diameter for scoring or
14. Remove capscrews to remove plate and wear pads. other damage and ovality and tapering. Replace as nec-
essary.
15. Remove the rod from the holding fixture. Remove the
cylinder head gland. Discard the o-rings, back-up rings, 11. If applicable, inspect rod and barrel bearings for signs of
rod seals, and wiper seals. correct excessive wear or damage. Replace as necessary.

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

3121628 5-101
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 gland groove.

Figure 5-134. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.

IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

ROD WEAR
WEAR SEAL RING BACKUP
WIPER RING RING
SEAL O-RING

Figure 5-136. Cylinder Head Seal Installation

5-102 3121628
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 gland groove. Install a new wear end of rod must be free of oil.
ring into the applicable cylinder head gland groove.
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 5-137. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head.

Figure 5-139. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in rota-

tion 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;
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
Figure 5-138. Installation of Head Seal Kit between the capscrews.

4. Install plate on to the rod. Use capscrews to attach wear

pads on the plate.
5. Carefully install the head gland on the rod, ensuring that
the wiper and rod seals are not damaged or dislodged. PISTON
Push the head along the rod to the rod end, as applica-
ble. TAPERED
6. Install o-rings inside grooves of the piston spacer. Care- BUSHING
fully slide the spacer on the rod. ROD

7. Using suitable protection, clamp the cylinder rod in a

vise or similar holding fixture as close to piston as possi-
ble. CAPSCREW

8. Place a new o-ring and back-up rings in the inner piston

BRASS SHAFT
diameter groove.
Figure 5-140. Seating the Tapered Bearing
9. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.
10. Thread piston onto rod until it abuts the spacer end and
install the tapered bushing.

3121628 5-103
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

14. Rotate the capscrews evenly and progressively in

rotation to 9 ft.lbs. (12 Nm).
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
15. Remove the cylinder rod from the holding fixture. HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
16. Place new hydrolock seal and guidelock rings in the CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
outer piston diameter groove. (A tube, with I.D. slightly
larger than the O.D. of the piston is recommended to 18. With barrel clamped securely, and while adequately sup-
install the solid seal). porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston loading o-ring and seal ring
are not damaged or dislodged.
BACKUP WEAR RING 19. Continue pushing the rod into the barrel until the cylin-
O-RING RING O-RING SEAL der head gland can be inserted into the barrel cylinder.
T-SEAL

Figure 5-141. Piston Seal Kit Installation Figure 5-142. Rod Assembly Installation

17. Position the cylinder barrel in a suitable holding fixture. 20. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 35 ft.lbs. (50 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 valve assembly. Torque capscrews to 9 ft.lbs.
(12 Nm).

5-104 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Tower Boom Telescope Cylinder 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.

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.

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.
Figure 5-144. Capscrew Removal
3. If applicable, remove the cartridge-type holding valve
and fittings from the cylinder port block. Discard o- 6. Attach a suitable pulling device to the cylinder rod port
rings. block end or cylinder rod end, as applicable.

4. Place the cylinder barrel into a suitable holding fixture.

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.

Figure 5-143. Cylinder Barrel Support

Figure 5-145. Cylinder Rod Support

3121628 5-105
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5PSRVFGUMCT /N

1001188840 A

1. Barrel 8. Wiper 15. Seal 22. Support Pad 29. Capscrew

2. Rod 9. Seal 16. Lock Ring 23. Flatwasher 30. Clamp
3. Piston 10. O-ring 17. O-ring Plug 24. Bolt 31. Target Plate
4. Tapered Bushing 11. Backup Ring 18. O-ring Plug 25. Locknut 32. Target Plate
5. Bolt 12. Wear Ring 19. Head 26. Capscrew 33. O-ring
6. Tube Spacer 13. O-ring 20. Washer Ring 27. O-ring Plug
7. Setscrew 14. Backup Ring 21. Support Pad 28. Valve Assembly

Figure 5-146. Tower Boom Telescopic Cylinder

5-106 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

3. Inspect threaded portion of rod for excessive damage.

PISTON Dress threads as necessary.
TAPERED
BUSHING 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

CAPSCREW 5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
ROD
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

Figure 5-147. Tapered Bushing Removal sharp edges. Dress applicable surfaces as necessary.

11. Screw the piston counterclockwise, by hand, and 8. Inspect cylinder head inside diameter for scoring or
remove the piston from cylinder rod. other damage and for ovality and tapering. Replace as
necessary.
12. Remove and discard the piston o-rings, seal rings, and
backup rings. 9. Inspect seal and o-ring grooves in head for burrs and
13. Remove setscrew from the piston spacer. Remove sharp edges. Dress applicable surfaces as necessary.
spacer from the rod.
10. Inspect cylinder head outside diameter for scoring or
14. Remove the rod from the holding fixture. Remove cap- other damage and ovality and tapering. Replace as nec-
screws, target plate and washer ring. Remove the cylin- essary.
der head gland. Discard the o-rings, back-up rings, rod
seals, and wiper seals. 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

3121628 5-107
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 gland groove.

Figure 5-148. Composite Bearing Installation

12. Inspect spacer for burrs and sharp edges. If necessary,

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 ROD
WEAR O-RING SEAL
RING

WIPER
SEAL

Figure 5-150. Cylinder Head Seal Installation

5-108 3121628
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 gland groove. Install a new wear end of rod must be free of oil.
ring into the applicable cylinder head gland groove.
10. 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 5-151. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable

outside diameter groove of the cylinder head.

Figure 5-153. Tapered Bushing Installation

11. Tighten the capscrews evenly and progressively in rota-

4. Install washer ring onto rod, carefully install the head

gland on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the PISTON
rod to the rod end, as applicable.

5. Carefully slide the piston spacer on the rod. Install set- TAPERED
screw on the spacer. BUSHING
ROD
6. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to piston as possi-
ble.
CAPSCREW
7. Place a new o-ring and back-up rings in the inner piston
diameter groove. BRASS SHAFT
8. Carefully thread the piston on the cylinder rod hand Figure 5-154. Seating the Tapered Bearing
tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.

9. Thread piston onto rod until it abuts the spacer end and
install the tapered bushing.

3121628 5-109
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Figure 5-155. Hydrolock Piston Seal Installation

15. Place new hydrolock seal and guidelock rings in the

outer piston diameter groove. (A tube, with I.D. slightly Figure 5-157. Rod Assembly Installation
larger than the O.D. of the piston is recommended to
install the solid seal). 19. Apply JLG Threadlocker P/N 0100011 to the socket head
bolts and secure the cylinder head gland using the
washer ring and bolts. Torque bolts to 55 ft.lbs. (74 Nm).
HYDROLOCK
SEAL BACKUP 20. After the cylinder has been reassembled, the rod should
O-RING RING be pushed all the way in (fully retracted) prior to the re-
GUIDELOCK
RING installation of any holding valve or valves.
21. Install the valve assembly. Torque capscrews to 9 ft.lbs.
(12 Nm).

Figure 5-156. Piston Seal Kit Installation

16. 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.

5-110 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.4 CYLINDER REMOVAL AND INSTALLATION NOTE: The Main Boom weighs approximately 2528 lbs. (1147 kg).

Main Boom Telescope Cylinder Removal 4. Using a suitable sling and lifting device, secure the plat-
form end of the boom.
1. Place machine on a flat and level surface, with main
5. Place blocking under the main lift cylinder to prevent it
boom in the horizontal position.
from falling when the attaching hardware is removed.
2. Extend the boom to gain access to main fly boom tele-
6. Remove the hardware securing the main lift cylinder rod
scope cylinder rod end pin.
attach pin to the boom. Using a suitable brass drift, drive
3. Remove the hardware securing the telescope cylinder out the cylinder rod attach pin.
rod attach pin to the boom. Using a suitable brass drift,
drive out the cylinder rod attach pin.

Figure 5-158. Components Main Boom and Tower Boom

3121628 5-111
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

7. Using auxiliary power from ground controls, retract the

lift cylinder rod completely.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-
8. Remove hardware securing cover plate on the rear of CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS-
the main boom. Remove cover plate. TEM
9. Remove mounting hardware securing the telescope cyl-
inder barrel to the main base boom. 11. Tag and disconnect hydraulic lines from telescope cylin-
der. Use suitable container to retain any residual hydrau-
lic fluid. Cap hydraulic lines and ports.

NOTE: The Telescope Cylinder weighs approximately 522 lbs. (237

kg).

12. Secure the telescope cylinder with a suitable sling and

lifting device.
13. Carefully remove the telescope cylinder from the main
boom assembly and place in a suitable work area.

10. Using an external pump, extend the cylinder as far as

the hydraulic lines will allow to enable a lifting device to
be attached to the telescope cylinder.

5-112 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Main Boom Telescope Cylinder Installation 5. Remove the lifting device from the main telescope cylin-
der and retract the main telescope cylinder.
1. Using suitable lifting equipment, carefully insert the cyl-
6. Extend the main lift cylinder using the auxiliary control
inder into the boom assembly.
from the ground controls to align with rod end hole in
2. Carefully install main telescope cylinder rod pin through main base boom.
the fly boom and secure it with the retaining rings.
7. Carefully insert the main lift cylinder rod end pin thro-
ugh the base boom and install the mounting hardware.

3. Remove applicable hydraulic line and port caps and

properly connect the hydraulic lines to the telescope
cylinder. Ensure all hoses are correctly routed.
4. Carefully install the telescope cylinder barrel end sup- 8. Using all applicable safety precautions, operate the
port into mounting block in base boom and secure with boom functions. Check for proper operation and
blocks and torque the bolts to 35 ft.lbs. (48 Nm). Use JLG hydraulic leaks. Secure as necessary.
Threadlocker P/N 0100011 on bolts. Shim as necessary.
9. Check fluid level of hydraulic tank and adjust as neces-
sary.

3121628 5-113
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Main Lift Cylinder Removal

NOTE: The Main Boom weighs approximately 2528 lbs. (1147 kg).

1. Place the machine on a flat and level surface. Attach a

suitable lifting device and sling, sufficient to lift the main
boom assembly, to the approximate center of the main
boom assembly.
2. Place blocking under the cylinder to prevent it from fall-
ing when the attaching hardware is removed.
3. Remove the hardware securing the main lift cylinder rod
attach pin to the boom. Using a suitable brass drift, drive
out the cylinder rod attach pin.

9. Using a suitable brass drift drive out the barrel end

attach pin from the tower upright. Raise the main boom
assembly with the lifting device and sling to allow
enough space to remove the main lift cylinder from the
upright top.
10. Carefully lift the cylinder clear of the boom assembly
and lower to the ground or suitably supported work
area.
11. Lower the boom assembly to the stowed position.

4. Using auxiliary power from ground controls, retract the

lift cylinder rod completely.
5. Disconnect, cap, and tag the main boom lift cylinder
hydraulic lines and ports.
6. Attach a suitable lifting device and sling to the main lift
cylinder.
7. Remove hardware securing cover plate on the bottom
of the upright. Remove cover plate.

NOTE: The Main Lift Cylinder weighs approximately 445 lbs. (202
kg).

8. Use a suitable brass drift and hammer to remove main

lift cylinder barrel end pin from Upright.

5-114 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Main Lift Cylinder Installation 5. Using a suitable drift drive cylinder rod attach pin
through the aligned holes, taking care to align the
1. Lift the main boom to allow enough space to lower the grooved pin holes. Secure the pin in place and torque
main boom lift cylinder to align with pin mounting the bolt to 285 ft. lbs. (388 Nm). Use JLG Threadlocker
holes of the tower fly boom and barrel end of main lift P/N 0100011 on bolts.
cylinder.
2. Using a suitable brass drift, drive barrel end attach pin
through the mounting holes in the lift cylinder and the
tower fly boom. Secure in place with the pin and torque
the bolts to 35 ft. lbs. (48 Nm). Use Threadlocker P/N
0100011 on bolts.

6. Remove lifting device and sling. Activate hydraulic sys-

tem.
7. Using all applicable safety precautions, operate the
boom functions. Check for proper operation and
3. Remove cylinder port plugs and hydraulic line caps and
hydraulic leaks. Secure as necessary.
attach lines to cylinder ports as tagged during removal.
8. Check fluid level of hydraulic tank and adjust as neces-
4. Using auxiliary power extend the cylinder rod until the
sary.
attach pin hole aligns with those in the main boom.

3121628 5-115
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Upright Level Cylinder Removal NOTE: The Upright weighs approximately 1136 lbs. (515 kg).

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

1. Remove the Main Boom. Refer to Main Boom removal.

2. Tag and disconnect hydraulic lines to the main lift cylin-
der. Use suitable container to collect any residual
hydraulic fluid. Cap hydraulic lines and ports.
3. Remove mounting hardware from the main boom lift
cylinder barrel end. Use a suitable brass drift and
hammer to remove main lift cylinder barrel end pin from
Upright and remove main lift cylinder.
4. Disconnect the Upright Level Cylinder as follows: 5. Before extending the tower boom, support the tower
boom from the bottom.
a. Use a suitable lifting device to support the Upright.
6. Extend the Tower Boom to get access to the Upright
b. Remove mounting hardware securing the Upright
level cylinder rod end pin by using an external auxiliary
Level Cylinder to the upright. Use a suitable brass
pump.
drift and hammer to remove upright level cylinder
barrel end pin from upright and disconnect the 7. Tag, disconnect and cap the hydraulic lines of the
upright level cylinder from the Upright. Upright level Cylinder barrel.
8. Attach a suitable lifting device to support the Upright
Level Cylinder.
9. Remove mounting hardware from the upright level cyl-
inder rod end and remove the pin.

MAIN BOOM
TELESCOPE CYLINDER

10. Remove the Upright Level Cylinder from the Tower Fly
UPRIGHT Boom. Place the Upright level Cylinder in a suitable work
area.

MAIN BOOM UPRIGHT LEVEL

LIFT CYLINDER CYILINDER
MAIN LIFT CYLINDER UPRIGHT LEVEL
BARREL END PIN CYILINDER BARREL END PIN

5-116 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Upright Level Cylinder Installation 9. Use all applicable safety precautions, operate the boom
functions. Check for proper operation and hydraulic
1. Put the leveling cylinder in position in the tower boom, leaks.
align holes in the tower boom and leveling cylinder rod 10. Check fluid level of hydraulic tank and add fluid, if
end. required.

2. Secure the leveling cylinder rod end pin to tower boom Tower Boom Lift Cylinder Removal
and torque the bolts to 35 ft. lbs. (48 Nm). Use JLG
Threadlocker P/N 0100011 on bolts. 1. Place machine on a flat and level surface. Place the main
boom in a horizontal position with the telescope cylin-
der fully retracted. Place the tower boom in a fully ele-
vated and fully retracted position.

NOTE: The Main Boom weighs approximately 2528 lbs. (1147 kg),
Upright weighs approximately 1136 lbs. (515 kg) & Tower
Boom weighs approximately 2944 lbs. (1335 kg).

2. Support the main boom, upright and tower boom with

adequate overhead crane.

NOTE: The Tower lift cylinder weighs approximately 544 lbs. (247
kg).

3. Adequately support the tower lift cylinder.

4. Remove mounting hardware securing the lift cylinder
rod pin to the tower boom. Using a suitable brass drift,
3. Remove Cylinder Port plugs and hydraulic line caps. drive out the tower lift cylinder rod attach pin.
Properly attach lines to Cylinder ports as tagged during
removal.

4. Use all applicable safety precautions, operate the lifting

device to move upright assembly into proper position.

5. Align holes in upright and barrel end of level cylinder.

Use a suitable rubber mallet to install level barrel end
pin. Secure pin and torque the bolt 285 ft. lbs. (388 Nm).
Use JLG Threadlocker P/N 0100011 on bolts.

5. Using all applicable safety precautions, operate auxiliary

power, activate tower lift down and fully retract lift cylin-
der.
6. Tag, disconnect, and cap the tower lift cylinder hydraulic
lines and ports.

6. Install Main Lift Cylinder.

7. Install Main Boom. Refer to Main Boom installation.

8. Remove hydraulic line caps and attach all the hydraulic

and electrical lines as tagged during removal.

3121628 5-117
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

7. Remove mounting hardware securing the tower lift cyl- 4. Using an appropriate brass drift, drive the tower lift cyl-
inder barrel pin to the turntable. Using a suitable brass inder rod end attach pin through the aligned bushings.
drift, drive out the tower lift cylinder barrel pin. Secure pin and torque the bolt 35 ft. lbs. (48 Nm). Use
JLG Threadlocker P/N 0100011 on bolts.

8. Carefully remove the tower lift cylinder from turntable.

Place in a suitable work area. 5. Remove main boom support and lifting device support-
ing the upright.
Tower Boom Lift Cylinder Installation
6. Using all applicable safety precautions, operate the
1. Support the main boom and tower boom, place the boom functions. Check for proper operation and
tower lift cylinder on the turntable and align the holes. hydraulic leaks. Secure as necessary.
Install the cylinder barrel pin and torque the bolt to 285
ft. lbs. (388 Nm). Use JLG Threadlocker P/N 0100011 on 7. Check fluid level of hydraulic tank and add fluid, if
bolts. required.

2. Remove caps from cylinder hydraulic lines properly and

install lines to cylinder as previously tagged.
3. Using auxiliary power, activate tower lift function and
extend cylinder rod until the cylinder rod bushing aligns
with bushings on boom.

5-118 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Tower Telescope Cylinder Removal Platform (Slave) Cylinder Removal

1. Place machine on flat and level surface. 1. Place the machine on a flat surface and lower the main
boom and tower boom to the lowest position.
2. Remove the tower telescope cylinder rod end trunion
hardware. 2. Using auxiliary power, retract the platform (slave) cylin-
der rod completely.
3. Using an external pump, extend the tower telescope cyl-
inder as far enough to attach the lifting device. NOTE: Step 3 is applicable for 800AJ models only.
4. Tag, disconnect and cap hydraulic hoses to Tower Tele-
3. Raise the jib to gain access to the Platform (Slave) Cylin-
scope Cylinder. Plug cylinder ports. Remove the hoses.
der piston end Pin.
NOTE: The Tower Telescope Cylinder weighs approximately 233
NOTE: The Platform (Slave) Cylinder weighs approximately 68 lbs
lbs. (105kg).
(31 kg).
5. Properly secure the Tower Telescope Cylinder by using a
4. Using a suitable lifting device, properly secure the plat-
suitable sling or support.
form to prevent the platform from tilting backward or
6. Remove the tower telescope cylinder barrel end trunion forward during removal of the platform (slave) cylinder.
hardware.
5. Tag and disconnect the platform (slave) cylinder hydrau-
7. Carefully remove the Tower Telescope Cylinder from the lic hoses. Cap hoses to prevent the hydraulic system
Boom. Place cylinder on a suitable work area. from being contaminated.
6. Properly secure the platform (slave) cylinder by using a
Tower Telescope Cylinder Installation suitable sling or support.
1. Slide the telescope cylinder into the boom, aligning the
NOTE: The Platform (Slave) cylinder weighs approximately 68 lbs
cylinder port block end with slotted holes in Base Boom.
(31 kg).
2. Secure the telescope cylinder barrel end to the fly boom
by using retaining plate and torque the bolts 35 ft. lbs. 7. Remove the platform (slave) cylinder pin retaining hard-
(48Nm). Use JLG Threadlocker P/N 0100011 on bolts. ware. Using a suitable brass drift, remove the platform
(slave) cylinder pins from the rod and barrel ends.
3. Secure telescope cylinder rod end and torque the bolts
to 35 ft. lbs. (48 Nm). Use JLG Threadlocker
P/N 0100011 on bolts.
4. Remove caps and plugs from hydraulic lines and ports.
Properly connect hydraulic lines to cylinder. Reinstall
cover plate.
5. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.
6. Check fluid level of hydraulic tank and add fluid, if
required.

8. Carefully remove the platform (slave) cylinder.

9. Clean and inspect the cylinder pins and retaining hard-
ware for reuse. Replace if necessary.

3121628 5-119
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Platform (Slave) Cylinder Installation 5.5 HYDRAULIC PUMP W/HAYES PUMP DRIVE
1. Remove caps from the hydraulic hoses and attach hoses COUPLING LUBRICATION
to the proper cylinder ports. Any time pump or pump drive coupling is removed coat,
NOTE: The Platform (Slave) cylinder weighs approximately 68 lbs pump and drive coupling splines with Lithium Soap Base
(31 kg). Grease (TEXACO CODE 1912 OR EQUIVALENT ) coupling is
greased prior to assembly.
2. Use suitable slings or support to position the Platform
(Slave) cylinder in place. Align barrel end mounting 5.6 PRESSURE SETTING PROCEDURES
holes with the holes in main fly boom. Cold temperatures have a significant impact on pressure read-
3. Use suitable mallet to install the barrel end attach pin ings. JLG Industries Inc. recommends operating the machine
and torque the bolts to 35 ft. lbs. (48 Nm). until the hydraulic system has warmed to normal operating
temperatures prior to checking pressures. JLG Industries Inc.
4. Extend the platform (slave) cylinder rod until the rod also recommends the use of a calibrated gauge. Pressure read-
attach pin hole aligns with holes in the platform pivot. ings are acceptable if they are within ± 5% of specified pres-
Use suitable mallet and keeper to install the rod end pin. sures.

To ensure all pressures are set correctly, the following proce-

dures must be followed in order.
1. All applicable steps must be followed.
2. Set up of the function pump.
3. Adjustments Made at the Main Valve Block.
4. Adjustments Made at the Platform Valve Block

5. Remove lifting device from the platform (slave) cylinder

and support from the platform.
6. Use all applicable safety precautions, start the machine
from the ground control. Fully raise and lower the main
boom through several cycles to bleed the platform level
hydraulic circuit.
7. Check for proper operation and hydraulic leaks.
8. Check the fluid level of hydraulic tank. Fill the tank, if
required.

5-120 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Set Up the Function Pump wise to decrease. The pressure should read between
400-440 psi (27.58-30.34 bar).
(the pump that is mounted on the back of the drive pump).
2. Set High pressure relief
1. Set Stand by pressure or load sense pressure

Gauge port M2
Gauge port M2 0-300 bar [0-5000 psi]
0-300 bar [0-5000 psi]
9/16-18 M14
9/16-18 M14
1/4 in 6mm
1/4 in 6mm
34-68 N• m 27-35 N• m
34-68 N•m 27-35 N•m [25-50 lbf• ft] [20-26 lbf• ft]
[25-50 lbf•ft] [20-26 lbf•ft] LS/remote PC
signal port X

Case drain port L1

LS adjustment screw
0-10 bar [0-100 psi] PC adjustment screw Case drain port L1
6mm
7/8-14 6mm 0-10 bar [0-100 psi]
LS set screw
4mm 3/8 in PC set screw 7/8-14

7-11 N•m [6-8 lbf•ft] 54-136 N•m 4mm 3/8 in

[40-100 lbf•ft] 7-11 N•m [6-8 lbf•ft] 54-136 N• m
[40-100 lbf• ft]
Figure 5-159. Load Sensing Control Adjustment
Figure 5-160. Pressure Compensation Control
a. Install a low pressure gauge at port “MP” of the Adjustment
main valve block. A gauge capable of reading 400
psi (27.58 bar). a. Install a high pressure gauge at the “MP” port of the
b. Remove the wires from the main boom lift, valve main valve block.
coils on the main boom main valve block. Start the b. Activate main boom telescope in. The gauge should
engine and activate main lift up or down. Hold the read 2600 psi (179 bar).
function for 10-15 seconds. This bleeds the air out of
the sense line. The gauge should be reading c. To make an adjustment to this pressure, go back to
between 400-440 psi (28-30 bar). the engine compartment to the function pump. The
c. To make an adjustment to this pressure, go to the high pressure relief adjustment is the lower one of
engine compartment, locate the function pump. the (2) on the compensator. To adjust this, a 4 mm
There are (2) adjustments at the top of the pump. and 6 mm Allen wrench will be needed. The adjust-
They are located on the pump compensator which ment screw is facing the front of the pump, or
has (4) bolts mounting it to the pump. The stand by toward the engine.
adjustment is at the top. d. First, using the 4 mm wrench, loosen the setscrew
d. To adjust this, a 4 mm and 6 mm Allen wrench will on the side of the compensator (facing you) which is
be needed. The adjustment screw is facing the front in line with the adjustment screw. This is a jam nut
of the pump, or toward the engine. First, using the 4 screw which holds the main adjustment from turn-
mm wrench, loosen the setscrew on the side of the ing. Loosen it 1 turn.
compensator (facing you) which is in line with the
adjustment screw. This is a jam nut screw which e. Then using the 6 mm wrench adjust the main
holds the main adjustment from turning. Loosen it 1 adjustment clockwise to increase or counter-clock-
turn. wise to decrease. This is the maximum relief pres-
sure for all functions governed by this pump.
e. Then using the 6 mm wrench adjust the main
adjustment clockwise to increase or counter-clock-

3121628 5-121
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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Figure 5-161. Main Control Valve Pressure Adjustments

5-122 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

This page left blank intentionally.

3121628 5-123
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

1. Rear Steer Right Solenoid 4. Shuttle Valve 7. Main Tele In Solenoid 9. Tower Tele In Solenoid
2. Front Steer Right Solenoid 5. Swing left Solenoid 8. Tower Lift Up Solenoid 10. Tower Tele Relief
3. Front Steer left Solenoid 6. Main Lift Down Solenoid

Figure 5-162. Main Valve Components - Sheet 1 of 2

5-124 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

1. Rear Steer Left Solenoid 4. Main Boom Lift Down Solenoid 7. Main Lift Down Solenoid 10. Tower Lift Down Solenoid
2. Front Steer Left Solenoid 5. Swing Left or Right Relief 8. Flow Control Valve 11. Tower Tele Out Solenoid
3. Front Steer Right Relief 6. Swing Right Solenoid 9. Main Tele Out Solenoid

Figure 5-163. Main Valve Components - Sheet 2 of 2

3121628 5-125
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

$
(

Ft. Lbs. Nm NOTE: When removing control valves from the manifold, it is important to observe the tag on the
face of the valve, as the new valve must be installed with the tag facing the same way as
A 25-30 33.8-40.6 the tag on the valve that was removed. The bolt pattern on the control valves is not sym-
B 25.1-30.2 34-41 metrical, so if the bolts seem difficult to turn when installing, it would indicate the valve is
C 121.1-132.8 164.2-180 upside down and forcing the bolts will result in cross-threading. Check the tag, and if neces-
D 28.8-37.6 39-51 sary, rotate the valve 180 degrees.
E 30-35 40.6-47.5

Figure 5-164. Valve Component Torque - Sheet 1 of 2

5-126 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Ft. Lbs. Nm NOTE: When removing control valves from the manifold, it is important to observe the tag on the
face of the valve, as the new valve must be installed with the tag facing the same way as
A 25-30 33.8-40.6 the tag on the valve that was removed. The bolt pattern on the control valves is not sym-
metrical, so if the bolts seem difficult to turn when installing, it would indicate the valve is
upside down and forcing the bolts will result in cross-threading. Check the tag, and if neces-
sary, rotate the valve 180 degrees.

Figure 5-165. Valve Component Torque - Sheet 2 of 2

3121628 5-127
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

LEVEL UP RELIEF VALVE

LEVEL DOWN RELIEF VALVE Adjust to 1800 PSI
Adjust to 2800 PSI (124 bar)
(193 bar)

800A

LEVEL UP RELIEF VALVE

LEVEL DOWN RELIEF VALVE Adjust to 1800 PSI
Adjust to 2800 PSI (124 bar)
(193 bar)

JIB RELIEF VALVE

Adjust to 1500 PSI
(103 bar)

800AJ

Figure 5-166. Platform Control Valve Pressure Adjustments

5-128 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

"
"

"
#
"

"
" #
#
" "

A. 20 ft.lbs (27 Nm)

B. 13 ft.lbs (17 Nm)
C. 5 ft.lbs (7 Nm)

$ $
"+

Figure 5-167. Platform Control Valve Component Torque

3121628 5-129
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Adjustments Made at the Main Valve Block TOWER TELESCOPE OUT

MAIN LIFT DOWN 1. Install a high pressure gauge at gauge port “M2”
located on the right side of the valve block, at the bot-
1. Install a high pressure gauge at the “MP” port of the tom.
main valve block.
2. Activate tower telescope out, the gauge should read
2. Activate main boom lift down. The gauge should read 2200 psi (152 bar). This can be done with the tower lift
1400 psi (97 bar). down or up. If the tower lift is up, you must run tower
telescope out to the end of stroke.
3. The adjustment cartridge is located to the right of port
#11. Turn clockwise to increase, counterclockwise to 3. The tower telescope out relief valve is located on the left
decrease. side, at the bottom next to port #2. Turn clockwise to
increase, counterclockwise to decrease.
SWING
Adjustments Made at the Platform Valve Block
NOTE: left and right are done with one adjustment.
PLATFORM LEVEL UP
1. Install a high pressure gauge at the “MP” port of the
main valve block. Lock the turn-table lock pin. 1. Install a high pressure gauge at the gauge port “M1” of
the platform valve. There is pressure trapped at this test
2. Activate swing, the gauge should read 1400 psi (97 port.
bar). The adjustment cartridge is located on the right
side of the block, right above “MP”. 2. To release this Pressure, activate level down to the end
of stroke (the pressure in the up side goes to 0). This will
3. Turn clockwise to increase, and counterclockwise to allow you to snap a gauge on at this port.
decrease.
3. Activate level up to the end of stroke, the gauge should
2 WHEEL STEER read 2600psi (179 bar). The level up relief valve is located
next to the port “M1”.
1. Install a high pressure gauge at the “MS” port of the 4. Turn clockwise to increase, and counterclockwise to
main valve block. Activate steer left or right. The gauge decrease.
should read 1800 psi (124 bar) (2-wheel steer) both
directions. PLATFORM LEVEL UP
2. One relief cartridge is located on the right side of the
1. Install a high pressure gauge at the gauge port “M1” of
block, above port “MS”. The other one is located on the
the platform valve.
left side next to port #15.
2. The gauge port has a 12" hose plumbed into it for easy
3. Turn clockwise to increase, and counterclockwise to
access. Activate jib down, you should read 1200 psi (82
decrease.
bar). The down relief valve is located on the right side of
the jib block toward the back. Turn clockwise to
4 WHEEL STEER
increase, and counterclockwise to decrease.
1. Install a high pressure gauge at the “MS” port of the
main valve block.

2. Activate front wheel steer left or right. One relief car-

tridge is located on the right side of the block, above
port “MS”. The other one is located on the left side next
to port #15.Turn clockwise to increase, counterclockwise
to decrease.

3. Adjust 2350 psi (162 bar) front steer. Remove the coil
from the front wheel steer directional valve.

4. Activate 4 wheel steer. Adjust the rear wheel steer reliefs

to 2250 psi (155 bar). Those reliefs are located on the
both sides of the 4-wheel steer block bolted on the top
of the main control valve.|
Figure 5-168. Articulating Jib Boom Pressure adjust.

5-130 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

4 WHEEL STEER (IF EQUIPPED) NOTE: If a pump or motor is being replaced due to internal dam-
age, the remaining units (pump or motors) need to be
1. At the platform console using the steer select switch inspected for damage and contamination, and the entire
activate “4 wheel steer”. hydraulic system will need to be flushed and the fluid
replaced. Failure to do so may cause considerable damage
2. Install a pressure gauge in port "G" on the control valve. to the entire system.
3. With the aid of an assistant, activate steer left and right,
adjust front steer relief valve to 2500 psi (172.4 bar). The inlet line leading from the reservoir to the pump must be
This pressure only affects the front axle. filled prior to start-up. Check the inlet line for property tight-
ened fittings and make sure it is free of restrictions and air
4. At the platform console using the steer select switch leaks.
activate “crab” or “coordinated” steer.
NOTE: In most cases, the reservoir is above the pump inlet so that
5. At the main control valve block disconnect the wire din the pressure head created by the higher oil level helps to
connectors on the front steer valve. When steer is acti- keep the inlet pressures within an acceptable range and
vated only the rear steer will work. prevent high vacuum levels. However, due to hose routing
or low reservoir locations, there may be air trapped within
6. Install a pressure gauge in port "G" on the control valve.
this line. It is important to assure that the air is bled from
7. With the aid of an assistant, activate steer left and right, this line. This can be accomplished by loosening the hose at
adjust rear steer relief valve to 2500 psi (172 bar) Read- the fitting closest the pump. When oil begins to flow, the
ing at the valve bank. 2500 psi (172 bar) will give you line is full, the air has been purged, and the fitting can be
2000 psi (138 bar) at the cylinders. retightened to its specified torque. If the tank needs to be
pressurized in order to start the flow of oil, a vacuum read-
8. Re-connect the front steer din connectors at the valve ing should be taken at the inlet of the pump during opera-
bank. tion in order to verify that the pump is not being asked to
draw an inlet vacuum higher than it is capable of.
5.7 HYDRAULIC COMPONENT START-UP
PROCEDURES AND RECOMMENDATIONS Be certain to fill the pump and/or motor housing with clean
hydraulic fluid prior to start up. Fill the housing by pouring fil-
From a hydrostatic component standpoint, the goal at system tered oil into the main case drain port.
start up is to put into functional operation, the hydrostatic sys-
tem in such a way as to preserve the designed life span of the NOTE: It is highly recommended to use the highest possible case
system. The following start-up procedure should be adhered drain port, this ensures that the housing contains as much
to whenever a new pump or motor is initially installed into a oil as possible and offers the greatest amount of lubrica-
machine, or a system is restarted after either a pump or motor tion to the internal components.
has been removed and/or replaced.
NOTE: In initial start-up conditions, it may be convenient to fill the
housing, just prior to installing the case drain line. Compo-
nent, (especially motor), location may be such that access
THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED
to the case drain port after installation is not realistic.
(WHEELS RAISED OFF THE GROUND, WORK FUNCTIONS DISCONNECTED, ETC.).
WHILE PERFORMING THE PROCEDURE IN ORDER TO PREVENT INJURY. TAKE
NECESSARY SAFETY PRECAUTIONS BEFORE MOVING THE VEHICLE/MACHINE. NOTE: Make certain that the oil being used to fill the component
housing is as clean as possible, and store the fill container
in such a way as to prevent it from becoming contami-
Prior to installing the pump and/or motor, inspect the unit(s)
nated.
for damage that may have been incurred during shipping and
handling. Make certain that all system components (reservoir,
hoses, valves, fittings, heat exchanger, etc.) are clean prior to Install a 60 bar (or 1000 psi) pressure gauge in the charge pres-
filling with fluid. sure gauge port in order to monitor the charge pressure dur-
ing start-up.
Fill the reservoir with recommended hydraulic fluid. This fluid
should be passed through a 10 micron (nominal, no bypass) It is recommended that the external control input signal, (elec-
filter prior to entering the reservoir. The use of contaminated trical connections for EDC), be disconnected at the pump con-
fluid will cause damage to the components, which may result trol until after initial start-up. This will ensure that the pump
in unexpected vehicle/machine movement. remains in its neutral position.

3121628 5-131
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

b. Determine if the hydraulic oil tank sight level gauge

is higher than all hydraulic hope loops and the rout-
DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSITION (0 ings between the hydraulic tanks and the hydraulic
DEGREES SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PREVENT MACHINE drive pump assembly.
MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START-UP. c. If sight level gauge is the highest hydraulic oil level
point, proceed to step 3.
"Jog" or slowly rotate the engine until charge pressure starts to d. if sight level gauge is NOT the highest oil level point,
rise. Start the engine and run at the lowest possible RPM until low pressure air may need to applied to the hydrau-
charge pressure has been established. Excess air should be lic oil tank (fill cap via air regulator) in conjunction
bled from the system lines as close to the motors as possible. with step 4 to get hydraulic oil to move over the air
NOTE: With the engine on low idle, "crack", (loosen-don't remove), locks created by these high spots.
the system lines at the motor(s). Continue to run the engine 3. If the machine is to be equipped with a hydraulic oil
at low idle and tighten the system lines as soon as oil is cooler option.
observed to leak from them. When oil is observed to "leak"
at the motor the line is full, the air has been purged, and a. Determine if there is hydraulic “tee” fittings installed
the system hoses should be retightened to their specified at the hydraulic drive pump that has a “cap” fittings
torque. attached to it. (this will generally be at or near the
top of the hydraulic drive pump body). This “cap” fit-
Once charge pressure has been established, increase speed to ting is to be used to manually fill the hydraulic drive
normal operating RPM. Charge pressure should be as indi- pump case.
cated in the pump model code. If charge pressure is inade- b. Remove “cap” fitting.
quate, shut down and determine the cause for improper c. Fill hydraulic drive pump case with hydraulic oil.
pressure.
d. Attach and torque “cap” fitting.
e. Pre-filling of hydraulic drive pump w/oil cooler
option is complete. (Step #4 can be omitted at this
INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR'S ABILITY TO point).
CONTROL THE MACHINE.
4. If machine is NOT equipped with a hydraulic oil cooler
option.
Shut down the engine and connect the external control input
signal. Also reconnect the machine function(s), if discon- a. Locate a case access port on the hydraulic drive
nected earlier. Start the engine, checking to be certain the pump. Preferably one located on at or near the top
pump remains in neutral. With the engine at normal operating or under sides of the pump.
RPM, slowly check for forward and reverse machine operation. b. Using the proper wrench, Remove the O-ring plug
to allow air to escape from the hydraulic drive pump
Charge pressure may slightly decrease during forward or
case.
reverse operation. Continue to cycle slowly between forward
and reverse for at least five minutes. c. Hydraulic oil will flow by gravity from the hydraulic
tank to the drive pump.
Shut down engine, remove gauges, and plug ports. Check res-
d. The pump is full, when hydraulic oil starts to flow
ervoir level and add filtered fluid if needed.
out of this port.
The machine is now ready for operation. e. Install the O-ring plug and torque.
5. Pre-filled of the hydraulic drive pump is complete.
5.8 HYDRAULIC DRIVE PUMP PRE-FILL PROCEDURE

HYDRAULIC DRIVE PUMP MUST BE PRE-FILLED BEFORE

STARTING THE ENGINE. FAILURE TO DO SO CAN CAUSE
PREMATURE FAILURE OF THE PUMP.

1. Fill the hydraulic reservoir.

2. Determine if the hydraulic oil tank sight level gauge is

higher than other hydraulic components.

a. Determine if the hydraulic oil tank sight level gauge

is higher than the hydraulic drive pump assembly.

5-132 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.9 FUNCTION PUMP Installation

Removal NOTE: The function pump weighs approximately 35 lbs. (16 kg).

1. Place machine on level surface and allow the engine and 1. Use a suitable device to support the function pump.
system fluids to cool.
2. If applicable, install the o-ring on to the function pump.
2. Properly relieve any pressure in hydraulic system.
3. Align and install the function pump to the drive pump.
3. Tag and disconnect the hydraulic lines and fittings from
NOTE: Make sure that the pump shaft is properly aligned.
the function pump. Use a suitable container to retain
any residual hydraulic fluid. Immediately cap lines and
ports.

NOTE: The function pump weighs approximately 35 lbs. (16 kg). INCORRECT SHAFT ALIGNMENT MAY RESULT IN DAMAGE TO DRIVE SHAFT,
BEARINGS, OR SEAL WHICH CAN CAUSE EXTERNAL OIL LEAKAGE.
4. Use a suitable device to support the function pump.
4. Secure function pump with two bolts and washers as
5. Remove two bolts and washers attaching the function shown. Apply JLG Threadlocker P/N 0100011 to the
pump to the drive pump. Remove function pump from bolts before installation. Torque bolts to 85 ft. lbs.
the machine as shown. (116Nm).

6. Remove and discard o-ring, if applicable. 5. Remove tag and reconnect the hydraulic lines to the
7. Place function pump in the clean work area. function pump.
6. Reconnect the battery power and make sure for proper
working of the function pump.

3121628 5-133
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-33. Symbols Used

Symbol Meaning Symbol Meaning

Non-reusable part, use a new Inspect for wear or damage
part
Option - either part may exist Note correct orientation

Internal hex head Torque specification

O-ring boss port Pull out with tool - press fit

Lubricate with hydraulic Cover splines with installa-

fluid tion sleeve
Apply grease /petroleum Pressure measurement /
jelly gauge location or specifica-
tion
The symbols above can be found in the pump illustrations. The legend above is provided to
define each symbol and explain its purpose.

Case drain port L1

SAE J1926/1,0.875-14

Inlet port S System gauge po rt M2 Outlet port B

SAE J1926/1,0.4375-20 SAE J1926/1,1.3125-12
Case drain port L2 SAE J1926/1,1.875-12
SAE J1926/1,0.875-14

Figure 5-170. Gauge Port Locations

Table 5-34. Gauge and Port information

Port Purpose Range of Pump Fitting
M2 System pressure 0-5000 psi [0-300 bar] 7/16 - 20 o-ring fitting
M4 Servo pressure 0-5000 psi [0-300 bar] 7/16 - 20 o-ring fitting
L1,L2 Case pressure 0-100 psi [0-10 bar] 7/8 - 14 o-ring fitting
X1 Load Sense signal 0-5000 psi [0-300 bar] 7/16 - 20 o-ring fitting (tee into Load Sense signal line)

5-134 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Initial Start-up Procedures 6. While watching the pressure gauge installed at M2, jog
the engine or run at the lowest possible speed until sys-
Follow this procedure when starting-up a new pump or when tem pressure builds to normal levels (minimum 160 psi
the pump has been removed. [11 bar]). Once system pressure is established, increase
1. Install the pump on the engine. Ensure the pump shaft is to full operating speed. If system pressure is not main-
properly aligned. tained, shutdown the engine, determine cause, and take
corrective action. Refer to Troubleshooting.
7. Operate the hydraulic system for at least fifteen minutes
INCORRECT SHAFT ALIGNMENT MAY RESULT IN DAMAGE TO DRIVE SHAFT, under light load conditions.
BEARINGS, OR SEAL WHICH CAN CAUSE EXTERNAL OIL LEAKAGE. 8. Check and adjust control settings as necessary after
installation. Refer to Adjustments.
2. Fill the main pump housing with clean hydraulic fluid.
Pour filtered oil directly into the main most case drain 9. Shut down the engine and remove the pressure gauge.
port. Replace plug at port M2.

3. Fill the inlet line leading from the pump to the reservoir. 10. Check the fluid level in the reservoir; add clean filtered
Check the inlet line for properly tightened fittings and fluid if necessary. The pump is now ready for operation.
be certain it is free of restrictions and air leaks.
4. To ensure the pump stays filled with oil, install the case
drain line in the main most case drain port.
5. Install a gauge at port M2 to monitor system pressure
during start up.

3121628 5-135
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Troubleshooting

Table 5-35. Excessive Noise and/ or Vibration

Item Description Action

Check fluid level in reservoir. Insufficient hydraulic fluid will cause cavitation. Fill the reservoir to proper level.

Check for air in system. Air in system will cause noisy, erratic control. Purge air and tighten fittings. Check inlet for leaks.

Check pump inlet pressure / vacuum. Improper inlet conditions will cause erratic behavior and Correct pump inlet pressure / vacuum conditions. Refer to
low output flow. Hydraulic parameters.

Inspect shaft couplings. A loose or incorrect shaft coupling will cause excessive Repair or replace coupling and ensure that correct coupling
noise and/or vibration. is being used.

Check shaft alignment. Misaligned shafts will create excessive noise and/or vibra- Correct shaft misalignment.
tion.

Hydraulic fluid viscosity above acceptable limits. Hydraulic fluid viscosity above acceptable limits or low Allow system to warm up before operation or use fluid with
fluid temperature will not allow the pump to fill or control the appropriate viscosity grade for expected operating
to operate properly. temperatures.

Table 5-36. Actuator Response Is Sluggish

Item Description Action

Check external system relief valve setting. Low external relief valve setting will slow down system. Adjust external relief valve setting per manufacturer’s rec-
ommendations. External relief setting must be above Pres-
sure Compensator setting for proper operation.

Check Pressure Compensator and LS control setting. Low Pressure Compensator setting will prevent the pump Adjust Pressure Compensator and Load Sense setting.
from achieving full stroke. Low Load Sense setting will Refer to Adjustments.
limit output flow.

Check Load Sense control signal pressures. Incorrect Load Sense signal will not allow pump to operate Inspect system, ensure that proper Load Sense signal is
correctly. transmitted to the pump.

Internal system leaks. Worn internal parts will not allow the pump to operate Refer to Authorized Service Center for repairs as required.
properly.

Check external system valving. Malfunctioning valving may not allow system to respond Repair or replace system valving as required.
properly.

Check pump case pressure. High case pressure will cause the system to be sluggish. Correct case drain line restrictions.

Check pump inlet pressure / vacuum. High inlet vacuum will cause low output flow. Correct inlet pressure conditions.

5-136 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Table 5-37. System Operating Hot

Item Description Action

Check fluid level in reservoir. Insufficient volume of hydraulic fluid will not meet cooling Fill reservoir to proper level. Verify proper size of reservoir.
demands of system.

Inspect heat exchanger. Check air flow and input air tem- Insufficient air flow, high input air temperature, or under- Clean, repair, or replace heat exchanger as required. Verify
perature for the heat exchanger. sized heat exchanger will not meet cooling demands of the proper size of heat exchanger.
system.

Check external system relief valve setting. Fluid passing through relief valve adds heat to system. Adjust external system relief valve setting per manufac-
turer’s recommendations. External relief valve setting
must be above Pressure Compensator setting for proper
operation.

Check pump inlet pressure / vacuum. High inlet vacuum adds heat to system. Correct inlet pressure / vacuum conditions.

Table 5-38. Low Pump Output Flow

Item Description Action

Check fluid level in reservoir. Insufficient hydraulic fluid will limit output flow and cause Fill the reservoir to proper level.
internal damage to pump.

Hydraulic fluid viscosity above acceptable limits. Fluid viscosity above acceptable limits or low fluid temper- Allow system to warm up before operation or use fluid with
ature will not allow the pump to fill or control to operate the appropriate viscosity grade for expected operating
properly. temperatures.

Check external system relief valve setting. External relief valve set below Pressure Compensator set- Adjust external relief valve per manufacturer’s recommen-
ting will cause low output flow. dation. External relief valve setting must be above Pressure
Compensator setting for proper operation.

Check Pressure Compensator and Load Sense control set- Low Pressure Compensator setting will prevent the pump Adjust Pressure Compensator and Load Sense setting.
ting. from achieving full stroke. Low Load Sense setting will Refer to Adjustments.
limit output flow.

Check pump inlet pressure / vacuum. High inlet vacuum will cause low output flow. Correct inlet pressure conditions.

Check input speed. Low input speeds decrease flow. Adjust input speed.

Check pump rotation. Incorrect rotational configuration will cause low flow. Use pump with appropriate rotational configuration.

3121628 5-137
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

K010
C118
K020
6mm
C138
C117
6mm
C116
C136
C117
C135
C114

C134
C115
C133
C113
C102 (2pl.)
4mm
Figure 5-171. Shaft Seal and Retaining Ring 7-11 N•m
[6-8 lbf•ft]
A lip type shaft seal is used in the pump and can be replaced
without major disassembly of the unit. Replacement of the C200
shaft seal requires removal of the pump from the machine.
C107A
REMOVAL
1. Using the appropriate snap-ring pliers, remove the
retaining ring (K010) from the housing. C300 (4pl.) C107
5mm 3/16 in
2. Remove the shaft seal (K020) from the bore in the pump 11-14 N•m
15-18 N•m
housing and discard. Avoid damaging the pump hous- [11-13 lbf•ft] [8-10 lbf•ft]
ing or shaft. Puncture the face of the seal with a packing
hook, or use a slide-hammer type puller to remove the C112
C132
seal.
C106A
INSTALLATION C103A
C106
1. Inspect the pump housing and new seal for damage. C103 3/16 in
Inspect the sealing area on the shaft for rust, wear, or 3/16 in 11-14 N•m
contamination. Polish the sealing area on the shaft if 11-14 N•m [8-10 lbf•ft]
necessary. [8-10 lbf•ft]

2. Lubricate the lip of the new shaft seal with clean hydrau-
lic fluid. Place a protective sleeve over the shaft end to Figure 5-172. Control Assembly
prevent damage to the seal during installation.

PREMATURE BEARING FAILURE CAN RESULT IF THE SHAFT SEAL CONTACTS

THE SHAFT BEARING. PRESS THE SEAL INTO THE HOUSING ONLY FAR ENOUGH
TO CLEAR THE RETAINING RING GROOVE.

3. Keeping the seal perpendicular to the shaft, press the

new seal into the housing just far enough to clear the
retaining ring groove. Install seal with the cupped side
toward the shaft bearing. Do not damage the seal dur-
ing installation.
4. Using the appropriate snap ring pliers, install the seal
retaining ring.
5. Remove the installation sleeve.

5-140 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

DISASSEMBLY NOTE: For Pressure Compensator only controls, skip steps 15 and
16.
1. Remove the four screws (C300) holding the control hou-
sing onto the end cap. 3. Install the Load Sense spool, spherical end first, into the
2. Remove the control and discard the three interface o- Load Sense bore. The Load Sense spool is the longer of
rings (C200). the two. Using a new o-ring, install the plug (C106).
Torque to 8-10 ft.lb. [11-14 Nm].
3. Remove the Pressure Compensator set screw (C102),
Pressure Compensator adjustment screw (C138), o-ring 4. Place the two Load Sense springs onto the spring guide
(C136), springs (C135, C134), and seat (C133). Discard and install into the Load Sense bore. Place a new o-ring
the o-ring. and backup rings onto the Load Sense adjustment sc-
rew and thread it into the Load Sense bore until flush,
4. Remove the plug (C103), o-ring (C103A),and Pressure then make another full turn. Install and torque the set
Compensator spool (C132) from the control housing; screw to 6-8 ft.lb. [7-11 Nm].
discard the o-ring. Note orientation of the spool for reas-
sembly. 5. Using a new o-ring, install the plug (C107). Torque to 8-
10 ft.lb. [11-14 Nm].
5. Remove the plug (C107) and o-ring (C107A); discard the
o-ring. 6. Using petroleum jelly to retain them, install the three
interface o-rings (C200) in the recesses on the control
NOTE: For Pressure Compensator only controls, skip steps 6 and 7. housing.
7. Install the control assembly onto the endcap using the
6. Remove the Load Sense set screw (C102), Load Sense
four screws (C300). Torque to 11-13 ft.lb. [15-18 Nm].
adjustment screw (C118), o-ring (C116), back-up rings
Torque screws in a criss-cross pattern and re-torque the
(C117), springs (C114, C115), and seat (C113); discard the
first screw to ensure proper torque retention.
o-ring.
7. Remove the plug (C106), o-ring (C106A), and Load Sense
spool (C112) from the control housing; discard the o-
ring. Note orientation of the spool for reassembly.

INSPECTION
1. Inspect the adjustment screws for wear at the tips and
where they contact the springs; replace as necessary.
2. Inspect the springs and spring guides for wear or dam-
age; replace as necessary.
3. Carefully inspect the spools. Ensure the sealing lands are
free of nicks and scratches. Check the ends that contact
the spring guides for wear. Replace spools as necessary.
4. Inspect the control housing for damage. Check the
spool bores for excessive wear.
5. Clean all parts and lubricate spools, springs, guides and
new o-rings with clean hydraulic fluid.

REASSEMBLY
1. Install the Pressure Compensator spool, spherical end
first, into the Pressure Compensator bore. The Pressure
Compensator spool is the shorter of the two. Using a
new o-ring, install the plug (C103). Torque to 8-10 ft.lb.
[11-14 Nm].
2. Place the two Pressure Compensator springs onto the
spring guide and install into the Pressure Compensator
bore. Place a new o-ring onto the Pressure Compensator
adjustment screw and thread it into the Pressure Com-
pensator bore until flush, then make another full turn.
Install and torque the set screw to 6-8 ft.lb. [7-11 Nm].

3121628 5-141
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Plug and Fitting Sizes and Torques composite. Your configuration may differ but the appropriate
wrench size and torque can be found here.
If any plugs or fittings are removed from the unit during ser-
vice, install and torque as indicated here. This drawing is a

J041/J043/J044/J046

$ M14 $ 9/16 in
6mm 1/4 in
27-35 N•m 34-68 N•m
[20-26 lbf•ft] [25-50 lbf•ft]

K045
$ 7/8 in
3/8 in
54-136 N•m
[40-100 lbf•ft]

J080/J081/J082
$ M18 $ M14
8mm 6mm
41-95 N•m 27-35 N•m
[30-70 lbf•ft] [20-26 lbf•ft]

K040
$ 7/8 in
J040
3/8 in
$ (M14)
54-136 N•m
6mm [40-100 lbf•ft]
27-35 N•m
[20-26 lbf•ft]

Figure 5-173. Plug Locations, Sizes, and Torques

5-142 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.10 DRIVE PUMP Installation

Removal NOTE: The drive pump weighs approximately 62 lbs. (28 kg).

NOTE: Remove the function pump from the machine first, refer 1. Use a suitable device to support the drive pump.
Section 5.9, Function Pump. 2. Install the new o-ring in to the drive pump groove.
1. Tag and disconnect the hydraulic lines and fittings from 3. Align and install the drive pump to the engine assembly.
the drive pump. Use a suitable container to retain any
NOTE: Make sure that the pump shaft is properly aligned.
residual hydraulic fluid. Immediately cap lines and ports.

NOTE: The drive pump weighs approximately 62 lbs. (28 kg).

2. Use a suitable device to support the drive pump. INCORRECT SHAFT ALIGNMENT MAY RESULT IN DAMAGE TO DRIVE SHAFT,
BEARINGS, OR SEAL WHICH CAN CAUSE EXTERNAL OIL LEAKAGE.
3. Remove two bolts and washers attaching the drive
pump to the engine assembly. Remove drive pump from 4. Secure drive pump with two bolts and washers as
the machine as shown. shown.

NOTE: Apply JLG Threadlocker P/N 0100011 to the bolts before

installation.

5. Torque bolt to 50 ft. lbs. (68Nm).

4. Remove and discard o-ring from the drive pump groove.

5. Place drive pump in the clean work area.

6. Remove tag and reconnect the hydraulic lines and fit-

tings to the drive pump.

3121628 5-143
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Servo Controlled Piston Pump Endcover Inspection

• Check the bearing (press fit) in endcover. If needles remain
DISASSEMBLY in cage, move freely, and setting is at the dimension shown
in Figure 5-174. removal not required.
The following instructions apply to a single servo controlled
• Check roll pin in endcover. If tight and set to the dimension
piston pump with or without a gerotor charge pump. A tan-
shown in Figure 5-174. removal not required.
dem pump assembly should be separated into individual
pumps before disassembly.
Numbered End
1. Position the pump into a protected jaw vise, clamping
onto the outer portion of the flange, with the cap screws
up. Mark the relationship of the working ports (for
assembly identification) to the servo control assembly
2.29 mm 4.39 mm
with a scribe. Remove the four cap screws retaining end- (0.09 in.) (0.173 in.)
cover.
2. Lift the charge pump adapter assembly straight up off
endcover, shaft and gerotor. Gerotor may stay in adapter
or on endcover.
3. Remove o-ring from charge pump adapter.
Figure 5-174. Endcover Inspection
4. Remove outer gerotor ring from either the charge pump
adapter or the inner gerotor ring.
1. Remove housing gasket from housing or endcover.
NOTE: Refer to “Charge Pump Adapter Assembly” for disassembly
and inspection of charge pump adapter assembly. 2. With pump still in vise, remove the six cap screws retain-
ing the manual servo control assembly. Remove the
5. Remove the inner gerotor ring and key from drive shaft control assembly and control housing gasket from the
or inner gerotor ring and coupler assembly from shaft. housing. Remove orifice plates, noting location for reas-
sembly. Remove nut and lock washer from control arm,
6. Lift endcover straight up off shaft and housing. Remove remove arm. Note position of control arm for reassem-
valve plate from endcover or from rotating kit assembly, bly.
still in housing.
NOTE: Refer to “Manual Servo Control Basic Assembly” for disas-
7. From endcover, remove bypass valve or plug, and relief
sembly and Inspection of control assembly.
valve assemblies. Note: Mark the relief valve in relation-
ship to the cavity it was removed, for reassembly pur-
3. To remove rotating kit assembly from housing, first
poses.
remove pump from vise holding the rotating kit assem-
bly in position. Lower pump so that the shaft end (flange
end) is up. Set the rear of housing onto table with hous-
ing flat and rotating kit assembly at rest on table. (Hole
in table, for protruding shaft, is required.) Lift and
remove the housing and shaft from rotating kit assem-
bly, and swashplate.
4. Remove swash plate from rotating kit assembly and
servo piston follower from swashplate.

NOTE: Refer to “Rotating Kit Assembly” for disassembly and

Inspection of rotating kit.

5-144 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Swashplate Inspection Bushing Inspection

• The finish on the piston shoe surfaces of the swash plate • Inspect bushing for contamination embedment within
should show no signs of scoring. coating of bushing surface coming in contact with swash-
plate.
• Inspect swashplate bushing surface for wear and surface
1. Remove all plugs from housing.
for coating transfer from bushing.
2. Discard the shaft seal, gaskets, and o-rings from all
1. To remove servo piston assembly from housing, start assemblies. Replace with new seals upon reassembly.
with the four each cap screws and washers retaining
each cover plate.
ASSEMBLY
2. In removing the cover plate from the servo piston bolt,
1. All parts should be cleaned and critical moving parts
remove jam nut, washer, and seal washer. Hold the servo lubricated before reassembly.
piston bolt with hex key and unscrew cover plate off of
bolt. 2. If necessary, press new bearing in housing to dimension
shown in Figure 5-175. with the numbered end of bear-
3. Remove servo piston assembly and seal sub-assemblies ing outward.
(two sets) from housing. 3. Install the two new seal sub-assemblies into the servo
piston cavity of housing.
NOTE: Disassembly of servo piston assembly is not required.
4. Screw the cover plate onto the servo piston assembly.
4. Remove retaining ring from the front of housing. Press Install new cover plate gasket in place on housing.
Install servo piston assembly and cover plate into servo
the shaft, shaft seal or spacer, and washer from housing.
piston bore in right side of housing (as shown in Figure
Remove retaining ring, thrust washer, thrust bearing,
5-176. Retain cover plate with four each washers and
second thrust washer, and second retaining ring from cap screws. Torque cap screws 40 to 48 in.lbs (4.5 to 5.4
shaft. Nm). To obtain neutral, centering the servo piston
assembly is required. Measure in from the left side and
Housing Inspection set servo piston 0.5 in. (12.7 mm) from surface of hous-
ing servo bore as shown in Figure 5-176..
• Check the bearing (press fit) in housing. If needles remain
in cage, move freely, and setting at the dimension shown in NOTE: Re-adjustment may be required for neutral at unit start-up.
Figure 5-175., removal not required.
12.7 mm
(0.5 in.)
Flange End of Housing
Numbered End
Left Side
Right Side
1.78 mm
(0.07 in.)

Front Flange- Drive shaft End of pump

Adjust to centre piston
Install servo piston
in this direction.

Figure 5-176. Servo Piston Installation

Figure 5-175. Housing Inspection

5. Install new seal washer, washer, and jam nut to servo
piston bolt. Holding servo piston bolt with hex key
1. To remove cradle sub-assembly, remove the two cap wrench Torque jam nut (150 to 160 in.lbs) 17 to 18 Nm.
screws retaining cradle inside housing. Removing cradle Check the centering of servo piston assembly. Install
subassembly from housing. new cover plate gasket and cover plate to left side of
servo piston and retain with four each washers and #10-
2. Remove button head cap screws (2 Qty.) to remove 24 cap screws. Torque cap screws 40 to 48 in.lbs (4.5 to
bushing from cradle. 5.4 Nm).

3121628 5-145
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

6. To assemble cradle sub-assembly, install bushing onto 18. Install key and inner ring gerotor onto shaft or coupler
cradle retaining with button head cap screws. Torque assembly. Lubricate inner ring gerotor.
button head cap screw 14 to 16 in.lbs (1.6 to 1.8 Nm).
NOTE: Refer to “Charge Pump Adapter Assembly” for assembly of
7. Place cradle sub-assembly into housing making sure charge relief valve in adapter plate.
cradle is completely seated into housing. Retain cradle
sub-assembly with two cap screws. Torque cap screws 19. Insta ll o-ring and outer ring gerotor onto adapter plate.
20 to 24 ft.lbs (27 to 33 Nm). Lubricate both a-ring and outer ring to hold in position
during assembly of adapter plate. Install adapter plate
8. To install shaft, place exterior retaining ring, thrust race, onto endcover. Make sure o-ring and gerotor ring stay in
thrust bearing, second thrust race, and second retaining place.
ring onto shaft. Position washer and shaft seal or spacer
onto shaft. 20. Retain endcover and adapter plate (when used) with
four cap screws, Torque 27 to 31 ft.lbs (37 to 42 Nm).
9. Install shaft assembly into front of housing for units with
spacer, retain with interior retaining ring and go on to NOTE: Refer to “Manual Servo Control Basic Assembly” for reas-
step 10. For units with shaft seal. seat seal into position sembly of manual servo control assembly.
with seal driver and retain with interior retaining ring.
21. Install control housing gasket onto housing. Install ori-
10. Install servo piston follower onto swashplate dowel pin. fices into control assembly and retain in position with
Install swashplate carefully onto bushing (coat bushing petroleum jelly. Position the feedback link at 90 degrees
surface with hydraulic oil), aligning servo piston follower from control housing. Install manual servo control
with slot in servo piston assembly. assembly onto housing making sure feedback link
entered small groove in servo piston assembly.
NOTE: Refer to “Rotating Kit Assembly” for reassembly of rotating
kit assembly. 22. Retain control assembly with six cap screws, torque 40
to 48 in.lbs (4.5 to 5.4 Nm).
11. To install rotating kit assembly, leave housing and shaft 23. Install control arm onto control assembly input arm.
in the horizontal position. Holding swashplate into posi- Retain with lock washer and nut, torque 4 to 6 ft.lbs (5 to
tion with screw driver thru controller linkage passage- 8 Nm).
way at the top of housing. place rotating kit assembly
24. Install new o-rings on all plugs. Install plugs into hous-
over shaft and into housing until pistons are in against
ing. Torque 3/4 in. plug 21 to 24 ft.lbs (28 to 32 Nm).
swashplate. Make sure all parts are in housing com-
Torque 1-1/4 in. plug 40 to 45 ft.lbs (54 to 61 Nm).
pletely and properly positioned. Return the pump to the
vise with open end of housing up. clamping housing on 25. Refer to “Start-up Procedure”.
the outer portion of the flange.

12. Install gasket on to housing.

13. If necessary, press new bearing and roll pin in endcover

to dimension shown in figure 1-3. Bearing installed with
the numbered end outward. Roll pin installed with split
oriented away from bearing.

14. Install new o-ring on relief valves. Install relief valve in its
original cavity in endcover that it was removed. Torque
100 to 110 ft.lbs (136 to 149 Nm).

15. Install new o-ring on bypass valve or plug. Install bypass

valve or plug into endcover. Note: Make sure paddle of
bypass valve is perpendicular to relief valve axis prior to
installing or damage could result.

16. Apply a small amount of petroleum jelly to the steel side

of valve plate to hold in place for installation. Aligning
the index pin, place the valve plate in position onto the
endcover, with steel side against endcover.

17. Install endcover assembly onto housing assembly. Make

sure ports are positioned correctly, valve plate and gas-
ket stay in place.

5-146 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Charge Pump Adapter Assembly

DISASSEMBLY

1. Remove plug, shims, spring, and poppet from adapter 2

assembly as shown in Figure 5-178.
3
Inspection 1
• Inspect the charge pump relief valve seat inside the charge Gerotor Ring
pump adapter. Check to insure that seat is smooth and free Pocket
of burrs or other defects.
• Inspect the charge pump relief valve spring.
• Inspect the bearing or bushing inside the charge pump
adapter. The bearing needles must remain in the bearing 4
cage and bearing at dimension shown in Figure 5-177. The
bushing must have no excessive scoring. 5 Charge Pump
Suction Port
• Inspect the gerotor pocket inside the charge pump
adapter assembly. It should not be scored excessively. 6
7
Numbered End
Flange
8

1. Charge Pump Adapter 5. Spring

2. Bearing 6. Shims
2.41 mm 3. Bushing 7. 0-ring
(0.095 in.) 4. Poppet 8. Plug

Figure 5-178. Charge Pump Adapter Assembly

Gerotor Pocket

Figure 5-177. bearing or bushing Inspection

ASSEMBLY
1. If necessary, press new bearing or bushing in adapter
assembly. The bearing to dimension shown in Figure 5-
177. with the numbered end of bearing outward and
closest to mounting flange. The bushing is to be pressed
flush to 0.254 mm [0.010 in.) recessed.
2. Install poppet. spring, shims, new o-ring on plug, and
plug into adapter assembly. Torque plug 30 to 27 ft.lbs.
(40.7 to 36.6 Nm).

3121628 5-147
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Manual Servo Control Basic Assembly 2. Install valve spool into control housing making sure that
metering notches on valve spool can be seen in the
metering ports. Notches shown in Figure 5-179.
DISASSEMBLY
1. Remove wiper seal with screw driver. Remove set screw 3. Position bell crank in housing. Slide feedback link into
retaining input shaft and remove input shaft from con- position between clevis on valve spool. aligning holes,
trol housing. and install dowel pin retaining with E-ring.

2. Remove set screw from plug retaining valve spool and 4. Install new o-ring onto input shaft. Hold bell crank in
remove plug. position with feedback link slot and align splined hole of
bell crank with input shaft cavity. Install input shaft into
3. Remove E-ring from pin retaining feedback link and control housing and bell crank.
valve spool. Remove pin. feedback link. valve spool, and
bell crank from control housing. 5. JLG Threadlocker P/N 0100011 or equivalent to set
screw and install, retaining input shaft. Adjust set screw
4. Compress spring and remove E-ring. spring retainer. until it bottoms out on input shaft and back out one-
spring. and second spring retainer from valve spool. quarter turn.
5. Remove o-rings from plug and input shaft. Clean all 6. Install wiper seal on input shaft as shown in Figure 5-
parts and lubricate in prep for reassembly. 179. Install new o-ring onto plug. retaining valve spool,
and install plug. Adjust plug until there is no play in the
ASSEMBLY valve spool with input shaft held stationary. Lock in
1. Install spring retainer, spring. and second spring retainer place with set screw. Torque set screw 17 to 25 in.lbs (2
onto spool. Compress spring with retainer and retain to 3 Nm).
with E-ring onto valve spool.

3
4
5
6
5 Wiper Seal

16
7 15
Metering Notches

14
1
Metering Notches

Wide Band Neutral Spool

Identification Mark

12
10

9
13
17 Head pin removal not required
11 From bell crank.

1. Control Housing 6. Spool Centering Spring 10. Dowel Pin 14. Input Shaft
2. Plug 7. Valve Spool 11. Retaining Ring 15. 0-ri ng
3. 0-ring 8. Set Screw 12. Bell Crank 16. Wiper Seal
4. Retaining Ring 9. Feedback Link 13. Set Screw 17. Head Pin
5. Spring Retainer

Figure 5-179. Manual Servo Control Basic Assembly

5-148 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Manual Servo Control Assembly Options ASSEMBLY - DESTROKE VALVE ASSEMBLY OPTION
1. Install new o-rings and back-up washers onto destroke
DISASSEMBLY - DESTROKE VALVE ASSEMBLY valve.
OPTION
2. Install destroke valve into manifold by hand until top o-
1. Remove the two cap screws and lock washers from man- ring is met by manifold. Then wrench tighten to 25 ft.lbs.
ifold. Removing destroke valve assembly and two a- (34 Nm) max. Loosen Nut retaining coil to reposition if
rings. necessary and re-torque 4 to 5 ft.lbs. (5.4 to 7 Nm).
2. Remove destroke valve from manifold in order to 3. Lubricate the two o-rings and install onto manifold.
remove o-rings and back-up washers. Note: in order to Install destroke valve assembly onto control assembly.
remove destroke valve the solenoid may need to be Retain with lock washers and cap screws. Torque 2.2 to
removed from core first (not shown). 2.6 ft.lbs. (3 to 3.5 Nm).

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1. 0-ring 6. O-ring 10. Neutral Lockout Adapter 14. Set Screw

2. manifold 7. Lock Washer 11. Ball 15. Neutral Lockout Switch
3. Destroke Valve 8. Cap Screw 12. O-ring 16. Ball Plunger
4. 0-ring 9. O-ring 13. Pin 17. Nut Seal
5. Back-up Washer

Figure 5-180. Manual Servo Control Basic Assembly Option

3121628 5-149
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

DISASSEMBLY - NEUTRAL LOCKOUT SWITCH DISASSEMBLY - NEUTRAL DETENT OPTION

ASSEMBLY OPTION
1. Loosen seal nut and remove ball plunger from control
1. Loosen set screw in adapter and remove neutral lockout housing.
switch from adapter.
ASSEMBLY- NEUTRAL DETENT OPTION
2. Remove neutral lockout adapter from control assembly.
1. Install ball plunger into control housing until contact
3. Remove pin, ball. and a-rings from adapter. with bell crank detent is detected. After contact screw in
1/2 turn and retain with seal nut. Torque nut 10 to 22
ASSEMBLY - NEUTRAL LOCKOUT SWITCH ASSEMBLY ft.lbs. (14 to 30 Nm).
OPTION
1. Install new a-ring onto adapter and new o-ring onto pin.
2. Install ball and pin into adapter. Lubricate with petro-
leum jelly to hold in place during installation.
Step 4-c ’’A’’
3. Install adapter into control assembly. Torque 44 to 53
ft.lbs. (60 to 70 Nm).
4. Apply Loctite #222 or equivalent to threads of switch
and install neutral lockout switch into adapter. The
adjustment procedures for the switch are as follows.
a. Install switch, while moving control arm back and
forth, until “detent” action is detected. Back out the
Step 4-d ’’B’’
switch until the “detent” action is very slight.
b. Obtain a test light or use a multimeter. Attach the
leads from the test light to the switch or the wiring
connector.
c. Move the control arm out of the detent position.
The test light will go on. Screw in the switch until
the light goes off. Mark this as position “A”. See Fig-
ure 5-181. Move the control arm to the detent posi-
tion and the test light should come back on.
d. Leaving the control arm in the detent position, the Step 4-e
’’B’’
light will remain on. Screw in the switch until the
light goes off. Mark this position"B".
e. Unscrew the switch one third of the distance
between "B" and "A". Install and tighten the hex
socket head set screw in one of the main quadrants
of the hex of the switch adapter. See Figure 5-181.
Torque set screw 2.3 to 2.8 in.lbs (3.2 to 3.8 Nm).
5. Test the switch by moving the control arm to the detent ’’A’’
position, the light should be on. Move the control arm
out of detent, the light should go off. Figure 5-181. Neutral Lockout Switch Assembly
6. Remove test light and put servo control assembly into
operation.

5-150 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Rotating Kit Assembly The following parts are required to disassemble the cylinder
barrel:
DISASSEMBLY 2 ea. 3/8 in. I.D. x 1-1/8 in. O.D. flat washers
Disassembly of rotating assembly is required for inspection 1 ea. 3/8 in. x 3-1/4 in. N.C. cap screw, and
only.
1 ea. 3/8 in. N.C. nut
1. Remove the nine piston assemblies, shoe retainer, and
shoe retainer pivot from cylinder barrel. To remove spring, place one of the flat washers over the 3/8 in.
x 3-1/4 in. cap screw. Put cap screw through the center of the
Inspection cylinder barrel and apply the second washer. Let washer rest
on the three pins and retain with nut. Turning nut and com-
• Examine the O.D. of the pistons for finish condition. They pressing spring inside the barrel. Use a pair of retaining ring
should not show wear or deep scratches. Inspect the shoes pliers and remove the internal retaining ring. Remove nut,
for a snug fit on the ball end of the pistons and a flat bolt, and the two washers from barrel. Remove the washer,
smooth surface that comes in contact with the swashplate. spring, second washer, three pins, and pin keeper at the same
Do not lap piston shoes. time.
• Examine the shoe retainer for wear in the pivot area. ASSEMBLY
• Examine the pivot to insure smoothness and no signs of 1. To reassemble the rotating kit assembly complete the
wear. following: Compress the pin keeper and install in the
spline of the cylinder barrel. Insta ll the three pins with
• Inspect the cylinder barrel surface that makes contact with head end to the inside of the barrel and position in the
valve plate. This surface should be smooth and free of deep special grooves of the cylinder barrel spline.
scratches. Do not lap piston block.
2. Install the washer, spring, and second washer into the
• The pistons should move freely in the cylinder barrel bore. cylinder barrel. Use the two 3/8 in. I. D. washers, nut, and
If they are sticky in the bore, examine the bore for scoring 3/8 in. x 3-1/4 in. cap screw to compress the spring and
or contamination. retain with retaining ring. Remove the nut. cap screw,
and the two washers.
2. To inspect pins and spring caution should be taken in
removing spring. The spring is highly compressed and 3. Install the pivot onto the three pins, shoe retainer on the
the retaining ring should not be removed without com- pivot, and piston assemblies thru the shoe retainer and
pressing the spring safely. into cylinder barrel. resting on shoe retainer.

9
7
8
7
6
5

4
2 3

1. Piston assemblies 4. Retainer 6. Pins 8. Spring

2. Shoe Retainer 5. Cylinder Barrel 7. Washer 9. Retaining Ring
3. Shoe Retainer Pivot

Figure 5-182. Rotating Kit Assembly

3121628 5-151
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Fault- logic Trouble Shooting RECOMMENDED GAUGE LOCATIONS

Gauges Recommended
Match the transmission symptoms with the problem state-
ments and follow the action steps shown in the box diagrams. Inlet vacuum gauge: 30 PSI to 14.8 PSI (2 bar to 1 bar)
This will give expedient aid in correcting minor problems elim- System pressure gauge: 10,000 PSI (700 bar)
inating unnecessary machine down time.
Charge pressure gauge: 0 to 600 PSI (0 to 50 bar)
Following the fault - logic diagrams are diagram action com-
Case pressure gauge: 0 to 300 PSI (0 to 25 bar)
ments of the action steps shown in the diagrams. Where appli-
cable, the comment number of the statement appears in the
action block of the diagrams.

Charge Pump Suction Port

Tee in line to check Inlet Vaccum

Pressure Ports
Tee in line to check System
Pressure

Auxilliary Port
Check Charge Pressure

Drain Port
Tee in line to check Case
Pressure

Figure 5-183. Gauge Locations

5-152 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Figure 5-184. Fault- logic Troubleshooting

3121628 5-153
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Figure 5-185. Fault- logic Troubleshooting

5-154 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Figure 5-186. Fault- logic Troubleshooting

3121628 5-155
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

DIAGRAM ACTION STEP COMMENTS 10. Check System Pressure:

1. Inspect External Control Linkage for: a. See Figure 5-179. for location of pressure gauge
installation
a. Misadjusted or disconnected
b. Consult owner/operators manual for maximum sys-
b. Binding, bent or broken tem relief valve settings
2. Inspect Control Valve for: 11. Check Charge Pressure:
a. Plugged control orifice(s) a. See Figure 5-179. for location of charge pressure
b. Damaged mounting gasket gauge installation

c. Misadjusted, damaged or broken neutral return b. Consult owner/operators manual for maximum
spring charge relief valve settings

d. Broken control connector pin 12. Inspect Charge Relief Valve for:
e. Faulty destroke valve (if used) a. Improper charge relief pressure setting
f. Galled or stuck control spool b. Damaged or broken spring
g. Neutral detent or lockout switch misadjusted (if c. Poppet valve held off seat
used)
13. Inspect Motor for:
3. Inspect System Relief Valves for: a. Consult owner/operator manual for motor opera-
a. Improper pressure relief setting tion and trouble shooting
b. Damaged or broken spring 14. Inspect Charge Pump for:
c. Valve held off seat a. Broken or missing drive key
d. Damaged valve seat b. Damaged or missing o-ring
4. Inspect Servo Piston for: c. Excessive gerotor clearance
d. Galled or broken gerotor set
a. Misadjusted, damaged or broken neutral return
spring assembly
b. Galled or stuck servo piston System/Charge Relief Valve Pressure Settings
c. Damaged or missing o-ring and/or back-up ring Inlet Vacuum 2.94 PSI (0.203 bar) max.
5. Check Oil Level in Reservoir: Case Pressure 25 PSI (1.7 bar) maximum

a. Consult owner/operators manual for the proper Charge Pressure 250 to 300 PSI (17.24 to 20.68 bar)
type fluid and level System Pressure 5000 PSI (345 bar) maximum

6. Inspect Heat Exchanger for: 3000 PSI (207 bar) continuous

a. Obstructed air flow (air cooled) The high pressure relief valves are all factory preset and can-
b. Obstructed water flow (water cooled) not be readjusted.
c. Improper plumbing (inlet to outlet) The pressure setting is stamped on each valve with a three
digit number. To identify, multiply the noted number by 10 to
d. Obstructed fluid flow
get the valves pressure setting.
7. Inspect Heat Exchanger Bypass Valve for:
Example: 10 x 500 = 5000 PSI (345 bar)
a. Improper pressure adjustment
b. Stuck or broken valve
8. Inspect Bypass Valve for: {if used)
a. Held in a partial or full open position
9. Inspect Inlet Screen or Filter for:
a. Plugged or clogged screen or filter element
b. Obstructed inlet or outlet
c. Open inlet to charge pump

5-156 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

Start-up Procedure 6. After the system starts to show signs of fill, slowly move
pump swashplate to a slight cam angle. Continue to
When initially starting a new or a rebuilt transmission system. operate system slowly with no load on motors until sys-
it is extremely important that the start-up procedure be fol- tem responds fully.
lowed. It prevents the chance of damaging the unit which
might occur if the system was not properly purged of air 7. Check fluid level in the reservoir and refill if necessary to
before start-up. the proper level with an approved filtered oil.

1. After the transmission components have been properly 8. Check all line connections for leaks and tighten if neces-
installed, fill the servo pump housing at least half full sary.
with filtered system oil. Connect all hydraulic lines and 9. The machine is now ready to be put into operation.
check to be sure they are tight.
10. Frequent filter changes are recommended for the first
2. Install and adjust all control linkage. two changes after placing the machine back into opera-
3. Fill the reservoir with an approved oil that has been fil- tion. Change the first filter in 3-5 hours and the second
tered through a 10 micron filter. Refer to Eaton Hydrau- at approximately 50 hours. Routinely scheduled filter
lics Technical Data sheet number 3-401 titled Hydraulic changes are recommended for maximum life of the
Fluid Recommendations. hydraulic system.

4. Gasoline or L.P. engines: remove the coil wire and turn

the engine over for 15 seconds. Diesel engines: shut off
the fuel flow to the injectors and turn the engine over
for 15 seconds.
5. Replace the coil wire or return the fuel flow to the injec-
tors. Place the transmission unit in the neutral position,
start the engine and run it at a low idle. The charge
pump should immediately pick up oil and fill the system.
If there is no indication of fill in 30 seconds, stop engine
and determine the cause.

3121628 5-157
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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5-158 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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Figure 5-188. Hydraulic Schematic - Sheet 2 of 6

3121628 5-159
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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Figure 5-189. Hydraulic Schematic - Sheet 3 of 6

5-160 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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Figure 5-190. Hydraulic Schematic - Sheet 4 of 6

3121628 5-161
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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Figure 5-191. Hydraulic Schematic - Sheet 5 of 6

5-162 3121628
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

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Figure 5-192. Hydraulic Schematic - Sheet 6 of 6

3121628 5-163
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

NOTES:

5-164 3121628
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

3121628 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 controller module located in the plat- erly, the analyzer will display the following:
form box or at the controller module in the ground con-
trol box and connect the remaining end of the cable to
the analyzer.

NOTE: The cable has a four pin connector at each end of the cable;
the cable cannot be connected backwards.

2. Power up the Control System by turning the 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 3121628
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 access level
2 which enables you to only view most settings which cannot
be changed until you enter a password to advance to a lower
level. This ensures that a setting cannot be accidentally
altered. To change the access level, the correct password must
be entered. To enter the password, scroll to the ACCESS LEVEL
menu. For example:

LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the last fault the system
has seen, if any are present. You may scroll through the fault
logs to view what the last 25 faults were. Use the right and left
arrow keys to scroll through the fault logs. To return to the

beginning, press ESCAPE two times. STARTUP (2/1)

indicates a power up.

ACCESS LEVEL:
CODE 00000

3121628 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:

PERSONALITIES:
DRIVE ACCEL 1.5s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if the UP

arrow is pressed when at the maximum value nor will

the value decrease if the DOWN arrow is pressed and

the value is at the minimum value for any particular personal-
ity. If the value does not change when pressing the up and
MENU:
down arrows, check the access level to ensure you are at
ACCESS LEVEL 1
access level 1.
Repeat the above steps if the correct access level is not dis-
played or you can not adjust the personality settings.

6-4 3121628
SECTION 6 - JLG CONTROL SYSTEM

Machine Setup
ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC-
TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
When a machine digit item is selected, press the UP or AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES
INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI-
DOWN arrow keys to adjust its value, for example: MUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM THESE COMPONENTS. IF
ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT
BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

Level Vehicle Description

A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE
FOLLOWING PROCEDURE IS PERFORMED.

DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE.

GROUND ALARM:
2 = LIFT DOWN
The effect of the machine digit value is displayed along with
its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
sound when 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

Place machine in stowed position with the boom between the
factory settings.
rear wheels.

NOTE: Password 33271 will give you access to level 1, which will To level machine chose:
permit you to change all machine personality settings.
CALIBRATION:
There is a setting that JLG strongly recommends that you do TILT SENSOR
not change. This setting is so noted below:
ELEVATION CUTBACK Press ENTER .

When prompted, swing machine 180°

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF

YOUR MACHINE. Press ENTER .

3121628 6-5
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

6-6 3121628
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 main or UP
V VOLT
VER VERSION
VLV VALVE
WIT WITNESS
YEL YELLOW

3121628 6-7
SECTION 6 - JLG CONTROL SYSTEM

Figure 6-2. ADE Block Diagram

6-8 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

NOTE: For version 6.X software, some screens may not be available depending upon machine configuration and software ver-
sions.

NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal-
ity settings first and then changing the model number of the machine configuration will cause the personality settings
to return to default values.

MODEL NUMBER: 1 400S 1

1
2 450A

3 510A

4 600S

5 600A

6 600SC

7 601S

8 740A

9 800A

10 800S

MARKET: 0 ANSI USA 0

2
1 ANSI EXPORT

2 CSA

3 CE

4 AUSTRALIA

5 JAPAN

6 GB

3121628 6-9
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

ENGINE: 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 14

3*
* Engine selections vary 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
depending on model selec-
tion. 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1)

4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1)

5 CAT. 3024C: CAT 3024C Diesel (Tier 2)

6 CAT. 3044C: CAT 3044C Diesel (Tier 2)

7 PERKINS 404C (Tier 2)

8 DEUTZ F4 TIER2: Deutz F4M2011 Diesel (Tier 2)

9 DEUTZ F3 TIER2: Deutz F3M2011 Diesel (Tier 2)

10 FORD GAS TIER2: Ford LRG425 EFI Gas (Tier 2)

11 FORD D/F TIER2: Ford LRG425 EFI Dual Fuel (Tier 2)

12 DEUTZ ECM: Engine Control Module - ECM (Tier 2 and Tier 3)

13 DUAL FUEL ECM: GM/PSI 3.0L Dual Fuel (Tier 2)

14 PERKINS ECM

15 CAT ECM

16 DEUTZ ECM T4F: Deutz Engine Control Module (Tier 4 Final)

FLYWHEEL TEETH: 0 133 TEETH: 133 flywheel teeth. 1

4*
*This menu item is only vis- 1 110 TEETH: 110 flywheel teeth.
ible if Deutz engine selec-
tions 3 or 4 are selected.

6-10 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 2

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.

2 IN-CYLINDER: Glow plugs installed in each cylinder.

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

1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permit-
ted until pre-glow is finished.

FUEL CUTOUT 0 RESTART: Engine allowed to be restarted multiple times when very low fuel level is reached. 0
7
* This menu item is only vis- 1 ONE RESTART: Engine allowed to be restarted once for 2 minutes when very low fuel level is reached.
ible if non dual fuel engines
are selected. 2 ENGINE STOP: Engine not able to restart when very low fuel level is reached.

ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

8
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil
pressure is less than 8 PSI.

TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more 1
9* than 5 degrees and above elevation; also reduces drive speed to creep.
* Certain market selections
will limit tilt options and 2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees
alter default setting. and above elevation; also reduces drive speed to creep.

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

6 5 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 5
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.

3121628 6-11
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

JIB: 0 NO: No jib installed. 0

10*
* Only visible under certain 1 YES: Jib installed which has up and down movements only.
model selections.

4 WHEEL STEER: 0 NO: No four-wheel steer installed. 0

11*
* Only visible under certain 1 YES: Four-wheel steer installed.
model selections.

ST TOUCH / SKYGUARD: 0 NONE: No soft touch or skyguard system installed. 0

12
1 SOFT TOUCH - Soft touch only installed.

2 SKYGUARD - Skyguard only installed.

3 BOTH (CUTOUT) - Soft touch and Skyguard installed.

GEN SET/WELDER: 0 NO: No generator installed. 0

13
1 BELT DRIVE: Belt driven setup.

GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
14*
* Only visible if Gen Set / 1 MOTION CUTOUT: Motion cutout in platform mode only.
Welder Menu selection is
not 0.

H & T LIGHTS: 0 NO: No head and tail lights installed. 0

15
1 YES: Head and tail lights installed.

CABLE SWITCH: 0 NO: No broken cable switch installed. 0

16*
* Only visible under certain 1 YES: Broken cable switch installed.
model selections.
* Certain market and
model selections will alter
the default setting.

6-12 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

LOAD SYSTEM: 0 NO: No load sensor installed. 0

17*
* Only visible under certain 1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
market selections.
* Certain market selections 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
will limit load system
options or alter default set- 3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
ting. sec ON, 2 sec OFF).
* LOAD SYSTEM will not be
visible in CE and defaulted 4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform
to CUTOUT ALL for alarm beeps (5 sec ON, 2 sec OFF).
machines equipped with
MSSO.

LOAD SENSOR: 0 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the Leveling Platform 1
18* Module.
* Only visible if Load Sensor
Menu selection is not 0 and 1 4 UNDER PLATFORM: Use the EIM for load sensing.
under certain market selec-
tions.
* Certain market selections
will limit load sensor
options.

FUNCTION CUTOUT: 0 NO: No drive cutout. 0

19*
* Only visible under certain 1 BOOM CUTOUT: Boom function cutout while driving above elevation.
market selections.
* Certain market selections 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
will limit function cutout
options or alter default set- 3 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
ting.

GROUND ALARM: 0 NO: No ground alarm installed. 3

20*
* Certain market selections 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
will alter default setting.
2 DESCENT: Descent alarm sounds when lift down is active (Option).

3 MOTION: Motion alarm sounds when any function is active (Option).

DRIVE: 0 4WD: Four wheel drive. 0

21*
* Only visible under certain 1 2WD: Two wheel drive.
model selections.
2 2WD W/ 2-SPEED: Two wheel drive with 2-speed valve.

3121628 6-13
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

DISPLAY UNITS: 0 IMPERIAL: DEG F , PSI, LBS. 0

22*
* Certain market selections 1 METRIC: DEG C, KPA, KGS
will alter default setting.

LEVELING MODE: 0 ALL FUNCTIONS: Platform level with all functions. 0

23*
* Only visible on 800S 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
models.

DRIVE CONTROL: 0 NORMAL: Drive coils are energized from the Ground Module. 2
24
1 PROPULSION: Drive coils are energized from the Propulsion Module.

2 ENHANCED: Drive coils are energized from the Ground Module and the ground side of the
drive coils are brought back to current feedback returns.

DRIVE PUMP 0 SAUER DANFOSS: Machine equipped with Sauer Danfoss drive pump 0
25
*Only visible on 600A, 1 EATON: Machine equipped with Eaton drive pump
600S, and 800S models.
2 M46 - XXXX: Machine equipped with M46 - XXXX drive pump

3 830XXXXX: Machine equipped with 830XXXXX: drive pump

BOOM CONTROL: 0 NORMAL: Boom function coils are energized from the Ground Module. 0
26
1 ENHANCED: Boom function are energized from the Ground Module and the ground side of the drive coils
and brought back to current feedback returns.

FUNCTION SPEED KNOB 0 YES: Machine is equipped with Function Speed Knob. 0
27
1 NO: Machine is equipped with Operation Speed Switch.

CLEARSKY: 0 NO: Clearsky (telematics) option is disabled. 0

28
1 YES: Clearsky (telematics) option is enabled.

6-14 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

CRIBBING OPTION: 0 NO: Cribbing Option is disabled. 0

29
1 YES: Cribbing Option is enabled.

FUEL TANK SIZE: 0 31 Gallon Tank 0

30
1 52 Gallon Tank

ALARM / HORN: 0 SEPERATE: Separate alarm and horn. 0

31
1 COMBINED: Combination alarm / horn.

ALERT / BEACON: 0 OFF FOR CREEP: Alert beacon will not flash while in Creep. 0
32
1 20FPS FOR CREEP: Alert beacon will flash at 20FPS while in Creep.

TEMP CUTOUT: 0 NO: Temp Cutout is Disabled 0

33
1 YES: Temp Cutout is Enabled

PLAT LVL OVR CUT: 0 NO: Platform Level Override will always be functional. 0
34
1 YES: Platform Level Override will only be functional when In Transport.

4150364-O

3121628 6-15
SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. 800A Machine Configuration Programming Table 6-3. 800A Machine Configuration Programming
Settings Settings

ANSI Export
ANSI Export

Australia
ANSI USA
Australia
ANSI USA
800 A 800 A

Japan
Japan

CSA
CSA

CE
CE
Model Number 9 9 9 9 9 9 Function Cutout 0 0 0 0 0 0
Market 0 1 2 3 4 5 X 1 1 1 1 1
Engine 12 12 12 12 12 12 2 2 2 X 2 2
Flywheel Teeth 0 0 0 0 0 0 X 3 3 X 3 3
1 1 1 1 1 1 Ground Alarm 0 0 0 0 0 0
Glow Plugs 0 0 0 0 0 0 1 1 1 1 1 1
1 1 1 1 1 1 2 2 2 2 2 2
2 2 2 2 2 2 3 3 3 3 3 3
Starter Lockout 0 0 0 0 0 0 Drive Type 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2
Fuel Cutout 0 0 0 0 0 0
1 1 1 1 1 1
Display Units 0 0 0 0 0 0

2 2 2 2 2 2 1 1 1 1 1 1
Engine Shutdown 0 0 0 0 0 0 Leveling Mode 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1
Tilt 1 1 1 X X 1 Drive Control 0 0 0 0 0 0
1 1 1 1 1 1
2 2 2 X 2 2
3 3 3 X 3 3 2 2 2 2 2 2
4 4 4 4 4 4 Drive Pump 0 0 0 0 0 0
5 5 5 5 5 5 1 1 1 1 1 1
6 6 6 X X 6 X X X X X X
X X X X X X
Jib 0 0 0 0 0 0
Boom Control 0 0 0 0 0 0
4 Wheel Steer 0 0 0 0 0 0
1 1 1 1 1 1
Soft Touch/Skyguard 0 0 0 0 0 0
Function Speed Knob 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
3 3 3 3 3 3
Clearsky 0 0 0 0 0 0
1 1 1 1 1 1
Gen Set / Welder 0 0 0 0 0 0
1 1 1 1 1 1
Cribbing Option 0 0 0 0 0 0
1 1 1 1 1 1
Gen Set Cutout 0 0 0 0 0 0
1 1 1 1 1 1
Fuel Tank Size 0 0 0 0 0 0
1 1 1 1 1 1
Head & Taillights 0 0 0 0 0 0
1 1 1 1 1 1
Alarm / Horn 0 0 0 0 0 0
1 1 1 1 1 1
Cable Breaks Switch 0 0 0 0 0 0
1 1 1 1 1 1
Alert Beacon 0 0 0 0 0 0
1 1 1 1 1 1
Load System 0 0 0 0 0 0
X 1 X X X 1
Temp Cutout X 0 X 0 X X
X 1 X 1 X X
X 2 X 2 2 2
Plat Lvl Ovr Cut 0 0 0 0 0 0
X 3 X 3 X 3
1 1 1 1 1 1
X 4 X X X 4
BOLD TEXT indicates the default setting. Plain text indicates another available
Load Sensor 0 0 0 0 0 0
selection. ITALIC TEXT indicates the default when option is factory installed.
1 1 1 1 1 1 SHADED CELLS indicate hidden menu or selection.

6-16 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. 800AJ Machine Configuration Programming

Table 6-4. 800AJ Machine Configuration Programming
Settings
Settings

ANSI Export
ANSI Export

Australia
ANSI USA
Australia
ANSI USA
800 AJ

Japan
800 AJ

Japan

CSA

CE
CSA

CE
Function Cutout 0 0 0 0 0 0
Model Number 9 9 9 9 9 9
X 1 1 1 1 1
Market 0 1 2 3 4 5
2 2 2 X 2 2
Engine 12 12 12 12 12 12
X 3 3 X 3 3
Flywheel Teeth 0 0 0 0 0 0
Ground Alarm 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Glow Plugs 0 0 0 0 0 0
2 2 2 2 2 2
1 1 1 1 1 1
3 3 3 3 3 3
2 2 2 2 2 2
Drive Type 0 0 0 0 0 0
Starter Lockout 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
Fuel Cutout 0 0 0 0 0 0 Display Units 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
Leveling Mode 0 0 0 0 0 0
Engine Shutdown 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Drive Control 0 0 0 0 0 0
Tilt 1 1 1 X X 1
1 1 1 1 1 1
2 2 2 X 2 2
2 2 2 2 2 2
3 3 3 X 3 3
Drive Pump 0 0 0 0 0 0
4 4 4 4 4 4
1 1 1 1 1 1
5 5 5 5 5 5
X X X X X X
6 6 6 X X 6
X X X X X X
Jib 1 1 1 1 1 1 Boom Control 0 0 0 0 0 0
4 Wheel Steer 0 0 0 0 0 0 1 1 1 1 1 1
Soft Touch/Sky- 0 0 0 0 0 0 Function Speed 0 0 0 0 0 0
guard 1 1 1 1 1 1 Knob 1 1 1 1 1 1
2 2 2 2 2 2 Clearsky 0 0 0 0 0 0
3 3 3 3 3 3
1 1 1 1 1 1
Gen Set / Welder 0 0 0 0 0 0 Cribbing Option 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Gen Set Cutout 0 0 0 0 0 0 Fuel Tank Size 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Head & Taillights 0 0 0 0 0 0 Alarm / Horn 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Cable Breaks Switch 0 0 0 0 0 0 Alert Beacon 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Load System 0 0 0 0 0 0
Temp Cutout X 0 X 0 X X
X 1 X X X 1 X 1 X 1 X X
X 2 X 2 2 2 Plat Lvl Ovr Cut 0 0 0 0 0 0
X 3 X 3 X 3 1 1 1 1 1 1
X 4 X X X 4 BOLD TEXT indicates the default setting. Plain text indicates another available
Load Sensor 0 0 0 0 0 0 selection. ITALIC TEXT indicates the default when option is factory installed.
1 1 1 1 1 1 SHADED CELLS indicate hidden menu or selection.

3121628 6-17
SECTION 6 - JLG CONTROL SYSTEM

6.2 MACHINE PERSONALITY SETTINGS AND NOTE: Personality settings can be adjusted within the adjustment
range in order to achieve optimum machine performance.
FUNCTION SPEEDS
Table 6-5. Machine Personality Settings

SUBMENU DEFAULTS DEFAULTS

(DISPLAYED ON PERSONALITY RANGE (800A (800A
ANALYZER 1ST LINE) Sauer Danfoss) Eaton)
DRIVE: ACCELeration 0.0 to 5.0s 2.0 2.0
DECELeration 0.0 to 3.0s 2.0 2.0
FORward MINimum speed 1 to 35% 4 15
FORward MAXimum speed 1 to 100% 30 55
REVerse MINimum speed 1 to 35% 4 15
REVerse MAXimum speed 1 to 100% 34 55
ELEVATED MAXimum speed 1 to 100% 15 28
CREEP MAXimum speed 1 to 90% 15 32

STEER: MAXimum speed 1 to 100% 100 100

MAIN LIFT: ACCELeration 0.0 to 5.0s 2.9 2.9

DECELeration 0.0 to 3.0s 1.0 1.0
MINimum LEFT speed 1 to 60% 26 26
MAXimum LEFT speed 1 to 100% 88 88
CREEP maximum LEFT speed 1 to 65% 62 62
MINimum RIGHT speed 1 to 60% 25 25
MAXimum RIGHT speed 1 to 100% 95 95
CREEP maximum RIGHT speed 1 to 75% 69 69

TOWER LIFT: ACCELeration 0.0 to 5.0s 2.8 2.8

DECELeration 0.0 to 3.0s 0.8 0.8
MlNimum UP speed 1 to 60% 53 53
MAXimum UP speed 1 to 100% 90 90
MINimum DOWN speed 1 to 60% 53 53
MAXimum DOWN speed 1 to 100% 90 90
Medium Speed 0.01 to 1.00 0.30 0.30

SWING ACCELeration 0.0 to 5.0s 2.8 2.8

DECELeration 0.0 to 3.0s 2.5 2.5
MINimum LEFT speed 1 to 50% 25 25
MAXimum LEFT speed 1 to 100% 70 70
CREEP maximum LEFT speed 1 to 65% 62 62
MINimum RIGHT speed 1 to 50% 25 25
MAXimum RIGHT speed 1 to 100% 73 73
CREEP maximum RIGHT speed 1 to 65% 62 62

6-18 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Personality Settings

SUBMENU DEFAULTS DEFAULTS

(DISPLAYED ON PERSONALITY RANGE (800A (800A
ANALYZER 1ST LINE) Sauer Danfoss) Eaton)

MAIN TELESCOPE: ACCELeration 0.0 to 5.0s 3.5 3.5

DECELeration 0.0 to 3.0s 0.8 0.8
MINimum IN speed 1 to 65% 40 40
MAXimum IN speed 1 to 100% 75 75
MINimum OUT speed 1 to 65% 40 40
MAXimum OUT speed 1 to 100% 70 70
Medium Speed 0.01 to 1.00 0.50 0.50

TELESCOPE TOWER: ACCELeration 0.0 to 5.0s 1.0 1.0

DECELeration 0.0 to 3.0s 0.5 0.5
MINimum IN speed 1 to 65% 45 45
MAXimum IN speed 1 to 100% 90 90
MINimum OUT speed 1 to 65% 55 55
MAXimum OUT speed 1 to 100% 90 90
Medium Speed 0.01 to 1.00 0.40 0.40

PLATFORM LEVEL: ACCELeration 0.0 to 5.0s 2.5 2.5

DECELeration 0.0 to 3.0s 1.0 1.0
MINimum UP speed 1 to 65% 45 45
MAXimum UP speed 1 to 100% 55 55
MlNimum DOWN speed 1 to 65% 45 45
MAXimum DOWN speed 1 to 100% 55 55
Medium Speed 0.01 to 1.00 0.60 0.60

PLATFORM ROTATE: ACCELeration 0.0 to 5.0s 1.8 1.8

DECELeration 0.0 to 3.0s 0.5 0.5
MlNimum LEFT speed 1 to 100% 25 25
MAXimum LEFT speed 1 to 100% 60 60
MINimum RIGHT speed 1 to 100% 25 25
MAXimum RIGHT speed 1 to 100% 60 60
Medium Speed 0.01 to 1.00 0.35 0.35

JIB LIFT Lift ACCELeration 0.0 to 5.0s 2.5 2.5

Lift DECELeration 0.0 to 3.0s 1.0 1.0
MINimum UP speed 1 to 65% 27 27
MAXimum UP speed 1 to 100% 50 50
MINimum down 1 to 65% 26 26
Max Down 1 to 100% 45 45
Medium Speed 0.01 to 1.00 0.35 0.35

3121628 6-19
SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Personality Settings

SUBMENU DEFAULTS DEFAULTS

(DISPLAYED ON PERSONALITY RANGE (800A (800A
ANALYZER 1ST LINE) Sauer Danfoss) Eaton)

GROUND MODE Tower LIFT UP speed 1 to 100% 89 89

Tower LIFT DOWN speed 1 to 100% 89 89
Main LIFT UP speed 1 to 100% 87 87
Main LIFT DOWN speed 1 to 100% 94 94
SWING speed 1 to 100% 65 65
Main TELEscope speed 1 to 100% 69 69
Tower TELEscope speed 1 to 100% 89 89
PLATFORM ROTATE speed 1 to 100% 59 59
PLATFORM LEVEL speed 1 to 100% 54 54
JIB LIFT speed 1 to 100% 44 44
Note: Ground Mode speed are automatically limited to being lower than platform speed for a given function.
4150365-I

6-20 3121628
SECTION 6 - JLG CONTROL SYSTEM

6.3 MACHINE ORIENTATION WHEN SETTING Test Notes

FUNCTION SPEEDS 1. Stop watch should be started with the function, not
Tower Lift: main Boom Horizontal, Telescoped In. Tower Lift with the controller or switch.
Up, Record Time. Tower Lift Down, Record Time.
2. Drive test results reflect 15x19.5 or 18x19.5 tires, pneu-
Tower Telescope: Tower Lift Fully Elevated, main Boom Hori- matic or foam filled.
zontal, Telescoped In. Tower Tele Out, Record Time. Tower Tele
In, Record Time. 3. All speed tests are run from the platform. These speeds
do not reflect the ground control operation.
Lift: Tower Lift Fully Elevated, Tower Telescope Fully Extended,
Main Telescope Fully Retracted. 4. The platform speed knob control must be at full speed
(turned clockwise completely).
Swing: Boom at Full Elevation. Telescope Retracted. Swing the
Turntable off center and stop. Swing the opposite direction 5. Function speeds may vary due to cold, thick hydraulic
and start the test when the turntable is centered up. This elim- oil. Test should be run with the oil temperature above
inates ramp up and down on the controller affecting times. 100° F (38° C).
Telescope: Boom at Full Elevation; Telescope Retracted; Tele- 6. Some flow control functions may not work with the
scope Out, Record Time. Telescope In, Record Time. speed knob clicked into the creep position.
Drive (Forward/Reverse): Test should be done on a smooth
level surface. Drive Select Switch should be set to high speed. Table 6-6. Function Speeds
Start approximately 25 ft. (7.62 m) from the starting point so
Function Speed (In Seconds)
that the unit is at maximum speed when starting the test.
Results should be recorded for a 200 ft. (60.96 m) course. Drive Main Lift Up 45 - 50
Forward, Record Time. Drive Reverse, Record Time. Main Lift Down 45 - 50
Drive (Above Horizontal): Test should be done on a smooth, Swing Right & Left 79 - 101
level surface. Drive Select Switch should be set to Low Engine, NOTE: No more than 10% difference between swing left and
Low Drive. The Platform Speed Control Knob should be posi- swing right.
tioned to Creep Speed. This simulates machine speed when Main Telescope In
the boom is above horizontal. Results should be recorded for a 800A 30-40
50 ft. (15.2 m) course. Drive Forward, Record Time. Drive 800AJ 24-34
Reverse, Record Time.
Main Telescope Out
Platform Rotate: Platform level and completely rotated one 800A 35-45
direction. Rotate the opposite direction, Record Time. Rotate 800AJ 30-40
the other direction, Record Time. Platform Rotate Right & Left 19 - 30
Articulating Jib: Platform level and centered with the boom. NOTE: No more that 15% difference between rotator left and
Start with the Jib down. Jib Up, Record Time. Jib Down, Record rotator right.
Time. Jib Up 20-30
Jib Down 30-40
Tower Lift Up 57 - 70
Tower Lift Down 44 - 53
Tower Telescope Out 24 - 32
Tower Telescope In 15-25
Drive (2WD) Forward & Reverse 33-45
Drive (4WD) Forward & Reverse 33-45
Drive Horizontal Above Elevation
(2 & 4WD) Forward & Reverse (CE) 122 Min
Drive Horizontal Above Elevation
2WD Forward & Reverse (ANSI) 61-70
Drive Horizontal Above Elevation
4WD Forward & Reverse (ANSI) 122 Min
4150241-G

3121628 6-21
SECTION 6 - JLG CONTROL SYSTEM

6.4 CANBUS COMMUNICATIONS Interlocks: Any device that sends an electrical input. (For an
example a limit switch, proximity switch, etc;)
CANbus: CAN (Control Area Network) is a two wire differential
serial link between the Platform Module, Jib Module, Ground Platform Level: The GROUND MODULE stores the default val-
Module, Boom Length Angle Module and the Chassis Module ues and handles interlocks. The PLATFORM MODULE reads the
providing bi-directional communications. sensors mounted on the platform assembly and controls the
Level Up / Down valves to maintain setpoint sent from the
Two-wire: One wire (red) is driven high (5v) and the other low GROUND MODULE.
(black) (0v) to send a signal; both wires ”float” (2.5v) when no
Steer: The GROUND MODULE stores crack points and sends
signal is being sent.
desired drive direction, steering mode and axle extend/retract
commands. The PLATFORM MODULE reports the steering
Differential: Any electrical line noise can affect the high or the
switch position to the GROUND MODULE.
low wires but never both, so communications is not corrupted.
Drive: The GROUND MODULE stores crack points, sends com-
Serial Link: Messages are being sent bit by bit along the wires; mands for each drive pump. (Command is computed from
the high bus speed allow all modules to be constantly drive joystick input, interlocks, wheel angle, etc).
updated around 20 times per second. Typical traffic is 300 -
Lift, Tele, & Swing: The GROUND MODULE stores default val-
500 messages per second.
ues and handles interlocks and calibration information. Lift,
Telescope and Swing commands are dependent upon inter-
A complete CANbus circuit is approximately 60 ohms, which
locks through out the machine. Boom angle, length and swing
can be verified at the ”T” fitting inside the ground station or
are controlled by the GROUND MODULE.
below the BLAM. Each individual circuit from the modules is
approximately 120 ohms.

The GROUND MODULE (UGM) is the master system controller.

Most functions are dispatched and coordinated from this
module, The PLATFORM MODULE handle sub-tasks. All charac-
terized information (values) are stored into the ground mod-
ule (i.e., Personalities or Calibrations).

6-22 3121628
SECTION 6 - JLG CONTROL SYSTEM

TO
DIAGNOSTICS:
SYSTEM

NOTE: The layout shown includes all possi-

ble analyzer screens. Please note
TO that some screens may not be avail-
MENU :
SYTEM TEST able depending upon machine con-
figuration and software versions.

Figure 6-3. Analyzer Flow Chart_Version 6.X Software -Sheet 1 of 8

3121628 6-23
SECTION 6 - JLG CONTROL SYSTEM

FROM TO
DIAGNOSTICS: DIAGNOSTICS:
ENGINE CAN STATISTICS

NOTE: The layout shown includes all possi-

ble analyzer screens. Please note
that some screens may not be avail-
able depending upon machine con-
figuration and software versions.

Figure 6-4. Analyzer Flow Chart_Version 6.X Software -Sheet 2 of 8

6-24 3121628
SECTION 6 - JLG CONTROL SYSTEM

FROM
DIAGNOSTICS:
LOAD

NOTE: The layout shown includes all possi-

ble analyzer screens. Please note
that some screens may not be avail-
able depending upon machine con-
figuration and software versions.

Figure 6-5. Analyzer Flow Chart_Version 6.X Software -Sheet 3 of 8

3121628 6-25
SECTION 6 - JLG CONTROL SYSTEM

FROM
MENU :
DIAGNOSTICS

TO
PERSONALITIES:
MAIN TELESCOPE

TO
MENU :
MACHINE SETUP

NOTE: The layout shown includes all possi-

ble analyzer screens. Please note
that some screens may not be avail-
able depending upon machine con-
figuration and software versions.

Figure 6-6. Analyzer Flow Chart_Version 6.X Software -Sheet 4 of 8

6-26 3121628
SECTION 6 - JLG CONTROL SYSTEM

FROM
PERSONALITIES:
TOWER LIFT

NOTE: The layout shown includes all possible

analyzer screens. Please note that
some screens may not be available
depending upon machine configura-
tion and software versions.

Figure 6-7. Analyzer Flow Chart_Version 6.X Software -Sheet 5 of 8

3121628 6-27
SECTION 6 - JLG CONTROL SYSTEM

FROM
MENU :
PERSONALITIES

TO
TO
LOAD SYSTEM:
MENU :
NO
CALIBRATIONS

NOTE: The layout shown includes all possi-

ble analyzer screens. Please note that
some screens may not be available
depending upon machine configura-
tion and software versions.

Figure 6-8. Analyzer Flow Chart_Version 6.X Software -Sheet 6 of 8

6-28 3121628
SECTION 6 - JLG CONTROL SYSTEM

FROM
CABLE SWITCH :
NO

NOTE: The layout shown includes all possible

analyzer screens. Please note that
some screens may not be available
depending upon machine configura-
tion and software versions.

Figure 6-9. Analyzer Flow Chart_Version 6.X Software -Sheet 7 of 8

3121628 6-29
SECTION 6 - JLG CONTROL SYSTEM

FROM
MENU :
MACHINE SETUP

NOTE: The layout shown includes all possible

analyzer screens. Please note that
some screens may not be available
depending upon machine configura-
tion and software versions.

Figure 6-10. Analyzer Flow Chart_Version 6.X Software -Sheet 8 of 8

6-30 3121628
SECTION 6 - JLG CONTROL SYSTEM

Figure 6-11. Fault Code Light Location

3121628 6-31
SECTION 6 - JLG CONTROL SYSTEM

PLATFORM CONNECTION

GROUND CONTROL CONNECTION

Figure 6-12. Analyzer Connecting Points

6-32 3121628
SECTION 6 - JLG CONTROL SYSTEM

Connector

1001103667 U

Figure 6-13. Ground Control Module - Sheet 1 of 3

3121628 6-33
SECTION 6 - JLG CONTROL SYSTEM

Connector

1001103667 U

Figure 6-14. Ground Control Module - Sheet 2 of 3

6-34 3121628
SECTION 6 - JLG CONTROL SYSTEM

Connector

1001103667 U

Figure 6-15. Ground Control Module - Sheet 3 of 3

3121628 6-35
SECTION 6 - JLG CONTROL SYSTEM

CONNECTOR PIN ASSIGNMENT FUNCTION

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

CONNECTOR PIN ASSIGNMENT FUNCTION

1 UNALLOCATED DIGITAL INPUT
2 UNALLOCATED DIGITAL INPUT
3 BATTERY VOLTAGE HS DIGITAL INPUT
4 DRIVE ORIENTATION SYSTEM OVERRIDE SWITCH HS DIGITAL INPUT
5 UNALLOCATED 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 BROKEN CABLE INDICATOR LAMP OUTPUT
11 PLATFORM OVERLOADED INDICATOR LAMP OUTPUT
12 500 LB CAPACITY INDICATOR LAMP OUTPUT
13 1000 LB CAPACITY INDICATOR LAMP OUTPUT
14 DRIVE ORIENTATION SYSTEM INDICATOR LAMP OUTPUT
15 GENERATOR ON INDICATOR LAMP OUTPUT
16 SOFT TOUCH TRIGGERED INDICATOR LAMP OUTPUT
17 GLOW PLUG ENGAGED INDICATOR LAMP OUTPUT
J2 18 LAMP RETURN GROUND
GRAY 19 DRIVE DISABLED INDICATOR LAMP OUTPUT
20 UPRIGHT TILTED INDICATOR 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 FUEL LEVEL INDICATORS RETURN GROUND
26 ANALYZER POWER ANALYZER POWER
27 ANALYZER GROUND ANALYZER GROUND
28 ANALYZER RX ANALYZER RX
29 ANALYZER TX ANALYZER TX
30 BATTERY VOLTAGE BATTERY VOLTAGE
31 BATTERY VOLTAGE BATTERY VOLTAGE
32 BATTERY VOLTAGE BATTERY VOLTAGE
33 BATTERY VOLTAGE BATTERY VOLTAGE
34 SWITCH POWER BATTERY VOLTAGE
35 FULL FUEL LEVEL INDICATOR LAMP OUTPUT

1001106938 A

Figure 6-16. Platform Control Module - Sheet 1 of 2

6-36 3121628
SECTION 6 - JLG CONTROL SYSTEM

CONNECTOR PIN ASSIGNMENT FUNCTION

1 MODULE GROUND GROUND
J8 2 MODULE POWER BATTERY VOLTAGE

CONNECTOR PIN ASSIGNMENT FUNCTION

1 LIFT / SWING JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE
2 LIFT CENTER TAP INPUT
3 LIFT SIGNAL INPUT
J5 4 SWING SIGNAL INPUT
NATURAL 5 SWING CENTER TAP INPUT
6 NOT CONNECTED INPUT
7 LIFT / SWING JOYSTICK RETURN GROUND
8 GROUND RETURN GROUND

CONNECTOR PIN ASSIGNMENT FUNCTION

1 DRIVE / STEER JOYSTICK SUPPLY VOLTAGE 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 RETURN GROUND
8 GROUND RETURN 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 (FUNCTION ENABLE SWITCH) POWER BATTERY VOLTAGE
5 GENERATOR SWITCH POWER BATTERY VOLTAGE
6 JIB BLOCK LIMIT SWITCH POWER BATTERY VOLTAGE
7 SOFT TOUCH LIMIT SWITCH POWER BATTERY VOLTAGE
8 FOOTSWITCH SIGNAL DIGITAL INPUT
9 GENERATOR ON SIGNAL DIGITAL INPUT
10 +7 REFERENCE VOLTAGE +7 REFERENCE VOLTAGE
11 LOAD CELL INPUT 1 ANALOG INPUT
12 LOAD CELL INPUT 2 ANALOG INPUT
13 UNALLOCATED ANALOG INPUT
14 GROUND RETURN GROUND
15 LOAD CELL REFERENCE VOLTAGE +7 REFERENCE VOLTAGE
16 LOAD CELL RETURN GROUND
17 JIB BLOCK LIMIT SWITCH HS DIGITAL INPUT
J7 18 SOFT TOUCH LIMIT SWITCH HS DIGITAL INPUT
BLACK 19 PLATFORM ALARM LAMP OUTPUT
20 ALARM RETURN GROUND
21 PLATFORM LEVEL UP ME DIGITAL OUTPUT
22 PLATFORM LEVEL DOWN ME DIGITAL OUTPUT
23 GROUND RETURN GROUND
24 GROUND RETURN GROUND
25 JIB UP ME DIGITAL OUTPUT
26 JIB DOWN ME DIGITAL OUTPUT
27 UNALLOCATED ME DIGITAL OUTPUT
28 UNALLOCATED ME DIGITAL OUTPUT
29 GROUND RETURN GROUND
30 CAN LOW CAN LOW
31 CAN HIGH CAN HIGH
32 CAN SHIELD CAN SHIELD
33 PLATFORM ROTATE LEFT ME DIGITAL OUTPUT
34 PLATFORM ROTATE RIGHT ME DIGITAL OUTPUT
35 GROUND RETURN GROUND

1001106938 A

Figure 6-17. Platform Control Module - Sheet 2 of 2

3121628 6-37
SECTION 6 - JLG CONTROL SYSTEM

Analyzer Diagnostics Menu Structure

In the following structure descriptions, an intended item is move between items in the same level. The UP or

selected by pressing ENTER; pressing ESC steps back to DOWN arrow keys alter a value if allowed

the next outer level. The LEFT /RIGHT arrow keys

Table 6-7. ADJUSTMENTS - Personality Descriptions

DRIVE

ACCEL Displays/adjusts drive acceleration

DECEL Displays/adjusts drive deceleration

MIN FORWARD Displays/adjusts minimum forward drive speed

MAX FORWARD Displays/adjusts maximum forward drive speed

MIN REVERSE Displays/adjusts minimum reverse drive speed

MAX REVERSE Displays/adjusts maximum reverse drive speed

ELEVATED MAX Displays/adjusts maximum drive speed

NOTE: used when elevation cutout switches are limiting maximum speed

CREEP MAX Displays/adjusts maximum drive speed

NOTE: used when creep switch on pump pot is active

STEER MAX Displays/adjusts the maximum steer speed

LIFT

ACCEL Displays/adjusts main lift acceleration

DECEL Displays/adjusts main lift deceleration

MIN UP Displays/adjusts minimum main lift up speed

MAX UP Displays/adjusts maximum main lift up speed

CREEP UP Displays/adjusts maximum main lift up speed

NOTE: used when creep switch on pump pot is active

MIN DOWN Displays/adjusts minimum main lift down speed

MAX DOWN Displays/adjusts maximum main lift down speed

CREEP DOWN Displays/adjusts maximum main lift down speed

NOTE: used when creep switch on pump pot is active

SWING

ACCEL Displays/adjusts swing acceleration

DECEL Displays/adjusts swing deceleration

MIN LEFT Displays/adjusts minimum swing left speed

MAX LEFT Displays/adjusts maximum swing left speed

6-38 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-7. ADJUSTMENTS - Personality Descriptions

CREEP LEFT Displays/adjusts maximum swing left speed

NOTE: used when creep switch on pump pot is active

MIN RIGHT Displays/adjusts minimum swing right speed

MAX RIGHT Displays/adjusts maximum swing right speed

CREEP RIGHT Displays/adjusts maximum swing right speed

NOTE: used when creep switch on pump pot is active

main TELESCOPE

ACCEL Displays/adjusts telescope acceleration

DECEL Displays/adjusts telescope deceleration

MIN IN Displays/adjusts minimum telescope in speed

MAX IN Displays/adjusts maximum telescope in speed

MIN OUT Displays/adjusts minimum telescope out speed

MAX OUT Displays/adjusts maximum telescope out speed

BASKET LEVEL

ACCEL Displays/adjusts basket level acceleration

DECEL Displays/adjusts basket level deceleration

MIN UP Displays/adjusts minimum basket level up speed

MAX UP Displays/adjusts maximum basket level up speed

MIN DOWN Displays/adjusts minimum basket level down speed

MAX DOWN Displays/adjusts maximum basket level down speed

BASKET ROTATE

ACCEL Displays/adjusts basket rotate acceleration

DECEL Displays/adjusts basket rotate deceleration

MIN LEFT Displays/adjusts minimum basket rotate left speed

MAX LEFT Displays/adjusts maximum basket rotate left speed

MIN RIGHT Displays/adjusts minimum basket rotate right speed

MAX RIGHT Displays/adjusts maximum basket rotate right speed

JIB LIFT Not displayed if JIB = NO

ACCEL Displays/adjusts jib acceleration

DECEL Displays/adjusts jib deceleration

MIN UP Displays/adjusts minimum jib up speed

MAX UP Displays/adjusts maximum jib up speed

MIN DOWN Displays/adjusts minimum jib down speed

3121628 6-39
SECTION 6 - JLG CONTROL SYSTEM

Table 6-7. ADJUSTMENTS - Personality Descriptions

MAX DOWN Displays/adjusts maximum jib down speed

MIN LEFT Displays/adjusts minimum jib left speed

MAX LEFT Displays/adjusts maximum jib left speed

MIN RIGHT Displays/adjusts minimum jib right speed

MAX RIGHT Displays/adjusts maximum jib right speed

STEER

MAX SPEED Displays/adjusts maximum steer speed, which applies when vehicle speed is at
minimum

GROUND MODE

LIFT UP Displays/adjusts fixed lift up speed

LIFT DOWN Displays/adjusts fixed lift down speed

SWING Displays/adjusts fixed swing speed

TELE Displays/adjusts fixed telescope speed

BASKETLEVEL Displays/adjusts fixed basket level speed

BASKETROTATE Displays/adjusts fixed basket rotate speed

JIB (U/D) Displays/adjusts jib lift speed

Not displayed if JIB = NO

JIB (L/R) Displays/adjusts jib swing speed

Not displayed if JIB = NO

6-40 3121628
SECTION 6 - JLG CONTROL SYSTEM

6.5 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).

3121628 6-41
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 6-8, Diagnostic Menu Descriptions details the structure
To access the Diagnostic Menu, use the LEFT and RIGHT of the Diagnostic Menu, and describes the meaning of each
piece of information presented.
Arrow keys to select DIAGNOSTICS from the Top Level

Menu. Press the ENTER key to view the menu.

Table 6-8. Diagnostic Menu Descriptions

Diagnostics Menu Parameter (Displayed on Parameter Value

Description
(Displayed on Analyzer 1st Line) Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
PLATFORM LOAD STATE: OK / OVERLOAD LSS Status.
PLATFORM LOAD ACTUAL: XXX.X KG Calibrated weight of the platform.
??? if Platform Load is Unhealthy**.
PLATFORM LOAD (service*) GROSS: XXX.X KG Gross weight of the platform.
??? if both Cells are Unhealthy**.
PLATFORM LOAD (service*) OFFSET 1: XXX.X KG Stored offset weight of Cell 1.
??? if LSS is not calibrated.
PLATFORM LOAD (service*) OFFSET 2: XXX.X KG Stored offset weight of Cell 1.
??? 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

6-42 3121628
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).

3121628 6-43
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 6-9, Accessory Weights. Use the up and

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

ENTER . The screen will read:

8. If the platform is empty, press ENTER . The screen

will read:

Table 6-9. Accessory Weights

Accessory Weight

LOAD SENSI NG: SkyWelder (stick welder) 70 lb (32 kg)

accessory xxxlbs: SkyWelder Prep Prep only = 15 lb (7 kg)
Full install = 70 lb (32 kg)
SkyCutter (plasma cutter) 70 lb (32 kg)
SkCutter / SkyWelder Combo 140 lb (64 kg)
Fire Extinguisher 45 lb (20 kg)
Overhead SoftTouch 80 lb (36 kg)
Work Surface 20 lb (9 kg)
NOTE: Not all Accessories are available on every JLG model.
Some Accessory combinations are prohibited due to
excessive weight and/or load restriction. If any installed
JLG Accessories are labeled with weight decals but are
not listed in the table above, include their weight when
entering the ACC WEIGHT value.

6-44 3121628
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:

3121628 6-45
SECTION 6 - JLG CONTROL SYSTEM

12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-11. Pipe Rack Capacity Reductions

ENTER . The control system will default to an esti- PLATFORM OVRLD

Capacity PLATFORM OVRLD
mate of unrestricted capacity, which can be adjusted if RESTRICT
necessary. Refer to Table 6-10, SkyGlazier Capacity 500 lb (227 kg) 400 lb (181 kg) n/a
Reductions and Table 6-11, Pipe Rack Capacity Reduc- 550 lb (250 kg) 450 lb (204 kg) n/a
tions.
600 lb (272 kg) 500 lb (227 kg) n/a
The screen will read: 750 lb (340 kg) n/a 650 lb (295 kg)
1000 lb (454 kg) n/a 900 lb (408 kg)
Note: If both SkyGlazier and Pipe Racks are configured, capacity will be the lower of the
two values.

13. Press ENTER . The following screen will be dis-

played for restricted capacity, which can be adjusted if
necessary. Refer to Table 6-10, SkyGlazier Capacity
Reductions and Table 6-11, Pipe Rack Capacity Reduc-
tions.

Table 6-10. SkyGlazier Capacity Reductions

PLATFORM OVRLD
Capacity PLATFORM OVRLD
RESTRICT
500 lb (227 kg) 400 lb (181 kg) n/a
550 lb (250 kg) 400 lb (181 kg) n/a
600 lb (272 kg) 400 lb (181 kg) n/a
750 lb (340 kg) n/a 590 lb (268 kg)
1000 lb (454 kg) n/a 750 lb (340 kg)
Note: If both SkyGlazier and Pipe Racks are configured, capacity will be the lower of the
two values.

6-46 3121628
SECTION 6 - JLG CONTROL SYSTEM

14. Press ENTER . If calibration is successful, the screen

will read:

3121628 6-47
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).

6-48 3121628
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 6-12. LSS Troubleshooting Chart

Difficulty Possible Resolution

Empty Platform Weight (DIAGNOSTICS, PLAT- The LSS System is unable to properly measure the platform weight.
FORM LOAD) is not within ±15lbs (±7kg) of
zero. 1. The Load Cell is not properly plugged into the LSS Harness. It is possible poor electrical contact is made.
or
Platform Load readings (DIAGNOTICS, PLTLOAD) 2. Wiring leading to the Load Cell is damaged. Carefully inspect sensor wiring where it passes through cable clamps for signs of damage.
are unstable by more than ±2lbs (±1kg) (with- Inspect wiring where damage to the channel is apparent.
out the influence of vibration or wind).
or 3. The Load Cell was not assembled properly during installation. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAG-
There are large variations in Platform Load NOSTICS, CELL, LOAD displays and determine if the readings are reasonable. It is often helpful to apply slight downward pressure above the
(DIAGNOSTICS, PLTLOAD) based on the location sensor and observe that its output increases (increasing force measurement; decreasing means the sensor is mounted upside-down).
of the load. Tolerance to variations is 20lbs for
an evaluation using the technician’s weight, 4. The Load Cell is contaminated by debris or moisture. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS,
and +5% of Rated Load when using calibrated CELL, LOAD displays and determine if the readings are reasonable and stable (not changing by more than ±2lbs (±1kg) (without the influ-
weights. ence of vibration or wind). Lack of measurement stability is a key indication of contamination. Unplug the connector and inspect for dirt or
moisture. Look carefully into the female connector on the sensor’s cordset for evidence of contamination. Debris should be brushed away
with a soft bristle brush (do not introduce any cleaners as they will leave conductive residue). Moisture should be allowed to evaporate or
accelerated with a heat-gun (use low heat and be carefully to not melt connector materials). Moisture intrusion into the molded portion of
the connector (capillary action into the wire bundle) or the Shear Beam Load Cell itself will require replacement of the sensor.

5. The Load Cell has been mechanically damaged. If the Load Cell is physically deformed or has damage to the cover it should be replaced
immediately. It is also possible to have invisible mechanical damage resulting from an extreme overload (>6000lbs [>2722kg]).
The Visual and Audible Overload Warnings fail The Control System is failing to regard the overload signal from the LSS System, or the signal is shorted.
to sound when platform is loaded beyond Rated
Load, or when simulated by unplugging the 1. The Load Sensing System must be enabled within the Control System. Plug the JLG Analyzer into the Control System, enter the Access
Load Cell. Controls remain functional at Plat- Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu. The selection “2=CUTOUT PLT” should be displayed (plat-
form and Ground Control positions. form controls prevented during overload, ground controls remain operational). In country- or customer-specific circumstance, the selec-
tion “3=CUTOUT ALL” is used (platform and ground controls prevented during overload).
The Ground Audible Warning fails to sound, but The Ground Alarm is missing or improperly installed. Verify that the device is mounted. Verify wiring from the Main Terminal Box and
the Platform Audible Warning sounds properly. Ground Module.
Controls remain functional at the Ground Con- The JLG Control System is configured to prevent platform controls only in the event of overload. Alternately, the Host Control System can be
trol position during an overload, or when simu- configured to prevent ground and platform controls for country- or customer-specific circumstances.
lated by unplugging the Load Cell. The Controls Using the JLG Analyzer, enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter to
at the Platform Control position are prevented “2=CUTOUT PLT” to prevent platform controls in the event of overload. Set this parameter to “3=CUTOUT ALL” to prevent platform and
when using the engine, but not when using the ground controls in the event of overload.
Auxiliary Power Unit.

3121628 6-49
SECTION 6 - JLG CONTROL SYSTEM

6.6 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 Down 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 .

6-50 3121628
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.

3121628 6-51
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

001 00 1 EVERYTHING OK The normal help message in Platform No response required for this
Mode. DTC.
002 00 2 GROUND MODE OK The normal help message in Platform No response required for this
Mode. DTC.
0010 00 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX" Response described in Drive
while the vehicle is out of transport posi- Modes section.
tion.The normal help message in Ground
Mode.
000 00 0 <<< HELP COMMENT >>>
0011 00 11 FSW OPEN (Foot switch open) A drive / boom function was selected with The UGM shall not Enable the
the Footswitch open. Machine.
0012 00 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the The UGM shall limit the
Creep Switch is open. machine to Creep speed.
0013 00 13 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All functions at creep while the Platform is
elevated and the Chassis is tilted.
0014 00 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 degrees for more Not reported during power-
then 4 seconds. up.
0015 00 15 LOAD SENSOR READING UNDER WEIGHT The Load Sensing System indicates > 20%
under calibrated zero point.
0031 00 31 FUEL LEVEL LOW - ENGINE SHUTDOWN Engine Shutdown has occurred due to Fuel Response described in Fuel
Level = EMPTY condition. Shutdown section.
0035 00 35 APU ACTIVE Auxiliary Power/Emergency Descent Response described in Auxil-
Mode is active. iary Power/Emergency
Descent Mode section.
0039 00 39 SKYGUARD ACTIVE - FUNCTIONS CUTOUT Response described in Auxiliary Power/ Response described in Sky-
Emergency Descent Mode section. Guard section.
0040 00 40 RUNNING AT CREEP - CREEP SWITCH CLOSED All Function speeds are limited to creep
because the creep switch is closed.
210 21 0 <<< POWER-UP >>>
211 21 1 POWER CYCLE The normal help message is issued at each
power cycle.
212 21 2 KEYSWITCH FAULTY Both Platform and Ground modes are The UGM shall assume a sta-
selected simultaneously. tion selection of Ground.
213 21 3 FSW FAULTY Both Footswitches are closed for more then The UGM shall not Enable the
one second. Machine.
220 22 0 <<< PLATFORM CONTROLS >>>
227 22 7 STEER SWITCHES FAULTY Both Steer Left and Steer Right inputs are The UGM shall prohibit Steer;
closed simultaneously. The UGM shall limit Drive to
Creep
The Steer Left switch input =
Low;
The Steer Right switch input =
Low;
Steer and full Drive speed per-
mitted after
controls are initialized
2211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed for more then Can be reported during
seven seconds. power- up.

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SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

2212 22 12 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected with Foot- Can be reported during
switch open. power- up.
2213 22 13 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected with Foot- The UGM shall not Enable the
switch open. Machine.
2214 22 14 DRIVE/STEER LOCKED - JOYSTICK MOVED BEFORE ENABLE Drive/Steer was selected before Enable
switch activated.
2216 22 16 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference voltage is Resistive joysticks.
> 8.1V. If the reference voltage is >
7.7V then the reference
voltage is out of tolerance of a
short to battery has
occurred.
2217 22 17 D/S JOY. CENTER TAP BAD The D/S Joystick center tap voltage is Resistive joysticks.
< 3.08V or > 3.83V. - There is a +/-.1V range.
around these values due to
resistor tolerances.
2219 22 19 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference voltage is Resistive joysticks.
> 8.1V. - If the reference voltage is >
7.7V then the reference
voltage is out of tolerance of a
short to battery has
occurred.
2220 22 20 L/S JOY. CENTER TAP BAD The L/S Joystick center tap voltage is < Resistive joysticks.
3.08V or > 3.83V. - There is a +/- .1V range.
around these values due to
resistor tolerances.
2221 22 21 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A lift / swing function was selected with If triggered by the Lift and/or
Footswitch open. Swing joystick not being in
the neutral position at
Startup, the UGM shall pro-
hibit Lift and Swing.
If triggered by Lift and/or
Swing joystick is not in the
neutral position when Foot-
switch becomes active or
while DTC 2212, 2213 or 2223
is active, the UGM shall not
Enable the Machine.
2222 22 22 WAITING FOR FSW TO BE OPEN The Footswitch was closed during Platform Can be reported during
selection. power- up.
2223 22 23 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE A boom function was selected with Foot- The UGM shall not Enable the
switch open. Machine.
2224 22 24 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed during engine The UGM shall prohibit
start. Engine Start.
2269 22 69 FUNCTION PROBLEM - HIGH SPEED & CREEP ACTIVE
TOGETHER

3121628 6-53
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

234 23 4 FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM A boom function has both directions Disable whichever boom
selected together. functions whose boom control
inputs are triggering the fault.
If Engine Start/Aux at fault,
disable Engine Start but per-
mit Auxiliary Power/
Emergency Descent.
235 23 5 FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX A boom function was selected
POWER before aux power.
236 23 6 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START A boom function was selected
SWITCH before engine start.
237 23 7 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH The Start Switch was closed during power- The UGM shall prohibit
up. Engine Start.
23163 23 163 FUNCTION PROBLEM - MSSO PERMANENTLY SELECTED The MSSO switch input = Low at Startup. No response required for this
DTC Power Cycled.
240 24 0 <<< OTHER CONTROLS >>>
241 24 1 AMBIENT TEMPERATURE SENSOR - OUT OF RANGE LOW MACHINE SETUP > TEMP CUTOUT = YES; The UGM shall set Low Tem-
Ambient Temperature sensor reading - perature Cutout state = Faulty
50C. If the Machine is in Platform
Mode and if the Boom is
Above Elevation;
The UGM shall suspend
motion;
If the Machine is in Ground
Mode; No response required
for this DTC.
242 24 2 AMBIENT TEMPERATURE SENSOR - OUT OF RANGE HIGH Ambient Temperature sensor reading Check Ambient Temperature
≥ 85C. sensor reading < 85C.
250 25 0 <<< FUNCTION PREVENTED >>>
259 25 9 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been changed. Disable all machine and
engine functions (i.e., com-
mand engine shutdown and
do not permit start).
2513 25 13 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the vehicle The UGM shall not Enable the
generator is running AND is configured to Machine.
prevent drive.
2514 25 14 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the The UGM shall prohibit all
vehicle is being driven AND is configured to boom functions.
not allow simultaneous drive & boom
operation.
2516 25 16 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while Boom func- The UGM shall prohibit Drive
tions are selected AND is configured to not and Steer.
allow simultaneous drive & boom opera-
tion.
2517 25 17 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Driving is not possible while the vehicle is The UGM shall prohibit Drive
tilted and above elevation AND is config- and Steer.
ured to prevent drive while tilted and
above elevation.

6-54 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

2518 25 18 DRIVE PREVENTED - BOOM SELECTED MACHINE SETUP > FUNCTION CUTOUT = The UGM shall prohibit Drive
BOOM CUTOUT and Steer.
The boom is Above Elevation
Any boom function is already active The
operator attempts to activate Drive or
Steer.
2519 25 19 DRIVE PREVENTED - TILTED & EXTENDED OR HIGH ANGLE Drive Selected while tilted and extended
and tilt is configured to cutout drive.
2520 25 20 FUNCTIONS LOCKED OUT - CONSTANT DATA VERSION
IMPROPER
2530 25 30 UMS SENSOR FORWARD LIMIT REACHED The Upright angle relative to the turntable
is less than -4.0 degree.
2531 25 31 UMS SENSOR OUT OF USABLE RANGE Both the turntable tilt sensor and the UMS
sensor read greater then +/-10 degree in
the same direction.
2532 25 32 UMS SENSOR BACKWARD LIMIT REACHED The Upright angle relative to the turntable
is greater than +2.5 degree.
2563 25 63 SKYGUARD SWITCH - DISAGREEMENT MACHINE SETUP > SKYGUARD = YES; Response detailed in Sky-
Machine is in Platform Mode; Guard section.
[(SkyGuard input #1 Platform Module J7-
18) ≠ (SkyGuard input #2 Platform Module
J1-23)] > 160ms
2568 25 68 TEMPERATURE CUTOUT ACTIVE - AMBIENT TEMPERATURE Low Temperature Cutout = Active If the Boom is Above Elevation;
TOO LOW The UGM shall suspend
motion; The UGM shall limit
the machine to Creep speed
after controls initialized
If the Machine is in Platform
Mode and if the Boom is not
Above Elevation.
2576 25 76 PLATFORM LEVEL PREVENTED - ABOVE ELEVATION Platform Level Override Cutout = Enabled; The UGM shall suspend Plat-
The Platform Level Up or Down switch form Level Up and Down
input = High; commands;
Footswitch is active. The UGM shall prohibit Plat-
form Level Up and Down
2577 25 77 DRIVE PREVENTED - START BATTERY CONNECTED Start battery is connected Check the battery.
330 33 0 <<< GROUND OUTPUT DRIVER >>>
331 33 1 BRAKE - SHORT TO BATTERY There is a Short to Battery to the Brake Check Harness for damage.
Valve.
332 33 2 BRAKE - OPEN CIRCUIT There is an Open Circuit to the Brake Valve. Check Harness for damage.
3311 33 11 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the Ground Ground Alarm equipped vehi-
Alarm. cles only.
3336 33 36 ALTERNATOR POWER - SHORT TO GROUND There is a Short to Ground to the Alterna- Check Harness for damage.
tor/ECM.
3340 33 40 AUX POWER - SHORT TO GROUND There is a Short to Ground to the Auxiliary Check Harness for damage.
Power Pump Relay.
3341 33 41 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
Auxiliary Power Pump Relay.
3342 33 42 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the Auxiliary Check Harness for damage.
Power Pump Relay.

3121628 6-55
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

3346 33 46 ELECTRIC FAN - SHORT TO GROUND There is a short to ground to the Electric Check Harness for damage.
Fan.
3347 33 47 ELECTRIC FAN - OPEN CIRCUIT There is an Open Circuit to the Electric Fan. Check Harness for damage.
3348 33 48 ELECTRIC FAN - SHORT TO BATTERY There is a Short to Battery to the Electric Check Harness for damage.
Pump.
3349 33 49 ELECTRIC PUMP - SHORT TO GROUND There is a Short to Ground to the Pump Check Harness for damage.
Relay.
3350 33 50 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
Pump Relay.
3351 33 51 ELECTRIC PUMP - SHORT TO BATTERY There is a Short to Battery to the Pump Check Harness for damage.
Relay.
3352 33 52 LP LOCK - SHORT TO GROUND There is an Open Circuit to the Check Harness for damage.
LP Lock.
3353 33 53 LP LOCK - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
LP Lock.
3354 33 54 LP LOCK - SHORT TO BATTERY There is a short to Battery to the LP Lock. Check Harness for damage.
3355 33 55 LP START ASSIST - SHORT TO GROUND There is a short to ground to the LP Start Check Harness for damage.
Assist.
3356 33 56 LP START ASSIST - OPEN CIRCUIT There is an Open Circuit to the LP Start Check Harness for damage.
Assist.
3357 33 57 LP START ASSIST - SHORT TO BATTERY There is a short to battery to the LP Start Check Harness for damage.
Assist.
3358 33 58 MAIN DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the Main Check Harness for damage.
Dump Valve.
3359 33 59 MAIN DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
Main Dump Valve.
3360 33 60 MAIN DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the Main Check Harness for damage.
Dump Valve.
3361 33 61 BRAKE - SHORT TO GROUND There is a Short to Ground to the Check Harness for damage.
Brake Valve.
3362 33 62 START SOLENOID - SHORT TO GROUND There is a Short to Ground to the Start Check Harness for damage.
Relay.
3363 33 63 START SOLENOID - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
Start Relay.
3364 33 64 START SOLENOID - SHORT TO BATTERY There is a Short to Battery to the Start Check Harness for damage.
Relay.
3365 33 65 STEER DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the Steer Check Harness for damage.
Dump Valve.
3366 33 66 STEER DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
Steer Dump Valve.
3367 33 67 STEER DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the Steer Check Harness for damage.
Dump Valve.
3368 33 68 TWO SPEED VALVE - SHORT TO GROUND There is a Short to Ground to the Check Harness for damage.
Two Speed Valve.
3369 33 69 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
Two Speed Valve.
3370 33 70 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the Check Harness for damage.
Two Speed Valve.

6-56 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

3371 33 71 GROUND ALARM - SHORT TO GROUND There is a Short to Ground to the Ground Check Harness for damage.
Alarm.
3372 33 72 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the Ground Check Harness for damage.
Alarm.
3373 33 73 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the Generator Check Harness for damage.
Relay.
3374 33 74 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the Generator Check Harness for damage.
Relay.
3375 33 75 GEN SET/WELDER - SHORT TO BATTERY There is a Short to Battery to the Generator Check Harness for damage.
Relay.
3376 33 76 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the Head Light Check Harness for damage.
Relay.
3377 33 77 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the Head Light Check Harness for damage.
Relay.
3378 33 78 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the Head Light Check Harness for damage.
Relay.
3379 33 79 HOUR METER - SHORT TO GROUND There is a Short to Ground to the Hour Check Harness for damage.
Meter.
3382 33 82 PLATFORM LEVEL UP VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Check Harness for damage.
Level Up Valve
3383 33 83 PLATFORM LEVEL UP VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Check Harness for damage.
Level Up Valve.
3384 33 84 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY There is a Short to Battery to the Platform Check Harness for damage.
Level Up Valve
3388 33 88 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Check Harness for damage.
Level Down Valve
3389 33 89 PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Check Harness for damage.
Level Down Valve.
3390 33 90 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the Platform Check Harness for damage.
Level Down Valve
3394 33 94 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Check Harness for damage.
Rotate Left Valve.
3395 33 95 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Check Harness for damage.
Rotate Left Valve.
3396 33 96 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the Platform Check Harness for damage.
Rotate Left Valve.
3397 33 97 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Check Harness for damage.
Rotate Right Valve.
3398 33 98 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Check Harness for damage.
Rotate Right Valve.
3399 33 99 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the Platform Check Harness for damage.
Rotate Right Valve.
33100 33 100 JIB LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Lift Up Check Harness for damage.
Valve.
33101 33 101 JIB LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Lift Up Check Harness for damage.
Valve.
33102 33 102 JIB LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Lift Up Check Harness for damage.
Valve.

3121628 6-57
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

33103 33 103 JIB LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Lift Check Harness for damage.
Down Valve.
33104 33 104 JIB LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Lift Down Check Harness for damage.
Valve.
33105 33 105 JIB LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Lift Check Harness for damage.
Down Valve.
33106 33 106 TOWER LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the Tower Lift Check Harness for damage.
Up Valve.
33107 33 107 TOWER LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the Tower Lift Up Check Harness for damage.
Valve.
33108 33 108 TOWER LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the Tower Lift Check Harness for damage.
Up Valve.
33109 33 109 TOWER LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the Tower Lift Check Harness for damage.
Down Valve.
33110 33 110 TOWER LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the Tower Lift Check Harness for damage.
Down Valve.
33111 33 111 TOWER LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the Tower Lift Check Harness for damage.
Down Valve.
33112 33 112 TOWER TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the Tower Check Harness for damage.
Telescope In Valve.
33113 33 113 TOWER TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the Tower Tele- Check Harness for damage.
scope In Valve.
33114 33 114 TOWER TELESCOPE IN VALVE - SHORT TO BATTERY There is a Short to Battery to the Tower Check Harness for damage.
Telescope In Valve.
33115 33 115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND There is a Short to Ground to the Tower Check Harness for damage.
Telescope Out Valve.
33116 33 116 TOWER TELESCOPE OUT VALVE - OPEN CIRCUIT There is an Open Circuit to the Tower Tele- Check Harness for damage.
scope Out Valve.
33117 33 117 TOWER TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the Tower Check Harness for damage.
Telescope Out Valve.
33118 33 118 SWING RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Swing Check Harness for damage.
Right Valve.
33119 33 119 SWING RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the Swing Right Check Harness for damage.
Valve.
33120 33 120 TELESCOPE IN VALVE - SHORT TO BATTERY There is a Short to Battery to the Main Tele- Check Harness for damage.
scope In Valve.
33121 33 121 SWING RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the Swing Check Harness for damage.
Right Valve.
33122 33 122 SWING LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Swing Left Check Harness for damage.
Valve.
33123 33 123 TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the Main Tele- Check Harness for damage.
scope Out Valve.
33130 33 130 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the Throttle Check Harness for damage.
Actuator.
33131 33 131 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the Throttle Check Harness for damage.
Actuator.
33132 33 132 THROTTLE ACTUATOR - SHORT TO BATTERY There is a Short to Battery to the Throttle Check Harness for damage.
Actuator.

6-58 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

33170 33 170 LIFT DOWN VALVE - OPEN CIRCUIT There is a Short to Ground to the Lift Down Check Harness for damage.
Valve.
33171 33 171 LIFT DOWN VALVE - SHORT TO BATTERY There is an Open Circuit to the Lift Down Check Harness for damage.
Valve.
33172 33 172 LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Battery to the Lift Down Check Harness for damage.
Valve.
33175 33 175 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Rotate Check Harness for damage.
Left Valve.
33176 33 176 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Rotate Check Harness for damage.
Left Valve.
33177 33 177 JIB ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Rotate Check Harness for damage.
Left Valve.
33178 33 178 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Rotate Check Harness for damage.
Right Valve.
33179 33 179 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Rotate Check Harness for damage.
Right Valve.
33180 33 180 JIB ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Rotate Check Harness for damage.
Right Valve.
33182 33 182 LIFT VALVES - SHORT TO BATTERY There is a Short to Battery to the Lift Valves. Check Harness for damage.
33186 33 186 TELESCOPE OUT VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Tele- Check Harness for damage.
scope Out Valve.
33188 33 188 TELESCOPE OUT VALVE - SHORT TO GROUND There is a Short to Ground to the Main Tele- Check Harness for damage.
scope Out Valve.
33189 33 189 TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Tele- Check Harness for damage.
scope In Valve.
33190 33 190 TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the Check Harness for damage.
Main Telescope In Valve.
33207 33 207 HORN - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
Horn.
33208 33 208 HORN - SHORT TO BATTERY There is a Short to Battery to the Horn. Check Harness for damage.

33209 33 209 HORN - SHORT TO GROUND There is a Short to Ground to the Check Harness for damage.
Horn.
33279 33 279 GLOWPLUG - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
Glow Plugs.
33280 33 280 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the Check Harness for damage.
Glow Plugs.
33281 33 281 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the Check Harness for damage.
Glow Plugs.
33287 33 287 LIFT - CURRENT FEEDBACK READING TOO LOW The Engine State = ENGINE RUNNING; The UGM shall suspend Lift
The UGM commanded current > 250mA; Up and Down command and
The difference between the commanded revert to Open Loop Current
current and the measured feedback cur- control for Lift;
rent > [the larger of (125mA) or (15% The UGM shall limit Lift Up
of the commanded function Max)] for lon- and Down to Creep speed
ger than 1 second after controls initialized
33295 33 295 SWING LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the Swing Left Check Harness for damage.
Valve.

3121628 6-59
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

33306 33 306 SWING LEFT VALVE - SHORT TO BATTERY There is short to Battery to the Swing Left Check Harness for damage.
Valve.
33314 33 314 FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the Flow Control Check Harness for damage.
Valve.
33315 33 315 FLOW CONTROL VALVE - SHORT TO BATTERY There is short to Battery to the Flow Control Check Harness for damage.
Valve
33316 33 316 FLOW CONTROL VALVE - SHORT TO GROUND There is short to Ground to the Flow Control Check Harness for damage.
Valve
33317 33 317 DRIVE FORWARD VALVE - OPEN CIRCUIT There is an Open Circuit to the Drive For- Check Harness for damage.
ward Valve.
33318 33 318 DRIVE FORWARD VALVE - SHORT TO BATTER There is short to Battery to the Drive For- Check Harness for damage.
ward Valve.
33319 33 319 DRIVE FORWARD VALVE - SHORT TO GROUND There is short to Gropund to the Drive For- Check Harness for damage.
ward Valve.
33320 33 320 DRIVE REVERSE VALVE - OPEN CIRCUIT There is an Open Circuit to the Drive Check Harness for damage.
Reverse Valve.
33321 33 321 DRIVE REVERSE VALVE - SHORT TO BATTERY There is a short to Battery to the Drive Check Harness for damage.
Reverse Valve.
33322 33 322 DRIVE REVERSE VALVE - SHORT TO GROUND There is a short to Ground to the Drive Check Harness for damage.
Reverse Valve.
33323 33 323 LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Up Valve. Check Harness for damage.

33324 33 324 LIFT UP VALVE - SHORT TO BATTERY There is a short to Battery to the Lift Up Check Harness for damage.
Valve.
33325 33 325 LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the Lift Up Check Harness for damage.
Valve.
33331 33 331 DRIVE - CURRENT FEEDBACK READING TOO LOW The Engine State = ENGINE RUNNING; The UGM shall suspend Drive
The UGM commanded current > 250mA; Forward and Reverse com-
The difference between the commanded mand and revert to Open Cur-
current and the measured feedback current loop control for Drive;
rent > [the larger of (125mA) or (15% of The UGM shall limit Drive For-
the commanded function Max)] for longer ward and Reverse to Creep
than 1 second speed after controls initialized

33410 33 410 DRIVE - CURRENT FEEDBACK READING LOST Measured feedback current < 225mA The UGM shall suspend Drive
while PWM output > 40% for a period of Forward and Reverse com-
100ms. mand and revert to Open Cur-
rent loop control for Drive;
The UGM shall limit Drive For-
ward and Reverse to Creep
speed after controls initialized
33412 33 412 SWING VALVES - SHORT TO BATTERY There is a short to Battery to the Swing Check Harness for damage.
Valves.
33414 33 414 SWING - CURRENT FEEDBACK READING TOO LOW Current feedback into controller is below Check wiring and coil.
threshold value.

6-60 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

33415 33 415 FLOW CONTROL VALVE - CURRENT FEEDBACK READING TOO The Engine State = ENGINE RUNNING; The UGM shall suspend Flow
LOW The UGM commanded current > 250mA; Control and revert to Open
The difference between the commanded Current loop control for Flow
current and the measured feedback cur- Control.
rent > [the larger of (125mA) or (15% of
the commanded function Max)] for longer
than 1 second .
33417 33 417 LIFT - CURRENT FEEDBACK READING LOST Measured feedback current < 225mA The UGM shall suspend Lift
while PWM output > 40% for a period of Up and Down command and
100ms. revert to Open Loop Current
control for Lift;
The UGM shall limit Lift Up
and Down to Creep speed
after controls initialized.
33418 33 418 SWING - CURRENT FEEDBACK READING LOST Current feedback into controller not Check wiring and coil.
detected.
33419 33 419 FLOW CONTROL VALVE - CURRENT FEEDBACK READING LOST Measured feedback current < 225mA The UGM shall suspend Flow
while PWM output >40% for a period of Control and revert to Open
100ms. Current loop control for Flow
Control.
33488 33 488 SWING FLOW CONTROL VALVE - SHORT TO GROUND There is a short to the Ground to the Swing Check Harness for damage.
Flow Control Valve.
33575 33 575 ECM PULL DOWN RESISTOR - OPEN CIRCUIT There is an Open Circuit to the ECM Pull Check Harness for damage.
Down Resistor.
340 34 0 <<< PLATFORM OUTPUT DRIVER >>>
341 34 1 PLATFORM LEVEL UP VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Check Harness for damage.
Level Up Valve.
342 34 2 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY There is a Short to Battery to the Platform Check Harness for damage.
Level Up Valve.
343 34 3 PLATFORM LEVEL UP VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Check Harness for damage.
Level Up Valve.
344 34 4 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open Cir- Check Harness for damage.
CIRCUIT cuit to the Platform Level Up Valve.
345 34 5 PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Check Harness for damage.
Level Down Valve.
346 34 6 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY There is a short to Battery to the Platform Check Harness for damage.
Level Down Valve.
347 34 7 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a short to the Ground to the Plat- Check Harness for damage.
form Level Down Valve.
348 34 8 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN There is a Short to Battery or an Open Cir- Check Harness for damage.
CIRCUIT cuit to the Platform Level Down Valve.
349 34 9 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Check Harness for damage.
Rotate Left Valve.
3410 34 10 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY There is a short to Battery to the Platform Check Harness for damage.
Rotate Left Valve.
3411 34 11 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND There is a short to Ground to the Platform Check Harness for damage.
Rotate Left Valve.
3412 34 12 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Check Harness for damage.
Rotate Right Valve.

3121628 6-61
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

3413 34 13 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a short to Battery to the Platform Check Harness for damage.
Rotate Right Valve.
3414 34 14 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a short to Ground to the Platform Check Harness for damage.
Rotate Right Valve.
3415 34 15 JIB LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Lift Up Check Harness for damage.
Valve.
3416 34 16 JIB LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Lift Up Check Harness for damage.
Valve.
3417 34 17 JIB LIFT UP VALVE - SHORT TO GROUND There is a short to Ground to the JIB Lift Up Check Harness for damage.
Valve.
3418 34 18 JIB LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Lift Down Check Harness for damage.
Valve.
3419 34 19 JIB LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Lift Check Harness for damage.
Down Valve.
3420 34 20 JIB LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Lift Check Harness for damage.
Down Valve.
3421 34 21 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Rotate Check Harness for damage.
Left Valve.
3422 34 22 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Rotate Check Harness for damage.
Left Valve.
3423 34 23 JIB ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Rotate Check Harness for damage.
Left Valve.
3424 34 24 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Rotate Check Harness for damage.
Right Valve.
3425 34 25 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Rotate Check Harness for damage.
Right Valve.
3426 34 26 JIB ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Rotate Check Harness for damage.
Right Valve.
430 43 0 <<< ENGINE >>>
431 43 1 FUEL SENSOR - SHORT TO BATTERY OR OPEN CIRCUIT The Fuel Sensor reading is > 4.3V. Energize fuel sensor per Sys-
tem Indicators

432 43 2 FUEL SENSOR - SHORT TO GROUND The Fuel Sensor reading is < 0.2V. Energize fuel sensor per Sys-
tem Indicators
433 43 3 OIL PRESSURE - SHORT TO BATTERY The Oil Pressure Sensor reading is > 6.6V. Deutz engine only.
434 43 4 OIL PRESSURE - SHORT TO GROUND The Oil Pressure Sensor reading is < 0.1V Deutz engine only.
for more then 5 seconds. - Not reported during engine
start.
435 43 5 COOLANT TEMPERATURE - SHORT TO GROUND The Coolant Temperature Sensor reading is Deutz engine only.
< 0.1V.
436 43 6 FORD FAULT CODE ## All ford fault codes except 63 are simply
passed through from the Ford ECM. They
only occur if a Ford Engine is selected in the
machine configuration digits. Can be
reported during power-up sequence.

6-62 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

437 43 7 ENGINE TROUBLE CODE Displays engine SPN FMI code. Report and log in Help
If [(MACHINE SETUP > DEUTZ
EMR2) or (MACHINE SETUP >
DEUTZ EMR4) and SPN:FMI =
535:7], prohibit engine
cranking.
438 43 8 HIGH ENGINE TEMP (Ford engine only) The engine tempera- Ford / Deutz engine only.
ture is > 117 C. (Deutz engine only) The
engine temperature is > 130 C.
439 43 9 AIR FILTER BYPASSED The Air Filter is clogged. Check Airfilter for clogging
4310 43 10 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts for more Activate the No Charge indica-
then 15 seconds after engine start. tor J4-26 per System Indica-
tors.
4311 43 11 LOW OIL PRESSURE (Ford engine only) The ECM has reported a Ford / Deutz engine only.
low oil pressure fault. (Deutz engine only)
Oil pressure is < 8 PSI for more then 10 sec-
onds after engine start.
4312 43 12 485 COMMUNICATIONS LOST This fault only occurs with a Ford Engine. It
occures when no response are received
from the ECM for 2.5 seconds. Can be
reported during power-up sequence.
4313 43 13 THROTTLE ACTUATOR FAILURE The engine RPM is > XXX for more then XX
seconds.
4314 43 14 WRONG ENGINE SELECTED - ECM DETECTED A ECM was detected with a non- ECM type
engine selected.
4322 43 22 LOSS OF ENGINE SPEED SENSOR The engine RPM sensor indicates 0 RPM Diesel engine only.
AND the Oil Pressure Sensor indicates > 8
PSI for three seconds.
4323 43 23 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indicates > 4000 Diesel engine only.
RPM.
4331 43 31 SOOT LOAD WARNING - LOW SPN/FMI Check Engine.
3719 / 16
3703 / 31
4332 43 32 SOOT LOAD WARNING - HIGH SPN/FMI Check Engine.
3719 / 0
3714 / 31
4333 43 33 SOOT LOAD WARNING - SEVERE SPN/FMI Check Engine.
3715 / 31
4334 43 34 ENGINE COOLANT - LOW LEVEL MACHINE SETUP > ENGINE = DEUTZ EMR4; MACHINE SETUP > ENGINE
ECM transmits a J1939 DM1 message for an SHUTDOWN = ENABLED then
engine coolant low level fault (SPN:FMI shutdown the engine;
111:1) on CAN2 or uses the J1939 Activate High Engine Temper-
Transport Protocol every one second to ature indicator J4-28.
send this information if multiple engine
faults exist.
440 44 0 <<< BATTERY SUPPLY >>>
441 44 1 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Battery voltage is < 9V.
442 44 2 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Battery voltage is > 16V.
445 44 5 BATTERY VOLTAGE LOW Battery voltage is < 11V for more then 5
seconds.

3121628 6-63
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

660 66 0 <<< COMMUNICATION >>>
662 66 2 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN communication lost.
664 66 4 CANBUS FAILURE - ACCESSORY MODULE The accessory module is not receiving CAN Check the Wiring.
messages. This is probably due to wiring
problem.
666 66 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN ECM equipped engine only.
6620 66 20 CANBUS FAILURE - UMS SENSOR communication lost.
6622 66 22 CANBUS FAILURE - TCU MODULE Machine Setup/ Telematics=YES, No
device heartbeat for 30 sec
6623 66 23 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telematics=YES, No
device heartbeat for 30 sec
6629 66 29 CANBUS FAILURE - TELEMATICS CANBUS LOADING
TOO HIGH
6657 66 57 CANBUS FAILURE - TEMPERATURE SENSOR MACHINE SETUP > TEMP CUTOUT = YES; The UGM shall set Low Tem-
UGM does not receive any CAN messages perature
from the Ambient Temperature sensor in Cutout state =
250ms Faulty
If the Machine is in Platform
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 Platform
Mode and if the Boom is not
Above Elevation.
671 67 1 ACCESSORY FAULT
680 68 0 <<< TELEMATICS >>>
681 68 1 REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNC-
TIONS IN CREEP
810 81 0 <<< TILT SENSOR >>>
813 81 3 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not been cali-
brated.
815 81 5 CHASSIS TILT SENSOR DISAGREEMENT
816 81 6 UMS SENSOR NOT CALIBRATED The Control System detects a sensor out of
range condition or a not calibrated fault
with UMS angle sensor
817 81 7 UMS SENSOR FAULT The system detects that the UMS sensor
frequency outside the 100Hz+/- 5Hz
range or the duty cycle is outside 50% +/-
21% Range
820 82 0 <<< PLATFORM LOAD SENSE >>>
825 82 5 LSS HAS NOT BEEN CALIBRATED The Load Sensing System Module has not UGM to set Platform Load
been calibrated. State = Overloaded

6-64 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

826 82 6 RUNNING AT CREEP - PLATFORM OVERLOADED All functions at creep, the Load Sensing
System
indicates the Platform is overloaded
AND is configured to warn only while the
Platform is overloaded.
827 82 7 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are not possi-
ble while the Load Sensing System indi-
cates the Platform is overloaded AND is
configured to prevent drive and boom
functions while the Platform is over-
loaded.
828 82 8 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED Lift up and telescope out are not possible
while the Load Sensing System indicates
the Platform is overloaded AND is config-
ured to prevent Lift up and telescope out
while the Platform is overloaded.
8639 86 39 FRONT LEFT STEER VALVE - OPEN CIRCUIT There is an open circuit to the Front Left Check Harness for damage.
Steer Valve
8640 86 40 FRONT LEFT STEER VALVE - SHORT TO BATTERY There is a short to Battery to the Front Left Check Harness for damage.
Steer Valve
8641 86 41 FRONT LEFT STEER VALVE - SHORT TO GROUND There is a short to Ground to the Front Left Check Harness for damage.
Steer Valve
8642 86 42 FRONT RIGHT STEER VALVE - OPEN CIRCUIT There is an open circuit to the Front Right Check Harness for damage.
Steer Valve
8643 86 43 FRONT RIGHT STEER VALVE - SHORT TO BATTERY There is a short to Battery to the Front Right Check Harness for damage.
Steer Valve
8644 86 44 FRONT RIGHT STEER VALVE - SHORT TO GROUND There is a short to Ground to the Front Right Check Harness for damage.
Steer Valve
8645 86 45 REAR LEFT STEER VALVE - OPEN CIRCUIT There is an open circuit to the Rear Left Check Harness for damage.
Steer Valve
8646 86 46 REAR LEFT STEER VALVE - SHORT TO BATTERY There is a short to Battery to the Rear Left Check Harness for damage.
Steer Valve
8647 86 47 REAR LEFT STEER VALVE - SHORT TO GROUND There is a short to Ground to the Rear Left Check Harness for damage.
Steer Valve
8648 86 48 REAR RIGHT STEER VALVE - OPEN CIRCUIT There is an open circuit to the Rear Right Check Harness for damage.
Steer Valve
8649 86 49 REAR RIGHT STEER VALVE - SHORT TO BATTERY There is a short to Battery to the Rear Right Check Harness for damage.
Steer Valve
8650 86 50 REAR RIGHT STEER VALVE - SHORT TO GROUND There is a short to Ground to the Rear Right Check Harness for damage.
Steer Valve
871 87 1 RETURN FILTER BYPASSED Hydraulic Return Filter Clogged Check Hydraulic Return Filter.
872 87 2 CHARGE PUMP FILTER BYPASSED Charge Pump Filter Clogged Check Charge Pump Filter.
873 87 3 MACHINE SAFETY SYSTEM OVERRIDE OCCURRED MSSO = Active Response described in MSSO
Influence on Machine Opera-
tion section.

3121628 6-65
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

998 99 8 EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has reported an Disable all machine and
EEPROM failure. engine functions (i.e., com-
mand engine shutdown and
do not permit start); reset the
section of EEPROM where the
failure occurred to defaults.
9910 99 10 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE The Platform Module software version is Activate the platform alarm
VERSION IMPROPER not compatible with the rest of the system. continuously
Creep mode is active
If Platform Mode is active,
disable all Drive, Steer, and
Boom functions and do not
permit Machine Enable.
9914 99 14 PLATFORM MODULE SOFTWARE UPDATE REQUIRED The Platform Module software requires an
update.
9915 99 15 CHASSIS TILT SENSOR NOT GAIN CALIBRATED The Chassis Tilt Sensor gain calibration has
been lost.
9916 99 16 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain calibration has
become corrupted.
9919 99 19 GROUND SENSOR REF VOLTAGE OUT OF RANGE The Ground Module has reported that its Not reported during power-
sensor reference voltage is outside accept- up.
able range.
9920 99 20 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE The Platform Module has reported that its Not reported during power-
sensor reference voltage is outside accept- up.
able range.
9921 99 21 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT The Ground Module has reported that its
FAULTY high side driver cutout failed.
9922 99 22 PLATFORM MODULE FAILURE - HWFS CODE 1 The Platform Module has reported that the
V(Low) FET has failed.
9923 99 23 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has reported that the
V(Low) FET has failed.
9924 99 24 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED The machine is powered up and no model Display ??? or NO MODEL at
has been selected yet in the MACHINE Analyzer MACHINE SETUP
SETUP menu menu MACHINE SETUP-
>MODEL NUMBER
Do not report any other faults
Disable all machine and
engine functions (i.e., com-
mand engine shutdown and
do not permit start).
9944 99 44 CURRENT FEEDBACK GAINS OUT OF RANGE The factory set current feedback gains are A gain of 1 is used for the fac-
out of range. tory gain(s) that was out of
range; all functions shall be
placed in Creep mode.

6-66 3121628
SECTION 6 - JLG CONTROL SYSTEM

Table 6-13. Diagnostic Trouble Code Chart

DTC Flash Code Sequence Fault Message Fault Description Check

9945 99 45 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT The factory set current feedback checksum
is not correct.
9979 99 79 FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VER- Temporary fault for the telematics project. Disable all machine and
SION IMPROPER The model needs to be a 600S or 1350S if engine functions (i.e., com-
not this fault will be generated and Plat- mand engine shutdown and
form controls will be prevented. do not permit start).
This fault was to ensure that the software
will only work for these two models.

3121628 6-67
SECTION 6 - JLG CONTROL SYSTEM

NOTES:

6-68 3121628
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. Check what reading is expected, the location of the signal and
that the leads are connected to the device under test correctly.
NOTE: Some of the procedures/connectors shown in this section Also check that the lead on the "COM" port goes to the Ground
may not be applicable to all models. or negative side of the signal and the lead on the other port
goes to the positive side of the signal.
7.2 MULTIMETER BASICS
A wide variety of multimeters or Volt Ohm Meters (VOM) can
Scale
be used for troubleshooting your equipment. This section M = Mega = 1,000,000 * (Displayed Number)
shows diagrams of a common, digital VOM configured for sev-
eral different circuit measurements. Instructions for your VOM k = kilo = 1,000 * (Displayed Number)
may vary. Please consult the meter operator’s manual for more m = milli = (Displayed Number) / 1,000
information.
μ = micro = (Displayed Number) / 1,000,000
Grounding Example: 1.2 kW = 1200 W
“Grounding the meter” means to take the black lead (which is Example: 50 mA = 0.05 A
connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the Voltage source. Voltage Measurement

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.

Min/Max
Use of the "Min/Max" recording feature of some meters can
help when taking measurements of intermittent conditions
while alone. For example, you can read the Voltage applied to
a solenoid when it is only operational while a switch, far from Figure 7-1. Voltage Measurement (DC)
the solenoid and meter, is held down.
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual).
• Use firm contact with meter leads.

3121628 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 3121628
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-
ductivity between pins when wet.
Figure 7-4. Current Measurement (DC) Use the following procedure to apply Silicone Dielectric Com-
pound to the electrical connectors. This procedure applies to
• Set up the meter for the expected current range. all plug connections not enclosed in a box. Silicone grease
• Be sure to connect the meter leads to the correct jacks 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.

3121628 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 the female contact (fill it Platform and Ground Modules.
approximately ½ full; see example below).
Apply dielectric grease to the female contact. If trapped air
3. Leave a thin layer of dielectric grease on the face of the prevents the connector from latching, pierce one of the
connector. unused wire seals. After assembly, install a seal plug (JLG
4. Assemble the connector system immediately to prevent #4460905) in that location to prevent moisture ingress.
moisture ingress or dust contamination. Note that seal plugs may be installed by the wire harness man-
5. Pierce one of the unused wire seals prior to assembly if ufacturer if an unused wire seal becomes compromised (wire
the connector system tends to trap air (i.e. AMP Seal) inserted in the wrong cavity during assembly and then cor-
and then install a seal plug. rected).

Figure 7-5. Application to Female Contacts

7-4 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

DIN Connectors
This connector is typically used on hydraulic valves. Follow the
installation instructions.

Figure 7-6. Use of Seal Plugs

Exclusions
A limited number of connectors do not benefit from dielectric
AMP Mate-N-Lok grease, or may be permanently damaged by application.
Follow the installation instructions. Dielectric grease may not be required in properly sealed
enclosures.

3121628 7-5
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER

The connector uses gold contact material to resist corrosion This type of connector uses back-seals for moisture integrity.
and an o-ring seal for moisture integrity. If dielectric grease is However, the low-force contacts cannot displace dielectric
mistakenly applied to this connector system, the low-force grease and create electrical contact. It is possible to use sol-
contacts cannot displace the grease to achieve electrical con- vents (i.e. contact cleaner or mineral spirits) for the removal of
tact. Once contaminated, there is no practical way to remove improperly applied dielectric grease. The EMR2 engine control
the dielectric grease (replacement of female contacts module from Deutz employs this connector system (for exam-
required). The JLG Load Sensing System and 1250AJP Rotary ple).
Angle Sensors are examples of components with the M12 con-
nector system.

7-6 3121628
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 7-9.).

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 7-9.).
position (See Figure 7-7.). Proceed as follows:

Figure 7-7. Connector Assembly Figure 1

Figure 7-8. AMP Connector

3121628 7-7
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-9. 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 7-11.).
Release the locking latches by squeezing them inward
(See Figure 7-10.).

Figure 7-11. Connector Assembly Figure 4

Figure 7-10. Connector Assembly Figure 3

7-8 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-12. Connector Disassembly

Disassembly Service - Voltage Reading

5. Insert a 4.8 mm (3/16") wide screwdriver blade between
the mating seal and one of the red wedge lock tabs.
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
6. Pry open the wedge lock to the open position.
It has been common practice in electrical troubleshooting to
7. While rotating the wire back and forth over a half turn probe wires by piercing the insulation with a sharp point. This
(1/4 turn in each direction), gently pull the wire until the practice should be discouraged when dealing with the
contact is removed. AMPSEAL plug assembly, or any other sealed connector sys-
tem. The resulting pinholes in the insulation will allow mois-
NOTE: The wedge lock should never be removed from the housing
ture to invade the system by traveling along the wire strands.
for insertion or removal of the contacts.
This nullifies the effectiveness of the connector seals and
could result in system failure.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.

3121628 7-9
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-13. Connector Installation

7-10 3121628
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 7-14. DT/DTP Contact Installation Figure 7-15. 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.

3121628 7-11
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly

A B A B

C C
Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal

8. Grasp contact about 25mm behind the contact crimp

11. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
9. Hold connector with rear grommet facing you.
12. Slide tool along into the insert cavity until it engages
10. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm that it is
13. Pull contact-wire assembly out of connector.
properly locked in place.

Figure 7-19. HD/HDP Unlocking Contacts

Figure 7-17. HD/HDP Locking Contacts Into Position
NOTE: Do Not twist or insert tool at an angle.
NOTE: For unused wire cavities, insert sealing plugs for full envi-
ronmental sealing.

7-12 3121628
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

3121628 7-13
7-14
MS1619-3 MS1619-1

MS1619-2
X1609

MS1620-1

S1614
MS1618-2
S1615
MS1620-3
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

MS1620-2
MS1618-3
CO1613-J2
CO1613-J1

X1606

Figure 7-20. Telematics Gateway Harness - Sheet 1 of 3

3121628
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 7-21. Telematics Gateway Harness - Sheet 2 of 3

3121628 7-15
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 7-22. Telematics Gateway Harness - Sheet 3 of 3

7-16 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121628 7-17
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

PLATFORM
SOFT TOUCH WORK LIGHTS
LIMIT SWITCH

4000W &
7500W
GENERATOR
PLATFORM
BOX
GENERATOR
J7 SWITCH

J1
J5 J6

J2
MAIN BOOM
ELEVATION
J8

LIMIT SWITCH
TOWER BOOM
ELEVATION
LIMIT SWITCH
BOOM CAPACITY
ANGLE LIMIT
SWITCH (TOWER)

BOOM LENGTH
LIMIT SWITCH

PLATFORM
CONTROL
BOX

TOWER
PLATFORM TELE & LIFT
VALVE PROXIMITY
SWITCHES

GROUND
CONTROL
BOX

J8
J7

J12 J7
J7

J3 J4

HEADLIGHTS

DIAGNOSTIC
ANALYZER

TAILLIGHTS
MAE19440

Figure 7-23. Electrical Components Installation - Sheet 1 of 2

7-18 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

OR
2500W
GENERATOR
RELAY
2500W
GENERATOR
CONTROL BOX

2500W 4000W & 7500W 7500W

GENERATOR GENERATOR 4000W & 7500W
GENERATOR
CONTROL BOX RELAYS SKYPOWER
GENERATOR

BOSCH FUEL
ENGINE REGULATOR
CONTROL (GM)
EGR VALVE
ENGINE TO FUEL WATER IN (DEUTZ D2011) SWITCH
CONTROL (DEUTZ
PUMP FUEL IND. OR D2011)
(DEUTZ TD2.9L4) ECU
ENGINE MODULE
HARNESS GM
(DEUTZ D2011)

DEUTZ TD2.9L4 TO GLOW PLUGS

COMPONENTS
TO ENGINE EIC (FORD)
FUEL
TO COOLANT REGULATOR AUX
LEVEL IND (GM HARNESS) PUMP

RELAY
(DEUTZ BOLT ON
D2011) ENGINE
POWER START
MODULE RELAY BATTERY
RELAY GLOW
STROBE PLUGS
LIGHT 2 SPEED
& BRAKE
VALVE
GLOW
PLUG START
RELAY RELAY
HYDRAULIC (DEUTZ)
PUMPS AUX
RELAY
STARTER
ALTERNATOR
(DEUTZ DRIVE
TD2.9L4 ORIENTATION
SWITCH GENERATOR
& FORD) HOURMETER

HORN
JIB
VALVE
MAIN
FUEL 4WS CONTROL
LEVEL VALVE VALVE
SENSOR ALARM
MAE19450

Figure 7-24. Electrical Components Installation - Sheet 2 of 2

3121628 7-19
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-25. Electrical Schematic GM - Sheet 1 of 2

7-20 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001131992 A

Figure 7-26. Electrical Schematic GM - Sheet 2 of 2

3121628 7-21
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

8 7 6 5 4
SEE
SHT 1
ZONE B2

RED 30 AMP
BLACK 18 BLK/WHT (12) 18 BLACK (12)
SEE SHT 7 ZONE F1 PLATFORM
WORK LIGHTS 5 SEE ZONE A5
H OR AMP
SEE SHT 6 ZONE G6 YEL/RED 2-40-9
RED MAIN TELE IN
BLACK MAIN TELE OUT
STROBE LIGHT

TO BATTERY NEG.
ROTATE RIGHT
ROTATE LEFT
15 YEL/BLK(18) 15 BLU/ORN 52-11 1
LEVEL UP

RED 1-90
BLU/ORN 52-11 15 AMP 2 LEVEL DOWN
C.B. START SWITCH
PLATFORM BOX AUX POWER/ENABLE
YEL/RED MTB
2-5-1 SELECT
SWITCH
YEL/RED YEL/RED
2-5 13 ORN/BLK 13 2-5 MTB
MAIN TELE IN BROWN 13-1 5 19 JIB UP
ORN/RED 49-4 ALARM EMS
MAIN TELE OUT YEL/RED JIB DOWN
BROWN 14-1 6 20 BLACK YEL/RED 2
10 ORN(12) 10 B1 YEL/RED MAIN LIFT UP
ROTATE RIGHT GRAY 24-1 7 2-2(12) 2-2(12)
33 GRAY 23-1 3 PLATF ROTATE LEFT 4 2-4 (12) MAIN LIFT DOWN
ROATE LEFT GRAY 23-1 8 PLATFORM SEE YEL/RED 2-2-2
G 34 GRAY 24-1 4 PLATF ROTATE RIGHT EMS 1 B YEL/RED SWING RIGHT
LEVEL UP PINK 25-1 9 SHEET 1
21 PINK 25-1 2 PLATF LEVEL UP ZONE G2 3 2-1(12) SWING LEFT
LEVEL DOWN PINK 26-1 10
22 PINK 26-1 1 PLATF LEVEL DOWN TOWER LIFT UP
JIB UP BLUE 27-1 11

YEL/RED 2-3(16)

ZONE B6
ZONE B6
ZONE B6
J7 (BLACK)

25 BLUE 27-1 5 JIB UP TOWER LIFT DOWN

ZONE B6
ZONE B6
ZONE B6
JIB DOWN BLUE 28-1 12 26 BLUE 28-1 6 JIB DOWN YEL/RED TOWER TELE IN
FUEL SELECT BLU/ORN 52-20 33 VALVE GROUND YEL/RED 2-1-3
Ref.V 23 BLACK 7 TOWER TELE OUT
RED/ORN 4 RED/WHT 55-30 34 2-30-4 (12)
PUMP 28 SEE
WIPER GREEN 6 RED/WHT 55-31 35 X1001 BRN/WHT 47-9
POTENTIOMETER 29 SHEET 1
ZONE G2
GND BRN/BLK 5 BLACK 13 10 30 HOURMETER
CREEP 2 ORN/RED 49-11 32 13
BLACK SK 2 SEE SHT 7 86 85 87a
19 14 ZONE F1 87 ENGINE LOW
CAN HI OIL PRESSURE
15 YEL/RED 2-37 20 31 RED (18) A 3 RED (18) 3 ENGINE HIGH
ORN/YEL
BLU/YEL

21 30 CAN LO BLACK (18) B 2 BLACK (18) 2 TEMPERATURE

22 CAN SHIELD NO CHARGE

BLACK 0-1
32 C 1 SHIELD 1
EMS PTF TO MTB output YEL/RED 2-3-1
23 3 4 ORANGE (18) 4 SYSTEM DISTRESS
3 GND MODE

BLACK (10)
24 1 YEL/RED 2-30-1
J1 (WHITE)

PTF EMS PLATFORM

F ORN 55-52 25 2 X1002 OVERLOAD
YEL/RED 2-10 18 27

J1-19
TAN 5-1 1 BLACK BOOM MALFUNCTION

YEL/RED 2-1-1(12)
TOWER UP 35 TO SOFT TOUCH IND. FOOTSWITCH 2
TOWER DOWN TAN 6-1 2 8 ORN/RED 49-70 7 INDICATOR
BLACK
BROWN 15-1 3 4 ORN/RED 49-71 GREEN 6 YELLOW (18) 6 CRIBBING ENABLED
TOWER TELE IN 8 WHITE 7
TOWER TELE OUT BROWN 16-1 4

{
17 WHITE GLOW PLUG
YELLOW 55-16 16 JIB BLOCK LIMIT SW 8 HOLE PLUG 8
CRAB STEER 6 BLACK

SEE SHT 4, ZONE D7

SEE SHT 5, ZONE E4
14

SEE SHT 2, ZONE E6

COORDINATED STEER YELLOW 55-17 17 14 HOLE PLUG
ORN/RED 49-69-1 SEE SHT 7 ZONE F1
26 17 HOLE PLUG 17
14 18 ORN/RED 49-69 SEE
START SWITCH WHT/YEL 48-1 SHT 6 19 HOLE PLUG 19
AUX POWER BRN/ORN 53-1 15 7 YEL/RED 2-63 ZONE H8, F8
ENGINE SPEED WHT/YEL 48-5 28 SEE SHT 7
TWO SPEED YEL/RED 2-63-1 ZONE F1 16 BLACK (12) 16 BLACK (12)
ORANGE 55-46 27 9 BLU/ORN 52-4 1
HORN 12 RED (12) 12 YEL/RED 2-1-2(12)
BLU/ORN 52-1 31 GENERATOR
SOFT TOUCH OVERIDE 5 BLU/ORN 52-3 2
HEAD/TAIL LIGHTS 29 11 BLU/BLK 11
ORN/RED 49-40 11 ORN/RED 49-72 9
BLU/ORN 52-12 30 9 RED/BLK (18)
E 12 ORN/RED 49-73 10 9
15 ORN/RED 49-75 12 7 BROWN (18) 7
30
TILT 16 ORN/RED 49-74 11 5 BLUE (18) 5
ORN/RED 49-3 6
SYSTEM DISTRESS 24 SEE SHT 6 ZONE E2 RED (18)
BRN/WHT 47-12 8
BLACK (18)
WHITE
BLACK

FOOTSWITCH/ENABLE YEL/RED 2-21 7 GND FROM GND MODULE

RED

1 BLACK (12)
J8 (BLACK)

CREEP ORN/RED 49-15 9 GND EMS YEL/RED 2-3-1

2 YEL/RED 2-1-2
CABLE SERVICE ORN/RED 49-101 10 4 3 2 1 IGN POWER
UPRIGHT TILT SENSOR YEL/RED 2-30
CONNECTOR
OVERLOAD ORN/RED 49-100 11 LOCATED IN UPRIGHT YEL/RED 2-2-1
J2 (GRAY)

YEL/RED 2-30-1
226KG/500# CAPACITY RED/YEL 54-2 12 GROUND - 4 BLACK
PWMY - 3 WHITE YEL/RED 2-4 (16)
453KG/1000# CAPACITY RED/YEL 54-3 13 CAN HI
PWMX - 2 GREEN RED (18)
CAN LO
DRIVE ORIENTATION ORN 55-51 14 VCC - 1 RED BLACK (18)
CAN SHIELD
GENERATOR ON BLU/ORN 52-4-1 15 DRIVE ORIENTATION
YEL/RED 2-63
YEL/RED 2-75
YEL/RED 2-90

PROX. SW.
D
YEL/RED 2-1-99 (16)

GLOW PLUG 10 BLK

WHT/YEL 48-6 17 CAPACITY ANGLE SWITCH
DUAL CAPACITY WHT 9
DRIVE DISABLED BRN/WHT 47-14 19 MACHINES ONLY BLK 8
CAPACITY LENGTH SWITCH
UPRIGHT TILTED WHT 7
ORN/RED 49-102 20 TRANSPORT LENGTH
SWITCH (CE ONLY)
BLACK 0-8

BLACK 18
6 SWING 4 ORN/RED 49-62 5 WHT BLK 6
35
ORN/RED 49-77
1 5 WHITE 5K
23 1 RED/BLU ORN/RED 49-76 3 ORN/RED 49-60 2 BLK WHT 1
TO J7-35
J5 (WHITE)

SOFT TOUCH ORN/RED 49-42 16 4 GRN/YEL BLK WHT

2 GREEN TOWER ELEVATION
YEL/RED 2-42

24
LOW FUEL LAMP A B C BROWN 2
21 TOWER LIFT
{

BRN/WHT 47-13 3 BROWN LIFT PROX. SWITCH 4 1 BLACK 3

BUSS BAR BLACK BLACK 25 7 BLACK OR BLU/YEL 5K (800 A/AJ ONLY)
BLU 0-27-2 2
SEE SHT 1 ZONE C1

Lb
SEE SHT 4, ZONE C5

ZONE B8
SEE SHT 2, ZONE F7

SEE SHT 5, ZONE F5

34 1 BLUE 3
C DRIVE ORIENTATION ORN 55-50 4 5 WHT/GRN LEFT TOWER TELE. BROWN 5
OVERRIDE SWITCH STEER 4 1 BLACK 6
33 6 WHT/YEL RIGHT PROX. SWITCH
La
14 YEL/RED 2-36-1 YEL/RED 2-36 32 4 (800 A/AJ ONLY}
J6 (BLACK)

22 2 BLUE 3 BLUE 4
ZONE B8 WHT 2-18-2
RED ORN/RED 49-92 26 1 RED OR WHT/RED
11
GREEN 10 ORN/RED 49-91 28 3 BROWN
WHITE 9 ORN/RED 49-90 29 7 BLACK
BLACK/SHIELD ORN/RED 49-89 27 DRIVE
8
3
31
5
ANALYZER TRANSMIT
ANALYZER GROUND
ANALYZER RECEIVE
ANALYZER POWER

5
ZONE G5 AMP
ZONE G6
ZONE C8
B ZONE G5
ZONE C8
ZONE G6

1 2 3 4 ZONE G5
ZONE G6
GRY CAN LO

GRY CAN LO
WHT 2-18-2

SHIELD (18)
SHIELD (18)
BLK CAN HI

BLK CAN HI
BLACK (18)
BLU 0-27-2

BLACK (18)

RED (18)
RED (18)

CE MARKET ONLY
MDI

1 2 3 4 5 8 7 6 5 10 9 4 3 12 11 2 1 BLACK (18) 3
RED (18) 4
CO99 5
LSS
6
MS509
SEE ZONE H4 BLUE 102-1 1
CANBUS
BROWN 103-1 2
A

PCV : PLATFORM CONTROL VALVE

SHEET 1
8 7 6 5 4

Figure 7-27. Electrical Schematic - Sheet 1 of 13

7-22 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1
SEE
SHT 1
ZONE B2 GROUND CONTROL BOX

30 AMP
BLK/WHT (12) 18 BLACK (12) RED 1-2(10)

5 SEE ZONE A5 BLUE 102-1

AMP H
YEL/RED 2-40-9 24
MAIN TELE IN BROWN 13-2 7 17 BLACK
BROWN 14-2 30 13 RED/WHT 50-1 MAIN DUMP
MAIN TELE OUT
STROBE LIGHT GRAY 24-2 18 1 YELLOW 55-2 STEER DUMP

TO BATTERY NEG.
ROTATE RIGHT
ROTATE LEFT GRAY 23-2 6 9 YELLOW 12-1 RIGHT REAR STEER
YEL/BLK(18) 15 BLU/ORN 52-11 1 PINK 25-2 17 20 YELLOW 11-1 LEFT REAR STEER
LEVEL UP

RED 1-90
LEVEL DOWN PINK 26-2 5 29 RED 1-91
2 1
START SWITCH WHT/YEL 48-1 4 5 BLACK 0-0 2
AUX POWER/ENABLE BRN/ORN 53-2 16 7 BRN/WHT 47-9 TELEMATICS
MTB SEE SHEET 1 ZONE F4 (SEE NOTE) 3
12 YEL/RED 2-2-2
SELECT 20 SEE SHEET 1 ZONE F5 4
SWITCH 23
YEL/RED 9 IN TOWER TELE
13 ORN/BLK 13 3 BROWN 15-3 NOTE: FOR CE MACHINES CONNECT

J4 (BLUE)
2-5 MTB JIB UP BLUE 27-2 19 OUT TOWER TELE
EMS 15 BROWN 16-3 WIRE BRN/WHT 47-9 TO J4-12 ON GROUND
JIB DOWN BLUE 28-2 8 CONTROL BOX.
YEL/RED 2 B1 YEL/RED 30 BLACK
10 ORN(12) 10 MAIN LIFT UP TAN 3-2 23
2-2(12) 33 TAN 5-3
4 2-4 (12) TAN 4-2 UP TOWER LIFT
SEE YEL/RED 2-2-2 MAIN LIFT DOWN 33
1 32 TAN 6-3 DOWN TOWER LIFT
SHEET 1 B YEL/RED SWING RIGHT WHITE 22-2 35 G
4 BROWN 13-3

J2 (GRAY)
ZONE G2 3 2-1(12) WHITE 21-2 34 IN MAIN TELE
SWING LEFT BROWN 14-3
16 OUT MAIN TELE
TOWER LIFT UP TAN 5-2 10 8 YELLOW 10-1 RIGHT FRONT STEER
TOWER LIFT DOWN TAN 6-2
ZONE B6
ZONE B6
ZONE B6

21 19 YELLOW 9-1
BROWN 15-2 LEFT FRONT STEER
YEL/RED TOWER TELE IN 11
YEL/RED 31 RED/WHT 50-6 FLOW CONTROL WHT/BLK 12-1
2-1-3 TOWER TELE OUT BROWN 16-2 22
2-30-4 (12) 11 TAN 3-3 UP MAIN LIFT WHT/BLK 33-5
SEE
BRN/WHT 47-9 YEL/RED 2-40 25 22 TAN 4-3
SHEET 1 DOWN MAIN LIFT WHT/BLK 33-6
ZONE G2 35
2 WHITE 22-3 RIGHT SWING WHT/BLK 11-2
30 HOURMETER 34 WHITE 21-3 LEFT SWING WHT/BLK 11-3
86 85 BRN/WHT 47-8 12
87a ENGINE LOW 2
87
OIL PRESSURE BRN/WHT 47-5-1 29 14 BLACK
3 ENGINE HIGH
BRN/WHT 47-6-1 28 10
2 TEMPERATURE HEAD/TAIL LIGHT OUTPUT
NO CHARGE 21
BLACK 0-1

1 BRN/WHT 47-8-1 26 87
4 SYSTEM DISTRESS 87a
BRN/WHT 47-10-1 27 ALARM 85 86
BLACK (10)

PLATFORM 27 BLU/ORN 52-10 30 14 GA.

OVERLOAD ORN/RED 49-100 14 FUSE LINK F
26 BLU/ORN 52-12 12 BLU/ORN 52-12 RED 1-1 (12)
13 18 BLACK 0-5 13
J1-19

BOOM MALFUNCTION
YEL/RED 2-1-1(12)

INDICATOR BRN/WHT 47-15 15 24

28 SPARE-GND
6 CRIBBING ENABLED BRN/WHT 47-75 1
25 BRN/WHT 47-12 FUEL SENSOR (SIGNAL) LOW FUEL LIGHT
WHT/YEL 48-6
{

GLOW PLUG 3 6 BLACK SENSOR (GROUND) IN PLATFORM

8
BLACK 31
SEE SHT 4, ZONE D7
SEE SHT 5, ZONE E4

14
SEE SHT 2, ZONE E6

ORN/RED 49-86 32 1
17
19 GND FROM BATTERY 2
1 3 ORANGE 7-2 DRIVE FORWARD WHT/BLK 58-1-1
MTB EMS input
2 6 ORANGE 8-2 DRIVE REVERSE WHT/BLK 58-1-2
GND TO PLATFORM
J8 (BLACK)

16 BLACK (12) 3 23 ORANGE 55-45 BRAKE

MTB EMS TO PLATFORM
12 YEL/RED 2-1-2(12) 4 20 ORANGE 55-47 2-SPEED
11 5 BLACK
18
9 27 E
7 4 AUXILIARY POWER
5 20 8 NOTE: NOT ALL BLACK GROUND WIRES PUMP
RED (18) CAN HI 9 ARE NUMBERED ON ALL MODELS MOTOR
13 M
CAN LO 12
BLACK (18) 24
CAN SHIELD 13
J1 (WHITE)

18 BRN/ORN 53-2
YEL/RED 2-3-1 PTF EMS 1 28 YEL/RED ANALYZER POWER 1
29 ORN/RED 49-91 ANALYZER RECEIVE 2
YEL/RED 2-30 MTB MODE SELECT 30 ORN/RED 49-90 ANALYZER TRANSMIT 3
3
PLATFORM MODE INPUT ANALYZER GROUND 4
YEL/RED 2-2-1 2 31 BLACK
MTB MODE OUTPUT
YEL/RED 2-30-1 14 10
YEL/RED 2-4 (16) 9 11
CAN HI 14 WHT/BLK 11-1
RED (18) 23
CAN LO
BLACK (18) BROWN 103-1 25 15
CAN SHIELD 5
DRIVE ORIENTATION 22 SEE
YEL/RED 2-63 31
YEL/RED 2-90

PROX. SW. 16 SHT 2, ZONE G5

ORN/RED 49-106 35
35
SHT 4, ZONE E6 D
ORN/RED 49-66 4
YEL/RED 2-1-99 (16)

BLK 10
CAPACITY ANGLE SWITCH 25
DUAL CAPACITY WHT 9 YEL/RED 2-62 16
26
J7 (BLACK)

MACHINES ONLY BLK 8 ORN/RED 49-65 7

CAPACITY LENGTH SWITCH 7
WHT 7 YEL/RED 2-61 26
TRANSPORT LENGTH 21
12
SWITCH (CE ONLY) 17
4 ORN/RED 49-62 5 WHT BLK 6 ORN/RED 49-64 29 34 WHT/BLK 33-7
ORN/RED 49-77 32 19
33 ORN 100-1 B+
ORN/RED 49-76 3 ORN/RED 49-60 2 BLK WHT 1 YEL/RED 2-60 11
32
BLK WHT MAIN BOOM ELEVATION 8 24 ORN/RED 49-103
TOWER ELEVATION 28
A B C BROWN 2 ORN/RED 49-87 34 14
TOWER LIFT CRIBBING
{

12 VDC
PROX. SWITCH 4 1 BLACK 3 ORN/RED 49-88 22 4 ENABLE
SWITCH BATTERY
(800 A/AJ ONLY) 6 8
SEE SHT 4, ZONE C5
SEE SHT 2, ZONE F7

SEE SHT 5, ZONE F5

1 BLUE 3 17 9 BLU/ORN 52-75 13 12 YEL/RED 2-75

BROWN 5 ORN/RED 49-84 33 5 OPTION C
J3 (BLACK)

TOWER TELE.
PROX. SWITCH 4 1 BLACK 6 ORN/RED 49-85 21 7
(800 A/AJ ONLY} 13 SEE
3 BLUE 4 ORN/RED 49-93 19 2 SHT 1
12 ZONE
27 C6
10 ORN 100-2
11 YEL/RED 2-42
30
1 WHT/BLK 58-1
BLACK 0-8 10 6 WHT/BLK 12-1
YEL/RED 2-21 15 3

1
2 A
ORN 100-3

BLACK
5 3 CAN HI C
AMP 4 CAN LO D DIAGNOSTICS
J12

5 CAN SHIELD E CONNECTOR

6 YEL/RED 2-90 H
7 WHT/YEL RED 1-90 B
8 SW1003 B
CLEARSKY SEE
ENABLE SHEET 1 CE MARKET ONLY
ZONE H4 MSSO
ORN 101-1

CE MARKET ONLY
MDI

BLACK (18) 3
RED (18) 4
5
6
SEE ZONE H4 BLUE 102-1 1
BROWN 103-1 2
A

SHEET 1
5 4 3 2 1

MAE19500I

Figure 7-28. Electrical Schematic - Sheet 2 of 13

3121628 7-23
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4

D D

GENERATOR
BATTERY + CONTROL
SHEET 1
ZONE D1 7500 W BOX
GENERATOR B A C

STARTER
MOTOR BLU/ORN 52-6

YEL/RED 2-20
87 87a
A
GENERATOR BLU/ORN 52-5 86 85
PLUG 30
C B C
87 87a
BRN/WHT 47-8-2 86 85
SEE VENDOR 30
SCHEMATIC DETAIL

RED
SHEET 3 GLOW 5 AMP
ZONE E/G2 PLUGS
RED RED

POWERMITE
2500 W GENERATOR
14 GA FUSE LINK GENERATOR

SEE VENDOR B+
SCHEMATIC DETAIL
SHEET 3
D+
ZONE E/G2
87 87a
A
GENERATOR BLU/ORN 52-5 86 85
REGULATOR

B PLUG 30 B
B

JLG GENERATOR
WIRING

A A

SHEET 2
1 2 3 4

MAE19510I

Figure 7-29. Electrical Schematic - Sheet 3 of 13

7-24 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

H H

G G

RECTIFER
B+ FUSIBLE
LINK
STATOR

RED 1-1(10)
STARTER ALTERNATOR
MOTOR
SOL. REGULATOR
STARTER SENSING AND
MOTOR SWITCHING
CIRCUITS D+

F F

WHT/YEL 48-13 (8)

WHT/YEL 48-12(12)

BRN/WHT 47-8-1
IN HEAD GLOW PLUGS

BATTERY CABLE (1 GA.)

sol.
sol.
J1-22
ON
SHEET 1
ZONE D3
11

E E
WHT/YEL 48-3

A
WHT/YEL 48-9

GENERATOR BLU/ORN 52-5

RECEPTACLE BRN/WHT 47-8-2
B

{
SEE J1-11
SHEET 1
ZONE D3 J1-12
T4i ENGINE HARNESS
BRN/WHT 47-8 BRN/WHT 47-8-1 DEUTZ ENGINE
B+
SHEET 1
87 87a ZONE D1
COOLANT 2 8 GRD(TempAll)
86 85
D TEMPERATURE 1 9 ADC7(TEMP3) 1 D
EMR2 ENGINE CONTROL TO ENGINE

30
ENGINE 2 13 SPEED 2
SPEED
1 12 GRD (SPEED)
MTB TO EMR2 ENGINE CONTROL

CAMSHAFT 10
YEL/RED 2-6-2

TERMINAL B 1 23 GRD (ACD2)

11
BLACK

YEL/RED 2-4-1 (12) MTB STATION CHARGE AIR 2 4 ADC5(TEMP1)

PRESSURE 3 25 +5Vref(ADC2) 12
SELECT SWITCH
SHEET 1, ZONE G5 4 24 ADC2
13
1 22 +5Vref(ADC4)
ENGINE OIL
PRESSURE 2 21 ADC4 14
J1-10
ON 3 20 GND (ADC4)
SHEET 1
SEE 1 14 ActorOut
ZONE D3
SHEET 1 2 15 ActorOut
YEL/RED 2-1-99-1

EMR
ZONE F4 ACTUATOR 3 17 RackMeasCom
4 19 RackMeasSignal
5 18 RackMeasRef
C 120 OHM C
RESISTOR
BLACK (16)
CAN SHIELD

BLACK 0-1
CAN LO
CAN HI

ORN/RED 49-199
ORN/RED 49-198
YEL/RED 2-1-99

YEL/RED 2-1-98
BLACK (18)
RED (18)

B B
B L K A
C
B
A

J1-8
{

DEUTZ
DIANOSTICS
PLUG
SEE SHEET 1
ZONE C5

SEE SHEET 1, ZONE E3

A A

SHEET 3
1 2 3 4 5

MAE19520I

Figure 7-30. Electrical Schematic - Sheet 4 of 13

3121628 7-25
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4

D FOR MATING CONNECTOR ON THE ENGINE REFER D

SCHEMATIC ZONE H-3

SEE
SHEET 1
ZONE C5

A YEL/RED 2-1-99 (16)

B BRN/WHT 47-8-1
C C
C BLACK FUEL
ENGINE D WHT/YEL 48-8 PUMP
CONNECTOR F J1-11 ON SHEET 1 ZONE D3
WHT/YEL 48-3

}
N RED CAN HI
P BLK CAN LO SEE SHEET 1, ZONE C5
SHIELD

BRN/WHT 47-8

87 87a
14 BLU/ORN 52-5
YEL/RED 2-6-2 86 85
BRN/WHT 47-8-2

YEL/RED 2-4-1 (12) TERMINAL B

J1-10 MTB STATION
J1-22
BLACK

B ON B
ON SELECT SWITCH
SHEET 1 SHEET 1, ZONE G5
SHEET 1
A B ZONE D3
ZONE D3
GENERATOR
RECEPTACLE SEE
SHEET 1
ZONE F4

JLG SCHEMATIC
A FOR A

GM/PSI ENGINE

SHEET 4
1 2 3 4

MAE19530I

Figure 7-31. Electrical Schematic - Sheet 5 of 13

7-26 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121628 7-27
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

8 7 6 5 4
ECM-J2 EIC BUSSMANN DIODE PACK
BLK 248-33 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT)
33 62 (BLUE)
BLK 248-16 INJECTOR 1 1.5mm² YELLOW CONNECTOR
16 35
BLK 248-48 INJECTOR 4 1.5mm² GENERIC
48 42
BLK 248-18 INJECTOR 4 1.5mm² RELAY, POWER MODULE
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
3 41
H 6
BLK 248-5 MPROP ACTUATOR 1.5mm²
2
5 20

MS932

RL930-B+
BLK 248-4 MPROP ACTUATOR 1.5mm²

RL930-1

RL930-2
D

H
G
A
C
B

1
1

1
2

1
E
F
4 19

RL930
BLK 248-37 ENGINE SPEED CAMSHAFT 0.75mm²
37 14

BUSBAR
BLK 248-52 ENGINE SPEED CAMSHAFT 0.75mm²

YEL 2-1-99 IGNITION 18AWG

BLK 248-23 GLOW SENSE 0.75mm²
ORG 248-23-1 GLOW SENSE 18AWG
52 13

BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

WHT 48-96 FUEL PUMP 14AWG

YEL 2-48-1 IGNITION 16AWG
SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm²

YEL 2-48-4 IGNITION 18AWG

RED 1-148-135 ECM PWR 8AWG

53 9
BLK 248-39 ENGINE SPEED CRANKSHAFT 0.75mm²
39 15
BLK 248-54 ENGINE SPEED CRANKSHAFT 0.75mm²
54 21
SHLD 248-38 ENGINE SPEED CRANKSHAFT 0.75mm²
38 1
BLK 248-7 RAIL PRESSURE FUEL 0.75mm²
7 32
8 57
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
BLK 248-20 EHXAUST GAS RECIRCULATION 1.5mm²
20 48
G 21 12
22 59
BLK 248-23 GLOW SENSE 0.75mm²

S946
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
44 26
F 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
1.5MM (7,29,51,73) 7
8
9
10
11
E 12
BLK 148-13 COOLANT LEVEL SIG 0.75mm²
13

S951
14
BLK 148-15-68 CLUTCH SWITCH
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 RELAY CONTROL GND 0.75mm²
28
1.5MM (7,29,51,73) 29 BLK 148-29 COOLANT LEVEL PWR 0.75mm²
30
31
32
D 33
34
BLK 148-35 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
1.5MM (7,29,51,73) 51
52
GRN CAN 2 LO DIAG CAN LOW S968
C 53
YEL CAN 1 HI CUSTOMER CAN HIGH
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 X965
YEL CAN 2 HI DIAG CAN HIGH 120 OHM
59 A A
ECM CONNECTOR 60
GRN CAN 2 LO DIAG CAN LOW
B B
61 BLK 148-61 FUEL LOW PRESSURE 0.75mm² C C
62 X966
63
BLK 148-64 WATER IN FUEL SW 0.75mm²
64
65
66
67 X955
BLK 148-15-68 CLUTCH SWITCH 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
1.5MM (7,29,51,73) BLK 148-73 START RELAY IGN 0.75mm²
73
B 74 S969
YEL CAN 2 HI DIAG CAN HIGH
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
93
94
RED 148-5 ECM PWR 2.5mm²
A 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
2.5MM (1-6) 2 S945
BLK 148-4 ECM GND 2.5mm²
4
BLK 148-6 ECM GND 2.5mm²
6
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
NC

SHEET 5
8 7 6 5 4

Figure 7-32. Electrical Schematic - Sheet 6 of 13

7-28 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1
BUSSMANN DIODE PACK
FUEL PUMP 20A (SW), ECM 30A (CONT)
(BLUE)
YELLOW CONNECTOR
GENERIC
RELAY, POWER MODULE
GLOWPLUG SOLENOID
150 AMP
GLOWPLUGS

T4F ENGINE HARNESS SCHEMATICS

5A 10A

GENERIC

85
GENERIC
ALTERNATOR
H

B+
MS932

RL930-B+

RL931-85
RL931-87

RL931-87

RL931-30

RL931-86
RL931-87

W
RL930-1

RL930-2
D

H
G
A
C
B

1
2

1
2
E
F

L
RL930

EC18
BUSBAR

EC241-B+

EC241-W
EC241-L
YEL 2-1-99 IGNITION 18AWG

1
BLK 248-23 GLOW SENSE 0.75mm²
ORG 248-23-1 GLOW SENSE 18AWG

BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²

BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

WHT 48-96 FUEL PUMP 14AWG

YEL 2-48-1 IGNITION 16AWG

YEL 2-48-4 IGNITION 18AWG

RED 1-148-135 ECM PWR 8AWG

ORG 248-23-1 GLOW SENSE 18AWG

BATTERY

RED 48-14 GLOW 8AWG

150A
RED 48-13 GLOW 8AWG

RED 48-13 GLOW 8AWG

RED 48-14 GLOW 8AWG

RED 47-8 ALT EXCITE 16AWG

YEL 2-48-3 IGNITION 18AWG

RED - - 4AWG
POSITIVE

BUSBAR
BUSBAR

RED - - 2/0AWG
X923

RED - - 2/0AWG
1
150A
G

BUSBAR
EC971-B+
1 M
S946

EC971

GENERIC
GENERIC
1
EC971-B-
1

RL974
BLK 148-28 START RELAY CONTROL GND 0.75mm²
1 DEUTZ PROVIDED
BLK 148-73 START RELAY IGN 0.75mm²
2
START RELAY

X901
1 VSW
BLK 148-35 START 0.75mm²
2
YEL CAN 1 HI CUSTOMER CAN HIGH START
3
GRN CAN 1 LO CUSTOMER CAN LO CAN + (HI)
RED 47-8 ALT EXCITE 16AWG
4 VEHICLE INTERFACE 1
5 CAN - (LOW)
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
6
ALT EXCITE F
CAN SHIELD

X902
YEL 2-1-99 IGNITION 18AWG
1 EMR4 IGNITION
2
GROUND
3
4 GENERATOR ENABLE

5 GLOW VEHICLE INTERFACE 2

6
GENERATOR POWER
7
8 GENERATOR GROUND

PLUGGED

1
2 WHT/YEL 48-3 J1-11 ON SHEET 1, ZONE D3

}
3 RED CAN HI
VEHICLE 4 BLK CAN LO SEE SHEET 1, ZONE C5
INTERFACE 1 5 BRN/WHT 47-8 SHIELD
E
6
S951

J1-32 ON SHEET 1, ZONE C3

1 YEL/RED 2-1-99(16) J1-10 ON SHEET 1, ZONE D3

S952

2
3 BLU/ORG 52-5 J1-22 ON SHEET 1, ZONE D3
VEHICLE 4
INTERFACE 2 5 YEL/RED 2-20(16) SEE SHEET 1, ZONE C6
6 BLACK
7
8
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
GRN CAN 2 LO DIAG CAN LOW D
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
SN939 PWR
BLK 148-29 COOLANT LEVEL PWR 0.75mm²
NORMALLY CLOSED

1
COOLANT LEVEL

BLK 148-13 COOLANT LEVEL SIG 0.75mm²

3 SIG
BLK 148-87 COOLANT LEVEL GND 0.75mm²
2
4
GND

X941 X942
WIF SWITCH

BLK 148-64 WATER IN FUEL SW 0.75mm² BLK 148-64 WATER IN FUEL SW 16AWG
1 1 1
BLK 148-57 WATER IN FUEL SW RTN 0.75mm² BLK 148-57 WATER IN FUEL SW RTN 16AWG
WHT 48-96 FUEL PUMP 14AWG
2 2
WHT 48-96 FUEL PUMP 14AWG
2
SN959
WATER IN FUEL
3 3
BLK 000-48-1 ENG GND 14AWG BLK 000-48-1 ENG GND 14AWG
4 4
120 OHM
A
FUEL PUMP

B 1
M
C
X956 EC958
2 FUEL PUMP
X958A EC958+
WHT 48-96 FUEL PUMP
FUEL PUMP

1 1
2 EC958- M B
BLK 000-48-1 ENG GND
1

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

SHEET 5
5 4 3 2 1

MAE19540I

Figure 7-33. Electrical Schematic - Sheet 7 of 13

3121628 7-29
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

8 7 6 5 4

PLATFORM SENSOR
H
ORN/RED 49-69
SEE 3 YEL/RED P1 ZONE D6
SHT 1
ZONE E6 YEL/RED 2-63
PLATFORM SENSOR
6 YEL/RED P8
13
YEL/RED P9 ZONE D6

YEL/RED P2 ZONE E2
OR SEE SHEET 7
ZONE E1

SOFT TOUCH AND PLATFORM SENSOR

YEL/RED P3
ORN/RED 49-69 SEE
SEE 3 YEL/RED P1 ZONE D6 SHT 1
SHT 1 ZONE F8
ZONE E6 YEL/RED 2-63
6 BLK L WHT 5
SOFT
13 BLK BLK 4 TOUCH
R
F
YEL/RED P9 ZONE D6
YEL/RED P2 ZONE E2
OR SEE SHEET 7
ZONE E1

PLATFORM SENSOR
WHT ORN/RED P4
4
BLK ORN/RED P5
3
BLK BLK P6
2
E WHT YEL/RED P10
1

YEL/RED P1
YEL/RED P9
D

LOW TEMPERATURE CUTOUT OPTION P-J8A

YEL/RED EMS GND 2-1-3
X3
2 CONNECT TO P8
BLK GND
1 (MATING CONNECTOR OF J8)
C
MOLEX SHT 1 ZONE D-7
042818-0212
PARKER SENSOR
X1 YEL/RED EMS GND 2-1-3
YEL/RED EMS GND 2-1-5 YEL/RED EMS GND 2-1-4
1
BLK GND S531
2
3
BLK CAN L
RED CAN H BLK GND
BLK GND
BLK GND
X4
4 B
CONNECT TO X1002
NC S532 A
C SHT 1 ZONE F-6
BLK CAN L
BLK CAN L BLK CAN L DEUTSCH
B S533 RED CAN H
RED CAN H RED CAN H JLG PN 4460536
S534
SHIELD CANSHD X5
SHIELD CANSHD SHIELD CANSHD B
CONNECT TO X1001
X2 S535
A
C SHT 1 ZONE F-6
YEL/RED EMS GND 2-1-4
CONNECT TO J8 2
BLK GND
SHT 1 ZONE D-7 1 DEUTSCH
JLG PN 4460539
P-J8
MOLEX
042816-0212
A
LTC OPTION BOOM HARNESS

SHEET 6
8 7 6 5 4

Figure 7-34. Electrical Schematic - Sheet 8 of 13

7-30 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1

PLATFORM SENSOR

YEL/RED P3 YEL/RED P3 87
1

YEL/RED P9-1 30
1

RELAY, 12V
87a
1
F

ORN/RED P5 85
1
ORN/RED P5-1
ORN/RED P4 86
1
PLATFORM SENSOR ORN/RED P4-1
WHT ORN/RED P4
4
BLK ORN/RED P5
3
BLK P6 SEE
BLK 2 SHT 1
WHT YEL/RED P10 YEL/RED P2 ZONE E7 E
1
18 ohm 25W

YEL/RED P1 YEL/RED P1 87
1
YEL/RED P9 YEL/RED P9
YEL/RED P9-1 30
1 D
RELAY, 12V

87a
1

ORN/RED P5-1 85
1
P-J8A ORN/RED P4-1 86
1
X3
CONNECT TO P8
2
BLK GND
(MATING CONNECTOR OF J8)
1
NOTE: C
MOLEX SHT 1 ZONE D-7 SKYGUARD RELAYS LOCATED ON THE RIGHT SIDE OF THE CONTROL PLATFORM BOX.
042818-0212 IF SKYGUARD RELAYS ARE ON THE LEFT SIDE, SEE SHEET 7.

X4
B
A
CONNECT TO X1002
C SHT 1 ZONE F-6
DEUTSCH
JLG PN 4460536 B

X5
B
CONNECT TO X1001
A
C SHT 1 ZONE F-6
DEUTSCH
JLG PN 4460539

SHEET 6
5 4 3 2 1

MAE19550I

Figure 7-35. Electrical Schematic - Sheet 9 of 13

3121628 7-31
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4 5

H H

ALERT BEACON OPTION

12
11
10
9
8
RED - BEACON PWR
G 7 G
6
BEACON MODULE
5
4
3
BLK - GROUND
X3 2
RED - BEACON PWR WHT - IGNITION
1 1
BLK - GROUND S1
2 X1
BLK - GROUND

F F

S2
TO ENG DIAG CONN (ORIGINAL)
WHT - CAN SHIELD

RED - CAN HIGH

TO ENG DIAG CONN (NEW)

BLK - CAN LOW

WHT - CAN SHIELD

RED - CAN HIGH

WHT - IGNITION

WHT - IGNITION
BLK - CAN LOW

BLK - CAN LOW

RED - BATTERY

RED - BATTERY
BLK - GROUND

BLK - GROUND
BEACON MODULE

CAN TERMINATOR

E E
X2

X4
12
11
10
9
8
7
6
5
4
3
2
1

1
3
5
2
4
6
11
9
7
12
10
8

J
H
G
F
E
D
C
B
A

C
B
A

J
H
G
F
E
D
C
B
A

D HARNESS,GEN 2 PLAT INTERFACE D

PLTFM SNSR
PLTFM SNSR PLTFM SNSR
RELAY #1 RELAY #2
87a

87a
87
30

85
86

86
85

30
87

C C
4
3
2
1
RL503

RL502

X500
4
3
2
1
WHT P1
WHT P9-1

WHT P5-1
WHT P4-1

WHT P4-2
WHT P5-2

WHT P9-2
WHT P3

WHT P5
WHT P4
WHT P6
WHT P10

NOTE:
6 PIN CONNECTOR AND RELAYS LOCATED
ON THE LEFT SIDE OF THE CONTROL PLATFORM BOX.
IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE, SEE SHEET 6.

S191 INTERFACE

X5B KL
S192
B B
WHT P6 BLACK SK 2
2 SEE SHT 1 ZONE F6

WHT P1 ORN/RED 49-69-1

4 SEE SHT 1 ZONE F6
WHT P3 YEL/RED P3
5 SEE SHT 1 ZONE H8
18 OHM
IP144 WHT P2 YEL/RED 2-63-1
1 SEE SHT 1 ZONE E6
YEL/RED P2
3 SEE SHT 6 ZONE F6 OR G6

A A

SHEET 7
1 2 3 4 5

MAE19560I

Figure 7-36. Electrical Schematic - Sheet 10 of 13

7-32 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1 2 3 4

D D

FOR MATING CONNECTOR ON THE ENGINE REFER

SCHEMATIC ZONE H-3
SEE
SHEET 1
ZONE C5

C 1 YEL/RED 2-1-99 (16) C

18 BLACK FUEL
ENGINE 5 WHT/YEL 48-8 PUMP
CONNECTOR
15 WHT/YEL 48-3 J1-11 ON SHEET 1 ZONE D3
28
29
RED CAN HI
BLK CAN LO
SHIELD } SEE SHEET 1, ZONE C5

BRN/WHT 47-8

14 BLU/ORN 52-5
87 87a
BRN/WHT 47-8

YEL/RED 2-6-2 86 85
30
J1-22
B ON YEL/RED 2-4-1 (12) TERMINAL B B
J1-10
BLACK

SHEET 1 MTB STATION

B ON SELECT SWITCH
ZONE D3 A
SHEET 1 SHEET 1, ZONE G5
GENERATOR ZONE D3
RECEPTACLE
SEE
SHEET 1
ZONE E5

JLG SCHEMATIC
FOR
A FORD ENGINE A

SHEET 8
1 2 3 4

MAE19570I

Figure 7-37. Electrical Schematic - Sheet 11 of 13

3121628 7-33
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

8 7 6 5 4

HDGCP90

Value

SHEET 9
8 7 6 5 4

Figure 7-38. Electrical Schematic - Sheet 12 of 13

7-34 3121628
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1

EDI FORD ENGINE HARNESS SCHEMATICS

ALTERNATOR

Value

NOTES:
ALL WIRE IS SAE J1128 TXL TYPE
HARNESS TO BE LABELED WITH ECI PART NUMBER AND REVISION

SHEET 9
5 4 3 2 1

MAE19580I

Figure 7-39. Electrical Schematic - Sheet 13 of 13

3121628 7-35
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

7-36 3121628
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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