Service Manual

Models
3614RS
4017RS
PVC 1911
PVC 2005
31211337

'FCSVBSZ , 2021 - Rev C

An Oshkosh Corporation Company

 EFFECTIVITY PAGE

DATE REVISION DESCRIPTION

November 11, 2019 A Original Issue of Manual.
July 08, 2020 B Added page 7-4
Revised pages 2-4, 2-5, 4-8, 4-9, 7-3, 7-11, 9-12 thru 9-20, 9-40 thru 9-46,
9-48 thru 9-57, 9-59 thru 9-171
February 01, 2021 C Revised pages 2-4, 2-5, 2-15 thru 2-25, 2-27 thru 2-33, 2-35 thru 2-37, 2-39, 2-41 thru
2-69, 2-74, 3-8, 3-16, 3-25, 3-30, 3-33, 3-35, 3-38, 3-39, 6-5, 7-2, 7-17, 8-4, 8-5,
8-13 thru 8-15, 8-19, 8-23 thru 8-25, 9-30, 9-40 thru 204

3614RS, 4017RS 31211337 i

 READ THIS FIRST

Modifications
Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations.
Any modification must be approved by JLG.

Machine Configuration
Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel
Decal (1) as indicated below.
• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Ultra
Low Sulfur (ULS) from this point forward.
• If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Low
Sulfur (LS) from this point forward.

S 15 mg/kg

1 D
1001139654 A
OZ4390

ii 31211337 3614RS, 4017RS

 SECTION CONTENTS
Section Subject Page

Section 1
Safety Practices ......................................................................................................................... 1-1
1.1 Introduction ........................................................................................................................................................... 1-2
1.2 Disclaimer ................................................................................................................................................................ 1-2
1.3 Operation & Safety Manual ............................................................................................................................... 1-2
1.4 Do Not Operate Tags ........................................................................................................................................... 1-2
1.5 Safety Information ............................................................................................................................................... 1-2
1.6 Safety Instructions ................................................................................................................................................ 1-3
1.7 Safety Decals .......................................................................................................................................................... 1-4

Section 2
General Information and Specifications ................................................................................. 2-1
2.1 Replacement Parts and Warranty Information .......................................................................................... 2-3
2.2 Specifications ......................................................................................................................................................... 2-4
2.3 Fluids and Lubricant Capacities ...................................................................................................................... 2-7
2.4 Service and Maintenance Schedules ............................................................................................................. 2-10
2.5 Lubrication Schedule .......................................................................................................................................... 2-13
2.6 ThreadLocking Compound ............................................................................................................................... 2-15
2.7 Torque Charts ........................................................................................................................................................ 2-16
2.8 Hydraulic Connection Assembly and Torque Specification ................................................................. 2-26

Section 3
Boom .............................................................................................................................. 3-1
3.1 Boom System Component Terminology - 3614RS ................................................................................... 3-3
3.2 Boom System - 3614RS ....................................................................................................................................... 3-4
3.3 Boom Assembly Maintenance - 3614RS ....................................................................................................... 3-4
3.4 Boom Chain Removal/Installation - 3614RS ............................................................................................... 3-12
3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - 3614RS ............................................................. 3-14
3.6 Extend/Retract Cylinder Removal/Installation - 3614RS ........................................................................ 3-15
3.7 Boom Sections Adjustment - 3614RS ............................................................................................................ 3-16
3.8 Boom System Component Terminology - 4017RS ................................................................................... 3-17
3.9 Boom System - 4017RS ....................................................................................................................................... 3-18
3.10 Boom Assembly Maintenance - 4017RS ....................................................................................................... 3-18
3.11 Hose Carrier Assembly ........................................................................................................................................ 3-30
3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - 4017RS ............................................. 3-31
3.13 Boom Chain Removal/Installation - 4017RS ............................................................................................... 3-33
3.14 Boom Sections Adjustment - 4017RS ............................................................................................................ 3-33
3.15 Boom Extend and Retract Chains - 3614RS & 4017RS ............................................................................. 3-34
3.16 Boom Wear Pads ................................................................................................................................................... 3-38
3.17 Quick Coupler ........................................................................................................................................................ 3-39
3.18 Forks .......................................................................................................................................................................... 3-40
3.19 Boom Prop (if equipped) ................................................................................................................................... 3-40
3.20 Emergency Boom Lowering Procedure ....................................................................................................... 3-41
3.21 Troubleshooting ................................................................................................................................................... 3-43

3614RS, 4017RS 31211337 i

Section Subject Page

Section 4
Cab .............................................................................................................................. 4-1
4.1 Operator Cab Component Terminology ..................................................................................................... 4-2
4.2 Operator Cab ......................................................................................................................................................... 4-3
4.3 Cab Components ................................................................................................................................................. 4-3
4.4 Cab Removal .......................................................................................................................................................... 4-11
4.5 Cab Installation ..................................................................................................................................................... 4-13

Section 5
Axles, Drive Shafts, Wheels and Tires ...................................................................................... 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology ......................................................................... 5-2
5.2 Axle Serial Number .............................................................................................................................................. 5-4
5.3 Axle Specifications and Maintenance Information .................................................................................. 5-4
5.4 Axle Replacement ................................................................................................................................................ 5-4
5.5 Brake Inspection ................................................................................................................................................... 5-7
5.6 Park Brake adjustment - 3614RS ..................................................................................................................... 5-7
5.7 Steering Angle Adjustment .............................................................................................................................. 5-7
5.8 Axle Assembly and Drive Shaft Troubleshooting ..................................................................................... 5-8
5.9 Drive Shafts ............................................................................................................................................................. 5-11
5.10 Wheels and Tires ................................................................................................................................................... 5-12
5.11 Towing a Disabled Machine ............................................................................................................................. 5-13

Section 6
Transmission ............................................................................................................................. 6-1
6.1 Transmission Assembly Component Terminology .................................................................................. 6-2
6.2 Transmission Serial Number ............................................................................................................................. 6-3
6.3 Specifications and Maintenance Information ............................................................................................ 6-3
6.4 Transmission Replacement ............................................................................................................................... 6-3
6.5 Torque Converter Flex Plate ............................................................................................................................. 6-7
6.6 Troubleshooting ................................................................................................................................................... 6-7

Section 7
Engine .............................................................................................................................. 7-1
7.1 Introduction ........................................................................................................................................................... 7-2
7.2 Engine Serial Number ......................................................................................................................................... 7-5
7.3 Specifications and Maintenance Information ............................................................................................ 7-5
7.4 Engine Cooling System ...................................................................................................................................... 7-5
7.5 Engine Electrical System .................................................................................................................................... 7-8
7.6 Fuel System ............................................................................................................................................................ 7-8
7.7 Engine Exhaust System ...................................................................................................................................... 7-10
7.8 Air Cleaner Assembly .......................................................................................................................................... 7-14
7.9 Engine Replacement .......................................................................................................................................... 7-15
7.10 Troubleshooting ................................................................................................................................................... 7-17

ii 31211337 3614RS, 4017RS

Section Subject Page

Section 8
Hydraulic System ...................................................................................................................... 8-1
8.1 Hydraulic Component Terminology .............................................................................................................. 8-2
8.2 Safety Information ............................................................................................................................................... 8-4
8.3 Specifications ......................................................................................................................................................... 8-4
8.4 Hydraulic Pressure Diagnosis ........................................................................................................................... 8-4
8.5 Hydraulic Circuits .................................................................................................................................................. 8-5
8.6 Hydraulic Schematics .......................................................................................................................................... 8-7
8.7 Hydraulic Reservoir .............................................................................................................................................. 8-11
8.8 Engine Implement Pump .................................................................................................................................. 8-13
8.9 Control Valves ........................................................................................................................................................ 8-14
8.10 Hydraulic Cylinders .............................................................................................................................................. 8-23

Section 9
Electrical System ....................................................................................................................... 9-1
9.1 Electrical Component Terminology ............................................................................................................... 9-3
9.2 Specifications ......................................................................................................................................................... 9-4
9.3 Safety Information ............................................................................................................................................... 9-4
9.4 Power Distribution Board .................................................................................................................................. 9-4
9.5 Electrical System Schematics ........................................................................................................................... 9-12
9.6 Dielectric Grease Application ........................................................................................................................... 9-19
9.7 Engine Start Circuit .............................................................................................................................................. 9-21
9.8 Battery ...................................................................................................................................................................... 9-23
9.9 Wiper/Washer Wiper Motor .............................................................................................................................. 9-24
9.10 Solenoids, Sensors and Senders ...................................................................................................................... 9-28
9.11 Dash Switches ........................................................................................................................................................ 9-33
9.12 Load Stability Indicator (LSI) (if equipped) .................................................................................................. 9-35
9.13 Machine Data ......................................................................................................................................................... 9-38
9.14 Analyzer Software Accessibility ....................................................................................................................... 9-48
9.15 Fault Codes ............................................................................................................................................................. 9-69
9.16 Machine Fault Codes Version P 18.0 .............................................................................................................. 9-70
9.17 Engine Diagnostic ................................................................................................................................................ 9-205

3614RS, 4017RS 31211337 iii

Section Subject Page

iv 31211337 3614RS, 4017RS

 Section 1
Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

3614RS, 4017RS 31211337 1-1

 Safety Practices

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and the
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any service or
procedures in this manual will help assure safety and maintenance. Remove key and disconnect battery leads.
equipment reliability.
Read, understand and follow the information in this manual, 1.5 SAFETY INFORMATION
and obey all locally approved safety practices, procedures,
rules, codes, regulations and laws. To avoid possible death or injury, carefully read, understand
and comply with all safety messages.
These instructions cannot cover all details or variations in the
equipment, procedures, or processes described, nor provide In the event of an accident, know where to obtain medical
directions for meeting every possible contingency during assistance and how to use a first aid kit and fire extinguisher/
operation, maintenance, or testing. When additional fire suppression system. Keep emergency telephone
information is desired consult the local JLG dealer. numbers (fire department, ambulance, rescue squad/
paramedics, police department, etc.) nearby. If working
Many factors contribute to unsafe conditions: carelessness, alone, check with another person routinely to help assure
fatigue, overload, inattentiveness, unfamiliarity, even drugs personal safety.
and alcohol, among others. For optimal safety, encourage
everyone to think, and to act, safely.
1.5.1 Safety Alert System and Signal Words
Appropriate service methods and proper repair procedures
are essential for the safety of the individual doing the work,
for the safety of the operator, and for the safe, reliable
operation of the machine. All references to the right side, left
DANGER
side, front and rear are given from the operator seat looking in
a forward direction. DANGER indicates an imminently hazardous situation
Supplementary information is available from the which, if not avoided, will result in death or serious injury.
manufacturer in the form of Service Bulletins, Service
Campaigns, Service Training Schools, the service website,
other literature, and through updates to the manual itself. WARNING
1.2 DISCLAIMER
WARNING indicates a potentially hazardous situation which,
All information in this manual is based on the latest product if not avoided, could result in death or serious injury.
information available at the time of publication. The
manufacturer reserves the right to make changes and
improvements to its products, and to discontinue the CAUTION
manufacture of any product, at its discretion at any time
without public notice or obligation.
CAUTION indicates a potentially hazardous situation which,
1.3 OPERATION & SAFETY MANUAL if not avoided, may result in minor or moderate injury.

The mechanic must not operate the machine until the

Operation & Safety Manual has been read and understood,
training has been accomplished and operation of the
machine has been completed under the supervision of an
experienced and qualified operator.
An Operation & Safety Manual is supplied with each machine
and must be kept in the manual holder located in the cab. In
the event that the Operation & Safety Manual is missing,
consult the local JLG dealer before proceeding.

1-2 31211337 3614RS, 4017RS

 Safety Practices

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be
Following are general safety statements to consider before
safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab clean,
procedures are located throughout this manual and are and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the injury
For all safety messages, carefully read, understand and follow may seem. Know the location of a First Aid Kit, and know how
the instructions before proceeding. to use it.
CLEANLINESS: Wear eye protection, and clean all
1.6.1 Personal Hazards components with a high pressure or steam cleaner before
PERSONAL SAFETY GEAR: Wear all the protective clothing attempting service.
and personal safety gear necessary to perform the job safely. When removing hydraulic components, plug hose ends and
This might include heavy gloves, safety glasses or goggles, connections to prevent excess leakage and contamination.
filter mask or respirator, safety shoes or a hard hat. Place a suitable catch basin beneath the machine to capture
LIFTING: NEVER lift a heavy object without the help of at fluid run off.
least one assistant or a suitable sling and hoist. It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing the
1.6.2 Equipment Hazards machine is needed, ensure the machine is shut down before
pressure-washing. Should pressure-washing be utilized to
LIFTING OF EQUIPMENT: Before using any lifting equipment
wash areas containing electrical/electronic components, JLG
(chains, slings, brackets, hooks, etc.), verify that it is of the
recommends a maximum pressure of 52 bar (750 psi) at a
proper capacity, in good working order, and is properly
minimum distance of 30,5 cm (12 in) away from these
attached.
components. If electrical/electronic components are
NEVER stand or otherwise become positioned under a sprayed, spraying must not be direct and for brief time
suspended load or under raised equipment. The load or periods to avoid heavy saturation,
equipment could fall or tip.
Check and obey all Federal, State and/or Local regulations
DO NOT use a hoist, jack or jack stands only to support regarding waste storage, disposal and recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job; keep
tools clean and in good working order, and use special
service tools only as recommended.

3614RS, 4017RS 31211337 1-3

 Safety Practices

1.6.4 Operational Hazards FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic
systems near an open flame, sparks or smoking materials.
ENGINE: Stop the engine before performing any service
unless specifically instructed otherwise. NEVER drain or store fluids in an open container. Engine fuel
and hydraulic fluid are flammable and can cause a fire and/or
VENTILATION: Avoid prolonged engine operation in
explosion.
enclosed areas without adequate ventilation.
DO NOT mix gasoline or alcohol with diesel fuel. The mixture
SOFT SURFACES AND SLOPES: NEVER work on a machine
can cause an explosion.
that is parked on a soft surface or slope. The machine must be
on a hard level surface, with the wheels blocked before PRESSURE TESTING: When conducting any test, only use test
performing any service. equipment that is correctly calibrated and in good condition.
Use the correct equipment in the proper manner, and make
FLUID TEMPERATURE: NEVER work on a machine when the
changes or repairs as indicated by the test procedure to
engine, cooling or hydraulic systems are hot. Hot
achieve the desired result.
components and fluids can cause severe burns. Allow
systems to cool before proceeding. LEAVING MACHINE: Lower the forks or attachment to the
ground before leaving the machine.
FLUID PRESSURE: Before loosening any hydraulic or diesel
fuel component, hose or tube, turn the engine OFF. Wear TIRES: Always keep tires inflated to the proper pressure to
heavy, protective gloves and eye protection. NEVER check help prevent tipover. DO NOT over inflate tires.
for leaks using any part of your body; use a piece of NEVER use mismatched tire types, sizes or ply ratings.
cardboard or wood instead. If injured, seek medical attention Always use matched sets according to machine
immediately. Diesel fluid leaking under pressure can specifications.
explode. Hydraulic fluid and diesel fuel leaking under
MAJOR COMPONENTS: Never alter, remove, or substitute any
pressure can penetrate the skin, cause infection, gangrene
items such as counterweights, tires, batteries or other items
and other serious personal injury.
that may reduce or affect the overall weight or stability of the
Engine fuel lines are pressurized. DO NOT attempt repairs machine.
unless specific training has been completed.
BATTERY: DO NOT charge a frozen battery.Charging a frozen
Refer to the engine manufacturers manual for specific details
battery may cause it to explode. Allow the battery to thaw
concerning the fuel system.
before jump starting or connecting a battery charger.
Relieve all pressure before disconnecting any component,
part, line or hose. Slowly loosen parts and allow release of 1.7 SAFETY DECALS
residual pressure before removing any part or component.
Before starting the engine or applying pressure, use Check that all safety decals are present and readable on the
components, parts, hoses and pipes that are in good machine. Refer to the Operation & Safety Manual supplied
condition, connected properly and are tightened to the with machine for information.
proper torque. Capture fluid in an appropriate container and
dispose of in accordance with prevailing environmental
regulations.
COOLANT SYSTEM CAP: The cooling system is under
pressure, and escaping coolant can cause severe burns and
eye injury. To prevent personal injury, NEVER remove the
coolant system cap while the cooling system is hot. Wear
safety glasses. Turn the coolant system cap to the first stop
and allow pressure to escape before removing the cap
completely. Failure to follow the safety practices could result
in death or serious injury.
Properly disconnect battery(s) prior to service the fuel or
hydraulic systems.

1-4 31211337 3614RS, 4017RS

 Section 2
General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.5 Transmission Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3 Fluids and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.1 Fluids (if equipped for ULS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.2 Fluids (if equipped for LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.1 Every 10 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.2 First 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.3 Every 50 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.4 First 250 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.5 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.6 Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.7 Every 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.8 Every 3000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.9 Every 6000 Hours or 4 years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.5 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5.1 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5.2 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.6 ThreadLocking Compound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.7 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.7.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.7.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

3614RS, 4017RS 31211337 2-1

 General Information and Specifications

2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-26

2.8.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections 2-28
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections. 2-30
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.8.5 Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings. . . . . . . . . . . . . . . . . . . 2-36
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . 2-38
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings . . . . . . . . . . . . . . . . 2-52
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends . . . . . . . . . 2-60
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . 2-62
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62) . . . . . . . . . . . . . . 2-70
2.8.14 Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
2.8.15 FFWR and TFFT Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
2.8.16 Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
2.8.17 O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

2-2 31211337 3614RS, 4017RS

 General Information and Specifications

2.1 REPLACEMENT PARTS AND WARRANTY

INFORMATION

1
MAE34840

Before ordering parts or initiating service inquiries, make

note of the machine serial number. The machine serial
number plate (1) is located on the frame behind the right
front tire.
Note: The replacement of any part on this machine with any
other than factory authorized replacement parts can adversely
affect the performance, durability, or safety of the machine,
and will void the warranty. JLG disclaims liability for any claims
or damages, whether regarding property damage, personal
injury or death arising out of the use of unauthorized
replacement parts.
A warranty registration form must be filled out by the local
JLG dealer.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed to
guarantee full warranty service.

3614RS, 4017RS 31211337 2-3

 General Information and Specifications

2.2 SPECIFICATIONS

2.2.1 Travel Speeds

APPROXIMATE MAXIMUM SPEED

TRANSMISSION
74,4 kW 55,0 kW
First Gear 5 kph (3 mph) 5 kph (3 mph)
Second Gear 12 kph (7 mph) 9.5 kph (6 mph)
Third Gear 25 kph (15 mph) 19.3 kph (12 mph)

2.2.2 Hydraulic Cylinder Performance

Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 54°C (130°F) minimum, engine at operating
temperature.

APPROXIMATE TIMES (seconds)

FUNCTION
3614RS 4017RS
Boom Extend (Boom Level) 14.5 25
Boom Retract (Boom Level) 12.5 20.0
Boom Lower 10cm Extend 15.0 17.0
Boom Lift 15.0 21.0
Boom Lower 12.0 15.0
Quick Coupler Raise 3.5 3.5
Quick Coupler Lower 2.5 2.5
Frame Level - Full Right to Left 11.0 13.0
Frame Level - Full Left to Right 11.0 13.0
Outrigger - Both Down 10.0 10.0
Outrigger - Both Up 8.0 8.0
Outrigger - Single Down 5.0 5.0
Outrigger - Single Up 4.0 4.0

2-4 31211337 3614RS, 4017RS

 General Information and Specifications

2.2.3 Electrical System

Description Standard
Battery
Type, Rating 12 V, Negative (-) Ground, Tapered Top Post, Maintenance Free
Quantity 1
Cranking Performance 1 - 830 Cold Cranking Amps @ -18°C (0°F)
Group/Series BCI Group 31
Alternator 14V, 120 Amps
Starter 12V, 4 KW

2.2.4 Engine Performance Specifications

Specifications
Description
74,4 kW 55,0 kW
Engine Make/Model Deutz TCD 3.6 L4 Deutz TCD 3.6 L4
Displacement 3,6 liters (276 in³) 3,6 liters (276 in³)
Low Idle 945-955 rpm 935-965 rpm
High Idle 2295-2345 rpm 2295-2345 rpm
Horsepower 74,4 kW (99.7 HP) @ 2200 rpm 55,4 kW (74.3 HP) @ 2200 rpm
Peak Torque 410 Nm (302 lb-ft) @ 1600 rpm 405Nm (299 lb-ft) @ 1300 rpm
Fuel Delivery Fuel Injection Fuel Injection
Dry Type, Replaceable Primary and Safety Dry Type, Replaceable Primary and Safety
Air Cleaner
Elements Elements

2.2.5 Transmission Performance Specifications

Engine kW (Horsepower) Transmission Stall Speed

Deutz TCD 3.6 L4 74,4 (99.7) 3 Speed 2030 rpm 2050 rpm
Deutz TCD 3.6 L4 55,4 (74.3) 3 Speed 1930 rpm 1950 rpm

3614RS, 4017RS 31211337 2-5

 General Information and Specifications

2.2.6 Tires
Note: Wheel lug nut torque is 430-470 Nm (317-347 lb-ft)
Note: Pressures for foam filled tires are for initial fill ONLY.

a. 3614RS

Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
15.5/80-24 TR01 16 Ply Pneumatic 4,1 Bar (59 psi)
Pneumatic 4,0 Bar (58 psi)
15.5-25 L-2 12 Ply
Foam 186 kg (410 lb)
400/80-24 Power CL N/A Pneumatic 4,0 Bar (58 psi)
370/75-28 DuraForce MH 14 Ply Pneumatic 5,25 Bar (76 psi)

b. 4017RS

Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
14-24 TG02 16 Ply Pneumatic 4,25 Bar (62 psi)
Pneumatic 4,75 Bar (69 psi)
14-24 SGG-2A 16 Ply
Foam 245 kg (540lb)
14-24 L2/G2 Radial Pneumatic 5,5 Bar (80 psi)
400/75-28 DuraForce MH 16 Ply Pneumatic 5,25 Bar (76 psi)

2-6 31211337 3614RS, 4017RS

 General Information and Specifications

2.3 FLUIDS AND LUBRICANT CAPACITIES

2.3.1 Fluids (if equipped for ULS)

Ambient Temperature Range
Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
Deutz Specification SAE 15W-40 14 120 -10 49
Engine Crankcase DQC III-10 LA SAE 10W-40 5 120 -15 49
DQC IV-10 LA SAE 5W-40 -22 104 -30 40
Transmission and Transfer Mobilfluid 424 10W-30 0 104 -20 40
Case Mobilfluid LT 75W-80 -40 0 -40 -20
SAE140 50 122 10 50
80W-140
14 122 -10 50
85W-140
SAE90
Axle Differential and API GL5 with 32 104 0 40
SAE90LS
Wheel End LS Additives
80W-90
-4 104 -20 40
85W-90
75W-90 -40 104 -40 40
75W -40 50 -40 10
Mobilfluid 424 10W-30 0 104 -20 40
Hydraulic System
Exxon Univis HVI -40 0 -40 -20
Cylinder, Boom Wear
Pad and Boom Chain Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Lubricant
Axle Grease Extreme Pressure Grease NLGI Grade 2EP 5 122 -15 50
Ethylene Glycol 50/50 Mix Standard
Engine Coolant
and Water 60/40 Mix Cold Weather
EN590
ASTM D975 Grade 2-D Ultra Low Sulfur
Fuel
ASTM D975 Grade 1-D (S < 15 mg/kg)
(Maximum B5 Biodiesel)
Brake Fluid (if equipped
Mobil ATF 220 -40 122 -40 50
with 55 kW engine)
Air Conditioning Refrigerant R-134-a Tetrafluoroethane

3614RS, 4017RS 31211337 2-7

 General Information and Specifications

2.3.2 Fluids (if equipped for LS)

Ambient Temperature Range
Compartment or System Type and Classification Viscosities °F °C
Min Max Min Max
Deutz Specification SAE 15W-40 14 120 -10 49
Engine Crankcase DQC III-10 SAE 10W-40 5 120 -15 49
DQC IV-10 SAE 5W-40 -22 104 -30 40
Transmission and Transfer Mobilfluid 424 10W-30 0 104 -20 40
Case Mobilfluid LT 75W-80 -40 0 -40 -20
SAE140 50 122 10 50
80W-140
14 122 -10 50
85W-140
SAE90
Axle Differential and API GL5 with 32 104 0 40
SAE90LS
Wheel End LS Additives
80W-90
-4 104 -20 40
85W-90
75W-90 -40 104 -40 40
75W -40 50 -40 10
Mobilfluid 424 10W-30 0 104 -20 40
Hydraulic System
Exxon Univis HVI -40 0 -40 -20
Cylinder, Boom Wear
Pad and Boom Chain Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Lubricant
Axle Grease Extreme Pressure Grease NLGI Grade 2EP 5 122 -15 50
Ethylene Glycol 50/50 Mix Standard
Engine Coolant
and Water 60/40 Mix Cold Weather
EN590
ASTM D975 Grade 2-D Low Sulfur
Fuel
ASTM D975 Grade 1-D (S < 500 mg/kg)
(Maximum B5 Biodiesel)
Air Conditioning Refrigerant R-134-a Tetrafluoroethane

2-8 31211337 3614RS, 4017RS

 General Information and Specifications

2.3.3 Capacities

Engine Crankcase Oil

Capacity with Filter Change 8,0 liter (8.5 quart)
Fuel Tank
Capacity 150 liter (39.6 gallon)
Cooling System
System Capacity 19,0 liter (20 quart)
Transmission System
Capacity with Filter Change 13,5 liter (14.3 qt)
Transfer Case
Capacity 0,75 liter (0.79 qt)
Hydraulic System
System Capacity 145 liter (38.3 gallon)
Reservoir Capacity to Full Mark 90 liter (23.8 gallon)
Auxiliary Hydraulic Circuit Max Flow 80 lpm (21.1 gpm)
Axles
Differential Housing Capacity
3614RS
Front Axle 7,3 liter (7.7 quart)
Rear Axle 7,5 liter (7.9 quart)
4017RS
Front Axle 6,7 liter (7.1 quart)
Rear Axle 7,5 liter (7.9 quart)
Wheel End Capacity
3614RS 1,4 liter (1.5 quart)
4017RS
Front Axle 2,1 liter (2.2 quart)
Rear Axle
If Equipped with Pneumatic Tires 1,4 liter (1.5 quart)
If Equipped with Foam Filled Tires 2,1 liter (2.2 quart)
Air Conditioning System (if equipped)
System Capacity 1,0 kg (2.2 lb)

3614RS, 4017RS 31211337 2-9

 General Information and Specifications

2.4 SERVICE AND MAINTENANCE

SCHEDULES

2.4.1 Every 10 Hours

OC0880 OC0910 OC0920 OC0890 OC0970 OC0930

Check Fuel Level Check Engine Oil Check Hydraulic Check Tire Check Engine Check
Level Oil Level Condition & Coolant Level Transmission Oil
Pressure Level

2.4.2 First 50 Hours

OC1110 OC1130 MAE19460 OC0990

Check Axle Check Wheel End Check Boom Chain Check Wheel Lug
Differential Oil Oil Level & Tension Nut Torque
Level

2.4.3 Every 50 Hours

OC0960 OC0950 MAE19470 OC1150 OC1020 MAE8060

Drain Fuel/Water Check Air Filter Lubrication Check Check Washer Check cab Air Filter
Separator Schedule Battery Fluid Level
(if equipped)

OF0620

Check
LSI System

2-10 31211337 3614RS, 4017RS

 General Information and Specifications

2.4.4 First 250 Hours

OC1070 OC1060 OC1040 OC1050

Check Change Transfer Change Axle Change Wheel End

Transmission Oil & Case Oil Differential Oil Oil
Filter

2.4.5 Every 250 Hours

OC1100 MAE19480 OC1110 OC1130 MAE19490 MAE19460

Check Transfer Check Fan Belt Check Axle Check Wheel End Check Boom Wear Check Boom Chain
Case Oil Level Differential Oil Oil Level Pads & Tension
Level

2.4.6 Every 500 Hours

OC1220 OC1140 MAE19620 OC0990 MAE19470

Change Fuel Filter Change Engine Oil Change Air Filter Check Wheel Lug Lubrication
and Filter Elements Nut Torque Schedule

3614RS, 4017RS 31211337 2-11

 General Information and Specifications

2.4.7 Every 1000 Hour

OC1070 OC1060 OC1230 OC1040 OC1050

MAE19590
Change Change Transfer Change Hydraulic Change Axle Change Wheel End Check LSI
Transmission Oil & Case Oil Fluid & Filter Differential Oil Oil Calibration
Filter

2.4.8 Every 3000 Hours

OC1160

Change Belt

2.4.9 Every 6000 Hours or 4 years

OC1240

Change Engine
Coolant
Note: If hour and year intervals are listed, use the interval that occurs first. Refer to Engine Operation & Maintenance Manual for
additional information.

2-12 31211337 3614RS, 4017RS

 General Information and Specifications

2.5 LUBRICATION SCHEDULE

2.5.1 3614RS

OAM3780

3614RS, 4017RS 31211337 2-13

 General Information and Specifications

2.5.2 4017RS

OAM3790

2-14 31211337 3614RS, 4017RS

 General Information and Specifications

2.6 THREADLOCKING COMPOUND

JLG PN Loctite ND Industries Description

0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue)
1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue)
0100019 271™ Vibra-TITE™ 140 High Strength (Red)
0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red)
Loctite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.

3614RS, 4017RS 31211337 2-15

 General Information and Specifications

2.7 TORQUE CHARTS

2.7.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Tensile Stress Clamp Torque Torque (Loctite® 242™ or 271™ or
Size TPI Bolt Dia (Loctite® 262™ or
Area Load (Dry) Lubricated Vibra-TITE™
111 or 140) Vibra-TITE™ 131)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

2-16 31211337 3614RS, 4017RS

 General Information and Specifications

2.7.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Tensile Stress (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.20
K=0.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%.
3. * ASSEMBLY USES HARDENED WASHER.

3614RS, 4017RS 31211337 2-17

 General Information and Specifications

2.7.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Torque
Tensile Stress (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia Clamp Load (Dry)
Area Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.17
K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%.
3. * ASSEMBLY USES HARDENED WASHER

2-18 31211337 3614RS, 4017RS

 General Information and Specifications

2.7.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Tensile Stress (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.17
K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%.
3. * ASSEMBLY USES HARDENED WASHER

3614RS, 4017RS 31211337 2-19

 General Information and Specifications

2.7.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SOCKET HEAD CAPSCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

2-20 31211337 3614RS, 4017RS

 General Information and Specifications

2.7.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAPSCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

3614RS, 4017RS 31211337 2-21

 General Information and Specifications

2.7.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or
Size Pitch Torque (Lube) (Loctite® 262™ or 271™ or
Area See Note 4 (Dry or Loctite® 263™) Vibra-TITE™ 111
Vibra-TITE™ 131)
or 141)

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

2-22 31211337 3614RS, 4017RS

 General Information and Specifications

2.7.2 Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

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

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

3614RS, 4017RS 31211337 2-23

 General Information and Specifications

2.7.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Torque (Lube or Loctite® 242™ or (Loctite® 262™ or
Clamp Load
Size Pitch Tensile Stress Area (Dry or Loctite® 263™) 271™ or
See Note 4 Vibra-TITE™ 131)
K=0.17 Vibra-TITE™ 111 or 140) K=0.15
K=0.16
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

2-24 31211337 3614RS, 4017RS

 General Information and Specifications

2.7.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

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

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

3614RS, 4017RS 31211337 2-25

 General Information and Specifications

2.8 HYDRAULIC CONNECTION ASSEMBLY SAE - 45° flare per SAE J512
AND TORQUE SPECIFICATION

2.8.1 Definitions

a. Tapered Thread Types

NPTF - National tapered fuel (dry seal) per SAE J476/J512

MAE9030

ORFS - O-ring face seal per SAE J1453

MAE9000 MAE9040

MBTL - Metric flareless bite type fitting, pressure rating L

BSPT - British standard pipe tapered per ISO7-1
(medium) per ISO 8434, DIN 2353
MBTS - Metric flareless bite type fitting, pressure rating S (high)
per ISO 8434, DIN 2353

MAE9050
MAE9010

BH - Bulkhead connection – JIC, ORFS, MBTL, or MBTS types

b. Straight Thread Types, Tube and Hose Connections

JIC - 37° flare per SAE J514

MAE9060
MAE9020

2-26 31211337 3614RS, 4017RS

 General Information and Specifications

c. Straight Thread Types, Port Connections d. Flange Connection Types

FL61 - Code 61 flange per SAE J518, ISO 6162
ORB - O-ring boss per SAE J1926, ISO 11926
FL62 - Code 62 flange per SAE J518, ISO 6162
MPP - Metric pipe parallel O-ring boss per SAE J2244,
ISO 6149, DIN 3852

MAE9090

MAE9070
e. Tightening Methods

MFF - Metric flat face port per ISO 9974-1 Torque - Application of a twisting force to the applicable
connection by use of a precise measurement instrument
BSPP - British standard parallel pipe per ISO 1179-1, (i.e. torque wrench).
DIN 3852-2
Finger Tight (Hand Tight) - The point where the connector
will no longer thread onto the mating part when tightened
by hand or fingers. Finger Tight is relative to user strength
and will have some variance. The average torque applied by
this method is 4 Nm (3 ft-lbs).
TFFT - Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by
hand (fingers) and applying an additional rotation counted
by a defined number of turns by use of a tool.
FFWR (Flat method) - Flats From Wrench Resistance;
Application of a preload to a connection by tightening to
the point of initial wrench resistance and turning the nut a
described number of flats. A flat is one side of the hexagonal
tube nut and equates to 1/6 of a turn.

f. Assembly and Torque Specifications

MAE9080
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the
connector being installed.

g. General Tube Type Fitting Assembly Instructions

1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling
or assembly. Nicks and scratches in sealing surfaces can
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting
attachment to ensure that the tube has not been
damaged.

3614RS, 4017RS 31211337 2-27

 General Information and Specifications

3. The assembly process is one of the leading causes for 6. Refer to the appropriate section in this manual for more
contamination in air and hydraulic systems. specific instructions and procedures for each type of
Contamination can prevent proper tightening of fittings fitting connection.
and adapters from occurring.
a. Avoid using dirty or oily rags when handling fittings. 2.8.2 Assembly Instructions for American
Standard Pipe Thread Tapered
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as
Connections
necessary before reinstalling. 1. Inspect components to ensure male and female port
c. Sealing compounds should be applied where threads are free of rust, splits, dirt, foreign matter, or
specified; however, care should be taken not to burrs.
introduce sealant into the system. 2. Apply a suitable thread sealant, such as high
d. Avoid applying sealant to the area of the threads temperature high thread sealant with PTFE to the male
where the sealant will be forced into the system. pipe threads if not already applied. Ensure the first 1 to
This is generally the first two threads of a fitting. 2 threads are uncovered to prevent system
contamination.
e. Sealant should only be applied to the male threads.
3. Assemble connection hand tight.
f. Straight thread fittings do not require sealants.
O-rings or washers are provided for sealing. 4. Mark fittings, male and female
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 NOTICE
recommended.
Over tightening may cause deformation of the pipe
h. When installing fittings with O-rings, lubrication
fitting and damage to the joining fitting, flange or
shall be used to prevent scuffing or tearing of the
O-ring. Refer to Section 2.8.17, “O-ring Installation component may occur.
(Replacement)”, for procedure.
4. Take care to identify the material of parts to apply the
correct torque values.
a. Verify the material designation in the table headings
NOTICE
b. If specifications are given only for steel fittings and Never back off (loosen) pipe threaded connectors to
components, the values for alternate materials shall achieve alignment. Meet the minimum required turns
be as follows: and use the last turn for alignment.
Aluminum and Brass - reduce steel values by 35%
Stainless Steel - Use the upper limit for steel. 5. Rotate male fitting the number of turns as per below
5. To achieve the specified torque, the torque wrench is to mentioned table. Refer to Section 2.8.15, “FFWR and
be held perpendicular to the axis of rotation. TFFT Methods”, for procedure.
Note: TFFT values provided in below mentioned table are
applicable for the following material configurations:
a. Steel fittings with steel mating components
b. Steel fittings with aluminum or brass mating
components
c. Aluminum or brass fittings with steel mating
components
d. Aluminum or brass fittings with aluminum or brass
mating components.

MAE9100

2-28 31211337 3614RS, 4017RS

 General Information and Specifications

a. NPTF Pipe Thread

MAE9110

TYPE/FITTING IDENTIFICATION
Turns From Finger Tight
Thread Size ØA*
Material Dash Size (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
4 1/4 - 18 0.54 13.61 2 to 3
STEEL, ALUMINUM, OR 6 3/8 - 18 0.67 17.05 2 to 3
BRASS FITTINGS
8 1/2 - 14 0.84 21.22 2 to 3
WITH STEEL,
ALUMINUM, OR 12 3/4 - 14 1.05 26.56 2 to 3
BRASS
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
MATING
COMPONENTS 20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5

NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for TFFT procedure requirements.

3614RS, 4017RS 31211337 2-29

 General Information and Specifications

2.8.3 Assembly Instructions for British

Standard Pipe Thread Tapered
Connections
1. Inspect components to ensure male and female port
NOTICE
threads are free of rust, splits, dirt, foreign matter, or Never back off (loosen) pipe threaded connectors to
burrs. achieve alignment. Meet the minimum required turns
2. Apply a suitable thread sealant, such as high and use the last turn for alignment.
temperature high thread sealant with PTFE, to the male
5. Rotate male fitting the number of turns as per below
pipe threads if not already applied. Ensure the first 1 to 2
mention table.
threads are uncovered to prevent system
contamination. Note: TFFT values provided in below table are applicable for
3. Assemble connection hand tight. the following material configurations:

4. Mark fittings, male and female. a. Steel fittings with steel mating components
b. Steel fittings with aluminum or brass mating
NOTICE components
c. Aluminum or brass fittings with steel mating
components
Over tightening may cause deformation of the pipe
fitting and damage to the joining fitting, flange or d. Aluminum or brass fittings with aluminum or brass
component may occur. mating components.

a. BSPT Pipe Thread

MAE9120

TYPE/FITTING IDENTIFICATION
Turns From Finger Tight
Thread Size ØA* (TFFT)**
Material Dash Size
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
4 1/4 - 19 0.52 13.16 2 to 3
STEEL, ALUMINUM, OR
BRASS FITTINGS 6 3/8 - 19 0.66 16.66 2 to 3
WITH STEEL, 8 1/2 - 14 0.83 20.96 2 to 3
ALUMINUM, OR 12 3/4 - 14 1.04 26.44 2 to 3
BRASS 16 1 - 11 1.31 33.25 1.5 to 2.5
MATING
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
COMPONENTS
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

NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for TFFT procedure requirements.

2-30 31211337 3614RS, 4017RS

 General Information and Specifications

2.8.4 Assembly Instructions for 37° (JIC) Flare 2. Align tube to fitting and start threads by hand.
Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
NOTICE
surface is smooth, free of rust, weld and brazing splatter, The torque method should NOT be used on lubricated or
splits, dirt, foreign matter, or burrs. If necessary, replace oily fittings. No lubrication or sealant is required. The
fitting or adapter. lubrication would cause increased clamping force and
cause fitting damage.
NOTICE 3. Torque assembly to value listed in below mentioned
table while using the Double Wrench Method.
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint Note: Torque values provided in below table are segregated
eventually leading to leakage. based on the material configuration of the connection.

a. 37° Flare (JIC) Thread - Steel

MAE9130

TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max

2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --

3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2
STEEL FITTINGS
WITH STEEL 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
MATING
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
THREADS
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

NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for FFWR procedure requirements.

3614RS, 4017RS 31211337 2-31

 General Information and Specifications

b. 37° Flare (JIC) Thread - Aluminum Brass

MAE9130

TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max

2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --

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

ALUMINUM/BRASS 6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2

FITTINGS OR
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
ALUMINUM/BRASS
MATING 10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
THREADS 14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1

NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for FFWR procedure requirements.

2-32 31211337 3614RS, 4017RS

 General Information and Specifications

3614RS, 4017RS 31211337 2-33

 General Information and Specifications

2.8.5 Assembly Instructions for 45° SAE Flare

Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
surface is smooth, free of rust, weld and brazing splatter,
splits, dirt, foreign matter, or burrs. If necessary, replace
fitting or adapter.

NOTICE
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint
eventually leading to leakage.

2. Align tube to fitting.

3. Tighten fitting by hand until hand tight.

NOTICE
The torque method should NOT be used on lubricated or
oily fittings. No lubrication or sealant is required. The
lubrication would cause increased clamping force and
cause fitting damage.

Torque fitting to value listed in below table while using the

Double Wrench Method outlined in this section.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
‘Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following material
configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.

2-34 31211337 3614RS, 4017RS

 General Information and Specifications

a. 45° Flare (SAE)

MAE9140
STEEL

TYPE/FITTING IDENTIFICATION TORQUE

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material 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 FITTINGS
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33
WITH STEEL MATING
COMPONENTS; 8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
UN-LUBRICATED
THREADS 10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125

NOTE: * ØA and ØB thread dimensions for reference only.

ALUMINUM BRASS

TYPE/FITTING IDENTIFICATION TORQUE

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max

ALUMINUM/BRASS 4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12

FITTINGS OR 6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20
ALUMINUM/BRASS
MATING 8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41
COMPONENTS;
UN-LUBRICATED 10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
THREADS
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83

NOTE: * ØA and ØB thread dimensions for reference only.

3614RS, 4017RS 31211337 2-35

 General Information and Specifications

2.8.6 Assembly Instructions for O-Ring Face

Seal (ORFS) Fittings
1. Ensure proper O-ring is installed. If O-ring is missing
install per O-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement)”, for
procedure.
2. Ensure that surface is smooth, free of rust, weld and
brazing splatter, splits, dirt, foreign matter, or burrs. If
necessary, replace fitting or adapter.

NOTICE
Care to be taken when lubricating O-ring. Avoid adding
oil to the threaded connection of the fitting. The
lubrication would cause increased clamping force and
cause fitting damage.

3. Pre-lubricate the O-ring with hydraulic oil.

4. Place the tube assembly against the fitting body so that
the flat face comes in contact with the O-ring. Hand
thread the nut onto the fitting body.
5. Torque nut to value listed in below mentioned table
while using the Double Wrench Method. Refer to
Section 2.8.15, “FFWR and TFFT Methods”, for procedure
if using the FFWR method.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following
material configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.

2-36 31211337 3614RS, 4017RS

 General Information and Specifications

a. O-ring Face Seal (ORFS)

MAE9150

STEEL

TYPE/FITTING IDENTIFICATION TORQUE

Thread
Dash ØA* ØB* [Ft-Lb] [Nm] Tube Swivel &
Material Size
Size Nuts Hose Ends
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
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 FITTINGS 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
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
STEEL MATING
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
COMPONENTS;
UN-LUBRICATED 16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
THREADS 20 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

NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for FFWR procedure requirements.

ALUMINUM/BRASS
FLATS FROM
WRENCH
TYPE/FITTING IDENTIFICATION TORQUE
RESISTANCE
(F.F.W.R)**
Thread
ØA* ØB* [Ft-Lb] [Nm]
Dash Size Tube Swivel &
Material
Size Nuts Hose Ends
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max

4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS 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
FITTINGS OR
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
MATING 12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
COMPONENT;
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
UN-LUBRICATED
THREADS 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

NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for FFWR procedure requirements.

3614RS, 4017RS 31211337 2-37

 General Information and Specifications

2.8.7 Assembly Instructions for DIN 24° Flare

Bite Type Fittings (MBTL and MBTS)

NOTICE
A non-square tube end can cause improperly seated
fittings and leakage.
6. Inspect the components to ensure free of
contamination, external damage, rust, splits, dirt,
foreign matter, or burrs. Ensure tube end is visibly
square. If necessary, replace fitting or tube.
7. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
8. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
9. Push the tube end into the coupling body.
10. 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 while using the Double
Wrench Method. The tube must not turn with the nut.

2-38 31211337 3614RS, 4017RS

 General Information and Specifications

a. DIN 24° CONE (MBTL & MBTS)

MAE9160

DIN 24° CONE FLARELESS BITE FITTING

TYPE/FITTING IDENTIFICATION
(WITH OR WITHOUT O-RING)
Tube Thread Torque Flats From
ØA* ØB* C* ØD*
O.D. M Size [Ft-Lb] [Nm] Wrench
Material Type
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
8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75
FFWR is the recommended method of
10 M16 x 1.5 14.50 16.00 7.00 10.20 fitting assembly. 1.5 to 1.75
DIN 12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
Torque values are application specific
24° CONE 15 M22 x 1.5 20.50 22.00 7.00 15.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
BITE (MBTL) 18 M26 x 1.5 24.50 26.00 7.50 18.20 characteristic of the connection. 1.5 to 1.75
FITTING 22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75
Consult Engineering on the
28 M36 x 2 33.90 36.00 7.50 28.20 generation of torque values for the 1.5 to 1.75
particular application.
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75

STEEL Tube Thread Torque Flats From

ØA* ØB* C* ØD*
FITTINGS WITH O.D. M Size [Ft-Lb] [Nm] Wrench
Type
STEEL MATING Resistance
COMPONENTS (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

FFWR is the recommended method of
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75
fitting assembly.
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
DIN 12 M20 x 1.5 18.50 20.00 7.50 12.20 Torque values are application specific 1.5 to 1.75
24° CONE 14 M22 x 1.5 20.50 22.00 8.00 14.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
16 M24 x 1.5 22.50 24.00 8.50 16.20 characteristics of the connection. 1.5 to 1.75
BITE (MBTS)
FITTING 20 M30 x 2 27.90 30.00 10.50 20.20 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 Consult Engineering on the 1.5 to 1.75
generation of torque values for the
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
particular application.
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75

NOTE: * ØA, ØB,C, & ØD thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for FFWR procedure requirements.

3614RS, 4017RS 31211337 2-39

 General Information and Specifications

2.8.8 Assembly Instructions for Bulkhead (BH)

Fittings
1. Ensure that 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 while using the Double Wrench
Method.

2-40 31211337 3614RS, 4017RS

 General Information and Specifications

a. Bulkhead Fittings (BH) - INCH

MAE9170

FASTENING JAM NUT

TYPE/FITTING IDENTIFICATION
FOR BULKHEAD CONNECTORS
Thread Torque
Dash Size
Material Type [Ft-Lb] [Nm]
Size
(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
8 13/16-16 55 58 61 75 79 83
O-RING FACE 10 1-14 85 90 94 115 122 127
SEAL (ORFS)
12 1 3/16-12 135 142 149 183 193 202
BULKHEAD
FITTING 14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Thread Torque
Dash Size
Type [Ft-Lb] [Nm]
Size
STEEL (UNF) Min Nom Max Min Nom Max
FITTINGS 3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
37° FLARE (JLIC) 10 7/8-14 85 90 94 115 122 127
BULKHEAD
12 1 1/16-12 135 142 149 183 193 202
FITTING
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

3614RS, 4017RS 31211337 2-41

 General Information and Specifications

b. Bulkhead Fittings (BH) - METRIC

MAE9180

FASTENING JAM NUT

TYPE/FITTING IDENTIFICATION
FOR BULKHEAD CONNECTORS
Connecting Thread Torque
Material Type Tube O.D. M Size [Ft-Lb] [Nm]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
DIN 24° CONE
FLARELESS BITE 15 M22 x 1.5 44 47 50 60 64 68
(MBTL) BULKHEAD 18 M26 x 1.5 70 75 80 95 102 108
FITTING
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
Connecting Thread Torque
STEEL Tube O.D. M Size
Type [Ft-Lb] [Nm]
FITTINGS
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
DIN 24° CONE
FLARELESS BITE 14 M22 x 1.5 44 47 50 60 64 68
(MBTS) BULKHEAD 16 M24 x 1.5 70 75 80 95 102 108
FITTING 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

2-42 31211337 3614RS, 4017RS

 General Information and Specifications

3614RS, 4017RS 31211337 2-43

 General Information and Specifications

2.8.9 Assembly Instructions for O-Ring Boss

(ORB) Fittings
1. Inspect components to ensure that male and female
port threads are free of rust, splits, dirt, foreign matter,
or burrs.
2. Ensure proper O-ring is installed. If O-ring is missing
install per O-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement)”, for
procedure.

NOTICE
Care to be taken when lubricating O-ring. Avoid adding
oil to the threaded connection of the fitting. The
lubrication would cause increased clamping force and
cause fitting damage.

3. Pre-lubricate the O-ring with hydraulic oil.

4. For non-adjustable and plugs, thread the fitting by hand
until contact.
5. For adjustable fittings, refer to Section 2.8.16,
“Adjustable Stud End Assembly”, for proper assembly.
6. Torque the fitting or nut to value while using the
Double Wrench Method.
a. The table headings identify the straight thread
O-ring port and the type on the other side of the
fitting. The torque will be applied to the straight
thread O-ring port.
b. Torque values are segregated based on the material
configuration of the connection. ‘Aluminum/brass
fittings or aluminum/brass mating components’
indicate either the following material
configurations:
• Steel fittings with aluminum or brass mating
components
• Aluminum or brass fittings with steel mating
components
• Aluminum or brass fittings with aluminum or brass
mating components.
7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.

2-44 31211337 3614RS, 4017RS

 General Information and Specifications

a. O-ring Boss (ORB) - Table 1 of 6

MAE9190

HEX TYPE PLUGS & STUD ENDS

TYPE/FITTING IDENTIFICATION
WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 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
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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
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
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

3614RS, 4017RS 31211337 2-45

 General Information and Specifications

b. O-ring Boss (ORB) - Table 2 of 6

MAE9190

STUD ENDS
TYPE/FITTING IDENTIFICATION
WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 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
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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
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
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

2-46 31211337 3614RS, 4017RS

 General Information and Specifications

c. O-ring Boss (ORB) - Table 3 of 6

MAE9210

ADJUSTABLE STUD END

TYPE/FITTING IDENTIFICATION
WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 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
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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
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
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

3614RS, 4017RS 31211337 2-47

 General Information and Specifications

d. O-ring Boss (ORB) - Table 4 of 6

MAE9220

ADJUSTABLE STUD END

TYPE/FITTING IDENTIFICATION
WITH (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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
5 1/2-20 0.50 12.70 30 32 33 40 43 45
STEEL FITTINGS 6 9/16-18 0.56 14.28 35 37 39 46 50 53
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 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
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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 10 11 11 14 15 15
5 1/2-20 0.50 12.70 20 21 21 27 28 28
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 23 24 24 31 33 33
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

2-48 31211337 3614RS, 4017RS

 General Information and Specifications

e. O-ring Boss (ORB) - Table 5 of 6

MAE9230

TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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
5 1/2-20 0.50 12.70 14 15 16 19 20 22
STEEL FITTINGS 6 9/16-18 0.56 14.28 34 36 38 46 49 52
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 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
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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
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
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 22 24 25 30 33 34
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

3614RS, 4017RS 31211337 2-49

 General Information and Specifications

f. O-ring Boss (ORB) - Table 6 of 6

MAE9240

ZERO LEAK GOLD®

TYPE/FITTING IDENTIFICATION
HOLLOW HEX PLUGS
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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
5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
STEEL FITTINGS WITH
STEEL MATING 8 3/4-16 0.75 19.10 28 30 32 38 41 43
COMPONENTS; 10 7/8-14 0.87 22.22 46 48 50 62 65 68
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
THREADS
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
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(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
5 1/2-20 0.50 12.70 9 10 11 12 14 15
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 11 12 13 15 16 18
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 28 30 32 38 41 43
MATING 10 7/8-14 0.87 22.22 46 48 50 62 65 68
COMPONENTS; 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
UN-LUBRICATED
THREADS 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
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50

NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

2-50 31211337 3614RS, 4017RS

 General Information and Specifications

3614RS, 4017RS 31211337 2-51

 General Information and Specifications

2.8.10 Assembly Instructions for Adjustable

Port End Metric Fittings
1. Inspect components to ensure that male and female
threads and surfaces are free of rust, splits, dirt, foreign
matter, or burrs.
2. If O-ring is not pre-installed, install proper size, taking
care not to damage it. Refer to Section 2.8.17, “O-ring
Installation (Replacement)”, for procedure.

NOTICE
Care to be taken when lubricating O-ring. Avoid adding
oil to the threaded connection of the fitting. The
lubrication would cause increased clamping force and
cause fitting damage.

3. Pre-lubricate the O-ring with hydraulic oil.

4. For non-adjustable fittings and plugs, thread the fitting
by hand until contact.
5. For adjustable fittings, refer to Section 2.8.16,
“Adjustable Stud End Assembly”, for proper assembly.
6. Torque the fitting or nut to value while using the
Double Wrench Method.
a. The table headings identify the Metric port and the
type on the other side of the fitting. The torque will
be applied to the Metric port.
b. Torque values are segregated based on the material
configuration of the connection. ‘Aluminum/brass
fittings or aluminum/brass mating components’
indicate either the following material
configurations:
• Steel fittings with aluminum or brass mating
components
• Aluminum or brass fittings with steel mating
components
• Aluminum or brass fittings with aluminum or brass
mating components.
7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.

2-52 31211337 3614RS, 4017RS

 General Information and Specifications

a. Metric Flat Face Port (MFF) L Series - Table 1 of 3

MAE9260

MAE9250

FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING STUD ENDS STUD ENDS
IDENTIFICATION WITH 37° (JIC) or L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
OPPOSITE END OPPOSITE END

Thread Connecting Torque Torque

Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]

(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
STEEL FITTINGS
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
WITH STEEL
MATING M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
UN-LUBRICATED
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
THREADS
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 Connecting Torque Torque

Material M Size Tube O.D

[Ft-Lb] [Nm] [Ft-Lb] [Nm]

(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
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22

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

3614RS, 4017RS 31211337 2-53

 General Information and Specifications

b. Metric Flat Face Port (MFF) L Series - Table 2 of 3

MAE9280

MAE9270

FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING STUD ENDS STUD ENDS
IDENTIFICATION WITH 37° (JIC) OR L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
OPPOSITE END OPPOSITE END

Thread Connecting Torque Torque

Material M Size Tube O.D

[Ft-Lb] [Nm] [Ft-Lb] [Nm]

(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
STEEL FITTINGS
WITH STEEL M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
MATING M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
COMPONENTS; M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
UN-LUBRICATED M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
THREADS
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 Connecting Torque Torque

Material M Size Tube O.D

[Ft-Lb] [Nm] [Ft-Lb] [Nm]

(UNF) (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
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
BRASS FITTINGS
OR ALUMINUM/ M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
BRASS M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
MATING M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
COMPONENTS; M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386

2-54 31211337 3614RS, 4017RS

 General Information and Specifications

c. Metric Flat Face Port (MFF) L Series - Table 3 of 3

MAE9310
MAE9290 MAE9300

HIGH PRESSURE BANJO

BANJO FITTINGS FORM E (EOLASTIC
TYPE/FITTING FITTINGS
WITH L SERIES DIN (MBTL) SEALING RING)
IDENTIFICATION WITH L SERIES DIN (MBTL)
OPPOSITE END HOLLOW HEX PLUGS
OPPOSITE END

Thread Connecting Torque Torque Torque

Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]

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

Thread Connecting Torque Torque Torque

Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]

(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
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
BRASS FITTINGS
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
OR ALUMINUM/
BRASS M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
MATING M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
COMPONENTS;
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
UN-LUBRICATED
THREADS 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

3614RS, 4017RS 31211337 2-55

 General Information and Specifications

d. Metric Flat Face Port (MFF) S Series - Table 1 of 3

MAE9320 MAE9330

FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING STUD ENDS STUD ENDS
IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)
OPPOSITE END OPPOSITE END

Thread Connecting Torque Torque

Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
STEEL FITTINGS
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
WITH STEEL
MATING M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
COMPONENTS; M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
UN-LUBRICATED
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
THREADS
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 Connecting Torque Torque

Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(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
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
BRASS FITTINGS
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
OR ALUMINUM/
BRASS M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
MATING M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
COMPONENTS;
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500

2-56 31211337 3614RS, 4017RS

 General Information and Specifications

e. Metric Flat Face Port (MFF) S Series - Table 2 of 3

MAE9350

MAE9340

FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING STUD ENDS STUD ENDS
IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)
OPPOSITE END OPPOSITE END

Thread Connecting Torque Torque

Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
STEEL FITTINGS
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
WITH STEEL
MATING M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
COMPONENTS; M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
UN-LUBRICATED
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
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 Connecting Torque Torque

Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(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
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
ALUMINUM/ M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
BRASS FITTINGS
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
OR ALUMINUM/
BRASS M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
MATING M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
COMPONENTS;
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386

3614RS, 4017RS 31211337 2-57

 General Information and Specifications

f. Metric Flat Face Port (MFF) S Series - Table 3 of 3

MAE9310
MAE9290 MAE9300

HIGH PRESSURE BANJO

BANJO FITTINGS FORM E (EOLASTIC
TYPE/FITTING FITTINGS
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION WITH S SERIES DIN (MBTS)
OPPOSITE END HOLLOW HEX PLUGS
OPPOSITE END

Thread Connecting Torque Torque Torque

Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
STEEL FITTINGS
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
WITH STEEL
MATING M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
UN-LUBRICATED
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
THREADS
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] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(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 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
ALUMINUM/
BRASS M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
FITTINGS OR M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
ALUMINUM/ M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
BRASS
MATING M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
COMPONENTS; M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
UN-LUBRICATED M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
THREADS
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --

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 General Information and Specifications

3614RS, 4017RS 31211337 2-59

 General Information and Specifications

2.8.11 Assembly Instructions for Metric ISO

6149 Port Assembly Stud Ends
1. Inspect components to ensure that male and female
threads and surfaces are free of rust, splits, dirt, foreign
matter, or burrs.
2. If O-ring is not pre installed, install proper size, taking
care not to damage it. Refer to Section 2.8.17, “O-ring
Installation (Replacement)”.

NOTICE
Care to be taken when lubricating O-ring. Avoid adding
oil to the threaded connection of the fitting. The
lubrication would cause increased clamping force and
cause fitting damage.

3. Pre-lubricate the O-ring with hydraulic oil.

4. For non-adjustable fittings and plugs, thread the fitting
by hand until contact.
5. For adjustable fittings, refer to Section 2.8.16,
“Adjustable Stud End Assembly”, for proper assembly.
6. Torque the fitting or nut to value while using the
Double Wrench Method.
a. The table headings identify the Metric port and the
type on the other side of the fitting. The torque will
be applied to the Metric port.
b. Torque values are segregated based on the material
configuration of the connection. ‘Aluminum/brass
fittings or aluminum/brass mating components’
indicate either the following material
configurations:
• Steel fittings with aluminum or brass mating
components
• Aluminum or brass fittings with steel mating
components
• Aluminum or brass fittings with aluminum or brass
mating components.
7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.

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 General Information and Specifications

a. Metric Pipe Parallel O-Ring Boss (MPP)

MAE9370 MAE9380
MAE9360

TYPE/FITTING STUD ENDS WITH 37° (JIC) OR L SERIES STUD ENDS WITH (ORFS) OR S SERIES
IDENTIFICATION DIN (MBTL) OPPOSITE END DIN (MBTS) OPPOSITE END

Thread Connecting Torque Torque

Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
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
STEEL FITTINGS M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
WITH STEEL M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
MATING
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
COMPONENTS;
UN-LUBRICATED M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
THREADS M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
Thread Connecting Torque Torque
Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(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
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
ALUMINUM/ M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
BRASS FITTINGS M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
OR ALUMINUM/ M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
BRASS
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
MATING
COMPONENTS; M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
UN-LUBRICATED M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
THREADS 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

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 General Information and Specifications

2.8.12 Assembly Instructions for Adjustable

Port End (BSPP) Fittings
1. Inspect components to ensure that male and female
threads and surfaces are free of rust, splits, dirt, foreign
matter, or burrs.
2. If O-ring is not pre installed, install proper size, taking
care not to damage it. Refer to Section 2.8.17, “O-ring
Installation (Replacement)”, for instructions.

NOTICE
Care to be taken when lubricating O-ring. Avoid adding
oil to the threaded connection of the fitting. The
lubrication would cause increased clamping force and
cause fitting damage.

3. Pre-lubricate the O-ring with hydraulic oil.

4. For non-adjustable fittings and plugs, thread the fitting
by hand until contact.
5. For adjustable fittings, refer to Section 2.8.16,
“Adjustable Stud End Assembly”, for proper assembly.
6. Torque the fitting or nut to value while using the
Double Wrench Method.
a. The table headings identify the BSPP port and the
type on the other side of the fitting. The torque will
be applied to the BSPP port.
b. Torque values are segregated based on the material
configuration of the connection. ‘Aluminum/brass
fittings or aluminum/brass mating components’
indicate either the following material
configurations:
• Steel fittings with aluminum or brass mating
components
• Aluminum or brass fittings with steel mating
components
• Aluminum or brass fittings with aluminum or brass
mating components.
7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.

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a. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3

MAE9390 MAE9400

FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING STUD ENDS WITH 37° (JIC) or STUD ENDS
IDENTIFICATION L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
OPPOSITE END OPPOSITE END

Torque Torque
Connecting
BSPP
Tube O.D.
Material Thread [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
MATING G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
COMPONENTS; G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
UN-LUBRICATED G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
THREADS 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

Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(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/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
BRASS
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
MATING
COMPONENTS; G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
UN-LUBRICATED G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
THREADS G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386

NOTE: ** Non typical for Straight Male Stud Fittings, reference only.

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 General Information and Specifications

b. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3

MAE9410 MAE9420

FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH 37° (JIC) OR STUD ENDS WITH 37° (JIC) OR
IDENTIFICATION
L SERIES DIN (MBTL) OPPOSITE END L SERIES DIN (MBTL) OPPOSITE END

Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
MATING G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
UN-LUBRICATED G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS 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

Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(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/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
BRASS
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
MATING
COMPONENTS; G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
UN-LUBRICATED G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321

NOTE: ** Non typical for Straight Male Stud Fittings, reference only.

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c. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3

MAE9310
MAE9290 MAE9300

HIGH PRESSURE BANJO

BANJO FITTINGS FORM E (EOLASTIC
TYPE/FITTING FITTINGS WITH
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION S SERIES DIN (MBTS)
OPPOSITE END HOLLOW HEX PLUGS
OPPOSITE END
Torque Torque Torque
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
WITH STEEL
MATING G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
UN-LUBRICATED
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
THREADS
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
Torque Torque Torque
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(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
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
ALUMINUM/
BRASS G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
FITTINGS OR G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
ALUMINUM/ G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
BRASS
MATING G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
COMPONENTS; G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
UN-LUBRICATED G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
THREADS
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

NOTE: ** Non typical for Straight Male Stud Fittings, reference only.

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 General Information and Specifications

d. British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3

MAE9430 MAE9440

FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH (ORFS) OR STUD ENDS WITH (ORFS) OR
IDENTIFICATION
S SERIES DIN (MBTS) OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END

BSPP Connecting Torque Torque

Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
STEEL FITTINGS
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
WITH STEEL
MATING G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
COMPONENTS; G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
UN-LUBRICATED
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
THREADS
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 Connecting Torque Torque
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size (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
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
BRASS FITTINGS
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
OR ALUMINUM/
BRASS G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
MATING G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
COMPONENTS;
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS 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

NOTE: ** Non typical for Straight Male Stud Fittings, reference only.

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e. British Standard Parallel Pipe Port (BSPP) S Series - Table 2 of 3

MAE9460
MAE9450

FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING

TYPE/FITTING STUD ENDS AND HEX TYPE PLUGS RING) STUD ENDS & ADJUSTABLE
IDENTIFICATION WITH (ORFS) or S SERIES DIN (MBTS) STUD ENDS WITH (ORFS) OR
OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END

Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
STEEL FITTINGS
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
WITH STEEL
MATING G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
COMPONENTS; G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
UN-LUBRICATED
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
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

Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(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
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
ALUMINUM/ G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
BRASS FITTINGS
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
OR ALUMINUM/
BRASS G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
MATING G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
COMPONENTS;
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386

NOTE: * Typical for Straight Male Stud Fittings

***Typical for Adjustable Fittings.

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 General Information and Specifications

f. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3

MAE9290 MAE9300

MAE9470

BANJO FITTINGS HIGH PRESSURE BANJO

TYPE/FITTING JIS/BSPP O-RING
WITH S SERIES DIN (MBTS) FITTINGS WITH S SERIES
IDENTIFICATION ONLY
OPPOSITE END DIN (MBTS) OPPOSITE END

Torque Torque Torque

BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77 Fitting type not typically
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 specified on Caterpillar
WITH STEEL
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133 applications.
MATING
COMPONENTS; G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Refer to the specific
UN-LUBRICATED
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 procedure
THREADS
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353 in this Service Manual.
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
Torque Torque Torque
BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(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
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/ G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50 Fitting type not typically
BRASS FITTINGS
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 specified on Caterpillar
OR ALUMINUM/
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87 applications.
BRASS
MATING G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Refer to the
COMPONENTS;
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 specific procedure in
UN-LUBRICATED
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229 this Service Manual.
THREADS
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499

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 General Information and Specifications

3614RS, 4017RS 31211337 2-69

 General Information and Specifications

2.8.13 Assembly Instructions for Flange

Connections (FL61 and FL62)
1. Ensure sealing surfaces are free of rust, splits, scratches,
dirt, foreign matter, or burrs.
2. Pre-lubricate the O-ring with hydraulic oil.
3. Position flange and clamp halves.
4. Place lock washers on bolt and bolt through clamp
halves.
5. Tighten all bolts by hand.
6. Torque bolts in diagonal sequence in two or more
increments to the torque listed.

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 General Information and Specifications

a. Flange Code (FL61 & FL62) - Inch Fasteners

MAE9480

TYPE/FITTING IDENTIFICATION
STEEL 4-BOLT FLANGE SAE J518
(INCH FASTENERS)
Fastener Torque for Fastener Torque for
Inch Bolt Flanges Equipped with Flanges Equipped with
Flange Flange
A* Thread GRADE 5 Screws GRADE 8 Screws
Type SAE Size
Size
Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
CODE 61 24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
SPLIT
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
FLANGE
(FL61) 40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325

Inch Bolt Fastener Torque for Flanges Fastener Torque for Flanges
Flange Flange Equipped with GRADE 5 Screws Equipped with GRADE 8 Screws
A* Thread
Type SAE Size
Size
Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66
CODE 62 16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
SPLIT
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
FLANGE
(FL62) 20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495

NOTE: * A dimension for reference only.

3614RS, 4017RS 31211337 2-71

 General Information and Specifications

b. Flange Code (FL61 & FL62) - Metric Fasteners

MAE9480

TYPE/FITTING STEEL 4-BOLT FLANGE SAE J518

IDENTIFICATION (INCH FASTENERS)
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE CLASS 8.8 Screws CLASS 10.9 Screws
Size
Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
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
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
CODE 61 24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
SPLIT
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
FLANGE
(FL61) 40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE GRADE 5 Screws GRADE 8 Screws
Size
Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77
CODE 62 16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
SPLIT
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
FLANGE
(FL62) 20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605

NOTE: * A dimension for reference only.

2-72 31211337 3614RS, 4017RS

 General Information and Specifications

2.8.14 Double Wrench Method

To prevent undesired hose or connector rotation, two
wrenches must be used; one torque wrench and one
back- up wrench. If two wrenches are not used,
inadvertent component rotation may occur which
absorbs torque and causes improper joint load and leads
to leaks. For hose connections, the ‘layline’ printed on the
hose is a good indicator of proper hose installation. A
twisted lay-line usually indicates the hose is twisted.

Double Wrench Method to Prevent Hose Twist

MAE9490

3614RS, 4017RS 31211337 2-73

 General Information and Specifications

2.8.15 FFWR and TFFT Methods 2.8.16 Adjustable Stud End Assembly
1. FFWR (Flats from Wrench Resistance Method) For Adjustable Stud End Connections; the following
a. Tighten the swivel nut to the mating fitting until no assembly steps are to be performed:
lateral movement of the swivel nut can be detected; a. Lubricate the O-ring with a light coat of hydraulic
finger tight condition. oil.
b. Mark a dot on one of the swivel hex nut flats and b. Position #1 – The O-ring should be located in the
another dot in line on the connecting tube adapter. groove adjacent to the face of the backup washer.
c. Use the double wrench method per Appendix A, The washer and O-ring should be positioned at the
turn the swivel nut to tighten. The nut is to be extreme top end of the groove as shown.
rotated clockwise the number of hex flats. c. Position #2 – Position the locknut to just touch the
d. After the connection has been properly tightened, backup washer as shown. The locknut in this
mark a straight line across the connecting parts, not position will eliminate potential backup washer.
covering the dots, to indicate the connection has
been properly tightened. 2.8.17 O-ring Installation (Replacement)
Care must be taken when installing O-rings over threads
FFWR Method
during replacement or installation. O-rings could become
nicked or torn. A damaged O-ring could lead to leakage
problems.
1. Inspect O-ring for tears or nicks. If any are found replace
O-ring.
2. Ensure proper O-ring to be installed. Many O-rings look
the same but are of different material, different
hardness, or are slightly different diameters or widths.
MAE9500
3. Use a thread protector when replacing O-rings on
fittings.
2. TFFT (Turns from Finger Tight Method)
4. In ORB; ensure O-ring is properly seated in groove. On
a. Tighten the swivel nut to the mating fitting until no straight threads, ensure O-ring is seated all the way past
lateral movement of the swivel nut can be detected; the threads prior to installation.
finger tight condition.
5. Inspect O-ring for any visible nicks or tears. Replace if
b. Mark a dot on one of the swivel hex nut flats and
another dot in line on the connecting tube adapter. found.
c. Use the double wrench method per Appendix A,
turn the swivel nut to tighten. The nut is to be
rotated clockwise the number of turns.
d. 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.

2-74 31211337 3614RS, 4017RS

 Section 3
Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Second, Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.3 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.4 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.5 Second and Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.6 Complete Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4 Boom Chain Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.1 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.2 Retract Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4.3 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4.4 Extend Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - 3614RS. . . . . . . . . . . . . . . . . . . . . 3-14
3.5.1 Tilt/Auxiliary Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5.2 Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6 Extend/Retract Cylinder Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.1 Extend/Retract Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.2 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7 Boom Sections Adjustment - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7.1 Chain Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.8 Boom System Component Terminology - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.9 Boom System - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.9.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10 Boom Assembly Maintenance - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.10.2 Second, Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.10.3 Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.10.4 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.10.5 Fourth Boom Section Removal Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.10.6 Hose Carrier Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10.7 Fourth Boom Section Installation Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10.9 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.10.10 Second, Third and Fourth Boom Section Installation. . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.10.11 Complete Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3614RS, 4017RS 31211337 3-1

 Boom

3.11 Hose Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3.11.1 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.11.2 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - 4017RS . . . . . . . . . . . . . 3-31
3.12.1 Tilt Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.12.2 Tilt Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.12.3 Carrier Tilt Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.12.4 Carrier Tilt Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.13 Boom Chain Removal/Installation - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.14 Boom Sections Adjustment - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.14.1 Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.15 Boom Extend and Retract Chains - 3614RS & 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15.2 Inspection Guidelines - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15.3 Inspection Guidelines - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.15.4 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.15.5 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.16 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.16.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.16.2 Boom Wear Pad Installation/Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.17 Quick Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.17.1 Quick Coupler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.17.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.18 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.19 Boom Prop (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.19.1 Installation and Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.20 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.20.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.20.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3-2 31211337 3614RS, 4017RS

 Boom

3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY - 3614RS
The following illustrations identify the components that are
referred to throughout this section.

EXTEND/RETRACT
CYLINDER

RETRACT CHAIN
(INSIDE BOOM)

EXTEND CHAINS
(INSIDE BOOM)
THIRD BOOM
SECTION

FIRST BOOM
SECTION

SECOND BOOM
SECTION

AUXILIARY
CONNECTIONS
(IF EQUIPPED)

TILT CYLINDER
(INSIDE BOOM HEAD)
MZ7070

3614RS, 4017RS 31211337 3-3

 Boom

3.2 BOOM SYSTEM - 3614RS 3.3 BOOM ASSEMBLY MAINTENANCE -

3614RS
3.2.1 Boom System Operation
These instructions must be completed in sequence. The
The three section boom consists of the first, second and third second and third boom sections are removed from the first
assemblies with first and second section extend chains, and boom section. The third boom section is removed from the
a single first and second section retract chain. second boom section or the complete boom assembly can
As the extend/retract cylinder, which is anchored at the top be removed from the machine.
rear of the first boom section, and the top front of the second Before beginning, conduct a visual inspection of the
boom section begins to extend, it pushes the second boom machine and work area, and review the task about to be
section out of the first boom section. undertaken. Read, understand and follow these
The boom sections are connected by extend and retract instructions.The boom assembly consists of the first, second
chains. These chains are routed around rollers on the front and third section booms and supporting hardware.
and the rear of the second boom section. As the extend/ Note: Before removing the boom or boom section, the carriage
retract cylinder is forced out hydraulically, the third boom or any other attachment must be removed from the quick
section is pulled out by the extend chains. coupler.
As hydraulic pressure is applied to the retract port on the
Before beginning, conduct a visual inspection of the
extend/retract cylinder, the retract chain pulls the third boom
machine and work area, and review the task about to be
section back into the second boom section as the extend/
undertaken. Read, understand and follow these instructions.
retract cylinder pulls the second boom section into the first
boom section. During service of the boom, perform the following:
This mechanical linkage formed by the chains and 1. Check wear pads.
supporting hardware, extends and retracts the third boom (Refer to Section 3.16.1, “Wear Pad Inspection”)
section into the second boom section at the same rate. 2. Check chain rollers.
The boom section lifts and lowers via action of the lift 3. Apply grease at all lubrication points (grease fittings).
cylinder. (Refer to Section 2.5, “Lubrication Schedule”)
4. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.

WARNING
NEVER weld or drill the boom unless approved in writing
by JLG. The structural integrity of the boom will be
impaired if subjected to any repair involving welding or
drilling.

3-4 31211337 3614RS, 4017RS

 Boom

3.3.1 Boom Removal

While the boom sections can be separated from each other
on the machine, it is much safer, more efficient and more cost
effective to remove the complete boom assembly from the
machine and place it on suitable supports for separation.
Work can then progress at a normal working height.
Note: When removing a complete boom assembly use a hoist
or crane with a minimum lift capacity of 2721 kg (6000 lbs). 1
1. Remove any attachment from the quick coupler. Refer
to Operation & Safety Manual.
2. Remove the quick coupler assembly. Refer to 1
Section 3.17.1, “Quick Coupler Removal”.
3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
cylinder pin and the compensation cylinder pin, place 1
the transmission in (N) NEUTRAL, engage the park brake 1 MAE34610
and shut the engine OFF.
11. Remove the shims, boom pivot pins and lock bolts from
4. Place a Do Not Operate Tag on both the ignition key the rod end of the compensation cylinder being careful
switch and the steering wheel. not to drop the cylinder. Lower the cylinder to a secure
5. Open the engine cover. Allow the system fluids to cool. position.
6. Properly disconnect the battery. Refer Section 9.8, 12. Lower the boom assembly to level.
“Battery”, for procedure. 13. Place a sling around the first boom section at the
7. Close engine cover to access lift/lower cylinder pin and balance points.
the compensation cylinder pin. 14. Label, disconnect and cap all hydraulic hoses attached
8. Properly support the boom assembly using a hoist or to the tubes on the bottom of the boom. Cap all fittings
crane. and openings to keep dirt and debris from entering the
hydraulic system.
9. Remove boom angle sensor arm. Refer to Section 9.10.7,
“Boom Angle Sensor”. 15. Raise the boom assembly to allow the removal of the
boom assembly pivot pins.
10. Remove the pin from the rod end of the lift/lower
cylinder being careful not to drop the cylinder. Lower 16. Confirm that the boom assembly is balanced with the
the cylinder to a secure position. sling and remove the boom assembly pivot pins (1).
17. Lift the boom assembly from the machine and lower
onto suitable supports.

3614RS, 4017RS 31211337 3-5

 Boom

3.3.2 Second, Third Boom Section Removal

1. Verify the boom assembly is setting on stable, secure
and suitable supports.

3
2 6 9
8
4
5

MAE35090

Note: Before removing the extend chains, measure the

distance between the face of the jam nut to the end of the chain
clevis. This measurement will be used when reassembling the
boom.
MZ7090
10. Disconnect both tilt hoses (6) and (if equipped) both
2. Properly support the extend/retract cylinder (2) using a auxiliary hoses (7) (if equipped) at the bottom of the
hoist or crane. first boom section. Plug the hose ends and cap the tube
3. Label, disconnect and cap the extend/retract cylinder ends to prevent dirt and debris from entering the
hoses (3) from the extend/retract cylinder. Cap all hydraulic system. Pull the disconnected hoses out from
fittings and openings to prevent dirt and debris from the rear of the boom.
entering the hydraulic system. 11. Loosen and remove the lock nut and jam nut (8) on the
4. Loosen and remove the extend/retract cylinder retract chain at the front of the first boom section.
bracket (4). 12. Loosen and remove the lock nut and jam nut (9) on the
5. Remove one retaining ring from the mounting pin (5) at extend chain at the front of the first boom section.
each end of the extend/retract cylinder.
6. Remove each mounting pin and remove the
extend/retract cylinder and place in a secure location.
7. Label, disconnect and cap the tilt circuit hoses from the
tilt cylinder at the front of the third boom section. Label,
disconnect and cap the auxiliary circuit hoses from the
quick disconnect fittings at the front of the third boom
section. Cap all fittings and openings to prevent dirt and
debris from entering the hydraulic system.
8. Place a sling through the opening at the top of the
boom head and around the tilt cylinder and remove the 10
retaining rings and pin at the barrel end of the tilt
cylinder. Lower the tilt cylinder and place in a secure
location.
9. Loosen and remove the rear cover and door assembly
from the rear of the first boom section. 11 MZ7120

3-6 31211337 3614RS, 4017RS

 Boom

13. Remove the circlip and pin (10) from the retract 3.3.3 Third Boom Section Removal
chain (11) at the rear of the third boom section. Lay the
retract chain over the rear edge of the first boom 13
section.

12
MZ7130 MZ7160

14. Pull the second and third boom sections out of the first 1. Pull the tilt hoses and the auxiliary hoses (if equipped)
boom section approximately 304 mm (12 in) to access from the rear of the third boom section.
the front first section wear pads. Note: The bracket (13) holding the tilt hoses and auxiliary
15. Remove all wear pads, shims and backing plates from hoses (if equipped) will still secure the tilt hoses and auxiliary
the front inside of the first boom section (12). Label and hoses (if equipped) when the top rear wear pads are removed.
tag each set of wear pads being removed.
16. Pull the second and third boom sections out of the first
boom section. Relocate the lifting slings and slowly pull
the two boom sections clear of the first boom section.
Lower onto suitable supports.
17. Inspect the first boom and welds. Consult your local
authorized service distributor if structural damage is
detected.
18. Inspect hoses, hardware, wear pads, mounting points,
chains and other components visible with the first 14
boom section. Replace any item if damaged. (Refer to
Section 3.15, “Boom Extend and Retract Chains - 3614RS
& 4017RS” and Section 3.16.1, “Wear Pad Inspection”)
Note: It is recommended that if any chain or hose is damaged MZ7200
that ALL chains or hoses are replaced.
Note: After removing the second and third boom section the Note: Remove the individual brackets (14) securing the tilt
retract chain is left laying on the inside of the first boom section hoses and auxiliary hoses (if equipped) to the main mounting
and can be removed, cleaned, inspected and replaced if bracket (13).
required.

3614RS, 4017RS 31211337 3-7

 Boom

3.3.4 Third Boom Section Installation

Note: During reassembly use medium strength threadlocking
compound on all bolt threads.
16 Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear
Pads”. You may have to final adjust the wear pads after the
15 boom assembly is installed on the machine and hydraulic
power is available.
Note: Coat the interior of all bushings and bores with Lithium
Grease prior to the installation of pins and bushings. Wear pads
and slide areas must be lubricated with Lithium Grease or an
equivalent.
1. Place the second boom section on suitable supports.
17 MZ7190
2. Lubricate the inside second boom section on areas
2. Loosen and remove the mounting bolt (15) and where the third boom section wear pads will slide.
bracket (16) securing the extend chain clevis (17). 3. Lubricate and place the extend chain in the center of
the second boom section.
4. Using a suitable sling, balance the third boom section
and carefully slide the 1 m - 1,2 m (3 ft - 4 ft) of the third
boom section into the front of the second boom
section.
5. Set the third boom section onto a suitable support and
reset the sling under the boom head of the third boom
section. Carefully slide the third boom section into the
second boom section.
6. Leave 152 mm - 203 mm (6 in - 8 in) of the third boom
section out to be able to install the wear pads in the
front of the second boom section.
18 7. With the sling still under boom head, install the wear
pads and spacers in the front of the second boom
section.
MZ7150

3. Remove all wear pads, shims and backing plates from

the front inside of the second boom section (18). Label
and tag each set of wear pads being removed.
4. Place a sling around the third boom section, lift and
slowly pull the third boom section approximately half
way out of the second boom section. Lower the third 13
boom section onto a suitable support.
5. Relocate the sling or using two slings for better stability,
balance the third boom section and slowly pull it out of
the second boom section being careful not to damage
the hydraulic hoses or chains. Lower the third boom
sections onto suitable supports.
Note: After removing the third boom section the extend chain
MZ7210
is left laying on the inside of the second boom section and can
be removed, cleaned, inspected and replaced if required. 8. Install the previously removed tilt hoses and
(if equipped) the auxiliary hoses mounting bracket (13).

3-8 31211337 3614RS, 4017RS

 Boom

6. Using a suitable sling, balance the second and third

boom sections and carefully slide 0,9 m - 1,22 m
(3 ft - 4 ft) into the front of the first boom section.
16 7. Set the second and third boom sections onto a suitable
support and reset the sling under the boom head of the
third boom section.
15
8. Carefully slide the two boom sections into the first
boom section. Leave 152 mm - 203 mm (6 in - 8 in) in of
the two boom sections out to be able to install the wear
pad block and the wear pads in the front of the first
boom section.

17 MZ7190

9. Install the extend chain clevis (17), mounting

bracket (16) and secure with bolt (15).

3.3.5 Second and Third Boom Section

Installation
1. Place the first boom section on suitable supports.

6
12
MZ7130

7 9. Install the wear pads, spacers and shims at the front of

the first boom section (12).

MAE35080

2. From the rear of the boom, feed the tilt hoses (6) and
auxiliary hoses (7) (if equipped) to the proper tube
connections on the bottom of the first boom section.
3. Tighten and torque the tilt hoses and auxiliary hoses (if 10
equipped). Verify the hoses are aligned square to the
boom.
4. Lubricate the inside first boom section on area’s where
the second boom section wear pads will slide.
5. Lubricate and place the retract chain in the center of the 11 MZ7120
second boom section with 254 mm (10 in) extending
from the rear of the first boom section. 10. Install the pin (10) and circlip securing the retract
chain (11) at the rear of the third boom section.

3614RS, 4017RS 31211337 3-9

 Boom

19
9
8

20

MZ7230

MAE35090
14. Install the tilt cylinder in the boom head, install the
11. Install the retract chain at the front of the first boom mounting pin and keeper bolt, locking the mounting
section. Install the lock nut and jam nut (8). Do Not pin and tilt cylinder (19) into position.
Tighten at this time. 15. Connect the tilt cylinder hoses to the proper fittings on
12. Install the extend chain at the front of the first boom the tilt cylinder.
section. Install the lock nut and jam nut (9). Do Not 16. If equipped, connect the auxiliary hoses to the proper
Tighten at this time. fittings (20) on the boom head.

14

MZ7200

17. Install the individual brackets (14) securing the tilt

MZ7120 hoses and auxiliary hoses (if equipped) to the main
mounting bracket.
13. Feed the tilt hoses (6) and auxiliary hoses (7)
(if equipped) through the top of the third boom section.

3-10 31211337 3614RS, 4017RS

 Boom

3.3.6 Complete Boom Installation

Note: Lubrication of the boom wear surfaces with
Multipurpose Grease is recommended to keep the boom wear
5 surfaces lubricated properly. Lubrication of the boom wear
3 surfaces is also recommended when the machine is stored, to
2 help prevent rusting.
1. Park the machine on a hard, level surface, place the
transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.
4
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
5
Note: Grease the boom pivot bores, compensating cylinder rod
end, lift/lower cylinder rod end and pins before installing.

MZ7090

18. Properly support the extend/retract cylinder (2) using a

hoist or crane and lower into place.
1
19. Install each mounting pin (5) in the extend/retract
cylinder.
20. Install one retaining ring to the mounting pin (5) at each
end of the extend/retract cylinder. 1

21. Remove caps and/or plugs from all fittings and

openings. Connect the extend/retract cylinder
hoses (3) to the extend/retract cylinder. 1
22. Install the extend/retract cylinder bracket (4). 1 MAE34610

3. Using suitable slings, balance the boom assembly, lift

and carefully guide the boom into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install shims, boom pivot pins and lock bolt (1).
4. With the sling still in place, install the compensating
cylinder, pin and lock bolts.
5. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt. Apply
medium strength threadlocking compound and torque
to 90 Nm (66 lb-ft).
Note: Raising the boom up or down with the sling may be
necessary so the boom, compensating and lift/lower cylinder
bores can be aligned for easier pin installation.
6. Uncap and connect the previously labeled extend/
retract cylinder hoses to the extend/retract cylinder.
7. Uncap and connect the previously labeled tilt hoses and
auxiliary hoses (if equipped) to the appropriate cylinder.

3614RS, 4017RS 31211337 3-11

 Boom

8. Install the boom angle sensor arm. Refer to 3.4 BOOM CHAIN REMOVAL/INSTALLATION
Section 9.10.7, “Boom Angle Sensor”, for procedure. - 3614RS
9. Remove slings and/or supports from the boom
assembly.
3.4.1 Retract Chain Removal
10. Properly connect the battery. Refer Section 9.8,
The removal of the retract chain can be accomplished with
“Battery”, for procedure.
out the complete tear down of the boom sections.
11. Start the engine and operate all boom functions several
1. Remove any attachment from the quick coupler
times to bleed any air out of the hydraulic system. Check
assembly. Refer to Operation & Safety Manual.
for fluid leaks. Check the hydraulic fluid level in the tank
and add fluid as required. 2. Park the machine on a hard, level surface, fully retract
the boom, level the boom assembly, place the
12. Lower the boom assembly and shut engine OFF.
transmission in (N) NEUTRAL, engage the park brake
13. Clean up all debris, hydraulic fluid, etc., in, on, near and and shut the engine OFF.
around the machine.
3. Place a Do Not Operate Tag on both the ignition key
14. Remove the Do Not Operate Tag from both the ignition switch and the steering wheel.
key switch and the steering wheel.
4. Open the engine cover. Allow the system fluids to cool.
5. Loosen and remove the rear cover and door assembly
from the rear of the first boom section.
6. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure.

MZ7250
1

7. Remove the extend chain lock nut, adjusting nut (1) and
roller assembly (2). Secure extend chain to access the
removal of the retract chain.
8. Remove the retract chain lock nut and adjusting nut (3).
Fasten a rope/wire to the end of the clevis to aid in
reinstallation.

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 Boom

3.4.3 Extend Chain Removal

The removal of the extend chains can be accomplished with
out the complete tear down of the boom sections.
1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Safety Manual.
2. Park the machine on a hard, level surface, fully retract
the boom, level the boom assembly, place the
transmission in (N) NEUTRAL, engage the park brake
4 and shut the engine OFF.
5 3. Place a Do Not Operate Tag on both the ignition key
6 switch and the steering wheel.
4. Open the engine cover. Allow the system fluids to cool.
5. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure.
6. Loosen and remove the rear cover and door assembly
MZ7120 from the rear of the first boom section.
9. Remove the circlip and pin (4) securing the retract chain
clevis (5) at the rear of the third boom section.
10. Pull the retract chain (6) from between the first and
second boom sections from the rear of the boom
assembly.
11. Unfasten the rope/wire from the retract chain clevis.

3.4.2 Retract Chain Installation

1. Fasten the rope/wire left in the boom from the retract
chain removal to the new retract chain clevis and pull 8
the chain through the boom sections to the
approximate final position. Remove the rope/wire.
2. Install the retract chain, pin and circlip (4) at the rear of 7
the third boom section.
3. Install the retract chain roller assembly, lock nut and MZ7250

adjusting nut (3) at the front of the first boom section 7. Loosen the extend chain lock nut and adjusting nut (7)
below the boom head. from the extend chain at the bottom of the first boom
4. Install the rear cover and door assembly to the rear of section.
the first boom section. 8. Remove the cotter pin and pin (8) securing the extend
5. Properly connect the battery. Refer Section 9.8, chain to the extend chain clevis. Fasten a rope/wire to
“Battery”, for procedure. the end of the clevis to aid in reinstallation.
6. Close and secure the engine cover.
7. For chain adjustments see Section 3.7.1, “Chain
Adjustments”.

3614RS, 4017RS 31211337 3-13

 Boom

3.5 TILT AND AUXILIARY CIRCUIT HOSE

REMOVAL/INSTALLATION - 3614RS
10 Hoses that need replaced and are still in one piece can be
removed and replaced without removing sections of the
boom.
9
3.5.1 Tilt/Auxiliary Hose Removal

11 MZ7190

1
Note: Removal of the retract chain from the rear of the third
boom section may be required to access the extend chain clevis
assembly.
9. Loosen and remove the mounting bolt (9) and 2
bracket (10) securing the extend chain clevis (11).
10. Pull the extend chain from between the second and
third boom sections at the rear of the machine.
11. Unfasten the rope/wire from the extend chain. MZ7230

3.4.4 Extend Chain Installation 1. Label, disconnect and cap both hoses from the tilt
cylinder (1) and auxiliary fittings (2) (if equipped) at the
1. Fasten the rope/wire left in the boom from the extend
front of the boom. Cap all fittings and openings to keep
chain removal to the new extend chain and pull the
dirt and debris from entering the hydraulic system.
chain through the boom sections to the approximate
final position. Remove the rope/wire.
2. Install the extend chain clevis bracket (10) and
mounting bolt (9) to the extend chain clevis at the rear
of the third boom section.
3. Install the pin and cotter pin (8) securing the extend
chain to the extend chain clevis at the front of the boom
assembly. 3

4. Install the extend chain lock nut and adjusting nut (7) at
the front of the first boom section. 4
5. Install the rear cover and door assembly to the rear of
the first boom section.
6. Properly connect the battery. Refer Section 9.8,
“Battery”, for procedure.
7. Close and secure the engine cover.
8. For chain adjustments refer Section 3.7.1, “Chain
Adjustments”. MAE35080

2. Label, disconnect and cap both tilt hoses (3) attached to

the tubes on the bottom of the boom. If equipped,
label, disconnect and cap both auxiliary hoses (4)
attached to the tubes on the bottom of the boom. Cap

3-14 31211337 3614RS, 4017RS

 Boom

all fittings and openings to keep dirt and debris from 3.6 EXTEND/RETRACT CYLINDER REMOVAL/
entering the hydraulic system. INSTALLATION - 3614RS
3. Fasten a rope/wire to the hose end below the first boom
section. The extend/retract cylinder hydraulically extends and
retracts the third boom section.
Seal kits for the extend/retract cylinders are available from
the local JLG dealer.

3.6.1 Extend/Retract Cylinder Removal

1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Safety Manual.
2. Park the machine on a hard, level surface, extend the
boom to gain access to the extend/retract cylinder pin
5 in the third boom section, level the boom assembly,
place the transmission in (N) NEUTRAL, engage the park
brake and shut the engine OFF.
3. Place a Do Not Operate Tag on both the ignition key
MZ7200 switch and the steering wheel.

4. Loosen and remove the clamps (5) securing the tilt

hoses and auxiliary hoses (if equipped) at the rear of the
third boom section. 4
2
5. From the rear of the boom, pull the tilt hoses from
between the first and second boom sections. 1
6. From the rear of the boom, pull the tilt hoses from
inside the third boom section.
7. Unfasten the rope/wire from each end of the hose 3
assembly.

3.5.2 Tilt/Auxiliary Hose Installation 4

1. Fasten the rope/wire left in the boom from the hose
removal to each end of the new hose at the rear of
boom.
2. Slowly pull the rope/wire from the boom head until the
hose end is visible at the boom head.
3. Slowly pull the rope/wire from below the first boom
section until the hose end is visible at the tube MZ7090

connections. 4. Properly support the extend/retract cylinder (1) using a

4. Unfasten the rope/wire from each end of the hose. hoist or crane.
5. Uncap and connect the hoses to the previously labeled 5. Label, disconnect and cap the extend/retract cylinder
tubes under the first boom section. Refer to Section 2.2, hoses (2) from the extend/retract cylinder. Cap all
“Specifications”, for proper hose torque. fittings and openings to prevent dirt and debris from
6. Uncap and connect the hoses to the previously labeled entering the hydraulic system.
fittings at the tilt cylinder or the auxiliary fittings. Refer 6. Loosen and remove the extend/retract cylinder
to Section 2.2, “Specifications”, for proper hose torque. bracket (3).
7. Install and tighten the clamps holding the tilt hoses at 7. Remove one retaining ring from the mounting pin (4) at
the rear of the third boom section. each end of the extend/retract cylinder.
8. Properly connect the battery. Refer Section 9.8, 8. Remove each mounting pin and remove the extend/
“Battery”, for procedure. retract cylinder and place in a secure location.

3614RS, 4017RS 31211337 3-15

 Boom

3.6.2 Extend/Retract Cylinder Installation

A
1. Install the extend/retract cylinder (1) onto the top of the
boom assembly.
2. Install one mounting pin (4) at each end of the
extend/retract cylinder and secure with retaining ring.
3. Uncap and connect the hoses (2) to the previously
labeled fittings at the extend/retract cylinder.
4. Instal the extend/retract cylinder bracket (3).
5. Properly connect the battery. Refer Section 9.8,
“Battery”, for procedure.
6. Start the machine and cycle the extend/retract cylinder
checking for leaks or any alignment problems.
MZ7820
3.7 BOOM SECTIONS ADJUSTMENT - 4. Adjust the boom chains to obtain dimension (A)
3614RS 175,0 - 190,0 mm (6.9 - 7.4 in).
Note: Ensure that there is a minimum of one full thread of the
3.7.1 Chain Adjustments clevis showing beyond the lock nut.
The chains are adjusted by tightening and/or backing off the 5. Start the machine and slowly extend and retract the
adjusting nuts at the threaded end of the chains. The boom three times.
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed. 6. Retract the extend/retract cylinder completely. Turn
OFF engine
The chains are properly adjusted whenever the following
parameters are met. 7. Repeat step 4 and 5 if necessary.

1. Start the machine, level the boom and retract the 8. Tighten the extend/retract chain lock nuts (10 and 11)
extend/retract cylinder completely. Turn OFF engine. to 120 Nm (86 lb-ft) against the adjusting nut.
Note: Ensure that there is a minimum of one full thread of the
clevis showing beyond the lock nut.
9. Start the machine and cycle the extend/retract cylinder
to verify the boom extends and retracts properly.
2

D
C
B
MZ7830

10. With the boom level, extend the boom completely and
1 MZ7810 retract 50,0 mm (2.0 in).
2. At the bottom front of the boom section, adjust the 11. Verify dimensions (B) 375,0 mm (147.6 in) and (C)
extend chain (1) and retract chain (2) to achieve the 1875,0 mm (73.8 in) are correct.
proper boom measurements.
12. Verify the SAG dimension (D) is
3. Loosen the jam nut on each chain clevis. 160 mm - 165 mm (6.3 in - 6.5 in).
13. Adjust extend chain (1) if required. Repeat steps 9, 10
and 11 if necessary.

3-16 31211337 3614RS, 4017RS

 Boom

3.8 BOOM SYSTEM COMPONENT

TERMINOLOGY - 4017RS
To understand the safety, operation and maintenance
information presented in this section, it is necessary that the
operator/mechanic be familiar with the name and location of
the major assemblies of the boom system. The following
illustration identifies the components that are referred to
throughout this section.

EXTEND/RETRACT CYLINDER

RETRACT CHAIN
(FOURTH BOOM SECTION)
(INSIDE BOOM)

EXTEND CHAIN
(FOURTH BOOM FIRST BOOM
SECTION) SECTION

RETRACT CHAIN
FOURTH BOOM (THIRD BOOM SECTION)
SECTION (INSIDE BOOM)

EXTEND CHAINS
(THIRD BOOM SECTION)
(INSIDE BOOM)

SECOND BOOM
SECTION

THIRD BOOM
SECTION

MAE21500

TILT CYLINDER

3614RS, 4017RS 31211337 3-17

 Boom

3.9 BOOM SYSTEM - 4017RS 3.10 BOOM ASSEMBLY MAINTENANCE -

4017RS
3.9.1 Boom System Operation
These instructions must be completed in sequence. The
The four section boom consists of the first, second, third and second, third and fourth boom sections are removed from
fourth assemblies with double third section extend chains, a the first boom section.The third and fourth boom sections
single fourth section extend chain, a single third and fourth are removed from the second boom section.The fourth
section retract chains. boom section is removed from the third boom section.
As the extend/retract cylinder, which is anchored at the front Before beginning, conduct a visual inspection of the
of the second boom section, and the rear of the first boom machine and work area, and review the task about to be
section begins to extend, it forces the second boom section undertaken. Read, understand and follow these
out of the first boom section. instructions.The boom assembly consists of the first, second
The first, second, third and fourth boom sections are and third section booms and supporting hardware.
connected by extend and retract chains. These chains are Note: Before removing the boom or boom section, the carriage
routed around sheaves on the second and third boom or any other attachment must be removed from the quick
sections. As the second and third boom sections are forced coupler.
out, the extend chains pull the third and fourth boom
sections out of the second boom section. Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
As hydraulic pressure is applied to the retract port on the
undertaken. Read, understand and follow these instructions.
extend/retract cylinder, the second boom section is pulled
back into the first boom section, and the retract chains pulls During service of the boom, perform the following:
the third and fourth boom sections back into the second 1. Check wear pads.
boom section. (Refer to Section 3.16.1, “Wear Pad Inspection”)
This mechanical linkage formed by the chains and 2. Check chain rollers.
supporting hardware, extends and retracts the third and
3. Apply grease at all lubrication points (grease fittings).
fourth boom sections at the same rate.
(Refer to Section 2.5, “Lubrication Schedule”)
The first boom section does not extend or retract, but lifts
4. Check for proper operation by operating all boom
and lowers via action of the lift cylinder.
functions through their full ranges of motion several
times.
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.

WARNING
NEVER weld or drill the boom unless approved in writing
by JLG. The structural integrity of the boom will be
impaired if subjected to any repair involving welding or
drilling.

3-18 31211337 3614RS, 4017RS

 Boom

3.10.1 Boom Removal

While the boom sections can be separated from each other
on the machine, it is much safer, more efficient and more
cost- effective to remove the complete boom assembly from
the machine and place it on suitable supports for separation.
Work can then progress at a normal working height.
Note: When removing a complete boom assembly use a hoist
or crane with a minimum lift capacity of 6000 lbs. 1

1. Remove any attachment from the quick coupler

assembly. Refer to Operation & Safety Manual.
2. Remove the quick coupler assembly. Refer to
Section 3.17.1, “Quick Coupler Removal”. 1
3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
cylinder pin and the compensation cylinder pin, place 1
1 MAE21520
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF. 11. Remove the shims, boom pivot pins and lock bolts from
the rod end of the compensation cylinder being careful
4. Place a Do Not Operate Tag on both the ignition key
not to drop the cylinder. Lower the cylinder to a secure
switch and the steering wheel.
position.
5. Open the engine cover. Allow the system fluids to cool.
12. Lower the boom assembly to level.
6. Properly disconnect the battery. Refer Section 9.8,
13. Place a sling around the first boom section at the
“Battery”, for procedure.
balance points.
7. Close engine cover to access lift/lower cylinder pin and
14. Label, disconnect and cap all hydraulic hoses attached
the compensation cylinder pin.
to the tubes on the bottom of the boom. Cap all fittings
8. Properly support the boom assembly using a hoist or and openings to keep dirt and debris from entering the
crane. hydraulic system.
9. Remove boom angle sensor arm. Refer to Section 9.10.7, 15. Raise the boom assembly to allow the removal of the
“Boom Angle Sensor”. boom assembly pivot pins (1).
10. Remove the pin from the rod end of the lift/lower 16. Confirm that the boom assembly is balanced with the
cylinder being careful not to drop the cylinder. Lower sling and remove the boom assembly pivot pins.
the cylinder to a secure position.
17. Lift the boom assembly from the machine and lower
onto suitable supports.

3614RS, 4017RS 31211337 3-19

 Boom

3.10.2 Second, Third and Fourth Boom Section

Removal
1. Verify the boom assembly is setting on stable, secure
and suitable supports.

3
7
2 8
5
6
4

MAE21720
MAE21510
7. Label, disconnect and cap the tilt circuit hoses (6) from
2. Properly support the extend/retract cylinder (2) using a the tilt cylinder (7) at the front of the forth boom
hoist or crane. section. Cap all fittings and openings to prevent dirt and
3. Label, disconnect and cap the extend/retract cylinder debris from entering the hydraulic system.
hoses (3) from the extend/retract cylinder. Cap all 8. Place a sling through the opening at the top of the
fittings and openings to prevent dirt and debris from boom head and around the tilt cylinder and remove the
entering the hydraulic system. retaining rings and pin (8) at the barrel end of the tilt
4. Loosen and remove the extend/retract cylinder cylinder. Lower the tilt cylinder and place in a secure
bracket (4). location.

5. Remove one retaining ring from the mounting pins (5) 9. Loosen and remove the rear cover and door assembly
at each end of the extend/retract cylinder (2). from the rear of the first boom section.

6. Remove each mounting pin and remove the

extend/retract cylinder (2) and place in a secure
location.

10

9
11
MAE21530

Note: Before removing the extend chains, measure and note

the distance between the face of the jam nut to the end of the
chain clevis. This measurement will be used when reassembling
the boom.

3-20 31211337 3614RS, 4017RS

 Boom

10. Loosen and remove the lock nut and jam nut (9) on the
retract chain at the front of the first boom section.
11. Loosen and remove the lock nuts and jam nuts (10) on
the extend chains at the front of the first boom section.
12. Label, disconnect and cap the tilt hoses (11) from tubes
at bottom front of first boom section. Plug all fittings to
prevent dirt and debris from entering hydraulic system.
Clean and inspect the hoses. Replace if damaged.

15

MAE21650

16. Pull the second, third and fourth section booms out
152 - 203 mm (6 - 8 in) and remove all the wear pads,
shims and backing plates from the front inside of the
first section boom (15). Label all parts for installation.
12 17. Place a sling around the front of the second boom
13 section, lift and slide the three boom section 3/4 of the
MAE21540 way out of the first boom section. Set the boom head
14
down on a suitable support, then center the sling to be
13. At the rear of the boom, label, disconnect and cap tilt able to balance the three boom sections being
hoses (12) from the bracket attached to the third boom removed. Carefully pull the three boom sections the
section. Cap all fittings to prevent dirt and debris from remainder of the way out of the first boom section and
entering the hydraulic system. set the two boom sections down on suitable supports.
14. Pull tilt hoses (12) through the rear of the first boom 18. Remove the retract chain from the inside of the first
section. boom section. Clean and inspect chains. Replace if
15. Remove the clip and pin (13) from the retract chain damaged.
clevis that is attached to the rear of the third section 19. Inspect the boom and welds. Consult your local
boom. Lay the retract chain (14) over the rear of the first authorized service distributor if structural damage is
boom section. detected.
20. Inspect hoses, hardware, wear pads, mounting points,
chains and other components visible with the first
boom section. Replace any item if damaged. (Refer to
Section 3.15, “Boom Extend and Retract Chains - 3614RS
& 4017RS” and Section 3.16.1, “Wear Pad Inspection”).
Note: It is recommended that if any chain or hose is damaged
that ALL chains or hoses are replaced.

3614RS, 4017RS 31211337 3-21

 Boom

3.10.3 Third and Fourth Boom Section Removal

1. Verify the boom assembly is setting on stable, secure
and suitable supports. 20

19

18

18

MAE21660

4. At the top front of the second boom section (19),

16 17 remove the jam nuts and nuts and washers from the
MAE21550
16
extend chain clevis (20).
Note: Removal of the retract chain roller from the rear of the
5. Pull the third and fourth boom section out
second boom section may be required to access the extend
152 - 203 mm (6 - 8 in). Remove the top wear pads,
chain clevis assemblies.
shims and backing plate from the second boom section.
2. Loosen and remove the mounting bolts (16) and Label and tag each set of wear pads being removed.
bracket (17) securing each extend chain clevises (18). 6. Remove the side wear pads, shims and backing plates
3. Fasten a rope/wire to each extend chain clevis. from either side of the rear of the second boom section.
Label and tag each set of wear pads being removed.
7. Place a sling around the front of the third boom section,
lift and slide the two boom section 3/4 of the way out of
the second boom section. Set the boom head down on
a suitable support, then center the sling to be able to
balance the two boom sections being removed.
Carefully pull the two boom sections the remainder of
the way out of the second boom section and set the
two boom sections down on suitable supports.
8. Remove the extend chains from bottom of second
boom section. Clean and inspect chain. Replace if
damaged.
9. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is
detected.

3-22 31211337 3614RS, 4017RS

 Boom

10. Inspect hardware, wear pads, mounting points, chains

and other components visible with the second boom
section. Replace any item if damaged. (Refer to 26
Section 3.15, “Boom Extend and Retract Chains - 3614RS
& 4017RS” and Section 3.16.1, “Wear Pad Inspection”).
Note: It is recommended that if any chain or hose is damaged
that ALL chains or hoses are replaced.

3.10.4 Fourth Boom Section Removal 25

27
1. Verify the boom assembly is setting on stable, secure
and suitable supports.

23

MAE21670

6. At the top front of the third boom section (25), lay the
extend chain and clevis (26) over the front of the fourth
boom section (27).
7. Remove the top wear pads, shims and backing plate
from the third boom section. Label and tag each set of
21 wear pads being removed.
8. Remove all wear pads, shims and backing plates from
the front of the third boom section. Label and tag each
set of wear pads being removed.
MAE21560 9. Place a sling around the front of the fourth boom
24 22 section, lift and slide the fourth boom section 3/4 of the
way out of the third boom section. Set the boom head
2. At the rear of the boom, loosen and remove the tilt hose
down on a suitable support, then center the sling to be
bracket (21) attached to the third boom section
able to balance the fourth boom section being
securing tilt hoses (22). Label, disconnect and cap tilt
removed. Carefully pull the fourth boom section the
hoses. Cap all fittings to prevent dirt and debris from
remainder of the way out of the third boom section and
entering the hydraulic system.
set the fourth boom section down on suitable supports.
3. Remove the clip and pin from the retract chain
clevis (23) that is attached to the rear of the fourth
section boom. Lay the retract chain over the rear of the
third boom section.
4. Remove the retract chain from top of third boom
section. Clean and inspect chain. Replace if damaged.
5. Loosen and remove the two bolts securing the hose
carrier (24) to the third boom section.

3614RS, 4017RS 31211337 3-23

 Boom

3.10.5 Fourth Boom Section Removal Only

28
Note: Removal and installation of the hose carrier can also be
performed by removing only the fourth boom section if
required.

29

MAE21570 30
10. Remove the extend chain (28) from top of fourth boom
section. Clean and inspect chain. Replace if damaged.
31 MAE21580
11. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is 1. Disconnect the extend chain clevis (29) from the rear of
detected. the fourth boom section.
12. Inspect hardware, wear pads, mounting points, chains 2. At the rear of the boom, label, disconnect and cap tilt
and other components visible with the second boom hoses (30) from the tubes attached to the third boom
section. Replace any item if damaged. (Refer to section. Cap all fittings to prevent dirt and debris from
Section 3.15, “Boom Extend and Retract Chains - 3614RS entering the hydraulic system.
& 4017RS” and Section 3.16.1, “Wear Pad Inspection”). 3. Loosen and remove the two bolts securing the hose
Note: It is recommended that if any chain or hose is damaged carrier (31) to the third boom section.
that ALL chains or hoses are replaced. 4. Remove all wear pads, shims and backing plates from
the front of the third boom section. Label and tag each
set of wear pads being removed.
5. Place a sling around the front of the fourth boom
section, lift and slide the three boom sections 3/4 of the
way out of the fourth boom section. Set the boom head
down on a suitable support, then center the sling to be
able to balance the fourth boom section being
removed. Carefully pull the fourth boom section the
remainder of the way out of the three boom sections
and set the fourth boom section down on suitable
supports.

3-24 31211337 3614RS, 4017RS

 Boom

3.10.6 Hose Carrier Removal/Installation 3.10.8 Fourth Boom Section Installation

Refer to Section 3.11, “Hose Carrier Assembly”, for detailed Note: During reassembly use medium strength threadlocking
hose carrier removal and installation. compound on all bolt threads.
Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear
3.10.7 Fourth Boom Section Installation Only Pads”. You may have to final adjust the wear pads after the
1. Using a suitable sling, balance the fourth boom section boom assembly is installed on the machine and hydraulic
and carefully slide 914 - 1219 mm (3 - 4 ft) into the front power is available.
of the third boom section. Set the fourth boom section
Note: Coat the interior of all bushings and sheaves with
head onto suitable support and reset sling under the
Lithium Grease prior to the installation of pins and bushings.
boom head of the fourth boom section. Carefully slide
Wear pads and slide areas must be lubricated with Mystik
the fourth boom section into the third boom section.
Tetrimoly Grease XD#2 or an equivalent.
Leave 1829 - 2438 mm (6 - 8 ft) of the fourth boom
28
section out to be able to install wear pads in front of the
third boom section.
2. With the sling still under boom head install the bottom
front wear pads and backing plates on the third boom
section. Lower the fourth boom section and install the
top front and side wear pads and backing plates on the
third boom section. Tighten as required.
3. Install the two bolts securing the hose carrier (31) to the
third boom section.
4. At the rear of the boom, remove the caps from both tilt
hoses (30). Connect each hose to the previously labeled
tubes attached to the third boom section.
5. Connect the extend chain clevis (29) to the rear of the
fourth boom section.

MAE21570

1. Install the extend chain (28) on the top rear of fourth

boom section. Lay the extend chain the length of fourth
boom section.
2. Grease the inside third boom section on area’s where
the fourth boom section wear pads will slide.
3. Using a suitable sling, balance the fourth boom section
and carefully slide 914 - 1219 mm (3 - 4 ft) into the front
of the third boom section. Set the fourth boom section
head onto suitable support and reset sling under the
boom head of the fourth boom section. Carefully slide
the fourth boom section into the third boom section.
Leave 1829 - 2438 mm (6 - 8 ft) of the fourth boom
section out to be able to install wear pads in front of the
third boom section.
4. With the sling still under boom head install the bottom
front wear pads and backing plates on the third boom
section. Lower the fourth boom section and install the
top front and side wear pads and backing plates on the
third boom section. Do not shim or tighten bolts at this
time.
3614RS, 4017RS 31211337 3-25
 Boom

Note: Grease wear pads, bores and pins during assembly. 3.10.9 Third and Fourth Boom Section
5. Retract the fourth boom section the remainder of the
Installation
way into the third boom section. 1. Install the extend chains on the bottom inside of second
6. Shim all wear pads on the front of the third boom boom section. Lay the extend chain the length of
section. Torque bolts to 90 Nm (66 lb-ft). second boom section.

23

18

18

21

16 17
MAE21550
MAE21560
16
24 22 2. Grease the inside second boom section on areas where
the third boom section wear pads will slide.
7. At the rear of the boom, install the hose bracket (21) to
the third boom section securing tilt hoses (22). 3. Using a suitable sling, balance the third and fourth
boom sections and carefully slide 914 - 1219 mm
8. Remove caps on tilt hoses. Install hoses and torque as
(3 - 4 ft) into the front of the second boom section. Set
required.
the third and fourth boom sections onto a suitable
9. Lay the retract chain (23) the length of third boom support and reset the sling under the boom head of the
section. fourth boom section. Carefully slide the third and fourth
10. Install the pin and clip to the retract chain clevis to the boom sections into the second boom section. Leave
top rear of the fourth section boom. 152 - 203 mm (6 - 8 in) of the third boom section out to
be able to install the wear pads in the front of the
11. Install the two bolts securing the hose carrier (24) to the
second boom section.
third boom section. Torque as required.
4. With the sling still under third boom section, install the
bottom front wear pads and backing plates on the
second boom section. Lower the third boom section
and install the top front and side wear pads and backing
plates on the second boom section. Do not shim or
tighten bolts at this time.
Note: Installation of the retract chain roller from the rear of the
second boom section may be required if removed to access the
extend chain clevis assemblies.
5. Secure the extend chains to the each extend chain
clevises (18).

3-26 31211337 3614RS, 4017RS

 Boom

6. Install the mounting bolts (16) and bracket (17) 3.10.10 Second, Third and Fourth Boom Section
securing each extend chain clevises (18). Installation
Note: Grease wear pads, bores and pins during assembly.

20

10

9
11
MAE21530
19
1. Install the retract chain to bottom front inside of the first
boom section. Install the lock nut and jam nut (9). Lay the
retract chain over the rear of the first boom section.
2. Install the tilt hoses (11) to the tubes mounted at the
bottom front of the first boom section. Verify both sets
of hoses are run through the opening at the bottom
front of the first boom section and parallel with the
retract chain. Lay the tilt hoses over the rear of the first
boom section.
MAE21660
Note: Keep the retract chain and tilt hoses centered in the first
7. Install the extend chain (20) to the top front of the boom section while installing the second boom section into the
second boom section (19). Install the lock nut and jam first boom section.
nut. 3. Grease the inside first boom section on area’s where the
8. Shim all wear pads on the rear of the third boom section second boom section wear pads will slide.
and front of the second boom section. Torque bolts to 4. Using a suitable sling, balance the second, third and
90 Nm (66 lb-ft). fourth boom sections and carefully slide
914 - 1219 mm (3 - 4 ft) into the front of the first boom
section. Set the second, third and fourth boom sections
onto a suitable support and reset sling under the boom
head of the fourth boom section. Carefully slide the
second, third and fourth boom sections into the first
boom section. Leave 152 - 203 mm (6 - 8 in) of the
second boom section out to be able to install wear pads
in front of the first boom section.
5. With the sling still under the third boom section, install
the bottom front wear pads and backing plates on the
first boom section. Lower the third boom section and
install the top front and side wear pads and backing
plates on the first boom section. Do not shim or tighten
bolts at this time.

3614RS, 4017RS 31211337 3-27

 Boom

6. Retract the second, third and fourth boom sections the

remainder of the way into the first boom section.
Note: Shim wear pads as needed to maintain an even gap of
0,5 - 1,5 mm (0.002 - 0.06 in) between the wear pads and the
next boom section. The number of shims can vary at each shim
point.
7. Shim all wear pads on the rear of the second boom
section and front of the first boom section. Torque as 7
8
required.
8. Attach the extend chains at the bottom front of the first
6
boom section. Install the lock nut and jam nut.

MAE21720

11. Using a suitable sling around the barrel end of the tilt
cylinder (7), raise the tilt cylinder into boom head. Align
the tilt cylinder barrel end bore with the boom head
bore and install the tilt cylinder pin and mounting bolt
and nut (8).
Note: Grease Tilt cylinder barrel end bore and pin before
12 installing.
13
MAE21540
12. Remove the plugs from the fittings on the tilt cylinder
14 and the caps from the Tilt hoses from the hose carrier.
9. Attach the retract chain (14), pins and clips to the Install both tilt hoses (6). Torque as required.
clevises (13) at the rear of the second boom section.
Note: Adjust all extend chains using the measurement taken in
the beginning of the tear down procedure. Depending on the
3
extent of the parts being replaced, the above measurement is to
be used as a starting point ONLY. 2
10. Remove the caps from the tilt hoses (12) and connect to 5
the appropriate fittings at the rear of the second boom
section. Torque as required. 4

MAE21510

3-28 31211337 3614RS, 4017RS

 Boom

13. Attach a sling around a balance point on the Note: Raising the boom up or down with the sling may be
extend/retract cylinder (2) and carefully set on top of necessary so the boom, compensating and lift/lower cylinder
the first boom section. bores can be aligned for easier pin installation.
Note: Grease Extend/Retract cylinder barrel end bore and rod 6. Uncap and connect the previously labeled
end bore and pins before installing. extend/retract cylinder hoses to the extend/retract
cylinder.
14. Align the Extend/Retract cylinder barrel end with bore
at rear of the first boom section. Install the pin and 7. Uncap and connect the previously labeled tilt hoses and
retaining clip (5). (if equipped) auxiliary hoses to the appropriate cylinder.
15. Align the Extend/Retract cylinder rod end with bore at 8. Install the boom angle sensor arm. Refer to
front of the second boom section. Install the pin and Section 9.10.7, “Boom Angle Sensor”.
retaining clip (5). 9. Remove slings and/or supports from the boom
16. Install Extend/Retract cylinder support (4). Torque as assembly.
required. 10. Start the engine and operate all boom functions several
17. Uncap and connect the previously labeled extend/ times to bleed any air out of the hydraulic system. Check
retract cylinder hoses (3) to the extend/retract for fluid leaks. Check the hydraulic fluid level in the tank
cylinder.Torque extend and retract chains lock/jam nuts to and add fluid as required.
115 - 125 Nm (85 - 92 lb-ft). 11. Lower the boom assembly and shut engine OFF.
12. Clean up all debris, hydraulic fluid, etc., in, on, near and
3.10.11 Complete Boom Installation around the machine.
1. Park the machine on a hard, level surface, place the
transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

1 MAE21520
1
3. Using suitable slings, balance the boom assembly, lift
and carefully guide the boom into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install shims, boom pivot pins and lock bolt (1).
4. With the sling still in place, install the compensating
cylinder, pin and lock bolts.
5. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt.

3614RS, 4017RS 31211337 3-29

 Boom

3.11 HOSE CARRIER ASSEMBLY 3.11.2 Hose Carrier Installation

1. Place a sling around the center of the hose carrier to be
Note: Removal and installation of the hose carrier can also be
able to balance the hose carrier while being installed.
performed by removing only the fourth boom section if
required. 2. Carefully slide the hose carrier (5) halfway into the
fourth boom section.
3.11.1 Hose Carrier Removal 3. Remove the sling and push the hose carrier assembly
1. Refer to Section 3.10.4, “Fourth Boom Section Removal”, the remainder of way into the fourth boom section.
for detailed removal instructions. 4. Apply medium strength threadlocking compound to
2. Set the forth boom section on level ground, reposition the previously removed mounting bolts.
the slings and slowly turn the boom section over. 5. Install the twelve bolts (six per side) (4) on the fourth
Reposition the slings and set the boom section on boom section.
suitable supports. 6. Install the mounting bolts (3) securing the tilt hoses
brackets at the rear of the fourth boom section.
1 7. Insert the tilt hoses (6) into the hose carrier tray (2).
8. Install the hose carrier tray (2) into the fourth boom
2
section and secure the hose carrier tray with mounting
bolts (1).
9. Using slings, slowly turn the boom section over.
6 Reposition the slings and set the boom section on
suitable supports.
10. Refer to Section 3.10.8, “Fourth Boom Section
Installation”, for detailed installation instructions.

3 3
MAE21620
5
3. Loosen and remove the two bolts (1) securing the hose
carrier tray (2).
4. Pull the tray (2) from the rear of the fourth boom
section.
5. With fourth boom section setting on suitable supports
loosen and remove the each bolt (3) securing the tilt
hoses brackets at the rear of the fourth boom section.
6. Loosen and remove the twelve bolts (six per side) (4) on
the fourth boom section.
7. Pull the hose carrier (5) halfway out of fourth boom
section by hand and set on a suitable support. Place a
sling around the center of the hose carrier to be able to
balance the hose carrier while being removed.
8. Carefully slide the hose carrier (5) the remainder of the
way out of the fourth boom section and set down on
suitable supports.
9. Secure the tilt hoses with nylon ties. Remove tilt hoses.

3-30 31211337 3614RS, 4017RS

 Boom

3.12 BOTTOM TILT AND AUXILIARY CIRCUIT

HOSE REMOVAL/INSTALLATION -
4017RS
1
3.12.1 Tilt Hose Removal
The following procedures can be performed without
disassembling the boom assembly.
1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Maintenance Manual.
2. Remove the quick coupler assembly. Refer to
Section 3.17.1, “Quick Coupler Removal”.
3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
cylinder pin and the compensation cylinder pin, place
MAE21690
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF. 8. Label, disconnect and cap both tilt hoses (1) attached to
4. Place a Do Not Operate Tag on both the ignition key the tubes on the bottom of the boom. Cap all fittings
switch and the steering wheel. and openings to keep dirt and debris from entering the
hydraulic system.
5. Open the engine cover. Allow the system fluids to cool.
9. Fasten a rope/wire to the hose end below the first boom
6. Properly disconnect the battery. Refer to Section 9.8,
section.
“Battery”, for procedure.
10. From the rear of the boom, pull the tilt hoses from
between the first and second boom sections.
11. Unfasten the rope/wire from the end of the hose
assembly.

3.12.2 Tilt Hose Installation

1. Fasten the rope/wire left in the boom from the hose
removal to each end of the new hose at the rear of
boom.
2. Slowly pull the rope/wire from below the first boom
section until the hose end is visible at the tube
connections.
3. Unfasten the rope/wire from each end of the hose.
4. Uncap and connect the hoses to the previously labeled
1
tubes under the first boom section. Refer to
Section 2.2, “Specifications”, for proper hose torque.
MAE21680 5. Uncap and connect the hoses to the previously labeled
7. Label, disconnect and cap tilt hoses (1). Cap all fittings fittings at the tilt cylinder. Refer to Section 2.2,
to prevent dirt and debris from entering the hydraulic “Specifications”, for proper hose torque.
system. 6. Properly connect the battery. Refer to Section 9.8,
“Battery”, for procedure.

3614RS, 4017RS 31211337 3-31

 Boom

3.12.3 Carrier Tilt Hose Removal

4
3

MAE21700

6. Label, disconnect and cap both tilt hoses (2). Cap all
fittings to prevent dirt and debris from entering the
hydraulic system.
7. Slowly pull each hose assembly the remainder of the
way out of the rear boom assembly.
MAE21710
3 2 8. Disconnect the rope/wire from each end of the hose
assemblies.
1. Label, disconnect and cap tilt hoses (2). Cap all fittings
to prevent dirt and debris from entering the hydraulic
system. 3.12.4 Carrier Tilt Hose Installation
2. Fasten a rope/wire to the end of each disconnected 1. Connect the previously removed rope/wire to the new
hose. tilt hoses (3) and both auxiliary hoses (4) (if equipped).
3. Loosen and remove lower clamp (3) securing tilt 2. Carefully feed the hoses through the rear of the boom
hoses (2). assembly while pulling the wire/rope connected to the
hose from the front of the boom head.
4. Slowly pull each hose assembly halfway out of the rear
boom assembly. 3. Carefully feed the hoses through the rear of the boom
assembly while pulling the wire/rope connected to the
5. Loosen and remove upper clamp (4) securing tilt
hose from the bottom rear of the boom assembly.
hoses (3).
4. Remove any caps and connect each tilt hoses (3) and
both auxiliary hoses (4) (if equipped) to the previously
labeled connection. Torque as required.
5. At the rear of the boom, tighten the previously
loosened clamps (5 and 6) securing the tilt hoses (3)
and both auxiliary hoses (4) (if equipped).

3-32 31211337 3614RS, 4017RS

 Boom

3.13 BOOM CHAIN REMOVAL/INSTALLATION

- 4017RS
3
The removal of the extend and/or retract chain can only be
accomplished with the complete tear down of the boom.

3.14 BOOM SECTIONS ADJUSTMENT -

4017RS

3.14.1 Chain Adjustments MZ7870

4
The chains are adjusted by tightening and/or backing off the 1 2
adjusting nuts at the threaded end of the chains. The
1. Loosen the locknuts on the extend and retract chains.
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed. Fully retract and level 2. Adjust extend chains (1) and retract chain (2) to ensure
the boom. a gap of (B) between the back of the second boom
section and the back of the third boom section.
AA B B
3. Adjust extend chain (3) and retract chain (4) to ensure a
gap of (A) between the back of the third boom section
CC
and the back of the fourth boom section.
4. Tighten the extend and retract chain lock nuts to
120 Nm (86 lb-ft) against the adjusting nut.
Note: Ensure that there is a minimum of one full thread of the
clevis showing beyond the lock nut.
5. Start the machine and slowly extend and retract the
boom three times.
6. Retract the extend/retract cylinder completely. Turn
OFF engine.
7. Verify boom section dimensions. Repeat steps 1 thru 3 if
necessary.
8. Start the machine, lower the out riggers if necessary and
extend the boom to maximum extension, then retract
51 mm to 76 mm (2 to 3 in). Shut machine off.
MAE35060
5
The boom is properly adjusted whenever the following
parameters are met.
A. 210 mm -230 mm (8.3 - 9.0 in)
B. 145mm -165 mm (5.71 - 6.50 in)
C. 45 mm (1.77 in) (No Adjustment)
If adjustments are needed: Start the machine, level the
boom and extend the boom 0,91 mm - 1,2 mm (3 ft - 4 ft).
Turn OFF engine.
MZ7990
6
9. Measure the distance (5) between the top of extend
chain and the top of the third boom section.
10. Measure the distance (6) between the top of both
extend chains and the bottom of the second boom
section.

3614RS, 4017RS 31211337 3-33

 Boom

11. The distance between the extend chains and the each Following are some examples of dynamic shock loading
boom section should measure which can impose abnormal loads above the endurance limit
140 mm - 145 mm (5,5 in - 5,7 in). of a leaf chain.
12. Loosen the locknuts on the extend chains and adjust if • High velocity movement of load, followed by
necessary. Tighten locknuts to 120 Nm (86 lb-ft). sudden, abrupt stops.
13. Start the machine and cycle the extend/retract cylinder • Carrying loads in suspension over irregular surfaces
to verify the boom extends and retracts properly. such as railroad tracks, potholes, and rough terrain.
• Attempting to “inch” loads which are beyond the
3.15 BOOM EXTEND AND RETRACT rated capacity of the vehicle.
CHAINS - 3614RS & 4017RS The above load cycles and environmental conditions make it
impossible to predict chain life. It is therefore necessary to
3.15.1 Boom Chain Inspection conduct frequent inspections until replacement life can be
predicted.
The boom chain’s normal life expectancy can be expressed
WARNING as a maximum percent of elongation. This is generally 3%.
As the chain flexes back and forth over the sheave, the
Worn pins, stretched or cracked links or corrosive bearing joints (pins and inside link plates) gradually incur
environments can cause chain failure. A chain failure wear due to articulation.
could result in uncontrolled boom movement, loss of
load or machine instability. 3.15.2 Inspection Guidelines - 3614RS
Under normal operating conditions the boom chains will
a. Retract Chain
need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every 1. Park the machine on a firm, level surface, raise the boom
1000 hours of operation. Refer to the Service Manual for the to a horizontal (level) position, place the transmission in
proper procedure. Environmental conditions and dynamic (N) NEUTRAL, engage the park brake switch.
impulse/shock loads can drastically affect normal operating
conditions and require more frequent inspection intervals. 2. Fully extend the boom until the retract chain is taut.
Shut the engine off.
Environments in which material handling vehicles operate
can vary widely from outdoor moisture to temperature to 3. The retract chain will be visible for inspection with the
mildly corrosive or highly corrosive industrial atmospheres, vehicle in this state.
in addition to abrasive exposures such as sand and grit. 4. While doing the chain inspection, check all chain clevis
Some effects can be as follows: ends, pins for distortion or cracking and sheaves for
• Moisture - Corrosive rusting reduces chain strength bearing wear or grooving from the chain.
by pitting and cracking.
• Temperature - Low temperature reduces chain b. Extend Chains
strength by embrittlement. Going in and out of 1. Park the machine on a firm, level surface, raise the boom
cold storage results in moisture from condensation. to a horizontal (level) position, place the transmission in
• Chemical Solutions or Vapors - Corrosive attack on (N) NEUTRAL, engage the park brake switch.
the chain components and/or the mechanical 2. Fully retract the boom. Shut the engine off.
connections between the chain components.
Cracking can be (and often is) microscopic. Going 3. Both extend chain clevises and pins will be visible for
from microscopic cracking to complete failure can inspection with the vehicle in this state.
be either abrupt or may require an extended period 4. Limited visual inspection of the extend chains is
of time. possible. For complete extend chain inspection, the
• Abrasives - Accelerated wearing and scoring of the extend chains must be removed from the boom. For
articulating members of the chain (pins and plates), extend chain removal, refer to Section 3.4.3, “Extend
with a corresponding reduction in chain strength. Chain Removal” and Section 3.4.4, “Extend Chain
Due to the inaccessibility of the bearing surfaces Installation”.
(pin surfaces and plate apertures), wear and scoring
are not readily noticeable to the naked eye. 5. Inspect the extend and retract chains every 250 hours of
operation.

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 Boom

6. Inspect the chains for the following conditions: 3.15.3 Inspection Guidelines - 4017RS
Edge Wear 1. Park the machine on a firm, level surface, raise the boom
to a horizontal (level) position, place the transmission in
(N) NEUTRAL, engage the park brake switch.
2. Fully extend the boom until the extend chain is taut.
1 2 Shut the engine off.
3. The extend chains will be visible for inspection with the
vehicle in this state.

MZ1463
4. While doing the chain inspection, check all chain clevis
ends for distortion or cracking and sheaves for bearing
Check the chain for wear on the link plate edges caused wear or grooving from the chain.
by running back and forth over the sheave. The
maximum reduction of material should not exceed 5%. 5. Inspect the retract chains every 1000 hours of
Measure and compare to a normal link plate height by operation. Refer to the Service Manual for proper
measuring a portion of chain that does not run over the procedure.
sheave. If the measured plate height (1) is 5% less than 6. Inspect the chains for the following conditions:
the normal plate height (2), discard and replace the
chain. Edge Wear
Elongation Check the chain for wear on the link plate edges caused
by running back and forth over the sheave. The
It is important to measure the chain in the section that maximum reduction of material should not exceed 5%.
moves over the sheaves because it receives the most This can be compared to a normal link plate height by
frequent articulation. Measuring the chain near its clevis measuring a portion of chain that does not run over the
terminals could give an inaccurate reading. The ends of sheave.
the chains, near the clevis terminal, will not have flexed
as frequently, if at all, as the middle of the chains. a. Extend Chains (fourth to third section)
It is best to measure in 12 pin increments from pin
The extend chains between the fourth and third boom
center to pin center. For example, if the links are
sections measures 18 mm (0.713 in) (1). If the
25 mm (1 in) from pin center to pin center, the distance
measurement of the worn chain is less than
should be 305 mm (12 in). If the links are 19 mm (0.75 in)
17 mm (0.677 in) (2), the chain should be replaced.
apart, the distance after 12 pins should be
229 mm (9 in).
b. Extend Chains (third to second section)
4
3

2 1

MZ1463

The extend chains between the third and second boom

sections measures 29,6 mm (1.2 in) (1). If the
measurement of the worn chain is less than
28,6 mm (1.1 in) (2), the chain should be replaced.
MY1360

If the distance measured (3) is 3% greater than the

normal length (4), discard and replace the chain.

3614RS, 4017RS 31211337 3-35

 Boom

Elongation Distorted or Battered Link Plates

It is important to measure the chain in the section that
moves over the sheaves because it receives the most 85
frequent articulation. Measuring the chain near its clevis
terminals could give an inaccurate reading. The ends of
the chains, near the clevis terminal, will not have flexed
as frequently, if at all, as nearer the middle of the chains.

a. Extend Chains (fourth to third section)

MZ1466
4
3
Distorted or battered link plates (5) on a leaf chain can cause
tight joints and prevent flexing.
Turning or Protruding Pins
Highly loaded chain, operating with inadequate
lubrication can generate abnormal frictional forces
between pin and link plates. When chain is allowed to
operate in this condition, a pin or series of pins, can
begin to twist out of a chain, resulting in failure.

7
MY1360
6
When the original length (3) of 305 mm (12.00 in) per 8
foot of extend chain between the fourth and third
MZ1465
boom sections has elongated from wear to a length (4)
of 313 mm (12.36 in), the chain should be discarded and
replaced. Examine the pin head rivets to determine if the “VEE”
flats are still in correct alignment (6). Chain with
Measure across a span of 16 pins at the center of the rotated/displaced heads (7) or abnormal pin
extend chain. Measure from pin center to pin center. protrusion (8) should be replaced immediately.
Because the retract chain is inside the boom you will not
be able to measure the chain. DO NOT attempt to repair the chain by welding or
driving the pin(s) back into the chain. Once the press fit
The maximum measurement allowed is 313 mm(12.36 integrity between outside plates and pins has been
in). If the measurement is more than 313 mm (12.36 in), altered, it cannot be restored.
the chain should be replaced.
Any wear pattern on the pin heads or the sides of the
link plates indicates misalignment in the system. This
b. Extend Chains (third to second section)
condition damages the chain as well as increases
When the original length (3) of 317 mm (12.5 in) per frictional loading and should be corrected.
foot of extend chain between the third and second
boom sections has elongated from wear to a length (4)
of 325 mm (12.8 in), the chain should be discarded and
replaced.
Measure across a span of 10 pins at the center of the
extend chain. Measure from pin center to pin center.
Because the retract chain is inside the boom you will not
be able to measure the chain.
The maximum measurement allowed is
325 mm(12.8 in). If the measurement is more than
325 mm (12.8 in), the chain should be replaced.

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 Boom

Cracked Plates 3.15.4 Expose Chains for Inspection

Inspect the chains very carefully, front and back as well
as side to side, for any evidence of cracked plates. If any c. Retract Chain
one crack is discovered, the chain should be replaced in 1. Park the machine on a firm, level surface. Place the
its entirety. transmission in (N) NEUTRAL, engage the park brake
It is important, however to determine the cause of the switch and raise the boom to a horizontal (level)
crack before installing a new chain so the condition position.
does not repeat itself. 2. Fully extend the boom until the retract chain is taut.
The types of cracks are: Shut the engine OFF.
• Fatigue Cracking - The retract chain will be visible for inspection with the
Fatigue cracks (1) are a machine in this state.
1
result of repeated cyclic While doing the chain inspection, check all chain clevis ends
loading beyond the MZ1467 for distortion or cracking and sheaves for bearing wear or
chain’s endurance limit.
grooving from the chain.
• Stress Corrosion If during the inspection, if any chain is found to be damaged
Cracking - The outside
or stretched, the chain must be replaced. It is recommended
link plates are
particularly 2 MZ1468
that when any chain is replaced, that all the chains and
susceptible to stress clevises be replaced at the same time.
corrosion cracking (2).
d. Extend Chains
• Corrosion Fatigue Cracking - Corrosion fatigue
cracks are very similar to fatigue cracks in The extend chains are only partially visible through the rear
appearance. Corrosion fatigue is the combined of the boom with all the sections retracted. It is possible to
action of an aggressive environment and cyclic see a section of the extend chain as the boom is slowly
stress. extended. If there is ANY question that one or both extend
Other Modes of Failure chains are damaged, the extend chains should be removed,
inspected and replaced if necessary.
• Ultimate Strength Failure -
These types of failures are Refer to Section 3.15, “Boom Extend and Retract Chains -
caused by overloads far in 3 3614RS & 4017RS”.
excess of the design load. MZ1469
Note: DO NOT attempt to repair a chain. Replace a stretched
Either fractured plates (3) or 4 or damaged chain with a new part. Always replace both the
enlarged holes (4) can occur. If
either of these failures occurs, chain and the clevis. It is recommended that when any chain is
the chain should be replaced MZ1470 replaced, that all chains and clevis’ be replaced at the same
immediately. time.
• Tight Joints -
All joints in
the chain
should flex
freely. Tight
joints (5) 5 MZ1471
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or bent
pins, replace the chain.

3614RS, 4017RS 31211337 3-37

 Boom

3.15.5 Chain Lubrication 3.16 BOOM WEAR PADS

After inspection and before being returned to service,
chains must be lubricated with Multipurpose Grease-NLGI The boom wear pads are flat rectangular plastic blocks with
Grade 2. metal inserts.

The lubricant must penetrate the chain joint to prevent 3.16.1 Wear Pad Inspection
wear. Applying lubricant to the external surfaces will
prevent rust, but the chains should be articulated to make 1
sure the lubricant penetrates to the working surfaces
between the pins and links.
To prepare the chain for lubrication, the chain plates should
be brushed with a stiff brush or wire brush to clear the space
between the plates so that lubricant can penetrate to the
working surfaces.
Lubricant may be applied with a narrow paint brush or 1
directly poured on, but the chain should be well flooded
MAE2120
with lubricant and the boom should be extended and
retracted to be sure that the lubricant penetrates to the Inspect all wear pads for wear. If the angle indicators (1) on
working surfaces. All surplus lubricant should be wiped the ends of the wear pads are visible, the wear pads can be
away from the external surfaces. DO NOT use a solvent for reused. If the pads show uneven wear (front to back), they
this wiping operation.
should be replaced. Replace pads as a set if worn or
Regular application of lubricant is necessary to make sure damaged.
that all working surfaces are adequately lubricated. In
extremely dusty conditions, it may be necessary to lubricate 3.16.2 Boom Wear Pad Installation/Lubrication
the chains more often. Refer to Section 2.4, “Service and
Maintenance Schedules” and Section 2.5, “Lubrication The boom has been factory lubricated for proper wear pad
Schedule” for detailed information. break-in and will normally require minor further lubrication.
However, after replacing any wear pad(s), or after prolonged
Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special periods of inoperation, lubrication of the boom wear surfaces
consideration. Contact the JLG dealer for guidance. with Multipurpose Grease is recommended to keep the
boom wear surfaces lubricated properly. Lubrication of the
boom wear surfaces is also recommended when the
machine is stored, to help prevent rusting.
The following wear pad procedure must be followed to
insure the proper wear pad installation:
• The wear pad inserts and mounting bolts MUST be
clean before mounting bolts are installed.
• Apply medium strength threadlocking compound to all
wear pad mounting bolts.

MAM1390

• A spacer (2) with holes must be used before any

3-38 31211337 3614RS, 4017RS

 Boom

shim (3) is used. Boom Section Wear Pad Pathway Lubrication:

• A shim (3) must inserted between the spacer (2) and • Clean and lightly grease all wear pad pathways with
wear pad support plate, block or boom section (4). Multipurpose Grease.
• The number of shims can vary at each shim point. • Clean and lightly grease the hose carrier guide bar
• The bottom wear pads must be shimmed equally on pathway with Multipurpose Grease.
each side.
3.17 QUICK COUPLER
Note: The following procedures covers all styles of quick
couplers.

3.17.1 Quick Coupler Removal

1. Lower attachment to ground, tilt forward to access
coupler pin, set park brake and turn off engine.
2. If equipped with a hydraulic quick coupler device, refer
to Operation & Safety Manual.
5

MZ7660

• Maintain a total boom section clearance of

0,5 - 1,5mm (0.020 - 0.060 in) between the wear pad and
the next boom section (5).
A

3
B
3 4

MY3620

• The length of the wear pad bolt depends on the MZ7690

number of shims, spacers and washers being used. 1 2
• The thickness of each threaded wear pad insert is 3. Remove the bolts and lock bracket (1) holding the rod
10 mm (0.393 in) (A). end tilt cylinder pin to the quick coupler assembly.
• The bolt length should be determined by measuring Remove the rod end pin (2).
the distance from the face of the insert to the face of the
boom (B) including any spacer, shim(s) and washer(s). 4. Support the quick coupler assembly. Remove the
bolts (3) and pin (4) from the quick coupler assembly.
• Bolt thread engagement in the wear pad insert should
not extend. 5. Inspect the above pins for nicks or surface corrosion.
• One or two hardened washers are to be used on each Use fine emery cloth to fix minor nicks or corrosion. If
wear pad bolt except where noted otherwise. damaged or if it cannot be repaired the pin must be
DO NOT use more than two hardened washers. replaced.
• Use only one hardened washer if mounting bolts are
recessed.
• Wear Pad Bolt Torque:
M12 x 20, 95 - 105 Nm - M12 x 25, 95 - 105 Nm
M12 x 30, 95 - 105 Nm - M12 x 35, 95 - 105 Nm
M12 x 40, 95 - 105 Nm - M12 x 80, 95 - 105 Nm
• Lubricate the face and pockets of each wear pad after
being installed.

3614RS, 4017RS 31211337 3-39

 Boom

3.17.2 Quick Coupler Installation 2. Angle (7) between upper face of blade and front face of
shank should not exceed 93 degrees.
1. Apply medium strength threadlocking compound to all
mounting bolts. 3. Thickness of blade (5) and shank (6) should not be
reduced to 90 percent of original thickness.
2. Assemble the quick coupler to the boom head. Line up
the quick coupler between the mounts on the boom Note: Contact the local JLG dealer with the fork part number to
head. The quick coupler should be centered in the find the manufactured dimensions of the fork blade.
boom head.
4. Ensure fork length (8) is adequate for intended loads.
3. Coat the quick coupler pivot pin with Anti-Seize Lube.
5. Fork markings should be legible, re-stamp if required.
Insert the quick coupler pivot pin (4) through the quick
coupler and boom head. Secure with the previously 6. Compare fork tips (9) when mounted on a carriage.
removed bolts (3). Maximum difference in height of fork tips is 3 percent of
the length of the blade (8).
4. Align the quick coupler with the rod end tilt cylinder
and insert the coupler pin (2) and replace the lock
bracket and bolt assembly (1). 3.19 BOOM PROP (IF EQUIPPED)
5. If equipped, reconnect the hydraulic attachment hoses
to the quick disconnect fittings on the left side of the
boom head. WARNING
A raised boom can fall if a hydraulic component is
3.18 FORKS removed. Remove any load, retract the boom and install
the boom prop or a suitable supporting stand before
Forks should be cleaned and inspected prior to being working under a raised boom.
attached to carriage. If the following criteria is not met, forks
must be removed from service immediately. 3.19.1 Installation and Removal Procedures

3 a. Prop Installation

6 1. Park the machine on a firm, level surface. Place the

transmission in (N) NEUTRAL, engage the park brake
7 5 switch.
4
2. Raise the boom to an angle of approximately
2 20 degrees. Stop engine.
1 3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
6

5 9

8 MH6460

Daily Inspection
1. Inspect forks (1) for cracks, paying special attention to
heel (2) and mounting tubes (3).
2. Inspect forks for broken or bent tips (4) and twisted
blades (5) and shanks (6).
Yearly Inspection
1. Straightness of the upper face of blade (5) and the front
face of shank (6) should not exceed 0.5 percent of the
length of blade or height of shank.

3-40 31211337 3614RS, 4017RS

 Boom

4. Before installing the boom prop, inspect the prop for 3.20 EMERGENCY BOOM LOWERING
damage. DO NOT use if the prop is damaged or if the PROCEDURE
locking pins are damaged or missing.

WARNING
To avoid instability of the machine, the extend/retract
cylinder MUST BE fully retracted prior to retracting the
lift cylinder. If circumstances prevent retraction of the
extend/retract cylinder first, lower the lift cylinder the
minimum amount necessary and resume retraction of the
extend/retract cylinder as soon as possible.

3
3.20.1 Equipment and Supplies Required
Auxiliary Hydraulic Power Supply:
• Portable hydraulic unit or another machine with an
auxiliary hydraulic power supply with a capacity to
2 hold up to 35 L (9 gal) of hydraulic oil from the
1 machine during lowering process.

2
NOTICE
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power Supply
hydraulic oil must be compatible with hydraulic oil shown
MAM4080
in Section 2.3.2, “Fluids (if equipped for LS)”.
5. Align lift cylinder prop (1) so the locking pins (2) are on Hoses:
the bottom side of the lift/lower cylinder rod (3). Install
the boom prop (1) onto the lift/lower • Two Hydraulic Hoses - Approximately 3,0 m
cylinder (1). Install locking pins (2). (10 ft) each, with a minimum I.D. of
9,5 mm (0.375 in) and a minimum rating of
6. Start the engine and SLOWLY lower the boom until 275,8 bar (4000 psi).
there is a clearance of 6 mm (0.25 in) between the end
of the boom prop and the lift/lower cylinder rod Fittings:
end (3). • Two -8 EO Caps
• Two -8 EO Plugs
NOTICE Adaptors:
EQUIPMENT DAMAGE. DO NOT operate with the boom • Two -8 EO Adaptors
prop in place. Damage to the boom prop and/or the Note: Machine extend/retract and lift/lower hoses are -8 ORFS.
lift/lower cylinder could occur. The adaptor size may vary depending on the hose ends of the
auxiliary hydraulic power supply.
7. Shut OFF engine.

b. Prop Removal
1. If needed, start machine and slowly raise the boom until
the boom prop is clear of the lift/lower rod end.
2. Remove the locking pins (2) and boom prop (1) from
the lift cylinder. Return the boom prop to the proper
location and secure.
3. Lower boom, shut engine OFF.

3614RS, 4017RS 31211337 3-41

 Boom

3.20.2 Lowering Procedure 7. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil”. Dispose
a. Retract the boom as follows: of used oil at an approved recycling facility.
1. Remove the cover at the rear corner of the cab. 8. Clean up all debris, hydraulic fluid, etc., in, on, near and
around the machine.
2. Place a suitable receptacle under the main control valve.
b. Lower the boom as follows:
1. Place a suitable receptacle under the main control valve.
2. Label and disconnect the lift/lower cylinder
hoses (3 and 4) from the main control valve. Install
plugs in hoses to prevent fluid loss. Cap all fittings and
openings to keep dirt and debris from entering the
4 hydraulic system.

2 Note: Loss of hydraulic oil is limited to the amount trapped

within each hose.
3. Using the hoses and fittings specified, connect the
hoses between the auxiliary hydraulic power supply
and the hoses removed from the main control valve
lift/lower section of the affected machine. Hose (4) is
the supply (lower) and hose (3) is the return. Connect
the hoses in the proper order to ensure that the boom is
1 lowered, not raised.
3 4. Use the auxiliary power supply to lower the boom.
5. Loosen and remove the jumper hoses and reconnect
the lift/lower cylinder hoses.
6. Transfer any hydraulic oil into a suitable, covered
MZ7710 container, and label the container as “Used Oil”. Dispose
VIEW FROM REAR OF CAB
of used oil at an approved recycling facility.
3. Label and disconnect the extend/retract cylinder 7. Clean up all debris, hydraulic fluid, etc., in, on, near and
hoses (1 and 2) from the main control valve. Install around the machine.
plugs in hoses to prevent fluid loss. Cap all fittings and 8. Install the previously removed rear cover.
openings to keep dirt and debris from entering the
hydraulic system.
Note: Loss of hydraulic oil is limited to the amount trapped
within each hose.
4. Using the hoses and fittings specified, connect the
hoses between the auxiliary hydraulic power supply
and the hoses removed from the main control valve
extend/retract section of the affected machine. Retract
hose (2) is the supply and extend hose (1) is the return.
Connect the hoses in the proper order to ensure that
the cylinder is retracted, not extended.
5. Use the auxiliary power supply to retract the
extend/retract cylinder.
6. Loosen and remove the jumper hoses and reconnect
the extend/retract cylinder hoses.

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 Boom

3.21 TROUBLESHOOTING
This section provides an easy reference guide covering the
most common problems that occur during operation of the
boom.

Problem Possible Causes Remedy

1. Boom will not extend or retract 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s) or
tube(s) and/or connections tube(s), tighten connections.
leaking.

2. Extend/retract hydraulic system 2. Refer to Section 8.5, “Hydraulic

not operating properly. Circuits”.

3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to

Section 8.10.1, “General Cylinder
Removal Instructions”.

2. Boom shifts to right or left when 1. Boom side wear pads improperly 1. Shim wear pads to correct gap.
extending. shimmed or worn. Replace wear pads as needed.
Refer to Section 3.16, “Boom Wear
Pads”.

3. Excessive pivot pin noise and/or 1. Insufficient lubrication. 1. Lubricate at regular intervals.
wear. Refer to Section 2.5, “Lubrication
Schedule”. Replace worn pins as
needed.

2. Worn bearing(s). 2. Replace bearing(s) and lubricate

at regular intervals. Refer to
Section 2.5, “Lubrication
Schedule”.

4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/or Refer to Section 2.5, “Lubrication
wear. Schedule”. Replace worn pins as
needed.

2. Worn bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals.

5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s) or
and/or connection leaks. tube(s), tighten connections.

2. Lift/lower hydraulic system not 2. Refer to Section 8.5, “Hydraulic

operating properly. Circuits”.

3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

8.10.1, “General Cylinder Removal
Instructions”.

4. Seized boom pivot pin bushing. 4. Replace bushing.

3614RS, 4017RS 31211337 3-43

 Boom

Problem Possible Causes Remedy

6. Drooping chain, or jerky boom 1. Chain(s) tension not properly 1. Adjust chain(s).
extend or retract functions. adjusted.

2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to

Section 3.7, “Boom Sections
Adjustment - 3614RS”.

3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to Section

excessively worn or damaged. 3.16, “Boom Wear Pads”.

4. Contaminated, corroded or rusted 4. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).

5. Extend/Retract hydraulic system 5. Refer to Section 8.5, “Hydraulic

not operating properly. Circuits”.

6. Damaged boom section. 6. Replace the damaged boom

section.

7. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

pivot pin noise and/or wear. Refer to Section 2.4, “Service and
Maintenance Schedules”. Replace
worn pins as needed. Refer to
Section 8.10.1, “General Cylinder
Removal Instructions”.

2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals. Refer to
Section 2.5, “Lubrication
Schedule”.

8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct
as needed. Refer to Section 3.16,
“Boom Wear Pads”.

2. Rapid cycle times with heavy 2. Reduce cycle times.

loads.

3. Contaminated, corroded or rusted 3. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).

4. Operating in extremely dusty/ 4. Clean equipment frequently.

abrasive conditions.

9. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.5, “Hydraulic
operate. operating properly. Circuits”.

3-44 31211337 3614RS, 4017RS

 Boom

Problem Possible Causes Remedy

10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer to
Section 3.15, “Boom Extend and
Retract Chains - 3614RS &
4017RS”- Replace chains as
needed.

2. Chain sheave(s) not properly 2. Lubricate chain sheave. Refer to

lubricated. Section 2.4, “Service and
Maintenance Schedules”.

3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer to

freely. Section 2.4, “Service and
Maintenance Schedules”. Repair
or replace chain sheave(s) as
needed.

4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.4, “Service and
Maintenance Schedules”. Replace
chains as needed.

3614RS, 4017RS 31211337 3-45

 Boom

3-46 31211337 3614RS, 4017RS

 Section 4
Cab

Contents

PARAGRAPH TITLE PAGE

4.1 Operator Cab Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Operator Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Serial Number Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Steering Column/Orbital Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.3 Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 Electronic Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.5 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.6 Window Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.7 Heater System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.8 Heater and Air Conditioning System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

3614RS, 4017RS 31211337 4-1

 Cab

4.1 OPERATOR CAB COMPONENT

TERMINOLOGY
To understand safety, operation and maintenance
information presented in this section, it is necessary that the
operator/mechanic be familiar with names and locations of
major assemblies of machine cab. The following illustration
identifies components that are referred to throughout this
section.
LSI
INDICATOR

FRAME LEVEL
INDICATOR

INSTRUMENT
CLUSTER ACCESSORY
CONTROL
STEERING LEVER
STEERING IGNITION
WHEEL
COLUMN SWITCH
TRANSMISSION ADJUSTER
CONTROL LEVER
(IF EQUIPPED) CONSOLE
SWITCHES
CAPACITY
CHART JOYSTICK
CLIMATE
CONTROLS

CONSOLE
SWITCHES

FRAME LEVEL
SWITCH

ACCELERATOR
PEDAL

SERVICE BRAKE
PEDAL

12 VOLT POWER
HYDRAULIC PARK OUTLET
BRAKE LEVER
(4017RS)
MECHANICAL
PARK BRAKE LEVER
MAE34850
(3614RS)

4-2 31211337 3614RS, 4017RS

 Cab

4.2 OPERATOR CAB 4.3 CAB COMPONENTS

4.3.1 Steering Wheel

WARNING
a. Steering Wheel Removal
DO NOT service the machine without following all safety
precautions as outlined in Section 1, “Safety Practices”, of 1. Park machine on a firm, level surface, level machine fully
this manual. retract boom, lower boom, place transmission in (N)
NEUTRAL, engage park brake and shut engine OFF.
4.2.1 Operator Cab Safety 2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.

WARNING 3. Open engine covers. Allow system fluids to cool.

4. Properly disconnect battery. Refer Section 9.8, “Battery”,
The protection offered by this ROPS/FOPS will be for procedure.
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using fasteners of 1
correct size, grade, and torqued to their specified value.

WARNING 2
DO NOT weld, grind, drill, repair or modify the cab in any
way. Any modification or damage to cab structural
components requires cab replacement.
Refer to the appropriate parts manual for ordering 3
information.

4.2.2 Serial Number Plate

The cab serial number plate is located on the left side of the MAE8790
cab, below the seat. Information specified on the serial
number plate includes the cab model number, the cab serial 5. Remove steering insert (1) out of steering wheel (2).
number and other data. Write this information down in a 6. Mark steering wheel (2) and shaft to ensure proper
convenient location to use in cab correspondence. installation. Remove nut and washer (3) securing the
steering wheel (2) to splined steering column shaft.
7. Use a steering wheel puller to remove steering wheel (2)
from splined shaft.

b. Steering Wheel Installation

1. Install steering wheel (2) onto splined steering column
shaft.
2. Secure steering wheel with previously removed nut and
washer (3). Torque as required.
3. Install steering insert (1) on the steering wheel (2).
4. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
5. Close and secure engine covers.
6. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

3614RS, 4017RS 31211337 4-3

 Cab

4.3.2 Steering Column/Orbital Valve

a. Steering Column and Orbital Valve Removal

1. Park machine on a firm, level surface, level machine fully
retract boom, lower boom, place transmission in (N)
NEUTRAL, engage park brake and shut engine OFF. 7
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
3. Open engine cover. Allow system fluids to cool. 8
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
2
5. Remove lower dash panel in cab.
6
10

9 MAM3930

7. Label, disconnect and cap hydraulic hoses attached to

orbital valve (6).
4
8. Remove steering wheel (2). Refer to Section 4.3.1,
“Steering Wheel”.
9. Disconnect and remove the accessory control lever (7),
and if equipped, transmission control lever (8).
Disconnect control lever(s) harness from the main cab
5 harness.
10. Have an assistant hold the orbital valve (6) from outside
of cab. Remove bolts and washers (9) securing orbital
valve (6) to cab.
11. Remove the steering column (10) through the dash
panel opening.
MZ7771 Note: DO NOT disassemble orbital valve (6). The orbital
valve (6) is not serviceable and must be replaced fully, if
6. Remove access covers (4 and 5) from front of cab.
defective.

b. Steering Column and Orbital Valve Installation

1. Install steering column (10) to original orientation in
cab.
2. Have an assistant hold orbital valve (6) in original
orientation from outside cab. Install steering
column (10) to orbital valve (6) with previously removed
hardware. Torque as required.
3. Install accessory control lever (7) and if equipped,
transmission control lever (8). Connect control lever(s)
harness connector to main cab harness and install steering
wheel assembly. Refer to Section 4.3.1, “Steering Wheel”.
4. Uncap and connect previously labeled hydraulic hoses
to orbital valve (6).

4-4 31211337 3614RS, 4017RS

 Cab

5. Carefully examine all connections one last time before 4.3.4 Electronic Throttle Pedal
engine start-up. Rectify any faulty conditions.
6. Properly connect battery. Refer Section 9.8, “Battery”, a. Throttle Pedal Removal
for procedure. 1. Park machine on a firm, level surface, level machine fully
7. Start engine and check operation of steering system. retract boom, lower boom, place transmission in (N)
Check for hydraulic fluid leaks. Check hydraulic fluid NEUTRAL, engage park brake and shut engine OFF.
level in tank and add fluid as required. 2. Place a Do Not Operate Tag on both ignition key switch
8. Install access covers (4 and 5) to front of cab. and steering wheel.
9. Install lower dash panel in cab. 3. Open engine covers. Allow system fluids to cool.
10. Close and secure engine cover. 4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
11. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

c. Steering Test
Conduct a pressure check of the steering hydraulic circuits at
the main control valve. Refer to Section 8.4.1, “Pressure
Checks and Adjustments”. 4

4.3.3 Service Brake

a. Brake Valve Removal

Refer to Section 8.9.2, “Service Brake Valve”, for removal 5
information.

b. Brake Valve Installation

Refer to Section 8.9.2, “Service Brake Valve”, for installation
information.

MZ7771

5. Remove access covers (4 and 5) from front of cab.

11

MZ7790

6. Remove hardware (11) securing pedal assembly.

3614RS, 4017RS 31211337 4-5

 Cab

4.3.5 Joystick Assembly

a. Joystick Assembly Removal

1. Park machine on a firm, level surface, level machine fully
12 retract boom, lower boom, place transmission in (N)
NEUTRAL, engage park brake and shut engine OFF.
13
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.

MD0590

7. Disconnect electrical connection (12) to pedal

assembly (13).
8. Remove throttle pedal assembly (13) from cab.
15
b. Throttle Pedal Installation
1. Position throttle pedal (13) in its mounting location in
14
cab.
2. Reconnect electrical connection (12) to pedal
assembly (13).
3. Secure throttle pedal (13) into position with previously
used hardware (11).
4. Install access covers (4 and 5) to front of cab.
5. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
6. Close and secure engine cover.
7. Remove Do Not Operate Tag from ignition key switch
and the steering wheel.
16

MAE3930

5. Raise rubber boot (14) from base of joystick.

6. Remove hardware (15) securing joystick assembly.
7. Lift joystick from its mounting position.
8. Label and disconnect electrical connector (16) attached
to joystick.
9. Remove joystick assembly.

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 Cab

b. Joystick Assembly Installation

1. Connect previously labeled electrical connector (16)
to joystick.
2. Secure joystick assembly to cab using previously
removed hardware (15). Torque to 2 - 2.5 Nm
16
(1.5 - 1.8 lb-ft).
3. Seat rubber boot (14) to joystick base.
4. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
5. Test joystick functions.
6. Close and secure engine cover. MZ7850

7. Remove Do Not Operate Tag from ignition key switch

and steering wheel. 9. Remove heater cover (16) inside cab.

4.3.6 Window Wiper Assembly

Refer to Section 9.9, “Wiper/Washer Wiper Motor”, for
removal and installation information.
4
4.3.7 Heater System (if equipped)

a. Heater Assembly Removal

1. Park machine on a firm, level surface, level machine fully
retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF. 5
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
3. Open engine covers. Allow system fluids to cool.
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
5. Place a suitable container beneath radiator. Slowly turn MZ7771
surge tank cap and allow any pressure to escape. 10. If equipped, remove windshield wiper assembly.
Remove surge tank cap.
11. Remove access covers (4 and 5) from front of cab.
6. Place a funnel at base of radiator to channel drained
coolant into container. Remove drain plug and allow
coolant to drain.
7. Transfer coolant to a container with a cover, and label as
“Used Coolant”. Dispose of used coolant at an approved
recycling facility.
8. Tighten radiator drain plug.

3614RS, 4017RS 31211337 4-7

 Cab

b. Heater Assembly Installation

1. Position heater assembly to original orientation to cab.
Secure with previously removed hardware (18).
2. Connect previously labeled electrical connections.
18 3. Connect previously labeled heater hoses to appropriate
locations.
4. Fill cooling system completely with coolant, allowing
17 time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluids and
18
Lubricant Capacities”.
5. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
6. Start engine, run it briefly at low idle and check machine
MAE45040 for any visual sign of fluid leakage.
Note: STOP engine immediately if any leakage is noted, and
12. Label and disconnect electrical connections of
make any necessary repairs before continuing.
heater (17).
13. Remove hardware (18) securing heater assembly to cab. 7. Wait for engine to cool and check coolant level. Add
Remove heater assembly. coolant as required to bring coolant to proper level.
8. Install access covers (4 and 5) to front of cab.
9. Install heater cover (16) inside cab.
10. Close and secure the engine cover.
11. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

19

17

MAE3981
19
14. Label and remove heater hoses (19) connected to the
heater assembly (17).

4-8 31211337 3614RS, 4017RS

 Cab

4.3.8 Heater and Air Conditioning System

(if equipped)

a. Heater and Air Conditioning System Removal

1. Park machine on a firm, level surface, level machine fully
retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF. 4
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
3. Open engine covers. Allow system fluids to cool.
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure. 5
5. Place a suitable container beneath radiator. Slowly turn
surge tank cap and allow any pressure to escape.
Remove surge tank cap.
6. Place a funnel at base of radiator to channel drained
coolant into container. Remove drain plug and allow
coolant to drain.
MZ7771
7. Transfer coolant to a container with a cover, and label as
11. If equipped, remove windshield wiper assembly.
“Used Coolant”. Dispose of used coolant at an approved
recycling facility. 12. Remove access covers (4 and 5) from front of cab.
8. Tighten radiator drain plug. 13. If equipped, install windshield wiper assembly.
9. Drain the refrigerant from the air conditioning system.
21
Note: The local JLG dealer or certified air conditioning service
20
center or personnel to perform the refrigerant removal from the
system.

19
16

17

MZ7850 23
22
10. Remove heater cover (16) inside cab. 19 MAE3151

14. Label and disconnect hoses (20) attached to the

condenser assembly (21).
15. Label and disconnect all electrical connections attached
to the condenser assembly.
16. Remove bolts securing the condenser assembly (21) to
cab roof. Remove condenser assembly from rear of the
cab roof.

3614RS, 4017RS 31211337 4-9

 Cab

17. Label and disconnect all electrical connections attached Note: STOP engine immediately if any leakage is noted, and
to the heater assembly (17). make any necessary repairs before continuing.
18. Label and remove heater hoses (19) connected to the 14. Wait for engine to cool and check coolant level. Add
heater assembly (17). coolant as required to bring coolant to proper level.
19. Label and disconnect air conditioning hoses (22) 15. Install access covers (4 and 5) to front of cab.
attached to heater assembly (17).
16. If equipped, install windshield wiper assembly.
20. Remove hardware securing heater assembly (17) to cab.
17. Install heater cover (16) inside cab.
Remove heater assembly (17).
18. Close and secure the engine cover.
21. Label and disconnect air conditioning hoses attached to
compressor (23). 19. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
22. Remove hardware securing compressor to engine.
Remove compressor (23).

b. Heater and Air Conditioning Installation

1. Install cab condenser assembly (21) to cab roof. Secure
with previously removed hardware.
2. Connect previously labeled electrical connections to
the condenser assembly (21).
3. Connect previously labeled hoses (20) to condenser
assembly (21).
4. Position heater assembly (17) to original orientation to
cab. Secure with previously removed hardware.
5. Connect previously labeled electrical connections to
heater assembly (17).
6. Connect previously labeled heater hoses (19) to
appropriate locations.
7. Connect previously labeled air conditioning hoses (22)
to appropriate locations.
8. Connect previously labeled air conditioning hoses
attached to compressor (23).
9. Install compressor (23) to engine.
10. Fill cooling system completely with coolant, allowing
time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluids and
Lubricant Capacities”.
11. Fill air conditioning system completely with refrigerant.
Refer Section 2.3, “Fluids and Lubricant Capacities”, for
refrigerant type and capacity.
Note: The local JLG dealer or certified air conditioning service
center or personnel to perform the refrigerant installation to
the system.
12. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
13. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage.

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 Cab

4.4 CAB REMOVAL .

WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural 1
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using fasteners of
correct size and grade, and torqued to their specified
value.

Note: To help ensure safety and optimum performance,

replace cab if it is damaged. Refer to appropriate parts manual 2
for ordering information.
Inspect cab, its welds and mounts. If modification, damage, a
cracked weld and/or fatigued metal is discovered, replace
cab. Contact local JLG dealer with any questions about
suitability or condition of a cab.
Note: Remove and label cab components as needed before MZ7771
removing cab from machine. Label, disconnect and cap 8. If equipped, remove windshield wiper assembly.
hydraulic hoses. Transfer cab parts to replacement cab after
replacement cab is securely mounted on machine. 9. Remove access covers (1 and 2) from front of cab.
10. Label and disconnect cab heater hoses and/or air
1. Park machine on a firm, level surface. Allow sufficient
conditioning hoses. Refer to Section 4.3.7, “Heater
overhead and side clearance for cab removal. Level
System (if equipped)” or Section 4.3.8, “Heater and Air
machine, fully retract boom, lower boom, place
Conditioning System (if equipped)”.
transmission in (N) NEUTRAL position, engage park
brake and shut engine OFF.
2. Block all four wheels to help prevent machine from
moving. Assure that there is sufficient overhead and 3 4
side clearance for cab removal.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
5. Place a funnel at base of cooling system to channel
drained coolant into suitable container. Remove drain
plug and allow coolant to drain.
6. Transfer coolant to a container with a cover, and label as
MZ7840
“Used Coolant”. Dispose of used coolant at an approved
recycling facility. 11. Label, disconnect and cap all hydraulic hoses attached
7. Replace and tighten drain plug. to the steering orbital valve (3). Cap all fittings and
openings to keep dirt and debris from entering
hydraulic system.
12. Label, disconnect and cap all hydraulic hoses attached
to the brake assembly (4). Cap all fittings and openings
to keep dirt and debris from entering hydraulic system.

3614RS, 4017RS 31211337 4-11

 Cab

MAE34860

13. Remove and retain inside rear cover (5) and securing
hardware from cab.

6
MAE35020

14. Remove and retain right side rear cover (6) and securing
hardware from cab.
15. Disconnect cab ground strap.
16. Label and disconnect the rear frame harness connectors
(7). Move the harnesses clear of the cab to prevent
damage during cab removal.

8 8

MZ7910

17. Install four lifting eye bolts with a minimum lifting

capacity of 383 kg (844 lb) in the existing lifting holes (8)
at the top corners of the cab.

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 Cab

18. Use a hoist or overhead crane and sling with a minimum 4.5 CAB INSTALLATION
lifting capacity of 383 kg (844 lb) attached to the four
eye bolts. DO NOT attempt to lift the cab at this point. 1. Block all four wheels to help prevent machine from
moving. Assure that there is sufficient overhead and
side clearance for cab installation.
2. Attach a sling with a minimum lifting capacity of
9 383 kg (844 lb) through lifting eyes of cab.
3. Use a hoist or overhead crane and sling attached to cab.
Carefully begin to align cab with mounting holes in
frame. Stop and check that wiring, hydraulic hoses,
cables, etc., will not be pinched or damaged as cab is
positioned. Readjust position of sling as needed to help
balance cab during installation.
4. Install four cab to frame mount bolts, washers and nuts to
145 - 155 Nm (107 - 114 lb-ft).
5. Connect previously labeled rear frame harness
connectors (7) to their appropriate locations.
6. Reconnect cab ground strap.
7. Uncap and reconnect previously labeled hydraulic
hoses to their appropriate locations.
8. Reconnect any remaining electrical connections to their
appropriate locations.
9. Reconnect heater hoses to cab heater. Refer to
9 MAE34800
Section 4.3.7, “Heater System (if equipped)”.
19. Remove four mount bolts, washers and nuts (9)
10. Reconnect heater hoses and/or air conditioning hoses
securing cab to frame.
to cab heater. Refer to Section 4.3.7, “Heater System (if
20. Remove mirrors and all other cab components as equipped)” or Section 4.3.8, “Heater and Air
needed, if not previously removed. Conditioning System (if equipped)”.
21. When all wiring, hydraulic hoses and fasteners are 11. Fill cooling system completely with coolant, allowing
disconnected or removed, carefully and slowly lift cab time for coolant to fill engine block. The cooling system
and remove it from frame. Readjust position of sling as capacity is listed in Section 2.3, “Fluids and Lubricant
needed to help balance cab during removal. Capacities”.
22. When cab is completely clear of machine, carefully Note: If machine is equipped with air conditioning, air
lower it to ground. Block up or support cab so it does conditioning system must be charged by local distributor or
not move or fall. certified air conditioning service center.
23. Assure that no personnel enter cab while it is being
removed from machine.
24. Inspect and replace machine parts that are exposed
with cab removed. Repair or replace as required.

3614RS, 4017RS 31211337 4-13

 Cab

12. Properly connect battery. Refer Section 9.8, “Battery”,

for procedure.
13. Carefully examine all cab components, fasteners, etc.,
one last time before engine start-up. Rectify any faulty
conditions.
14. Start engine and check operation of all controls. Check for
hydraulic fluid leaks. Check hydraulic fluid level in tank
and add fluid as required.
Note: When engine is initially started, run it briefly at low idle
and check machine for any visual sign of fluid leakage. STOP
engine immediately if any leakage is noted. Make any
necessary repairs before continuing.
15. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.
16. Install access covers (1 and 2) to front of cab.
17. If equipped, install windshield wiper assembly.
18. Install the mirrors and all other cab components as
needed, if removed.
19. Reinstall right side rear cover (6) with previously
removed hardware to cab.
20. Reinstall inside rear cover (5) with previously removed
hardware to cab.
21. Unblock wheels.
22. Close and secure engine cover.
23. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

4-14 31211337 3614RS, 4017RS

 Section 5
Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.1 3614RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.2 4017RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Axle Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Axle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.1 Axle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.6 Park Brake adjustment - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.7 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.8 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.9 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.2 Drive Shaft Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.5 Drive Shaft Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.10 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.1 Removing Wheel and Tire Assembly from Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.11 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.11.1 3614RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.11.2 4017RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.11.3 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

3614RS, 4017RS 31211337 5-1

 Axles, Drive Shafts, Wheels and Tires

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that the
operator/mechanic be familiar with the names and locations
of the major assemblies of the axles, drive shafts, wheels and
tires. The following illustration identifies the components
that are referred to throughout this section.

5.1.1 3614RS

REAR AXLE
ASSEMBLY

REAR STEERING
CYLINDER

TRANSMISSION
REAR AXLE
WHEEL HUB
REAR
DRIVE SHAFT

FRONT STEERING
CYLINDER

FRONT
DRIVE SHAFT

MZ8362

FRONT AXLE FRONT AXLE

ASSEMBLY WHEEL HUB

5-2 31211337 3614RS, 4017RS

 Axles, Drive Shafts, Wheels and Tires

5.1.2 4017RS

REAR AXLE
ASSEMBLY

REAR STEERING
CYLINDER

TRANSMISSION

REAR AXLE
WHEEL HUB
REAR
DRIVE SHAFT
FRONT STEERING
CYLINDER

FRONT
DRIVE SHAFT

FRONT AXLE
ASSEMBLY MZ8352

FRONT AXLE
WHEEL HUB

3614RS, 4017RS 31211337 5-3

 Axles, Drive Shafts, Wheels and Tires

5.4 AXLE REPLACEMENT

WARNING 5.4.1 Axle Removal

DO NOT service the machine without following all safety
precautions as outlined in Section 1, “Safety Practices”, of
this manual.
WARNING
An improperly supported machine can fall. Safely raise
and adequately support the machine so that it will
5.2 AXLE SERIAL NUMBER
remain stable and in place before attempting to remove
Front and rear axle serial number plate is located on top of an axle.
the center section. The front and rear axle assemblies differ in that front axle
Information on the serial number plate is required in assembly is equipped with a parking brake mechanism and a
correspondence regarding the axle. limited slip feature; rear axle has neither. The following steps
Supply information from the axle serial number plate when outline a typical axle removal procedure, suitable for either
communicating about the axle assembly or the front or rear axle assembly.
axle components. Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
5.3 AXLE SPECIFICATIONS AND spraying water or cleaning solution on electrical
MAINTENANCE INFORMATION components. If using a steam cleaner, seal all openings
before steam cleaning.
For axle, oil specifications and maintenance information,
Note: Clear the work area of all debris, unnecessary personnel,
refer to Section 2.3, “Fluids and Lubricant Capacities”.
etc. Allow sufficient space to raise the machine and to remove
Detailed axle service instructions are provided in the the axle.
following publications:
1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in (N)
Model Publication Type Publication # NEUTRAL, engage parking brake, and shut engine OFF.
3614RS, Service Manual 31200162 2. Place a Do Not Operate Tag on both ignition key switch
4017RS and steering wheel.
Parts Manual 31211338
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
5. Remove bolts securing fender assembly to axle.

5-4 31211337 3614RS, 4017RS

 Axles, Drive Shafts, Wheels and Tires

8. If axle will be disassembled after removal, place a

FRONT AXLE suitable receptacle under axle (1) and wheel hub (2)
4 drain plugs. Remove drain plugs and allow oil to drain
3 into receptacle. Transfer used oil into a suitable covered
container, and label container as “Used Oil.” Dispose of
used oil at an approved recycling facility.
9. Install previously removed drain plugs (1 and 2).
10. Label and disconnect the electrical connections.
11. Disconnect LSI sensor at the rear axle.
12. Label, disconnect and cap steering and brake lines at
MAE8800
axle. Wipe up any spilled oil.
13. 3614RS Front Axle Only - Disconnect park brake cable.
1
14. Block front and rear of both tires on axle that is not
being removed. Ensure that machine will remain in
place during axle removal before proceeding.
REAR AXLE 4
15. Raise machine using a suitable jack or hoist. Place
suitable supports under both sides of frame and lower
3
machine onto supports. Ensure that machine will
remain in place during axle removal.
16. Support axle that is being removed with a suitable jack,
hoist or overhead crane and sling. DO NOT raise axle or
machine.
17. Remove both the wheel and the tire assemblies
from the axle that is being removed. Refer to
MAE8810 Section 5.10.1, “Removing Wheel and Tire Assembly
from Machine”.
1 Note: The wheel and tire assemblies must be re-installed later
with the directional tread pattern “arrows” facing in the
direction of forward travel.
WHEEL HUB 18. Remove the drive shaft assembly. Refer toSection 5.9.3,
“Drive Shaft Removal”.
19. On front axle, remove capscrew and locknuts securing
lower position cylinder-mount pin to the front cylinder.
Tap the cylinder mount pin out, and move the cylinder
to prevent it from interfering with axle removal.
20. Remove bolts and locknuts securing axle to frame.
21. Remove axles from machine using jack, hoist or
overhead crane and sling supporting axle. DO NOT raise
MAE8830 or otherwise disturb machine while removing axle.
2 Balance axle and prevent it from tipping, turning or
falling while removing it from beneath machine. Place
6. Rotate axle hub until drain plug is positioned at the the axle on a suitable support or holding stand.
bottom of the hub.
7. Loosen and remove the axle oil fill plug (3) and check fill
plug (4).

3614RS, 4017RS 31211337 5-5

 Axles, Drive Shafts, Wheels and Tires

5.4.2 Axle Installation

FRONT AXLE
1. If applicable, raise machine using a suitable jack or
4
hoist. Place suitable supports beneath the frame and
lower the machine onto the supports, allowing enough 3
room for axle installation.
2. Before proceeding, ensure machine will remain in place
during axle installation.
3. Block front and rear of both tires on axle that is already
installed on machine.
4. Using a suitable jack, hoist or overhead crane and sling,
remove axle from its support or holding stand. Balance
MAE8800
axle and prevent it from tipping, turning or falling while
positioning it beneath machine. DO NOT raise or
1
otherwise disturb machine while installing the axle.
5. Keep axle supported and balanced on the jack, hoist or
REAR AXLE
4
overhead crane and sling throughout the installation
procedure. 3
6. Position axle under frame, and align axle housings with
holes in frame.
7. Apply high strength threadlocking compound to each
mounting bolt.
8. Install axle mounting bolts and nuts. Tighten and torque
as required.
9. Install the drive shaft assemblies. Refer to Section 5.9.5,
MAE8810
“Drive Shaft Installation”.
10. If reinstalling an axle previously removed from machine, 1
position driveshaft yoke on axle according to alignment
marks made earlier.
11. If installing a new axle, note position of driveshaft yoke WHEEL HUB
at transmission. Align driveshaft yoke on axle in same
plane as yoke on transmission.
12. Connect the steering and brake lines at axle.
13. 3614RS Front Axle Only - Connect park brake cable.

MAE8850

14. Tighten axle oil drain plugs (1). Fill until oil level reaches
bottom of check fill plug. Refer to Section 2.3, “Fluids
and Lubricant Capacities”, for proper oil and capacities.
15. Rotate wheel hubs 90 degrees so wheel hub drain plug
becomes the fill plug (2). Refer to Section 2.3, “Fluids
and Lubricant Capacities”, for proper oil and capacities.
16. Install and tighten the axle oil fill plug (3) and check fill
plug (4).

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 Axles, Drive Shafts, Wheels and Tires

17. Install the wheel and tire assemblies. Refer to 5.6 PARK BRAKE ADJUSTMENT - 3614RS
Section 5.10.2, “Installing Wheel and Tire Assembly onto
Machine”. 1. Park the machine on a slight grade, fully retract boom,
18. Carefully remove jack, hoist or overhead crane and sling level the boom, place transmission in (N) NEUTRAL, set
supporting axle. the parking brake. The machine should not move. If the
machine moves, adjust the park brake.
19. Carefully raise machine using a suitable jack or hoist.
Remove supports from beneath frame and lower 2. Apply service brake and disengage the park brake.
machine to ground.
20. Remove blocks from front and rear of both tires on
2
other axle.
Note: ALWAYS use new O-rings when servicing machine.
21. Install new O-rings into fittings. Lubricate O-rings with
clean hydraulic oil.
22. Uncap and connect steering and brake lines at their axle
fittings.
1
23. Check hydraulic reservoir oil level.
24. Start engine. Turn steering wheel several times
lock to lock, operate frame tilt function several
times in both directions and check function of brakes.
Check for hydraulic leaks, and tighten or repair as
necessary.
MM
25. Install fender assembly. Torque as required. 60
3
26. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
27. Close and secure engine cover.
28. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
Note: Service brake circuit will need to bled after axle MAM4100

installation. Refer to Section 8.9.3, “Service Brake Bleeding”.

3. Depress the release lever (1) and push the park brake
5.5 BRAKE INSPECTION lever (2) down.
4. Adjust the park brake cable by turning the adjuster
Detailed axle service instructions are provided in the Axle
knob (3) clockwise to increase park brake force. Turn the
Service Manual, refer to Section 5.3, “Axle Specifications and
adjuster knob counterclockwise to decrease park brake
Maintenance Information”.
force.
5. If park brake cannot be adjusted, refer to Section 5.3,
“Axle Specifications and Maintenance Information”, for
detailed axle information.

5.7 STEERING ANGLE ADJUSTMENT

Detailed axle service instructions are provided in the Axle
Service Manual, refer to Section 5.3, “Axle Specifications and
Maintenance Information”.

3614RS, 4017RS 31211337 5-7

 Axles, Drive Shafts, Wheels and Tires

5.8 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING

Problem Possible Causes Remedy

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.3, “Fluids and Lubricant
Capacities”.

2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level.
low. Refer to Section 2.3, “Fluids and
Lubricant Capacities”.

3. Incorrect alignment of ring and 3. Correct alignment by adding or

pinion gears. removing shims as needed.

4. Incorrect pinion (input) shaft 4. Correct bearing preload by

bearing preload. adding or removing shims as
needed.

5. Worn or damaged bearings. 5. Replace bearings as needed.

6. Worn or broken gear teeth. 6. Replace gears as needed.

7. Contamination in the axle. 7. Drain axle and/or wheel end

housings and fill to correct level.
Refer to Section 2.3, “Fluids and
Lubricant Capacities”.

8. Axle housing damaged. 8. Replace damaged parts.

2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal joints
traveling. damaged. as needed.

2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.

3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.

2. Drive shaft universal joint(s) worn 2. Repair or replace universal joints

or damaged. as needed.

3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as needed.

unbalanced.

5-8 31211337 3614RS, 4017RS

 Axles, Drive Shafts, Wheels and Tires

Problem Possible Causes Remedy

4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace O-rings as needed and
(differential housing and/or loose and/or O-rings damaged or tighten plugs to 130 Nm (96 lb-ft).
axle housings). missing.

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or 3. Replace seal and/or joint coupling

missing and/or worn or damaged fork shaft (axle shaft).
shaft sealing surfaces.

4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or

damaged or missing and/or worn input shaft. Adjust ring and pinion
or damaged pinion (input) shaft alignment and bearing preload as
sealing surfaces. described in the JLG Repair
Manuals.

5. Axle casing to brake housing 5. Replace O-rings and seals.

and/or brake housing to
differential assembly O-rings
and/or seals worn or damaged.

6. Axle housing mounting nuts and 6. Tighten housing nuts and

capscrews loose. capscrews. Refer torque value
described in the manufacturer
Service Manual.

7. Differential and/or axle housing(s) 7. Replace housing(s) as needed.

damaged.

5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace O-rings as needed and
housing (planet carrier). O-rings damaged or missing. tighten plugs to 60 Nm (44 lb-ft).

2. O-ring between hub and housing 2. Replace O-ring.

(planet carrier) damaged or
missing.

3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

and/or worn or damaged shaft shaft.
sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews. Refer

torque value described in the
manufacturer Service Manual.

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder O-rings and/or 2. Replace O-rings and seals.
seals worn or damaged.

3. Piston rod seal worn or damaged. 3. Replace piston rod seal.

4. Cylinder tube damaged. 4. Replace cylinder tube.

3614RS, 4017RS 31211337 5-9

 Axles, Drive Shafts, Wheels and Tires

Problem Possible Causes Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. Refer to
Section 2.3, “Fluids and Lubricant
Capacities”.

2. Axle and/or wheel end housings 2. Drain axle and fill to correct level.
filled with incorrect oil or oil Refer to Section 2.3, “Fluids and
contaminated or oil level low. Lubricant Capacities”.

3. Dragging park brake. 3. Adjust park brake cable as

needed. Refer to Section Note:,
“Service brake circuit will need to
bled after axle installation. Refer
to Section 8.9.3, “Service Brake
Bleeding”.”

8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
operating properly. Circuits”.

2. Excessive joint housing swivel 2. Correct bearing preload by

bearing preload. adding or removing shims as
needed.

3. Worn or damaged swivel 3. Replace swivel bearings as

bearings. needed.

9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
operating properly. Circuits”.

2. Steering cylinder leaking 2. Repair or replace steering cylinder

internally. as needed.

10. Excessive noise when brakes are 1. Brake discs worn. 1. Check brake discs for wear. Refer
engaged. to Section 5.5, “Brake Inspection”.

2. Brake discs damaged. 2. Replace brake discs.

11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
operating properly. Circuits”.

2. Brake piston O-rings and seals 2. Replace O-rings and seals.

damaged (leaking).

12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear. Refer
machine or braking power to Section 5.5, “Brake Inspection”.
reduced.
2. Brake (hydraulic) system not 2. Refer to Section 8.9.3, “Service
operating properly. Brake Bleeding”.

3. Brake piston O-rings and seals 3. Replace O-rings and seals.

damaged (leaking).

5-10 31211337 3614RS, 4017RS

 Axles, Drive Shafts, Wheels and Tires

5.9 DRIVE SHAFTS

1 2
5.9.1 Drive Shaft Inspection
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each drive
shaft in both directions. Look for excessive looseness,
missing parts, cracks or other damage. Worn or damaged 3 2
4 1
drive shafts and cross and bearing assemblies may cause an 1 2
excessive amount of vibration or noise.
Note: To ensure optimum performance, the driveshaft 3
4
assemblies are specially balanced as a unit at the factory. When
servicing any flange yoke, slip yoke or drive shaft tube, order a 3
4
complete assembly if components are bent or damaged. Refer 2
to the appropriate parts manual for ordering information. 1
MAE8870
Note: Any bolt removed from the drive shaft assembly MUST 3
be replaced. DO NOT re-torque. 4

5.9.2 Drive Shaft Maintenance 7. Remove bolts (1) and straps (2) securing bearing cross
to the transmission output shaft flange. Discard bolts.
Refer to Section 2.3, “Fluids and Lubricant Capacities”, for
8. Remove bolts (3) and straps (4) securing bearing crosses
information regarding the lubrication of the grease fittings
to front axle. Discard bolts.
on the drive shafts.
9. Remove front drive shaft assembly.
5.9.3 Drive Shaft Removal 10. Repeat above procedure on rear drive shaft.
1. Park machine on a firm, level surface, level machine, fully 5.9.4 Drive Shaft Cleaning and Drying
retract boom, lower boom, place transmission in
(N) NEUTRAL, engage parking brake, and shut engine 1. Disassemble and clean all parts using an approved
OFF. cleaning fluid. Allow to dry.
2. Place a Do Not Operate Tag on both ignition key switch 2. Remove any burrs or rough spots from all machined
and steering wheel. surfaces. Re-clean and dry as required.
3. Open engine cover. Allow system fluids to cool. 5.9.5 Drive Shaft Installation
4. Properly disconnect battery. Refer Section 9.8, “Battery”, 1. Raise drive shaft assembly into position. The slip yoke
for procedure. end of drive shaft mounts toward axle. If reinstalling a
5. Block the wheels. drive shaft previously removed, align flange yokes
according to the alignment marks made during
6. The drive shaft assembly is a balanced assembly. Mark removal.
the yoke and axle, transmission and the shaft and slip
yoke so that these components can be returned to their Note: Yokes at both ends of drive shaft must be in same plane
original positions when reinstalled. Yokes at both ends to help prevent excessive vibration.
of the drive shaft must be in the same plane to help 2. Apply medium strength threadlocking compound to all
prevent excessive vibration. mounting bolts.
3. Install two straps (2) and four new bolts (1) securing
front drive shaft bearing crosses to transmission. Install
two straps (4) and four new bolts (3) securing front drive
shaft bearing crosses to front axle. Torque bolts to
34 - 42 Nm (25 - 28 lb-ft).
4. Install two straps (4) and four new bolts (3) securing rear
drive shaft bearing crosses to transmission. Install two
straps (2) and four new bolts (1) securing rear drive

3614RS, 4017RS 31211337 5-11

 Axles, Drive Shafts, Wheels and Tires

shaft bearing crosses to rear axle. Torque bolts to 5.10.1 Removing Wheel and Tire Assembly from
74 - 82 Nm (55 - 60 lb-ft). Machine
5. Properly connect battery. Refer Section 9.8, “Battery”, 1. Park machine on a firm, level surface, level machine, fully
for procedure. retract boom, lower boom, place transmission in
6. Close and secure engine cover. (N) NEUTRAL, engage parking brake, and shut engine
OFF.
7. Unblock wheels.
2. Place a Do Not Operate Tag on both ignition key switch
8. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
and steering wheel.
3. Loosen but DO NOT remove the lug nuts on the wheel
5.10 WHEELS AND TIRES and tire assembly to be removed.
4. Place a suitable jack under axle pad closest to wheel
being removed. Raise machine and position a suitable
WARNING support beneath axle. Allow sufficient room to lower
machine onto support and to remove wheel and tire
Mismatched tire sizes, ply ratings or mixing of tire types assembly.
(radial tires with bias-ply tires) may compromise machine
5. Lower machine onto support.
stability and may cause machine to tip over.
6. Remove lug nuts and washers in alternating pattern.
It is recommended that a replacement tire to be same size,
7. Remove wheel and tire assembly from machine.
ply and brand as originally installed. Refer to appropriate
parts manual for ordering information. If not using an
5.10.2 Installing Wheel and Tire Assembly onto
approved replacement tire, it is recommended that
Machine
replacement tires have following characteristics:
• Equal or greater ply/load rating and size of original
1
• Tire tread contact width equal or greater than original
• Wheel diameter, width and offset dimensions equal to
original
• Approved for application by the tire manufacturer
(including inflation pressure and maximum tire load)
The rims installed have been designed for stability
requirements which consist of track width, tire pressure and
load capacity. Size changes such as rim width, center piece
location, larger or smaller diameter, etc., without written
factory recommendations, may result in unsafe condition
regarding stability. MZ6020

Foam filled tires have a positive effect on the weight, stability

Note: The wheel and tire assemblies must be installed with
and handling characteristics of the machine, especially
directional tread pattern “arrows” facing in direction of forward
under load. The use of hydrofill as a tire-fill substance is not
travel.
recommended because of possible environmental impact.
Large-bore valve stems are used to help expedite tire Note: Verify valve stems face outward on all wheel and tire
inflation and deflation. An inner tube may be used if a tire assemblies.
does not provide an airtight seal. Check tire inflation 1. Position wheel onto studs on wheel end of axle.
pressures when the tires are cold. When mounting a tire on
2. Install wheel washers onto studs.
the wheel, the tire must be mounted on the wheel respective
of the directional tread pattern of the tire; this produces a left 3. Start all lug nuts by hand to prevent cross threading.
or right tire and wheel assembly. Apply one drop of lubrication oil.

5-12 31211337 3614RS, 4017RS

 Axles, Drive Shafts, Wheels and Tires

5.11 TOWING A DISABLED MACHINE

1 8
Towing a disabled machine should only be attempted after
exhausting all other options. Make every effort to repair
6 3 machine and move it under its own power.

5.11.1 3614RS
9 10 1. Fully retract the boom. Position attachment
approximately 610 mm (24 in) above the ground.
Note: If total loss of power has occurred, refer to Section 3.20,
“Emergency Boom Lowering Procedure”.
4 5

7 2 MY4200 WARNING
DO NOT attempt to tow a machine that is loaded or the
4. Tighten lug nuts in an alternating pattern as indicated in
boom/attachment is raised more than approximately 610
previous figure. Torque to 440 - 480 Nm (325 - 354 lb-ft).
mm (24 in).
5. Remove machine from supports.
2. Remove load from machine.
6. Remove Do Not Operate Tag from ignition key switch
and steering wheel. 3. Place transmission in (N) NEUTRAL, engage park brake
and shut the engine OFF.
7. Connect analyzer diagnostic tool.
4. Block all four wheels.
8. Use Operator Tools > Tyre Selection, to select the tire
option that best matches presently installed tire.
Note: It is critical to select appropriate tire to display accurate WARNING
speed on the dash gauge. Block all four wheels when preparing the machine for
towing to prevent ay unexpected movement.

5. Remove front and rear drive shafts. Refer to Section 5.9,

“Drive Shafts”, for procedure.

3614RS, 4017RS 31211337 5-13

 Axles, Drive Shafts, Wheels and Tires

FRONT VIEW
WARNING
Use a vehicle of sufficient capacity to tow the machine.
Tow vehicle must be capable of providing braking for
both vehicle and machine.

7. Clear area of any unnecessary personnel.

8. Have an operator seated in machine operator cab.
9. Remove blocks from all four wheels.
10. Disengage machine park brake.
11. Tow machine to a secure location.
Note: Tow machine at a very slow speed.
12. After towing is complete, engage park brake.
13. Block all four wheels.
14. Reinstall front and rear drive shafts. Refer to Section 5.9,
1
“Drive Shafts”.
15. Repair machine as necessary.
REAR VIEW
Note: Block the wheels of the machine BEFORE attempting to
release the park brake. Once the park brake is released the
machine’s park brake AND service brakes are inoperable.

MAE34680

6. Secure machine to a suitable towing vehicle.

a. For towing or retrieval from front of machine, attach
towing equipment to lifting points (1).
b. For towing or retrieval from rear of machine, attach
towing equipment to the retrieval hitch (2).

5-14 31211337 3614RS, 4017RS

 Axles, Drive Shafts, Wheels and Tires

5.11.2 4017RS Note: After machine has been towed to a secure location,
reactivate parking brake. Carefully follow procedures from start
1. Fully retract the boom. Position attachment
to finish. Contact local JLG dealer if you are unsure about any
approximately 610 mm (24 in) above the ground.
part of the procedure, or for specific instructions concerning
Note: If total loss of power has occurred, refer to Section 3.20, your particular situation.
“Emergency Boom Lowering Procedure”.

WARNING FRONT VIEW

DO NOT attempt to tow a machine that is loaded or the

boom/attachment is raised more than approximately 610
mm (24 in).

2. Remove load from machine.

3. Place transmission in (N) NEUTRAL, engage park brake
and shut the engine OFF.
4. Block all four wheels.

WARNING
Block all four wheels when preparing the machine for
towing to prevent ay unexpected movement.

5. Remove front and rear drive shafts. Refer to Section 5.9,

“Drive Shafts”. 1

a. Manually Releasing the brake REAR VIEW

3 3

3 3
MZ1020

1. Loosen the nuts of the screws (3) for the manual release
of the braking units. Draw the nuts back approximately
6 mm.
2. Tighten the screws until they are gently seated on the 2
driving plate.
3. Carefully tighten each release screw a 1/4 turn at a time MAE34680

in sequence until all have been turned on full turn 360°.

4. Repeat steps 1 thru 3 for other side of differential.

3614RS, 4017RS 31211337 5-15

 Axles, Drive Shafts, Wheels and Tires

5. Secure machine to a suitable towing vehicle. 5.11.3 Manually Resetting the Park Brake
a. For towing or retrieval from front of machine, attach Note: Block the wheels of the machine BEFORE attempting to
towing equipment to lifting points (1). release the machine’s park brake. Once the park brake is
b. For towing or retrieval from rear of machine, attach released the machine’s park brake AND service brakes are
towing equipment to the retrieval hitch (2). inoperable.
3 3
WARNING
Use a vehicle of sufficient capacity to tow the machine.
Tow vehicle must be capable of providing braking for
both vehicle and machine.
6. Clear area of any unnecessary personnel.
7. Have an operator seated in machine operator cab. 3 3
8. Remove blocks from all four wheels. MZ1020

9. Disengage machine park brake.

10. Tow machine to a secure location. 1. Loosen each release screw (3), only 1/4 turn at a time, in
sequence, until each screw has lost contact with the
Note: Tow machine at a very slow speed. guide pin.
11. After towing is complete, engage park brake. 2. Remove screws along with nuts and seals. Replace seals,
12. Block all four wheels. lubricate screws with a silicone-based grease and
re-install screws along with nuts.
13. Reinstall front and rear drive shafts. Refer to Section 5.9,
“Drive Shafts”. 3. Adjust the nut of the screw heads in relation to the arm
by 1.18 in (30 mm).
14. Repair machine as necessary.
4. Repeat steps 1 thru 3 for other side of differential.
Note: Block the wheels of the machine BEFORE attempting to
5. After repairs to machine have been made, start machine
release the park brake. Once the park brake is released the
and check park brake and service brakes for proper
machine’s park brake AND service brakes are inoperable.
function. Refer to Section 8.9.3, “Service Brake
Bleeding”, Section 8.9.4, “Service Brake Test” and
Section 8.9.5, “Steering Orbital Valve”.

5-16 31211337 3614RS, 4017RS

 Section 6
Transmission

Contents

PARAGRAPH TITLE PAGE

6.1 Transmission Assembly Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.4 Transmission Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5 Torque Converter Flex Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5.1 Torque Converter Flex Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5.2 Torque Converter Flex Plate Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

3614RS, 4017RS 31211337 6-1

 Transmission

6.1 TRANSMISSION ASSEMBLY

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that the
operator/mechanic be familiar with the names and locations
of the major assemblies of the transmission. The following
illustration identifies the components that are referred to
throughout this section.

ENGINE SPEED
SENSOR
TRANSMISSION
OIL FILTER
TRANSFER CASE
BREATHER
TRANSMISSION
BREATHER
TRANSFER CASE
OIL FILLER PLUG
TRANSMISSION
DIPSTICK

SHIFT
SOLENOIDS

FORWARD CLUTCH
PRESSURE CHECK
PORT OIL FILL
PLUG
MAGNETIC TRANSFER CASE
REVERSE CLUTCH DRAIN PLUG OIL LEVEL GLASS
PRESSURE CHECK
PORT

TRANSMISSION OIL
FILLER HOLE

MAGNETIC
DRAIN PLUG

TRANSMISSION LIFT
POINT

MZ7100

6-2 31211337 3614RS, 4017RS

 Transmission

6.3 SPECIFICATIONS AND MAINTENANCE

WARNING INFORMATION

DO NOT service the machine without following all safety For transmission, oil specifications and maintenance
precautions as outlined in Section 1, “Safety Practices”, of information, refer to Section 2.3, “Fluids and Lubricant
this manual. Capacities”.

Note: These instructions cover only the routine maintenance, Detailed transmission service instructions are provided in
removal, installation and troubleshooting of the transmission. the following publications:
Refer to the local JLG dealer and the applicable Transmission
Service Manual for assistance with comprehensive Model Publication Type Publication #
transmission diagnosis, repair and component replacement.
3614RS, Service Manual 31200163
6.2 TRANSMISSION SERIAL NUMBER 4017RS Parts Manual 31211338

6.4 TRANSMISSION REPLACEMENT

Cleanliness is of extreme importance. Before attempting to
remove the transmission, thoroughly clean the exterior of
the transmission to help prevent dirt from entering during
the replacement process. Avoid spraying water or cleaning
solution onto or near the transmission shift solenoids and
other electrical components.
1
WARNING
NEVER lift a transmission alone; enlist the help of at least
one assistant or use a suitable hoist or overhead crane
and sling with a minimum lifting capacity of
454 kg (1000 lb).
MZ7110

The transmission serial number plate (1) is located on the 6.4.1 Transmission Removal
front of the transmission case behind the oil dipstick. 1. Park machine on a firm, level surface, level machine,
Information contained in the serial number is required in fully retract boom, lower boom, place transmission in
correspondence with the transmission manufacturer. (N) NEUTRAL, engage park brake and shut engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure.
5. Drain hydraulic oil reservoir. Refer to Section 8.7.1,
“Hydraulic Oil Reservoir Draining”.
6. If not previously removed, remove the implement
pump. Refer to Section 8.8.1, “Pump Replacement”.
7. Refer to Section 7.9, “Engine Replacement”, for detailed
removal instructions.
8. Thoroughly clean the transmission and the surrounding
area, including all hoses and fittings, before proceeding.

3614RS, 4017RS 31211337 6-3

 Transmission

12. Turn engine over slowly by hand and align each of

torque convertor flex plate bolts to be accessed.
Remove them one at a time.
5

2 6

MAE18710
1
9. Place a suitable receptacle under transmission/transfer
case drain plugs. Remove the transmission drain plug
(1), and allow the transmission oil to drain into the
receptacle. Repeat the drain procedure with the transfer MZ7160

case (2). 13. Remove bolts and washers (5) holding transmission to
10. Transfer used transmission oil into a suitable, covered engine.
container, and label container as “Used Oil.” Dispose of 14. Use a suitable hoist or overhead crane, secure the
used oil at an approved recycling facility. Clean and transmission with a lifting strap or chain to lifting
reinstall the transmission and transfer case drain plugs. bracket secured to lifting point (6).
Note: Lifting bracket is NOT included with transmission.
15. Lift transmission clear of engine, and lower it onto
suitable supports or secure it to a stand built especially
for transmission or engine service. Secure transmission
so that it will not move or fall.
16. Remove any external transmission components as
required. Cover all transmission openings.

6.4.2 Transmission Inspection and Internal

4
Repair
Refer to Section 6.3, “Specifications and Maintenance Information”.
3
MZ7140

11. Remove access cover (3) from the engine bell

housing (4). This will allow access to remove torque
convertor flex plate bolts and washers from the engine
flywheel.

6-4 31211337 3614RS, 4017RS

 Transmission

6.4.3 Transmission Installation

WARNING
NEVER lift a transmission alone; enlist the help of at least
one assistant or use a suitable hoist or overhead crane
and sling.
Note: Apply medium strength threadlocking compound to all
transmission bolts before installation.
1. Use a suitable hoist or overhead crane, secure 7
transmission with a lifting strap or chain to transmission
lifting bracket.
2. Install transmission to engine and secure with
previously removed bolts and washers (5).
Torque to 72 Nm (53 lb-ft).
3. Remove hoist or overhead crane and sling. MZ7160

4. Turn engine over slowly by hand and align and install 11. Remove the transmission dipstick (7) and check the oil
each of torque convertor flex plate bolts and washers to level. The oil level should be at the MAX line.
engine flywheel through access opening on engine bell
12. If oil is low, add oil as required.
housing. Install them one at a time. DO NOT fully
tighten until all of bolts are in place. Torque flex plate 13. Replace the transmission dipstick (7).
bolts to 35 - 39 Nm (26 - 29 lb-ft). 14. Install the engine cover.
5. Install the hydraulic pump. Refer to Section 8.8.1, “Pump 15. Close and secure engine cover.
Replacement”.
16. Recheck all drain plugs, lines, connections, etc., for leaks,
6. Refer to Section 7.9.4, “Engine/Transmission and tighten where necessary. Close and secure the
Installation”, for detailed engine/transmission engine cover.
installation instructions.
17. Remove the Do Not Operate Tags from both the ignition
7. Fill the transmission. Refer to Section 2.3, “Fluids and key switch and the steering wheel.
Lubricant Capacities”, for proper capacity.
8. Properly connect the battery. Refer Section 9.8,
“Battery”, for procedure.
Note: Check transmission oil level with engine at idle and
transmission oil cold.
9. Apply park brake, place transmission in (N) NEUTRAL
position and lower the forks or attachment to the
ground.
10. Open engine cover

3614RS, 4017RS 31211337 6-5

 Transmission

6.4.4 Transmission Fluid Level Check 10. Allow the engine to run at idle for 30 seconds.
Note: Final transmission oil level must always be checked with 11. Repeat steps 9 and 10 three more times, or until the
engine at idle and transmission oil at operating temperature transmission temperature warning light illuminates.
(minimum 80°C/176°F). 12. Place the transmission in (N) NEUTRAL and apply the
1. Start machine on a firm, level surface, level machine, park brake. Allow the engine to run at idle for
fully retract boom, lower boom, place transmission in 30 seconds.
(N) NEUTRAL, engage park brake and run engine at idle. 13. Open the engine cover.
2. Open engine cover. 14. Verify that top of transmission oil cooler is warm and oil
is circulating through the cooler. If the top tank of the
transmission oil cooler is not warm, repeat steps
6 thru 10.
15. Remove the transmission dipstick (7) and check the oil
level. The oil level should be in FULL level mark.
16. Add oil as required.
17. Replace the transmission dipstick.
18. Close and secure the engine cover.
19. Shut engine OFF.

MZ7160

3. Remove the transmission dipstick (7) and check the oil

level. The oil level after 2 - 3 minutes of idle must be
between the ADD and FULL oil level marks.
Note: Depending on the amount of fluid remaining in the
transmission oil cooler, the oil level may read substantially
above the MAX level mark at this time. The correct oil level can
be obtained after the transmission fluid is at operating
temperature.
4. If the oil is low, add oil as required.
5. Replace the transmission dipstick.
6. Close and secure the engine cover.
7. Ensure that the front of the machine is clear of persons
or obstacles.
8. Apply the service brake and disengage the park brake.
Place the transmission in (F) FORWARD at 3rd gear.
9. Stall the transmission against the service brake at full
throttle a maximum of 60 seconds. If transmission
temperature warning light illuminates, go to step 12.

6-6 31211337 3614RS, 4017RS

 Transmission

6.5 TORQUE CONVERTER FLEX PLATE 6.6 TROUBLESHOOTING

Refer to Section 6.3, “Specifications and Maintenance
6.5.1 Torque Converter Flex Plate Removal Information”, for detailed Torque Converter Information.
1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF.
Note: In order to remove engine flex plates, engine and
transmission must be separated.
2. Refer to Section 6.4.1, “Transmission Removal” or
Section 7.9.1, “Engine/Transmission Removal”, for
transmission removal.
1

4 2

MAE9810
3
3. Remove eight bolts holding flex plates (1) to flywheel.
4. With transmission removed with flex plates (1) and
torque converter (2), loosen and remove six bolts and
washers (3) holding the support ring (4) and flex
plates (1) to the torque converter (2).
5. Replace three flex plates (1) if damaged.

6.5.2 Torque Converter Flex Plate Installation

1. Install three new flex plates (1) on torque converter (2)
with support ring (4) and previously removed bolts with
washers (3).
2. Refer to Section 6.4.2, “Transmission Inspection and
Internal Repair” or Section 7.9.4, “Engine/Transmission
Installation”, for transmission installation.

3614RS, 4017RS 31211337 6-7

 Transmission

6-8 31211337 3614RS, 4017RS

 Section 7
Engine

Contents

PARAGRAPH TITLE PAGE

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.1 Surge Tank Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.3 Radiator Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6.2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.9 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.9.1 Engine/Transmission Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.9.2 Transmission Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.9.3 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.9.4 Engine/Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

3614RS, 4017RS 31211337 7-1

 Engine

7.1 INTRODUCTION

WARNING
DO NOT service the machine without following all safety
precautions as outlined in Section 1, “Safety Practices,” of
this manual

WARNING
Engine fuel lines are pressurized. DO NOT attempt repairs
unless specific training has been completed.

7.1.1 Disclaimer and Scope

These instructions are written for worldwide use. In
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that after
maintenance, service and repair of the engine, engine
operation does not violate local regulations.
Note: Detailed engine service instructions (covering
disassembly, inspection, internal repair, assembly, adjustment
and troubleshooting information) are provided in appropriate
engine service manual. A gradual running-in (break-in) of a
new engine is not necessary. Full load can be applied to a new
engine as soon as the engine is put into service and the coolant
temperature is at least 60°C (140°F). Extended light-load
operation during the early life of the engine is not
recommended. DO NOT run the engine at high, no-load
speeds. DO NOT apply an overload to the engine.

7-2 31211337 3614RS, 4017RS

 Engine

7.1.2 Component Terminology

To understand the safety, operation and maintenance
information presented in this section, it is necessary that the
operator/mechanic be familiar with the names and locations
of the engine components. The following illustration
identifies the components that are referred to throughout
this section.

ALTERNATOR

TURBO CHARGER

OIL FILTER

MZ7390

3614RS, 4017RS 31211337 7-3

 Engine

BELT ROUTING (WITHOUT A/C)

STARTER

FUEL INJECTOR
PUMP

MZ7400

BELT ROUTING (WITH A/C)

A/C COMPRESSOR

MAE45050

7-4 31211337 3614RS, 4017RS

 Engine

7.2 ENGINE SERIAL NUMBER 7.4 ENGINE COOLING SYSTEM

The engine serial number is stamped on the engine block,
above the oil filter. Information contained in the serial
7.4.1 Surge Tank Cap
number is required in correspondence with the engine A 1 Bar (14.5 psi) cap is used on the surge tank. An incorrect
manufacturer. or malfunctioning cap can result in the loss of coolant and a
hot running engine.
7.3 SPECIFICATIONS AND MAINTENANCE
INFORMATION 7.4.2 Thermostat Replacement
Before considering thermostat replacement, check the
For engine, coolant and oil specifications, and maintenance coolant level, fan belt tension and instrument cluster
information, refer to Section 2, “General Information and temperature indicator.
Specifications”.
• If engine seems to take a long time to warm up,
thermostat may be stuck in the open position and
requires replacement.
• If engine runs hot, check temperature of upper
radiator hose.
• If hose is not hot, thermostat may be stuck in closed
position.
• If engine has overheated, performance may suffer,
indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.

a. Thermostat Removal
1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in
(N) NEUTRAL, engage parking brake, and shut engine
OFF.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
5. Slowly turn surge tank cap to first stop and allow any
pressure to escape. Remove surge tank cap.
6. Place a funnel at base of radiator to channel drained
coolant into container. Loosen the drain plug and slowly
remove to allow coolant to drain. Transfer coolant into a
properly labeled container. Dispose of properly if
coolant needs to be replaced. Replace the radiator drain
plug.

3614RS, 4017RS 31211337 7-5

 Engine

7.4.3 Radiator Assembly Replacement

1
Before considering radiator assembly replacement for other
than obvious damage, conduct a cooling system pressure
test check coolant specific gravity, coolant level, fan belt
tension and dash panel temperature indicator.
• If engine runs hot, check temperature of upper
radiator hose.
• If hose is not hot, thermostat may be stuck in closed
position.
• If engine has overheated, performance may suffer,
indicating other damage including a leaking cylinder
head gasket, cracked cylinder head or block, and/or
other internal engine damage.
MAE8980
a. Radiator Assembly Removal
7. Remove capscrews securing thermostat housing (1) to
engine. 1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in
8. Remove thermostat housing, old gasket and
(N) NEUTRAL, engage parking brake, and shut engine
thermostat. Clean all gasket surfaces. DO NOT let any
OFF.
debris into thermostat opening.
2. Place a Do Not Operate Tag on both ignition key switch
Note: ALWAYS use correct thermostat and install a new gasket. and steering wheel.
NEVER operate engine without a thermostat, or engine
3. Open engine cover. Allow system fluids to cool.
damage will result.
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
b. Thermostat Installation for procedure.
1. Install engine thermostat, thermostat gasket and
thermostat housing. Secure with the previously 2
removed capscrews.
2. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
3. Open surge tank cap, and fill the radiator completely
with a 50/50 mixture of ethylene glycol and water. Add
coolant solution at a maximum rate of 1.3 gallons per
minute (5 liters per minute). Replace and tighten
radiator cap. Add coolant to surge tank until 1/4 to 1/2
full. This overfilling will compensate for any air trapped 3
in cooling system.
4. Run engine to operating temperature. Visually check for
leaks with engine running. Check coolant level in surge
MZ7441
tank and fill, or drain, as necessary.
4
5. Close and secure engine cover.
5. Remove hood (2), end cover (3) and belly pan (4) from
6. Remove Do Not Operate Tags from both ignition key
engine compartment.
switch and steering wheel.
6. Place a suitable receptacle under transmission drain
plug. Remove transmission drain plug, and allow the
transmission oil to drain into receptacle.

7-6 31211337 3614RS, 4017RS

 Engine

7. Transfer used transmission oil into a suitable, covered

container, and label container as “Used Oil.” Dispose of 9
7 6
used oil at an approved recycling facility. Clean and
8
reinstall transmission drain plug.
8. Drain hydraulic oil reservoir. Refer to Section 8.7.1,
“Hydraulic Oil Reservoir Draining”.
9. Slowly turn surge tank cap to first stop and allow any
pressure to escape. Remove surge tank cap.
10. Place a suitable container beneath radiator drain.
11. Place a funnel at base of radiator to channel drained
coolant into a container. Open drain plug and slowly
remove to allow coolant to drain. Transfer coolant into a
properly labeled container. Dispose of properly if
coolant needs replaced. Close radiator drain plug.

MZ7450
5
8 9

13. Label and disconnect both transmission cooler

hoses (6). Cap all fittings and openings to prevent dirt
and debris from entering hydraulic system.
14. Loosen and remove radiator assembly mounting bolts,
washers and (if equipped) shims. Note the number of
shims being used and there location.
15. Label, disconnect and cap hoses attached to coolant
recovery tank (7). Remove coolant recovery tank and
mounting plate.
16. Loosen and remove air intercooler tubes (8) from
5 radiator assembly.
17. Loosen and remove the radiator hoses (9) from radiator
assembly.
MZ7430 18. Carefully lift the radiator assembly out of the
engine compartment.
12. Label and disconnect the outer hydraulic cooler
hose (5). Cap all fittings and openings to prevent dirt Note: Fan Guard can be removed after radiator assembly is
and debris from entering hydraulic system. removed and placed in a secure location.

3614RS, 4017RS 31211337 7-7

 Engine

b. Radiator Assembly Installation 7.5 ENGINE ELECTRICAL SYSTEM

1. Place radiator assembly in engine compartment at the
The engine electrical system, including the starter, alternator
original orientation. Secure with the previously used
and primary wiring, is described in Section 9.5, “Electrical
hardware.
System Schematics”.
2. Uncap and connect previously labeled hoses to radiator,
transmission cooler and oil cooler. 7.6 FUEL SYSTEM
3. Fill hydraulic oil reservoir. Refer to Section 8.7.2,
“Hydraulic Oil Reservoir Filling”.
7.6.1 Diesel Fuel
4. Fill transmission. Refer to Section 2.3, “Fluids and
Lubricant Capacities”. Fuel represents a major portion of machine operating costs
and therefore must be used efficiently. ALWAYS use a
5. Open surge tank cap and fill the radiator completely premium brand of high quality, clean diesel fuel. Low cost,
with coolant. Replace and tighten surge tank cap. Refer inferior fuel can lead to poor performance and expensive
to Section 2.3, “Fluids and Lubricant Capacities”, for engine repair.
proper capacities.
Refer Section 2.3, “Fluids and Lubricant Capacities”, for
6. Properly connect battery. Refer Section 9.8, “Battery”, for approved fuel specification.
procedure.
7. Run engine to operating temperature. Visually check for
leaks with engine running. Check all fluid levels for
correct levels.
8. Install the end cover, hood and belly pans on the engine
compartment.
9. Close and secure engine cover.
10. Remove Do Not Operate Tag from ignition key switch
and the steering wheel.

7-8 31211337 3614RS, 4017RS

 Engine

7.6.2 Fuel Tank 9. Disconnect fuel sender.

Note: Fuel tank is a one piece unit. It is located under the cab. If it is 10. Remove fuel tank drain plug, and drain fuel into
determined that fuel tank must be removed, fuel must be drained an approved and suitable container. Dispose of
before tank removal. Always dispose of fuel properly. fuel properly.

a. Fuel Tank Removal b. Disassembly

1. Park machine on a firm, level surface, level machine, fully Fuel tank is a one-piece unit and cannot be disassembled.
retract boom, lower boom, place transmission in Fuel level indicator can be removed and reused on new
(N) NEUTRAL, engage parking brake, and shut engine replacement tank. Dispose of old tank according to local
OFF. regulations concerning hazardous materials disposal.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel. c. Cleaning and Drying
3. Open engine cover. Allow system fluids to cool. If contaminated fuel or foreign material is in the tank, tank
4. Properly disconnect battery. Refer Section 9.8, “Battery”, can usually be cleaned.
for procedure. To clean the fuel tank:
Note: If replacing the tank, remove all internal and external 1. Have a dry chemical (Class B) fire extinguisher near work
components from the old tank, and retain for use on the area.
replacement tank. 2. Remove the fuel or oil tank drain plug, and safely drain
Note: Have a dry chemical (Class B) fire extinguisher near the any fuel into a suitable container. Dispose of fuel
work area. properly.
2 3. Clean fuel tank with a high pressure washer, or flush
tank with hot water for five minutes and drain water.
Dispose of contaminated water properly.
1 4. Add a diesel fuel emulsifying agent to tank. Refer to
manufacturer’s instructions for correct emulsifying
agent-to-water mixture ratio. Refill tank with water, and
agitate mixture for 10 minutes. Drain tank completely.
Dispose of contaminated water properly.
5. Refill fuel tank with water until it overflows. Completely
flush tank with water. Empty fuel tank, and allow it to
dry completely.

d. Assembly
Fuel level indicator can be removed and reused on new
replacement tank. Dispose of old tank according to
local regulations concerning hazardous materials
disposal regulations.

e. Inspection
1. Inspect fuel tank thoroughly for any cracks, slices, leaks
MZ7470 or other damage.
2. With fuel tank removed from machine, plug all
5. Remove hardware (1) securing fuel tank to frame.
openings except one elbow fitting. Install elbow fitting,
6. Support fuel tank with a floor jack or suitable supports. and apply approximately 7 - 10 kPa (1 - 1.5 psi) of air
Remove hardware (2) securing fuel tank pressure through elbow. Check reservoir for leaks by
support to cab. applying a soap solution to exterior and look for
7. Lower fuel tank and support bracket away from cab bubbles to appear at cracked or damaged area.
being careful to minimize fluid spillage.
8. Label, disconnect and cap fuel lines.
3614RS, 4017RS 31211337 7-9
 Engine

f. Fuel Tank Installation 7.7 ENGINE EXHAUST SYSTEM

1. Using a floor jack, lift fuel tank and support bracket to
Note: Emission Sensitive Exhaust. Assembly must be replaced
their original orientation on cab.
exactly as removed. Contact your local JLG dealer before
2. Connect previously labeled fuel hoses to their removing the muffler system.
appropriate locations. Secure with clamps. Connect fuel
sender. a. Exhaust System Removal - if ULS equipped
3. Secure the fuel tank with previously used hardware. 1. Park machine on a firm, level surface, level machine, fully
Remove floor jack. retract boom, lower boom, place transmission in
4. Fill fuel tank according to specifications. Refer to (N) NEUTRAL, engage parking brake, and shut engine
Section 2.3, “Fluids and Lubricant Capacities”. OFF.
5. Check fuel tank for leaks. 2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
6. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure. 3. Open engine cover. Allow system fluids to cool.
7. Close and secure engine cover. 4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
8. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

7.6.3 After Fuel System Service

1. Drain and flush the fuel tank if it was contaminated.
MZ7441
2. Vent air from fuel system in accordance with
instructions found in the appropriate Engine Operation 1
& Safety Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as required. 5. Remove belly pan (1).

2
3

MZ7490

6. Loosen and remove clamp (2) at exhaust pipe (3).

7. Loosen and remove clamp (4) securing tail pipe (5).

7-10 31211337 3614RS, 4017RS

 Engine

8. Remove tail pipe from exhaust pipe. b. Exhaust System Installation - if ULS equipped
Note: The emissions sensitive after-treatment unit must be
8 oriented properly as described below.
Note: DO NOT reinstall used gaskets or V-band clamps.
Note: Keep all clamps loosened until entire exhaust system is in
place.
1. Install exhaust pipe (3) and new gasket (14) to
after-treatment unit using new V-band clamp (13).
2. Install after-treatment unit and secure with
MZ8820 hangers (10). DO NOT tighten hangers.
6 7 3. Install the tail pipe (5) to the exhaust pipe (3) and secure
9. Label and disconnect both pressure sensor module to frame with previously used clamps (2 and 4). DO NOT
fittings (6)(7). tighten.
10. Label and disconnect both temperature sensors (8). 4. Install new exhaust pipe V-band clamps (9) and exhaust
pipe (10) with new gasket (11). DO NOT tighten.
5. Ensure exhaust pipe (10) is
installed with axis straight and
without offset or bends. The
flexible section of exhaust pipe
should measure between
244-264 mm
244 - 264 mm (9.6 - 10.4 in) (9.6 - 10.4 in)
3 14 10

11
MZ8840

6 7 15
13 9
12 18°

11. Loosen, remove and discard exhaust pipe V-band 4°

clamps (9) and exhaust pipe (10). Discard gasket (11).

20°- 30°
12. At bottom of after-treatment unit, loosen both 3
hangers (12). MZ8830

13. Carefully remove hangers and lower the after-treatment 6. Orient pressure sensor module fitting (6) approx 18°
unit from the machine. from horizontal axis.
14. Loosen, remove and discard V-band clamp (13) securing 7. Orient exhaust pipe (3) 4° from horizontal axis.
exhaust pipe (3) to after-treatment unit. Discard gasket 8. Torque hangers (12) to 25 - 35 Nm (18.4 - 26 lb-ft).
(14).
9. Torque clamps (2 and 4) to 11 - 13 Nm (8 - 9.5 lb-ft).
15. Remove exhaust pipe.
10. Torque new V-band clamps (9 and 13) to 11 - 13 Nm
(8 - 9.5 lb-ft).
11. Orient both DPF clamps (15) 20°- 30° from horizontal
axis. Torque to 16 - 20 Nm (12 - 15 lb-ft).
12. Connect pressure sensor fitting (6). Ensure fitting is
oriented upward, as shown.
Torque to 27 - 29 Nm (20 - 21 lb-ft).

3614RS, 4017RS 31211337 7-11

 Engine

13. Connect pressure sensor fitting (7). Ensure fitting is

oriented upward, as shown.
4
Torque to 19 - 21 Nm (14 - 15.5 lb-ft).
14. Connect both temperature sensors (8).
Torque to 40 - 50 Nm (29.5 - 40 lb-ft).
15. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
16. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed.
17. Install belly pan.
18. Close and secure engine cover.
19. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

c. Exhaust System Removal - if LS equipped

2 3
1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in
(N) NEUTRAL, engage parking brake, and shut engine
OFF.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel. MZ7490

3. Open engine cover. Allow system fluids to cool. 6. Loosen and remove clamp (2) at exhaust pipe (3).
4. Properly disconnect battery. Refer Section 9.8, “Battery”, 7. Loosen and remove clamp (4) securing tail pipe (5).
for procedure.
8. Remove tail pipe from exhaust pipe.

MZ7441
1

5. Remove belly pan (1).

7-12 31211337 3614RS, 4017RS

 Engine

d. Exhaust System Installation - if LS equipped

Note: Keep all clamps loosened until entire exhaust system is in
7
place.
1. Install exhaust pipe (3) to muffler and secure with
clamp (10).
2. Install muffler and secure with hardware removed
earlier. Do not tighten hangars.
3. Install the tail pipe (5) to the exhaust pipe (3) and secure
to frame with previously used clamps (2 and 4).
DO NOT Tighten.
8
4. Install exhaust pipe (8) to muffler with clamps (6).
DO NOT Tighten.
5. Secure exhaust pipe to engine exhaust pipe with
V-band clamp (7). DO NOT Tighten.

6
6. Adjust the muffler, tail and exhaust pipes for proper
clearance then tighten all clamps.
7. Torque clamps (7) to 16 - 20 Nm (12–15 lb-ft).
8. Torque clamps (2 and 4) to 11 - 13 Nm (8 - 9.5 lb-ft).
9
9. Torque clamps (6) to 9 - 11 Nm (6.6 - 8 lb-ft).
10 10. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
11. Start engine and check for exhaust leaks at all exhaust
3
connections. Adjust or repair as needed.
12. Install belly pan.
13. Close and secure engine cover.
14. Remove Do Not Operate Tag from ignition key switch
MZ7480
and steering wheel.

9. Loosen and remove exhaust pipe clamps (6).

10. Loosen and remove V-band clamp (7) securing exhaust
pipe (8).
11. Remove exhaust pipe (8).
12. Remove hardware (9) securing muffler to frame.
13. Carefully lower muffler from machine.
14. Loosen and remove clamp (10) securing exhaust
pipe (3) to muffler.
15. Remove exhaust pipe.

3614RS, 4017RS 31211337 7-13

 Engine

7.8 AIR CLEANER ASSEMBLY 7.8.2 Air Cleaner Assembly Installation

1. Install the air cleaner assembly (14) to the air cleaner

NOTICE mounting plate and secure with the previously used

hardware.
NEVER run the engine with only the inner safety element 2. Place the loosened clamp (12) over the air intake
installed. elbow (13) and install elbow on the air cleaner
assembly. Tighten clamp.
Note: Refer to the appropriate machine Operation & Safety
Manual for the correct element change procedure. 3. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
7.8.1 Air Cleaner Assembly Removal 4. Close and secure engine cover.
1. Park machine on a firm, level surface, level machine, fully 5. Remove Do Not Operate Tag from ignition key switch
retract boom, lower boom, place transmission in and steering wheel.
(N) NEUTRAL, engage parking brake, and shut engine
OFF.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
14

12

13
15

16
MZ7510

5. Loosen and remove clamp (12) securing air intake

tube (13) to air cleaner (14). Pull air intake elbow off air
cleaner.
6. Remove bolts (15) securing air cleaner straps (16) to air
cleaner (14). Remove air cleaner assembly.

7-14 31211337 3614RS, 4017RS

 Engine

7.9 ENGINE REPLACEMENT

1

WARNING
NEVER lift a engine/transmission alone; Use a suitable
hoist or overhead crane and sling with a minimum lifting
capacity of 700 kg (1543 lb).

7.9.1 Engine/Transmission Removal

Note: The radiator assembly must be removed from the
machine before engine/transmission removal. Refer to
Section 7.4.3, “Radiator Assembly Replacement” Several 2
additional components must be removed before engine/
transmission removal. They will be addressed in the following
MZ7441
procedures.
1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in 9. Remove hood (1), end cover (2) and belly pan from
(N) NEUTRAL, engage parking brake, and shut engine engine compartment.
OFF. 10. Remove the heater and cooling hoses attached to the
2. Place a Do Not Operate Tag on both ignition key switch engine.
and steering wheel. 11. Label, disconnect and cap/plug all hydraulic
3. Open engine cover. Allow system fluids to cool. connections on the engine/transmission.

4. Properly disconnect battery(s) and remove. Refer Note: Engine/transmission harness is routed and attached to
Section 9.8, “Battery”, for procedure. engine/transmission using hold-down clamps and plastic wire
ties at various places on engine. Before removing
5. Remove the oil pan cover from underneath the engine
engine/transmission, ensure that harness has been completely
compartment.
separated (disconnected) from engine/transmission. Move
6. Properly drain hydraulic oil system. Refer to Section 8.7, harness clear of engine/transmission, and with help of an
“Hydraulic Reservoir”, for detailed instructions. observer, ensure that engine/transmission clears the harness
7. Properly drain transmission. Refer to Section 6.4.1, during removal.
“Transmission Removal,” for detailed instructions. 12. Label and disconnect all electrical wire connections on
8. Mark position of cover to help with cover adjustment engine/transmission.
when being reinstalled.

3614RS, 4017RS 31211337 7-15

 Engine

19. Secure engine with a lifting strap or chain from

appropriate lifting points. Use a suitable hoist or
overhead crane.

5 MZ7551

20. Loosen and remove four engine/transmission mounting

bolts (5).
MZ7540 21. Slightly lift and pull engine/transmission out of
machine. Have an assistant ensure that
13. Disconnect and cap the fuel inlet line (3). engine/transmission clears all frame components
during removal.
22. Place engine/transmission on a flat, level surface.

7.9.2 Transmission Removal/Installation

1. Refer to Section 6.4, “Transmission Replacement,” for
detailed transmission removal and installation
instructions.
4
7.9.3 Engine Disassembly, Inspection
and Service
Engine disassembly, internal inspection, service, repair and
MZ7580 assembly procedures are covered in the Engine Service
Manual. Several special engine service tools are required to
14. Disconnect and cap the fuel return line (4) located near properly service the engine. Contact the local JLG dealer for
rear engine mount. further information.
15. Label and remove all clamps securing any fuel line on Note: If engine is being replaced, there may be external
engine. components that will be required to be transferred from original
16. Remove exhaust pipe from exhaust manifold. Refer to engine to replacement engine depending upon who you purchase
Section 7.7, “Engine Exhaust System”. new engine from and configuration of your replacement engine.
Refer to appropriate Engine user manual for detailed procedures
Note: Emission Sensitive Exhaust. Assembly must be replaced that cover transfer of original engine components to replacement
exactly as removed. engine.
17. Remove air cleaner assembly. Refer to Section 7.8, “Air
Cleaner Assembly”.
18. Remove drive shaft assemblies. Refer to Section 5.9.3,
“Drive Shaft Removal”.

7-16 31211337 3614RS, 4017RS

 Engine

7.9.4 Engine/Transmission Installation 19. Check for proper fluid levels prior to startup.
Refer to Section 2.3.2, “Fluids (if equipped for LS)”.
1. Attach a lifting chain to the front and rear engine
lift brackets, and lift engine/transmission clear of 20. Start engine and run to normal operating temperature
the ground. then shut off engine. While engine is cooling, check for
leaks.
Note: Apply medium strength threadlocking compound to the
engine mount bracket bolts before installation. 21. Allow engine to cool. Check radiator coolant level. Add
coolant as required.
2. Refer to Section 2.2, “Thread Locking Compound”, for all
22. Check for leaks from engine, main hydraulic pump and
thread locking requirements.
lines, transmission, hydraulic reservoir and fuel tank.
3. Lift engine/transmission and slowly push and lower into Check levels of all fluids and lubricants. Fill as required.
engine compartment. Have an assistant ensure that
engine/transmission clears frame, hose and harness Note: During full throttle check:
components during engine/transmission installation. • DO NOT operate any hydraulic function.
Position engine/transmission brackets over frame
• DO NOT steer or apply any pressure to the
mounts.
steering wheel.
4. Align motor mount holes and install front mounting
• Keep transmission in (N) NEUTRAL.
bolts and washers.
5. Align motor mount holes and install rear mounting 23. Check engine rpm at full throttle.
bolts and washers. 24. Purge the hydraulic system of air by operating all boom
6. Lower engine onto mounts. functions through their entire range of motion several
times.
7. Install flat washer, lock washer and nut on front two
mounting bolts. 25. Check hydraulic oil level. If oil is warm, oil level should
be visible in gauge window.
8. Remove lifting chains.
26. Check for proper operation of all components.
9. Torque engine /transmission mounting bolts (5)
to 241 Nm (178 lb-ft). 27. Turn engine OFF.

10. Install air cleaner. Refer to Section 7.8.2, “Air Cleaner 28. Install the oil pan cover underneath the
Assembly Installation”. engine compartment.

11. Install exhaust pipe. Refer to Section b, “Exhaust System 29. Close and secure engine cover.
Installation - if ULS equipped”. 30. Remove Do Not Operate Tag from ignition key switch
12. Install radiator assembly. Refer to Section 7.4.3, and steering wheel.
“Radiator Assembly Replacement”.
7.10 TROUBLESHOOTING
13. Install drive shaft assemblies. Refer to Section 5.9.5,
“Drive Shaft Installation”. Refer to Section 7.3, “Specifications and Maintenance
14. Connect and secure all the previously labeled hydraulic Information”, for detailed engine service information.
hoses, fuel lines and electrical wire connections on
engine and transmission.
15. Install heater and cooling hoses to engine and tighten
clamps (if equipped).
16. Install hood (1), end covers (2) and belly pan from engine
compartment and adjust if necessary.
17. Install and properly connect battery(s). Refer
Section 9.8, “Battery”, for procedure.
18. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
connections are correct and connected tightly.
Note: Have an assistant stand by with a Class B fire
extinguisher.

3614RS, 4017RS 31211337 7-17

 Engine

7-18 31211337 3614RS, 4017RS

 Section 8
Hydraulic System

Contents

PARAGRAPH TITLE PAGE

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.6.1 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.6.2 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.8 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.8.1 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9 Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.2 Service Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.9.3 Service Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.9.4 Service Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.9.5 Steering Orbital Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.9.6 Outrigger/Stabilizer Valve and Brake Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.9.7 Brake Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.9.8 Brake Damper Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.9.9 Pre-Charging Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.9.10 Checking Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.9.11 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.10 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.10.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.10.2 Cylinder Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.10.3 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.10.4 Cylinder Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

3614RS, 4017RS 31211337 8-1

 Hydraulic System

8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
hydraulic components of the machine. The following
illustration identifies the components that are referred to
throughout this section.

8.1.1 3614RS

COMPENSATION
CYLINDER
MAIN
LIFT/LOWER CONTROL
CYLINDER VALVE

EXTEND/RETRACT
CYLINDER

HYDRAULIC FLUID
RESERVOIR

IMPLEMENT
PUMP TILT
CYLINDER

LEVELING CYLINDER
MAE19711

OUTRIGGER
CYLINDER

8-2 31211337 3614RS, 4017RS

 Hydraulic System

8.1.2 4017RS

COMPENSATION
CYLINDER
MAIN
LIFT/LOWER CONTROL
CYLINDER VALVE

EXTEND/RETRACT
CYLINDER

HYDRAULIC FLUID
RESERVOIR

IMPLEMENT
PUMP TILT
CYLINDER

LEVELING CYLINDER

OUTRIGGER
CYLINDER MAE19721

3614RS, 4017RS 31211337 8-3

 Hydraulic System

8.2 SAFETY INFORMATION Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
WARNING properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.5, “Electrical System
DO NOT service the machine without following all safety Schematics” in this manual.
precautions as outlined in Section 1, “Safety Practices” of
this manual. 8.3 SPECIFICATIONS
Petroleum-based hydraulic fluids are used in this machine. Refer to Section 2.2, “Specifications”, for hydraulic system
The temperature of hydraulic fluid increases during the specifications.
operation of various hydraulic functions. A heated
petroleum-based hydraulic fluid presents a fire hazard,
8.4 HYDRAULIC PRESSURE DIAGNOSIS
especially when an ignition source is present.
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully 8.4.1 Pressure Checks and Adjustments
examine any deterioration and determine whether any When diagnosing trouble in the hydraulic system, use the
further use of the component would constitute a hazard. If in hydraulic testing information in Section 8.5.1, “Hydraulic
doubt, replace the component. Pressures”.
Whenever you disconnect a hydraulic line, coupler, fitting or In general, follow the steps below whenever conducting
other component, slowly and cautiously loosen the part pressure checks and performing adjustments:
involved. A hissing sound or slow seepage of hydraulic fluid
1. Park the machine on a firm, level surface. Engage the
may occur in most cases. After the hissing sound has ceased,
park brake, place the transmission in (N) NEUTRAL, level
continue removing the part. Any escaping oil should be
the boom and turn the engine OFF.
directed into an appropriate container. Cap or otherwise
block off the part to prevent further fluid seepage. 2. At the proper test port, install a pressure gauge capable
of measuring at least 10% more pressure than that
Hydraulic system maintenance will, at times, require that the
which the circuit being checked operates under.
engine be operated. Always follow safety precautions.
3. Start the engine. Operate machine functions several
A major cause of hydraulic component failure is
times to allow hydraulic oil to reach operating
contamination. Keeping the hydraulic fluid as clean as
temperature. The hydraulic oil temperature should be
possible will help avoid downtime and repairs. Dirty or
between 38 - 49°C (100 - 120°F). If a temperature gauge
contaminated hydraulic oil can damage internal
or thermometer is unavailable, the hydraulic oil reservoir
components and void the manufacturer’s warranty. When
should be warm to the touch.
servicing the system, cap or plug hydraulic fittings, hoses and
tube assemblies. Plug all cylinder ports, valves and the 4. Refer to Section 8.5.1, “Hydraulic Pressures”, for testing
hydraulic reservoir, and pump openings until installation procedures.
occurs. Protect threads from contamination and damage. 5. Fully depress the accelerator pedal if required. Place and
Manufacture’s recommended hydraulic oil cleanliness levels hold the joystick in the position needed to operate the
are based on the three digit ISO code for 4 micron/6 micron/ particular machine function being checked. Continue
14 micron particle sizes found in one ml of fluid (reference holding the joystick in position until pressure readings
ISO 4406: 199(E). The acceptable level is 19/17/14 or below; are taken.
anything higher requires system cleaning and filter 6. Check the pressure gauge reading. It should read as
replacement. specified in the Pressure Readings column of the charts
Note: The human eye can only distinguish particles down to found in Section 8.5.1, “Hydraulic Pressures”. If the
40 microns. reading is not as specified, turn the engine OFF and
check other components in the system. Verify that all
Reference Section 2.4, “Service and Maintenance Schedules”, related hydraulic components and electrical switches,
for the appropriate maintenance intervals based on hours of sensors, solenoids, etc. are operating correctly.
operation, but if your equipment is exposed to extremely
7. Adjust the relief valve by turning the adjustment screw.
dirty or hostile conditions service may be required more
Turning clockwise will increase the pressure; turning the
frequently. Always use OEM filters to assure the necessary
screw counterclockwise will decrease the pressure.
filtration requirements are met.

8-4 31211337 3614RS, 4017RS

 Hydraulic System

8. Start the engine and check the pressure again. Turn the b. Adjusting Maximum Pump Pressure
engine OFF. If there is pressure reading in the gauge,
1. Set park brake, start the machine, level and retract the
bleed it off then disconnect or remove the pressure
boom.
gauge from the machine.
2. Loosen the jam nut on the relief (1). Turn the relief
8.5 HYDRAULIC CIRCUITS clockwise to increase pressure or counter-clockwise to
decrease pressure. Set to the correct pressure.
This section covers the hydraulic circuits and includes listings Note: Always adjust the Main Relief Valve pressure to the low
for all hydraulic function pressures, where and how to check side of the specification, i.e. 270 Bar (3916 psi).
those pressures and a hydraulic schematic.
3. Torque the jam nut to 17 - 23 Nm (12.5 - 17 lb-ft) and
Electrical and hydraulic functions are often related. Verify
recheck the pressure at full throttle. If the reading is
that the electrical components of the circuit are functioning
within specification, remove the gauge from the test
properly whenever troubleshooting the hydraulic circuit.
port.
Always check the following before beginning to
4. If the proper pressure cannot be set, use the
troubleshoot a circuit that is not functioning correctly.
accompanying hydraulic schematic and/or the electrical
1. Check the hydraulic oil level in the reservoir. If oil is cold, schematic to help troubleshoot and correct the
oil level should be visible in the lower gauge window problem.
with all cylinders retracted.
2. Check hoses, tubes, fittings and other hydraulic
components for leaks, bends, kinks, interference, etc.
3. Check for air in the hydraulic system. Erratic machine
performance and/or spongy cylinder operation are
signs of air in the hydraulic system.
If air in the hydraulic system is suspected, you will hear
air leakage when hydraulic fittings are loosened and see
air bubbles in the hydraulic fluid.
Loose fittings, faulty O-rings or seals, trapped oil, leaks,
system opened for service, etc., can cause air in the
system. Determine what is causing air to enter the
system and correct it. Bleed air from the system.

8.5.1 Hydraulic Pressures

a. Checking Pressure
1. Start the machine and warm the hydraulic system to
operating temperature.
2. Shut off the machine and install a digital or a
345 bar (5000 psi) gauge to the appropriate test port on
the main control valve.
3. Start the machine, run the engine at idle and bottom
the appropriate hydraulic function. Refer to
Section 8.5.1. c, “Pressure Specifications”, for the correct
pressure rating.

3614RS, 4017RS 31211337 8-5

 Hydraulic System

c. Pressure Specifications
Note: All pressure check are to be performed at High Idle unless noted.

B
MZ7230

D
MZ7741

Hydraulic Adjustment
Test Port Procedure Pressure Range
Circuit Location
Connect gauge to A port on the boom
head, run engine at high idle, hold
Auxiliary 235 - 253 Bar
1 A auxiliary function and check pressure. NA
Pressure (3408 - 3669 PSI)
Note: Do not operate any other function
while checking pressure
Connect gauge to P1 (B) port, level
boom, run engine at high idle, and
Maximum Pump 270 - 275 Bar
2 P1 (B) bottom boom retract. 1
Pressure (3916 - 3988 PSI)
Note: Do not operate any other function
while checking pressure.
Connect gauge to LS1 (C) port, level
boom, run engine at high idle, and
256 - 261 Bar
3 Load Sense LS1 (C) bottom boom retract. NA
(3713 - 3785 PSI)
Note: Do not operate any other function
while checking pressure.
Connect gauge to V (D) port, level
boom, run engine at low idle. 34 - 36 Bar
4 Pilot Pressure V (D) NA
Note: Do not operate any functions (493 - 522 PSI)
while checking pressure.

8-6 31211337 3614RS, 4017RS

 8.6

8.6.1
8 7 6 5 4 3 2 1

3614RS, 4017RS
COMP' CYLINDER
LIFT CYLINDER BORE: 75MM
ROD: 50MM
V1
BORE: 150
H ROD: 90 H
STROKE: 1292
CLOSED CENTRES: 1698
CBV RATIO: 4:1
CBV SETTING: 320 BAR (LEFT) STABILIZER CYLINDER (RIGHT) STABILIZER CYLINDER
RETRACT/EXTEND
CYLINDER BORE: 125 BORE: 125
ROD: 55 ROD: 55
3614RS

V1 V2 STROKE: 400 STROKE: 400

BORE: 85 CLOSED CENTRES: 710 CLOSED CENTRES: 710
ROD: 65
STROKE: 3750 FRAME LEVELLING
CLOSED CENTRES: 4472 TILT CYLINDER
CBV RATIO: 4:1
CYLINDER
CBV SETTING: 320 BAR
BORE: 120
BORE: 95
ROD: 80
ROD: 50
STROKE: 368
STROKE: 168
V2 V2 V1 CLOSED CENTRES: 734
CLOSED CENTRES: 440
CBV RATIO: 3:1
CBV SETTING: 320 BAR

T1

T2 T1 T2 T1
G G

MALE AUXILIARY COUPLING V2 V1 V2 V1

V1

FEMALE AUXILIARY COUPLING

A1 B1 A2 B2 A3 B3 A4 B4 V2
280 280 280 240 240
a. If equipped for 74,4 kW engine

BAR BAR BAR BAR BAR

T2
HYDRAULIC SCHEMATICS

T1 T2
CONTAMINATION TEST POINT
270
F BAR
F

35 BAR

2 MM LS

LS 1
L/MIN

14
E BAR E
LS1

P1
BOOM RAISE/LOWER BOOM EXTEND/RETRACT COUPLER TILT BOOM AUXILIARIES (OPTION)
FRAME LEVEL AND STABILIZERS VALVE
T P MAIN CONTROL VALVE L
WHEN MOUNTED ON THE MACHINE THE 'B' (RETRACT) SERVICE PORTS AND ELECTRICAL CONNECTIONS ARE UPPERMOST

P
B1

D D

31211337
FRONT AXLE L
STEERING STROKE: 208MM
ANNULUS AREA: 47.7CM²
BRAKE VOL (AT 50 BAR): 10.4CC

RETURN FILTER NOMINAL STEER SYSTEM

STANDBY PRESSURE: 7 BAR
L
5µ BETA RATIO: 1000 P
BYPASS OPENS AT: 3.5 BAR 240
BLOCKAGE INDICATED AT 2.5 BAR BAR

C C
R1
LD P T SERVICE BRAKE
180
MASTER CYLINDER &
BAR FOOT PEDAL ASSEMBLY
TOTAL DISPLACEMENT: 27.5 TO
49CC

240
BAR

T R CRAB 4WS

A B
EF CF STEERING ORBITAL
DISPLACEMENT 200CC/REV

0.5MM 0.75MM

COOLER BYPASS
B B
CRACKING PRESSURE: 4 BAR 1.3MM REAR AXLE
STEERING STROKE: 208MM
4 ANNULUS AREA: 47.7CM²
BAR BRAKE VOL (AT 50 BAR): 8.3CC

PUMP PTO RATIO TO ENGINE 1.03:1

DIRECTION OF ROTATION: CLOCKWISE
ENGINE LOW IDLE (UNLOADED): 950 RPM
ENGINE HIGH IDLE (UNLOADED): 2300 RPM

IMPLEMENT PUMP
AIR FILTER DISPLACEMENT: 43.98CC/REV
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
10W PER 100 RPM

RESERVOIR
A A
FILL VOLUME: 105L
APPROXIMATE SYSTEM VOLUME: 180L
Hydraulic System

8 7 6 5 4 3 2 1

MZ7750C

8-7
8-8
1 2 3 4 5 6 7 8

COMP' CYLINDER
LIFT CYLINDER
BORE: 75MM
ROD: 50MM
BORE: 150 V1
ROD: 90
STROKE: 1292
CLOSED CENTRES: 1698
CBV RATIO: 4:1
CBV SETTING: 380 BAR
C2 C1
H (LEFT) STABILISER CYLINDER (RIGHT) STABILISER CYLINDER H
TELE/EXTEND
1 3 CYLINDER BORE: 125 BORE: 125
ROD: 55 ROD: 55
C1 V1 V2 STROKE: 400 STROKE: 400
BORE: 85 CLOSED CENTRES: 710 CLOSED CENTRES: 710
ROD: 65
STROKE: 3750 FRAME LEVELLING

3
CLOSED CENTRES: 4472 TILT CYLINDER
CBV RATIO: 4:1
CYLINDER
CBV SETTING: 380 BAR
BORE: 120

2
BORE: 95
ROD: 80
ROD: 50
STROKE: 368
V2 STROKE: 168
C2 CLOSED CENTRES: 734
2 CLOSED CENTRES: 440
CBV RATIO: 3:1
CBV SETTING: 310 BAR

1
T1

T2 T1 T2 T1

G V1 G
MALE AUXILIARY COUPLING
CAT MACHINES: ISO16028
JLG MACHINES: ISO7241-1 (SERIES A) V2 V1 V2 V1
Hydraulic System

V2 V1
FEMALE AUXILIARY
COUPLING
CAT MACHINES: ISO16028
A1 B1 A2 B2 A3 B3 A4 B4 JLG MACHINES: ISO7241-1 (SERIES A) V2
240 280 280 240 240
BAR BAR BAR BAR BAR
b. If equipped for 55,0 kW engine

T2

T1 T2
CONTAMINATION TEST POINT
+5
270 BAR
0
F F
35 BAR

2 MM LS

P
1.5

0.6

LS 1
L/MIN

14
BAR
E LS1 1.0
E
T

1.1
P1
BOOM RAISE/LOWER BOOM EXTEND/RETRACT COUPLER TILT BOOM AUXILIARIES (OPTION)
FRAME LEVEL AND STABILISERS VALVE
T PRESSURE DAMPER
P MAIN CONTROL VALVE L
WHEN MOUNTED ON THE MACHINE THE 'B' (RETRACT) SERVICE PORTS AND ELECTRICAL CONNECTIONS ARE UPPERMOST

31211337
B1

D D

R1
FRONT AXLE
STEERING STROKE:109.7MM
ANNULUS AREA: 47.7CM²
BRAKE VOL (AT 50 BAR): 10.4CC
L
SERVICE BRAKE
MASTER CYLINDER &
FOOT PEDAL ASSEMBLY
RETURN FILTER TOTAL DISPLACEMENT: 27.5 TO
49CC
L S
RETURN FILTER WITH THERMAL
LOCKOUT SWITCH VM3 CD.1/-2MO-30C T 0
5µ BETA RATIO: 1000 180 -7
C BYPASS OPENS AT: 3.5 BAR BAR C
P

LS P T

NOMINAL STEER SYSTEM

STANDBY PRESSURE: 7 BAR
R
P

CRAB 4WS

STEERING ORBITAL QAMP - RATIO 2:1 A B

EF CF DISPLACEMENT 100CC/REV

0.5MM 0.75MM
B B
COOLER BYPASS

CRACKING PRESSURE: 4 BAR 1.3MM REAR AXLE

STEERING STROKE: 109.7MM
4 ANNULUS AREA: 47.7CM²
BAR BRAKE VOL (AT 50 BAR): 10.4CC

PUMP PTO RATIO TO ENGINE 1.03:1

DIRECTION OF ROTATION: CLOCKWISE
ENGINE LOW IDLE (UNLOADED): 950 RPM
ENGINE HIGH IDLE (UNLOADED): 2300 RPM

IMPLEMENT PUMP
AIR FILTER DISPLACEMENT: 43.98CC/REV
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
10W PER 100 RPM
A A
RESERVOIR
FILL VOLUME: 105L
APPROXIMATE SYSTEM VOLUME: 180L

1 2 3 4 5 6 7 8

MAE8880A

3614RS, 4017RS
 8 7 6 5 4 3 2 1
8.6.2

3614RS, 4017RS
COMP' CYLINDER
LIFT CYLINDER BORE: 75MM
ROD: 50MM
V1
BORE: 170
ROD: 100
H STROKE: 1333 H
CLOSED CENTRES: 1782
CBV RATIO: 4:1
CBV SETTING: 320 BAR (LEFT) STABILIZER CYLINDER (RIGHT) STABILIZER CYLINDER
RETRACT/EXTEND
CYLINDER BORE: 125 BORE: 125
ROD: 55 ROD: 55
V1 V2 STROKE: 400 STROKE: 400
BORE: 110
4017RS

CLOSED CENTRES: 710 CLOSED CENTRES: 710

ROD: 80
STROKE: 3610 FRAME LEVELLING
CLOSED CENTRES: 4526 TILT CYLINDER
CBV RATIO: 4:1
CYLINDER
CBV SETTING: 320 BAR
BORE: 120
BORE: 105
ROD: 80
ROD: 55
STROKE: 368
STROKE: 168
V2 V2 V1 CLOSED CENTRES: 734
CLOSED CENTRES: 440
CBV RATIO: 3:1
CBV SETTING: 320 BAR

T1

T2 T1 T2 T1
G G

MALE AUXILIARY COUPLING V2 V1 V2 V1

V1

FEMALE AUXILIARY COUPLING

A1 B1 A2 B2 A3 B3 A4 B4 V2
280 280 280 240 240
a. If equipped for 74,4 kW engine

BAR BAR BAR BAR BAR

T2

T1 T2
CONTAMINATION TEST POINT
270
F BAR F
35 BAR

2 MM LS

LS 1
L/MIN

14
E BAR E
LS1

P1
BOOM RAISE/LOWER BOOM EXTEND/RETRACT COUPLER TILT BOOM AUXILIARIES (OPTION)
FRAME LEVEL AND STABILIZERS VALVE
T P MAIN CONTROL VALVE L
WHEN MOUNTED ON THE MACHINE THE 'B' (RETRACT) SERVICE PORTS AND ELECTRICAL CONNECTIONS ARE UPPERMOST

P
B1

2
D D

31211337
3

L 1
FRONT AXLE
STEERING STROKE: 208MM
ANNULUS AREA: 47.7CM²
BRAKE VOL (AT 50 BAR): 10.6CC

S
R B'

RETURN FILTER NOMINAL STEER SYSTEM

STANDBY PRESSURE: 7 BAR
L N
5µ BETA RATIO: 1000 P
BYPASS OPENS AT: 3.5 BAR 240
BLOCKAGE INDICATED AT 2.5 BAR BAR
B
C R1 C
PARK BRAKE
LD P T SERVICE BRAKE VALVE

180
MASTER CYLINDER & VALVE SHOWN WITH
BAR FOOT PEDAL ASSEMBLY THE BRAKE
TOTAL DISPLACEMENT: 27.5 TO DISENGAGED.
49CC RELEASE PRESSURE:
21 TO 35 BAR

240
BAR

T R CRAB 4WS

A B
EF CF STEERING ORBITAL
DISPLACEMENT 200CC/REV

0.5MM 0.75MM

COOLER BYPASS
B B
CRACKING PRESSURE: 4 BAR 1.3MM REAR AXLE
STEERING STROKE: 208MM
4 ANNULUS AREA: 47.7CM²
BAR BRAKE VOL (AT 50 BAR): 8.5CC

PUMP PTO RATIO TO ENGINE 1.03:1

DIRECTION OF ROTATION: CLOCKWISE
ENGINE LOW IDLE (UNLOADED): 950 RPM
ENGINE HIGH IDLE (UNLOADED): 2300 RPM

IMPLEMENT PUMP
AIR FILTER DISPLACEMENT: 43.98CC/REV
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
10W PER 100 RPM

RESERVOIR
A FILL VOLUME: 105L A
APPROXIMATE SYSTEM VOLUME: 190L
Hydraulic System

8 7 6 5 4 3 2 1

MZ7760C

8-9
8-10
1 2 3 4 5 6 7 8

COMP' CYLINDER
LIFT CYLINDER BORE: 75MM
ROD: 50MM
BORE: 170 V1
ROD: 100
STROKE: 1333
CLOSED CENTRES: 1782
H CBV RATIO: 4:1 H
CBV SETTING: 380 BAR C2 C1
(LEFT) STABILISER CYLINDER (RIGHT) STABILISER CYLINDER

1 TELE/EXTEND BORE: 125 BORE: 125

3 ROD: 55 ROD: 55
CYLINDER V2 STROKE: 400 STROKE: 400
C1 V1 CLOSED CENTRES: 710 CLOSED CENTRES: 710
BORE: 110 FRAME LEVELLING
ROD: 80 TILT CYLINDER
STROKE: 3610 CYLINDER

3
CLOSED CENTRES: 4526
CBV RATIO: 4:1 BORE: 120
BORE: 105

2
CBV SETTING: 380 BAR ROD: 80
ROD: 55
STROKE: 368
STROKE: 168
CLOSED CENTRES: 734
V2 CLOSED CENTRES: 440
C2 2 CBV RATIO: 3:1
CBV SETTING: 360 BAR

T1

1
T2 T1 T2 T1
G G
V1 MALE AUXILIARY COUPLING
CAT MACHINES: ISO16028
Hydraulic System

V2 JLG MACHINES: ISO7241-1 (SERIES A) V2 V1 V2 V1

V1
FEMALE AUXILIARY
COUPLING
CAT MACHINES: ISO16028
A1 B1 A2 B2 A3 B3 A4 B4 JLG MACHINES: ISO7241-1 (SERIES A) V2
240 280 280 240 240
BAR BAR BAR BAR BAR
b. If equipped for 55,0 kW engine

T2

T1 T2
CONTAMINATION TEST POINT
+5
270 BAR
F 0 F
35 BAR

2 MM LS

P
1.5

0.6

LS 1
L/MIN

14
E BAR
E
LS1 1.0

1.1
P1
BOOM RAISE/LOWER BOOM EXTEND/RETRACT COUPLER TILT BOOM AUXILIARIES (OPTION)
FRAME LEVEL AND STABILISERS VALVE
T PRESSURE DAMPER
P MAIN CONTROL VALVE L
WHEN MOUNTED ON THE MACHINE THE 'B' (RETRACT) SERVICE PORTS AND ELECTRICAL CONNECTIONS ARE UPPERMOST

B1

31211337
D D
2

R1 3

1
FRONT AXLE
STEERING STROKE: 109.7MM L
ANNULUS AREA: 47.7CM²
BRAKE VOL (AT 50 BAR): 10.4CC

R B'
RETURN FILTER S

RETURN FILTER WITH THERMAL L N

LOCKOUT SWITCH VM3 CD.1/-2MO-30C
5µ BETA RATIO: 1000 T P
C BYPASS OPENS AT: 3.5 BAR 0 C
180 -7 B
BAR

PARK BRAKE
LS P VALVE
T
VALVE SHOWN WITH
NOMINAL STEER SYSTEM THE BRAKE
STANDBY PRESSURE: 7 BAR DISENGAGED.
R RELEASE PRESSURE:
P 21 TO 35 BAR

CRAB 4WS SERVICE BRAKE

MASTER CYLINDER &
A B FOOT PEDAL ASSEMBLY
EF CF STEERING ORBITAL QAMP - RATIO 2:1 TOTAL DISPLACEMENT: 27.5 TO
DISPLACEMENT 100CC/REV 49CC

0.5MM 0.75MM
B B
COOLER BYPASS

CRACKING PRESSURE: 4 BAR 1.3MM REAR AXLE

STEERING STROKE: 109.7MM
4 ANNULUS AREA: 47.7CM²
BAR BRAKE VOL (AT 50 BAR): 10.4CC

PUMP PTO RATIO TO ENGINE 1.03:1

DIRECTION OF ROTATION: CLOCKWISE
ENGINE LOW IDLE (UNLOADED): 950 RPM
ENGINE HIGH IDLE (UNLOADED): 2300 RPM

IMPLEMENT PUMP
AIR FILTER DISPLACEMENT: 43.98CC/REV
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
A 10W PER 100 RPM A
RESERVOIR
FILL VOLUME: 105L
APPROXIMATE SYSTEM VOLUME: 190L

1 2 3 4 5 6 7 8

MAE8890A

3614RS, 4017RS
 Hydraulic System

8.7 HYDRAULIC RESERVOIR 8.7.2 Hydraulic Oil Reservoir Filling

1 1. Be sure the reservoir is clean and free of all debris.
5
4 2. Install a new hydraulic oil filter.
3
3. Fill the reservoir with oil until oil level is visible in the
gauge window (3). Refer to Section 2.3, “Fluids and
Lubricant Capacities”
4. Properly connect the battery. Refer Section 9.8,
6 “Battery”, for procedure.
6 5. Close and secure the engine cover.
2
6. Start machine and check all hydraulic functions for
MZ8000 proper operation. Check for any hydraulic oil leaks. Shut
machine OFF and check hydraulic oil level. If oil is warm,
The hydraulic reservoir (1) is located under the cab. oil level should be visible in the gauge window (3). Add
hydraulic oil if necessary.
8.7.1 Hydraulic Oil Reservoir Draining 7. Close the hydraulic oil filler cab access panel at the
1. Park the machine on a firm, level surface, level the bottom left rear of the cab.
machine, fully retract the boom, lower the boom, place 8. Remove the Do Not Operate Tag from the ignition key
the transmission in (N) NEUTRAL, engage the park brake switch and the steering wheel.
and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key 8.7.3 Hydraulic Oil Reservoir Removal/
switch and the steering wheel. Installation
3. Open the engine cover. Allow the system fluids to cool. If it is determined that the hydraulic oil reservoir must be
removed, the hydraulic oil must be drained before the
4. Properly disconnect the battery. Refer Section 9.8,
reservoir is removed. Always dispose of hydraulic oil
“Battery”, for procedure.
properly.
5. Open the hydraulic oil filler cab access panel at the
bottom left rear of the cab. a. Reservoir Removal
6. Open the filler cap on the hydraulic oil reservoir. 1. Park the machine on a firm, level surface, level the
Remove the drain plug (2) on the bottom of the machine, fully retract the boom, lower the boom, place
hydraulic oil reservoir. the transmission in (N) NEUTRAL, engage the park brake
7. Transfer the used hydraulic oil into a suitable covered and shut the engine OFF.
container, and label as “Used Oil”. Dispose of used oil at 2. Place a Do Not Operate Tag on both the ignition key
an approved recycling facility. Clean and reinstall the switch and the steering wheel.
drain plug. Torque drain plug to 35 Nm (25 lb-ft).
3. Open the engine cover. Allow the system fluids to cool.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area. 4. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure.
5. Drain the hydraulic oil reservoir. Refer to Section 8.7.1,
“Hydraulic Oil Reservoir Draining”.
6. Label, disconnect and cap all hydraulic hoses attached
to the hydraulic oil reservoir. Cap all fittings and
openings to keep dirt and debris from entering the
hydraulic system.
7. Remove the two bolts securing the fill tube/bracket (4).
8. Remove the bolt (5), nuts and strap (6) securing the
hydraulic oil reservoir to the frame.
9. Remove the hydraulic oil reservoir.

3614RS, 4017RS 31211337 8-11

 Hydraulic System

b. Disassembly d. Inspection
Dispose of the old reservoir according to local regulations 1. Inspect the hydraulic oil reservoir thoroughly for any
concerning hazardous materials disposal. cracks, slices, leaks or other damage.
2. With the hydraulic oil reservoir removed from the
machine, plug all openings except one elbow fitting.
Install the elbow fitting, and apply approximately
7 - 10 kPa (1 - 1.5 psi) of air pressure through the elbow.
Check the reservoir for leaks by applying a soap solution
to the exterior and look for bubbles to appear at the
cracked or damaged area.

e. Assembly
1. Install the previously removed fittings, adapters and
tubes in the correct orientation.
MZ8010
2. Properly torque all fittings and adapters as required.
1. Note the orientation of all fittings, adapters and tubes
f. Reservoir Installation
on the hydraulic tank.
2. Label and remove all fittings, adapters and tubes from 1. Place the hydraulic oil reservoir into its original
the hydraulic tank. orientation.
2. Secure the hydraulic oil reservoir to the frame with the
c. Cleaning and Drying previous mounting hardware.
If contaminated hydraulic oil or foreign material is in the 3. Uncap and connect the previously labeled hydraulic
tank, the tank can usually be cleaned. hoses to their appropriate locations. Be sure all lines are
free of kinks and sharp bends.
To clean the hydraulic oil reservoir:
4. Fill the reservoir with oil until oil level is visible in the
1. Have a dry chemical (Class B) fire extinguisher near the
gauge window. Refer to Section 2.3, “Fluids and
work area.
Lubricant Capacities”.
2. Remove the hydraulic oil reservoir drain plug, and safely
5. Check the hydraulic oil reservoir for leaks.
drain any hydraulic oil into a suitable container. Dispose
of hydraulic oil properly. 6. Properly connect the battery. Refer Section 9.8,
“Battery”, for procedure.
3. Clean the hydraulic oil reservoir with a high-pressure
washer, or flush the tank with hot water for five minutes 7. Close and secure the engine cover.
and drain the water. Dispose of contaminated water 8. Start machine and check all hydraulic functions for
properly. proper operation. Check for any hydraulic oil leaks. Shut
machine OFF and check hydraulic oil level. If oil is warm,
oil level should be visible in the gauge window. Add
hydraulic oil if necessary.
9. Remove the Do Not Operate Tag from the ignition key
switch and the steering wheel.

8-12 31211337 3614RS, 4017RS

 Hydraulic System

8.8 ENGINE IMPLEMENT PUMP b. Pump Installation

1. Apply medium strength threadlocking compound to all
8.8.1 Pump Replacement mounting bolts.
2. If the adapter plate was removed, place into position
a. Pump Removal with a new, oiled O-ring on the engine. Secure with the
1. Park the machine on a firm, level surface, level the previously used hardware.
machine, fully retract the boom, lower the boom, place 3. Place the pump and a new, oiled O-ring into position on
the transmission in (N) NEUTRAL, engage the park brake the adapter plate. Align the pump shaft with the
and shut the engine OFF. internal gear, so that the machined teeth mesh
2. Place a Do Not Operate Tag on both the ignition key together.
switch and the steering wheel. 4. Align the bolt holes with the pump mount holes. Secure
3. Open the engine cover. Allow the system fluids to cool. the pump to the adapter plate with the two bolts and
washers. Torque as required.
4. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure. 5. Uncap and connect the previously labeled hydraulic hoses
to their appropriate locations.
5. Drain the hydraulic reservoir. Refer to Section 8.7.1,
“Hydraulic Oil Reservoir Draining”. Note: Prime the pump by filling the case with fresh, filtered
6. Thoroughly clean the pump and surrounding area, hydraulic oil from a clean container through suction port (3)
including all hoses and fittings before proceeding. before installing hose and flanges.

Note: Cap all hoses as you remove them to prevent 6. Fill the hydraulic reservoir. Refer to Section 8.7.2,
unnecessary fluid spillage. “Hydraulic Oil Reservoir Filling”.
7. Check all routing of hoses and tubing for sharp bends or
7. Label, disconnect and cap the hydraulic hoses attached
interference with any rotating members.
to the pump.
3 8. Inspect for leaks and check all fluid levels. The hydraulic
2 reservoir oil level must be to the middle of the sight
1
gauge.
9. Properly connect the battery. Refer Section 9.8,
“Battery”, for procedure.
1 10. Close and secure the engine cover.
11. Start machine and verify proper operation.
12. Remove the Do Not Operate Tag from the ignition key
switch and the steering wheel.

c. Implement Pump Test

MZ8020
Refer to Section 8.4.1, “Pressure Checks and Adjustments”.
8. Remove the two bolts and two lockwashers (1) securing
the pump (2) to the adapter plate. Remove the O-ring
located between the plate and the pump. Wipe up any
hydraulic oil spillage.
9. If necessary, remove the four bolts securing the adapter
plate to the transmission. Remove the adapter plate.
Note: DO NOT disassemble the operating pump. The pump is
pre-set from the manufacturer.

3614RS, 4017RS 31211337 8-13

 Hydraulic System

8.9 CONTROL VALVES 9. Label, disconnect and cap all the hydraulic hoses, tubes
and wires at the main control valve. Slowly turn hose
fittings to allow any trapped pressure in the hydraulic
8.9.1 Main Control Valve system to escape.
The main control valve is mounted at the rear of the cab. 10. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
2
11. Support the valve and remove the four bolts securing
the main control valve to the frame. Remove the main
control valve.

b. Main Control Valve Disassembly

1. To disassemble the individual sections of the main
3 control valve, remove the nuts from one end of the tie
rods.
4
2. Disassemble each section assembly as required.
5 Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
1
Note: DO NOT adjust any of the relief valve assemblies.
Tampering with a relief valve will irrevocably alter pressure in the
affected circuit, requiring recalibration or a new relief valve.
MZ8060
Disassemble each Valve Section
6
1. Carefully separate the load sense outlet section (5) from the
The main control valve assembly (1) consists of working next section.
sections with their own valve assemblies, each providing a 2. Remove the O-rings from between the two sections.
specific hydraulic function. Those functions are:
lift/lower (2), extend/retract (3), tilt (4) and auxiliary (5). 3. Carefully separate each remaining section.
4. Remove any check valves, compensator valves, anti-
a. Main Control Valve Removal cavitation valves or shock valves from individual valve
section if equipped.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, place 5. Keep all parts being removed from individual valve
the transmission in (N) NEUTRAL, engage the park brake sections tagged and kept together.
and shut the engine OFF.
c. Main Control Valve Parts Cleaning
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel. Clean all components with a suitable cleaner, such as
3. Open the engine cover. Allow the system fluids to cool. triclorethylene, before continuing. Blow dry.
4. Properly disconnect the battery. Refer Section 9.8, d. Main Control Valve Parts Inspection
“Battery”, for procedure.
Inspect all parts and internal passageways for wear, damage,
5. Remove the main control valve cover.
etc. If inner surfaces of any component DO NOT display an
6. Thoroughly clean the main control valve and ultra-smooth, polished finish, or are damaged in any way,
surrounding area, including all hoses and fittings, replace the damaged part. Often, dirty hydraulic fluid causes
before proceeding. failure of internal seals, damage to the polished surfaces
7. Place a suitable container to catch hydraulic fluid within the component, and wear of and/or harm to other
drainage beneath the cab. parts.
8. Drain the hydraulic oil reservoir. Refer to Section 8.7.1,
“Hydraulic Oil Reservoir Draining”.

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 Hydraulic System

e. Main Control Valve Assembly 9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
Note: ALWAYS replace seals, O-rings, gaskets, etc., with new
parts to help ensure proper sealing and operation. Lubricate 10. Install main control valve cover.
seals and O-rings with clean hydraulic oil. 11. Close and secure the engine cover.
12. Remove the Do Not Operate Tag from the ignition key
Assemble each Valve Section
switch and the steering wheel.
1. Reassemble any check valves, compensator valves,
anti-cavitation valves or shock valves from each g. Main Control Valve Test
individual valve sections if equipped.
Conduct a pressure check of the hydraulic system in its
2. Install the end caps on each end of the valve section. entirety. Adjust pressure(s) as required. Refer to Section 8.5.1,
“Hydraulic Pressures”.
Assemble the Main Control Valve.
1. If removed, install all four tie rods into the end main
control valve section.
2. Stand the end main control valve section on end.
3. Install the proper O-rings and load sense shuttle on the
inner face of the end main control valve section. Align
the next valve section over the three tie rods and slide
onto the end main control valve section.
4. Using the proper O-rings and load sense shuttle, repeat
step three for the remaining valve sections and lastly
the inlet end valve section.
5. Install the nuts on the tie rods (6) and torque to
25 Nm (18.5 lb-ft).

f. Main Control Valve Installation

1. Install the main control valve onto the frame, aligning
the bolts with the holes in the end sections of the main
control valve. Slide the main control valve into position,
and tighten the bolts.
2. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a clean
container, before attaching the hoses.
3. Use new oiled O-rings as required. Uncap and connect
all hoses, clamps, etc. to the main control valve.
4. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps.
5. Fill the hydraulic oil reservoir. Refer to Section 8.7.2,
“Hydraulic Oil Reservoir Filling”.
6. Properly connect the battery. Refer Section 9.8,
“Battery”, for procedure.
7. Start the engine and run at approximately one-third to
one-half throttle for about one minute without moving
the machine or operating any hydraulic functions.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
3614RS, 4017RS 31211337 8-15
 Hydraulic System

8.9.2 Service Brake Valve If equipped with 55,0 kW engine

a. Service Brake Valve Removal

1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, place
the transmission in (N) NEUTRAL, engage the park brake 7
and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
10
3. Open the engine cover. Allow the system fluids to cool.
4. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure.
9
5. Remove the access covers from the outside of the cab.
If equipped with 74,4 kW engine 8

MAE4200

6. Label, disconnect and cap all hoses attached to the

7 service brake valve (7).
7. Remove the cover panel in the cab (8).
8. Disconnect and remove the brake pedal (9).
9. Remove the two nuts (10) securing the service brake
10 valve to the cab.
10. Remove the valve through the front of the cab.
Note: DO NOT disassemble the service brake valve. The service
brake valve is not serviceable and must be replaced in its
9 entirety, if defective.

8 MZ7720

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 Hydraulic System

b. Service Brake Valve Installation If equipped with 74,4 kW engine

1. Install the service brake valve to its original orientation
in the cab. Secure with the previously used hardware.
2. Install the service brake pedal.
3. Uncap and connect the previously labeled hydraulic
hoses to the service brake valve.
4. Check the routing of all hoses, and tubing for sharp
bends or interference with any rotating members, and
install tie wraps and/or protective conduit as required.
Tighten all tube and hose clamps.
5. Properly connect the battery. Refer Section 9.8,
“Battery”, for procedure.
6. Start the engine and run at approximately one-third to
one-half throttle for about one minute, without moving
11
the machine or operating any hydraulic functions.
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
9. Install the cover panel in the cab.
10. Install the access covers to the outside of the cab.
MZ8600
11. Close and secure the engine cover.
12. Remove the Do Not Operate Tag from the ignition key If equipped with 55,0 kW engine
switch and the steering wheel.

8.9.3 Service Brake Bleeding

Carefully bleed the brake lines as soon as the brake valve is
installed in the machine. Air in the system will not allow the 11
brakes to apply properly. There are three brake bleeder
locations, two on the front and rear axles and one on the
brake valve. Work with an assistant to perform this
procedure.
Note: The brake bleeding procedure must be performed using
a Vacuum Bleeder System.
1. Place the transmission in (N) NEUTRAL, engage the park
brake, and start the engine.

MAE4210

2. If equipped with 74,4 kW engine: Remove the plastic

cap from the brake valve bleeder (11). Attach the end of
the transparent tubing from the vacuum unit over the
brake valve bleeder.

3614RS, 4017RS 31211337 8-17

 Hydraulic System

3. Open the brake valve bleeder 1/4 turn. 9. Remove the plastic cap from the right rear axle brake
4. Pump the brake pedal until air bubbles no longer bleeder (2). Attach the end of the transparent tubing
appear in the oil. Release the brake pedal. Tighten the from the vacuum unit over the right axle bleeder.
brake valve bleeder. 10. Open the brake bleeder 1/4 turn.
5. Apply a small amount of pressure on the brake pedal, 11. Repeat steps 5, 6 and 7 until air bubbles no longer
open the brake valve bleeder and continue to apply appear in the oil.
brake pedal pressure until maximum brake pedal stroke 12. Repeat steps 5, 6 and 7 for the left rear axle brake
is achieved. bleeder, right front axle brake bleeder and left front axle
6. Closed brake valve bleeder and slowly release brake brake bleeder.
pedal. 13. Disconnect the vacuum unit from the pressurized air
7. Repeat steps 5 and 6 until air bubbles no longer appear connection.
in the oil. 14. Turn engine OFF.
8. Connect the vacuum unit to the pressurized air
connection. 8.9.4 Service Brake Test
4017RS 1. Install a digital or a 70 bar (1000 psi) gauge to the test
port on the brake valve (behind the front cover of the
cab).
2. Start the machine and apply pressure to the service
brake pedal. A maximum pressure of 44 bar
(638 psi) should be achieved.
3. If further testing is required, refer to Section 8.5.1,
“Hydraulic Pressures”.

8.9.5 Steering Orbital Valve

12
The steering orbital valve is located at the base of the
steering wheel shaft, concealed by the front access covers.
The valve is not serviceable and must be replaced in its
entirety if defective. For detailed information refer to Section
4.3.2, “Steering Column/Orbital Valve”.

3614RS

12

MZ8070

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 Hydraulic System

8.9.6 Outrigger/Stabilizer Valve and Brake 8. Remove the outrigger/stabilizer valve from the
Damper machine. Wipe up any hydraulic fluid spillage in, on,
near and around the machine.

b. Outrigger/Stabilizer Valve Disassembly, Cleaning,

Inspection and Assembly
1. Place the outrigger/stabilizer valve assembly on a
suitable work surface.
14
2. Separate the outrigger/stabilizer valve solenoids from
the spool. Discard the O-rings.
3. Clean all components with a suitable cleaner before
inspection.
4. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
13 Inspect the cartridge interior for contamination.
5. Inspect internal passageways of the steer select valve
MAE35040 for wear, damage, etc. If inner surfaces of the manifold
DO NOT display an ultra-smooth, polished finish, or
The outrigger/stabilizer valve (13) controls the direction of
components are damaged in any way, replace the
hydraulic fluid flow to each outrigger cylinder and the
manifold or appropriate part. Often, dirty hydraulic fluid
stabilizer cylinder. The outrigger/stabilizer valve (13) and
causes failure of internal seals and damage to the
brake damper (14) is attached inside the frame in front of the
polished surfaces within the secondary function
front axle.
manifold.
Verify the correct operation of the outrigger/stabilizer valve
solenoids before considering replacement of the valve. Refer Note: ALWAYS replace seals, O-rings, gaskets, etc., with new
to Section 9.5, “Electrical System Schematics” The body of the parts to help ensure proper sealing and operation. Lubricate
outrigger/stabilizer valve is not serviceable and must be seals and O-rings with clean hydraulic oil.
replaced if defective. 6. Install the solenoids in the outrigger/stabilizer valve
housing.
a. Outrigger/Stabilizer Valve Removal
1. Park the machine on a firm, level surface, level the c. Outrigger/Stabilizer Valve Installation
machine, fully retract the boom, raise and support the 1. Install the outrigger/stabilizer valve to the frame using
boom, place the transmission in (N) NEUTRAL, engage the previously removed nuts and washers.
the park brake, lower each outrigger and shut the engine
2. Connect all the hydraulic hoses, fittings, solenoid wire
OFF.
terminal leads, etc., to the outrigger/stabilizer valve
2. Place a Do Not Operate Tag on both the ignition key
3. Check the routing of all hoses, wiring and tubing for
switch and the steering wheel.
sharp bends or interference with any rotating members,
3. Open the engine cover. Allow the system fluids to cool. and install tie wraps and/or protective conduit as
4. Properly disconnect the battery. Refer Section 9.8, required. Tighten all hose clamps.
“Battery”, for procedure. 4. Properly connect the battery. Refer Section 9.8,
5. Remove the access cover from the top front of the “Battery”, for procedure.
frame. 5. Remove boom support.
6. Label, disconnect and cap the hydraulic hoses and the 6. Start the engine and run at approximately 1/3-1/2
electrical plugs connected to the outrigger/stabilizer throttle for about one minute without moving the
valve. machine or operating any hydraulic functions.
7. Remove the nuts holding the outrigger/stabilizer valve
to the frame.

3614RS, 4017RS 31211337 8-19

 Hydraulic System

7. Inspect for leaks and check the level of the hydraulic 5. Pump the brake pedal several times to dissipate any
fluid in the reservoir. Shut the engine OFF. excess pressure in the brake system.
Note: Check for leaks and repair as required before continuing.
Add hydraulic fluid to the reservoir as needed.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
9. Install the previously removed access cover.
14
10. Close and secure the engine cover.
15
11. Remove the Do Not Operate Tag from the ignition key
switch and the steering wheel.
d. Outrigger/Stabilizer Valve Test
Refer to Section 8.5.1, “Hydraulic Pressures”.
1. Conduct a pressure check of the outrigger/stabilizer
valve hydraulic circuit.
2. Check each outrigger/stabilizer valve mode for proper
function. MAE35040

6. Loosen and remove damper (14) from brake damper

8.9.7 Brake Damper
manifold (15).
The brake damper is a 250 bar (3626 psi) diaphragm damper. 7. Wipe up any hydraulic fluid spillage in, on, near and
The pneumatic damper is operated by compressed gas. Gas around the machine, work area and tools.
and hydraulic oil occupy the same container. When oil
pressure rises, incoming oil compresses the gas. When oil b. Damper Installation
pressure drops, the gas expands.
The gas is separated from the oil by a piston. This prevents 1. Install damper (14) to brake damper manifold (15).
the mixing of gas and oil and keeps gas out of the hydraulic 2. Remove the boom support.
system.
3. Properly connect the battery. Refer Section 9.8,
The damper must be “pre-charged” with gas before use in “Battery”, for procedure.
the hydraulic system. This is done by filling the gas chamber
4. Close and secure the engine cover.
with dry nitrogen to a pressure of 25 bar (507 psi). The
schrader valve is located under the protective cap at the top 5. Remove the Do Not Operate Tag from the ignition key
of the damper. The schrader valve is used for pre-charging switch and the steering wheel.
and testing the damper. 6. Refer to Section 8.9.9, “Pre-Charging Damper”, for
damper pre-charging instructions.
a. Damper Removal
1. Remove any attachment from the machine. Park the
machine on a firm level surface and fully retract the
boom. Raise the boom to allow sufficient work space
around the frame to allow the damper to be removed.
Support the boom. Place the transmission in
(N) NEUTRAL, engage the park brake, shut the engine
OFF and chock wheels.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to cool.
4. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure.

8-20 31211337 3614RS, 4017RS

 Hydraulic System

8.9.8 Brake Damper Charging Use the following steps to properly pre-charge each damper:
This section covers the charging of the damper system.
20
The damper is located and mounted at the front of the
machine, between the frame rails. The internal parts of the 21
damper are not serviceable. If the internal piston is leaking,
or the seals on the top or bottom cap are leaking, the damper
requires replacement.
16
The damper pre-charge pressure will vary depending on the
ambient temperature that the damper was pre-charged at
and the actual operating temperature of the damper. 14 18

8.9.9 Pre-Charging Damper

19
Note: Replacement damper are pre-charged when shipped. 17
MZ8110

WARNING 1. Thoroughly clean the top of each damper (14).

NEVER fill an damper with oxygen! An explosion could 2. Make sure the nitrogen supply is shut off.
result if oil and oxygen are mixed under pressure. Only fill 3. Attach the damper fill kit (16) to the nitrogen bottle.
damper with dry nitrogen. 4. Remove the protective cap from the gas valve on the
Pre-charge the damper with nitrogen gas only. Nitrogen gas damper.
is free of water vapor and oxygen which makes it harmless to 5. Back the “T” handle (17) on the damper fill kit all the
internal parts and will not react if mixed with oil under way out (counter-clockwise). Attach the schrader
pressure. adaptor (18) to the gas valve on the damper. Tighten
securely.
NOTICE 6. Turn the gas valve/bleed valve (19) on the damper fill kit
all the way in.
Never fill an damper with air. Air contains moisture which can
7. Turn the “T” handle (17) all the way in to open the valve
cause corrosion. This corrosion may damage seals and ruin
core on the damper.
the damper.
8. Open the valve (20) on the nitrogen bottle.
Never charge an damper to a pressure more than specified.
9. Slowly adjust the regulator (21) on the nitrogen bottle
The proper pressure for the damper is 25 bar (507 psi).
to read 35 bar (507 psi).
Note: Make sure the nitrogen bottle, as well as the charging 10. Close the main valve (20) on the nitrogen bottle.
and gauge assembly used is compatible with the schrader valve
assembly on the damper. The nitrogen bottle and all 11. Back the “T” handle (17) on the damper fill kit all the
components must be rated for a pressure at least as high as the way out (counter-clockwise).
nitrogen source. It is strongly recommended that the nitrogen 12. Let the pre-charge on the damper set for 10-15 minutes.
bottle has a high pressure regulator. This will allow the gas temperature to stabilize. If the
desired pre-charged range is exceeded, turn the “T”
A damper fill kit is required to properly charge the damper.
handle (17) all the way in. With the main valve (20)
Refer to the parts manual or contact the local JLG dealer.
closed on the nitrogen bottle, turn the gas valve/
bleeder valve (19) out to bleed pressure off the damper.
Turn the valve all the way in and check the pressure
reading on the regulator gauge.

3614RS, 4017RS 31211337 8-21

 Hydraulic System

13. When the correct pressure is reached, back the “T” 8.9.11 Steer Select Valve
handle (17) on the damper fill kit all the way out
(counter-clockwise). Bleed the pressure from the hose
by turning the gas valve/bleed valve out to relieve the
pressure.
14. Turn the gas valve/bleed valve (19) all the way in and
remove the schrader adapter (18) from the valve on the
damper.
15. Reassemble the protective cap onto the gas valve on
the damper.

8.9.10 Checking Pre-Charge

a. Gas Leaks 24

22

MZ8080

The machine can be used in the front-wheel, four-wheel or

crab steering mode. The steer select valve (24) controls the
direction of hydraulic fluid flow to the steering cylinder
23 mounted on each axle. The steer select valve is attached
MZ8100 inside the frame between the can and the front axle.
1. If an external leak is suspected, apply soapy water to the Verify the correct operation of the steer select valve
gas valve (22) and the fitting of the gas bottle (23). If solenoids before considering replacement of the valve. Refer
bubbles form, the damper has to be replaced. to Section 9.5, “Electrical System Schematics”. The housing of
the steer select valve is not serviceable and must be replaced
2. If an internal leak is suspected, check for foaming oil in if defective.
the hydraulic reservoir and/or no damper action. If any
of these signs are evident, the damper has to be a. Steer Select Manifold and Valve Removal
replaced.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, place
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to cool.
4. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure.
5. Label, disconnect and cap the hydraulic hoses and the
electrical plugs connected to the steering select valve.
6. Remove the bolts holding the steer select valve to the
mounting plate on the frame.
7. Remove the steer select valve from the machine. Wipe
up any hydraulic fluid spillage in, on, near and around
the machine.

8-22 31211337 3614RS, 4017RS

 Hydraulic System

b. Steer Select Manifold and Valve Disassembly, 9. Remove the Do Not Operate Tag from the ignition key
Cleaning, Inspection and Assembly switch and the steering wheel.
1. Place the steer select assembly on a suitable work
d. Steering Test
surface.
2. Separate the steer select solenoids from the spool. Refer to Section 8.5.1, “Hydraulic Pressures”.
Discard the O-rings. 1. Conduct a pressure check of the steering hydraulic
3. Clean all components with a suitable cleaner before circuit.
inspection. 2. Check each steering mode for proper function.
4. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is 8.10 HYDRAULIC CYLINDERS
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination. 8.10.1 General Cylinder Removal Instructions
5. Inspect internal passageways of the steer select valve 1. Remove any attachment from the machine. Park the
for wear, damage, etc. If inner surfaces of the manifold machine on a firm level surface and fully retract the
DO NOT display an ultra-smooth, polished finish, or boom. Allow sufficient work space around the hydraulic
components are damaged in any way, replace the cylinder being removed. Support the boom if the lift/
manifold or appropriate part. Often, dirty hydraulic fluid lower cylinder is being removed. Place the transmission
causes failure of internal seals and damage to the in (N) NEUTRAL, engage the park brake, shut the engine
polished surfaces within the secondary function OFF and chock wheels.
manifold.
2. Place a Do Not Operate Tag on both the ignition key
Note: ALWAYS replace seals, O-rings, gaskets, etc., with new switch and the steering wheel.
parts to help ensure proper sealing and operation. Lubricate
3. Open the engine cover. Allow the system fluids to cool.
seals and O-rings with clean hydraulic oil.
4. Label, disconnect and cap or plug hydraulic hoses in
6. Install the solenoids in the steer select housing. relation to the cylinder.
c. Steer Select Valve and Manifold Installation 5. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Make sure the device used can
1. Install the steer select valve to the mounting plate actually support the cylinder.
under the left front side of the frame using the two
6. Remove the lock bolt and/or any retaining clips
bolts.
securing the cylinder pins. Remove the cylinder pins.
2. Connect all the hydraulic hoses, fittings, solenoid wire
7. Remove the cylinder.
terminal leads, etc., to the steer select valve
8. Wipe up any hydraulic fluid spillage in, on, near and
3. Check the routing of all hoses, wiring and tubing for
around the machine, work area and tools.
sharp bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all hose clamps.
4. Properly connect the battery. Refer Section 9.8,
“Battery”, for procedure.
5. Start the engine and run at approximately
1/3 - 1/2 throttle for about one minute without moving
the machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before continuing.
Add hydraulic fluid to the reservoir as needed. MZ0400

7. Wipe up any hydraulic fluid spillage in, on, near and

around the machine, work area and tools.
8. Close and secure the engine cover.

3614RS, 4017RS 31211337 8-23

 Hydraulic System

a. General Cylinder Disassembly Some cylinder parts are sealed with a special organic sealant
and locking compound. Before attempting to disassemble
1. Clean the cylinder with a suitable cleaner before
these parts, remove any accessible seals from the area of the
disassembly. Remove all dirt, debris and grease from the
bonded parts. Wipe off any hydraulic oil, then heat the part(s)
cylinder.
uniformly to break the bond. A temperature of
2. Clamp the barrel end of the cylinder in a soft-jawed vise 149 - 204°C (300 - 400°F) will destroy the bond. Avoid
or other acceptable holding equipment if possible. overheating, or the parts may become distorted or damaged.
Apply sufficient torque for removal while the parts are still

WARNING hot. The sealant often leaves a white, powdery residue on

threads and other parts, which must be removed by
Significant pressure may be trapped inside the cylinder. brushing with a soft brass wire brush prior to reassembly.
Exercise caution when removing a counterbalance valve or a 9. Remove the piston head from the rod and carefully slide
pilot-operated check valve from a cylinder. the head gland off the end of the rod.
Note: Avoid using excessive force when clamping the cylinder 10. Remove all seals, backup rings and O-rings from the
in a vise. Apply only enough force to hold the cylinder securely. piston head and all seals, backup rings and O-rings from
Excessive force can damage the cylinder tube. the head gland.

3. If applicable, remove the counterbalance valve from the Note: The head gland bearing will need to be inspected to
side of the cylinder barrel. determine if replacement is necessary.

Note: DO NOT tamper with or attempt to adjust the DO NOT attempt to salvage cylinder seals, sealing rings or
counterbalance valve cartridge. If adjustment or replacement is O-rings. ALWAYS use a new, complete seal kit when
necessary, replace the counterbalance valve with a new part. rebuilding hydraulic components. Consult the parts catalog
for ordering information.
4. Extend the rod as required to allow access to the base of
the cylinder. b. Cylinder Cleaning Instructions
Note: Protect the finish of the rod at all times. Damage to the 1. Discard all seals, backup rings and O-rings. Replace with
surface of the rod can cause seal failure. new items from seal kit to ensure proper cylinder
5. Using a pin spanner wrench, unscrew the head gland function.
from the tube. A considerable amount of force will be 2. Clean all metal parts with an approved cleaning solvent
needed to remove the head gland. Carefully slide the such as trichlorethylene. Carefully clean cavities,
head gland down along the rod toward the rod eye, grooves, threads, etc.
away from the cylinder barrel.
Note: If a white powdery residue is present on threads or parts,
Note: When sliding the rod and piston assembly out of the it can be removed by using a soft brass wire brush. Wipe clean
barrel, prevent the threaded end of the barrel from damaging with Loctite® Cleaner prior to reassembly.
the piston. Keep the rod centered within the barrel to help
prevent binding. c. Cylinder Inspection
6. Carefully pull the rod assembly along with the head 1. Inspect internal surfaces and all parts for wear, damage,
gland out of the cylinder barrel. etc. If the inner surface of the cylinder barrel does not
7. Fasten the rod eye in a soft-jawed vise, and place a display a smooth finish, or is scored or damaged in any
padded support under and near the threaded end of way, replace the barrel.
the rod to prevent any damage to the rod. 2. Remove light scratches on the piston, head gland, rod
8. Remove the set screw from the piston head. or inner surface of the cylinder barrel with a
400 - 600 grit emery cloth. Use the emery cloth in a
Note: It may be necessary to apply heat to break the bond of rotary motion to polish out and blend the scratch(es)
the sealant between the piston and the rod before the piston into the surrounding surface.
can be removed.
3. Check the piston rod assembly for run-out. If the rod is
bent, it must be replaced.

8-24 31211337 3614RS, 4017RS

 Hydraulic System

d. General Cylinder Assembly Instructions e. General Cylinder Installation

1. Use the proper tools for specific installation tasks. Clean 1. Grease the bushings at the ends of the hydraulic
tools are required for installation. cylinder. Using an appropriate sling, lift the cylinder into
2. Install new seals, backup rings and O-rings on the piston it’s mounting position.
and new seals, backup rings, O-rings and bearing on the 2. Align cylinder bushing and install pin, lock bolt or
head gland. retaining clip.
Note: The extend/retract cylinder has a spacer that MUST be 3. Connect the hydraulic hoses in relation to the labels or
installed over the rod AFTER the head gland and BEFORE the markings made during removal.
piston head. 4. Before starting the machine, check fluid level of the
3. Fasten the rod eye in a soft-jawed vise, and place a hydraulic fluid reservoir and if necessary fill to full mark
padded support under and near the threaded end of with oil.
the rod to prevent any damage to the rod. 5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
Note: Protect the finish on the cylinder rod at all times.
both directions allowing cylinder to fill with hydraulic
Damage to the surface of the rod can cause seal failure.
oil.
4. Lubricate and slide the head gland over the cylinder 6. Inspect for leaks and check level of hydraulic fluid in
rod. Install the piston head on to the end of the cylinder reservoir. Add hydraulic fluid if needed. Shut the engine
rod. Apply medium strength threadlocking compound OFF.
and install the set screw in the piston head. Refer to
7. Wipe up any hydraulic fluid spillage in, on, near and
Section 8.10.4, “Cylinder Torque Specifications”, for
around the machine, work area and tools.
torque specifications for the piston head and the set
screw. 8. Close and secure the engine cover.
Note: Avoid using excess force when clamping the cylinder
8.10.2 Cylinder Pressure Checking
barrel in a vise. Apply only enough force to hold the cylinder
barrel securely. Excessive force can damage the cylinder barrel. Attach a 345 bar (5000 psi) gauge to the test port on the
P1 port on the hydraulic manifold to check the system
5. Place the cylinder barrel in a soft-jawed vise or other
pressure. For more information, refer to Section 8.4.1,
acceptable holding devise.
“Pressure Checks and Adjustments”.
Note: When sliding the rod and piston assembly into the
Note: If a hydraulic cylinder pressure is greater than the main
cylinder barrel, prevent the threaded end of the cylinder barrel
control valve pressure, increase the main control valve pressure
from damaging the piston head. Keep the cylinder rod centered
by adjusting the main relief. Generally, one half turn clockwise
within the barrel to prevent binding. will be adequate to check an individual circuit. Activate the
6. Carefully insert the cylinder rod assembly into the circuit and if pressure is obtained turn the main relief counter
cylinder barrel. clockwise one half turn. Re-check the main relief setting and
7. Screw the head gland into the cylinder barrel and adjust if necessary.
tighten with a spanner wrench. Refer to Section 8.10.4,
“Cylinder Torque Specifications”, for torque 8.10.3 Steering Cylinders
specifications for the head gland. The steer cylinder is attached to each axle center housing.
8. If applicable, install new counter balance valve into The steer cylinder is covered in the appropriate
block on the cylinder barrel. manufacturer’s axle literature. Detailed axle service
instructions (covering the axle, differential, brakes and
wheel-end safety, repair, disassembly, reassembly,
adjustment and troubleshooting information) are provided
in the appropriate Axle Disassembly & Assembly Manual.
Refer to Section 5.3, “Axle Specifications and Maintenance
Information”, for details.

3614RS, 4017RS 31211337 8-25

 Hydraulic System

8.10.4 Cylinder Torque Specifications

a. Lift/Lower Cylinder

Model Head Piston V1 Plug V2 Plug CB Valve

1500 Nm
3614 RS
(1106 lb-ft) 2000 Nm 85 Nm 85 Nm
N/A
480 Nm (1475 lb-ft) (63 lb-ft) (63 lb-ft)
4017RS
(354 lb-ft)

b. Extend/Retract Cylinder

Model Head Piston V1 Plug V2 Plug CB Valve

900 Nm 1000 Nm
3614 RS
(664 lb-ft) (738 lb-ft) 100 Nm 170 Nm
N/A
1000 Nm 900 Nm (74 lb-ft) (125 lb-ft)
4017RS
(738 lb-ft) (664 lb-ft)

c. Tilt Cylinder

Model Head Piston V1 Plug V2 Plug CB Valve

All 1200 Nm 1500Nm 85 Nm 85 Nm 85 Nm
Machines (885 lb-ft) (1106 lb-ft) (63 lb-ft) (63 lb-ft) (63 lb-ft)

d. Compensation Cylinder

Model Head Piston

800 Nm 1000 Nm
All Machines
(590 lb-ft) (738 lb-ft)

e. Frame Level Cylinder

Model Head Piston V1 Plug V2 Plug CB Valve

1200 Nm 1700 Nm
3614 RS
(885 lb-ft) (1254 lb-ft) 85 Nm 85 Nm 40 Nm
1000 Nm 900 Nm (63 lb-ft) (63 lb-ft) (30 lb-ft)
4017RS
(738 lb-ft) (664 lb-ft)

f. Outrigger Cylinder

Model Head Piston V1 Plug V2 Plug CB Valve

1500 Nm 1000 Nm 85 Nm 85 Nm 40 Nm
All Machines
(1106 lb-ft) (738 lb-ft) (63 lb-ft) (63 lb-ft) (30 lb-ft)

8-26 31211337 3614RS, 4017RS

 Section 9
Electrical System

Contents

PARAGRAPH TITLE PAGE

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.1 General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.1 Cab Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.2 Frame Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.4.3 Option 1 Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.6 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.7.2 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.7.3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.8.1 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.8.2 Battery Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.8.3 Battery Disconnect/Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.9 Wiper/Washer Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.9.1 Front Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.9.2 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.9.3 Roof Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.9.4 Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.10 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.10.1 Transmission Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.10.2 Transmission Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.10.3 Transmission Mounted Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.10.4 Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.10.5 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.10.6 Boom Retract Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.10.7 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.10.8 Reverse Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.11 Dash Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.11.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.11.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

3614RS, 4017RS 31211337 9-1

 Electrical System

9.12 Load Stability Indicator (LSI) (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35

9.12.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.12.2 LSI Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.12.3 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.13 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.13.1 Machine Data Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.13.2 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.13.3 Mobile Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.13.4 Analyzer Software Version P 18.0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.14 Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.14.1 Access Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.14.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.14.3 Machine Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.14.4 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
9.14.5 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.14.6 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-57
9.15 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69
9.16 Machine Fault Codes Version P 18.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
9.16.1 Help Comment (00x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
9.16.2 Power-Up (21x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
9.16.3 Platform Controls (22x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-75
9.16.4 Ground Inputs (23x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-77
9.16.5 Other Inputs (24x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-93
9.16.6 Function Prevented (25x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94
9.16.7 Line Contactor Open-Circuit (31x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-100
9.16.9 Output Drivers (33x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-102
9.16.10 Engine (43x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-136
9.16.11 Battery Supply (44x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-142
9.16.12 Transmission & Drive System (46x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-143
9.16.13 Communications (66x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-185
9.16.14 Envelope Control (84x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-189
9.16.15 Tilt Sensor (81x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-190
9.16.16 Load Moment (85x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-191
9.16.17 Steering (86x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-197
9.16.18 Service Required (87x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-198
9.16.19 Hardware (99x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-199
9.17 Engine Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-205

9-2 31211337 3614RS, 4017RS

 Electrical System

9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
electrical components of the machine. The following
illustration identifies the components that are referred to
throughout this section.

9.1.1 General Overview

CAB CONTROL
MODULE
BOOM ANGLE
SENSOR CAB POWER
DISTRIBUTION
BOARD

OPTION
REVERSE DISTRIBUTION
ALARM BOARD
LSI DISPLAY

JOYSTICK

DISPLAY
PANEL

IGNITION
LSI SENSOR KEY SWITCH

HORN

REAR FRAME
CONTROL
MODULE

ALTERNATOR

FRAME POWER
DISTRIBUTION BOARD ECM
CONTROL
STARTER

BATTERY
DISCONNECT
BATTERY

FRONT FRAME
CONTROL
MAE35050
MODULE

3614RS, 4017RS 31211337 9-3

 Electrical System

9.2 SPECIFICATIONS 9.4 POWER DISTRIBUTION BOARD

Electrical system specifications are listed in Section 2,
“General Information and Specifications”.
9.4.1 Cab Power Distribution Board
Power distribution board is located in cab. For access,
9.3 SAFETY INFORMATION remove screws securing the small side panel at the left side
of the dash.

WARNING Note: Connectors XA, XB, XC, XD, XE, XF, XG, XH and XJ are
marked with pin designation.
DO NOT service the machine without following all safety
precautions as outlined in Section 1, “Safety Practices” of
this manual.

B+ IGN GND

9 6 3
XD 8 5 2
P
E N 7 4 1
F D M
A C XB
G B L
H J K 1 4 1 4
XC 2 5 2 5
3 6 XG 3 6
K2

15 12 9 6 3
2 1 XF 14 11 8 5 2
4 3 XA 13 10 7 4 1

5 6 D1
1 4 7 10
XH 2 5 8 11
XE 1 2 3 4
3 6 9 12

F1 10 F6 5
F2 30 F7 5 12 9 6 3
F3 10 F8 10 XJ 11 8 5 2

F4 5 10 10 7 4 1
F9
F5 5 F10 5

IGN GND
B+

MAG9871

9-4 31211337 3614RS, 4017RS

 Electrical System

FUSE/RELAY FUNCTION AMP RATING

F1 AUXILIARY POWER 10

F2 MODULE POWER 30

F3 DISPLAY IGNITION, JOYSTICK IGNITION, RS232 POWER 10

SWITCH IGNITION (2), HI BEAM POWER, SHIFT IGNITION, COLUMN IGNITION,

F4 5
SEAT IGNITION

F5 TELEMATICS B+ 5

F6 TELEMATICS IGNITION 5

F7 HAZARD POWER, KEY BATTERY, BRAKE POWER 5

F8 HORN B+ (3) 10

F9 REVERSE SENSOR POWER, DOME IGNITION, REAR WIPER POWER 10

F10 BEACON POWER 5

K2 HORN RELAY 10

CONNECTOR PIN FUNCTION

A KEY IGNITION

B CAN1 HIGH

C CAN1 LOW

D SPARE

E SPARE

F KEY PLAT

G IGNITION OUT
XB
H SPARE

J HVAC COMPRESSOR OUT

K REVERSE SIGNAL 2

L REVERSE SIGNAL 1

M BOOM WORK LIGHTS

N HORN OUT

P LSI ORANGE (PASSIVE MODE)

3614RS, 4017RS 31211337 9-5

 Electrical System

CONNECTOR PIN FUNCTION

1 B+

2 B+

3 GND
XA
4 IGNITION

5 CLEAN IGNITION

6 CLEAN IGNITION

1 REVERSE SIGNAL 1

2 REVERSE SIGNAL 2

3 HVAC COMPRESSOR OUT

XC
4 BOOM WORK LIGHTS

5 HORN SW

6 SPARE

1 RS232 RX

2 RS232 TX

3 KEY PLAT

4 CAN1 HIGH

XD 5 KEY IGNITION

67 SPARE

7 CAN1 LOW

8 SPARE

9 SPARE

1 RS232 POWER

2 RS232 RX
XE
3 RS232 TX

4 RS232 GND

1 GND

2 TELEMATICS B+

3 TELEMATICS IGNITION
XG
4 SHIELD

5 CAN 2 LOW

6 CAN2 HIGH

9-6 31211337 3614RS, 4017RS

 Electrical System

CONNECTOR PIN FUNCTION

1 HAZARD POWER

2 HORN B+

3 REVERSE SENSOR POWER

4 KEY BATTERY

5 MARKER LT MODULE

6 DOME IGNITION
XH
7 BRAKE POWER

8 D1

9 REAR WIPER POWER

10 IGNITION OUT

11 -

12 BEACON POWER

1 SHIELD

2 CAN2 LOW

3 CAN2 HIGH

4 SEAT IGNITION

5 COLUMN IGNITION

6 SHIFT IGNITION

7 HIGH BEAM POWER

XF 8 SWITCH IGNITION

9 SWITCH IGNITION

10 JOYSTICK IGNITION

11 JOYSTICK IGNITION

12 DISPLAY IGNITION

13 MODULE POWER

14 MODULE POWER

15 AUXILIARY POWER SOCKET

XJ ALL PINS GROUND

3614RS, 4017RS 31211337 9-7

 Electrical System

9.4.2 Frame Power Distribution Board

Power distribution board is located at left side of the engine,
inside the frame.

K1
K4
K5
J2

K6
J6

K7

K2
F11

F12
F10

F8
F6

F9

F7
J7

K3
F1

F2
MEGA

MEGA
J1

FUSE

FUSE
J4

F5

F3
F4
J5
J3

MD0891

9-8 31211337 3614RS, 4017RS

 Electrical System

FUSE/RELAY FUNCTION AMP RATING

F1 GLOW PLUGS 150

F2 ALTERNATOR 200

F3 REAR FRAME 80

F4 FRONT FRAME 80

F5 CAB 80

F6 ECM IGNITION 25

F7 FRAME IGNITION 15

F8 ECM B+ 30

F9 CAB B+ 25

F10 AC FANS 30

F11 STARTER 30

F12 CAB MODULE 30

K1 FRONT FRAME IGNITION 70

K2 REAR FRAME IGNITION 70

K3 SYSTEM IGNITION 70

K4 SYSTEM IGNITION 70

K5 ECM IGNITION 30

K6 AC FAN POWER 30

K7 START SIGNAL TO ENGINE (STARTER OUT) 30

HIGH POWER CONNECTIONS

LOCATION FUNCTION AMP RATING SIZE

J1 B+ 200 M10

J2 ALTERNATOR 200 M10

J3 GLOW PLUGS 150 M10

J4 FRONT FRAME 80 M8

J5 REAR FRAME 80 M8

J6 CAB 80 M8

3614RS, 4017RS 31211337 9-9

 Electrical System

9.4.3 Option 1 Distribution Board

Option 1 distribution board is located in the cab. For access,
remove screws securing the rear panel at the right side of the
cab.
Note: Connectors XK, XL and XM are marked with pin
designation.

4 5 6
XK
K1 2 3
1

1 4 7 10
XL 2 5 8 11
10 F11 10 F16
3 6 9 12
10 F12 10 F17

10 F13 25 F18
12 9 6 3
10 F14 10 F19
XM 11 8 5 2
25 F15 5 F20
10 7 4 1

B+ IGN GND

MAE0911

FUSE/RELAY FUNCTION AMP RATING

F11 BOOM WORK LIGHTS 10

F12 FRONT WORK LIGHTS 10

F13 REAR WORLK LIGHTS 10

F14 REAR WIPER POWER 10

F15 WIPER POWER 25

F16 IGNITION 10

F17 ROOF WIPER POWER 10

F18 HVAC BLOWER POWER 25

F19 ROOF WIPER POWER 10

F20 AC FANS 5

K1 LIGHTS

9-10 31211337 3614RS, 4017RS

 Electrical System

CONNECTOR PIN FUNCTION

1 GND

2 GND

3 GND
XK
4 REAR WIPER POWER

5 WIPER POWER

6 LIGHTS ON SIGNAL

1 SW IGNITION

2 HVAC BLOWER POWER

3 ROOF WIPER POWER

4 COLUMN IGNITION

5 HVAC COMPRESSOR OUT

6 ROOF WIPER POWER

XL
7 HI BEAM IGNITION

8 AC CMD

9 IGNITION

10 BOOM WORKLIGHT POWER

11 FT WORKLIGHT POWER

12 RR WORKLIGHT POWER

XM ALL PINS GROUND

3614RS, 4017RS 31211337 9-11

 9.5

9-12
1 2 3 4 5 6 7 8
LOCATED BEHIND DASH HEATER FAN MOTOR LOCATED BEHIND DASH LEFT STEERING WHEEL SWITCHES SWITCH,HAZARDS
LOCATED ON WASHER UNIT UNDER DASH LOCATED ON TOP OF REAR WINDOW
LEFT SWITCHES
TANK,DUAL WASHER,PUMPS LOCATED ON WASHER UNIT UNDER DASH SWITCH,TURN/WIPER COLUMN WIPER,REAR
LOCATED UNDER DASH RIGHT SWITCHES SWITCH,FAN
REAR FRONT WIPER, FRONT MOTOR LOCATED IN FRONT OF CABIN

M
LAMP, HI BEAM & INDIC

M
HORN

+
+
+
+
+
+
+
+

M
M
M
[7,F]
[7,F]
SW769-2 INDIC HI BEAM
3

HI
GND
LOW
MED
31b
53
6 LOCATED BEHIND REAR TRIM

12v
7
8
3
2
1
6
5
4
9
10
7
8
3
2
1
6
5
4
9
10
7
8
1
2
3
4
5
6
9
10
7
8
3
2
1
4
5
6
9
10

L
P

H
2 WHT 300-2 KEY STRT

+
+
PWR
LOW
MED
HI
P
L
G 31
V+ 53a
5

LOCATED UNDER DASH

1 TO ROOF WIPER X401

SW,DRIVING LIGHTS
RIGHT SWITCHES
LOCATED BEHIND DASH
SW410

SW411
SWITCH, FOG LIGHTS
0 (09B3)

RIGHT SWITCHES

RIGHT SWITCHES
LOCATED BEHIND DASH
LOCATED BEHIND DASH

SWITCH,REAR WIPER
SW412
SW409
P 4

STEERING WHEEL SWITCHES

6
3
10
9
8
7
5
2
4
1
+
2
3
4
1
3
4
1
2
1
2
3
4
5
6
2
1
2
1
6
5
4
3
2
1
2
1
4
3
2
1
LOCATED BEHIND DASH RIGHT
3 3

WH69
AH254
a. Cab Harness
2

LB91
X523
WH384
BLK 028-6 GND
2

SW263
WH116-F
1

WH116-R

WH262-F
H H
0 1
P

F.WIPE L
F.WIPE H
FLASH 49A
DRV LT

F.WIPE PWR
FLASH BATT
MAIN BEAM

LH TURN
LO BEAM

F.WASH
RH TURN

HORN
3
SW769

WHT 415-7 SW BACKLT

2

401-1 FOG LT

1
2
8
12
2
1
10
9
11
6
7
4
3
5
6

WHT 411 DR LT

BLK 028-6 GND

BLK 028-5 GND
BLK 028-5 GND
BLK 028-4 GND
BLK 028-4 GND
BLK 028-3 GND
BLK 028-3 GND
BLK 028-2 GND

YEL 206 SW IGN

1

BLK 028-3-1 GND

BLK 028-3-1 GND
BLK 028-2-1 GND
BLK 028-2-1 GND

WHT 608 R WASH

WHT 609 R WASH
WHT 608 R WASH
YEL 206-2 SW IGN
YEL 206-2 SW IGN
YEL 206-1 SW IGN
YEL 206-1 SW IGN
0 5

WHT 401-1 FOG LT

BLK 046 GND

P

WHT 400-1 HAZ SW

YEL 111 HORN

BLK 030 GND

WHT 410 MARKER SW
BLK 028-2 GND

WHT 415-7 SW BACKLT

WHT 415-6 SW BACKLT
WHT 415-6 SW BACKLT
WHT 415-5 SW BACKLT
WHT 415-5 SW BACKLT
WHT 415-4 SW BACKLT
WHT 415-4 SW BACKLT
WHT 415-3 SW BACKLT

BLK 030-1 GND

BLK 030-1 GND
WHT 418-9-1 HAZARDS
WHT 418-9-1 HAZARDS
3 4

BLK 029 GND

SW370-TURN

SW370-WASH
YEL 200-2 KEY IGN BLK 028-1 GND

WHT 607 R WIPE P1.5mm²

BLK 029-1 GND

BLK 029-1 GND
WHT 606 R WIPE L 1.5mm²
2

WHT 425 HAZ PWR 1.5mm²

3

WHT 401 FOG LT SW 0.75mm²

WHT 609 R WASH

YEL 218 R WIPE PWR 1.5mm²

BLK 050 GND 1.5mm²

WHT 610 RF WASH
WHT 610 RF WASH
1 WHT 415-3 SW BACKLT

WHT 419-1-1 LH TURN

WHT 418-1-1 RH TURN
YEL 218-1 R WIPE PWR 1.5mm²

WHT 604-1 F WIPE L

WHT 604-3 F WIPE P
BLK 032 GND 1.5mm²
7

WHT 600 FAN L 1.5mm²

WHT 600 FAN L 1.5mm²

WHT 602 FAN H 1.5mm²

WHT 602 FAN H 1.5mm²
BLK 038 GND 1.5mm²
0

WHT 601 FAN M 1.5mm²

WHT 601 FAN M 1.5mm²

+
P 2 WHT 415-2 SW BACKLT

WHT 415-9 SW BACKLT

YEL 229 FAN PWR 1.5mm²

RED 104-2 KEY BATT 8

WHT 607 R WIPE P1.5mm²

WHT 606 R WIPE L 1.5mm²

WHT 611 F WASH 1.5mm²

1 WHT 421 2WS IND

WHT 605 F WIPE H 1.5mm²

WHT 409-1 HI BEAM 0.75mm²

3

YEL 111 HORN

YEL 227-1 F WIPE PWR 1.5mm²

YEL 218-1 R WIPE PWR 1.5mm²
WHT 324 2WS

YEL 290 RF WIPER PWR 1.5mm²

BLK 090 RF WIPER GND 1.5mm²
2

WHT 411 DR LT
SWITCH, IGNITION WHT 329 2WS LOCK
1

6
2
1
5
3
4

SW16C
JLG

D3
423 4WS IND

WHT 419-2 LH TURN

WHT 418-2 RH TURN
YEL 240 PWR 1.5mm²
TO SW16A WHT 405-3 RH TURN WHT 422 CRAB IND

WHT 611 F WASH 1.5mm²

(02E1)

WHT 604 F WIPE L 1.5mm²

YEL 227-2 F WIPER 1.5mm²

WHT 605 F WIPE H 1.5mm²
D2

WHT 414 LO BEAM 0.75mm²

LOCATED UNDER DASH SWITCHES 6

WHT 409-2 HI BEAM 0.75mm²

YEL 210 COLUMN IGN 1.5mm²

WHT 310 STEER PWR
5

(SHOWN IN 2WS)

[1,B]
FC518-XK WHT 406-3 LH TURN WHT 324 2WS
4

SWITCH,STEER SELECT
(03F7)
D1 9
BLK 038 GND 1.5mm²

+
1
10

LOCATED BEHIND DASH RIGHT SWITCHES

BLK 029 GND
2
BLK 032 GND 1.5mm² SW376
G 3 G
WHT 604-2 F WIPE P BLK 028-7 GND
Electrical System

4 7
YEL 227 F WIPER 1.5mm² WHT 415-8 SW BACKLT +
5 8
YEL 178-2 WORKLIGHTS 1.5mm² S48 S115 WHT 214 JYSTK LOCK 0.75mm²
6 1
YEL 215 KEY IGN
FC518-XL 2
(03E7) 3
YEL 178-1 WORKLIGHTS 1.5mm² WHT 329 2WS LOCK
1 4
YEL 229 FAN PWR 1.5mm² YEL 216 KEY IGN
2 5
YEL 290 RF WIPER PWR 1.5mm² WHT 310 STEER PWR
3 6
YEL 229-2 FAN PWR YEL 215 KEY IGN
4 9
LOCATED BEHIND DASH LEFT

WHT 955 J2L4 +

STEERING WHEEL SWITCHES

5 10
SWITCH,JOYSTICK OVERRIDE

6 SW142
7
WHT 956 AC
8 BLK 028-6 GND
YEL 179 RADIO IGN 1.5mm² [5,H]
9 WHT 415-7 SW BACKLT
[5,H]
10 CAB MODULE BLK 028-7 GND
7
11 LOCATED BEHIND REAR

OPTION 1 PDB
WHT 415-8 SW BACKLT +
CO516-J2 CABINE TRIM CO516-J1 8
12 YEL 216 KEY IGN
YEL SYS CANH 0.75mm² 3

S362
FC518-XM [8,D] A1 CAN1H AI TYPE 1 A1 YEL 217 KEY IGN
YEL EXTEND/RETRACT CAN2H 2
(03D7) A2 CAN2H AI TYPE 1 A2 WHT 528 LSI CANCEL 0.75mm²
BLK 090 RF WIPER GND [4,E] 1

LOCATED BEHIND RIGHT SIDE REAR TRIM

1 A3 DI TYPE 3 DI TYPE 1 A3
F 4 F
2 A4 DI TYPE 3 DI TYPE 3 A4
GENERIC

BLK 081 GND 1.5mm² 5

3 B1 CAN1T AGND B1
BLK 082 GND 1.5mm² WHT EXTEND/RETRACT CAN2T WHT 414 LO BEAM 0.75mm² 6

D6
4 B2 CAN2T DI TYPE 1 B2
LOCATED BEHIND DASH LEFT

BLK 083 GND 1.5mm² 9

SWITCH,LSI OVERRIDE
STEERING WHEEL SWITCHES

5 B3 DI TYPE 3 DI TYPE 1 B3 +
BLK 084 GND 1.5mm² WHT 214 JYSTK LOCK 0.75mm² 10
6 B4 D1 TYPE 3 DI TYPE 1 B4
BLK 028-1 GND SW375
7 C1 CAN1S AI TYPE 1 C1
BLK 050 GND 1.5mm² WHT 409-3 HI BEAM 0.75mm² WHT 415-2 SW BACKLT
8 C2 CAN2S DI TYPE 1 C2
WHT 300 KEY STRT 0.75mm² BLK 028 SW GND
9 C3 DI TYPE 1 DI TYPE 1 C3 7
WHT 415-1 SW BACKLT +
10 C4 D1 TYPE 1 DI TYPE 1 C4 8
BLK 028 SW GND GRN SYS CANL 0.75mm² WHT 524 LEVEL L 0.75mm²
11 [8,D] D1 CAN1L AI TYPE 1 D1 3
GRN EXTEND/RETRACT CAN2L WHT 419-2 LH TURN YEL 217 KEY IGN
12 D2 CAN2L DI TYPE 1 D2 2
WHT 314 DRIVE FWD 0.75mm² WHT 526 LEVEL R 0.75mm²
D3 D1 TYPE 1 D1 TYPE 1 D3 1
WHT 528 LSI CANCEL WHT J1-D4-1 4W STEER SWITCH 0.75mm² YEL 224 KEY PWR
[7,F] D4 D1 TYPE 1 DI TYPE 1 D4 4
LOCATED UNDER DASH SWITCHES E1 CAN1T AI TYPE 1 E1 5
WHT EXTEND/RETRACT CAN2T WHT 418-2 RH TURN
SW16 SW16B SW16A E2 CAN2T DI TYPE 1 E2 6
WHT 319 GEAR 3 0.75mm² WHT 315 DRIVE NEUT 0.75mm²
ELECTRICAL SYSTEM SCHEMATICS

LOCATED UNDER RIGHT

CONSOLE TRIM

6 6 6 E3 DI TYPE 1 DI TYPE 1 E3 9
SWITCH,FRAME LEVEL

WHT 316 DRIVE REV 0.75mm² +

2 2 2 E4 D1 TYPE 3 DI TYPE 1 E4 10
YEL 200-1 KEY IGN YEL 200 KEY IGN 1.5mm²
1 1 1 F1 +5V AREF AI TYPE 1 F1 SW414
S519 WHT 524 LEVEL L 0.75mm² D7
5 5 5 F2 +5V AREF DI TYPE 3 F2

D4
GD86
WHT 300-1 KEY STRT WHT 300 KEY STRT 0.75mm² WHT 526 LEVEL R 0.75mm²
3 3 3 F3 DI TYPE 1 DI TYPE 3 F3 NC CAN SHLD
RED 104-1 KEY BATT RED 104-1 KEY BATT 1.5mm² WHT 318 GEAR 2 0.75mm² WHT 523 PARK BRAKE SW 0.75mm²
4 4 4 F4 DI TYPE 1 DI TYPE 1 F4 14
E WHT J1-G1-1 2W STEER SWITCH 0.75mm² E

KEY SWITCH CAT

G1 AGND DI TYPE 1 G1 13
WHT 323 SEAT SW1 D8 WHT 422 CRAB IND
G2 DI TYPE 3 DI TYPE 1 G2 12 4W CRAB STEER
WHT 317 GEAR 1 0.75mm² WHT 201 MARKER SW S651 S650 WHT 423 4WS IND
G3 DI TYPE 1 DI TYPE 1 G3 11 4W STEER
WHT 360 SEAT SW2 0.75mm² WHT 415 SW BACKLT WHT 421 2WS IND
SW415 G4 DI TYPE 1 DO TYPE 3 G4 10 2W STEER
FWD PWR YEL 212 KEY PWR WHT 003 RS232 TX 0.75mm² WHT J1-H1-1 CRAB STEER SWITCH 0.75mm² S652
1 H1 RS232 TX DI TYPE 1 H1 S540 9 STEERING PRES
NEUT F WHT 314 DRIVE FWD 0.75mm² WHT 002 RS232 RX 0.75mm²
4 H2 RS232 RX +5V AREF H2 8 PARK BRAKE
REV N WHT 315 DRIVE NEUT 0.75mm² WHT 250 IGN RLY D9 GRN SYS CANL 0.75mm²
3 H3 DI TYPE 1 DO TYPE 4 H3 7 CAN LO
DISPLAY

I R WHT 316 DRIVE REV 0.75mm² WHT 433 BUZZER OUT YEL SYS CANH 0.75mm²
5 H4 DI TYPE 1 DO TYPE 3 H4 6 CAN HI
II I WHT 317 GEAR 1 0.75mm²
LOCATED BEHIND DASH

6 J1 DI TYPE 2 5 FUEL SENSE

SWITCH,FNR
II WHT 318 GEAR 2 0.75mm² WHT 401-2 FOG LT SW 0.75mm² CO516-J3 BLK 040 DISP GND
2 J2 DI TYPE 1 4 GND
III III WHT 319 GEAR 3 0.75mm² CAN LO

LOCATED BEHIND DASH LEFT

7 J3 DI TYPE 1 DI TYPE 1 A1 3

STEERING WHEEL SWITCHES

8 J4 DI TYPE 1 DI TYPE 1 A2 2 CAN HI
WHT 500-1 LSI PWR 0.75mm² YEL 203 DISP PWR
K1 ANALYZER PWR DI TYPE 1 A3 1 IGN RUN
LOCATED ON BRAKE PEDAL WHT 501 LSI GREEN1 0.5mm²
K2 ANALYZER GND DO TYPE 4 A4
SWITCH, BRAKE PEDAL WHT 502 LSI GREEN2 0.5mm²
K3 DI TYPE 1 DO TYPE 4 B1
WHT 612 AC CMD 0.75mm²
1 K4 DI TYPE 1 DI TYPE 1 B2
YEL 205 BRK LT PWR 1.5mm² YEL 200-1 KEY IGN WHT 503 LSI GREEN3 0.5mm² MS529
2 L1 DI TYPE 2 DO TYPE 4 B3 YEL SYS CANH 0.75mm²

31211337
WHT 420 BRK LT SW 1.5mm² WHT 420 BRK LT SW 1.5mm² WHT 504 LSI GREEN4 0.5mm² [4,F] 1
3 L2 DI TYPE 2 DO TYPE 4 B4 YEL SYS CANH 0.75mm²
YEL 270-1 MOD IGN 0.75mm² 2
4 L3 AGND MASTER PWR/IGN C1 YEL SYS CANH 0.75mm²
WHT 955 J2L4 3
SW76 L4 DI TYPE 3 DI TYPE 1 C2 YEL SYS CANH 0.75mm²
WHT 400 HAZ SW 10
D M1 DI TYPE 2 DI TYPE 1 C3 D
BLK 060 MOD GND 1.5mm² WHT 505 LSI YELLOW 0.5mm² 11
FC517-XC M2 MASTER GND DO TYPE 4 C4
FC517-XA (03F4) WHT 951-1 CONT AUXILIARY PWR YEL 270-2 MOD IGN 0.75mm² 12
M3 DO TYPE 3 MASTER PWR/IGN D1 GRN SYS CANL 0.75mm²
WHT 950 ASH LOAD PWR WHT 771 HEST/REGEN [4,F] 4
1 1 M4 DO TYPE 3 DI TYPE 1 D2 GRN SYS CANL 0.75mm²
5
2 2 N/C D3 GRN SYS CANL 0.75mm²
CAN BUSS

WHT 956 AC BLK 070 MOD GND 0.75mm² 6

3 3 MASTER GND D4
UNDER CAB MODULE

GRN SYS CANL 0.75mm²

(03F1) YEL 260-1 MOD IGN 0.75mm² 7
4 4 MASTER PWR/IGN E1
LOCATED BEHIND REAR TRIM

8
5 5 DI TYPE 1 E2
YEL 229-2 FAN PWR 9
6 6 N/C E3
FC517-XD AI TYPE 1 E4
YEL 260-2 MOD IGN 0.75mm²
(03F4) MASTER PWR/IGN F1 6 PLUGGED
WHT 002 RS232 RX 0.75mm² WHT 506 LSI RED 0.5mm²
1 DO TYPE 4 F2 5 PLUGGED
WHT 003 RS232 TX 0.75mm² GRN SYS CANL 0.75mm²
2 N/C F3 4 CANL
FC517-XB YEL SYS CANH 0.75mm²
3 AI TYPE 1 F4 3 CANH

D5
JOYSTICK

YEL SYS CANH 0.75mm² YEL 260-3 MOD IGN BLK 031 JOY GND
1 4 MASTER PWR/IGN G1 2 JS GND
YEL 200-2 KEY IGN YEL 209 JOY IGN
2 5 MASTER PWR/IGN G2 1 JS PWR
3 6 MASTER PWR/IGN G3 JS404
GRN SYS CANL 0.75mm² (03A3)
4 7 MASTER PWR/IGN G4
X524
5 8 MASTER PWR/IGN H1 WHT 501 LSI GREEN1 0.5mm²
WHT 507-1 LSI ORANGE 0.5mm² 2
6 9 MASTER PWR/IGN H2 WHT 502 LSI GREEN2 0.5mm²
3
(03F1) 7 FC517-XF MASTER PWR/IGN H3 WHT 503 LSI GREEN3 0.5mm²
C 4 C
8 (03E4) MASTER PWR/IGN H4 WHT 504 LSI GREEN4 0.5mm²
5
S520
S539

9 1 WHT 505 LSI YELLOW 0.5mm² TO LSI

6 LOCATED ON RIGHT PILLAR
10 2 WHT 506 LSI RED 0.5mm²
7
11 3 S859 WHT 500 LSI PWR 0.75mm²
YEL 210 SEAT IGN 1
12 4 S858 WHT 507 LSI ORANGE 0.5mm²
YEL 210 COLUMN IGN 1.5mm² 8
13 5
YEL 212 KEY PWR 9
14 6 IP857
YEL 240 PWR 1.5mm² 10
7
YEL 224 KEY PWR X122
8 YEL 231 CLEARSKY IGN
YEL 206 SW IGN 2 UNIVERSAL TELEMATICS
9 RED 113 CLEARSKY PWR
(09A6), (09D3)

HiBPwr
YEL 825-1 IGN 1mm² 1
10 BLK 056 CLEARSKY GND LOCATED UNDER CAB ON RIGHT SIDE
FC517-XE YEL 209 JOY IGN 3
11
YEL 203 DISP PWR
1 12 LB776
YEL 260 MOD IGN 1.5mm² BLK 064-4 GND
2 13 S851 6
(03F4) YEL 270 MOD IGN 1.5mm² WHT 951 CONT AUXILIARY PWR
3 14 3
YEL 207 PWR SKT 1.5mm² +
4 15 10
FC517-XH 9

LOCATED BEHIND RIGHT SIDE REAR TRIM

(03D4)
AL

8
WHT 425 HAZ PWR 1.5mm²
1 7
FC517-XG 2 IP854 5
BLK 064-4 GND
CA

B 1 3 2 B
RIGHT SWITCHES
LOCATED BEHIND DASH

RED 104-1 KEY BATT 1.5mm² BLK 064-3 GND BLK 064-3 GND
2 4 4
WHT 201 MARKER SW WHT 950 ASH LOAD PWR
3 5 1
CONT AUX/ASH LOAD

+
WHT 280 DOME IGN
4 6 S78 LB77
YEL 205 BRK LT PWR 1.5mm² BLK 064 GND IP855 BLK 064-1 GND 1.5mm²
5 7 6
WHT 410 MARKER SW [6,G] S850 WHT J1H3 ODI 1.5mm²
6 8 3
YEL 218 R WIPE PWR 1.5mm² +
9 10
(03D4) WHT 250 IGN RLY
10 9
11 8
DE

YEL 176 BEACON PWR

12 7
IP856 5
FC517-XJ

YEL 231 CLEARSKY IGN

ST

(03C4) 2

RED 113 CLEARSKY PWR

BLK 030 GND BLK 064-2 GND 1.5mm²
1 4
RIGHT SWITCHES
LOCATED BEHIND DASH

BLK 825-4 GND

BLK 064 GND WHT JIH4-1 OSI 1.5mm² WHT JIH4 OSI 1.5mm²
2 IP888 BLK 825-3 GND 1 +
BLK 033 BUZZER GND
LAMP,OUTRIGGER DEPLOYED

3 S849
S884
BLK 060 MOD GND 1.5mm²
4 IP887
BLK 031 JOY GND S357 S886
5 S825
BLK 040 DISP GND BLK 825-1 GND
6
BLK 046 GND BLK 825 GND
7
YEL 211 KEY 1
WHT 523 PARK BRAKE SW

BLK 070 MOD GND 0.75mm² S356 BLK 825-2 GND

8
BLK 056 CLEARSKY GND
9
3
1
2
SW77

YEL 211 KEY 1

WHT 360 SEAT SW2
YEL 213 KEY 1
WHT 323 SEAT SW1
YEL 210 SEAT IGN
YEL 213 KEY 1

BLK 825 GND

BLK 033 BUZZER GND
WHT 433 BUZZER OUT
A 10 A

MAIN POWER BOARD

BLK 057 GND 1.5mm²
11
SN57

4
3
2
1

BLK 080 DOME GND

BLK 825-3 GND

12
WHT 701-2 J3B1 REGEN
WHT 771 HEST/REGEN
YEL 825-1 IGN
WHT 700-2 J1C3 HEST
BLK 825-2 GND

AH118-

AH118 PULSE
AH118 CONT

YEL 179 RADIO IGN 1.5mm²

WHT 415-11 SW BACKLT
YEL 178-1 WORKLIGHTS 1.5mm²
YEL 178-2 WORKLIGHTS 1.5mm²
WHT 415-11 SW BACKLT
WHT 415-10 SW BACKLT
YEL 176 BEACON PWR

BLK 084 GND 1.5mm²

BLK 083 GND 1.5mm²
BLK 082 GND 1.5mm²
BLK 081 GND 1.5mm²
9
6
5
4
1
2
3
8
7

SW768
10

MS369

YEL EXTEND/RETRACT CAN2H

GRN EXTEND/RETRACT CAN2L
WHT 307 PED SIG 2
WHT 308 PED PWR
WHT 309 PED SIG 1
WHT 612 AC CMD 0.75mm²
WHT J1H3 ODI 1.5mm²
WHT JIH4-1 OSI 1.5mm²
WHT 406-3 LH TURN
WHT 405-3 RH TURN
WHT 701-2-1 J3B1 REGEN
WHT 700-2-1 J1C3 HEST

BLK 037 PED GND

1
N/O
WHT 308-2 PED PWR 1
WHT 309 PED SIG 1
WHT 308-1 PED PWR 2
WHT 307 PED SIG 2

N/C
BLK 037-2 PED GND 1
BLK 037-1 PED GND 2

YEL 207 PWR SKT 1.5mm²

+
+

BLK 080 DOME GND 2

X798
X792
X793
X811
2

2
1
5
4
3
2
1
3
2
1
3
2
1
1
2
3
4
5
6
7
8
9

X538A

BLK 057 GND 1.5mm²

10
11
12

WHT 280 DOME IGN 3 SHOWN IN OFF POSN

SN749

1 TO RADIO X799 TO BEACON X250 TO OPT CLEARSKY

F

TO WORKLIGHTS X252
E
B
A

D
C

POWER SOCKET PARK BRAKE

HEST/ REGEN

LB536 (09D5) (09D6) (09B1) (09B8) SEAT SWITCH TO REAR FRAME X538B
RIGHT SWITCHES
LOCATED BEHIND DASH

DOME LIGHT LOCATED UNDER RIGHT LOCATED BEHIND RIGHT BUZZER LOCATED NEAR SEAT THROTTLE PEDAL
LOCATED BEHIND RIGHT LOCATED BEHIND RIGHT LOCATED BEHIND RIGHT (05G1)
CONSOLE TRIM

1001247912-B
LOCATED ON CEILING OF CABINE SIDE REAR TRIM LOCATED UNDER DASH LOCATED UNDER SEAT LEFT SIDE LOCATED ON THROTTLE PEDAL LOCATED UNDER CAB ON RIGHT SIDE
SIDE REAR TRIM SIDE REAR TRIM SIDE REAR TRIM

1 2 3 4 5 6 7 8

MAE44950B

3614RS, 4017RS
 1 2 3 4 5 6 7 8

3614RS, 4017RS
H H
b. Cab Harness - PDB

MAIN POWER BOARD SECONDARY POWER BOARD

G G
HORN RELAY

87
30
87a
85
86

4
1
3
2
5
1
1

K2
IGN

GND

HORN B+
HORN B+
HORN SW

HORN OUT
GND
GND
GND
GND
GND
XB XC
REVERSE SIGNAL 1 REVERSE SIGNAL 1
L 1
REVERSE SIGNAL 2 REVERSE SIGNAL 2
K 2
HVAC COMPRESSOR OUT HVAC COMPRESSOR OUT
J 3 (02D1)
BOOM WORKLIGHTS BOOM WORKLIGHTS
M 4
HORN OUT HORN SW
N 5
(SPARE) (SPARE)
H 6
IGNITION OUT
G XD
(05F1) CAN1 HI CAN1 HI
B 4 XK
CAN1 LO CAN1 LO GND
C 7 1
(SPARE) (SPARE) GND
D 8 2
KEY IGN KEY IGN GND
F A 5 (02C1) 3 F
KEY PLAT KEY PLAT F14 - 10A REAR WIPER PWR REAR WIPER PWR (02G1)
F 3 6
(SPARE) (SPARE) F15 - 25A WIPER PWR WIPER PWR
E 6 5
LSI ORANGE LSI ORANGE LIGHTS ON SIGNAL
P 9
RS232 TX 4
2 K1
RS232 RX
1
GND LIGHTS ON SIGNAL
XA
IGN
4
GND
3
CLEAN IGN
(05F1) 5
CLEAN IGN
6 XE
B+ RS232 PWR

TO REAR FRAME HARNESS

1 1
B+ RS232 RX
2 2
RS232 TX (02B1)
3
RS232 GND
4

XL
F11 - 10A BM WKLT PWR BM WKLT PWR
10
XF F12 - 10A FT WKLT PWR FT WKLT PWR
F1 - 10A AUX POWER SOCKET AUX POWER SOCKET 11
15 F13 - 10A RR WKLT PWR RR WKLT PWR
MODULE POWER MODULE POWER 12
14 SW IGN SW IGN
F2 - 30A MODULE POWER MODULE POWER 1
13 F16 - 10A COLUMN IGN COLUMN IGN
DISPLAY IGN DISPLAY IGN 4
12
JOY IGN JOY IGN HI BEAM IGN HI BEAM IGN
11 7 (02G1)
F3 - 10A JOY IGN JOY IGN IGN IGN
E 10 9 E
RS232 PWR SWITCH IGN F17 - 10A ROOF WIPER PWR ROOF WIPER PWR
9 6
SWITCH IGN (02C1) F18 - 25A HVAC BLOWER PWR HVAC BLOWER PWR
8 2
SWITCH IGN HI BEAM POWER F19 - 10A ROOF WIPER POWER ROOF WIPER POWER
7 3
SWITCH IGN SHIFT IGN HVAC COMPRESSOR OUT
6 5
HI BEAM POWER COLUMN IGN F20 - 5A AC CMD AC CMD
5
SHIFT IGN SEAT IGN 8
4
COLUMN IGN SHIELD
1
F4 - 5A SEAT IGN CAN 2L
2
CAN 2H
3

XG XM
CAN 2H GND
6 1
F5 - 5A TELEMATICS B+ CAN 2L S149
5 2
SHIELD
4 3
GND
1 (02B1) 4
TELEMATICS B+
2 5
F6 - 5A TELEMATICS IGN TELEMATICS IGN
3 6 (02F1)
7
8
XH
HAZARD PWR HAZARD PWR 9
1
F7 - 5A KEY BAT KEY BAT 10
4
BRAKE PWR BRAKE PWR 11
7
D HORN B+ HORN B+ 12 D
2
F8 - 10A HORN B+ MARKER LT MODULE
5
HORN B+ D1

31211337
8 (02B1)
REV SEN PWR REV SEN PWR
3
F9 - 10A DOME IGN DOME IGN
6
REAR WIPER PWR REAR WIPER PWR
9
IGNITION OUT
10
11
F10 - 5A BEACON PWR BEACON PWR
12

XJ
1
S124
2
3
4
5
6
7 (02A1)
8
9
10
11
C 12
C

X872 X873
WHT XAL KEY ON
PDM TO REAR FRAME JUMPER (FUTURE RELEASE) WHT XAL KEY ON
A A
YEL SYS CANH 0.75mm² YEL SYS CANH 0.75mm²

B+
B B

IGN

GND

1
1
1
GRN SYS CANL 0.75mm² GRN SYS CANL 0.75mm²
C C
D D
E E
F F
WHT XAG IGN SIG WHT XAG IGN SIG
G G
WHT 640-2 AC HS WHT 640-2 AC HS
H H
WHT 613 AC HS WHT 613 AC HS
J J
K K
L L
TO FRAME X801-XB

M M
N N
TO CAB INTERFACE XB

WHT 5071 LSI PASSIVE MODE 0.75mm² WHT 5071 LSI PASSIVE MODE 0.75mm²
P P
XD
XB (02C1) (05F1)
B B
X871 X874
YEL 277 IGN 2mm² RED 280-1 CAB B+ 2mm²
1 1
XC XG YEL 276 IGN 2mm² RED 280-2 CAB B+ 2mm²
2 2
K2 YEL 275 IGN+ 10mm² BLK 013 CAB GND 10mm²
3 3
BLK 013 CAB GND 10mm² YEL 275 IGN+ 10mm²
4 4
RED 280-2 CAB B+ 2mm² YEL 276 IGN 2mm²
5 5
RED 280-1 CAB B+ 2mm² YEL 277 IGN 2mm²
6 6

XA XF (05F1)
TO FRAME X800-XA

(02D1)
TO CAB INTERFACE XA

XE

XH

A XJ A

1001247912-B
1 2 3 4 5 6 7 8
Electrical System

MAE44960B

9-13
 c.

9-14
1 2 3 4 5 6 7 8
LOCATED ON BASE OF RIGHT LOCATED ON BASE OF LEFT
STABILIZER STABILIZER LOCATED ON RIGHT LOCATED ON LEFT LOCATED ON LEFT
LOCATED ON RIGHT STABILIZER STABILIZER STABILIZER
RIGHT POS LEFT POS STABILIZER
SWITCH,PROX SWITCH,PROX RIGHT RET LEFT RET LEFT EXT
RIGHT EXT
SWITCH, PRES SWITCH, PRES SWITCH, PRES
SWITCH, PRES
+ - + -

SIG
SIG
SIG

GND
GND
GND

PWR
PWR
PWR

SIG
GND
PWR
A
B
C
A
B
C
A
B
C

3
1
2
3
1
2
A
B
C
H H

SN368
SN366
SN365

SN367

SN372
SN371

YEL 223-2 KEY IGN

YEL 223-1 KEY IGN

BLK 715-1 GND 1mm²

BLK 715-2 GND 1mm²

WHT 332 OUT LT POS

WHT 333 OUT RT POS

WHT 067 AGND 0.75mm²
WHT 068 AGND 0.75mm²
WHT 066 AGND 0.75mm²
WHT 065 AGND 0.75mm²

WHT 267 5V REF 0.75mm²

WHT 268 5V REF 0.75mm²
WHT 266 5V REF 0.75mm²
WHT 265 5V REF 0.75mm²
WHT 365 OUT LT EXT 0.75mm²

WHT 366 OUT LT RET 0.75mm²

WHT 367 OUT RT EXT 0.75mm²

WHT 368 OUT RT RET 0.75mm²
Front Frame Harness

S370
G G
Electrical System

YEL 223 KEY IGN

X646
WHT 701 J1C3 HEST
A
WHT 700 J3B1 REGEN
B
C
WHT 337 TRANS TEMP 0.75mm²
D
WHT 230 SPD SIG 0.75mm²
E
RED 302 TRANS SPD PWR
F
WHT 328 TRANS 2 0.75mm²
G
WHT 327 TRANS 1 0.75mm²
H
WHT 326 TRANS R 0.75mm²
F J F
WHT 325 TRANS F 0.75mm²
K
WHT 313 NEUTRAL SW 0.75mm²
L

(05C1)
WHT 338 ENG ST
M
YEL ENG CAN2H
N
GRN ENG CAN2L
O
WHT J1H3 ODI 1.5mm²
P

LOCATED BETWEEN CAB AND FRAME

WHT J1H4 OSI 1.5mm²
Q

TO REAR FRAME X645

WHT 530 HYD FLTR 0.75mm²
R
BLK 035 FUEL GND 0.75mm²
S
WHT 321 FUEL LVL 0.75mm²
T
YEL 223 KEY IGN
U
V
YEL SYS CANH
W
GRN SYS CANL
X

HV576
WHT 515 FRAME LVL LH 0.75mm²
1
BLK 715-3 GND
F.FRAME MODULE 2
E X644 E
FRM LVL LH

1 CO551-J2 CO551-J1
HV577
YEL SYS CANH WHT 365 OUT LT EXT 0.75mm² WHT 516 FRAME LVL RH 0.75mm²
2 A1 CAN1H AI TYPE 1 A1 1
YEL 274-2 IGN+ 10mm² YEL ENG CAN2H BLK 715-4 GND
3 A2 CAN2H 499 RES AI 3 A2 2
STABS VALVE

BLK 649-1 MSTR GND 10mm²

FR LEVEL

4 A3 LS CS 2 A3

(05C1)
DO TYPE 2 (PWM)
FRM LV RH
LOCATED ON LEVERING &

WHT 515 FRAME LVL LH 0.75mm²

5 A4 LS CS 4 DO TYPE 2 A4
6 B1 CAN1L AI TYPE 1 B1
WHT J2B2 CAN2
B2 CAN2L 499 RES AI 2 B2 HV582
WHT 516 FRAME LVL RH 0.75mm² WHT 514 SPD VLV 0.75mm²
B3 LS CS 2 DO TYPE 2 B3 1
WHT 517 LH O/R UP 0.75mm² WHT 513 SPD VLV RTN 0.75mm²

LOCATED BETWEEN CAB AND FRAME

B4 LS CS 4 DO TYPE 2 (PWM) B4 2

TO REAR FRAME X647

C1 CAN1S AI TYPE 1 C1
OUT FR LVL SP

C2 CAN2S 499 RES AI 1 C2

WHT 701 J1C3 HEST HV578
C3 LS CS 3 DO TYPE 2 C3
WHT 518 LH O/R DN 0.75mm² WHT 517 LH O/R UP 0.75mm²
C4 LS CS 5 DO TYPE 2 C4 1

INSIDE STABILIZERS VALVE COMPARTMENT

LOCATED ON THE LEFT FRONT FRAME WALL
GRN SYS CANL WHT 367 OUT RT EXT 0.75mm² BLK 586-1 GND
D1 CAN1L AI TYPE 1 D1 2
LH O/R UP

GRN ENG CAN2L

D2 CAN2L 499 RES AI 4 D2
WHT 519 RH O/R UP 0.75mm² HV579
D3 LS CS 3 DO TYPE 2 D3
WHT 327 TRANS 1 0.75mm² WHT 518 LH O/R DN 0.75mm²

31211337
D4 LS CS 5 DO TYPE 2 (PWM) D4 1
WHT 321 FUEL LVL 0.75mm² BLK 586-2 GND
E1 CAN1T AI TYPE 1A E1 2
LH O/R DN

WHT J2B2 CAN2

E2 CAN2T 499 RES AI 5 E2
OUTRIGGER

WHT J1E3 FUEL JUMP HV580

E3 LS CS 1 270 RES AI 5 E3
D WHT 326 TRANS R 0.75mm² WHT 519 RH O/R UP 0.75mm² D
E4 DO TYPE 1 (PWM) DO TYPE 2 (PWM) E4 1
LOCATED ON LEVERING & STABS VALVE

WHT 265 5V REF 0.75mm² BLK 586-3 GND

F1 +5V AREF AI TYPE 1 F1 2
RH O/R UP

WHT 267 5V REF 0.75mm²

F2 +5V AREF AI TYPE 1A F2
WHT 513 SPD VLV RTN 0.75mm² HV581
F3 LS CS 1 FI TYPE 1 F3
WHT 514 SPD VLV 0.75mm² WHT 520 RH O/R DN 0.75mm² WHT 520 RH O/R DN 0.75mm²
F4 DO TYPE 1 (PWM) DO TYPE 2 F4 1
BLK 586-4 GND
G1 RS232 RX FI TYPE 1 G1 2
RH O/R DN

G2 RS232 TX FI TYPE 1 G2
WHT 065 AGND 0.75mm²
G3 AGND DO TYPE 2A (PWM) G3
G4 DO TYPE 1 (PWM) DO TYPE 2A (PWM) G4
WHT 333 OUT RT POS WHT 230 SPD SIG 0.75mm²
H1 DI TYPE 1 FI TYPE 1 H1
H2 DI TYPE 1 +5V AREF H2 HV584
WHT J1H3 ODI 1.5mm² WHT 522 CRAB STR 0.75mm²
H3 AGND DO TYPE 2A H3 1
WHT 325 TRANS F 0.75mm² WHT J1H4 OSI 1.5mm² BLK 714-2 GND
H4 DO TYPE 1 (PWM) DO TYPE 2A H4 2
J1 DI TYPE 1
ALL WHL STR

WHT 332 OUT LT POS CO551-J3

J2 DI TYPE 1 HV583
BLK 035 FUEL GND 0.75mm² WHT 522 CRAB STR 0.75mm² WHT 521 4WS STR 0.75mm²
J3 AGND DO TYPE 2 A1 1
WHT 313 NEUTRAL SW 0.75mm² WHT 268 5V REF 0.75mm² BLK 714-1 GND
STEERING

J4 DO TYPE 1 (PWM) +5V AREF A2 2

CRAB STR

RED 302 TRANS SPD PWR WHT 068 AGND 0.75mm²

LOCATED ON STEERING PUMP

K1 ANALYZER PWR AGND A3

K2 ANALYZER GND DI TYPE 1A A4
WHT 067 AGND 0.75mm² WHT 700 J3B1 REGEN
K3 AGND DO TYPE 2 B1
WHT 266 5V REF 0.75mm²
C K4 DO TYPE 1 (PWM) +5V AREF B2 C
BLK 649-2 MSTR GND 2mm² WHT 066 AGND 0.75mm² BLK 586-4 GND
L1 MASTER GND AGND B3
BLK 649-1 MSTR GND 10mm² BLK 586-3 GND
L2 +5V AREF DI TYPE 1A B4 T585
S649 WHT 418 RH TURN LT WHT 328 TRANS 2 0.75mm² BLK 586-2 GND BLK 586 MAIN GND 2.5mm²
L3 DO TYPE 3 DO TYPE 2 C1 1
WHT 338 ENG ST BLK 586-1 GND S586 BLK 714 GND 2.5mm²
L4 DO TYPE 3 +5V AREF C2
BLK 649-3 MSTR GND 2mm²
M1 MASTER GND AGND C3
BLK 649-4 MSTR GND 2mm²
M2 MASTER GND DI TYPE 1A C4 BLK 714-1 GND BLK 714 GND 2.5mm²
M3 DO TYPE 3 DO TYPE 1 (PWM) D1 BLK 714-2 GND S714
M4 DO TYPE 3 +5V AREF D2
+5V AREF D3
BLK 556-2 GND 2mm² S556
DI TYPE 1A D4 T711
BLK 556-1 GND 2mm² BLK 556 GND 4mm² BLK 556 GND 4mm²
DO TYPE 1 (PWM) E1 1
NEAR FRAME MODULE

WHT 337 TRANS TEMP 0.75mm² BLK 715 GND 4mm²

CHASSIS GND

CO551-J4 DI TYPE 4 E2
WHT J1E3 FUEL JUMP BLK 715-4 GND 1mm²
LOCATED ON ON LEFT FRAME WALL

YEL 274-2 IGN+ 10mm² +5V AREF E3

1 MASTER PWR IN WHT 366 OUT LT RET 0.75mm² BLK 715-3 GND 1mm² BLK 715 GND 4mm²
AI TYPE 2 E4
WHT 521 4WS STR 0.75mm² BLK 715-2 GND 1mm² S715
DO TYPE 2 F1
BLK 715-1 GND 1mm²
DI TYPE 4 F2
WHT 530 HYD FLTR 0.75mm²
DI TYPE 1 F3
WHT 368 OUT RT RET 0.75mm²
AI TYPE 2 F4
WHT 413 LH HI BEAM LT 1.5mm²
DO TYPE 3 G1
WHT 421 LH SIDE LT LOW
DO TYPE 3 G2 LB308
B WHT 412 LH LO BEAM LT 1.5mm² BLK 556-1 GND 2mm² B
DO TYPE 3 G3 1
WHT 412 LH LO BEAM LT 1.5mm²
DI TYPE 1 G4 2
WHT 420 RH SIDE LT WHT 413 LH HI BEAM LT 1.5mm² HIGH
DO TYPE 3 H1 3
WHT 417 RH HI BEAM LT 1.5mm² WHT 421 LH SIDE LT
DO TYPE 3 H2 4
WHT 419 LH TURN LT WHT 419 LH TURN LT
DO TYPE 3 H3 5
WHT 416 RH LOW BEAM LT 1.5mm² SIDE
DO TYPE 3 H4 6
LIGHT,LEFT HEADLIGHT
LOCATED ON LEFT DRIVING LIGHT

TURN

TURN

6
WHT 418 RH TURN LT SIDE
5
WHT 420 RH SIDE LT
4
WHT 417 RH HI BEAM LT 1.5mm²
3
WHT 416 RH LOW BEAM LT 1.5mm² HIGH
2
BLK 556-2 GND 2mm²
1
LIGHT,RIGHT HEADLIGHT

LB309
LOCATED ON LEFT DRIVING LIGHT

A LOW A

1001247912-B
1 2 3 4 5 6 7 8

MAE44970B

3614RS, 4017RS
 1 2 3 4 5 6 7 8

LOCATED ON LEFT EXTERIOR FRAME

3614RS, 4017RS
WALL NEAR REAR FRAME MODULE

BUSS LOCATED ON RIGHT EXTERIOR FRAME WALL NEAR POWER DISTRIBUTION BOX

TO ENGINE X590B TO X720

(07F8), (08F8) (07E8), (08E8)

9
8
7
6
5
4
3
2
1
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
1
2
3
4

12
11
10
X590A

MS587
X722
H H

R.FRAME MODULE
CO552-J1 LOCATED ON LEFT EXTERIOR CO552-J2
320 BM ANG FRAME WALL, BACK OF CAB YEL SYS CANH 0.75mm²

WHT 338 ENG ST

WHT 327 TRANS 1

BLK 037 PED GND

WHT 325 TRANS F
WHT 328 TRANS 2

WHT 326 TRANS R

RED 230 SPD PWR
A1 AI TYPE 1 CAN1H A1

WHT 308 PED PWR

WHT 309 PED SIG 1
WHT 307 PED SIG 2
WHT 302 TRANS SPD
A2 499 RES AI 3 CAN2H A2

WHT 337 TRANS TEMP

WHT 313 NEUTRAL SW

YEL 810 ECM IGN 3mm²

YEL SYS CANH 0.75mm²

YEL SYS CANH 0.75mm²
YEL SYS CANH 0.75mm²
WHT 501 RTN 0.75mm² WHT 501 RTN 0.75mm²

GRN SYS CANL 0.75mm²

GRN SYS CANL 0.75mm²
GRN SYS CANL 0.75mm²
RED 719-2 ENG B+ 3mm²
RED 719-1 ENG B+ 3mm²
A3 DO TYPE 2 (PWM) LS CS 2 A3 2

YEL ENG CAN2H 0.75mm²

GRN ENG CAN2L 0.75mm²
WHT 700-1 J1C3 HEST WHT 525 AUX RTN 0.75mm² WHT 502 RETRACT 0.75mm²
RETRACT

12 A4 DO TYPE 2 LS CS 4 A4 1
WHT 701-1 J3B1 REGEN WHT SYS CANT 0.75mm²
11 B1 AI TYPE 1 CAN1L B1 HV295
WHT 405-2 RH TURN LT
10 B2 499 RES AI 2 CAN2L B2
WHT 406-2 LH TURN LT WHT 503 RTN 0.75mm² WHT 503 RTN 0.75mm²
9 B3 DO TYPE 2 LS CS 2 B3 2
d. Rear Frame Harness

WHT 527 AUX RTN 0.75mm² WHT 504 EXTEND 0.75mm²

EXTEND

8 B4 DO TYPE 2 (PWM) LS CS 4 B4 1
WHT J1H3 OSI 1.5mm²
7 C1 AI TYPE 1 CAN1S C1 HV294

(02A5)
WHT J1H4 ODI 1.5mm²
6 C2 499 RES AI 1 CAN2S C2
WHT 612 AC CMD WHT 505 TILT RTN 0.75mm² WHT 505 TILT RTN 0.75mm²
5 [8,D] C3 DO TYPE 2 LS CS 3 C3 2
WHT 309 PED SIG 1 WHT 5071 LSI PASSIVE MODE 0.75mm² WHT 506 TILT UP 0.75mm²
TILT UP

4 C4 DO TYPE 2 LS CS 5 C4 1

CAB, REAR SIDE OF CAB

WHT 308 PED PWR GRN SYS CANL 0.75mm²
3 D1 AI TYPE 1 CAN1L D1 HV296

LOCATED BETWEET FRAME AND

WHT 307 PED SIG 2
2 D2 499 RES AI 4 CAN2L D2
BLK 037 PED GND WHT 507 TILT RTN 0.75mm² WHT 507 TILT RTN 0.75mm²
1 D3 DO TYPE 2 LS CS 3 D3 2
G WHT 508 TILT DN 0.75mm² G
TILT DN

X538B D4 DO TYPE 2 (PWM) LS CS 5 D4 1

WHT SYS CANT 0.75mm²
E1 AI TYPE 1A CAN1T E1 HV297
E2 499 RES AI 5 CAN2T E2
MCV

WHT 509 LIFT RTN 0.75mm² WHT 509 LIFT RTN 0.75mm²
WHT 5071 LSI PASSIVE MODE 0.75mm² E3 270 RES AI 5 LS CS 1 E3 2
P WHT 510 LIFT DN 0.75mm² WHT 510 LIFT DN 0.75mm²
LIFT DN

E4 DO TYPE 2 (PWM) DO TYPE 1 (PWM) E4 1

LOCATED UNDER CAB

N
ON MAIN CONTROL VALVE

F1 AI TYPE 1 +5V AREF F1 HV293

M
F2 AI TYPE 1A +5V AREF F2
L WHT 511 LIFT RTN 0.75mm² WHT 511 LIFT RTN 0.75mm²
F3 FI TYPE 1 LS CS 1 F3 2
K WHT 512 LIFT UP 0.75mm² WHT 512 LIFT UP 0.75mm²
LIFT UP

WHT 613 AC HS F4 DO TYPE 2 DO TYPE 1 (PWM) F4 1

J [8,D]
WHT 640-2 AC HS G1 FI TYPE 1 RS232 RX G1 HV292
H
WHT XAG IGN SIG G2 FI TYPE 1 RS232 TX G2
G [8,D] WHT 525 AUX RTN 0.75mm²
G3 DO TYPE 2A (PWM) AGND G3 2
F WHT 504 EXTEND 0.75mm² WHT 526 AUX A 0.75mm²
AUX A

G4 DO TYPE 2A (PWM) DO TYPE 1 (PWM) G4 1

E
H1 FI TYPE 1 DI TYPE 1 H1 HV316
D
GRN SYS CANL 0.75mm² H2 +5V AREF DI TYPE 1 H2
C WHT 527 AUX RTN 0.75mm²

TO CAB INTERFACE
YEL SYS CANH 0.75mm² H3 DO TYPE 2A AGND H3 2
B WHT 502 RETRACT 0.75mm² WHT 528 AUX B 0.75mm²
AUX B

WHT XAL KEY ON H4 DO TYPE 2A DO TYPE 1 (PWM) H4 1

A [8,D] WHT 322 BM RETRACT 0.75mm²
DI TYPE 1 J1 HV317
X801-XB
CO552-J3 DI TYPE 1 J2
A1 DO TYPE 2 AGND J3
-

WHT 508 TILT DN 0.75mm²

F A2 +5V AREF DO TYPE 1 (PWM) J4 F
YEL 277 IGN 2mm² RED 306 LSI PWR 0.75mm² BLK 718-1 GND 1mm²
6 [8,D] A3 AGND ANALYZER PWR K1 2
YEL 276 IGN 2mm² WHT 322 BM RETRACT 0.75mm²
5 [8,D] A4 DI TYPE 1A ANALYZER GND K2 3
YEL 275 IGN+ 10mm² BLK 034 GND 0.75mm² YEL 221-1 FR IGN
4 [7,B] B1 DO TYPE 2 AGND K3 1

LOCATED IN CABINE ON MAIN POWER BOARD

BLK 013 CAB GND 10mm² WHT 506 TILT UP 0.75mm²
3 B2 +5V AREF DO TYPE 1 (PWM) K4
SWITCH, PROX

SN304
+
BOOM RETRACT

RED 280-2 CAB B+ 2mm² RED 280 CAB B+ BLK J2-L1 MASTER GND 2mm²
WALL, TIED TO A HOSE

2 [8,D] B3 AGND MASTER GND L1

LOCATED NEAR REAR FRAME

RED 280-1 CAB B+ 2mm² S800

1 B4 DI TYPE 1A +5V AREF L2
WHT 405-1 RH TURN LT
X800-XA C1 DO TYPE 2 DO TYPE 3 L3 AH313
WHT 400 REV ALARM WHT 400 REV ALARM
C2 +5V AREF DO TYPE 3 L4 1

TO CAB INTERFACE
BLK J2-M1 MASTER GND 2mm² BLK 717-5 GND 1mm²
C3 AGND MASTER GND M1 2
BLK J2-M2 MASTER GND 2mm²
C4 DI TYPE 1A MASTER GND M2
WHT 526 AUX A 0.75mm²
LOCATED ON REAR

ALARM,BACKUP

D1 DO TYPE 1 (PWM) DO TYPE 3 M3

RIGHT LIGHT BRACKET

WHT 401 FOG LT 1.5mm²

D2 +5V AREF DO TYPE 3 M4
D3 +5V AREF SN303
D4 DI TYPE 1A 034 GND BLK
WHT 528 AUX B 0.75mm² 1
E1 DO TYPE 1 (PWM) 320 BM ANG
3
E2 DI TYPE 4 CO552-J4 YEL 221-2 FR IGN
2
E3 +5V AREF YEL 273 IGN+ 10mm²
WHT 307 LSI SIG1 0.75mm² MASTER PWR IN 1
E4 AI TYPE 2
LOCATED ON REAR
LEFT LIGHT BRACKET

F1 DO TYPE 2
SENSOR, ANGLE, BOOM

F2 DI TYPE 4
E F3 DI TYPE 1 E
WHT 305 LSI SIG2 0.75mm² X640
F4 AI TYPE 2 WHT 639-1 AC FANS 1.5mm²
S327

S653
WHT 407 LH STOP LT 1
(09C8)

WHT 530 HYD FLTR 0.75mm² G1 DO TYPE 3 WHT 639-2 AC FANS 1.5mm²
1 WHT 403 TAIL LT 1.5mm² 2
OF CABINE

BLK 556-4 GND 1mm² G2 DO TYPE 3 WHT 640-1 AC HS

2 3
TO AC OPTION

WHT 408 LH REV LT

LOCATED ON BACK

G3 DO TYPE 3
SN251
G4 DI TYPE 1
403-3 LICENSE LT

FILTER UNDER CAB

H1 DO TYPE 3 X641

HYD FILTER PRES

WHT 404 RH STOP LT WHT 640-2 AC HS
H2 DO TYPE 3 1

LOCATED ON HYDRAULIC OIL

WHT 406-1 LH TURN LT
YEL 221 FR IGN

H3 DO TYPE 3 2
WHT 402 RH REV LT WHT 612 AC CMD
(09C8)

H4 DO TYPE 3 3
OF CABINE

GRN SYS CANL 0.75mm² BLK 718-3 GND 1mm²

X 4
TO AC OPTION
LOCATED ON BACK

YEL SYS CANH 0.75mm²

W
WHT 612 AC CMD
V [2,G]
YEL 223-1 KEY IGN
U
WHT 321 FUEL LVL 0.75mm² WHT 613 AC HS
T [2,G]
BLK 035 FUEL GND 0.75mm² S642
S
WHT 530 HYD FLTR 0.75mm²
R
WHT J1H3 OSI 1.5mm² S639
Q
WHT J1H4 ODI 1.5mm²
P
GRN ENG CAN2L 0.75mm²
O
YEL ENG CAN2H 0.75mm²
N

(04F1)
D WHT 338 ENG ST D
M
WHT 313 NEUTRAL SW
L

31211337
WHT 325 TRANS F
K
WHT 326 TRANS R
J
WHT 327 TRANS 1
H
WHT 328 TRANS 2
G
[2,F]
[2,F]
[2,F]
[2,F]
[2,F]

RED 230 SPD PWR

TO FRONT FRAME X646

F
WHT 302 TRANS SPD
E
WHT 337 TRANS TEMP
D
C
WHT 701-1 J3B1 REGEN
B
WHT 700-1 J1C3 HEST
A
X645

LOCATED ON LEFT EXTERIOR FRAME WALL UNDER CABINE

WHT XAL KEY ON
YEL 810 ECM IGN 3mm²
YEL 223-1 KEY IGN
YEL 221 FR IGN
WHT XAG IGN SIG
YEL 277 IGN
YEL 276 IGN
WHT 639 AC FANS 2mm²
WHT 640 AC HS

BLK 718-4 GND 1mm²

RED 719-2 ENG B+ 3mm²
RED 719-1 ENG B+ 3mm²
RED 280 CAB B+
BLK 718-2 GND 1mm²

9
4
5
8
7
6
3
2
1

19
18
17
16
14
13
11
10
15
12
FC632-J7

6
5
BLK 649 MSTR GND 10mm²
4
YEL 274-1 IGN+ 10mm²
F8
F7

C 3
C

(04E1)
F9
F12

2
1
X647
K6

TO FRONT FRAME X644

K5
F10

F6

WHT 405-2 RH TURN LT

K7

WHT 405-1 RH TURN LT

WHT 406-2 LH TURN LT

WHT 406-1 LH TURN LT
S789

S788
K4

SN302
F11

BLK 035 FUEL GND 0.75mm²

2
WHT 321 FUEL LVL 0.75mm²
S588

UNDER CAB
S589

FC632-J6
YEL 275 IGN+ 10mm²
F5
K3

LOCATED ON FUEL TANK

SENSOR, FUEL LEVEL
[2,F] 1
BLK 717-1 GND 2mm²
BLK 717-2 GND 2mm²
BLK 718-1 GND 1mm²
BLK 718-4 GND 1mm²

BLK 718-2 GND 1mm²

BLK 717-3 GND 1mm²

BLK 717-5 GND 1mm²
BLK 556-4 GND 1mm²
BLK 718-3 GND 1mm²

FOR PDM FC632-J5

YEL 273 IGN+ 10mm²
F3
K2

B 1 B
PDM
GENERIC

S717
S718

FUSE VALUE RELAY VALUE

LOCATED ON RIGHT INTERIOR FRAME WALL ON POWER DISTRIBUTION BOX

FC632-J4
YEL 274-1 IGN+ 10mm²
F4
K1

F1 150A K1 70A 1

F2 200A K2 70A FC632-J1

RED 01 BATT 00AWG
06-BATTERY-[2,C] 1

F3 80A K3 70A 150A FC632-J2

RED 112-1 ALT TO PDB
F2

07-ENGINE STAGE V-[4,G] 1

100A FC632-J3
F4 80A K4 70A RED 102-1 GLOW PWR
F1

BLK 717-1 GND 2mm²

WHT 405 RH TURN LT
WHT 404 RH STOP LT
WHT 403-2 RH TAIL LT
WHT 402 RH REV LT
WHT 401-2 RH FOG LT

07-ENGINE STAGE V-[6,G] 1

BLK 718 GND 4mm²

WHT 307 LSI SIG1 0.75mm²

RED 306 LSI PWR 0.75mm²
WHT 305 LSI SIG2 0.75mm²
BLK 717-2 GND 2mm²
WHT 401-1 LH FOG LT
WHT 408 LH REV LT
WHT 403-1 LH TAIL LT
WHT 407 LH STOP LT
WHT 406 LH TURN LT

403-3 LICENSE LT
BLK 717-3 GND 1mm²
BLK 717 GND 4mm²
BLK 013 CAB GND 10mm²
BLK 0-18 MASTER GND 10mm²
BLK 649 MSTR GND 10mm²

F5 80A K5 30A
LB312

1
2
3
4
5
6
7

LB306
T716
T592
T591
T648

X654

1
2
1
2
3
4
5
6
7
1
1
1
1
1

B
A

C
LB314

SN305

NC
F6 25A K6 30A
F7 15A K7 30A
-V
+V
BUSSBAR GND
F8 30A LOCATED ON ENGINE FRONT SUPPORT UNDER ENGINE
LIGHT,LICENCE
LIN BUS

A LOCATED ON REAR
A
F9 25A FRAME WALL
SENSOR, LSI
LOCATED UNDER FRAME
TAIL
FOG

F10 30A
BACK
STOP

TURN

NEAR OIL COOLING PIPE

TAIL
FOG

BACK
STOP

TURN

LIGHT,RIGHT TAIL
F11 30A LIGHT,LEFT TAIL
LOCATED ON REAR
LOCATED ON REAR RIGHT LIGHT BRACKET
F12 30A LEFT LIGHT BRACKET

1001247912-B
1 2 3 4 5 6 7 8
Electrical System

MAE44980B

9-15
9-16
1 2 3 4

SHEET 5
LOCATED ON ENGINE STARTER
GENERIC
e. Battery Harness

STARTER

M
D D

1
1
1
Electrical System

EC599
EC599-B-

EC599-B+
05-RFH-[7,B]
C C

RED 01 BATT

RED 100 00AWG

RED 01 BATT
BLK 001 00AWG
BLK 001 00AWG
BLK 002 00AWG
BLK 002 00AWG
BLK 005 00AWG
BLK 005 00AWG
BLK 004 00AWG
BLK 004 00AWG

31211337
X883
X605
X635
X634
X602
X603

1
1
1
1
1
1
1
1
1
1

BT600-

BT600+
MS604-A-1
MS604-B-1
BATTERY
GENERIC SWITCH FRAME
ENGINE BLOCK FRAME CAB
LOCATED IN THE ENGINE POD BATTERY DISCONNECT ENGINE BAY
B LOCATED ON ENGINE DISCONNECT LOCATED ON ENGINE NEAR LOCATED ON ENGINE LOCATED UNDER REAR
B
LOCATED ON ENGINE OIL LEVEL STICK FRONT SUPPORT TRIM
SWITCH NEAR BATTERY FRONT SUPPORT

A A

1001247912-B
1 2 3 4

MAE44990B

3614RS, 4017RS
 1 2 3 4
LOCATED ON FRAME WALL
5 6
LOCATED ON FRAME WALL
7 8 f.
NEAR CONTROL UNIT
NEAR CONTROL UNIT
GENERIC
LOCATED ON LEFT SIDE LOAD CENTER PIN H-G 15A - GLOW PLUG FUSE
X17 PIN H-G 25A - FUEL PUM FUSE
OF ENGINE NEAR STARTER

3614RS, 4017RS
PIN F-E 5A - ALT D+ FUSE
PIN C-D-F-E - FUEL PUMP RELAY LOCATED ON LEFT SIDE OF
X985 X984 LOCATED ON TOP OF ENGINE
WHT 730 TWISTED PAIR 3 + 1.5mm² WHT 730 TWISTED PAIR 3 + 1.5mm² TRANSMISSION
A 33 36 NEAR LAST INJECTOR LOCATED ON 200A CONTACTOR PIN D-C 5A- DIAGNOSTIC FUSE
BLK 731 TWISTED PAIR 3 - 1.5mm² BLK 731 TWISTED PAIR 3 - 1.5mm² LOCATED UNDER AIR CLEANEAR LEFT SIDE OF ENGINE
16 35 LOCATED ON FUEL PUMP SWITCH, TRANS TEMP GLOW PLUGS 15A 5A 5A
WHT 732 TWISTED PAIR 4 + 1.5mm² WHT 732 TWISTED PAIR 4 + 1.5mm² SWITCH, PRES, AIR FILTER NEAR WIP FILTER GLOW RELAY PIN B-A - 6A DIODE
48 42
BLK 733 TWISTED PAIR 4 - 1.5mm² BLK 733 TWISTED PAIR 4 - 1.5mm² LOCATED ON ALTERNATOR 25A FUEL PUMP
18 37 LONG CAP
WHT 734 TWISTED PAIR 5 + 1.5mm² WHT 734 TWISTED PAIR 5 + 1.5mm² LOCATED ON FUEL FILTER ALTERNATOR
32 38

M
H BLK 735 TWISTED PAIR 5 - 1.5mm² BLK 735 TWISTED PAIR 5 - 1.5mm² ALTERNATOR
H
2 39
WHT 736 TWISTED PAIR 6 + 1.5mm² WHT 736 TWISTED PAIR 6 + 1.5mm² FUEL FLT

B+
L
W
H
G
F
E
D
C
B
A
46 40
BLK 737 TWISTED PAIR 6 - 1.5mm² BLK 737 TWISTED PAIR 6 - 1.5mm²
3 41

MS736

1
2
3
4
1
1
H
G
D
F
E
C
B
A
1
1
1
1
1
1
1
1
BLK 739 TWISTED PAIR 7 - 1.5mm² BLK 739 TWISTED PAIR 7 - 1.5mm²

1
1
1
4 20
WHT 738 TWISTED PAIR 7 + 1.5mm² WHT 738 TWISTED PAIR 7 + 1.5mm²

MS783

X994
5 19

RL1037-1
RL1037-2

SN690
EC900

EC894-

EC894+

SN250-1
SN250-2
RL1037-3

EC885-L
RL1037-4

EC885-W

EC885-B+
6 62
YEL 740 TWISTED PAIR 8 + 0.75mm² YEL 740 TWISTED PAIR 8 + 0.75mm²
37 14
GRN 741 TWISTED PAIR 8 - 0.75mm² GRN 741 TWISTED PAIR 8 - 0.75mm²
52 13
01 TWISTED PAIR 8 SHLD 0.75mm² 01 TWISTED PAIR 8 SHLD 0.75mm²
53 9
YEL 742 TWISTED PAIR 9 + 0.75mm² YEL 742 TWISTED PAIR 9 + 0.75mm²

730-3 IGN 3mm²

730-4 IGN 1mm²
730-4 IGN 1mm²
39 15

525 ALT D+ 1mm²

525 ALT D+
GRN 743 TWISTED PAIR 9 - 0.75mm² GRN 743 TWISTED PAIR 9 - 0.75mm²
54 21

730-1 IGN YEL 3mm²

228 KEY 1 YEL 1.5mm²
02 TWISTED PAIR 9 SHLD 0.75mm² SHLD 02 TWISTED PAIR 9

337 TRANS TEMP

38 1

800 B+ RED 3mm²

801 B+ RED 3mm²
801 B+ RED 3mm²

043-1 GND BLK 1mm²

8 61

044 GND BLK 1.5mm²

336 PREHEAT SENSE 1.5mm²

311 AIR FLTR WHT 1mm²

WHT 744 TWISTED PAIR 10 + 1.5mm² WHT 744 TWISTED PAIR 10 + 1.5mm²

334 FUEL PUMP 1.5mm²

334 FUEL PUMP 1.5mm²
335 PREHEAT SENSE IN 1.5mm²
19 47

800 B+ RED 3mm²

BLK 745 TWISTED PAIR 10 - 1.5mm² BLK 745 TWISTED PAIR 10 - 1.5mm²

902 FUEL RL WHT 0.75mm²

20 48

590 GLOWPLUGS GRY 20mm²

WHT 347_1 GLOW RL

045 FUEL RL GND BLK 0.75mm²

36 10
WHT 353 RAIL PRESS WHT 353 RAIL PRESS
25 31

349 FUEL PRES SIG WHT 0.75mm²

350 FUEL PRES GND BLK 0.75mm²
112-1 ALT TO PDB RED 2AWG
RED 102-1 GLOW PWR 4AWG

348 FUEL PRES PWR WHT 0.75mm²

590 GLOWPLUGS GRY 20mm²
WHT 354 RAIL PRESS WHT 354 RAIL PRESS

335 PREHEAT SENSE IN 1.5mm²

26 25

047 GLOW RLY SW BLK 0.75mm²

WHT 352 RAIL PRESS WHT 352 RAIL PRESS
7 32
WHT 355 BST PRESS WHT 355 BST PRESS
27 29
WHT 356 COOL TEMP WHT 356 COOL TEMP
G 28 24 G
WHT 357 OIL PRESS WHT 357 OIL PRESS
24 30
S1000
Engine Harness (Stage V)

31 S996 16
BLK 921 GND OIL PRESURE BLK 921-1 GND OIL PRESURE
57 33
34 55
WHT 910 +5V EGR WHT 910 +5V EGR

05-RFH-[7,B]
22 50
WHT 911 SIG EGR WHT 911 SIG EGR
12 46
BLK 912 GND EGR S997 BLK 912-1 GND EGR
40 51 05-RFH-[7,A]
104 ENG START PWR RED 0.75mm²
41 58
23 56

LOCATED ON FRAME WALL ON CONTROL UNIT

WHT 900 COOL TEMP WHT 900 COOL TEMP
29 27
WHT 358 BST PRESS WHT 358 BST PRESS
42 28
WHT 359 BST PRESS WHT 359 BST PRESS
43 23
WHT 360 OIL PRESS WHT 360 OIL PRESS
44 26
WHT 354 BST PRESS WHT 354 BST PRESS
9 22
WHT 922 +5V EXH PRESURE
10 43
1 54
13 18 X590B
710 ENG CAN2H 6 YEL 0.75mm²
14 17 A
711 ENG CAN2L 6 GRN 0.75mm²
15 34 B
RED 104 ENG START PWR 309 PED SIG 1 0.75mm²
17 2 C
F WHT 339 ENG START RL 308 PED PWR 0.75mm² F
45 3 D
339 ENG START RL 0.75mm² 307 PED SIG 2 0.75mm²
50 57 E
916 DELTA P VENTURI PWR WHT 0.75mm² 037 PED GND BLK 0.75mm²
47 4 F
917 GND DVP BLK 0.75mm²
49 5 G
918 SIG DVP WHT 0.75mm² 338 ENG STRT 0.75mm²
51 6 H
920 EGR TEMP GND BLK 0.75mm² 313 NEUTRAL SW 0.75mm²
55 8 J
919 EGR TEMP SIG WHT 0.75mm² 325 TRANS F
56 7 K
365 DELTA P SENS PWR WHT 326 TRANS R
21 11 L
327 TRANS 1
30 12 M
(05H3)

WHT 923 EXHAUST PRESS WHT 923 EXHAUST PRESS 328 TRANS 2
11 44 N
BLK 921-2 EXHAUST GND 230 SPD PWR YEL
35 45 O
343 WIF SIG WHT 0.75mm² 905 IAT VLV FB 5V WHT 0.75mm² 302 TRANS SPD WHT
58 53 P
361-1 EXH GAS TEMP SIG WHT 0.75mm² 906 IAT VLV FB SIG WHT 0.75mm² 337 TRANS TEMP
59 49 Q
907 IAT VLV FB GND BLK 0.75mm²
60 52 R
908 IAT VLV POS WHT 0.75mm²
59 S
909 IAT VLV NEG WHT 0.75mm²
X986 60 T
105-1 ECM PWR RED 2.5mm²
TO REAR FRAME HARNESS 590A

1 U
LOCATED NEAR FRAME WALL LOWER LEVEL

006-1 GND BLK 2.5mm²

K 2 V
105-2 ECM PWR RED 2.5mm²
3 W
006-2 GND BLK 2.5mm²
4 X
105-3 ECM PWR RED 2.5mm²
E 5 E
006-3 GND BLK 2.5mm²
6
920 EGR TEMP GND BLK 0.75mm² 105-1 ECM PWR RED 2.5mm²
7 S880 X720
908 IAT VLV POS WHT 0.75mm² 105-2 ECM PWR RED 2.5mm² 105 ECM PWR RED3mm² 105 ECM PWR RED3mm²
8 1
909 IAT VLV NEG WHT 0.75mm² 105-3 ECM PWR RED 2.5mm² 105-4 ECM PWR RED3mm² 105-4 ECM PWR RED 3mm²
9 2
006-1 GND BLK 2.5mm² 730 IGN YEL 3mm²
(05H3)

10 3
006-2 GND BLK 2.5mm²
11 4
TO X722

006-3 GND BLK 2.5mm² 006 GND BLK 4mm²

12
345 COOLANT SIG WHT 0.75mm² S902
13
14
S670 313 NEUTRAL SW 0.75mm²
15
16
17
532 GND WHITE
18
313 NEUTRAL SW 0.75mm²
19
336 PREHEAT SENSE 0.75mm² 336 PREHEAT SENSE FLYW 1.5mm²
20
350 FUEL PRES GND BLK 0.75mm² S751
21
22
916 DELTA P VENTURI PWR WHT 0.75mm²
23
24
045 FUEL RL GND BLK 0.75mm²
25
D 26 D
27

31211337
28
29 730-1 IGN YEL 3mm² 730 IGN YEL 3mm²
30 730-3 IGN YEL 3mm² 312 ECM IGN 0.75mm²
31 S762
32
919 EGR TEMP SIG WHT 0.75mm²
33
34 S1087
338 ENG STRT 0.75mm² 338 ENG STRT 0.75mm²
35
531 GND WHT
36
230 SPD PWR YEL
37 1 SIG
043-1 GND BLK 1mm² 302 TRANS SPD WHT
38 2 GND
SPEED

901 AMB TEMP SIG BLK 0.75mm² 043 GND BLK 1.5mm²
SENSOR

39 SN97
40 S683
41 HV272
043-3 GND BLK
42 2
348 FUEL PRES PWR WHT 0.75mm² 327 TRANS 1
43 1
GENERIC
TRANS 1ST

44
308 PED PWR 0.75mm²
45
905 IAT VLV FB 5V WHT 0.75mm²
46 HV271
C 043-4 GND BLK C
47 2
328 TRANS 2
48 1
GENERIC
TRANS 2ND

49
50
51 HV273
043-5 GND BLK
52 2
727 DIAG CAN1L 14 GRN 0.75mm² S680 326 TRANS R
53 1
GENERIC
LOCATED ON RIGHT SIDE OF TRANSMISSION

716 ENG CAN2H 9 YEL 0.75mm² S679

LOCATED ON FRAME WALL ON CONTROL UNIT

TRANS REV

54
363 EXH GAS TEMP GND WHT 0.75mm²
55
364 EXH GAS TEMP SIG WHT 0.75mm²
56 HV274
043-6 GND BLK
57 2
349 FUEL PRES SIG WHT 0.75mm² 325 TRANS F
58 1
GENERIC
TRANS FL

59
900 AMB TEMP GND WHT 0.75mm²
60 X08
309 PED SIG 1 0.75mm² 228 KEY 1 YEL 1.5mm²
61 A
037 PED GND BLK 0.75mm² 007 GND BLK
62 B
63 C
907 IAT VLV FB GND BLK 0.75mm²
64 D
65 E
S989 713 ENG CAN2L 7 GRN 0.75mm²
66 F
S681 S915 721 DIAG CAN1L 11 GRN 0.75mm²
B 67 G B
347_3 SNSR RTN WHT 0.75mm² 720 DIAG CAN1H 11 YEL 0.75mm²
68 H
LOCATED ON AIR

S901 S901 S916

69 J
70 K
CLEANEAR BRACKET PLATES

71 L
047 GLOW RLY SW BLK 0.75mm² S990 712 ENG CAN2H 7 YEL 0.75mm²
72 M
902 FUEL RL WHT 0.75mm²
73 NC
74
726 DIAG CAN1H 14 YEL 0.75mm²
75
717 ENG CAN2L 9 GRN 0.75mm² S682
120 OHM
76 X917 X917T (09D3)
724 DIAG CAN1H 13 YEL 0.75mm²
77 A LOCATED ON TOP OF 200A CONTACTOR
725 DIAG CAN1L 13 GRN 0.75mm²
78 B LEFT SIDE OF ENGINE

79 C
906 IAT VLV FB SIG WHT 0.75mm²
80
918 SIG DVP WHT 0.75mm²
81
917 GND DVP BLK 0.75mm²
82
307 PED SIG 2 0.75mm²
83
84
85
532 GND WHITE
049 GND BLK
048 GND BLK
531 GND WHT
900 AMB TEMP GND WHT 0.75mm²
901 AMB TEMP SIG BLK 0.75mm²

YEL 718 ENG CAN2H 10

YEL 728 DIAG CAN1H 15

GRN 719 ENG CAN2L 10

311 AIR FLTR WHT 1mm² GRN 729 DIAG CAN1L 15
86
048 GND BLK
049 GND BLK
006 GND BLK 4mm²
007 GND BLK

BLK 044 GND

BLK 043 GND

346 COOLANT GND WHT 0.75mm²

87

364 EXH GAS TEMP SIG WHT

363 EXH GAS TEMP GND WHT
366 DELTA P SENS SIG WHT
362-2 EXH GAS GND WHT
365 DELTA P SENS PWR WHT
361-1 EXH GAS TEMP SIG WHT
362 EXH GAS TEMP GND BLK
343 WIF SIG WHT 0.75mm²
344 WIF GND BLK 0.75mm²
345 COOLANT SIG WHT 0.75mm²
346 COOLANT GND WHT 0.75mm²
347 COOLANT PWR WHT 0.75mm²
A 312 ECM IGN 0.75mm² A
88
2
1
SN767

X06
X07

X903
X906
89

2
1
4
3
2
1
2
1
2
1

B
A
B
A

C
C

2
1
1
2
3
2
1
X895
X901

SN826
SN831
SN827
1
1

X896

90
1

366 DELTA P SENS SIG WHT

X13
X14

X348 X345
X349 X346

91 WIF COOLANT LOCATED ON ENGINE FRONT SUPPORT

92 LOCATED UNDER

SIG
WIF FILTER LOCATED ON

GND
PWR
93 EXPANSION TANK

94 AMBIENT TEMP
TEMP 2 DPF DIFF PRESSURE TEMP1 GENERIC
120 OHM
120 OHM
1.5K 1/4W

1.5K 1/4W

LOCATED ON BOTTOM LOCATED ON FRAME WALL LOCATED ON TOP OF RADIATOR

LOCATED ON FRAME WALL
Electrical System

DS OF RADIATOR US NEAR CONTROL UNIT

1001247912-B
NEAR CONTROL UNIT

1 2 3 4 5 6 7 8

MAE45000B

9-17
9-18
1 2 3 4 5 6 7 8
LOCATED BEHIND DASH RIGHT
STEERING WHEEL SWITCHES
LOCATED ON LEFT LOCATED ON RIGHT LOCATED ON LEFT LOCATED ON RIGHT
RADIO WORKLIGHTS REAR WORK LIGHT REAR WORK LIGHT FRONT WORK LIGHT FRONT WORK LIGHT
GENERIC
SWITCH,CAB WORKLIGHTS
X797 WORKLIGHT RL WORKLIGHT RR WORKLIGHT FL WORKLIGHT FR
RED 798 B+ 1.5mm² RED 798 B+ 1.5mm²
g. Option Harnesses

1 1

15A
RED 798-1 B+ 1.5mm²
2

RIGHT TRIM
REAR TRIM
+
+
FC796

CAB PDB B+

RADIO B+ FUSE

LOCATED BEHIND
LOCATED BEHIND
7
8
3
2
1
6
5
4
9
10
1
2
1
2
1
2
1
2

MS21-1
1

LB12
LB11
LB10
LB09

SW864
2
3
RED 798-1 B+ 1.5mm²
4 X799
D 224 RADIO IGN YEL D
5 1
Electrical System

053 GND BLK

6 2

(02A2)
051-1 GND BLK
051-2 GND BLK

REAR TRIM
224 RADIO IGN YEL
430-1 F WRK LT
430-2 F WRK LT

431-2 R WRK LT
431-1 R WRK LT

050-2 GND BLK

050-1 GND BLK
7

051-4 GND BLK

TO CAB X798
LOCATED BEHIND
429 SW BACKLT
053 GND BLK
8
MS21
617 LH SPK+

RADIO
1 1 S357

225 F WRK LT YEL 1.5mm²

226 R WRK LT YEL 1.5mm²

S358

430 F WRK LT WHT 1.5mm²

431 R WRK LT WHT 1.5mm²

2 MS392LH+
616 LH SPK- 616 LH SPK- X252
3 1 225 F WRK LT YEL 1.5mm² S356 S359
617 LH SPK+ 1

LH SPEAKER
4 MS392LH- 226 R WRK LT YEL 1.5mm²
618 RH SPK+ 2
5 429 SW BACKLT

CEILING
619 RH SPK- 618 RH SPK+ 3
6 1 050 GND BLK 1.5mm²

(02A3)

LOCATED BEHIND RIGHT SIDE TRIM

4
7 MS393RH+ 051 GND BLK 1.5mm² 051-3 GND BLK 1.5mm²

LOCATED IN CABINE
619 RH SPK- 5
8 1 S98
6

RH SPEAKER
MS393RH-

TO CAB X792
REAR TRIM ON PCB BOARD
LOCATED BEHIND
X998-1
615-4 COND FAN 1.5mm² TO X640
AIRCON CHASSIS 1
615-3 COND FAN 1.5mm² (05E8)
2
613-1 AC PRESS WHT LOCATED ON BACK
3 OF CABINE

SPL_CATHODE SPL_ANODE X996-1

603 AC SW PWR WHT
1 TO X641
2 (05E8)
613-1 AC PRESS WHT LOCATED ON BACK
3 OF CABINE
056-1 GND BLK
4

LOCATED ON TOP OF CABINE

ON WIPER MOTOR
C LOCATED BEHIND DASH AIRCON CAB C
RIGHT STEERING WHEEL SWITCHES

614 AC2 COMP WHT

WIPER,ROOF
BEACON ROOF WIPER

GND BLK 1 mm²

LOCATED BEHIND DASH RIGHT SWITCH,WIPER ROOF
STEERING WHEEL SWITCHES

M
LOCATED ON TOP OF CABINE
BEACON SWITCH UP TO REAR WINDOW

X777
1

53
31b
SPL_COM
BEACON SOCKET LOCATED ON AC

+
+

V+ 53a
G 31
L
P
COMPRESSOR
BRACKET BOLT

+
+
1
2
3
4
7
8
3
2
1
6
5
4
9
10
058 GND BLK
059 GND BLK
615-4 COND FAN 1.5mm²
059 GND BLK
615-3 COND FAN 1.5mm²
058 GND BLK
603 AC SW PWR WHT
612 AC SWITCH SIG WHT
612 AC SWITCH SIG WHT
056-1 GND BLK
612 AC SWITCH SIG WHT

613-1 AC PRESS WHT

WH390

7
8
3
2
1
4
5
6
9
10
1
2
614 AC COMP WHT
613-1 AC PRESS WHT
612 AC SWITCH SIG WHT

SW256
614 AC1 COMP WHT

X776
1
B
A
B
A

LB83

SW94
SN252

2
1
1
1

WH753-2
WH753-1
SN153-2
SN153-1
F

A
B
E

C
D
SW154

LOCATED ON FRAME LEFT

2
1
WH1260
EXTERIOR WALL
+

M
M

622 RF WASH

053-2 GND BLK

055-2 GND BLK
428 SW BACKLT

427 SW BACKLT
AC COMPRESSOR SWITCH, PRES, AC SWITCH,AC TEMP SWITCH,AC
CONDENSOR FANS LOCATED ON AC LOCATED BEHIND DASH RIGHT

31211337
LOCATED ON AC LOCATED BEHIND RIGHT SIDE
LOCATED ON AC CONDENSOR FANS STEERING WHEEL SWITCHES
COMPRESSOR OF HVAC UNIT UNDER DASH

620 RF WIPE L 1.5mm²

620 RF WIPE L 1.5mm²

621 RF WIPE P 1.5mm²

621 RF WIPE P 1.5mm²
CONDENSOR FANS

222-3 RF WIPE PWR YEL

222-3 RF WIPE PWR YEL

055-1 GND BLK 1.5mm²

220 KEY 1 YEL 1.5mm²

053-1 GND BLK 1.5mm²

220 KEY 1 YEL 1.5mm²

X132
1

219 OPT PWR 1 YEL 1.5mm²

222-1 RF WIPE PWR YEL 1.5mm²
222-2 RF WIPE PWR YEL 1.5mm²
CLEARSKY

S400
2
3
X250 X401 231-1 CLEARSKY IGNT YEL 1mm²
219 OPT PWR 1 YEL 1.5mm² 222 RF WIPE PWR YEL 1.5mm² S399 4
1 1
053 GND BLK 1.5mm² 055 GND BLK 1.5mm² 5
2 2

(02A3)
427 SW BACKLT S99 428 SW BACKLT 6 3
B 3 3 751 CAN LO 18 GRN 0.75mm² 751 CAN LO 18 GRN 0.75mm² B
(02A3)

622 RF WASH 7 2

(02H3)
4 750 CAN HI 18 YEL 0.75mm²
8 1

REAR TRIM
SIDE REAR TRIM

TO CAB X793
TO CAB X811

9 X811-1

LOCATED BEHIND

LOCATED BEHIND REAR TRIM

LOCATED BEHIND RIGHT

6
10

TO CAB X523
11
12
13
14 LOCATED BEHIND RIGHT SIDE TRIM
231-1 CLEARSKY IGNT YEL 1mm² NEAR GROUND MODULE
15 2
056-4 GND BLK 1mm²
CLEARSKY MODULE

16 3 TO CAB X122
113-1 CLEARSKY BATT RED 1mm²
17 1 (02C8)
750 CAN HI 18 YEL 0.75mm²
18 X122-1_1
19
LOCATED BEHIND RIGHT SIDE TRIM ON CAN TCU

20
21
22
056-4 GND BLK 1mm²
23
113-1 CLEARSKY BATT RED 1mm²
24

UNIVERSAL TELEMATICS

A X1611 X122-3 A
RED 113-1 BATT PLUG INTO
UNIVERSAL 1 1
2 2 X122 SHEET 2,
TELEMATICS BLK 056-4 GND
3 3 ZONE C8
PLUG YEL 231-1 IGNT
4

1001247912-B
1 2 3 4 5 6 7 8

MAE45010B

3614RS, 4017RS
 Electrical System

9.6 DIELECTRIC GREASE APPLICATION AMP Faston

Dielectric grease helps to prevent corrosion of electrical This connector system is typically used on operator switches at
JLG. Follow the general guidance for installation.
contacts and improper conductivity between contacts from
moisture intrusion. Non-waterproof connectors benefit from
the application of dielectric grease.

9.6.1 Installation
1. The following is general guidance for the installation of
dielectric grease in a connector system.
2. Use dielectric grease in a tube for larger connection
points or apply with a syringe for small connectors.
3. Apply dielectric grease to plug/male connector housing Improper Proper
which typically contains sockets contact/female
terminals. AMP Micro-Fit
4. Leave a layer of dielectric grease on the mating face of
This connector system is typically used on control modules at
the connector, completely covering each connector
JLG. Follow the general guidance for installation.
terminal hole. Refer the pictures shown below.
5. Assemble the connector system immediately to prevent
moisture ingress or dust contamination.
The following connector systems are specifically addressed
because of their widespread use at JLG. However, this
guidance may be applied to similar devices.

AMP Mate-N-Lok
This connector system is widely used inside enclosures for gen- Improper Proper
eral-purpose interconnect. Follow the general guidance for
installation.
AMP Mini Fit Jr
This connector system is typically used on control modules at
JLG. Follow the general guidance for installation.

Improper Proper

Improper Proper

3614RS, 4017RS 31211337 9-19

 Electrical System

Mini Fit Sr Enclosures

This connector system is typically used on control modules at Application of dielectric grease is not required in properly sealed
JLG. Follow the general guidance for installation. enclosures. To meet criteria, the enclosure must be rated to at
least IP56 (dust protected; protected from powerful jets of
water).

Carling Switch Connectors

Carling switches may experience high impedance, or discontinuity,
due to silicone dielectric grease ingress when switching inductive
loads. Therefore, dielectric grease shall not be applied to Carling
switch mating connectors unless specifically noted.

Improper Proper

DIN Connectors
This connector is typically used on hydraulic valves. Follow the
installation instructions.

Improper Proper

Exceptions
Some waterproof connector applications do benefit from dielec-
tric grease, and some non waterproof connectors do not benefit
from dielectric grease.
In the exceptions below, we have found dielectric grease is not
needed for some applications, and in some cases can interfere
with the intended connection. Dielectric grease shall be used as
an exception in other applications.

9-20 31211337 3614RS, 4017RS

 Electrical System

9.7 ENGINE START CIRCUIT 4. For additional information on starting circuit, refer to
Section 9.5, “Electrical System Schematics”.
9.7.1 Starter c. Removal
Remove starter only if it fails. To remove starter:
1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in the
(N) NEUTRAL, engage parking brake, and shut engine
OFF.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer to Section 9.8,
1 “Battery”, for procedure.

MZ8040

a. Testing Starter on Engine

MZ7441
If starter (1) does not engage when ignition key switch is 2
turned, check following:
5. Remove belly pan (2).
1. Main fuse may be blown, requiring replacement. Check
for cause of blown fuse. 6. Remove wires from solenoid stud. Remove positive (+)
battery cable from starter. Label and disconnect wire
2. There may be a defect in ignition key switch, ignition
from starter solenoid housing stud. Record how wires
wiring or starter solenoid.
are installed to ensure correct installation later.
3. Check battery condition. Clean battery posts and
7. Loosen but DO NOT remove hardware securing starter.
connectors at each end of battery cables.
Support starter securely as it is relatively heavy and will
4. Check for broken wiring and damaged insulation on fall if not supported.
wiring. Replace all broken or damaged wiring.
8. Support starter and remove fasteners securing starter.
5. Check all connections at starter solenoid, key Remove negative (-) ground cable from its starter
switch and wiring harness plugs. Clean and tighten all mounting bolt.
connections.
9. Remove starter from machine.
6. If starter still does not operate after these checks have
been performed, check starting circuit. d. Installation

b. Starter Circuit Checks 1. Position starter in its mounting opening on flywheel

housing. Position negative (-) ground cable over correct
1. Check wires and connections for looseness, corrosion, starter mounting bolt. Secure starter with previously
damage, etc. used hardware.
2. If a “whirring” noise is heard but engine does not turn 2. Connect positive (+) battery cable to solenoid stud.
over, starter is spinning but not engaging flywheel. The Install wires to solenoid stud, and secure with lock
starter drive or solenoid that pushes drive forward to washer and nut.
engage flywheel may be defective. Missing or damaged
3. Connect battery negative (-) cable to battery negative (-)
teeth on flywheel can also prevent starter from cranking
terminal.
engine.
4. Close and secure engine cover.
3. If starter only “clicks” it may indicate that battery is
discharged, or that there is a loose or corroded battery 5. Remove Do Not Operate Tag from ignition key switch
cable connection. Check battery state of charge and and steering wheel.
battery condition first, then check cables and cable
connections.
3614RS, 4017RS 31211337 9-21
 Electrical System

9.7.2 Charging Circuit 5. Install a drive ratchet into square hole in serpentine belt
tensioner bracket. Note Belt routing for future
serpentine belt installation.
6. While lifting automatic belt tensioner away from belt,
remove fan serpentine belt.
Note: Record how alternator is installed to ensure correct
3 installation later.
7. Label and disconnect wire leads attached to alternator.
8. Remove lower mounting capscrew securing alternator to
lower mounting hole on engine.
9. While supporting alternator, remove upper mounting
hardware from upper alternator mount. Remove
alternator from machine.

b. Installation
1. Position alternator and align with upper alternator
mount on engine bracket. Insert upper (longer)
MZ8050 mounting hardware through alternator mount. Thread
longer capscrew into alternator front mount. DO NOT
Before using a battery charger, an attempt can be made to tighten completely at this time.
recharge battery by jump-starting machine (Refer to the
2. Align lower alternator mount hole with lower mounting
appropriate Operation & Safety Manual). Allow engine to
bracket on engine and insert lower mounting capscrew.
run, which will enable alternator (3) to charge the battery.
Tighten lower capscrew and upper capscrew securely.
If engine alternator charging warning indicator illuminates,
3. Place a drive ratchet into square hole on serpentine belt
perform following checks:
tensioner bracket. Apply pressure against tensioner
1. Check all battery cable connections at battery, and bracket and route serpentine belt onto alternator and
verify that they are clean and tight. engine pulleys. Release and check tensioner pulley to
2. Check external alternator wiring and connections, and verify that it is pivoting freely in order to provide the
verify that they are in good condition. proper tension on belt. Check for proper belt alignment.
(Refer to appropriate Operation & Safety Manual.)
3. Check fan belt condition and tension.
4. Connect previously labeled wire leads to alternator.
4. Run engine and check alternator for noise. A loose drive
pulley, loose mounting hardware, worn or dirty internal 5. Properly connect battery. Refer to Section 9.8, “Battery”,
alternator bearings, a defective stator or defective for procedure.
diodes can cause noise. Replace a worn or defective 6. Close and secure engine cover.
alternator.
7. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
9.7.3 Alternator

a. Removal
1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in the
(N) NEUTRAL, engage parking brake, and shut engine
OFF.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer to Section 9.8,
“Battery”, for procedure.

9-22 31211337 3614RS, 4017RS

 Electrical System

9.8 BATTERY 9.8.2 Battery Removal/Installation

Note: Eye protection is recommended before inspecting a. Removal

and/or replacing the battery.
1. Park machine on a firm, level surface, level machine,
fully retract boom, lift boom, place transmission in
9.8.1 Battery Inspection (N) NEUTRAL, engage parking brake and shut engine
1. Park machine on a firm, level surface, level machine, OFF.
fully retract boom, lower boom, place transmission in 2. Place a Do Not Operate Tag on both ignition key switch
(N) NEUTRAL, engage parking brake and shut engine and steering wheel.
OFF.
3. Open engine cover. Allow system fluids to cool.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel. 4. Turn OFF electrical master switch.

3. Open engine cover. Allow system fluids to cool. 5. Disconnect Negative battery cable (2).
6. Disconnect Positive battery cable (3).
7. Loosen and remove clamp securing battery (1).
8. Remove battery (1).

a. Installation
1. Properly install battery (1) and secure in place with
previously removed clamp.
2 2. Connect Positive battery cable (3).
3. Connect Negative battery cable (2).
3 4. Turn ON electrical master switch.
5. Close and secure engine cover.
6. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

1 MAE9800

4. Visually inspect the battery (1).

5. Check terminals for corrosion.
6. Replace the battery if it has a cracked, melted or
damaged case.
7. Close and secure engine cover.
8. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

3614RS, 4017RS 31211337 9-23

 Electrical System

9.8.3 Battery Disconnect/Connect 9.9 WIPER/WASHER WIPER MOTOR

a. Disconnect
9.9.1 Front Windshield Wiper Motor
1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place transmission in a. Removal
(N) NEUTRAL, engage parking brake and shut engine
1. Park machine on a firm, level surface, level machine, fully
OFF.
retract boom, lower boom, place transmission in the
2. Place a Do Not Operate Tag on both ignition key switch (N) NEUTRAL, engage parking brake, and shut engine
and steering wheel. OFF.
3. Open engine cover. Allow system fluids to cool. 2. Place a Do Not Operate Tag on both ignition key switch
4. Disconnect Negative battery cable (2). and steering wheel.
5. Disconnect Positive battery cable (3). 3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer to Section 9.8,
a. Connect “Battery”, for procedure.
1. Connect Positive battery cable (3). 5. Remove front access cover.
2. Connect Negative battery cable (2).
1
3. Close and secure engine cover.
4. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

MZ8160

6. Disconnect reservoir hose (1) from wiper linkage (2).

7. Remove wiper linkage (2).
8. Loosen and remove hardware (3) holding wiper
assembly mounting bracket to machine.
9. Disconnect electrical harness connectors from the
wiper motor.
10. Loosen and remove hardware holding wiper motor to
mounting bracket.
Note: Retain all hardware removed from wiper assembly for
possible reuse on replacement motor housing.
11. Remove motor from wiper assembly.

9-24 31211337 3614RS, 4017RS

 Electrical System

b. Disassembly 9.9.2 Rear Window Wiper Motor

DO NOT disassemble the motor. The motor is not
a. Removal
serviceable. Replace motor if found to be defective.
1. Park machine on a firm, level surface, level machine, fully
c. Inspection and Replacement retract boom, lower boom, place transmission in
(N) NEUTRAL, engage parking brake, and shut engine
Inspect motor terminals for continuity. Replace motor if
OFF.
continuity is not found.
2. Place a Do Not Operate Tag on both ignition key switch
d. Installation and Testing and steering wheel.
1. Align motor with mounting holes and secure motor to 3. Open engine cover. Allow system fluids to cool.
mounting bracket. 4. Properly disconnect battery. Refer to Section 9.8,
2. Connect electrical harness to wiper motor. “Battery”, for procedure.
3. Secure mounting bracket to machine with
hardware (3) removed earlier.
4. Connect wiper linkage to the wiper motor shaft.
6 4
Note: Align the wiper linkage arm with the flat on the motor
shaft to ensure wiper stroke covers window area, and it does
not swipe past the glass area.
5. Connect the reservoir hose to wiper linkage.
6. Properly connect battery. Refer to Section 9.8, “Battery”,
for procedure.
5
7. Turn ignition key switch to RUN position, and operate
windshield wiper in both LOW and HIGH speeds to
ensure proper operation and that correct wiper travel is
achieved. MZ8130

8. Install front access cover. 5. Remove hardware (4) securing motor access cover (5).

9. Close and secure engine cover. 6. Disconnect electrical harness connectors (6) from the
wiper motor.
10. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

7 8

MZ8120

7. Disconnect reservoir hose (7) from wiper linkage (8).

3614RS, 4017RS 31211337 9-25

 Electrical System

8. Remove wiper linkage (8). 9.9.3 Roof Window Wiper Motor

9. Loosen and remove hardware (9) holding wiper motor
assembly to window. a. Removal

Note: Retain all hardware removed from wiper assembly for 1. Park machine on a firm, level surface, level machine, fully
possible reuse on replacement motor housing. retract boom, lower boom, place transmission in
(N) NEUTRAL, engage parking brake, and shut engine
10. Remove wiper assembly from window. OFF.
2. Place a Do Not Operate Tag on both ignition key switch
b. Disassembly
and steering wheel.
DO NOT disassemble the motor. The motor is not 3. Open engine cover. Allow system fluids to cool.
serviceable. Replace motor if found to be defective.
4. Properly disconnect battery. Refer to Section 9.8,
c. Inspection and Replacement “Battery”, for procedure.

Inspect motor terminals for continuity. Replace motor if 12 11

continuity is not found.

d. Installation and Testing

1. Align wiper assembly with mounting holes and secure
assembly to window.
2. Connect wiper linkage to the wiper motor shaft.
Note: Align the wiper linkage arm with flat on motor shaft to
ensure wiper stroke covers window area, and it does not swipe
past the glass area.
3. Connect reservoir hose to wiper linkage.
4. Connect electrical harness to wiper motor.
5. Properly connect battery. Refer to Section 9.8, “Battery”, 10
for procedure.
6. Turn ignition key switch to RUN position, and operate MAE36390

windshield wiper in both LOW and HIGH speeds to 5. Remove hardware securing access cover (10) to the cab.
ensure proper operation and that correct wiper travel is
achieved. 6. Disconnect electrical harness connector (11) from the
dome light (12).
7. Secure motor access cover (5) with hardware removed
earlier. 7. Disconnect electrical harness connectors from the
wiper motor.
8. Close and secure engine cover.
9. Remove Do Not Operate Tag from ignition key switch
and steering wheel. 13

14
15
MZ8140

8. Disconnect reservoir hose (13) from wiper linkage (14).

9. Remove wiper linkage (14).

9-26 31211337 3614RS, 4017RS

 Electrical System

10. Loosen and remove hardware (15) holding wiper motor 9.9.4 Washer Tank
assembly to machine.
The washer motor and reservoir is located in cab underneath
Note: Retain all hardware removed from wiper assembly for the dash. It is labeled as a unit and cannot be serviced
possible reuse on replacement motor housing. separately.
11. Remove wiper assembly from window.
a. Removal
b. Disassembly 1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in
DO NOT disassemble the motor. The motor is not
(N) NEUTRAL, engage parking brake, and shut engine
serviceable. Replace motor if found to be defective.
OFF.
c. Inspection and Replacement 2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
Inspect motor terminals for continuity. Replace motor if
continuity is not found. 3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer to Section 9.8,
d. Installation and Testing “Battery”, for procedure.
1. Align wiper assembly with mounting holes and secure 5. Remove the outside cover at the front of the cab.
assembly to machine.
2. Connect wiper linkage to wiper motor shaft.
Note: Align wiper linkage arm with flat on motor shaft to
ensure wiper stroke covers window area, and it does not swipe
past glass area.
3. Connect reservoir hose to wiper linkage.
4. Connect electrical harness to wiper motor.
5. Properly connect battery. Refer to Section 9.8, “Battery”,
for procedure. 16
6. Turn ignition key switch to RUN position, and operate
windshield wiper in both LOW and HIGH speeds to
ensure proper operation and that correct wiper travel is
achieved. MAE9750

7. Secure access cover with hardware removed earlier.

6. Remove hardware (16) securing tank to machine.
8. Close and secure engine cover.
7. Label and disconnect harness connectors from washer
9. Remove Do Not Operate Tag from ignition key switch
tank connectors.
and steering wheel.
8. Remove washer hoses from washer tank.
9. Remove washer tank from cab.

3614RS, 4017RS 31211337 9-27

 Electrical System

b. Disassembly 9.10 SOLENOIDS, SENSORS AND SENDERS

DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective. 9.10.1 Transmission Solenoid Valves

c. Installation and Testing

1. Connect windshield washer hoses to washer tank.
2. Connect cab wiring harness connectors to washer tank 1
connectors.
3. Align washer tank with mounting holes and secure with
previously used hardware.
4. Fill the washer fluid reservoir with washer fluid.
5. Install the outside cover at the front of the cab.
6. Properly connect battery. Refer to Section 9.8, “Battery”.
7. Close and secure engine cover.
8. Remove Do Not Operate Tag from ignition key switch
and steering wheel. MZ8180

Note: If the transmission is not shifting properly, the

transmission shifter, wiring harness or transmission shift
solenoids (1) should be checked in order to determine
which component is defective. Specific information to
determine which travel position and corresponding
component is not responding can be found in the detailed
transmission service instructions (covering repair,
disassembly, reassembly and adjustment information) are
provided in the following publications:
Detailed transmission parts and service information can be
found in appropriate parts and/or service manuals.
The transmission should be checked, serviced and repaired
only by experienced service technicians who are aware of all
safety instructions and particular component features.
Note: Contact local JLG dealer if internal transmission repair is
required during the warranty period.

9.10.2 Transmission Oil Temperature Switch

a. Transmission Oil Temperature Switch Removal

The transmission oil temperature switch (2) is located next to
transfer case below converter housing.
1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer Section 9.7, “Battery”,
for procedure.

9-28 31211337 3614RS, 4017RS

 Electrical System

9.10.3 Transmission Mounted Speed Sensor

5

MZ8200

Transmission speed sensor (3) is located on the side of the

transmission bell housing.
MZ8190
a. Transmission Mounted Speed Sensor Removal
5. Unplug transmission oil temperature switch connector 1. Park machine on a firm, level surface, level machine,
from wiring harness connector. fully retract boom, lower boom, place transmission in
6. The switch is threaded into transmission housing. (N) NEUTRAL, engage park brake and shut engine OFF.
Remove the switch. 2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
b. Transmission Oil Temperature Switch Inspection and 3. Open engine cover. Allow system fluids to cool.
Replacement
4. Properly disconnect battery. Refer to Section 9.8,
Inspect switch and wiring harness connector terminals for “Battery”, for procedure.
continuity. Replace a defective or faulty switch with a new
5. Unplug the speed sensor connector (4) from the wiring
part.
harness connector.
c. Transmission Oil Temperature Switch Installation and 6. Loosen screw (5) holding clamp and remove sensor.
Testing
b. Transmission Mounted Speed Sensor Inspection and
1. Thread transmission oil temperature switch into Replacement
transmission housing snugly, then connect switch
connector to wiring harness connector. Inspect sensor and wiring harness connector terminals for
continuity. Replace a defective or faulty sensor with a new
2. Properly connect battery. Refer to Section 9.8, “Battery”,
part.
for procedure.
3. Check for proper fluid level. c. Transmission Mounted Speed Sensor Installation
4. Start engine, allow it to reach operating temperature and Testing
and observe operator display cluster for warning 1. Install sensor in transmission, install clamp on sensor.
indication. If switch is not defective, problem could be Secure with screw removed earlier.
elsewhere; possibly in a shorted wire, damaged
transmission, improper or low fluid, etc. 2. Connect sensor plug to wire harness.
5. Close and secure the engine cover. 3. Properly connect battery. Refer to Section 9.8, “Battery”,
for procedure.
6. Remove Do Not Operate Tag from ignition key switch
and steering wheel. 4. Close and secure engine cover.
5. Remove Do Not Operate Tag from ignition key switch
and the steering wheel.

3614RS, 4017RS 31211337 9-29

 Electrical System

9.10.4 Engine Coolant Temperature 4. Properly connect battery. Refer to Section 9.8, “Battery”,
Sensor for procedure.
5. Check for proper coolant level.
6. Start engine, allow it to reach operating temperature
and observe operator instrument cluster for warning
indication. If sensor is not defective, the problem could
6 be elsewhere; possibly in a shorted wire, improper-
running engine, improper or low coolant, obstructed or
faulty radiator, coolant pump, loose fan belt, defective
instrument display, etc.
7. Close and secure engine cover.
8. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

9.10.5 Fuel Level Sender

MZ6840
a. Fuel Level Indicator Testing
1. Fuel level sender wiring harness leads can be accessed
Engine coolant temperature sensor (6) is located on left side
from lowered fuel tank. Refer to Section 7.6.2, “Fuel
of engine.
Tank”, for detailed fuel tank removal and installation.
a. Engine Coolant Temperature Sensor Removal 2. Disconnect fuel level sender wiring harness leads.

1. Park machine on a firm, level surface, level machine, 3. With the help of an assistant, touch both harness leads
fully retract boom, lower boom, place transmission in together.
(N) NEUTRAL, engage park brake and shut engine OFF. 4. From operator cab, have assistant turn ignition key
2. Place a Do Not Operate Tag on both the ignition key switch to RUN position. DO NOT start engine. Observe
switch and steering wheel. fuel level indicator needle on operator instrument
cluster. Reading must be at FULL mark.
3. Open engine cover. Allow system fluids to cool.
5. Turn ignition key switch to OFF position. Fuel level
4. Properly disconnect battery. Refer to Section 9.8, indicator needle should return to EMPTY position.
“Battery”, for procedure.
5. Unplug engine coolant temperature sensor connector b. Fuel Level Circuit Tests
from wiring harness connector.
If fuel level sender is suspected of giving a false reading,
6. Loosen and remove engine coolant temperature sensor perform following checks:
from engine block.
1. If fuel level indicator needle does not move, check fuel
tank for fuel.
b. Engine Coolant Temperature Sensor Inspection and
Replacement 2. Check for loose or defective wiring, faulty ground
connections, and corrosion on fuel tank sender and
Inspect sensor and wiring harness connector terminals for wiring lead.
continuity. Replace a defective or faulty sensor with a new
part. 3. If fuel level indicator needle does not move after
ignition key switch is turned to RUN position, use a test
c. Engine Coolant Temperature Sensor Installation and lamp to determine whether current is flowing from
Testing ignition switch to fuel level sender.
4. If fuel level indicator does not move and a faulty or
1. Apply a lubricate to O-ring on temperature sensor.
defective fuel level sender in fuel tank has been ruled
2. Thread engine coolant temperature sensor into engine out, and in addition, wiring and connectors have been
block. Tighten and torque the sensor to checked and ruled out, fuel level indicator is defective
17 - 23 Nm (12.5 - 17 lb-ft). and must be replaced.
3. Connect sensor connector to wiring harness connector.

9-30 31211337 3614RS, 4017RS

 Electrical System

5. Check that ignition terminal has current and that fuse in 3614RS
fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between fuel level indicator wiring at
cab, fuse and relay panel, ignition key switch, and from
fuel level sender on fuel tank through wiring in the cab.
7. Check fuel level sender. A defective fuel level sender in
fuel tank may also prevent fuel level indicator from
moving. Refer to Section 9.5, “Electrical System
Schematics”, for further information.

9.10.6 Boom Retract Sensor

The boom retract sensor is located inside rear of boom.
8
a. Boom Retract Sensor Testing
1. Ensure boom is fully retracted and verify using cab 7
display that boom retract switch is activated.
2. Extend the boom 100 mm and verify using cab display MAG3470
that boom retract switch is deactivated.
4017RS
If boom retract sensor is suspected of giving a false reading,
perform following checks:
3. Check for loose or defective wiring, faulty ground
connections, and corrosion on boom retract sensor and
wiring lead.
4. Check that ignition terminal has current and that fuse in
fuse panel is not blown.
5. Check for broken, shorted, frayed, disconnected or
damaged wiring between display wiring at cab, fuse
and relay panel, ignition key switch, and from boom
retract sensor on boom through wiring in cab.

b. Boom Retract Sensor Removal

1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place transmission in 8
(N) NEUTRAL, engage park brake and shut engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect battery. Refer to Section 9.8,
“Battery”, for procedure.

MZ8260

3614RS, 4017RS 31211337 9-31

 Electrical System

5. Unplug boom retract sensor connector (7) from wiring

harness connector.
6. Loosen hardware securing boom retract sensor (8) and
remove boom retract sensor from boom. A&B

c. Boom Retract Sensor Inspection and Replacement

Inspect sensor and wiring harness connector terminals for
continuity. Replace a defective or faulty sensor with a new 9
part.

d. Boom Retract Sensor Installation

1. Secure boom retract sensor (8) to boom.
2. Connect boom retract sensor connector to wiring harness
MAE34830
connector.
3. Properly connect battery. Refer to Section 9.8, “Battery”, 6. Loosen and remove the nut holding the rod
for procedure. assembly (9) to the sensor arm.
4. Close and secure engine cover. 7. Loosen and remove the two bolts holding the sensor to
5. Remove Do Not Operate Tag from ignition key switch the sensor bracket.
and steering wheel. 8. Remove the sensor assembly.
9. If necessary, remove the sensor bracket.
9.10.7 Boom Angle Sensor
The boom angle sensor is located at the top left inside rear of b. Boom Angle Sensor Inspection and Replacement
the boom. Inspect the sensor and the wiring harness connector
terminals for continuity. Replace a defective or faulty sensor
a. Boom Angle Sensor Removal with a new sensor.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, place c. Boom Angle Sensor Installation
the transmission in (N) NEUTRAL, engage the park brake 1. If necessary, install the sensor bracket.
and shut the engine OFF.
2. Install the sensor assembly to the sensor seat and
2. Place a Do Not Operate Tag on both the ignition key tighten both bolts.
switch and the steering wheel, stating that the machine
should not be operated. 3. Install the rod end to the sensor arm and tighten nut.

3. Open the engine cover. Allow the engine to cool. 4. If necessary, measure and set the rod length (3) as
required.
4. Properly disconnect the battery. Refer to Section 9.8,
“Battery”, for procedure. Machine Rod Length
5. Disconnect the boom angle sensor electrical connector. 3614RS (A) 230 mm (9.05 in)
4017RS (B) 230 mm (9.05 in)

5. Plug the electrical connector into the sensor assembly.

6. Properly connect the battery. Refer to Section 9.8,
“Battery”, for procedure.
7. Close and secure the engine cover.
8. Remove the Do Not Operate Tag from the ignition key
switch and the steering wheel.

9-32 31211337 3614RS, 4017RS

 Electrical System

d. Boom Angle Sensor Adjustment 9.11 DASH SWITCHES

1. Enter Access Level 2 password 33271.
Note: For information on the front windshield wiper, rear
2. Choose Calibration menu and select “Boom Angle”. window wiper and washer systems, refer to Section 9.9, “Wiper/
3. Press OK button when asked “Calibrate Boom Angle Washer Wiper Motor”.
Sensor?”.
4. Follow prompts. First move boom to lowest position, 9.11.1 Ignition Key Switch
press OK button.
a. Ignition Key Switch Removal
5. Follow prompts. Move boom to highest position, press
OK button. 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, place
6. If calibration is successful, Analyzer will indicate the transmission in (N) NEUTRAL, engage the park brake
“Calibration: Complete”. and shut the engine OFF.
If calibration fails, Analyzer will indicate “Calibration
Failed”. The boom angle sensor position may need to be 2. Place a Do Not Operate Tag on both the ignition key
adjusted or the boom sensor rod may need adjusted. switch and the steering wheel, stating that the machine
should not be operated.
9.10.8 Reverse Alarm 3. Open the engine cover. Allow the engine to cool.
The reverse alarm is located at the rear of the machine. 4. Properly disconnect the battery. Refer to Section 9.8,
“Battery”, for procedure.
When the transmission shift lever is shifted to the
(R) REVERSE position, the reverse alarm will automatically 5. Remove the screws securing the lower dash panel.
sound. 6. Remove the hex nut securing the ignition key switch to
Place the transmission control lever in (R) REVERSE to test the the dash.
reverse alarm. The reverse alarm must not sound when the 7. Lower the dash panel to gain access to the rear of the
transmission control lever is in (N) NEUTRAL or (F) FORWARD. ignition switch. Push the switch through the panel.
Also, with the ignition key switch in the RUN position, the
8. Label and disconnect the electrical connections
reverse alarm will sound when the transmission control lever
attached to the switch.
is shifted into the (R) REVERSE position.
9. Remove the switch from the machine.
a. Disassembly
b. Disassembly
DO NOT disassemble the reverse alarm. Replace a defective
or faulty alarm with a new part. DO NOT disassemble the ignition key switch. Replace a
defective switch with a new part.

3614RS, 4017RS 31211337 9-33

 Electrical System

c. Inspection and Replacement 8. Start engine to verify proper operation of the ignition
switch.
To determine the proper operation of the ignition key switch,
using the following chart, test the wires on the back of the 9. Remove the Do Not Operate Tag from the ignition key
switch for continuity with an ohmmeter. switch and the steering wheel.

0 9.11.2 Dash Switches

P I

II a. Switch Removal
1. Park the machine on a firm, level surface, level the
III machine, fully retract the boom, lower the boom, place
the transmission in (N) NEUTRAL, engage the park brake
MZ2130
and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the system fluids to cool.
4. Properly disconnect the battery. Refer to Section 9.8,
“Battery”, for procedure.
5. Pull the frame out of the dash, disconnect the harness
connector to the switch in question and push the switch
MZ2140
out of the frame.
Test the ignition key switch for continuity, by checking from
the power (#30) wire to each of the following wires in each b. Disassembly
switch position. Continuity should be present as indicated in DO NOT disassemble the dash switch. Replace a defective
the following chart: switch with a new part.
Switch Position Test for Continuity Between Wire
#30 and wires: c. Inspection and Replacement
P #58 Inspect the switch terminals for continuity and shorting in
both the engaged and disengaged positions. Replace a
I #15
defective or faulty switch with a new switch.
II #15 & #19
III #15, #17 & #50 d. Switch Installation

If all connections do not show proper continuity, replace the 1. Connect the switch to the cab harness connector.
ignition switch. 2. Position the switch over the rectangular switch bezel
and snap into position.
d. Ignition Key Switch Installation 3. Properly connect the battery. Refer to Section 9.8,
1. Connect the previously labeled electrical connections “Battery”, for procedure.
to the ignition key switch. 4. Start the machine and check the replaced switch for
2. Push the ignition key switch through the hole in the proper function.
dash. 5. Close and secure the engine cover.
3. Secure the switch to the dash with the previously used 6. Remove the Do Not Operate Tag from the ignition key
hex nut. switch and the steering wheel.
4. Verify that each ignition position is properly connected.
5. Install the lower dash panel.
6. Properly connect the battery. Refer to Section 9.8,
“Battery”, for procedure.
7. Close and secure the engine cover.

9-34 31211337 3614RS, 4017RS

 Electrical System

9.12 LOAD STABILITY INDICATOR (LSI) (IF • As the telehandler reaches forward stability limitation
EQUIPPED) and the red LED (5) illuminates, the automatic function
cut-out is activated. All boom, frame-level and outrigger
functions are disabled except for boom retract (CE &
9.12.1 Load Stability Indicator AUS) and boom lift (CE). Retract boom to re-enable
functions.

WARNING • Travel in accordance with the requirements set forth in

Section 1 - General Safety Practices.
TIP OVER HAZARD. The LSI considers only longitudinal • When placing a load, ensure axles are not fully steered
stability limitations, observe all operating parameters. in either direction.
Failure to follow operating parameters of the telehandler
could damage the equipment and/or cause tip over.
Note: The Load Stability Indicator is NOT a serviceable item.
The LSI must be inspected and/or replaced by the local JLG
WARNING
dealer. TIP OVER HAZARD. If the green, yellow and red LEDs
4 flash and warning buzzer sounds, retract and lower boom
3 5
immediately. Determine cause and correct before
continued use.

9.12.2 LSI Sensor

1
2 6

MAE35030

The LSI (1) provides visual and audible indication of forward

stability limitations when machine is static on firm, level MZ8230

surface.
The LSI sensor (6) is bolted on the top left of the rear axle.
• When approaching forward stability limitations LEDs
Note: If the rear axle is removed or replaced, the LSI Sensor
progressively illuminate, green (3), then yellow (4) and
finally red (5). must be installed AFTER the rear axle is installed and setting on
all four wheels.
• If the red LED iluminates, the warning buzzer also
sounds.
• The orange LED (4) illuminates when the boom is fully
retracted in LSI passive mode.
• When approaching forward stability limitations, visual
and audible indication is provided and the automatic
function cut-out and/or slow down feature is disabled.

3614RS, 4017RS 31211337 9-35

 Electrical System

a. LSI Sensor Removal 4. Remove any excess degreasing agent and allow to dry.
1. Remove any attachment from the machine. 5. Inspect the bottom of the new LSI sensor to ensure the
mounting area is clean.
2. Park the machine on a firm, level surface, straighten all
four wheels and drive the machine in a straight line for
approximately 2 m (6.5 ft), level the machine using the
cab mounted level, fully retract the boom, fully raise the
boom, place the transmission in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
3. Place a Do Not Operate Tag on both the ignition key 8
switch and the steering wheel, stating that the machine
should not be operated.
4. Open the engine cover. Allow the engine to cool.
5. Properly disconnect the battery. Refer to Section 9.8,
“Battery”, for procedure.
6. Disconnect the LSI sensor at the electrical connection
7. Loosen, remove and discard the two bolts holding the
LSI assembly to the rear axle.
8. Remove and discard the sensor assembly. MZ8560

Note: Install the sensor to the axle within one minute of

b. LSI Sensor Installation
applying activator and adhesive for optimum adhesion.
Note: The machine MUST remain stationary for a minimum of
6. Apply a thin film of Loctite® Initiator #1 (may also be
two (2) hours.
denoted as Initiator #5) activator approximately
Note: If there is any difficulty preparing the axle surface to 6 cm² (1 in²) to each of the metallic surfaces (8) of the
mount the sensor, contact your local Caterpillar Dealer. sensor, ensuring the adhesive is spread evenly over the
entire surface.
1. Remove any adhesive and/or rust from the mounting
area.
2. Ensure threads of both bolt holes are clean and free
from rust, water and debris. If necessary, thread an M10
bottom tap through each hole. Verify holes are clean.

9
MZ8580

7. Apply an 3mm (0.125 in) bead of Loctite® A2460™ (F246)

Adhesive to the axle surface area (9) around each
7 mounting hole.
MZ8620
Note: Follow manufacturer’s recommendations for storage
3. Clean the bare metal with a degreasing agent, Loctite® life.Other adhesives must NOT be used as a substitute for
7063. Only use the necessary amount of degreasing Loctite® A2460™ (F246).
agent to clean the mounting area (7).
9-36 31211337 3614RS, 4017RS
 Electrical System

10. Connect the LSI sensor (7) at the electrical connection.

11. Scribe a permanent mark from each bolt head onto the
sensor.

10

12
11

MZ8570

8. Use a spatula PN 1001203023 (10) to evenly distribute

the adhesive over the axle surface area. Use the MZ8590
following sequence to minimize the amount of
adhesive entering into the threaded holes and to 12. Apply a black silicone sealant around the perimeter
distribute the adhesive properly. sensor in the following sequence:
A. Position the spatula (10) over the threaded hole. A. Start by positioning the nozzle under the harness
B. Move the spatula from the center of the hole to the lead (11) and apply a large bead (12) around the sensor.
left. B. Ensure that you end the bead Over The Starting Point.
C. Remove the excess adhesive from the spatula. 13. Using a spatula and soapy water, smooth the silicone
D. Move the spatula from the center of the hole to the around the sensor.
right.
E. Repeat steps A thru D on remaining hole. Note: DO NOT move the machine for a minimum of 1 hour.
14. Plug the electrical connector into the sensor assembly.
15. Properly connect the battery. Refer to Section 9.8,
6 “Battery”, for procedure.
16. Close and secure the engine cover.
17. Remove the Do Not Operate Tag from the ignition key
switch and the steering wheel.
18. Calibrate the LSI system, refer to Section 9.12.3, “LSI
System Calibration”.

MZ8230

9. Fit the sensor (6), ensuring the lead exits in the corner
direction. Secure with two new bolts - Socket HD
Capscrew M10x35x1.5, Grade 12.9 in the following
sequence:
A. Tighten each bolt finger tight.
B. Tighten each bolt to 30 - 35 Nm (22 - 26 lb-ft).
C. Tighten each bolt to 70 - 80 Nm (51 - 59 lb-ft).

3614RS, 4017RS 31211337 9-37

 Electrical System

9.12.3 LSI System Calibration 9.13 MACHINE DATA

To calibrate the LSI, certain conditions must be met:
• The sensor must be installed according to 9.13.1 Machine Data Access
Section 9.12.2, “LSI Sensor”. Machine and engine data can be accessed by connecting to
• The operator must remain in the cab. the appropriate locations shown below.

• If installed, remove the attachment from the machine.

• If equipped, fully deploy the outriggers before the
calibration. 1

• The machine must be on a level surface with the wheels

steered straight and park brake off, with straight driving
over a distance of at least 2 m (6.5 ft) being the last
movement before entering a calibration point.
• While utilizing the LSI override button, 10 times lift and
lower the boom stopping suddenly to induce the rear
axle to bounce.
• The calibration must be completed within 30 minutes
after starting procedure.
• Recalibrate LSI at regular maintenance intervals or if the
weight of the machine changed due to configuration
update.
Calibration Procedure:
1. Start and position the machine to perform the
calibration procedure.
2. Connect analyzer tool.
3. Enter access level 2 passcode 33271.
4. With JLG analyzer, navigate to;
Calibrations>Load Stability>Calibrate LSI Sensor.
5. If installed, remove attachments for the machine. Press MAE35070

Enter on analyzer.
6. If equipped, fully deploy the outriggers. Press Enter on
analyzer.
7. Fully retract the boom and fully lifted up. Press Enter on
analyzer.
8. Wait for Calibrating Load Stability 0% to finish.
9. Lower the boom.
10. If equipped, fully retract the outriggers. Press Enter on
analyzer.
11. Rear axle must be unloaded by raising the machine
frame at rear.
2
12. Press Enter on the Lift Down screen.
MAE3961
13. Wait for Calibrating Load Stability 100% to finish.
14. The system will display LSI Calibration Complete for
successful calibration or LSI Calibration Failed for
unsuccessful calibration. Press Enter on analyzer.

9-38 31211337 3614RS, 4017RS

 Electrical System

The machine analyzer plugs into the XE connector (1) of the 9.13.3 Mobile Analyzer
Power Distribution Board located behind the operator seat.
The mobile analyzer (PN 1001147542) is a Wi-Fi enabled
For machine diagnostics, refer to Section 9.16, “Machine
evolution of the hand held analyzer kit provides machine
Fault Codes Version P 18.0”.
diagnostic, configuration and troubleshooting capabilities
The engine data can be accessed through connector (2) in with an extended operator range of up to 45,72 m (150 ft).
the engine compartment utilizing engine diagnostic tool. For
engine diagnostics, refer to Section 9.17, “Engine
Diagnostic”.

9.13.2 Hand Held Analyzer

The hand held analyzer (PN 1001249695) can be used in
place of the display panel.
1

3
1 2

4
2 5

3 4

5 6

MAE0930

MZ6040 6
1. Analyzer Display Screen: To display full description
1. Cable Connector. readouts.
2. Analyzer Display Screen. 2. Escape Key: To return home or access previous menu.
3. Escape Key: To return home or access previous menu. 3. Enter Key: Stores and selects Top Level, Sub Level and
4. Enter Key: Stores and selects Top Level, Sub Level and Items Menus.
Items Menus. 4. Up/Down Arrow Keys: Change adjustable values.
5. Up/Down Arrow Keys: Change adjustable values. 5. Left and Right Arrow Keys: Used to move between Top
6. Left and Right Arrow Keys: Used to move between Top Level, Sub Levels and Item Menus.
Level, Sub Levels and Item Menus. 6. Disconnect: To disconnect the connection of the mobile
from the system.

3614RS, 4017RS 31211337 9-39

9-40
9.13.4
Note: The layout shows all possible analyzer screens. Please note, some screens may not be a visible depending upon machine conguration. (SHEET 1 of 8)
Electrical System

ANALYZER MENU
STRUCTURE

MENU: 3 HELP : ( 001 ) 3

HELP : PRESS ENTER SYSTEM OK

LOG: *( XXXXX ) 3
X: XXXXXXXXXXXXXX
Analyzer Software Version P 18.0

MENU : 3 BRAND : 1 VEHICLE : 1 MODEL : 1 MARKET: 1 ENGINE CONTROL : 1 TRANSMISSION : 1 LOAD STABILITY: 1 HYDRAULIC QUICK 1
MACHINE SETUP UNKNOWN UNKNOWN UNKNOWN UNKNOWN UNKNOWN UNKNOWN NO CONNECT : NO

AUX. FUNCTION 1 AUXILIARY F/R 1 AUXILIARY REAR 1 BOOM RIDE & FLOAT: 1 FAN CONTROL : 1 COLUMN SELECTOR : 1 JOYSTICK FNR : 1 OUTRIGGERS : 1 STEER PRESSURE: 1
SELECT: NO SELECT : NO SELECT : NO NONE NONE NO NO YES NO

31211337
AIR CONDITION: 1 HITCH: 1 REVERSE OBSTACLE 1 FWD GEAR LIMIT : 1 REV GEAR LIMIT : 1 PREMIUM DISPLAY : 1 PREMIUM DISPLAY 1 BACKUP CAMERA : 1 BLOCKING VALVE: 1
NO NO DETECTION : NO NO NO NO LOCKOUT : NO NO YES

LOAD MOMENT IND 1 REMOTE CONTROL : 1 ATTACHMENT 1 AR REGION : 1 TRAILER BRAKE : 1 SAHR BRAKE : 1 ROAD LIGHTING : 1 SPEED LIMIT : 1 LED HEADLIGHTS : 1
SYSTEM : NO NO RECOGNITION : NO UNKNOWN NO NO NO NONE NO

TRANS TEMP : 1 MOTION ALARM : 1 REVERSE LIGHTS : 1 PRECISION LOWER : 1 LED TAILLIGHTS : 1 AUXILIARY 1 SPEED SENSOR : 1 BRAKE OIL 1 BOOM DAMPING : 1
SENSOR NO NO NO NO HYDRAULICS : YES NO SENSORS : YES

TO
MENU

1001242707-I
MAE48590I
DIAGNOSTICS

3614RS, 4017RS
 FROM:
MENU :
MACHINE SETUP

3614RS, 4017RS
MENU : 3 DIAGNOSTICS : 3 DIAGNOSTICS : 3 DIAGNOSTICS : 3 DIAGNOSTICS : 3 DIAGNOSTICS : 3 DIAGNOSTICS: 3 DIAGNOSTICS : 3
TO
DIAGNOSTICS DRIVE / STEER CABIN JOYSTICK CABIN FUNCTIONS OUTRIGGERS FRAME LEVEL HITCH ENGINE DIAGNOSTICS
TRANSMISSION
DRIVE DIRECTION 3 CABIN JOYSTICK 3 RESPONSE CURVE : 3 OUTRIGGER LEFT 3 FRAME LVL LEFT 3 HITCH UP 3 OPERATING STATE : 3
INPUT : NEUTRAL X- AXIS : 0% TELEHANDLER INPUT : 0% SWITCH : OPEN SWITCH: OPEN ENGINE STOPPED
(SHEET 2 of 8)

DRIVE DIRECTION 3 CABIN JOYSTICK 3 MAIN LIFT 3 OUTRIGGER RIGHT 3 FRAME LVL LEFT 3 HITCH UP 3 ENGINE START 3
CMD: NEUTRAL X- AXIS : NEUTRAL INPUT : 0% INPUT : 0% OUTPUT: OFF OUTPUT: OFF SWITCH : OPEN
TO:
MENU :
CALIBRATIONS GEAR SELECTION 3 CABIN JOYSTICK 3 MAIN LIFT 3 LEFT OUTRIGGER 3 FRAME LVL RIGHT 3 3 ENGINE START 3
HITCH DOWN
CMD: 1 Y- AXIS : 0% COMMANDED : 0mA UP COIL : OFF SWITCH : OPEN SWITCH: OPEN OUTPUT: OFF 3
FAN SPEED
CMD : XXXXmA
DESIRED STEER 3 CABIN JOYSTICK 3 MAIN LIFT 3 LEFT OUTRIGGER 3 FRAME LVL RIGHT 3 HITCH DOWN 3 DRIVETRAIN 3
MODE : 2- WHEEL Y- AXIS : NEUTRAL ACTUAL: 0mA DOWN COIL : OFF OUTPUT: OFF OUTPUT: OFF NEUTRAL : OFF FAN SPEED 3
ACTUAL
ACTUAL : XXXXmA
CURRENT STEER 3 CABIN JOYSTICK 3 TELESCOPE 3 RIGHT OUTRIGGER 3 FRAME LEVEL 3 AIR FILTER 3
MODE: 2- WHEEL L - ROLLER : 0% INPUT : 0% UP COIL : OFF COMMAND: 0mA SWITCH : OPEN FAN SPEED 2 3
CMD : XXXX
ACTUAL : XXXX
mAmA
FRONT AXLE 3 CABIN JOYSTICK 3 TELESCOPE 3 RIGHT OUTRIGGER 3 SPEED CONTROL 3 BATTERY VOLTAGE : 3
STEER : CENTER L - ROLLER : NEUTRAL COMMANDED: 0mA DOWN COIL : OFF ACTUAL: 0mA XX. XV FAN SPEED 2 3
ACTUAL : XXXXmA
REAR AXLE 3 CABIN JOYSTICK 3 TELESCOPE 3 OUTRIGGER 3 FRAME LVL LEFT 3 ENGINE COOLANT 3
STEER : CENTER R- ROLLER : 0% ACTUAL: 0mA COMMAND : 0mA COMMAND: XXXXmA TEMP: +XXXC SPEED
FAN REVERSE 3
ACTUAL
VALVE : XXXXmA
: OFF

STEER PRESSURE 3 CABIN JOYSTICK 3 FORK TILT 3 OUTRIGGER 3 FRAME LVL LEFT 3 ENGINE OIL 3
SWITCH : OPEN R- ROLLER : NEUTRAL INPUT : 0% ACTUAL : 0mA ACTUAL: XXXXmA PRS : XPSI REV FAN : 3
OFF

STEER PRESSURE 3 DE- CLUTCH 3 FORK TILT 3 OUT EXT LEFT 3 FRAME LVL RIGHT 3 FUEL LEVEL 3
STATUS : LOW BUTTON : OFF COMMANDED: 0mA PRS : xPSI COMMAND : XXXXmA SENSOR : XXX% LAST REGEN : 3
XXXX. X HOURS

3 OUTRIGGER 3 3 AUX. FUNCTION 3 OUT RET LEFT 3 3 3

ALL WHEEL STEER FORK TILT FRAME LVL RIGHT THROTTLE PEDAL
COIL : OFF BUTTON: OFF ACTUAL: 0mA OUTPUT: OFF PRS : xPSI ACTUAL: XXXXmA RDG : XXX% REGEN STATE : 3
NO REGEN ACTIVE
BOOM FLOAT 3 AUX. F/R 3 OUTRIGGER LEFT 3
CRAB STEER 3 3 THROTTLE PEDAL 3

31211337
AUX . HYDRAULICS
BUTTON: OFF OUTPUT: OFF PRS : NOT SET REMAIN REGEN : 3
COIL : OFF INPUT : 0% RDG1: X. XXV
0 MIN
AUXILIARY HYD 3 AUX. REAR 3 OUT EXT RIGHT 3
SERVICE BRAKE 3 BUTTON: OFF AUX. HYDRAULICS 3 THROTTLE PEDAL 3
OUTPUT : OFF PRS : 0PSI 3
SWITCH : OPEN COMMANDED : 0mA RDG2 : X. XXV DE- CRYSTAL REQ :
NO
CABIN JOYSTICK 3 QUICK CONNECT 3 OUT RET RIGHT 3
PARK BRAKE 3 FNR: NEUTRAL AUX. HYDRAULICS 3 SWITCH: OPEN PRS : 0PSI ENGINE SPEED 3
STATUS : OFF ACTUAL: 0mA ACTUAL: 0 RPM MAINT . REQ: 3

3
NO
CABIN JOYSTICK QUICK CONNECT 3 OUTRIGGER RIGHT 3
3 UPSHIFT : OFF CONTINUOUS AUX. 3 OUTPUT: OFF PRS : NOT SET ANTI - STALL 3
PARK BRAKE
HEAT MOADE REQ: 3
VALVE : OFF SWITCH: OPEN CMD : XXXXmA
CABIN JOYSTICK 3 3 3
NO
JOYSTICK LOCK OUTRIGGER LEFT
DNSHIFT : OFF CONTINUOUS AUX. 3 ENGAGED NO POS : NOT SET
PARK BRAKE 3 ANTI - STALL 3
FEATURE: OFF HIGH SOOT LOAD 3
COMMAND : ####mA ACTUAL XXXXmA
SEAT SWITCH 1 3 OUTRIGGER RIGHT 3 REQ: NO
INPUT: OPEN POS : NOT SET
PARK BRAKE 3 FAN REV CYCLING 3
REGENERATION 3
ACTUAL : ####mA SWITCH: OPEN
SEAT SWITCH 2 3 SWITCH: OPEN
INPUT: OPEN
3 FAN REV DEMAND 3
PARK BRAKE 2
SWITCH: OPEN DPF STATUS: 3
VALVE : OFF
NO EXCHANGE REQD
HYD FLUID TEMP: 3
SAHR PRESSURE 3
+XXXC DPF ASH LOAD: 3
SWITCH : OFF
##%
INTERCOOLER AIR 3
SAHR PRESSURE 3 TEMP: +XXXC
DPF SOOT LOAD: 3
STATUS : LOW
##%
Electrical System

SAHR BRAKE 3
VALVE : OFF

PARK BRAKE REL 3

1001242707-I
MAE48600I
VALVE : OFF

9-41
9-42
FROM DIAGNOSTICS : 3 3 3 3 3 3 3
DIAGNOSTICS DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS : DIAGNOSTICS :
(SHEET 3 of 8)

ENGINE TRANSMISSION SYSTEM LIGHTING LOAD STABILITY LOAD MOMENT BOOM RIDE & FLOAT ATTACHMENT RECOG
TO
DIAGNOSTICS
3 3
CAN STATISTICS
DIRECTION CCM VOLTAGE : 3 LOW BEAM 3 LOAD STABILITY LSI CANCEL 3 BOOM RIDE 3 TAGS DETECTED : 3
SELECT : NEUTRAL PROP TRAVEL 3
XX. XV 3 SWITCH : OFF STATUS: UNSTABLE SWITCH : OPEN SWITCH : OFF X
SWITCH : OPEN TRANS GEAR 3 HYDRAULIC FILTER
Electrical System

SWITCH : OPEN SWITCH : OPEN

GEAR SELECT : 3 FFCM VOLTAGE : 3 LOW BEAM 3 LSI CANCEL 3 LIFT CYL HEAD 1 : 3 BOOM RIDE 3 PART NUMBER : 3
PROP TRAVEL 3
FIRST XX. XV 3 OUTPUT: OFF SWITCH: OPEN XXX. X BAR OUTPUT: OFF XXXXXXXXXX
SPEED : xxx% HIGH TRANS OIL 3 REVERSE ALARM
SWITCH : OPEN OUTPUT: OFF
TRANS FORWARD 3 3 RFCM VOLTAGE : 3 HIGH BEAM 3 LOAD STABILITY: 3 LIFT CYL HEAD 2 : 3 BOOM TANK 3 SIGNAL STRENGTH 3
PROP TRAVEL
COIL : OFF RDG : x. xxV XX. XV 3 SWITCH : OFF XXX% XXX. X BAR OUTPUT: OFF RSSI : -XXXdBm
TRANS FLUID 3 HYD FLUID TEMP :
TEMP: + XXXC +XXXC
TRANS REVERSE 3 BRAKE PEDAL 3 LCM VOLTAGE : 3 HIGH BEAM 3 LOAD CELL 1 RAW 3 LIFT CYL HEAD 1 : 3 BOOM FLOAT 3 STATUS : 3
COIL : OFF POS: xxx% XX. XV OUTPUT: OFF VALUE: XXX XX. XXmA SWITCH : OFF INACTIVE
AUTO / MANUAL 3 BRK PEDAL PRS : 3
SWITCH : OPEN XPSI
3 BRAKE PEDAL 3 3
TRANS FWD LOW TCM VOLTAGE : 3 HAZARD SWITCH : 3 LOAD CELL 2 RAW 3 LIFT CYL HEAD 2 : BOOM FLOAT 3 SOFTWARE REV : 3
COIL : OFF RDG: x.xxV
3 XX. XV 3 OFF VALUE: XXX XX. XXmA OUTPUT : OFF UNKNOWN
LOCK-UP CONVERT BRK PEDAL PRS : :
3 SWITCH : OPEN X. XXV
3
TRANS FORWARD
TRANS FWD HIGH AMBIENT TEMP : 3 LEFT TURN 3 LIFT CYL ROD 1 : 3 SOFTWARE TYPE : 3
COIL : xxxxmA
COIL : OFF +XXXC 3 SWITCH : OFF XXX. X BAR UNKNOWN
LOCK-UP CONVERT 3 TRAILER
BRK PEDAL
BRAKE
PRS :
TRANS REVERSE 3 COIL : OFF SWITCH
X. XXV : OPEN
TRANS 1ST GEAR 3 COIL : xxxxmA POWER STATE : 3 F - L TURN 3 LIFT CYL ROD 2 : 3 HARDWARE TYPE : 3
COIL : OFF NORMAL 3 OUTPUT: OFF XXX. X BAR UNKNOWN
TRANS DISCON : 3 TRAILER
BRK PEDALBRAKE
PRS : :
HYDROMOTOR 3 OFF VALVE
X. XXV: OFF
TRANS 2ND GEAR 3 CMD : xxxxmA BOOM ANGLE: 3 R- L TURN 3 LIFT CYL ROD 1 : 3 DEVICE ID : 3
COIL : OFF XX. X DEG 3 OUTPUT: OFF XX. XXmA UNKNOWN
PUMP PRESSURE 3 TRAILER
BRK
AG TRAILER
PEDALBRAKE
PRS
BRAKE
: :
GEAR 1 3
A: #.##V VALVE
SWITCH
X. : OPEN
XXV: OFF
3 SWITCH : OPEN LIFT CYL ROD 2 : 3
TRANS 3RD GEAR BOOM ANGLE RAW 3 RIGHT TURN 3
COIL : OFF COUNTS : XXXX SWITCH : OFF XX. XXmA
PUMP PRESSURE 3 TRAILER
BRK
AG TRAILER
PEDALBRAKE
PRS
BRAKE
: : 3

31211337
GEAR 2 3
A: ###.# BAR VALVE
X. XXV: OFF
SWITCH : OPEN COMP CYL HEAD 1 : 3
TRANS Y 1 3 3 F - R TURN 3
BOON ANGLE 1 RAW XXX. X BAR
COIL : OFF PUMP PRESSURE 3 COUNTS : XXXX 3 OUTPUT: OFF
ZERO DISPL 3 BRAKE
TRAILER
BRK PEDAL
OIL
BRAKE
LEVEL
PRS : : 3
B: #.##V FOG LIGHT
SWITCH : OPEN VALVE
SWITCH
X. : CLOSED
XXV: OFF
SWITCH : OPEN COMP CYL HEAD 2 : 3
TRANS Y2 3 3 R- R TURN 3
BOON ANGLE 2 RAW XXX. X BAR
COIL : OFF PUMP PRESSURE 3
GEARBOX SPEED: 3 COUNTS : XXXX BRAKE
TRAILER
BRK PEDAL
OILBRAKE
LEVEL
PRS : : 3 OUTPUT: OFF
B: ###.# BAR FOG LIGHT 3
xxxxx RPM VALVE
STATUS
X. : OK
XXV: OFF
OUTPUT: OFF COMP CYL HEAD 1 : 3
TRANS Y3 3 3 BRAKE PEDAL 3
SPEED SENSOR 3 BOOM RETRACTED XX.XXmA
COIL : OFF ECU ID : 3 SWITCH : OPEN 3 SWITCH : OPEN 3
RAW: ####HZ BRAKE
TRAILER
BRK PEDAL
OIL
BRAKE
PRESS
PRS : : TRAILER STATUS:
RC28 - 14/30 0012 VALVE
SWITCH
X. : OPEN
XXV: OFF CONNECTED COMP CYL HEAD 2 : 3 BOOM LENGTH : 3
TRANS Y4 3 3 3 BRAKE LIGHT 3 XX.XXmA X. XXV
TRANS GEAR BOOM EXTENDED
COIL : OFF REQ MACHINE 3 OUTPUT: OFF 3
SWITCH : OPEN SWITCH : OPEN TRAILER
BRK
BRAKE
PEDAL
OILBRAKE
PRESS
PRS : : 3 TRAILER LEFT
TYPE : x TURN: OFF
VALVE
STATUS
X. : OK
XXV: OFF COMP CYL ROD 1 : 3 LIGHT TOWER 3
TRANS Y5 3 WATCHDOG VALVE: 3 3 REVERSE LIGHT 3 XXX.X BAR GREEN : OFF
SAVED MACHINE 3 TELE STATUS :
COIL : OFF OFF TRAILER RIGHT 3
TYPE : x RETRACTED OUTPUT: OFF
TURN: OFF 3 3
COMP CYL ROD 2 : LIGHT TOWER
TRANS Y6 3 DRIVE FORWARD: 3 XXX.X BAR YELLOW : OFF
USED MACHINE 3 CHASSIS TILT1: 3 MARKER SWITCH : 3
COIL : OFF COMMAND : ####mA TRAILER MARKER 3
TYPE : x X - AXIS : 0.0 DEG OFF
LIGHTS: OFF 3 3
COMP CYL ROD 1 : LIGHT TOWER RED :
3 DRIVE FORWARD: 3 XX. XXmA OFF
TRAVEL MODE: 3 3 FRONT MARKER 3
INCHING VALVE ACTUAL : ####mA CHASSIS TILT1: TRAILER BRAKE 3
LOADER CMD : XXXXmA OUTPUT: OFF
Y - AXIS : 0.0 DEG LIGHTS: OFF 3 3
COMP CYL ROD 2 : LOAD PREDICT :
DRIVE REVERSE: 3 XX. XXmA +XXXXKG
ROADING TRAVEL 3 3 3 3
INCHING VALVE COMMAND : ####mA CHASSIS TILT2: 3 REAR MARKER TRAILER FOG
SWITCH : OPEN ACTUAL: XXXXmA OUTPUT: OFF LIGHTS: OFF
X - AXIS : 0.0 DEG BOOM LENGTH : 3
DRIVE REVERSE: 3 XXXXX MM
ACTUAL : ####mA 3
CHASSIS TILT2:
Y - AXIS : 0.0 DEG
MOTOR VALVE 3
COMMAND : ####mA

MOTOR VALVE 3

1001242707-I
MAE48610I
ACTUAL: ####mA

3614RS, 4017RS
 FROM DIAGNOSTICS : 3 DIAGNOSTICS : 3 DIAGNOSTICS : 3 DIAGNOSTICS : 3 DIAGNOSTICS : 1 DIAGNOSTICS : 1 DIAGNOSTICS : 1
ATTACHMENT CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS DEBUG CCM I/O DEBUG FFCM I/O DEBUG RFCM I/O TO

3614RS, 4017RS
RECOG DIAGNOSTICS
REMOTE CONTROL
CAN 1 STATISTICS 3 CALIBRATION DATA 3 3 1 1 1
DATALOG: ON - TIME 3 CABIN MODULE DEBUG DIAG : DEBUG DIAG : DEBUG DIAG :
RX / SEC : 0 LIFT CAL1: XXXX 0H 0M SOFTWARE: PX. X DIGITAL INPUTS DIGITAL INPUTS DIGITAL INPUTS

CAN 1 STATISTICS 3 3
CALIBRATION DATA DATALOG: ENGINE 3 CABIN MODULE 3 DEBUG DIAG : 1 DEBUG DIAG : 1 DEBUG DIAG : 1
TX /SEC : 0 LIFT CAL2: XXXX 0H 0M CNST DATA PX. X DIGITAL OUTPUTS DIGITAL OUTPUTS DIGITAL OUTPUTS
(SHEET 4 of 8)

CAN 1 STATISTICS 3
CALIBRATION DATA 3 3 3 1 1 1
BUSS OFF : 0 DATALOG: DRIVE CABIN MODULE DEBUG DIAG : DEBUG DIAG : DEBUG DIAG :
LIFT CAL3: XXXX 0H 0M HARDWARE : REV XX ANALOG INPUTS PWM OUTPUTS PWM OUTPUTS

CAN 1 STATISTICS 3
CALIBRATION DATA 3 DATALOG: LIFT 3 FRONT FRAME MOD 3 DEBUG DIAG : 1 DEBUG DIAG : 1
PASSIVE : 0
LIFT CAL4: XXXX 0H 0M SOFTWARE: PX. X ANALOG INPUTS ANALOG INPUTS

CAN 1 STATISTICS 3
MSG ERROR : 0 CALIBRATION DATA 3 DATALOG : TELE 3 FRONT FRAME MOD 3 DEBUG DIAG : 1
LSI 0% A : XXXXX 0H 0M HARDWARE : REV XX FREQUENCY INPUTS
CAN 2 STATISTICS 3
RX/SEC : 0 CALIBRATION DATA 3 3 3
DATALOG: LSI VFY REAR FRAME MOD
LSI 0% B: XXXXX 12345H - PASS SOFTWARE: PX. X
CAN 2 STATISTICS 3
TX / SEC : 0 CALIBRATION DATA 3
DATALOG: 3 REAR FRAME MOD 3
LSI 100% A:XXXXX
MAX VOLTS : 14 . 8V HARDWARE : REV XX
CAN 2 STATISTICS 3
CALIBRATION DATA 3
BUSS OFF : 0
LSI 100% B:XXXXX DATALOG: 1 LOAD MOMENT MOD 3
MAX SPD : ???? KPH SOFTWARE : PX.X
CAN 2 STATISTICS 3
CALIBRATION DATA 3
PASSIVE : 0
TILT1 X : +XXXX DATALOG: 3 LOAD MOMENT MOD 3
RENTAL : 0H 0M HARDWARE : REV XX
CAN 2 STATISTICS 3 3
CALIBRATION DATA
MSG ERROR : 0 TILT1 Y : +XXXX
DATALOG: 2 3
LMIS DATA LOAD
ERASE RENTAL ? CHARTS : PX.X
CALIBRATION DATA 3
TILT2 X : +XXXX

31211337
DATALOG: 2 3
CABIN DISPLAY
CALIBRATION DATA 3 ANTI - THEFT : 0000 SOFTWARE: PX. X
TILT2 Y : +XXXX

CABIN JOYSTICK 3
CALIBRATION DATA 3 SOFTWARE: x . x
BRK CAL 1: XXXX

TCM SOFTWARE : 3
CALIBRATION DATA 3 Px.x
BRK CAL 2 : XXXX

PREMIUM DISPLAY 3
SOFTWARE : PX. X

1001242707-I
MAE48620I
Electrical System

9-43
9-44
FROM FROM DIAGNOSTICS : 3 DIAGNOSTICS : 3 3 3
MENU ATTACHMENT DIAGNOSTICS : DIAGNOSTICS :
DIAGNOSTICS REMOTE CONTROL AUTO FORK LEVEL REAR AXLE STAB BOOM DAMPING
REML

REMOTE CONTROL 3 TILT CYLINDER 3 RAS RATE VALVE 3 LIFT CYL HEAD 1: 3
(SHEET 5 of 8)
SWITCH : OPEN A: ### . # MM CMD : XXXXmA XXX . XX BAR

MESSAGE RATE 3 TILT CYLINDER 3 RAS RATE VALVE 3 LIFT CYL HEAD 2: 3
RX/ S : 1 B: ### . # MM ACTUAL : XXXXmA XXX . XX BAR
Electrical System

SIGNAL STRENGTH 3 FORK TILT GRAV 3 HIRAS LOCK 3 LIFT CYL HEAD 1: 3
RSSI : - 100 dbm ANGLE: ## . ## ° VALVE 1: OFF XX. XX mA

MAIN LIFT 3 FORK TILT MECH 3 HIRAS LOCK 3 LIFT CYL HEAD 2: 3 LIFT ACCUMULATOR 3
INPUT : 0% ANGLE: ## . ## ° VALVE 2: OFF XX. XX mA 1: XX. XX mA

MAIN LIFT 3 RATE CONTROL 3 LIFT CYL ROD 1: 3

PRESSURE PT 1A: 3 LIFT ACCUMULATOR 3
COMMANDED : 0mA CMD : 9999 mA XXX . X BAR
999 . 9mA 2: XX. XX mA

MAIN LIFT 3 RATE CONTROL 3 LIFT CYL ROD 2: 3

PRESSURE PT 1B: 3 BOOM RIDE 3
ACTUAL : 0mA ACT : 9999 mA XXX . XX BAR
FORK TILT 3 999 . 9mA OUTPUT: OFF
ACTUAL : 0mA
TELESCOPE 3 PRESS CONTROL 3 LIFT CYL ROD 1: 3
PRESSURE PT 2: 3 BOOM TANK 3
INPUT : 0% CMD : 9999 mA XX. XX mA
AUX. HYDRAULICS 3 999 . 9BAR OUTPUT: OFF
INPUT : 0%

31211337
TELESCOPE 3 PRESS CONTROL 3 LIFT CYL ROD 2: 3
PRESSURE PT 2A: 3 BOOM DAMPING 3
COMMANDED : 0mA CMD : 9999 mA XX. XX mA
AUX. HYDRAULICS 3 999 . 9mA MODE : INACTIVE
COMMANDED : 0mA
TELESCOPE 3 HIRAS MODE : 3 LIFT ACCUMULATOR 3
PRESSURE PT 2B: 3
ACTUAL : 0mA ERROR 1: XXX . XX BAR
AUX. HYDRAULICS 3 999 . 9mA
ACTUAL : 0mA
FORK TILT 3 TIME SINCE LAST 3 LIFT ACCUMULATOR 3
PRESSURE PT 3: 3
INPUT : 0% CHECK : 9999 HRS 2: XXX . XX BAR
AUX. SELECT 3 999 . 9BAR
SWITCH : OPEN
FORK TILT 3 PRESSURE PT 1: 3
PRESSURE PT 3A: 3
COMMANDED : 0mA 999 . 9BAR
SPEED CONTROL 3 999 . 9mA
SWITCH : MEDIUM
PRESSURE PT 3B: 3
TO 3 99 . 9mA
MENU
ENGINE START
CALIBRATIONS SWITCH : OPEN

HORN SWITCH : 3
OPEN

1001242707-I
MAE48630I

3614RS, 4017RS
 FROM
MENU
DIAGNOSTICS

MENU : 3 CALIBRATIONS : 2 CALIBRATIONS : 2 CALIBRATIONS : 2 CALIBRATIONS : 3 CALIBRATIONS : 2 CALIBRATIONS : 2 CALIBRATIONS : 2 CALIBRATION : 2

CALIBRATIONS TILT SENSOR BOOM ANGLE BOOM RIDE TEST PARK BRAKE TEST TRANS SERVICE LOAD STABILITY FAN SPEED TEST BOOM LENGTH

3614RS, 4017RS
2 2 2 3 2 CALIBRATE LSI 2 PERFORM FAN 2 2
CALIBRATE CALIBRATE BOOM CONFIRM BOOM PERFORM PARK CONFIRM TRANS CALIBRATE BOOM
TILT SENSOR ? ANGLE SENSOR ? RIDE TEST BRAKE TEST ? SERVICE TEST SENSOR? SPEED TEST ? LENGTH SENSOR ?

REMOVE WEIGHTS 2 2
TILT CALIBRATION 2 PRESS ENTER AT 2 PRESS ENTER 2 SET PARK 3 PRESS ENTER 2 FAN SPD VALVE TELE IN. PRESS 2
AND ATTACHMENTS 0 mA
SET STABILIZERS LOWEST POSITION. WHEN TEST DONE BRAKE WHEN TEST DONE ENTER RETRACTED

FULLY DEPLOY 2 FAN SPD 2 VALVE 2

TILT SENSOR 2 LIFT UP. PRESS 2 SHIFT TO 3 0 mA TELE OUT. PRESS 2
OUTRIGGERS
CALIBRATING... ENTER AT TOP. SECOND GEAR ENTER EXTENDED
WARNING : DRIVE 3
WILL BE ENGAGE TELESCOPE IN AND 2
CALIBRATION 2 CALIBRATION 2 SHIFT TO 3 FULLY LIFT UP FULLY RETRACT 2 CALIBRATION 2
(SHEET 6 of 8)

COMPLETE COMPLETE THIRD GEAR OUTRIGGERS COMPLETE

FORWARD TO START 3
CALIBRATING LOAD 2
NEUTRAL TO PAUSE STABILITY 0% 2
2 2 SHIFT TO 3 UNLOAD REAR 2
CALIBRATION CALIBRATION CALIBRATION
FOURTH GEAR AXLE
FAILED FAILED FAILED
PARK BRAKE TEST 3 2
LIFT DOWN
COMPLETE CALIBRATING LOAD 2
CALIBRATION 2 CALIBRATION 2
STABILITY 100%
SENSOR FAULT SENSOR FAULT
PARK BRAKE TEST 3
LSI CALIBRATION 2
FAILED
COMPLETE

LSI CALIBRATION 2
FAILED

CALIBRATION : 2 CALIBRATION : 2 CALIBRATION : 2 CALIBRATION : 2 CALIBRATIONS : 2 CALIBRATIONS: 2 CALIBRATIONS: 2

RAS TEST BRAKE PEDAL POS START REFRESH LMIS SET MACHINE TYPE ATTACHMENT RECOG BOOM DAMPING

LIFT UP TO 2
2 2 2 2 LIFT UP TO 2 SET MACHINE 2 CALIBRATE 2 CHECK BOOM 2
RAS TEST YES : BRAKE PEDAL POS PRESS ENTER TO CALIBRATE LMIS ? HIGH CAL ANGLE
ENTER , NO: ESC YES : ENTER , NO: ESC START REGEN MID CAL ANGLE TYPE ? ATTACH. RECOG? DAMPING

CALIBRATING LOAD 2
CALIBRATING LOAD 2 SET DIRECTION 2 SEARCH FOR 2 PRESS ENTER W/ 2
RAS TEST : 2 RELEASE BRAKE 2 SENDING COMMAND 2 REMOVE WEIGHTS 2 MOMENT HRCAL UP
MOMENT MECAL UP TO NEUTRAL TAGS O/R SET AND BOOM
NORMAL PEDAL ESC TO EXIT
LIFT UP TO 2
LIFT UP TO 2 APPLY PARK 2 PART NUMBER : 2 2
DEPRESS BRAKE 2 FULLY DEPLOY 2 MAX BOOM ANGLE LIFT UP SLIGHTLY
HIGH CAL ANGLE BRAKE XXXXXXXXXX
PEDAL OUTRIGGERS
LIFT DOWN TO 2
CALIBRATING LOAD 2 REQUEST 2 2 2
HIGH CAL ANGLE WRITING PART PRESS ENTER AT
CALIBRATION 2 FULLY RETRACT 2 MOMENT HECAL UP

31211337
PARAMETER MODE NUMBER FULL EXTEND.
COMPLETE BOOM
CALIBRATING LOAD 2 2
LIFT UP TO SAVE PARAMETER 2 CALIBRATION 2 LIFT UP SLIGHTLY 2
2 2 MOMENT HRCAL DN MAX BOOM ANGLE
CALIBRATION LIFT DOWN TO MODE COMPLETE THEN PRESS ENTER
FAILED MIN BOOM ANGLE
LIFT DOWN TO 2 2
LIFT DOWN TO COMPLETE 2 2 2
MID CAL ANGLE CALIBRATION FULLY RETRACT
2 2 HIGH CAL ANGLE
CALIBRATION LIFT UP TO FAILED BOOM (NO LIFT)
SENSOR FAULT MAX BOOM ANGLE
CALIBRATING LOAD 2 CALIBRATING LOAD 2
MACHINE TYPE 2 ERROR - TOO 2 SEQUENCE FAULT - 2
MOMENT MRCAL DN MOMENT HECAL DN
LIFT DOWN TO 2 CAL FAILED MANY TAGS START OVER
MIN BOOM ANGLE
LIFT DOWN TO 2 LIFT DOWN TO 2
LOW CAL ANGLE ERROR - NO TAGS 2 HEALTH CHECK 2
MID CAL ANGLE
3 3 CALIBRATING 2 IN RANGE COMPLETE - OK
MENU : ACCESS LEVEL :
ACCESS LEVEL 3 CODE 00000 DYNAMIC RETRACT 2
CALIBRATING LOAD CALIBRATING LOAD 2
MOMENT LRCAL DN MOMENT MECAL DN HEALTH CHECK 2

LIFT UP TO 2 FAILED - RIDE

LOW CAL ANGLE FULLY EXTEND 2 2
TO LIFT DOWN TO
BOOM LOW CAL ANGLE HEALTH CHECK 2
OPERATOR TOOLS
FAILED - LIFT
CALIBRATING LOAD 2
MOMENT LRCAL UP LIFT DOWN TO 2 CALIBRATING LOAD 2
MIN BOOM ANGLE MOMENT LECAL DN

LIFT UP TO 2
LIFT UP TO 2 LMIS CALIBRATION 2
MID CAL ANGLE
MAX BOOM ANGLE COMPLETE

CALIBRATING LOAD 2
LIFT DOWN TO 2 LMIS CALIBRATION 2
MOMENT MRCAL UP
MIN BOOM ANGLE FAILED

CALIBRATING 2
DYNAMIC EXTENDED
Electrical System

LIFT UP TO 2
LOW CAL ANGLE

CALIBRATING LOAD 2
MOMENT LECAL UP

1001242707-I
MAE48640I

9-45
9-46
FROM
MENU
ACCESS LEVEL 3

MENU : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3

PERSONALITIES MAIN LIFT MAIN LIFT
BUCKET LIFT TELESCOPE X - AXIS TELESCOPE ROLLER BCKT TELE X - AXIS BCKT TELE ROLLER FORK TILT ROLLER FORK TILT X - AXIS

MAIN LIFT 2 BUCKET

MAIN LIFT
LIFT 2 TELESCOPE X - AXIS 2 TELESCOPE ROLLER 2 BCKT TELE X - AXIS 2 BACKT TELE ROLLER 2 FORK TILT ROLLER 2 FORK TILT X - AXIS 2
ACCEL UP : X. XS ACCEL UP : X. XS ACCEL IN : X. XS ACCEL IN : X. XS ACCEL IN : X. XS ACCEL IN : X. XS ACCEL IN : X. XS ACCEL IN : X. XS

MAIN LIFT : 2 BUCKET

MAIN LIFT
LIFT:: 2 TELESCOPE X - AXIS 2 TELESCOPE ROLLER 2 BCKT TELE X - AXIS 2 BCKT TELE ROLLER 2 FORK TILT ROLLER 2 FORK TILT X - AXIS 2
DECEL UP : X. XS DECEL UP : X. XS DECEL IN : X. XS DECEL IN : X. XS DECEL IN : X. XS DECEL IN : X. XS DECEL IN : X. XS DECEL IN : X. XS

MAIN LIFT 2 BUCKET

MAIN LIFT
LIFT 2 TELESCOPE X - AXIS 2 TELESCOPE ROLLER 2 BCKT TELE X - AXIS 2 BCKT TELE ROLLER 2 FORK TILT ROLLER 2 FORK TILT X - AXIS 2
(SHEET 7 of 8)

ACCEL DOWN : X. XS ACCEL DOWN : X. XS ACCEL OUT : X. XS ACCEL OUT : X. XS ACCEL OUT : X. XS ACCEL OUT : X. XS ACCEL OUT : X. XS ACCEL OUT : X. XS
Electrical System

MAIN LIFT 2 BUCKET

MAIN LIFT
LIFT 2 TELESCOPE X - AXIS 2 TELESCOPE ROLLER 2 BCKT TELE X - AXIS 2 BCKT TELE ROLLER 2 FORK TILT ROLLER 2 FORK TILT X - AXIS 2
DECEL DOWN : X. XS DECEL DOWN : X. XS DECEL OUT : X. XS DECEL OUT : X. XS DECEL OUT : X. XS DECEL OUT : X. XS DECEL OUT : X. XS DECEL OUT : X. XS

MAIN LIFT 2 BUCKET

MAIN LIFT
LIFT 2 TELESCOPE X - AXIS 2 TELESCOPE ROLLER 2 BCKT TELE X - AXIS 2 BCKT TELE ROLLER 2 FORK TILT ROLLER 2 FORK TILT X - AXIS 2
MIN UP : XXXXmA MIN UP : XXXXmA MIN IN : XXXXmA MIN IN : XXXXmA MIN IN : XXXXmA MIN IN : XXXXmA MIN IN : XXXXmA MIN IN : XXXXmA

MAIN LIFT 2 BUCKET

MAIN LIFT
LIFT 2 TELESCOPE X - AXIS 2 TELESCOPE ROLLER 2 BCKT TELE X - AXIS 2 BCKT TELE ROLLER 2 FORK TILT ROLLER 2 FORK TILT X - AXIS 2
MAX UP : XXXXmA MAX UP : XXXXmA MAX IN : XXXXmA MAX IN : XXXXmA MAX IN : XXXXmA MAX IN : XXXXmA MAX IN : XXXXmA MAX IN : XXXXmA

MAIN LIFT 2 BUCKET

MAIN LIFT
LIFT 2 TELESCOPE X - AXIS 2 TELESCOPE ROLLER 2 BCKT TELE X - AXIS 2 BCKT TELE ROLLER 2 FORK TILT ROLLER 2 FORK TILT X - AXIS 2
MIN DOWN: XXXXmA MIN DOWN: XXXXmA MIN OUT : XXXXmA MIN OUT : XXXXmA MIN OUT : XXXXmA MIN OUT : XXXXmA MIN OUT : XXXXmA MIN OUT : XXXXmA

MAIN LIFT 2 BUCKET

MAIN LIFT
LIFT 2 TELESCOPE X - AXIS 2 TELESCOPE ROLLER 2 BCKT TELE X - AXIS 2 BCKT TELE ROLLER 2 FORK TILT ROLLER 2 FORK TILT X - AXIS 2
MAX DOWN: XXXXmA MAX DOWN: XXXXmA MAX OUT: XXXXmA MAX OUT: XXXXmA MAX OUT: XXXXmA MAX OUT: XXXXmA MAX OUT: XXXXmA MAX OUT: XXXXmA

TO
OPERATOR TOOLS
PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3 PERSONALITIES : 3

31211337
BCKT TILT ROLLER BCKT TILT X - AXIS FRONT AUX REAR AUX OUTRIGGER L / R OUTRIGGER FRAME LEVEL

BCKT TILT ROLLER 2 BCKT TILT X - AXIS 2 FRONT AUX 2 REAR AUX 2 OUTRIGGERS 2 L / R OUTRIGGERS 2 FRAME LEVEL 2
ACCEL IN : X. XS ACCEL IN : X. XS ACCEL COILA : X. XS ACCEL COILA : X. XS ACCEL UP : X. XS ACCEL UP : X. XS ACCEL LEFT : X. XS

BCKT TILT ROLLER 2 BCKT TILT X - AXIS 2 FRONT AUX 2 REAR AUX 2 OUTRIGGERS 2 L / R OUTRIGGERS 2 FRAME LEVEL 2
DECEL IN : X. XS DECEL IN : X. XS DECEL COILA : X. XS DECEL COILA : X. XS DECEL UP : X. XS DECEL UP : X. XS DECEL LEFT : X. XS

BCKT TILT ROLLER 2 BCKT TILT X - AXIS 2 FRONT AUX 2 REAR AUX 2 OUTRIGGERS 2 L / R OUTRIGGERS 2 FRAME LEVEL 2
ACCEL OUT : X. XS ACCEL OUT : X. XS ACCEL COILB : X. XS ACCEL COILB : X. XS ACCEL DOWN: X. XS ACCEL DOWN: X. XS ACCEL RIGHT : X. XS

BCKT TILT ROLLER 2 BCKT TILT X - AXIS 2 FRONT AUX 2 REAR AUX 2 OUTRIGGERS 2 L / R OUTRIGGERS 2 FRAME LEVEL 2
DECEL OUT : X. XS DECEL OUT : X. XS DECEL COILB : X. XS DECEL COILB : X. XS DECEL DOWN : X. XS DECEL DOWN : X. XS DECEL RIGHT : X. XS

BCKT TILT ROLLER 2 BCKT TILT X - AXIS 2 FRONT AUX 2 REAR AUX 2 OUTRIGGERS 2 L / R OUTRIGGERS 2 FRAME LEVEL 2
MIN IN : XXXXmA MIN IN : XXXXmA MIN COILA : XXXXmA MIN COILA : XXXXmA MIN UP : XXXXmA MIN UP : XXXXmA MIN LEFT : XXXXmA

BCKT TILT ROLLER 2 BCKT TILT X - AXIS 2 FRONT AUX 2 REAR AUX 2 OUTRIGGERS 2 L / R OUTRIGGERS 2 FRAME LEVEL 2
MAX IN : XXXXmA MAX IN : XXXXmA MAX COILA : XXXXmA MAX COILA : XXXXmA MAX UP : XXXXmA MAX UP : XXXXmA MAX LEFT : XXXXmA

BCKT TILT ROLLER 2 BCKT TILT X - AXIS 2 FRONT AUX 2 REAR AUX 2 OUTRIGGERS 2 L / R OUTRIGGERS 2 FRAME LEVEL 2
MIN OUT : XXXXmA MIN OUT : XXXXmA MIN COILB : XXXXmA MIN COILB : XXXXmA MIN DOWN : XXXXmA MIN DOWN : XXXXmA MIN RIGHT : XXXXmA

BCKT TILT ROLLER 2 BCKT TILT X - AXIS 2 FRONT AUX 2 REAR AUX 2 OUTRIGGERS 2 L / R OUTRIGGERS 2 FRAME LEVEL 2
MAX OUT: XXXXmA MAX OUT: XXXXmA MAX COILB : XXXXmA MAX COILB : XXXXmA MAX DOWN : XXXXmA MAX DOWN : XXXXmA MAX RIGHT : XXXXmA

FRONT AUX 2
DE-COMP : XXXXmA

FRONT AUX 2
DE-COMP : X. XS

1001242707-I
MAE48650I

3614RS, 4017RS
3614RS, 4017RS
FROM
MENU
(SHEET 8of 8)

PERSONALITIES

MENU : 3 CHANGE ANTI - 2 CONFIRM MACHINE 2 REVIEW MAINT 2 ENABLE MAINT 3 SET MAINT 2 REVIEW LSI 1 VEHICLE SPEED 3 TEMPERATURE : 3 PRESSURE : 3
OPERATOR TOOLS THEFT CODE ? MAINT? HISTORY ? INTERVAL : NO INTRVAL : 500 H SHUTOFF HISTORY? UNITS : KPH CELSIUS BAR

ENTER CURRENT 2 MAINT COMPLETE ? 2 MAINT HISTORY 2 LSI HISTORY 1

CODE : 0000 YES : ENTER , NO : ESC 1: X, XXX H 1 : X, XXX H

ENTER NEW 2
CODE: 0000

STEER MODE : 3 REVIEW LSI 1 FAN REVERSE 3 FAN REVERSE 3 TYRE SELECTION : 3 DEFAULT GEAR 3 ELEVATED IDLE : 3
MANUAL SUSPENDED LOG? TIMER : 2 SEC INTERVAL : 20 MIN SELECTION : 2 OFF

LSI SUSPEND LOG 1

X : X, XXX H - ON

BRAKE LIGHT ON 3 BRAKE LIGHT OFF 3 DE - COMP FOR AUX 3 CABIN JOYSTICK 3

31211337
PRS : 40 PSI PRS : 35 PSI SELECT : OFF TELESCOPE : X - AXIS

MENU : 1 DEBUG : 1
DEBUG RESET EEPROM

RESET EEPROM 1
FAULT LOG

MAE48660I
1001242707-I
Electrical System

9-47
 Electrical System

9.14 ANALYZER SOFTWARE ACCESSIBILITY

9.14.1 Access Level

The access level screen allows to enter a five digit numeric
code to qualify user capability. Code entry determines level
of access.
a. Operator (Access Level 3) - No code required.
b. Service (Access Level 2) - 33271.

9.14.2 Diagnostics

Menu Description Access Level

Drive/Steer Displays the parameter related to the steering system Access Level 2, 3

Cabin Joystick Displays the parameter related to the joystick Access Level 2, 3

Cabin Functions Displays the cabin joystick input for the auxiliary Access Level 2, 3

Outriggers Displays the parameter related to the outrigger functions Access Level 2, 3

Frame Level Displays the parameter related to the frame leveling Access Level 2, 3

Hitch Displays the parameter related to the hitch functions Access Level 2, 3

Engine Displays the parameter related to the engine Access Level 2, 3

Transmission Displays parameter related to the drive/transmission Access Level 2, 3

System Displays the parameter related to the control system Access Level 2, 3

Lighting Displays the parameter related to the lighting Access Level 2, 3

Load Stability Displays the parameters related to load stability indicator Access Level 2, 3

Load Moment Displays the parameter related to the load moment Access Level 2, 3

Boom Ride and Float Displays the parameters related to the boom ride & float Access Level 2, 3

Attachment Recog Displays the parameters related to the attachment recog Access Level 2, 3

CAN statistics screen displays the parameters of the system bus

CAN Statistics Access Level 2, 3
and diagnostic bus

Allows to set the calibration values for all the calibrated sensors in
Calibration Data Access Level 2, 3
the control system

Displays all the logged values defined in the global parameter

Datalog Access Level 2, 3
database

Displays the version of the software, hardware and constant data

Versions Access Level 2, 3
of control modules in the machine

Debug CCM I/O Displays the parameters related to the debug CCM I/O Access Level 2, 3

9-48 31211337 3614RS, 4017RS

 Electrical System

Menu Description Access Level

Debug FFCM I/O Displays the parameters related to the debug FFCM I/O Access Level 2, 3

Debug RFCM I/O Displays the parameters related to the debug RFCM I/O Access Level 2, 3

Remote Control Displays the parameter related to the remote control Access Level 2, 3

Auto Fork Level Displays the parameters related to the auto fork level Access Level 2, 3

Rear Axel Stab Displays the parameters related to the rear axle stab Access Level 2, 3

Boom Damping Displays the parameters related to the boom damping Access Level 2, 3

3614RS, 4017RS 31211337 9-49

 Electrical System

9.14.3 Machine Set-up

Menu SETTING Description Access Level

UNKNOWN
Allows to configure the model number of the
Model 3614RS telehandler Access Level 2
4017RS

CE
Allows to set the applicable compliance
Market ANSI standard Access Level 2
AUSTRALIA

Deutz 55 kWS5 HRC

Engine Control Deutz 55 kW HRC Allows to configure the vehicle’s engine Access Level 2

Deutz 75 kWRS LRC

NO Allows to enable the column selector
Column Selector Access Level 2
YES functionality

NO Allows to enable the joystick to select FNR

Joystick FNR Access Level 2
YES and gears

NO Allows to enable control of the air

Air Condition Access Level 2
YES conditioning functionality

NO
1ST
2ND
Allows to enable a limit on Forward Gear
Fwd Gear Limit 3RD Access Level 2
Selection
4TH
5TH
6TH
NO
1ST
Allows to enable a limit on Reverse Gear
Rev Gear Limit 2ND Access Level 2
Selection
3RD
4TH
NO
Road Lighting Allows to enable Road Lights Access Level 2
YES
NONE
20KPH
25KPH
Speed Limit Allows to set the vehicle’s speed limit Access Level 2
30KPH
35KPH
40KPH
NO Allows to enable auxiliary hydraulics
Auxiliary Hydraulics Access Level 2
YES functionality

Note: Settings in BOLD are default values.

9-50 31211337 3614RS, 4017RS

 Electrical System

9.14.4 Personalities

Menu/Sub-
Function Description Default Values (Range) Access Level
menu Items
0.5
Main Lift Accel Up
(0.0 - 2.0S)

0.3
Main Lift Decel Up
(0.0 - 1.0S)

0.5
Main Lift Accel Down
(0.0 - 2.0S)
Screen allows the 0.3
Main Lift Decel Down operator to view
parameters (max/ (0.0 - 1.0S)
Main Lift Access Level 2, 3
min) related to fork 700mA
Main Lift Min Up tilt and extend/
(600 - 800mA)
retract cylinders
1250mA
Main Lift Max Up
(1150 - 1350mA)

660mA
Main Lift Min Down
(560 - 760mA)

1320mA
Main Lift Max Down
(1220 - 1420mA)
0.5
Telescope Accel In
(0.0 - 2.0S)

0.3
Telescope Decel In
(0.0 - 1.0S)

0.5
Telescope Accel Out
(0.0 - 2.0S)
Telescope (X-Axis)

Screen allows the 0.3

Telescope Decel Out operator to view
Fork Mode

parameters (max/ (0.0 - 1.0S)

Access Level 2, 3
min) related to fork 660mA
Telescope Min In tilt and extend/
(560 - 760mA)
retract cylinders
1210mA
Telescope Max In
(1110 - 1310mA)

670mA
Telescope Min Out
(570 - 770mA)

1200mA
Telescope Max Out
(1100 - 1300mA)

3614RS, 4017RS 31211337 9-51

 Electrical System

Menu/Sub-
Function Description Default Values (Range) Access Level
menu Items
0.5
Telescope Accel In
(0.0 - 2.0S)

0.3
Telescope Decel In
(0.0 - 1.0S)

0.5
Telescope Accel Out
(0.0 - 2.0S)
Screen allows the
Telescope (Roller)

0.3
Telescope Decel Out operator to view
parameters (max/ (0.0 - 1.0S)
Access Level 2, 3
min) related to fork 660mA
Telescope Min In tilt and extend/
(560 - 760mA)
retract cylinders
1210mA
Telescope Max In
(1110 - 1310mA)

670mA
Telescope Min Out
(570 - 770mA)

1200mA
Telescope Max Out
Fork Mode

(1100 - 1300mA)
0.5
Fork Tilt Accel Up
(0.0 - 2.0S)

0.3
Fork Tilt Decel Up
(0.0 - 1.0S)

0.5
Fork Tilt Accel Down
(0.0 - 2.0S)
Screen allows the
Fork Tilt (Roller)

0.3
Fork Tilt Decel Down operator to view
parameters (max/ (0.0 - 1.0S)
Access Level 2, 3
min) related to fork 670mA
Fork Tilt Min Up tilt and extend/
(570 - 770mA)
retract cylinders
1160mA
Fork Tilt Max Up
(960 - 1360mA)

700mA
Fork Tilt Min Down
(600 - 800mA)

1200mA
Fork Tilt Max Down
(1000 - 1400mA)

9-52 31211337 3614RS, 4017RS

 Electrical System

Menu/Sub-
Function Description Default Values (Range) Access Level
menu Items
0.5
Fork Tilt Accel Up
(0.0 - 2.0S)

0.3
Fork Tilt Decel Up
(0.0 - 1.0S)

0.5
Fork Tilt Accel Down
(0.0 - 2.0S)
Screen allows the
Fork Tilt (X-Axis)

0.3
Fork Tilt Decel Down operator to view
Fork Mode

parameters (max/ (0.0 - 1.0S)

Access Level 2, 3
min) related to fork 670mA
Fork Tilt Min Up tilt and extend/
(570 - 770mA)
retract cylinders
1160mA
Fork Tilt Max Up
(960 - 1360mA)

700mA
Fork Tilt Min Down
(600 - 800mA)

1200mA
Fork Tilt Max Down
(1000 - 1400mA)
0.4
Front Aux Accel Coil A
(0.0 - 2.0S)

0.2
Front Aux Decel Coil A
(0.0 - 1.0S)

0.4
Front Aux Accel Coil B
(0.0 - 2.0S)

0.2
Front Aux Decel Coil B
(0.0 - 1.0S)
Screen allows the
Front Auxiliary

operator to view the 700mA

Front Aux Min Coil A parameters (min/max (600 - 800mA)
values) related to Access Level 2, 3
front auxiliary Coil A 1300mA
Front Aux Max Coil A
and Coil B (if (1100 - 1500mA)
equipped)
700mA
Front Aux Min Coil B
(600 - 800mA)

1300mA
Front Aux Max Coil B
(1100 - 1500mA)

700mA
Front Aux DE-COMP
(700 - 900mA)

1.0S
Front Aux DE-COMP
(0.5 - 2.0S)

3614RS, 4017RS 31211337 9-53

 Electrical System

Menu/Sub-
Function Description Default Values (Range) Access Level
menu Items
0.8
Outriggers Accel Up
(0.0 - 2.0S)

0.3
Outriggers Decel Up
(0.0 - 1.0S)

0.8
Outriggers Accel Down
(0.0 - 2.0S)
Screen allows the 0.3
operator to view the
Outriggers

Outriggers Decel Down

parameters (min/max (0.0 - 1.0S)
Access Level 2, 3
values) related to 510mA
Outriggers Min Up outriggers function
(410 - 610mA)
speeds
800mA
Outriggers Max Up
(700 - 900mA)

510mA
Outriggers Min Down
(410 - 610mA)

800mA
Outriggers Max Down
(700 - 900mA)
0.5
Frame Level Accel Left
(0.0 - 2.0S)

0.5
Frame Level Decel Left
(0.0 - 1.0S)

0.5
Frame Level Accel Right
(0.0 - 2.0S)
Frame level screen 0.5
Frame Level

Frame Level Decel Right allows the operator

to view the (0.0 - 1.0S)
Access Level 2, 3
parameters (min/ 480mA
Frame Level Min Left max) related to frame
(430 - 530mA)
level function speeds
590mA
Frame Level Max Left
(540 - 640mA)

480mA
Frame Level Min Right
(430 - 530mA)

590mA
Frame Level Max Right
(540 - 640mA)

9-54 31211337 3614RS, 4017RS

 Electrical System

9.14.5 Operator Tools

Menu Settings Description Access Level

Enter Current CODE: Requires the existing code to be entered before a

0000 new one.
Change Anti-theft
Access Level 1, 2
Code?
Enter New CODE: 0000 Return to top level menu after entry.

Anti-theft Mode: Cabin + Remote Cabin Configures which operator stations will require
Access Level 1, 2
Cabin + Remote Only Remote Only anti-theft code entry at each startup.

Maintenance Complete?
Confirm Machine Records that preventive maintenance has been
YES:ENTER Access Level 1, 2
Maintenance? performed.
NO:ESC
Review
Maintenance History Displays the engine hours for the past fifteen
Maintenance Access Level 1, 2
nn:X,XXX H maintenance intervals.
History?

Enable Maint YES Enables the maintenance interval notification

Always
Interval NO (DTC 874)

Increment or decrement the engine hours before

Set Maintenance 500 hrs
the next maintenance interval; notification Access Level 1, 2
Interval (0 to 500 hrs)
(DTC 874)

Review LSI Shutoff LSI History Displays the engine hours for the past fifteen LSI
Access Level 1
History? nn:X,XXX H cancel switch uses.

Selects units for vehicle speed display; default to

KPH Access Level
Vehicle Speed Units MPH when machine setup’s market is ANSI; KPH
MPH 1, 2, 3
otherwise.
Selects units for temperature display; default to
Celsius Access Level
Temperature Fahrenheit when machine setup’s market is ANSI;
Fahrenheit 1, 2, 3
Celsius otherwise.

BAR Select units for pressure display; default to PSI when Access Level
Pressure
PSI machine setup’s market is ANSI; BAR otherwise. 1, 2, 3

Selects steering mode preference; default to

Automatic Access Level
Steer Mode Automatic when machine setup’s vehicle is LBP-AG,
Manual 1, 2, 3
LBP-PR, or LBP-HC, manual otherwise.
Displays engine hours when load stability is 100%;
Review LSI LSI Suspend Log
on during passive mode and off otherwise (last ten Access Level 1
Suspended Log? nn: X,XXXH - Nn
events).

3614RS, 4017RS 31211337 9-55

 Electrical System

Menu Settings Description Access Level

2 sec Sets the length of time that the fan will be reversed
Fan Reverse Timer
(2 - 10 sec) (cycling or demand).
Access Level
1, 2, 3
Fan Reverse 20 min
Sets the interval between cycling fan reversals.
Interval (5 - 60 min)

Selects the tire fitted for proper vehicle speed Access Level
Tire Selection (Multiple Tire Selections)
calibration 1, 2, 3

Access Level
1, 2, 3, 4
Sets the default transmission gear at power-up; 1, 2, 3
Default Gear
required when cabin joystick is used for gear
Selection
selection (except hydrostatic transmission). Access Level
1, 2, 3
1, 2, 3

Requests elevated idle for aftertreatment cleaning;

OFF Access Level
Elevated Idle default to off at power-up and when JLG analyzer is
ON 1, 2, 3
disconnected.
Configures the brake light activation pressure;
Brake Light On 40 PSI
PSI or BAR according to operator tools pressure
Pressure (10 -150 PSI)
setting. Access Level
Configures the brake light de-activation pressure; 1, 2, 3
Brake Light Off 35 PSI
PSI or BAR according to operator tools pressure
Pressure (10 - 150 PSI)
setting.

De-compression OFF Configure auxiliary de-compression during Access Level

For Auxiliary Select ON auxiliary select change. 1, 2, 3

Selects the cabin joystick resource that will be used

Cabin Joystick X-Axis Access Level
to control telescope; fork tilt is controlled by the
Telescope Roller 1, 2, 3
opposite.

Note: Settings in BOLD are default values.

9-56 31211337 3614RS, 4017RS

 Electrical System

9.14.6 Calibrations

Menu Sub-menu/Procedure Description Access Level

Used by technicians to calibrate the chassis

Calibrate Tilt Sensor?
tilt sensors; ENTER to confirm; ESC to exit

Displayed if Machine Setup’s OUTRIGGERS is YES;

Tilt Calibration Set Technician must use stabilizer and digital level to
Stabilizers properly position vehicle; ENTER to confirm; ESC to
exit

Tilt Sensor Access Level 1, 2,

Tilt Sensor Calibrating Displayed while control system acquires readings

Calibration offset was within +/- 5.0 degrees;

Calibration Complete
ENTER or ESC to exit

Calibration offset was outside +/- 5.0 degrees;

Calibration Failed
ENTER or ESC to exit

Calibrate Boom Angle Used by technicians to calibrate the boom angle

Sensor? sensor; press ENTER to confirm or ESC to exit

Press Enter at lowest Technician must lower boom to mechanical stop;

position press ENTER to confirm

Lift Up. Technician must raise boom to mechanical stop;

Press Enter at top press ENTER to confirm.

Boom Angle Access Level 1, 2

Calibration Complete Calibration was successful; press ESC key to exit

The minimum or maximum boom angle sensor

Calibration Failed counts were improper for this vehicle; press ESC
key to exit

DTC 2344, 2345, 2346,2353, or 6621 was active

Calibration Sensor and calibration could not succeed; press ESC key
Fault to
exit

Boom ride evaluation is required to check the

Confirm Boom Ride hydraulic accumulator gas charge while the
Test vehicle
is parked; press ENTER to continue or ESC to exit
Boom Ride Test Access Level 1, 2
Activate Boom Ride functionality until technician
Press Enter when test leaves menu or disconnects JLG Analyze; press
done ENTER to return to CONFIRM BOOM RIDE TEST
menu or ESC to exit

3614RS, 4017RS 31211337 9-57

 Electrical System

Menu Sub-menu/Procedure Description Access Level

Park brake evaluation is required at the end of the
manufacturing process, and daily by some mining
Perform park brake
customers; press ENTER to continue or ESC to exit;
test?
Automatic shifting is prevented for the duration of
this test to enable the Torque Converter Stall Test.

Prompt technician to apply park brake; press ENTER

Set park brake to continue or ESC to exit; test fails if park brake not
applied

Shift to second gear

Prompt technician to select proper gear; press
ENTER to continue or ESC to exit; test fails if proper
Shift to third gear gear not selected

Access Level 1, 2
Park Brake Test Shift to fourth gear

Prompt technician that vehicle will drive at next

Warning: drive will be step; menu persists for 2000mS; press ENTER
engaged
to continue or ESC to exit

Prompt technician to select direction and begin

Forward to start neutral test; direction and gear selection permitted with
to pause park brake applied; press ENTER to continue or
ESC to exit

Park brake test

Prompt technician about results; press ESC to exit
complete

Park brake test failed Prompt technician about results; press ESC to exit

Transmission service is required for diagnostics or to

Confirm trans Service
limp a vehicle home after a transmission solenoid
Test
issue; press ENTER to continue or ESC to exit.

Direction and gear selection permitted despite

transmission solenoid driver issues; prevent
Transmission
direction Access Level 1,2
Service
Press Enter when test and gear selection when technician leaves this
done menu
or disconnects JLG Analyzer; press ENTER to return
to
CONFIRM TRANS SERVICE TEST menu or ESC to exit.

9-58 31211337 3614RS, 4017RS

 Electrical System

Menu Sub-menu/Procedure Description Access Level

Used by technicians to calibrate LSI operation;
hydraulic functions will not be prevented by LSI
Calibrate LSI Sensor?
during calibration; Press ENTER to continue or ESC
to exit; disabled during LSI verification.

Remove Weights and Prompt technician to remove attachment and

Attachments weights; Press ENTER to continue or ESC to exit.

Displayed when machine setup’s outriggers is yes;

prompt technician to set the outriggers; if machine
setup’s o/r detection is press or press & prox,
Fully Deploy Outriggers
automatically proceed to next calibration step when
both left and right outriggers are set; Press ENTER
to continue or ESC to exit.

Telescope In and Fully Prompt technician to place vehicle in most stable

Lift Up position; Press ENTER to continue or ESC to exit.

Calibrating Load Prompt technician to wait for measurement

Load Stability Stability 0% stability; Press ENTER to continue or ESC to exit. Access Level 1,2
Prompt technician to lift down for next calibration
Lift Down
step; Press ENTER to continue or ESC to exit.

Displayed when machine setup’s outriggers is yes;

Fully Retract Outriggers prompt technician to pull up the outriggers; Press
ENTER to continue or ESC to exit.

Prompt technician to lift rear axle off the ground

Unload Rear Axle using overhead crane or jack; Press ENTER to
continue or ESC to exit.

Calibrating Load Prompt technician to wait for measurement

Stability 100% stability; Press ENTER to continue or ESC to exit.

Record LSI check point cell a & b, controller on-time

LSI Calibration Complete in non-volatile memory; Press ENTER to calibrate
and leave menu, or ESC to exit.

LSI Calibration Failed Calibration failed; Press ESC to exit.

Used by technicians at the factory for noise testing;

Perform Fan Speed Test?
press ENTER to begin or ESC to exit
Access Level 1,2
UP and DOWN keys directly adjust fan speed valve
Fan Speed Test Fan SPD Valve 0 mA
current

UP and DOWN keys directly adjust fan speed 2 valve

Fan SPD 2 Valve 0 mA Access Level 1,2
current in same manner as fan speed valve

3614RS, 4017RS 31211337 9-59

 Electrical System

Menu Sub-menu/Procedure Description Access Level

Used by technicians to calibrate the boom length
Calibrate Boom Length sensor; Hydraulic functions will not be prevented by
Sensor? LMIS during calibration; press ENTER to confirm or
ESC to exit.

TELE In. Press Enter Technician must retract boom completely; press
Retracted ENTER to confirm

TELE Out. Press Enter Technician must extend boom completely; press
Boom Length Extended ENTER to confirm. Access Level 1, 2

Calibration Complete Calibration was successful; press ESC key to exit

The minimum or maximum boom length sensor

Calibration Failed counts were improper for this vehicle; press ESC key
to exit

DTC 845 or 846 was active and calibration could not

Calibration Sensor Fault
succeed; press ESC key to exit

RAS TEST YES:ENTER, Used by technicians to test the Rear Axle Stability
NO:ESC system; press ENTER to confirm or ESC to exit

UP and DOWN keys select NORMAL, RAS LOCK, RAS

RAS Test RESTRICT, and RAS FLOAT; default is NORMAL; test Access Level 1,2
RAS TEST: NORMAL mode override normal functionality; default to
NORMAL on test exit, JLG Analyzer disconnected, or
power cycled

Press ENTER To START Used by technicians to trigger aftertreatment

REGEN refresh; press ENTER to trigger regeneration
START REFRESH Access Level 1,2
Sending Command
Press ESC to exit
ESC To EXIT

9-60 31211337 3614RS, 4017RS

 Electrical System

Menu Sub-menu/Procedure Description Access Level

Used by technicians to calibrate the brake pedal
Brake Pedal POS YES:
position sensor; press ENTER to confirm or ESC
ENTER, NO: ESC
to exit

Prompt technician to release brake pedal for

Release Brake Pedal
0%; press ENTER to calibrate or ESC to exit

Prompt technician to depress brake pedal for 100%;

Depress Brake Pedal
press ENTER to calibrate or ESC to exit
Brake Pedal POS Brake Pedal Position 0% &100% > 0.5V or < 4.50V; Access Level 1,2
Calibration Completed Brake Pedal Position 0% -100% > 0.25V; calibration
was successful; press ESC key to exit

Brake Pedal Position 0% / 100% were improper;

Calibration Failed press
ESC key to exit

DTC 23167 or 23168 was active and calibration

Calibration Sensor Fault
could not succeed; press ESC key to exit

3614RS, 4017RS 31211337 9-61

 Electrical System

Menu Sub-menu/Procedure Description Access Level

Used by technicians to calibrate the Load Moment
Indication System; Press LEFT or RIGHT to view LMIS
PASSIVE menu; Hydraulic functions will not be
Calibrate Load Moment
prevented by LMIS during calibration; press
Indicator System?
ENTER to continue or ESC to exit; proceed to LMIS
CALIBRATION FAIL if calibration is prevented for the
selected attachment
Prompt technician to remove weights; press ENTER
Remove Weights
to continue or ESC to exit

Prompt technician to set the outriggers; Displayed

when Machine Setup’s OUTRIGGERS is YES; If
Machine Setup’s OUTRIGGER DETECTION is PRESS or
Fully Deploy Outriggers PRESS & PROX, proceed when both left and right
outriggers are deployed; If Machine Setup’s
OUTRIGGER DETECTION is NONE, press ENTER to
continue; press ESC to exit

LMIS Prompt technician to fully retract boom for next

(Load Fully Retract Boom calibration point; press ENTER to continue or ESC to
Management exit Access Level 1, 2
Indicator System) Prompt technician to lift down for next calibration
Lift Down To MIN Boom
Angle step; press ENTER to continue or ESC to exit

Prompt technician to lift up to maximum boom

Lift Up To MAX Boom
angle; Press ENTER at maximum boom angle to
Angle
continue, or ESC to exit

Prompt technician to lift down to minimum boom

Lift Down To MIN Boom
angle; Press ENTER at minimum boom angle to
Angle
continue, or ESC to exit

Calibrating Dynamic Record dynamic retracted offsets for the selected

Retract attachment, then continue

Prompt technician to lift up to low calibration angle;

lift up prevented when boom angle is greater than
Lift Up To Low CAL Angle
or equal to calibration angle; press ENTER to
continue or ESC to exit

Record Low Retracted Up Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment LRCAL Up enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit.

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 Electrical System

Menu Sub-menu/Procedure Description Access Level

Prompt technician to lift up to middle calibration
angle; lift up prevented when boom angle is greater
Lift Up To MID Call Angle
than or equal to calibration angle; press ENTER to
continue or ESC to exit

Record Mid Retracted Up Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment MRCAL Up enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

Prompt technician to lift up to high calibration

Lift Up To High CAL angle; lift up prevented when boom angle is greater
Angle than or equal to calibration angle; press ENTER to
continue or ESC to exit

Record High Retracted Up Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment HRCAL UP enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

Lift Up To MAX Boom Prompt technician to lift up for next calibration

Angle step; press ENTER to continue or ESC to exit
LMIS
Prompt technician to lift down to high calibration
(Load
Lift Down To High CAL angle; lift down prevented when boom angle is less Access Level 1, 2
Management
Angle than or equal to calibration angle; press ENTER to
Indicator System)
continue or ESC to exit

Record High Retracted Down Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment HRCAL DN enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

Prompt technician to lift down to mid calibration

Lift Down To MID CAL angle; lift down prevented when boom angle is less
Angle than or equal to calibration angle; press ENTER to
continue or ESC to exit

Record Mid Retracted Down Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment MRCAL DN enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

Prompt technician to lift down to low calibration

Lift Down To Low CAL angle; lift down prevented when boom angle is less
Angle than or equal to calibration angle; press ENTER to
continue or ESC to exit

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 Electrical System

Menu Sub-menu/Procedure Description Access Level

Record Low Retracted Down Calibration for the
Calibrating Load selected attachment; Proceed if boom is stable
Moment LRCAL DN enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

Prompt technician to extend boom to Calibration

Length for next calibration step; telescope out
Fully Extend Boom prevented when boom length is greater than or
equal to Calibration Length, press ENTER to
continue or ESC to exit

Lift Down to Prompt technician to lift down for next calibration

Min Boom Angle step; press ENTER to continue or ESC to exit

Lift Up to Prompt technician to lift up to maximum boom

angle; Press ENTER at maximum boom angle to
Max Boom Angle continue, or ESC to exit

Lift Down to Prompt technician to lift down to minimum boom

angle; Press ENTER at minimum boom angle to
Min Boom Angle continue, or ESC to exit

Calibrating Dynamic Record dynamic extended offsets for the selected

Extended attachment, then continue
LMIS
(Load Prompt technician to lift up to low calibration angle;
Management Lift Up to lift up prevented when boom angle is greater than Access Level 1, 2
Indicator System) Low Cal Angle or equal to calibration angle; press ENTER to
continue or ESC to exit

Record Low Extended Up Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment LECAL Up enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

Prompt technician to lift up to mid calibration angle;

Lift Up to lift up prevented when boom angle is greater than
Mid Cal Angle or equal to calibration angle; press ENTER to
continue or ESC to exit

Record Mid Extended Up Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment MECAL Up enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

Prompt technician to lift up to high calibration

Lift Up to angle; lift up prevented when boom angle is greater
High Cal Angle than or equal to calibration angle; press ENTER to
continue or ESC to exit

Record High Extended Up Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment HECAL Up enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

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 Electrical System

Menu Sub-menu/Procedure Description Access Level

Prompt technician to lift up for next calibration
Lift Up
step; press ENTER to continue or ESC to exit

Prompt technician to lift down to high calibration

Lift Down to angle; lift down prevented when boom angle is less
High Cal Angle than or equal to calibration angle; press ENTER to
continue or ESC to exit

Record High Extended Down Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment HECAL DN enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

Prompt technician to lift down to mid calibration

Lift Down to angle; lift down prevented when boom angle is less
Mid Cal Angle than or equal to calibration angle; press ENTER to
continue or ESC to exit

Record Mid Extended Down Calibration for the

Calibrating Load selected attachment; Proceed if boom is stable
Moment MECAL DN enough to collect offset, else proceed to
LMIS
CALIBRATION FAILED; Press ESC to exit
(Load
Access Level 1, 2
Management Prompt technician to lift down to low calibration
Indicator System) Lift Down to angle; lift down prevented when boom angle is less
Low Cal Angle than or equal to calibration angle; press ENTER to
continue or ESC to exit

Record Static Low Extended Down Calibration for

Calibrating Load the selected attachment; Proceed if boom is stable
Moment LECAL DN enough to collect offset, else proceed to
CALIBRATION FAILED; Press ESC to exit

LMIS Calibration Save calibration offsets for current attachment;

Complete press ESC to exit

The calibration failed due to out of range offset or

boom instability; Technician should troubleshoot
LMIS Calibration Failed
any active fault codes, then reattempt calibration;
press ESC to exit

Hidden for suspended-load attachments such as a

truss or winch; Use UP or DOWN buttons to edit;
LMIS Passive:
Select ENABLE to disable LMIS cutouts, alarms, and
DISABLE
indicators for the selected attachment; press ESC to
exit

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 Electrical System

Menu Sub-menu/Procedure Description Access Level

Used by technicians to set the Bosch Hydrostatic
Set Machine Type Transmission’s Machine Type; press ENTER to
continue or ESC to exit

Set Direction To Prompt technician to set direction selection to

NEUTRAL neutral; press ENTER to continue or ESC to exit

Prompt technician to apply the park brake;

Apply Park Brake
press ENTER to continue or ESC to exit

Prompt technician that control system is checking

Request Access Level 1, 2,
Set Machine Type for preconditions; press ENTER to continue or ESC to
Parameter Mode 3
exit

Prompt technician that control system is saving

Save Parameter
machine type change; press ENTER to continue
Mode
or ESC to exit

Prompt technician that machine type change is

Complete
complete; press ENTER or ESC to exit

Prompt technician that machine type change was

Machine Type CAL Failed
not accepted; press ENTER or ESC to exit

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 Electrical System

Menu Sub-menu/Procedure Description Access Level

Used by technicians to program RFID Tags with
Calibrate Attachment
unique attachment part numbers; press ENTER to
Recognition?
continue or ESC to exit

Search for available tags in range; Continue when

Searching For Tags
finished or press ESC to exit

Prompt technician to enter attachment part

number from attachment serial plate; if part
Part Number: number contains less than 10 digits, enter zeros
0000000000 for unused digits; use UP/DOWN/LEFT/RIGHT to
set
each digit; press ENTER to continue or ESC to exit

Write attachment part number to RFID Tag; Skip

Writing Part Number if multiple tags or no tags are detected; Continue
Attachment when finished or press ESC to exit
Access Level 1, 2
Recognition
Prompt technician that attachment part number
Calibration Complete was successfully write to the RFID Tag; press ENTER
or ESC to exit

Prompt technician that RFID Tag could not be

written due to communication error; press ENTER or
Calibration Failed ESC to
exit

Prompt technician that RFID Tag could not be

written because too many tags are detected;
Error – Too Many Tags Technician must reposition vehicle so that only one
tag is
detected; press ENTER or ESC to exit

Prompt technician that RFID Tag could not be

written because no tags are detected; Technician
Error – No Tags In Range
must reposition vehicle so that only one tag is
detected; press ENTER or ESC to exit

3614RS, 4017RS 31211337 9-67

 Electrical System

Menu Sub-menu/Procedure Description Access Level

Used by technicians to check the health of Boom
Check Boom Damping Ride Valve and Lift Rod Pressure sensor which are
Component Health? impractical to check during normal system
operation; press ENTER to confirm or ESC to exit

Press Enter W/ Technician must set outriggers, fully retract

O/R Set and Boom Level/ boom, adjust boom angle to approximately level;
Retracted. press ENTER to confirm. Press ESC to exit Health
Check.

Technician must use lift up to re-balance pressures

on the lift cylinder before completing initial step;
Lift Up Slightly lifting up and control system sees correct
pressures resumes previous step. Press ESC to exit
Health Check.

Press Enter at Full Technician must fully extend boom and may not
Extend. Tele Extend Only use lift function; press ENTER to confirm full boom
(No Lift) extension. Press ESC to exit Health Check.

Technician must use lift up to re-balance pressures

Lift Up Slightly Then
on the lift cylinder at full boom extension; press
Boom Press Enter
ENTER to confirm. Press ESC to exit Health Check. Access Level 1, 2
Damping
Fully Retract Boom Technician must retract boom fully (until boom
(No Lift) status is retracted). Press ESC to exit Health Check

Technician uses Lift Function or Tele Function at

Sequence Fault - Start inappropriate time during evaluation or posturing
Over steps; press ENTER or ESC to return to Check starting
step.

All component checks completed successfully; press

Health Check Complete -
ENTER or ESC to exit. This step clears DTCs related to
Ok
health check, refer to DTCs 25101 and 25105.

Fault detected with Boom Ride Valve, refer to DTC

Health Check Failed -
25101. DTC may only be cleared by resolving related
Ride Valve
issues and completing this health check procedure.

Fault detected with Boom Tank Valve or Lift Rod

Health Check Failed - Lift Pressure Sensor, refer to DTC 25105. DTC may only
Rod Pressure Sensor be cleared by resolving related issues and
completing this health check procedure.

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 Electrical System

9.15 FAULT CODES

11 KPH

1127 RPM
127°C

MZ8280

Faults are detected while key switch is in RUN position,

during operation of machine itself. If a fault becomes active
(currently detected) at this time, a fault is logged in memory
and a snapshot of engine parameters is logged. The LCD
display (1) located within the instrument panel notifies the
operator.
If LCD display (1) shows a three to five digit fault (for example:
33185), refer to Section 9.16, “Machine Fault Codes Version P
18.0”, for a full list of fault codes.
If LCD display (1) shows 437 SPN:FMI fault (for example: 437
51:5), refer to Section 9.17, “Engine Diagnostic”, for a full list
of fault codes.

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 Electrical System

9.16 MACHINE FAULT CODES VERSION P 18.0

Note: Some fault codes may not be available depending upon machine configuration.

9.16.1 Help Comment (00x)

CABIN
HELP MESSAGE DTC ACTIONS TRIGGER LATCH CONDITION
ALARM
The system detects no
EVERYTHING OK 001 - - -
problems exist.

Machine Setup’s HYD TEMP

Main Lift, Telescope,
MGMT is YES; FFCM J1-B1 Hydraulic Oil
HIGH HYDRAULIC TEMPERATURE – Fork Tilt, and
0051 - FFCM J1-B1 Hydraulic Oil Temperature sensor falls
FUNCTIONS DERATED Auxiliary Hydraulics
Temperature Sensor exceeds below threshold
are derated
threshold

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 Electrical System

9.16.2 Power-Up (21x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
POWER CYCLE 211 - - Power was cycled ON. -

Machine Setup’s PLATFORM OPTION is YES;

Platform Mode; PLT J2-19 Function Enable
FUNCTION ENABLE
Platform controls Relay energized;
INPUTS – INVALID SIGNAL 214 5000mS Power cycled
prevented PLT J7-8 & RFCM J3-G4 Function Enable
STATES
Switch digital inputs not complementary for
1000mS

Cabin joystick’s X or Y axis is not neutral at

power-up. One or more of the following
events occurred:
• X-Axis Left switch closed (XAxisLeft)
• X-Axis Right switch closed (XAxisRi-
ght)
• X-Axis Position not zero (XAxis-
Value)
JOYSTICK AXES NOT IN Cabin Joystick’s X-
• Y-Axis Forward switch closed (YAx-
NEUTRAL POSITION AT 215 5000mS Axis and Y-Axis Cabin joystick neutral 150mS
isForward)
POWER UP regarded as 0%
• Y-Axis Backward switch closed
(YAxisBackward)
• Y-Axis Position not zero (YAxis-
Value)
• X-Axis Neutral switch not closed
(XAxisNeutral)
• Y-Axis Neutral switch not closed
(YAxisNeutral)

ENGINE START Platform Engine Machine Setup’s PLATFORM OPTION is YES;

PREVENTED – PLATFORM Start prevented Platform Mode; The switch is open
2111 5000mS
START SWITCH HIGH AT (switch regarded as PLT J1-14 Engine Start Switch is closed at momentarily
POWER UP open) power-up

Machine Setup’s PLATFORM OPTION is YES;

PLATFORM ROTATE LEFT Platform Rotate
Platform Mode;
PREVENTED – INPUT HIGH 2112 5000mS Left & Right Power cycled
PLT J1-8 Platform Rotate Left Switch is closed
AT POWER UP prevented
at power-up

Machine Setup’s PLATFORM OPTION is YES;

PLATFORM ROTATE RIGHT Platform Rotate
Platform Mode;
PREVENTED – INPUT HIGH 2113 5000mS Left & Right Power cycled
PLT J1-7 Platform Rotate Right Switch is
AT POWER UP prevented
closed at power-up

Machine Setup’s PLATFORM OPTION is YES;

PLATFORM LEVEL UP
Platform Level Up & Platform Mode;
PREVENTED – INPUT HIGH 2114 5000mS Power cycled
Down prevented PLT J1-9 Platform Level Up Switch is closed at
AT POWER UP
power-up

Machine Setup’s PLATFORM OPTION is YES;

PLATFORM LEVEL DOWN
Platform Level Up & Platform Mode;
PREVENTED – INPUT HIGH 2115 5000mS Power cycled
Down prevented PLT J1-10 Platform Level Down Switch is
AT POWER UP
closed at power-up in platform mode

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 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
• Platform
Lift Up &
Down
pre-
PLATFORM JOYSTICK NOT vented Machine Setup’s PLATFORM OPTION is YES;
Platform joystick neutral
IN NEUTRAL POSITION AT 2117 5000mS • Platform Platform Mode; platform joystick not neutral
momentarily (1,000mS)
POWER UP Tele- position at power-up
scope In
& Out
pre-
vented

• Machine Setup’s FRAME LEVELING

is YES or PROP; CCM J1-F3 Frame
Level Right Switch is closed (ener-
FRAME LEVEL RIGHT Frame Level Left & gized) within 500mS of power-up
2119 5000mS Power cycled
INPUT – INVALID SIGNAL Right prevented • Machine Setup’s FRAME LEVELING
is YES or PROP; CCM J1-F3 Frame
Level Right Switch detects a redun-
dancy disagreement for 500mS

• Machine Setup’s FRAME LEVELING

is YES or PROP; CCM J1-F2 Frame
Level Left Switch is closed (ener-
FRAME LEVEL LEFT INPUT Frame Level Left & gized) within 500mS of power-up
2120 5000mS Power cycled
– INVALID SIGNAL Right prevented • Machine Setup’s FRAME LEVELING
is YES or PROP; CCM J1-F2 Frame
Level Left Switch detects a redun-
dancy disagreement for 500mS

• Machine Setup’s HYDRAULIC QUICK

CONNECT is YES; CCM J1-A4
Hydraulic Quick Hydraulic Quick Connect Switch is
HYDRAULIC QUICK Connect high at power-up
CONNECT INPUT – 2121 5000mS functionality • Machine Setup’s HYDRAULIC QUICK Power cycled
INVALID SIGNAL prevented (switch CONNECT is YES; CCM J1-A4
regarded as open) Hydraulic Quick Connect Switch
detects a redundancy disagree-
ment for 500mS

Continuous
CONTINUOUS AUXILIARY Auxiliary Hydraulics Machine Setup’s VEHICLE is not LBP-RS, CCM
HYDRAULICS SWITCH 2122 5000mS functionality J1-B3 Continuous Auxiliary Switch is closed at Power cycled
HIGH AT POWER UP prevented (switch power-up
regarded as open)

Continuous
Auxiliary Hydraulics
functionality Machine Setup’s VEHICLE is LBP-RS,
CONTINUOUS AUXILIARY prevented AUXILIARY HYDRAULICS is YES, and Cabin
HYDRAULICS SWITCH 2122 5000mS Power cycled
Auxiliary De- Joystick Position 2 (middle pushbutton) is
HIGH AT POWER UP
Compression closed at power-up
functionality
prevented

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 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Left Roller not neutral at power-up. One or
more of the following conditions exist:
Left Roller neutral for 150mS
• Left Roller Forward switch closed
(LeftRollerForward) • Left Roller Neutral
JOYSTICK LEFT ROLLER switch closed (Lef-
Left Roller regarded • Left Roller Backward switch closed
NOT IN THE NEUTRAL 2124 5000mS tRollerNeutral)
as 0% (LeftRollerBackward)
POSITION AT POWER UP • Left Roller Posi-
• Left Roller Position not zero (Lef-
tion zero (Lef-
tRollerValue)
tRollerValue)
• Left Roller Neutral switch not
closed (LeftRollerNeutral)

Machine Setup’s AUXILARY HYDRAULICS is

YES, Right Roller not neutral at power-up, and Right Roller neutral for
any of the following conditions exist: 150mS
• Right Roller Forward switch closed • Right Roller Neu-
JOYSTICK RIGHT ROLLER (RightRollerForward) tral switch closed
Right Roller
NOT IN THE NEUTRAL 2125 5000mS • Right Roller Backward switch (RightRollerNeu-
regarded as 0%
POSITION AT POWER UP closed (RightRollerBackward) tral)
• Right Roller Position not zero • Right Roller Posi-
(RightRollerValue) tion zero (Right-
• Right Roller Neutral switch not RollerValue)
closed (RightRollerNeutral)

Machine Setup’s VEHICLE is not LBP-RS,

THROTTLE PEDAL NOT Engine speed set to Primary throttle pedal
2130 5000mS Primary throttle pedal position is greater than
RELEASED AT POWER UP Close Throttle RPM position is less than 10%
or equal to 10% at power-up

• Hitch Configured; CCM J1-F3 Hitch

Up Switch is closed (energized)
HITCH UP INPUT – Hitch Up & Down within 500mS of power-up
2131 5000mS Power cycled
INVALID SIGNAL prevented • Hitch Configured; CCM J1-F3 Hitch
Up Switch detects a redundancy
disagreement for 500mS

• Hitch Configured; CCM J1-F2 Hitch

Down Switch is closed (energized)
HITCH DOWN INPUT – Hitch Up & Down within 500mS of power-up
2132 5000mS Power cycled
INVALID SIGNAL prevented • Hitch Configured; CCM J1-F2 Hitch
Down Switch detects a redundancy
disagreement for 500mS

Machine Setup’s O/R JOYSTICKS is YES; DTC

23132 not active; DTC 23133 not active; and
OUTRIGGER LEFT Outrigger Left one of these conditions exists at power-up: Scaled Outrigger Left
JOYSTICK NOT NEUTRAL 2133 5000mS Joystick regarded • Scaled Outrigger Left Joystick (Pri- Joystick (Primary) & (Backup)
AT POWER UP as 0% mary) is not 0% are 0% for 1,000mS
• Scaled Outrigger Left Joystick
(Backup) is not 0%

Machine Setup’s O/R JOYSTICKS is YES; DTC

23135 not active; DTC 23136 not active; and
OUTRIGGER RIGHT Outrigger Right one of these conditions exists at power-up: Scaled Outrigger Right
JOYSTICK NOT NEUTRAL 2134 5000mS Joystick regarded • Scaled Outrigger Right Joystick (Pri- Joystick (Primary) & (Backup)
AT POWER UP as 0% mary) is not 0% are 0% for 1,000mS
• Scaled Outrigger Right Joystick
(Backup) is not 0%

3614RS, 4017RS 31211337 9-73

 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Auxiliary De-
AUX DE-COMP SWITCH Compression CCM J2-K4 Auxiliary De-Comp Switch is
2135 5000mS Power cycled
ACTIVE AT POWER UP prevented (switch closed (energized) at power-up
regarded as open)

Machine Setup’s OUTRIGGERS is YES; O/R

Outriggers
OUTRIGGER SWITCH JOYSTICKS is NO; and Cabin Joystick’s
2136 5000mS prevented (switch Power cycled
ACTIVE AT POWER-UP Outrigger Pushbutton closed at power-up
regarded as open)
(OutriggerBoomFloatPushbutton)

Machine Setup’s BOOM RIDE&FLOAT is

Boom Float
BOOM FLOAT SWITCH RIDE&FLOAT and Cabin Joystick’s Boom Float
2137 5000mS prevented (switch Power cycled
ACTIVE AT POWER-UP Pushbutton closed at power-up
regarded as open)
(OutriggerBoomFloatPushbutton)

Machine Setup’s AUX. FUNCTION SELECT is

Auxiliary 1/2
YES, VEHICLE is not HBP;
AUXILIARY 1/2 SWITCH functionality
2138 5000mS Cabin Joystick’s Auxiliary 1/2 Pushbutton Power cycled
ACTIVE AT POWER-UP prevented (switch
closed at power-up
regarded as open)
(AuxiliarySelectPushbutton)

Upshift
Machine Setup’s JOYSTICK FNR is YES;
UPSHIFT SWITCH ACTIVE functionality
2139 5000mS Cabin Joystick’s Upshift Pushbutton closed at Power cycled
AT POWER-UP prevented (switch
power-up (UpshiftPushbutton)
regarded as open)

Downshift
Machine Setup’s JOYSTICK FNR is YES;
DOWNSHIFT SWITCH functionality
2140 5000mS Cabin Joystick’s Downshift Pushbutton Power cycled
ACTIVE AT POWER-UP prevented (switch
closed at power-up (DownshiftPushbutton)
regarded as open)

De-Clutch
DE-CLUTCH SWITCH Cabin Joystick’s De-Clutch Pushbutton closed
2141 5000mS functionality Power cycled
ACTIVE AT POWER-UP at power-up (DeClutchPushbutton)
prevented

Machine Setup’s AUXILIARY F/R SELECT is

YES; DTC 23177 not active; DTC 23178 not
active; and one of these conditions exists at
REAR AUXILIARY 1 Rear Auxiliary 1 power-up: Scaled Rear Aux 1 Joystick
JOYSTICK NOT NEUTRAL 2143 5000mS Joystick regarded (Primary) & (Backup) are 0%
• Scaled Rear Auxiliary 1 Joystick (Pri-
AT POWER UP as 0% for 1,000mS
mary) is not 0%
• Scaled Rear Auxiliary 1 Joystick
(Backup) is not 0%

Machine Setup’s AUXILIARY REAR SELECT is

YES; DTC 23180 not active; DTC 23181 not
active; and one of these conditions exists at
REAR AUXILIARY 2 Rear Auxiliary 2 power-up: Scaled Rear Aux 2 Joystick
JOYSTICK NOT NEUTRAL 2144 5000mS Joystick regarded (Primary) & (Backup) are 0%
• Scaled Rear Auxiliary 2 Joystick (Pri-
AT POWER UP as 0% for 1,000mS
mary) is not 0%
• Scaled Rear Auxiliary 2 Joystick
(Backup) is not 0%

Agricultural Trailer Machine Setup’s TRAILER BRAKE is

AGRICULTURAL TRAILER
Brake Switch is AGRICULTURAL; CCM J2-F3 Agricultural
BRAKE SWITCH ACTIVE AT 2146 5000mS Power cycled
regarded as open Trailer Brake Switch is closed (energized) at
POWER-UP
(deenergized) powerup.

Regeneration
Machine Setup’s ENGINE CONTROL is DEUTZ
REGENERATION SWITCH Switch is regarded CCM J3-D2 Regeneration
2147 5000mS 55KWS5 HRC; CCM J3-D2 Regeneration
ACTIVE AT POWER-UP as open Switch is open for 1,000mS
Switch is closed (energized) at powerup.
(deenergized)

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 Electrical System

9.16.3 Platform Controls (22x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s PLATFORM OPTION is
PLATFORM LEVEL – YES; Platform Mode;
Platform Level Up &
CONFLICTING INPUT 2225 5000mS PLT J1-9 Platform Level Up Switch and PLT Power cycled
Down prevented
SIGNALS J1-10 Platform Level Down Switch closed
simultaneously

Machine Setup’s PLATFORM OPTION is

PLATFORM ROTATE – Platform Rotate YES; Platform Mode;
CONFLICTING INPUT 2226 5000mS Left & Right PLT J1-8 Platform Rotate Left Switch and Power cycled
SIGNALS prevented PLT J1-7 Platform Rotate Right Switch
closed simultaneously

All of the following are

met:

• Function Enable
Machine Setup’s PLATFORM OPTION is
Switch not
YES; Platform Mode; Function Enable
engaged
Switch closed after any of the following
events: • Platform Level
Up Switch open
• Platform Level Down Switch (PLT
J1-10) closed • Platform Level
FUNCTION ENABLE Down Switch
INTERLOCK – ENABLE Platform controls • Platform Rotate Left Switch (PLT
2227 5000mS open
SWITCH NOT SELECTED prevented J1-8) closed
FIRST • Platform Rotate
• Platform Rotate Right Switch
Left Switch open
(PLT J1-7) closed
• Platform Rotate
• Platform Lift Joystick (PLT J5-3)
Right Switch
not neutral
open
• Platform Telescope Joystick (PLT
• Platform Lift
J5-4) not neutral
Joystick neutral
• Platform Tele-
scope Joystick
neutral

Machine Setup’s REMOTE CONTROL is YES;

Remote Control Mode; Remote Function All of the following are
Enable Switch closed after any of the met:
following events:

FUNCTION ENABLE • Remote Control Joystick 1 not • Remote Func-

INTERLOCK – ENABLE Remote controls neutral tion Enable
2227 5000mS
SWITCH NOT SELECTED prevented • Remote Control Joystick 2 not Switch not
FIRST neutral engaged
• Remote Control Joystick 3 not • Remote Control
neutral Joysticks are
• Remote Control Joystick 4 not Neutral
neutral

Machine Setup’s PLATFORM OPTION is

FUNCTION ENABLE
Platform controls YES; Platform Mode; Function Enable Function Enable Switch
INTERLOCK – NOT 2228 N/A
prevented Switch engaged; 7,000mS expired before a not engaged
SELECTED IN TIME
hydraulic function was activated

3614RS, 4017RS 31211337 9-75

 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s REMOTE CONTROL
FUNCTION ENABLE OPTION is YES; Remote Control Mode; Remote Function Enable
Remote controls
INTERLOCK – NOT 2228 N/A Remote Function Enable Switch engaged; Switch
prevented
SELECTED IN TIME 7,000mS expired before a hydraulic not engaged
function was activated

All of the following are

met:
ENGINE START Machine Setup’s PLATFORM OPTION is • Function Enable
PREVENTED – FUNCTION Platform engine YES; Platform Mode; Function Enable Switch not
2229 5000mS
ENABLE SWITCH start prevented Switch engaged; Platform Engine Start engaged
ENGAGED Switch (PLT J1-14) closed • Platform Engine
Start Switch
open

All of the following are

met:
• Remote Func-
ENGINE START Machine Setup’s REMOTE CONTROL is YES;
tion Enable
PREVENTED – FUNCTION Remote engine Remote Control Mode; Remote Function
2229 5000mS Switch not
ENABLE SWITCH start prevented Enable Switch engaged; Remote Engine
engaged
ENGAGED Start Switch closed
• Remote Engine
Start Switch
open

• Platform
Lift Up &
Down Machine Setup’s PLATFORM OPTION is
pre- YES; Platform Mode;
vented any of the follow events occurs:
PLATFORM JOYSTICK –
2230 5000mS • Platform • PLT J5-3 Main Lift Joystick wiper Power cycled
OUT OF RANGE HIGH
Tele- is out of range
scope In • PLT J5-4 Main Telescope Joystick
& Out wiper is out of range
pre-
vented

• Platform
Lift Up &
Down Machine Setup’s PLATFORM OPTION is
pre- YES; Platform Mode;
vented any of the follow events occurs:
PLATFORM JOYSTICK –
2231 5000mS • Platform • PLT J5-2 Platform Lift Joystick Power cycled
CENTER TAP BAD
Tele- center tap is out of range
scope In • PLT J5-5 Platform Telescope Joy-
& Out stick center tap is out of range
pre-
vented

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 Electrical System

9.16.4 Ground Inputs (23x)

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Platform Engine • Machine Setup’s PLATFORM
Start prevented OPTION is YES; COLUMN
• Platform controls SELECTOR is YES; Transition to
prevented Platform Mode is requested; Column Selector set
OPERATING MODE Drive Forward or Drive to Drive Neutral
• Operating Mode
INTERLOCK – SHIFTER 239 5000mS Reverse selected Cabin Joystick’s FNR
transitions are pre-
NOT IN NEUTRAL • Machine Setup’s PLATFORM Switch set to
vented
OPTION is YES; JOYSTICK FNR Neutral
is YES; Transition to Platform
Mode is requested; Drive For-
ward or Reverse selected

• Remote Engine • Machine Setup’s REMOTE

Start prevented CONTROL is YES; COLUMN
• Remote controls SELECTOR is YES; Remote
prevented Control Mode is requested; Column Selector set
OPERATING MODE Drive Forward or Drive to Drive Neutral
• Operating Mode
INTERLOCK – SHIFTER 239 5000mS Reverse selected Cabin Joystick’s FNR
transitions are pre-
NOT IN NEUTRAL • Machine Setup’s REMOTE Switch set to
vented
CONTROL is YES; JOYSTICK Neutral
FNR is YES; Remote Control
Mode is requested; Drive For-
ward or Reverse selected

• Platform controls Machine Setup’s PLATFORM OPTION is

prevented NO and any of the following occur:
• Operating Mode • RFCM J3-E2 Platform Attached
PLATFORM OPTION transitions are pre- is closed
2311 5000mS vented Power cycled
NOT CONFIGURED • Platform Module CANbus
detected
• CCM J2-J1 Platform Mode
energized

• Hydraulic func-
tions prevented
• Direction Selection
OPERATING STATION CCM J2-J1 Platform Mode and CCM J2-
2314 5000mS Neutral Power cycled
SELECTION INVALID L1 Key-On energized simultaneously
• Operating Mode
transitions are pre-
vented

• Lift Up and Tele-

scope Out pre-
vented when the
boom angle is
greater than +10°
OPERATING MODE • Lift Down pre-
Machine Setup’s PLATFORM OPTION is
INTERLOCK – vented when the
2315 5000mS YES; Outriggers Set
OUTRIGGERS NOT boom angle is
Keyswitch Platform; Outriggers Not Set
DEPLOYED greater than +10°
and not fully
retracted
• Operating Mode
transitions are pre-
vented

3614RS, 4017RS 31211337 9-77

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Platform controls
prevented
OPERATING MODE Machine Setup’s PLATFORM OPTION is
• Platform Engine
INTERLOCK – YES;
2316 5000mS Start prevented Platform Attached
PLATFORM NOT Keyswitch Platform; RFCM J3-E2
ATTACHED • Operating Mode Platform Attached is open
transitions are pre-
vented

• Main Lift Up, Lift

Down, and Tele-
scope In function
speeds are de-
rated when the
chassis is tilted and
the engine is run-
OPERATING MODE ning (after power-
INTERLOCK – CHASSIS 2317 5000mS up) Keyswitch Platform; chassis tilted Chassis not tilted
NOT LEVEL
• Telescope Out is
prevented when
the chassis is tilted
(after power-up)
• Operating Mode
transitions are pre-
vented

• Engine start pre-

vented Machine Setup’s PLATFORM OPTION is
OPERATING MODE
YES; boom angle > +10°;
INTERLOCK – BOOM 2318 5000mS • Operating Mode Boom angle < +10°
transition from cabin to platform or
ANGLE TOO HIGH transitions are pre- platform to cabin in progress
vented

• Engine start pre-

vented Machine Setup’s PLATFORM OPTION is
OPERATING MODE
YES; boom not retracted; Boom fully
INTERLOCK – BOOM 2319 5000mS • Operating Mode transition from cabin to platform or retracted
NOT FULLY RETRACTED transitions are pre- platform to cabin in progress
vented

• Engine start pre-

vented
Machine Setup’s PLATFORM OPTION is
OPERATING MODE • Hydraulic func-
YES;
INTERLOCK – PARK 2320 5000mS tions prevented Park Brake applied
Transition to Platform Mode is
BRAKE NOT SET • Operating Mode requested; Park Brake released
transitions are pre-
vented

• Remote controls
prevented
Machine Setup’s REMOTE CONTROL is
OPERATING MODE • Remote engine
YES;
INTERLOCK – PARK 2320 5000mS start prevented Park Brake applied
Remote Control Mode is requested; Park
BRAKE NOT SET • Operating Mode Brake is released
transitions are pre-
vented

Machine Setup’s PLATFORM OPTION is

ERRATIC PLATFORM Platform assumed to be YES; RFCM J3-E2 Platform Attached
2321 5000mS Power cycled
ATTACHED SIGNAL attached changes state three times within
5,000mS

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 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
Machine Setup’s FRAME LEVELING is YES
or PROP; CCM J1-F2 Frame Level Left
CONFLICTING FRAME Frame Level Left & Right are
2322 5000mS Switch and CCM J1-F3 Frame Level Right Power cycled
LEVEL SIGNALS prevented
Switch are closed (energized)
simultaneously for 500mS

• Telescope In / Out Cabin Joystick’s X-Axis circuitry has

prevented in encountered one of the following
Framer Mode issues:
• Fork Tilt Up / Down • DM1 (520208:2) active
prevented in • DM1 (520209:2) active
Loader Mode
• DM1 (520210:2) active
• XAxisValue is ERROR (1022) or
CABIN JOYSTICK – X N/A (1023)
2323 Continuously Power cycled
AXIS FAULT • XAxisNeutral, XAxisLeft, or
XAxisRight is ERROR (2) or N/A
(3)
• XAxisNeutral, XAxisLeft, or
XAxisRight are CLOSED (1) at
the same time
• XAxisNeutral, XAxisLeft, and
XAxisRight are OPEN (0) at the
same time

Cabin Joystick’s Y-Axis circuitry has

encountered one of the following
issues:
• DM1 (520224:2) active
• DM1 (520225:2) active
• DM1 (520226:2) active
• YAxisValue is ERROR (1022) or
CABIN JOYSTICK – Y N/A (1023)
2324 Continuously Lift Up / Down prevented Power cycled
AXIS FAULT • YAxisNeutral, YAxisForward, or
YAxisBackward is ERROR (2) or
N/A (3)
• YAxisNeutral, YAxisForward, or
YAxisBackward are CLOSED (1)
at the same time
• YAxisNeutral, YAxisForward,
and YAxisBackward are OPEN
(0) at the same time

• Continuous Auxil- Machine Setup’s VEHICLE is LBP-RS,

iary Hydraulics AUXILIARY HYDRAULICS is YES, and
functionality pre- Cabin Joystick’s Position 2 (middle)
vented Pushbutton circuitry has encountered
CABIN JOYSTICK – AUX one of the following issues:
2330 Continuously • Auxiliary De-Com- Power cycled
CONTINUOUS FAULT
pression function- • Cabin Joystick DM1
ality prevented (520290:31) active
• Position 2 Pushbutton status
is ERROR (2) or N/A (3)

Hydraulic Filter Restriction Ten minutes after power-up, FFCM J3-F3 Hydraulic Filter
HYDRAULIC FILTER
2332 5000mS icon is shown on Parker Cabin Hydraulic Filter Pressure Switch is closed Pressure Switch
RESTRICTION
Display (energized) for 3,000mS open for 1,000mS

3614RS, 4017RS 31211337 9-79

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Boom Angle Sensor
is +99°
• RAS Restricted
• HIRAS Mode is
forced to ERROR
• Start HIRAS Integ-
BOOM ANGLE SENSOR rity Checks is pre- Boom Angle Sensor calibration factors Calibrate boom
2343 5000mS
– NOT CALIBRATED vented are defaults angle sensor
• Main Lift Derate for
Automatic Fork
Leveling is acti-
vated
• Boom Damping
prevented

• Boom Angle Sensor

is +99°
• RAS Restricted
Machine Setup’s CAN BOOM ANGLE is
BOOM ANGLE SENSOR • Main Lift Derate for NO;
2344 5000mS Automatic Fork Power cycled
– OUT OF RANGE HIGH RFCM J1-A1 Boom Angle Sensor Signal
Leveling is acti- >4.5V for 250mS
vated
• Boom Damping
prevented

• Boom Angle Sensor

is +99°
• RAS Restricted
Machine Setup’s CAN BOOM ANGLE is
BOOM ANGLE SENSOR • Main Lift Derate for NO;
2345 5000mS Automatic Fork Power cycled
– OUT OF RANGE LOW RFCM J1-A1 Boom Angle Sensor Signal
Leveling is acti- <0.5V for 250mS
vated
• Boom Damping
prevented

9-80 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Boom Angle Sensor All of the following conditions are
is +99° present:
• RAS Restricted / • Engine Operating State is
Locked Engine Running
• HIRAS Mode is • Debug’s BOOM NR is NO
forced to ERROR • BOOM ANGLE SENSOR – NOT
• Start HIRAS Integ- CALIBRATED (2343) fault not
rity Checks is pre- active
vented • BOOM ANGLE SENSOR – OUT
• Main Lift Derate for OF RANGE LOW (2345) fault
Automatic Fork not active
Leveling is acti- • BOOM ANGLE SENSOR – OUT
vated OF RANGE HIGH (2344) fault
• Boom Damping not active
prevented • LIFT – CURRENT FEEDBACK
READING TOO LOW (33287)
fault not active
• Boom angle > Lower Limit
BOOM ANGLE SENSOR (boom has not reached mini-
2346 5000mS Power cycled
– NOT RESPONDING mum angle)
• Boom angle < Upper Limit
(boom has not reached axi-
mum angle)
• Main Lift Up Command > Lift
Up Detection or Main Lift
Down Command > Stagna-
tion Lift Down Detection
(operator is commanding
boom lift or lower)
• Telescope Out Command <
Maximum Telescope Out and
Telescope In Command <
Maximum Telescope In (oper-
ator is not commanding
boom extend or retract)
• Boom angle reading does not
change > 0.5° for 4,000mS
(sensor is not detecting boom
motion)

Engine running, cabin mode, cabin

joystick is not neutral, and one of the
following situations occurs.
• Hydraulic Quick Connect
functionality de-activated
• Auxiliary De-Compression
Entire cabin joystick
SYSTEM INTERLOCK – Cabin Joystick X-Axis, Y-Axis, Switch closed
is
SET JOYSTICK INPUTS 2347 - Left Roller, and Right Roller • Bucket mode active and Plat- neutral
TO NEUTRAL prevented (0%) form becomes attached momentarily
• Joystick Lock functionality
active
• LSI Cancel Switch becomes
closed (Cabin Joystick must be
neutral prior to switch clo-
sure)

3614RS, 4017RS 31211337 9-81

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
CCM J1-C3 Start Switch is closed
ENGINE START INPUT – Switch is open for
2348 5000mS Engine Start prevented (energized) after the engine is running
INVALID SIGNAL 1,000mS
for more than 7,000mS

Remote Engine Start Switch is closed

ENGINE START INPUT – Switch is open for
2348 5000mS Engine Start prevented after the engine is running for more
INVALID SIGNAL 1,000mS
than 7,000mS

Cabin Joystick
neutral for 150mS
and any of the
Machine Setup’s MODEL is TH417D or following
4017RS and all of the following conditions are
conditions are present. present:
LIFT ANGLE DERATED –
OUTRIGGERS NOT 2349 5000mS Lift Up prevented • Outriggers are not set • Outrig-
DEPLOYED • Boom angle sensor healthy gers are
set
• Boom angle is greater than
+60° • Boom
angle is
less than
+55°

Cabin Joystick’s Left Roller circuitry has

encountered one of the following
issues:
• DM1 (520240:2) active
• DM1 (520241:2) active
• DM1 (520242:2) active
• Left Roller Value is ERROR
(1022) or N/A (1023)
• Left Roller Neutral, Left Roller
CABIN JOYSTICK – LEFT
2350 Continuously Left Roller prevented (0%) Forward, or Left Roller Back- Power cycled
ROLLER FAULT
ward is ERROR (2) or N/A (3)
• Left Roller Neutral, Left Roller-
Forward, or Left Roller Back-
ward are CLOSED (1) at the
same time
• Left Roller Neutral, Left Roller-
Forward, and Left Roller Back-
ward are OPEN (0) at the same
time

9-82 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
Machine Setup’s AUXILIARY
HYDRAULICS is YES, Cabin Joystick’s
Right Roller circuitry has encountered
one of the following issues:
• DM1 (520256:2) active
• DM1 (520257:2) active
• DM1 (520258:2) active
• RightRollerValue is ERROR
(1022) or N/A (1023)
CABIN JOYSTICK – • RightRollerNeutral, RightRol-
2351 Continuously Right Roller prevented (0%) Power cycled
RIGHT ROLLER FAULT lerForward, or RightRoller-
Backward is ERROR (2) or N/A
(3)
• RightRollerNeutral, RightRol-
lerForward, or RightRoller-
Backward are CLOSED (1) at
the same time
• RightRollerNeutral, RightRol-
lerForward, and RightRoller-
Backward are OPEN (0) at the
same time

• Boom Angle Sensor • Machine Setup’s CAN BOOM

is +99° ANGLE is YES; the primary and
• RAS Restricted / backup sensor readings dis-
Locked agree by more than 7 counts
(2.5°) for 1,000mS
• HIRAS Mode is
forced to ERROR • Machine Setup’s CAN BOOM
ANGLE is YES; the primary or
• Start HIRAS Integ- backup sensor reading was
rity Checks is pre- greater than 250 counts (out
BOOM ANGLE SENSOR vented
2353 Continuously of range) Power cycled
– INTERNAL FAILURE • Hydraulics pre-
vented in Platform
Mode
• Main Lift Derate for
Automatic Fork
Leveling is acti-
vated
• Boom Damping
prevented

• Lift Up, Lift Down,

Telescope In, and
Telescope Out Machine Setup’s PLATFORM OPTION
OPERATING INTERLOCK
function speeds is YES; Hydraulic Coupler
– ATTACHMENT
2354 5000mS de-rated Keyswitch Platform; Hydraulic Pin Engaged for
COUPLING PIN NOT
Coupler Pin Not Engaged 3,000mS
ENGAGED • Operating Mode
transitions are pre-
vented

3614RS, 4017RS 31211337 9-83

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
Cabin Joystick’s FNR Switch circuitry has
encountered one of the following
issues:
• DM1 (520272:2) active
• DM1 (520273:2) active
• DM1 (520274:2) active
• FNRSwitchValue is ERROR
(1022) or N/A (1023)
• FNRSwitchNeutral, FNR-
CABIN JOYSTICK – FNR FNR Switch prevented
23115 Continuously SwitchForward, or FNR- Power cycled
SWITCH FAULT (Neutral)
SwitchReverse is ERROR (2) or
N/A (3)
• FNRSwitchNeutral, FNR-
SwitchForward, or FNR-
SwitchReverse are CLOSED (1)
at the same time
• FNRSwitchNeutral, FNR-
SwitchForward, and FNR-
SwitchReverse are OPEN (0) at
the same time

• LSI Cancel Switch is Machine Setup’s LOAD STABILITY is YES;

ignored any of these conditions exist:
FUNCTION PROBLEM – • LSI Verification pre- • CCM J2-D4 LSI Cancel Switch
LSI OVERRIDE vented is closed (energized) at
23116 5000mS Power cycled
PERMANENTLY power-up
SELECTED • CCM J2-D4 LSI Cancel Switch
is closed for more than 30 sec-
onds

Machine Setup’s FAN CONTROL is

HIGH HYDRAULIC High Hydraulic Temperature Hydraulic Oil
HYDRAULIC, HYD W/ REV, or DUAL HYD;
TEMPERATURE 23117 5000mS Indicator is illuminated on Temperature less
Hydraulic Oil Temperature greater than
WARNING Parker Cabin Display than +100°C
+120°C for 3,000mS

Machine Setup’s HYD TEMP MGMT is

HIGH HYDRAULIC High Hydraulic Temperature Hydraulic Oil
YES and VEHICLE is LBP-HC or LBP-SC;
TEMPERATURE 23117 5000mS Indicator is illuminated on Temperature less
Hydraulic Oil Temperature greater than
WARNING Parker Cabin Display than +90°C
+95°C for 3,000mS

Machine Setup’s FAN CONTROL is HYD

W/ REV, DUAL HYD, or CLEANFIX; and
FAN REVERSE DEMAND one of these conditions exist:
SWITCH – Fan Reverse Demand • CCM J2-C4 Fan Reverse Switch
23118 5000mS Power cycled
PERMANENTLY prevented is closed at power-up
SELECTED • CCM J2-C4 Fan Reverse Switch
is closed for more than 10 sec-
onds

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 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Engine Start pre- All of the following
vented conditions are
• Direction Selection present:
is Neutral • Cabin joy-
Cabin Mode; Machine Setup’s stick neu-
• Main Lift prevented
OPERATOR PRESENCE is YES; Cabin tral
• Telescope pre- Mode; operator is not present; and at
vented least one of these conditions exist: • Frame
Level
• Auxiliary Hydrau- • Cabin joystick is not neutral Switches
lics prevented
• Frame Level Left Switch is open
• Hydraulic Quick closed • Outrig-
Connect prevented
• Frame Level Right Switch is ger joy-
• Auxiliary De-Com- closed sticks
OPERATING MODE pression prevented
• Outrigger Left Joystick is not neutral
INTERLOCK – 23120 Continuously
OPERATOR PRESENCE • Outriggers pre- neutral • Park
vented Brake
• Outrigger Right Joystick is not
• Frame Leveling neutral applied
prevented or Opera-
• Park Brake is released tor is
• Rear Auxiliary 1 Joystick is not Present
neutral • Rear Aux-
• Rear Auxiliary 2 Joystick is not iliary 1 & 2
neutral Joysticks
• Engine Start Switch is closed neutral
• Engine
Start
Switch is
open

• Machine Setup’s O/R JOY-

STICKS is YES; CCM J1-C1 Out-
rigger Left Joystick (Primary) is
OUTRIGGER LEFT greater than 4.75V
Outrigger Left Joystick
JOYSTICK – OUT OF 23132 5000mS Power cycled
position is 0% • Machine Setup’s O/R JOY-
RANGE HIGH
STICKS is YES; CCM J1-D1 Out-
rigger Left Joystick (Backup) is
greater than 4.75V

• Machine Setup’s O/R JOY-

STICKS is YES; CCM J1-C1 Out-
rigger Left Joystick (Primary) is
OUTRIGGER LEFT less than 0.25V
Outrigger Left Joystick
JOYSTICK – OUT OF 23133 5000mS Power cycled
position is 0% • Machine Setup’s O/R JOY-
RANGE LOW
STICKS is YES; CCM J1-D1 Out-
rigger Left Joystick (Backup) is
less than 0.25V

Machine Setup’s O/R JOYSTICKS is YES;

OUTRIGGER LEFT Scaled Outrigger Left Joystick (Primary)
Outrigger Left Joystick
JOYSTICK – VOLTAGE 23134 5000mS and Scaled Outrigger Left Joystick Power cycled
position is 0%
DISAGREEMENT (Backup) differ by more than 10% for
500mS

3614RS, 4017RS 31211337 9-85

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Machine Setup’s O/R JOY-
STICKS is YES; CCM J1-E1 Out-
rigger Right Joystick (Primary)
OUTRIGGER RIGHT is greater than 4.75V
Outrigger Right Joystick
JOYSTICK – OUT OF 23135 5000mS Power cycled
position is 0% • Machine Setup’s O/R JOY-
RANGE HIGH
STICKS is YES; CCM J1-F1 Out-
rigger Right Joystick (Backup)
is greater than 4.75V

• Machine Setup’s O/R JOY-

STICKS is YES; CCM J1-E1 Out-
rigger Right Joystick (Primary)
OUTRIGGER RIGHT is less than 0.25V
Outrigger Right Joystick
JOYSTICK – OUT OF 23136 5000mS Power cycled
position is 0% • Machine Setup’s O/R JOY-
RANGE LOW
STICKS is YES; CCM J1-F1 Out-
rigger Right Joystick (Backup)
is less than 0.25V

Machine Setup’s O/R JOYSTICKS is YES;

OUTRIGGER RIGHT Scaled Outrigger Right Joystick
Outrigger Right Joystick
JOYSTICK – VOLTAGE 23137 5000mS (Primary) and Scaled Outrigger Right Power cycled
position is 0%
DISAGREEMENT Joystick (Backup) differ by more than
10% for 500mS

Hitch Configured; CCM J1-F3 Hitch Up

CONFLICTING HITCH Hitch Up & Down are Switch and CCM J1-F2 Hitch Down
23138 5000mS Power cycled
SIGNALS prevented Switch are closed (energized)
simultaneously for 500mS

• All Wheel Steer Switch (CCM

J1-D4), Two Wheel Steer
Switch (CCM J1-G1), or Crab
Steer Switch (CCM J1-H1) are
energized simultaneously for
CONFLICTING STEER Current Steering Mode is 500mS
23139 5000mS Power cycled
SIGNALS maintained • All Wheel Steer Switch (CCM
J1-D4), Two Wheel Steer
Switch (CCM J1-G1), and Crab
Steer Switch (CCM J1-H1) are
de-energized simultaneously
for 500mS

Cabin joystick
FUNCTION PROBLEM – CCM J2-H4 Framer Mode Switch neutral and Framer
Previous Framer / Loader
FRAMER MODE SWITCH 23140 5000mS changed state while the cabin joystick Mode Switch state
Mode is maintained
CHANGED was not neutral is maintained for
1,000mS

Cabin joystick
FUNCTION PROBLEM – CCM J2-J4 Bucket Mode Switch changed neutral and Bucket
Previous Bucket Mode Switch
BUCKET MODE SWITCH 23146 5000mS state while the cabin joystick was not Mode Switch state
selection is maintained
CHANGED neutral is maintained for
1,000mS

Machine Setup’s OUTRIGGERS is YES, O/

R JOYSTICKS is NO, and the Cabin
Joystick encounters one of the following
CABIN JOYSTICK – Outrigger Pushbutton issues:
23156 5000mS Power cycled
OUTRIGGER SW FAULTY prevented (Open)
• DM1 (520289:31) active
• OutriggerBoomFloatPushbut-
ton is ERROR (2) or N/A (3)

9-86 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
Machine Setup’s BOOM RIDE&FLOAT is
RIDE&FLOAT and the Cabin Joystick
CABIN JOYSTICK – encounters one of the following issues:
Boom Float Pushbutton
BOOM FLOAT SW 23157 5000mS Power cycled
prevented (Open) • DM1 (520289:31) active
FAULTY
• OutriggerBoomFloatPushbut-
ton is ERROR (2) or N/A (3)

Machine Setup’s VEHICLE is not LBP-RS,

AUX FUNCTION SELECT is YES, Cabin
Joystick’s Auxiliary 1/2 Pushbutton
CABIN JOYSTICK – AUX Auxiliary 1/2 Pushbutton circuitry has encountered one of the
23158 5000mS following issues: Power cycled
1/2 SW FAULTY prevented (Open)
• DM1 (520290:31) active
• AuxiliarySelectPushbutton is
ERROR (2) or N/A (3)

Cabin Joystick’s Upshift Pushbutton

circuitry has encountered one of the
CABIN JOYSTICK – Upshift prevented following issues:
23159 5000mS Power cycled
UPSHIFT SW FAULTY Downshift prevented • DM1 (520292:31) active
• UpshiftPushbutton is ERROR
(2) or N/A (3)

Cabin Joystick’s Downshift Pushbutton

circuitry has encountered one of the
CABIN JOYSTICK – Upshift prevented following issues:
DOWNSHIFT SW 23160 5000mS Power cycled
Downshift prevented • DM1 (520293:31) active
FAULTY
• DownPushbutton is ERROR (2)
or N/A (3)

ANY of the following conditions are

present:
• Machine Setup’s VEHICLE is
not LBP-RS and JOYSTICK FNR
is NO
• Machine Setup’s VEHICLE is
LBP-RS
CABIN JOYSTICK – • Machine Setup’s VEHICLE is
23161 5000mS De-Clutch prevented not LBP-HC or LBP-SC Power cycled
DECLUTCH SW FAULTY

AND the Cabin Joystick’s De-Clutch

Pushbutton circuitry has encountered
one of the following issues:
• DM1 (520294:31) active
• DeClutchPushbutton is ERROR
(2) or N/A (3)

Machine Setup’s VEHICLE is LBP-AG;

PROPORTIONAL
Proportional Travel Speed is TRANSMISSION is BOSCH HYSTAT;
TRAVEL SPEED – OUT 23165 5000mS Power cycled
0% CCM J3-E4 Proportional Travel Speed <
OF RANGE LOW
0.25V for 500mS

Machine Setup’s VEHICLE is LBP-AG;

PROPORTIONAL
Proportional Travel Speed is TRANSMISSION is BOSCH HYSTAT;
TRAVEL SPEED – OUT 23166 5000mS Power cycled
0% CCM J3-E4 Proportional Travel Speed >
OF RANGE HIGH
4.75V for 500mS

3614RS, 4017RS 31211337 9-87

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
Brake Pedal Position Configured;
BRAKE PEDAL POSITION
23167 5000mS Brake Pedal Position is 0% CCM J3-F4 Brake Pedal Position < 0.25V Power cycled
– OUT OF RANGE LOW
for 500mS

Brake Pedal Position Configured;

BRAKE PEDAL POSITION
23168 5000mS Brake Pedal Position is 0% CCM J3-F4 Brake Pedal Position > 4.75V Power cycled
– OUT OF RANGE HIGH
for 500mS

Machine Setup’s VEHICLE is LBP-AG;

TRANSMISSION is BOSCH HYSTAT;
TRAVEL MODE SWITCH
23169 5000mS Loader Travel Mode selected CCM J3-A1 Proportional Travel Mode Power cycled
FAULTY
and CCM J3-A2 Roading Travel Mode are
both energized for 500mS

Machine Setup’s VEHICLE is LBP-AG and

one of these conditions exist:
HAND THROTTLE
• CCM J3-A3 Hand Throttle
SWITCH – Hand Throttle Switch is
23174 5000mS Switch is closed at power-up Power cycled
PERMANENTLY ignored
SELECTED • CCM J3-A3 Hand Throttle
Switch is closed for more than
10 seconds

• Brake Pedal Pres- Machine Setup’s BRAKE PEDAL

BRAKE PEDAL sure is 3000PSI PRESSURE is YES;
PRESSURE – OUT OF 23175 5000mS Power cycled
• De-Clutch pre- FFCM J1-F2 Brake Pedal Pressure <
RANGE LOW
vented 0.25V for 500mS

• Brake Pedal Pres- Machine Setup’s BRAKE PEDAL

BRAKE PEDAL sure is 3000PSI PRESSURE is YES;
PRESSURE – OUT OF 23176 5000mS Power cycled
• De-Clutch pre- FFCM J1-F2 Brake Pedal Pressure >
RANGE HIGH
vented 4.75V for 500mS

• Machine Setup’s AUXILIARY F/

R SELECT is YES; CCM J1-C1
Rear Auxiliary 1 Joystick (Pri-
REAR AUXILIARY 1 mary) is greater than 4.75V
Rear Auxiliary 1 Joystick
JOYSTICK – OUT OF 23177 5000mS Power cycled
position is 0% • Machine Setup’s AUXILIARY F/
RANGE HIGH
R SELECT is YES; CCM J1-D1
Rear Auxiliary 1 Joystick
(Backup) is greater than 4.75V

• Machine Setup’s AUXILIARY F/

R SELECT is YES; CCM J1-C1
Rear Auxiliary 1 Joystick (Pri-
REAR AUXILIARY 1 mary) is less than 0.25V
Rear Auxiliary 1 Joystick
JOYSTICK – OUT OF 23178 5000mS Power cycled
position is 0% • Machine Setup’s AUXILIARY F/
RANGE LOW
R SELECT is YES; CCM J1-D1
Rear Auxiliary 1 Joystick
(Backup) is less than 0.25V

Machine Setup’s AUXILIARY F/R SELECT

is YES;
REAR AUXILIARY 1
Rear Auxiliary 1 Joystick Scaled Rear Auxiliary 1 Joystick (Primary)
JOYSTICK – VOLTAGE 23179 5000mS Power cycled
position is 0% and Scaled Rear Auxiliary 1 Joystick
DISAGREEMENT
(Backup) differ by more than 10% for
500mS

9-88 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Machine Setup’s AUXILIARY
REAR SELECT; CCM J1-E1 Rear
Auxiliary 2 Joystick (Primary) is
REAR AUXILIARY 2 greater than 4.75V
Rear Auxiliary 2 Joystick
JOYSTICK – OUT OF 23180 5000mS Power cycled
position is 0% • Machine Setup’s AUXILIARY
RANGE HIGH
REAR SELECT is YES; CCM J1-
F1 Rear Auxiliary 2 Joystick
(Backup) is greater than 4.75V

• Machine Setup’s AUXILIARY

REAR SELECT is YES; CCM J1-
E1 Rear Auxiliary 2 Joystick
REAR AUXILIARY 2 (Primary) is less than 0.25V
Rear Auxiliary 2 Joystick
JOYSTICK – OUT OF 23181 5000mS Power cycled
position is 0% • Machine Setup’s AUXILIARY
RANGE LOW
REAR SELECT is YES; CCM J1-
F1 Rear Auxiliary 2 Joystick
(Backup) is less than 0.25V

Machine Setup’s AUXILIARY REAR

SELECT is YES;
REAR AUXILIARY 2
Rear Auxiliary 2 Joystick Scaled Rear Auxiliary 2 Joystick (Primary)
JOYSTICK – VOLTAGE 23182 5000mS Power cycled
position is 0% and Scaled Rear Auxiliary 2 Joystick
DISAGREEMENT
(Backup) differ by more than 10% for
500mS

Brake Pedal Position Configured and

one of the following occurs:
• Brake Pedal Position 0% Cali-
bration set to default
• Brake Pedal Position 100%
Calibration set to default
• Brake Pedal Position 0% Cali- Calibration
BRAKE PEDAL POSITION bration out of range (0.5 to
23183 5000mS Brake Pedal Position is 0% successful or
– NOT CALIBRATED 4.5V) power cycled
• Brake Pedal Position 100%
Calibration out of range (0.5
to 4.5V)
• Brake Pedal Position 0% Cali-
bration – Brake Pedal
Position 100% Calibration <
0.25V

• Outrigger Left
OUTRIGGER LEFT Extend Pressure is 0 Machine Setup’s O/R DETECTION is
EXTEND PRESSURE – 23184 5000mS PSI / BAR PRESS or PRESS & PROX; FFCM J1-A1 > Power cycled
OUT OF RANGE HIGH • Outrigger Left Not 4.75V for 500mS
Set

• Outrigger Left
OUTRIGGER LEFT Extend Pressure is 0 Machine Setup’s O/R DETECTION is
EXTEND PRESSURE – 23185 5000mS PSI / BAR PRESS or PRESS & PROX; FFCM J1-A1 < Power cycled
OUT OF RANGE LOW • Outrigger Left Not 0.25V for 500mS
Set

• Outrigger Left
OUTRIGGER LEFT Retract Pressure is Machine Setup’s O/R DETECTION is
RETRACT PRESSURE – 23186 5000mS 0 PSI / BAR PRESS or PRESS & PROX; FFCM J3-E4 > Power cycled
OUT OF RANGE HIGH • Outrigger Left Not 4.75V for 500mS
Set

3614RS, 4017RS 31211337 9-89

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Outrigger Left
OUTRIGGER LEFT Retract Pressure is Machine Setup’s O/R DETECTION is
RETRACT PRESSURE – 23187 5000mS 0 PSI / BAR PRESS or PRESS & PROX; FFCM J3-E4 < Power cycled
OUT OF RANGE LOW • Outrigger Left Not 0.25V for 500mS
Set

• Outrigger Right
OUTRIGGER RIGHT Extend Pressure is 0 Machine Setup’s O/R DETECTION is
EXTEND PRESSURE – 23188 5000mS PSI / BAR PRESS or PRESS & PROX; FFCM J1-D1 > Power cycled
OUT OF RANGE HIGH • Outrigger Right 4.75V for 500mS
Not Set

• Outrigger Right
OUTRIGGER RIGHT Extend Pressure is 0 Machine Setup’s O/R DETECTION is
EXTEND PRESSURE – 23189 5000mS PSI / BAR PRESS or PRESS & PROX; FFCM J1-D1 < Power cycled
OUT OF RANGE LOW • Outrigger Right 0.25V for 500mS
Not Set

• Outrigger Right
OUTRIGGER RIGHT Retract Pressure is Machine Setup’s O/R DETECTION is
RETRACT PRESSURE – 23190 5000mS 0 PSI / BAR PRESS or PRESS & PROX; FFCM J3-F4 > Power cycled
OUT OF RANGE HIGH • Outrigger Right 4.75V for 500mS
Not Set

• Outrigger Right
OUTRIGGER RIGHT Retract Pressure is Machine Setup’s O/R DETECTION is
RETRACT PRESSURE – 23191 5000mS 0 PSI / BAR PRESS or PRESS & PROX; FFCM J3-F4 < Power cycled
OUT OF RANGE LOW • Outrigger Right 0.25V for 500mS
Not Set

Machine Setup’s BRAKE OIL SENSORS is

YES or Machine Setup’s TRAILER BRAKE
is AGRICULTURAL; and all of the
Service Brake Fault indicator following conditions are present:
SERVICE BRAKE – LOW
23241 5000mS is energized on Parker Cabin Power cycled
OIL LEVEL • Engine Running for 10,000mS
Display
• CCM J2-H3 Service Brake Oil
Level Switch is open for
2,000mS .

Machine Setup’s BRAKE OIL SENSORS is

YES or Machine Setup’s TRAILER BRAKE
is AGRICULTURAL; and all of the
following conditions are present:
Service Brake Fault indicator
SERVICE BRAKE – LOW • Engine Running for 10,000mS
23242 5000mS is energized on Parker Cabin Power cycled
OIL PRESSURE • FFCM J3-E2 Service Brake
Display
Pressure Switch is closed for
2,000mS. Note: This corre-
sponds to a pressure of <10
Bar.

9-90 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
Machine Setup’s AUTO FORK LEVEL is
YES; Fork Tilt scaled input is not 0%
(operator commanding fork tilt); Fork
Tilt Angle does not change by more
• Main Lift Derate for than 1.00° and any the following
Automatic Fork conditions are present for >2,500mS :
Leveling is acti-
FORK TILT SENSOR – vated • Tilt Cylinder Status is not
23250 5000mS Power Cycled
NOT RESPONDING EXTENDED and Fork Tilt Up
• Fork Tilt Angle is Command is greater than
assumed to be 975mA
99.99°
• Tilt Cylinder Status is not
RETRACTED and Fork Tilt
Down Command is greater
than 975mA

Machine Setup’s AUTO FORK LEVEL is

YES; Tilt Cylinder Stroke does not
• Main Lift Derate for
change by more than 2.0mm and any of
Automatic Fork
the following conditions are present for
Leveling is acti-
>2,500mS :
vated
TILT CYLINDER STROKE • Tilt Cylinder Status is not
• Tilt Cylinder Stroke
SENSOR – NOT 23251 5000mS EXTENDED and Fork Tilt Up Power Cycled
is assumed to be
RESPONDING Command is greater than
999.9mm
850mA
• Tilt Cylinder Status
• Tilt Cylinder Status is not
is assumed to be
RETRACTED and Fork Tilt
ERROR
Down Command is greater
than 850mA

• Main Lift Derate for Machine Setup’s AUTO FORK LEVEL is

Automatic Fork YES and any of the following conditions
Leveling is acti- are present for 1,000mS:
vated • Channel A Position and Chan-
TILT CYLINDER STROKE
• Tilt Cylinder Stroke nel B Position disagree by
SENSOR – INTERNAL 23252 5000mS Power Cycled
is assumed to be more than 5mm
FAILURE
999.9mm • Channel A Error is not NO
• Tilt Cylinder Status ERROR
is assumed to be • Channel B Error is not NO
ERROR ERROR

Machine Setup’s REAR AXLE STAB is

HIGH INTEGRITY and any of the
• HIRAS Pressure PT1 following conditions are present:
is assumed to be
600.0 BAR • RFCM J1-C1 HIRAS Pressure
RAS PRESSURE 1 – OUT
23254 5000mS PT1 (Primary) is greater than Power Cycled
OF RANGE HIGH • Start HIRAS Integ- 23mA
rity Checks is pre-
vented • RFCM J1-B1 HIRAS Pressure
PT1 (Backup) is greater than
23mA

Machine Setup’s REAR AXLE STAB is

• HIRAS Pressure PT1 HIGH INTEGRITY; Engine Running or
is assumed to be Stopped and any of the following
RAS PRESSURE 1 – OUT 600.0 BAR conditions are present:
23255 5000mS Power Cycled
OF RANGE LOW • Start HIRAS Integ- • RFCM J1-C1 HIRAS Pressure
rity Checks is pre- PT1 (Primary) is less than 2mA
vented • RFCM J1-B1 HIRAS Pressure
PT1 (Backup) is less than 2mA

3614RS, 4017RS 31211337 9-91

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• HIRAS Pressure PT1
is assumed to be Machine Setup’s REAR AXLE STAB is
600.0 BAR HIGH INTEGRITY; RFCM J1-C1 HIRAS
RAS PRESSURE 1 –
23256 5000mS Pressure PT1 (Primary) and RFCM J1-B1 Power Cycled
DISAGREEMENT • Start HIRAS Integ- HIRAS Pressure PT1 (Backup) disagree
rity Checks is pre- by greater than +/-50.0BAR for 500mS.
vented

Machine Setup’s REAR AXLE STAB is

HIGH INTEGRITY and any of the
• HIRAS Pressure PT2 following conditions are present:
is assumed to be
600.0 BAR • RFCM J1-A1 HIRAS Pressure
RAS PRESSURE 2 – OUT
23257 5000mS PT2 (Primary) is greater than Power Cycled
OF RANGE HIGH • Start HIRAS Integ- 23mA
rity Checks is pre-
vented • RFCM J1-D1 HIRAS Pressure
PT2 (Backup) is greater than
23mA

• Machine Setup’s REAR AXLE

STAB is HIGH INTEGRITY;
• HIRAS Pressure PT2 Engine Running or Stopped
is assumed to be and any of the following con-
RAS PRESSURE 2 – OUT 600.0 BAR ditions are present:
23258 5000mS Power Cycled
OF RANGE LOW • Start HIRAS Integ- • RFCM J1-A1 HIRAS Pressure
rity Checks is pre- PT2 (Primary) is less than 2mA
vented
• RFCM J1-D1 HIRAS Pressure
PT2 (Backup) is less than 2mA

• HIRAS Pressure PT2

is assumed to be Machine Setup’s REAR AXLE STAB is
600.0 BAR HIGH INTEGRITY; RFCM J1-A1 HIRAS
RAS PRESSURE 2 –
23259 5000mS Pressure PT2 (Primary) and RFCM J1-D1 Power Cycled
DISAGREEMENT • Start HIRAS Integ- HIRAS Pressure PT2 (Backup) disagree
rity Checks is pre- by greater than +/-50.0BAR for 500mS.
vented

Machine Setup’s REAR AXLE STAB is

HIGH INTEGRITY and any of the
• HIRAS Pressure PT3 following conditions are present:
is assumed to be
600.0 BAR • RFCM J1-E1 HIRAS Pressure
RAS PRESSURE 3 – OUT
23260 5000mS PT3 (Primary) is greater than Power Cycled
OF RANGE HIGH • Start HIRAS Integ- 23mA
rity Checks is pre-
vented • RFCM J1-F2 HIRAS Pressure
PT3 (Backup) is greater than
23mA

Machine Setup’s REAR AXLE STAB is

• HIRAS Pressure PT3 HIGH INTEGRITY; Engine Running or
is assumed to be Stopped and any of the following
RAS PRESSURE 3 – OUT 600.0 BAR conditions are present:
23261 5000mS Power Cycled
OF RANGE LOW • Start HIRAS Integ- • RFCM J1-E1 HIRAS Pressure
rity Checks is pre- PT3 (Primary) is less than 2mA
vented • RFCM J1-F2 HIRAS Pressure
PT3 (Backup) is less than 2mA

• HIRAS Pressure PT3

is assumed to be Machine Setup’s REAR AXLE STAB is
600.0 BAR HIGH INTEGRITY; RFCM J1-E1 HIRAS
RAS PRESSURE 3 –
23262 5000mS Pressure PT3 (Primary) and RFCM J1-F2 Power Cycled
DISAGREEMENT • Start HIRAS Integ- HIRAS Pressure PT3 (Backup) disagree
rity Checks is pre- by greater than +/-50.0BAR for 500mS.
vented

9-92 31211337 3614RS, 4017RS

 Electrical System

9.16.5 Other Inputs (24x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s O/R DETECTION is PRESS &
PROX, Left Outrigger Position Sensor did not
FRONT LEFT Left Outrigger Position
Left Outrigger Status is transition from high to low for 500mS during
OUTRIGGER STOW 247 5000mS Sensor transitions from
assumed to be NOT SET transition of Left Outrigger Pressure Status from
SWITCH FAULTY high to low for 500mS
STOWED to NOT SET to SET or SET to NOT SET to
STOWED

Machine Setup’s O/R DETECTION is PRESS &

PROX, Left Outrigger Position Sensor did not
FRONT RIGHT Right Outrigger Status Right Outrigger Position
transition from high to low for 500mS during
OUTRIGGER STOW 248 5000mS is assumed to be NOT Sensor transitions from
transition of Left Outrigger Pressure Status from
SWITCH FAULTY SET high to low for 500mS
STOWED to NOT SET to SET or SET to NOT SET to
STOWED

• Lift Accumu-
lator Pres- Machine Setup's BOOM DAMPING is YES and
LIFT sure 1 is either of the following:
ACCUMULATOR 600.0 BAR • LCM J1-F2 Lift Accumulator Pressure
2433 5000mS Power cycled
PRESSURE - OUT • Lift Accumu- 1 > 20 mA for 500 mS
OF RANGE HIGH lator Pres- • LCM J1-F1 Lift Accumulator Pressure
sure 2 is 2 > 20 mA for 500 mS
600.0 BAR

• Lift Accumu-
lator Pres- Machine Setup's BOOM DAMPING is YES and
LIFT sure 1 is either of the following:
ACCUMULATOR 600.0 BAR • LCM J1-F2 Lift Accumulator Pressure
2434 5000mS Power cycled
PRESSURE - OUT • Lift Accumu- 1 < 2 mA for 500 mS
OF RANGE LOW lator Pres- • LCM J1-F1 Lift Accumulator Pressure
sure 2 is 2 < 2 mA for 500 mS
600.0 BAR

• Lift Accumu-
lator Pres-
LIFT sure 1 is Machine Setup's BOOM DAMPING is YES; LCM
ACCUMULATOR 600.0 BAR J1-F2 Lift Accumulator Pressure 1 and LCM J1-
2435 5000mS Power cycled
PRESSURE - • Lift Accumu- F1 Lift Accumulator Pressure 2 disagree by
DISAGREEMENT lator Pres- more than +/- 50 BAR for 500 mS
sure 2 is
600.0 BAR

3614RS, 4017RS 31211337 9-93

 Electrical System

9.16.6 Function Prevented (25x)

Help
DTC Cabin Alarm Actions Trigger Latch Condition
Message
MODEL • Hydraulic • Machine Setup’s MODEL was changed
CHANGED – functions are
HYDRAULICS 259 Continuously prevented • Machine Setup’s BRAND, VEHICLE, MAR- Power cycle
SUSPENDED – • Engine Start KET, or PERS DEFAULT was changed
CYCLE EMS is prevented

• CCM Application and ConstantData Ver-

sions do not match
• FFCM Application and ConstantData Ver-
FUNCTIONS • Hydraulic sions do not match
LOCKED OUT – functions are
prevented • RFCM Application and ConstantData Ver-
CONSTANT 2520 Continuously Power cycled
sions do not match
DATA VERSION • Engine Start
IMPROPER is prevented • LCM Application and ConstantData Ver-
sions do not match
• TCM Application and ConstantData Ver-
sions do not match

ENGINE START
CCM J1-C3 Start Switch closed (energized);
PREVENTED – Engine Start is
2525 5000mS CCM J1-F4 Park Brake Switch released (de- Power cycle
PARK BRAKE NOT prevented
energized)
SET

Machine Setup’s REMOTE CONTROL is YES;

ENGINE START
Operating Station is Remote Control; Remote
PREVENTED – Engine Start is
2525 5000mS Engine Start Switch is closed; Power cycle
PARK BRAKE NOT prevented
CCM J1-F4 Park Brake Switch released (de-
SET
energized)

All of the following conditions exist:

EXCESSIVE • Machine Setup’s HYDRAULIC QUICK CON-

BOOM ANGLE NECT is YES Hydraulic Quick
Hydraulic Quick
FOR HYDRAULIC 2527 5000mS • Boom Angle Sensor is Healthy (no active Connect Switch
Connect prevented
QUICK CONNECT faults related to boom angle sensor) opened
OPERATION • Boom Angle > +20°
• Hydraulic Quick Connect Switch closed
PLATFORM
ATTACHED – Machine Setup’s HYDRAULIC QUICK CONNECT is Hydraulic Quick
Hydraulic Quick
HYDRAULIC 2528 5000mS YES; Cabin Mode; platform attached; Hydraulic Connect Switch
Connect is prevented
QUICK CONNECT Quick Connect Switch is closed opened
CUTOUT

Cabin Mode, CCM J1-C3 Start Switch digital input

energized, and any one of these events occurs:
ENGINE START • Machine Setup’s COLUMN SELECTOR is
PREVENTED – YES; Column Direction Switch not neutral
2529 5000mS Engine Start prevented Power cycle
SHIFT LEVER NOT • Machine Setup’s JOYSTICK FNR is YES; FNR
IN NEUTRAL Switch not neutral
• Machine Setup’s COLUMN SELECTOR is
NO and JOYSTICK FNR is NO

SHORT • Hydraulic
DETECTED ON functions are FFCM, RFCM, LCM or TCM messages detected
IGNITION WIRING 2535 Continuously prevented before Power cycle
– CHECK • Engine Start ignition relay is active
HARNESS is prevented

9-94 31211337 3614RS, 4017RS

 Electrical System

Help
DTC Cabin Alarm Actions Trigger Latch Condition
Message
• Main Lift Der- Machine Setup’s AUTO FORK LEVEL is YES and any of
ate for Auto- the following conditions are present:
matic Fork • Boom Angle Sensor and Fork Tilt Sensor
Leveling is are Unhealthy
activated
• Tilt Cylinder Stroke Sensor and Fork Tilt
• Boom Recov- Sensor are Unhealthy
BOOM ery Mode for
Automatic • Boom Angle Sensor and Tilt Cylinder
PREVENTED - Stroke Sensor are Healthy (mechanical tilt
2550 5000mS Fork Leveling Power Cycle
FUNCTION correction); Mechanical Target Fork Angle
CUTOUT ACTIVE is activated
(operator and Mechanical Actual Fork Angle dis-
must manu- agree by more than 4.0° for 500mS (Both
ally adjust ConstantData)
fork tilt to Fork Tilt Sensor is Healthy (gravity tilt correction);
reenable Filtered Gravity Fork Angle and Fork Tilt Angle
main lift func- disagree by more than 4.0° for 500mS (Both
tion) ConstantData)

BOOM
RETRACTED Debug’s BOOM NR is NO;
Boom Retracted Status Boom Retracted Switch
SENSOR FAULTY 2560 5000mS Machine Setup’s LOAD STABILITY is YES;
is Boom Not Retracted healthy
– SENSING RFCM J2-J1 Boom Retracted Switch unhealthy
INVALID

Entire cabin joystick

neutral for 1000mS
Machine Setup’s VEHICLE is LBP-PR or LBP-RS;
and one of the
Machine Setup’s MARKET is not ANSI; Boom Angle
following occurred:
Sensor Healthy; operator attempted to move
outriggers and one of the following occurred: • Boom Not
OUTRIGGERS Retracted
• Boom Not Retracted and Boom Angle >
PREVENTED – 2567 5000mS Outriggers prevented and Boom
+20°
LOWER BOOM Angle < +19°
• Boom
• Boom Retracted and Boom Angle > +60°
Retracted
and Boom
Angle < +55°

Entire cabin joystick

neutral for 1000mS
Machine Setup’s VEHICLE is LBP-PR or LBP-RS; and one of the
Machine Setup’s MARKET is ANSI; Boom Angle following occurred:
Sensor Healthy; operator attempted to move • Boom Not
OUTRIGGERS outriggers and one of the following occurred: Retracted
PREVENTED – 2567 5000mS Outriggers prevented • Boom Not Retracted and Boom Angle > and Boom
LOWER BOOM +40° Angle < +38°
• Boom
• Boom Retracted and Boom Angle > +60° Retracted
and Boom
Angle < +55°

3614RS, 4017RS 31211337 9-95

 Electrical System

Help
DTC Cabin Alarm Actions Trigger Latch Condition
Message
ALL of the following
conditions are present:
Machine Setup’s VEHICLE is LBP-SC and ALL of the
• Outrigger
following conditions are present:
Left Joystick
OUTRIGGERS • Boom Angle Sensor Healthy and Outrig-
PREVENTED – 2567 5000mS Outriggers prevented • Outrigger Left Joystick or Outrigger Right ger Right
LOWER BOOM Joystick is not neutral (operator request- Joystick are
ing outriggers) both neutral
for 1000mS
• Boom Angle > +40°
• Boom Angle
< +38°

Frame Level Left and

Right Switches open
Machine Setup’s VEHICLE is LBP-PR or LBP-RS and for 1000mS and one of
MARKET is not ANSI, or VEHICLE is LBP-HC (any the following occurred:
MARKET); Boom Angle Sensor Healthy; operator • Boom Not
FRAME LEVELING attempted to frame level and one of the following Retracted
Frame Leveling occurred:
PREVENTED – 2577 5000mS and Boom
prevented
LOWER BOOM • Boom Not Retracted and Boom Angle > Angle < +19°
+20° • Boom
• Boom Retracted and Boom Angle > +60° Retracted
and Boom
Angle < +55°

Frame Level Left and

Right Switches open
for 1000mS and one of
Machine Setup’s VEHICLE is LBP-PR or LBP-RS;
the following occurred:
Machine Setup’s MARKET is ANSI; Boom Angle
Sensor Healthy; operator attempted to frame level • Boom Not
FRAME LEVELING and one of the following occurred: Retracted
Frame Leveling
PREVENTED – 2577 5000mS and Boom
prevented • Boom Not Retracted and Boom Angle >
LOWER BOOM Angle < +38°
+40°
• Boom
• Boom Retracted and Boom Angle > +60°
Retracted
and Boom
Angle < +55°

ALL of the following

Machine Setup’s VEHICLE is LBP-SC and ALL of the conditions are present:
following conditions are present: • Frame Level
• Boom Angle Sensor Healthy Left and
FRAME LEVELING
Frame Leveling Right
PREVENTED – 2577 5000mS • Frame Level Left Switch or Frame Level
prevented Switches
LOWER BOOM Right Switch is closed (operator request- open for
ing frame leveling) 1000mS
• Boom Angle > +40° • Boom Angle
< +38°

Machine Setup’s VEHICLE is LBP-SC and ALL of the

following conditions are present:
DRIVE • Boom Angle Sensor Healthy (no active
Direction Selection is
PREVENTED – 2584 5000mS faults) Boom Angle < +38°
forced to Neutral
LOWER BOOM • Boom Angle > +40°
• Direction Selection is not Neutral (vehicle
in drive)

9-96 31211337 3614RS, 4017RS

 Electrical System

Help
DTC Cabin Alarm Actions Trigger Latch Condition
Message
The following actions
apply continuously:
• Main Lift Up is
prevented
when Boom
Angle is
greater than
40°
• Frame Level-
ing Left/Right
HIRAS Cylinder Status is
are prevented
Healthy
• Cancel HIRAS
Note: HIRAS cylinder
Integrity
must be repaired.
Checks is pre-
Operator should apply
FUNCTIONS vented
Machine Setup’s REAR AXLE STAB is HIGH INTEGRITY park brake, fully lower
PREVENTED – and retract boom, then
and HIRAS Cylinder Status is Unhealthy (cylinder
REAR AXLE 2592 5000mS The following actions allow vehicle to idle
failed to lock or unlock during a periodic automatic
STABILIZATION apply until the vehicle until RAS indicator is off
integrity check)
ERROR can Start HIRAS (wait approximately 2
Integrity Checks: minutes). Vehicle will
automatically check
• HIRAS Mode
the RAS cylinder for
is forced to
errors while idling in
ERROR
this position.
• Rear Axle Sta-
bilization
Indicator
flashes (fast)
on Parker
Cabin Display
• Drive Speed
Restriction for
RAS Error is
forced

3614RS, 4017RS 31211337 9-97

 Electrical System

Help
DTC Cabin Alarm Actions Trigger Latch Condition
Message
The following actions
apply continuously:
• Main Lift Up is
prevented
when Boom
Angle is
greater than
40°
• Frame Level-
ing Left/Right Time Since Last
are prevented Successful Integrity
• Cancel HIRAS Check is less than 50
Integrity hours

FUNCTIONS Checks is pre- Note: Operator should

PREVENTED – vented apply park brake, fully
REAR AXLE Machine Setup’s REAR AXLE STAB is HIGH INTEGRITY lower and retract
STABILIZATION 2594 5000mS and Time Since Last Successful Integrity Check is boom, then allow
The following actions vehicle to idle until RAS
UNABLE TO apply until the vehicle greater than 50 hours
CHECK indicator is off (wait
can Start HIRAS approximately 2
INTEGRITY Integrity Checks: minutes). Vehicle will
• HIRAS Mode automatically check
is forced to the RAS cylinder for
ERROR errors while idling in
• Rear Axle Sta- this position.
bilization
Indicator
flashes (fast)
on Parker
Cabin Display
• Drive Speed
Restriction for
RAS Error is
forced

Machine Setup's BOOM DAMPING is YES;

CALIBRATIONS > BOOM DAMPING fails at step Maintained through
BOOM DAMPING
HEALTH CHECK FAILED - RIDE VALVE (issue detected Power Cycle;
PREVENTED -
Boom Damping is with the boom ride valve)
BOOM RIDE 25101 5000mS CALIBRATIONS >
prevented
VALVE BOOM DAMPING
UNHEALTHY completed
Note: Check the boom ride hydraulics (i.e.
accumulator, valves, hoses) for issues.

Machine Setup's BOOM DAMPING is YES; Boom

Damping Flag is set (active); Boom Angle < (Stored
BOOM DAMPING Boom Angle – Excessive Boom Settling Tolerance)
Boom Damping is
- EXCESSIVE 25102 5000mS for 200 mS Power cycled
prevented
BOOM SETTLING
Note: Check the boom ride hydraulics (i.e.
accumulator, valves, hoses) for issues.

Machine Setup's BOOM DAMPING is YES; Boom

Damping Flag is set (active); Lift Head Pressure <
RIDE VALVE OR
(Lift Accumulator Pressure - 10 BAR (Constant Data))
LIFT
Boom Damping is for 500 mS
ACCUMULATOR 25103 5000mS Power cycled
prevented
PRESSURE
SENSOR ERROR Note: Check the boom ride hydraulics (i.e.
accumulator, valves, hoses) for issues.

9-98 31211337 3614RS, 4017RS

 Electrical System

Help
DTC Cabin Alarm Actions Trigger Latch Condition
Message
Machine Setup's BOOM DAMPING is YES; Boom
LIFT BORE/LIFT Damping Flag is set (active) for >2000 mS
ACCUMULATOR Boom Damping is (debounce), Lift Head Pressure & Lift Accumulator
25104 5000mS Pressure disagree more than +/- 50 BAR for 500 mS Power cycled
PRESSURE prevented
DISAGREEMENT Note: Check the boom ride hydraulics (i.e.
accumulator, valves, sensors) for issues.

Machine Setup's BOOM DAMPING is YES;

BOOM DAMPING
CALIBRATIONS > BOOM DAMPING fails at step
PREVENTED - Maintained through
HEALTH CHECK FAILED - LIFT ROD PRESSURE
LIFT ROD Power Cycle;
SENSOR (issue detected with the lift rod pressure
PRESSURE Boom Damping is
25105 5000mS sensor or boom tank valve) CALIBRATIONS >
SENSOR OR prevented
BOOM TANK BOOM DAMPING
VALVE completed
Note: Check the boom ride hydraulics (i.e.
UNHEALTHY accumulator, valves, hoses) for issues.

3614RS, 4017RS 31211337 9-99

 Electrical System

9.16.7 Line Contactor Open-Circuit (31x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
IGNITION RELAY At startup, Ignition Voltage < 4.0V after
Hydraulic functions are
PERMANENTLY 316 Continuously CCM J1-H3 Ignition Relay is energized Power cycled
prevented
OFF for 140mS

9-100 31211337 3614RS, 4017RS

 Electrical System

9.16.8 Line Contactor Short-Circuit (32x)

CABIN LATCH
HELP MESSAGE DTC ACTIONS TRIGGER
ALARM CONDITION
IGNITION RELAY Hydraulic functions are At startup, Ignition Voltage > 6.0V before CCM
327 Continuously Power cycled
PERMANENTLY ON prevented J1-H3 Ignition Relay is energized

Machine Setup’s REMOTE CONTROL is YES,

Operating Mode is REMOTE CONTROL, and all
of the following conditions are present for
• Remote con- >2,000mS :
REMOTE CONTROL trols prevented
• RCM P1-M1 Remote Control Ignition
IGNITION RELAY 3215 Continuously • Remote Power Cycled
Relay digital output is deenergized
PERMANENTLY ON engine start (relay should be open to shut down
prevented engine)
• Engine Operating State is ENGINE
RUNNING (relay is stuck closed)

3614RS, 4017RS 31211337 9-101

 Electrical System

9.16.9 Output Drivers (33x)

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
GROUND ALARM -
Machine Setup’s VEHICLE is LBP-RS,
SHORT TO 3311 5000mS CCM J1-H4 Ground Alarm is prevented Power cycled
short to battery detected on CCM J1-H4
BATTERY

GROUND ALARM -
Machine Setup’s VEHICLE is LBP-RS,
SHORT TO 3371 5000mS CCM J1-H4 Ground Alarm is prevented Power cycled
short to ground detected on CCM J1-H4
GROUND

• RFCM J2-F4 Lift Up prevented

MAIN LIFT UP • Boom Ride prevented
VALVE – OPEN 33181 5000mS Open-circuit detected on RFCM J2-F4 Power cycled
CIRCUIT • Boom Float prevented
• Boom Damping prevented

• RFCM J2-F4 Lift Up prevented

• RFCM J2-E4 Lift Down pre-
vented
MAIN LIFT VALVES • RFCM J2-F3 / RFCM J2-E3 Main Short to battery detected on RFCM J2-F4
– SHORT TO 33182 5000mS Lift Up / Down Valve disabled Power cycled
or RFCM J2-E4
BATTERY
• Boom Ride prevented
• Boom Float prevented
• Boom Damping prevented

• RFCM J2-F4 Lift Up prevented

• RFCM J2-E4 Lift Down pre-
vented
MAIN LIFT UP • RFCM J2-F3 / RFCM J2-E3 Main
VALVE – SHORT TO 33183 5000mS Lift Up / Down Valve disabled Short to ground detected on RFCM J2-F4 Power cycled
GROUND
• Boom Ride prevented
• Boom Float prevented
• Boom Damping prevented

• RFCM J2-E4 Lift Down pre-

vented
MAIN LIFT DOWN
VALVE – OPEN 33184 5000mS • Boom Ride prevented Open-circuit detected on RFCM J2-E4 Power cycled
CIRCUIT • Boom Float prevented
• Boom Damping prevented

• RFCM J2-F4 Lift Up prevented

• RFCM J2-E4 Lift Down pre-
vented
MAIN LIFT DOWN • RFCM J2-F3 / RFCM J2-E3 Main
VALVE – SHORT TO 33185 5000mS Lift Up / Down Valve disabled Short to ground detected on RFCM J2-E4 Power cycled
GROUND
• Boom Ride prevented
• Boom Float prevented
• Boom Damping prevented

MAIN TELESCOPE
OUT VALVE – 33186 5000mS RFCM J2-G4 Telescope Out prevented Open-circuit detected on RFCM J2-G4 Power cycled
OPEN CIRCUIT

9-102 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J2-H4 Telescope In pre-
vented
MAIN TELESCOPE • RFCM J2-G4 Telescope Out pre-
vented Short to battery detected on RFCM J2-
VALVES – SHORT 33187 5000mS Power cycled
H4 or RFCM J2-G4
TO BATTERY • RFCM J2-A3 / RFCM J2-B3 Tele-
scope In / Out Valve disabled
• Boom Damping prevented

• RFCM J2-H4 Telescope In pre-

vented
MAIN TELESCOPE • RFCM J2-G4 Telescope Out pre-
OUT VALVE – vented Short to ground detected on RFCM J2-
33188 5000mS Power cycled
SHORT TO G4
GROUND • RFCM J2-A3 / RFCM J2-B3 Tele-
scope In / Out Valve disabled
• Boom Damping prevented

MAIN TELESCOPE • RFCM J2-H4 Telescope In pre-

IN VALVE – OPEN 33189 5000mS vented Open-circuit detected on RFCM J2-H4 Power cycled
CIRCUIT • Boom Damping prevented

• RFCM J2-H4 Telescope In pre-

vented
MAIN TELESCOPE • RFCM J2-G4 Telescope Out pre-
vented Short to ground detected on RFCM J2-
IN VALVE – SHORT 33190 5000mS Power cycled
H4
TO GROUND • RFCM J2-A3 / RFCM J2-B3 Tele-
scope In / Out Valve disabled
• Boom Damping prevented

FORK TILT UP • RFCM J2-K4 Fork Tilt Up pre- Machine Setup’s AUTO FORK LEVEL is
VALVE – OPEN 33191 5000mS vented NO, Open-circuit detected on RFCM J2- Power cycled
CIRCUIT K4

FORK TILT UP • RFCM J2-K4 Fork Tilt Up pre- Machine Setup’s AUTO FORK LEVEL is
VALVE – OPEN 33191 5000mS vented YES, Open-circuit detected on RFCM J2- Power cycled
CIRCUIT • Main Lift Down prevented K4

• RFCM J2-K4 Fork Up prevented

FORK TILT VALVES • RFCM J2-J4 Fork Down pre- Machine Setup’s AUTO FORK LEVEL is
– SHORT TO 33192 5000mS vented NO, Short to battery detected on RFCM Power cycled
BATTERY • RFCM J2-C3 / RFCM J2-D3 Fork J2-K4 or RFCM J2-J4
Tilt Up / Down Valve disabled

• RFCM J2-K4 Fork Up prevented

• RFCM J2-J4 Fork Down pre-
FORK TILT VALVES vented Machine Setup’s AUTO FORK LEVEL is
– SHORT TO 33192 5000mS • RFCM J2-C3 / RFCM J2-D3 Fork YES, Short to battery detected on RFCM Power cycled
BATTERY Tilt Up / Down Valve disabled J2-K4 or RFCM J2-J4
• Main Lift Up prevented
• Main Lift Down prevented

• RFCM J2-K4 Fork Up prevented

FORK TILT UP • RFCM J2-J4 Fork Down pre- Machine Setup’s AUTO FORK LEVEL is
VALVE – SHORT TO 33193 5000mS vented NO, Short to ground detected on RFCM Power cycled
GROUND • RFCM J2-C3 / RFCM J2-D3 Fork J2-K4
Tilt Up / Down Valve disabled

3614RS, 4017RS 31211337 9-103

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J2-K4 Fork Up prevented
• RFCM J2-J4 Fork Down pre-
FORK TILT UP vented Machine Setup’s AUTO FORK LEVEL is
VALVE – SHORT TO 33193 5000mS • RFCM J2-C3 / RFCM J2-D3 Fork YES, Short to ground detected on RFCM Power cycled
GROUND Tilt Up / Down Valve disabled J2-K4
• Main Lift Up prevented
• Main Lift Down prevented

FORK TILT DOWN • RFCM J2-J4 Fork Tilt Down pre- Machine Setup’s AUTO FORK LEVEL is
VALVE – OPEN 33194 5000mS vented NO, Open-circuit detected on RFCM J2- Power cycled
CIRCUIT J4

FORK TILT DOWN • RFCM J2-J4 Fork Tilt Down pre- Machine Setup’s AUTO FORK LEVEL is
VALVE – OPEN 33194 5000mS vented YES, Open-circuit detected on RFCM J2- Power cycled
CIRCUIT • Main Lift Up prevented J4

• RFCM J2-K4 Fork Up prevented

FORK TILT DOWN • RFCM J2-J4 Fork Down pre- Machine Setup’s AUTO FORK LEVEL is
VALVE – SHORT TO 33195 5000mS vented NO, Short to ground detected on RFCM Power cycled
GROUND • RFCM J2-C3 / RFCM J2-D3 Fork J2-J4
Tilt Up / Down Valve disabled

• RFCM J2-K4 Fork Up prevented

• RFCM J2-J4 Fork Down pre-
FORK TILT DOWN vented Machine Setup’s AUTO FORK LEVEL is
VALVE – SHORT TO 33195 5000mS • RFCM J2-C3 / RFCM J2-D3 Fork YES, Short to ground detected on RFCM Power cycled
GROUND Tilt Up / Down Valve disabled J2-J4
• Main Lift Up prevented
• Main Lift Down prevented

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY Valve prevented Machine Setup’s AUXILIARY
FUNCTION-A
33196 5000mS • RFCM J1-B4 Auxiliary Front / HYDRAULICS is YES, Open-circuit Power cycled
VALVE – OPEN
Rear Valve prevented detected on RFCM J3-D1 / RFCM J2-A4
CIRCUIT
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

9-104 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J3-D1 Auxiliary A pre-
vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY Valve prevented Machine Setup’s AUXILIARY
FUNCTION-A/B
33197 Continuously • RFCM J1-B4 Auxiliary Front / HYDRAULICS is YES, Short to battery Power cycled
VALVES – SHORT
Rear Valve prevented detected on RFCM J3-D1 / RFCM J3-E1
TO BATTERY
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY Valve prevented Machine Setup’s AUXILIARY
FUNCTION-A
33198 Continuously • RFCM J1-B4 Auxiliary Front / HYDRAULICS is YES, Short to ground Power cycled
VALVE – SHORT TO
Rear Valve prevented detected on RFCM J3-D1
GROUND
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

3614RS, 4017RS 31211337 9-105

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J3-D1 Auxiliary A pre-
vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY Valve prevented Machine Setup’s AUXILIARY
FUNCTION-B
33199 5000mS • RFCM J1-B4 Auxiliary Front / HYDRAULICS is YES, Open-circuit Power cycled
VALVE – OPEN
Rear Valve prevented detected on RFCM J3-E1
CIRCUIT
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY Valve prevented Machine Setup’s AUXILIARY
FUNCTION-B
33200 Continuously • RFCM J1-B4 Auxiliary Front / HYDRAULICS is YES, Short to ground Power cycled
VALVE – SHORT TO
Rear Valve prevented detected on RFCM J3-E1
GROUND
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

9-106 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J3-D1 Auxiliary A pre-
vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
Valve prevented
• RFCM J1-B4 Auxiliary Front / Machine Setup’s HYDRAULIC QUICK
HYDRAULIC QUICK Rear Valve prevented CONNECT is YES;
CONNECT SELECT 33204 5000mS • RFCM J1-D4 Auxiliary Rear 1/2 open-circuit is detected on RFCM J1-F4 Power cycled
– OPEN CIRCUIT Valve prevented Hydraulic Quick Connect Valve for
• RFCM J1-B4 Auxiliary Front / 500mS
Rear Valve prevented
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
HYDRAULIC QUICK Valve prevented Machine Setup’s HYDRAULIC QUICK
CONNECT SELECT CONNECT is YES;
33205 5000mS • RFCM J1-B4 Auxiliary Front / Power cycled
– SHORT TO short to battery is detected on RFCM J1-
Rear Valve prevented
BATTERY F4 Hydraulic Quick Connect Valve
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

3614RS, 4017RS 31211337 9-107

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J3-D1 Auxiliary A pre-
vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
HYDRAULIC QUICK Valve prevented Machine Setup’s HYDRAULIC QUICK
CONNECT SELECT CONNECT is YES;
33206 5000mS • RFCM J1-B4 Auxiliary Front / Power cycled
– SHORT TO short to ground is detected on RFCM J1-
Rear Valve prevented
GROUND F4 Hydraulic Quick Connect Valve
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

• FFCM J2-M3 Horn prevented Platform or Remote Control Mode;

HORN – OPEN
33207 5000mS open-circuit is detected on FFCM J2-M3 Power cycled
CIRCUIT
Horn

• FFCM J2-M3 Horn prevented Platform or Remote Control Mode; short

HORN – SHORT TO
33208 5000mS to battery is detected on FFCM J2-M3 Power cycled
BATTERY
Horn

• FFCM J2-M3 Horn prevented Platform or Remote Control Mode; short

HORN – SHORT TO
33209 5000mS to ground is detected on FFCM J2-M3 Power cycled
GROUND
Horn

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2 Machine Setup’s AUX. FUNCTION
AUXILIARY Valve prevented SELECT is YES;
FUNCTION SELECT 33216 5000mS • RFCM J1-B4 Auxiliary Front / Cabin Mode; open-circuit is detected on Power cycled
– OPEN CIRCUIT Rear Valve prevented RFCM J1-E4 Auxiliary Front 1/2 Valve for
• RFCM J1-D4 Auxiliary Rear 1/2 500mS
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

9-108 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J3-D1 Auxiliary A pre-
vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY Valve prevented Machine Setup’s AUX. FUNCTION
FUNCTION SELECT SELECT is YES;
33217 5000mS • RFCM J1-B4 Auxiliary Front / Power cycled
– SHORT TO Cabin Mode; short to battery is detected
Rear Valve prevented
BATTERY on RFCM J1-E4 Auxiliary Front 1/2 Valve
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY Valve prevented Machine Setup’s AUX. FUNCTION
FUNCTION SELECT SELECT is YES;
33218 5000mS • RFCM J1-B4 Auxiliary Front / Power cycled
– SHORT TO Cabin Mode; short to ground is detected
Rear Valve prevented
GROUND on RFCM J1-E4 Auxiliary Front 1/2 Valve
• RFCM J1-D4 Auxiliary Rear 1/2
Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

FRAME LEVEL LEFT Machine Setup’s FRAME LEVELING is

VALVE – OPEN 33234 5000mS • Frame Level Left is prevented YES; Power cycled
CIRCUIT open circuit is detected on FFCM J1-A4

Machine Setup’s FRAME LEVELING is

FRAME LEVEL LEFT
PROP;
VALVE – OPEN 33234 5000mS • Frame Level Left is prevented Power cycled
open circuit is detected on FFCM J1-B4 /
CIRCUIT
FFCM J2-E3

Machine Setup’s FRAME LEVELING is

FRAME LEVEL LEFT • Outriggers are prevented YES;
VALVE – SHORT TO 33235 5000mS Power cycled
• Frame Level is prevented short to battery is detected on FFCM J1-
BATTERY
A4

3614RS, 4017RS 31211337 9-109

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• FFCM J1-B4 Frame Level Left
Valve prevented
Machine Setup’s FRAME LEVELING is
FRAME LEVEL LEFT • FFCM J2-F4 Frame Level Right
PROP;
VALVE – SHORT TO 33235 5000mS Valve prevented Power cycled
short to battery is detected on FFCM J1-
BATTERY • FFCM J2-E3 / FFCM J2-F3 B4 / FFCM J2-E3
Frame Level Left / Right Valve
prevented

Machine Setup’s FRAME LEVELING is

FRAME LEVEL LEFT
YES;
VALVE – SHORT TO 33236 5000mS • Frame Level Left is prevented Power cycled
short to ground is detected on FFCM J1-
GROUND
A4

Machine Setup’s FRAME LEVELING is

FRAME LEVEL LEFT
PROP;
VALVE – SHORT TO 33236 5000mS • Frame Level Left is prevented Power cycled
short to ground is detected on FFCM J1-
GROUND
B4 / FFCM J2-E3

FRAME LEVEL Machine Setup’s FRAME LEVELING is

RIGHT VALVE – 33237 5000mS • Frame Level Right is prevented YES; Power cycled
OPEN CIRCUIT open circuit is detected on FFCM J1-B3

Machine Setup’s FRAME LEVELING is

FRAME LEVEL
PROP;
RIGHT VALVE – 33237 5000mS • Frame Level Right is prevented Power cycled
open circuit is detected on FFCM J2-F4 /
OPEN CIRCUIT
FFCM J2-F3

FRAME LEVEL Machine Setup’s FRAME LEVELING is

RIGHT VALVE – • Outriggers are prevented YES;
33238 5000mS Power cycled
SHORT TO • Frame Level is prevented short to battery is detected on FFCM J1-
BATTERY B3

FFCM J1-B4 Frame Level Left Valve

prevented
FRAME LEVEL Machine Setup’s FRAME LEVELING is
RIGHT VALVE – FFCM J2-F4 Frame Level Right Valve PROP;
33238 5000mS Power cycled
SHORT TO prevented short to battery is detected on FFCM J2-
BATTERY F4 / FFCM J2-F3
FFCM J2-E3 / FFCM J2-F3 Frame Level
Left / Right Valve prevented

FRAME LEVEL Machine Setup’s FRAME LEVELING is

RIGHT VALVE – YES;
33239 5000mS Frame Level Right is prevented Power cycled
SHORT TO short to ground is detected on FFCM J1-
GROUND B3

FRAME LEVEL Machine Setup’s FRAME LEVELING is

RIGHT VALVE – PROP;
33239 5000mS Frame Level Right is prevented Power cycled
SHORT TO short to ground is detected on FFCM J2-
GROUND F4 / FFCM J2-F3

CRAB STEER VALVE

33270 5000mS Steer Mode Change prevented Open-circuit is detected on FFCM J3-A1 Power cycled
– OPEN CIRCUIT

CRAB STEER VALVE

Short to battery is detected on FFCM J3-
– SHORT TO 33271 5000mS Steer Mode Change prevented Power cycled
A1
BATTERY

CRAB STEER VALVE

Short to ground is detected on FFCM J3-
– SHORT TO 33272 5000mS Steer Mode Change prevented Power cycled
A1
GROUND

ALL WHEEL STEER

VALVE – OPEN 33273 5000mS Steer Mode Change prevented Open-circuit is detected on FFCM J3-F1 Power cycled
CIRCUIT

9-110 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
ALL WHEEL STEER
Short to battery is detected on FFCM J3-
VALVE – SHORT TO 33274 5000mS Steer Mode Change prevented Power cycled
F1
BATTERY

ALL WHEEL STEER

Short to ground is detected on FFCM J3-
VALVE – SHORT TO 33275 5000mS Steer Mode Change prevented Power cycled
F1
GROUND

Machine Setup’s PLATFORM OPTION is

APU PUMP RELAY YES; open-circuit
33276 5000mS Platform Auxiliary Pump Relay prevented Power cycled
– OPEN CIRCUIT detected on FFCM J3-B1 Platform
Auxiliary Pump Relay

APU PUMP RELAY Machine Setup’s PLATFORM OPTION is

– SHORT TO 33277 Continuously Platform Auxiliary Pump Relay prevented YES; short to battery detected on FFCM Power cycled
BATTERY J3-B1 Platform Auxiliary Pump Relay

APU PUMP RELAY Machine Setup’s PLATFORM OPTION is

– SHORT TO 33278 5000mS Platform Auxiliary Pump Relay prevented YES; short to ground detected on FFCM Power cycled
GROUND J3-B1 Platform Auxiliary Pump Relay

ENGAGE STARTER
Short to battery is detected on FFCM J2-
OUTPUT – SHORT 33283 Continuously Engine Start is prevented Power cycled
L4
TO BATTERY

ENGAGE STARTER
Short to ground is detected on FFCM J2-
OUTPUT – SHORT 33284 5000mS Engine Start is prevented Power cycled
L4
TO GROUND

Machine Setup’s TRANSMISSION is

LINDE HYSTAT and one of the following
occur:
• TCM J2-K4 / J2-D3 Motor Dis-
placement Valve measured
FRONT MOTOR - • Direction Selection is forced to current is 250mA less than
CURRENT Neutral (drive prevented) command when command is
FEEDBACK 33286 5000mS Power Cycled
• TCM J2-K4 / J2-D3 Motor Dis- greater than 500mA for
READING TOO
placement Valve is prevented 1000mS
LOW
• TCM J2-K4 / J2-D3 Motor Dis-
placement Valve measured
current is less than 255mA
when PWM is greater than
40% for 500mS

Current Feedback Faults are enabled

and one of the following occurs:

• RFCM J2-F4 Lift Up prevented • RFCM J2-F3 / RFCM J2-E3 Main

Lift Up / Down Valve mea-
• RFCM J2-E4Lift Down pre- sured current is 250mA less
LIFT – CURRENT vented than command when com-
FEEDBACK
33287 5000mS • RFCM J2-F3 / RFCM J2-E3 Main mand is greater than 500mA Power cycled
READING TOO
Lift Up / Down Valve disabled for 1000mS
LOW
• Boom Ride prevented • RFCM J2-F3 / RFCM J2-E3 Main
• Boom Damping prevented Lift Up / Down Valve mea-
sured current is less than
255mA when PWM is greater
than 40% for 500mS

3614RS, 4017RS 31211337 9-111

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
Current Feedback Faults are enabled
and one of the following occurs:
• RFCM J2-A3 / B3 Telescope In /
• Telescope In prevented
TELESCOPE – Out Valve measured current is
CURRENT • Telescope Out prevented 250mA less than command
FEEDBACK 33288 5000mS • RFCM J2-A3 / B3 Telescope In / when command is greater Power cycled
READING TOO Out Valve disabled than 500mA for 1000mS
LOW • RFCM J2-A3 / B3 Telescope In /
• Boom Damping prevented
Out Valve measured current is
less than 255mA when PWM is
greater than 40% for 500mS

Machine Setup’s AUTO FORK LEVEL is

NO, Current Feedback Faults are
enabled and one of the following occurs:
• RFCM J2-K4 / J4 Fork Up /
FORK TILT – • Fork Up prevented Down Valve measured current
CURRENT
• Fork Down prevented is 250mA less than command
FEEDBACK 33290 5000mS Power cycled
• RFCM J2-K4 / J4 Fork Up / when command is greater
READING TOO
Down Valve disabled than 500mA for 1000mS
LOW
• RFCM J2-K4 / J4 Fork Up /
Down Valve measured current
is less than 255mA when PWM
is greater than 40% for 500mS

Machine Setup’s AUTO FORK LEVEL is

YES, Current Feedback Faults are
enabled and one of the following occurs:
Fork Up prevented
• RFCM J2-K4 / J4 Fork Up /
FORK TILT – Fork Down prevented
Down Valve measured current
CURRENT
RFCM J2-K4 / J4 Fork Up / Down Valve is 250mA less than command
FEEDBACK 33290 5000mS Power cycled
disabled when command is greater
READING TOO
Main Lift Up prevented than 500mA for 1000mS
LOW
• RFCM J2-K4 / J4 Fork Up /
Main Lift Down prevented
Down Valve measured current
is less than 255mA when PWM
is greater than 40% for 500mS

• RFCM J3-D1 Auxiliary A pre-

Machine Setup’s AUXILIARY
vented
HYDRAULICS is YES, Current Feedback
• RFCM J3-E1 Auxiliary B pre- Faults are enabled and one of the
vented following occurs:
• RFCM J2-A4 / RFCM J2-B4 Aux- • RFCM J2-A4 / RFCM J2-B4 Aux-
AUXILIARY iliary A / Auxiliary B Valve pre- iliary A / Auxiliary B Valve mea-
HYDRAULICS – vented sured current is 250mA less
CURRENT
33291 5000mS • RFCM J1-E4 Auxiliary Front 1/2 than command when com- Power cycled
FEEDBACK
Valve prevented mand is greater than 500mA
READING TOO
• Auxiliary De-Compression pre- for 1000mS
LOW
vented • RFCM J2-A4 / RFCM J2-B4 Aux-
• Continuous Auxiliary Hydrau- iliary A / Auxiliary B Valve mea-
lics prevented sured current is less than
255mA when PWM is greater
• Hydraulic Quick Connect pre-
than 40% for 500mS
vented

• Direction Selection is forced to Machine Setup’s TRANSMISSION is

FRONT MOTOR Neutral (drive prevented) LINDE HYSTAT, open circuit detected on
SWIVEL ANGLE - 33292 5000mS Power Cycled
• TCM J2-K4 / J2-D3 Motor Dis- TCM J2-K4 / J2-D3 Motor Displacement
OPEN CIRCUIT
placement Valve is prevented Valve

9-112 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
FRONT MOTOR • Direction Selection is forced to Machine Setup’s TRANSMISSION is
SWIVEL ANGLE - Neutral (drive prevented) LINDE HYSTAT, short to battery detected
33293 5000mS Power Cycled
SHORT TO • TCM J2-K4 / J2-D3 Motor Dis- on TCM J2-K4 / J2-D3 Motor
BATTERY placement Valve is prevented Displacement Valve

FRONT MOTOR • Direction Selection is forced to Machine Setup’s TRANSMISSION is

SWIVEL ANGLE - Neutral (drive prevented) LINDE HYSTAT, short to ground detected
33294 5000mS Power Cycled
SHORT TO • TCM J2-K4 / J2-D3 Motor Dis- on TCM J2-K4 / J2-D3 Motor
GROUND placement Valve is prevented Displacement Valve

• Direction Selection is forced to

Neutral (drive prevented)
• TCM J1-A4 Watchdog Valve is
DRIVE FORWARD prevented Machine Setup’s TRANSMISSION is
VALVE - OPEN 33317 5000mS LINDE HYSTAT, open circuit detected on Power Cycled
CIRCUIT • TCM J2-F4 / J2-F3 Drive For- TCM J2-F4 / J2-F3 Drive Forward Valve
ward Valve is prevented
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

• Direction Selection is forced to

Neutral (drive prevented)
• TCM J1-A4 Watchdog Valve is Machine Setup’s TRANSMISSION is
DRIVE FORWARD prevented LINDE HYSTAT, short to battery detected
VALVE - SHORT TO 33318 5000mS Power Cycled
• TCM J2-F4 / J2-F3 Drive For- on TCM J2-F4 / J2-F3 Drive Forward
BATTERY
ward Valve is prevented Valve
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

• Direction Selection is forced to

Neutral (drive prevented)
• TCM J1-A4 Watchdog Valve is Machine Setup’s TRANSMISSION is
DRIVE FORWARD prevented LINDE HYSTAT, short to ground detected
VALVE - SHORT TO 33319 5000mS Power Cycled
• TCM J2-F4 / J2-F3 Drive For- on TCM J2-F4 / J2-F3 Drive Forward
GROUND
ward Valve is prevented Valve
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

• Direction Selection is forced to

Neutral (drive prevented)
• TCM J1-A4 Watchdog Valve is
DRIVE REVERSE prevented Machine Setup’s TRANSMISSION is
VALVE - OPEN 33320 5000mS LINDE HYSTAT, open circuit detected on Power Cycled
CIRCUIT • TCM J2-F4 / J2-F3 Drive For- TCM J2-H4 / J2-B3 Drive Reverse Valve
ward Valve is prevented
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

• Direction Selection is forced to

Neutral (drive prevented)
• TCM J1-A4 Watchdog Valve is Machine Setup’s TRANSMISSION is
DRIVE REVERSE prevented LINDE HYSTAT, short to battery detected
VALVE - SHORT TO 33321 5000mS Power Cycled
• TCM J2-F4 / J2-F3 Drive For- on TCM J2-H4 / J2-B3 Drive Reverse
BATTERY
ward Valve is prevented Valve
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

3614RS, 4017RS 31211337 9-113

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Direction Selection is forced to
Neutral (drive prevented)
• TCM J1-A4 Watchdog Valve is Machine Setup’s TRANSMISSION is
DRIVE REVERSE prevented LINDE HYSTAT, short to ground detected
VALVE - SHORT TO 33322 5000mS Power Cycled
• TCM J2-F4 / J2-F3 Drive For- on TCM J2-H4 / J2-B3 Drive Reverse
GROUND
ward Valve is prevented Valve
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

Machine Setup’s FRAME LEVEL is PROP,

Current Feedback Faults are enabled,
and one of the following occur:
• FFCM J2-E3 / FFCM J2-F3
FFCM J1-B4 Frame Level Left Valve
Frame Level Left / Right Valve
FRAME LEVEL – prevented
measured current is 250mA
CURRENT
FFCM J2-F4 Frame Level Right Valve less than command when
FEEDBACK 33336 5000mS Power cycled
prevented command is greater than
READING TOO
FFCM J2-E3 / FFCM J2-F3 Frame Level 500mA for 1000mS
LOW
Left / Right Valve prevented • FFCM J2-E3 / FFCM J2-F3
Frame Level Left / Right Valve
measured current is less than
255mA when PWM is greater
than 40% for 500mS

• Main Lift Up prevented

BOOM RIDE VALVE • Boom Ride prevented Machine Setup’s BOOM RIDE&FLOAT is
– SHORT TO 33337 5000mS RIDE or RIDE&FLOAT; short to battery is Power cycled
BATTERY • Boom Float prevented detected on RFCM J1-A4
• Boom Damping prevented

BOOM RIDE VALVE • Boom Ride prevented Machine Setup’s BOOM RIDE&FLOAT is
– SHORT TO 33338 5000mS • Boom Float prevented RIDE or RIDE&FLOAT; short to ground is Power cycled
GROUND • Boom Damping prevented detected on RFCM J1-A4

• Boom Ride prevented Machine Setup’s BOOM RIDE&FLOAT is

BOOM RIDE VALVE
33339 5000mS • Boom Float prevented RIDE or RIDE&FLOAT; open-circuit is Power cycled
– OPEN CIRCUIT
• Boom Damping prevented detected on RFCM J1-A4

• Main Lift Up prevented

BOOM TANK • Boom Ride prevented Machine Setup’s BOOM RIDE&FLOAT is
VALVE – SHORT TO 33343 5000mS RIDE or RIDE&FLOAT; short to battery is Power cycled
BATTERY • Boom Float prevented detected on RFCM J1-B3
• Boom Damping prevented

BOOM TANK • Boom Ride prevented Machine Setup’s BOOM RIDE&FLOAT is

VALVE – SHORT TO 33344 5000mS • Boom Float prevented RIDE or RIDE&FLOAT; short to ground is Power cycled
GROUND • Boom Damping prevented detected on RFCM J1-B3

BOOM TANK • Boom Ride prevented Machine Setup’s BOOM RIDE&FLOAT is

VALVE – OPEN 33345 5000mS • Boom Float prevented RIDE or RIDE&FLOAT; open-circuit is Power cycled
CIRCUIT • Boom Damping prevented detected on RFCM J1-B3

• Main Lift Up prevented Machine Setup’s BOOM RIDE&FLOAT is

BOOM FLOAT
RIDE&FLOAT;
VALVE – SHORT TO 33340 5000mS • Boom Ride prevented Power cycled
short to battery is detected on RFCM J1-
BATTERY • Boom Float prevented A3

Machine Setup’s BOOM RIDE&FLOAT is

BOOM FLOAT • Boom Ride prevented RIDE&FLOAT;
VALVE – SHORT TO 33341 5000mS Power cycled
• Boom Float prevented short to ground is detected on RFCM J1-
GROUND
A3

9-114 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
BOOM FLOAT • Boom Ride prevented Machine Setup’s BOOM RIDE&FLOAT is
VALVE – OPEN 33342 5000mS RIDE&FLOAT; Power cycled
CIRCUIT • Boom Float prevented open-circuit is detected on RFCM J1-A3

• FFCM J2-K4 Anti-Stall Valve

prevented
• FFCM J2-D3 Anti-Stall Valve
prevented
• Anti-Stall Valve Command is
ANTI-STALL VALVE 0mA GEN3 HP Management configured;
– SHORT TO 33426 5000mS • Anti-Stall Valve Actual is 0mA short to battery is detected on FFCM J2- Power cycled
BATTERY D3 / FFCM J2-K4
If Machine Setup’s MODEL is TL943 and
ENGINE CONTROL is CAT C36 S5 55KW:
• Engine De-Rate for Pump
Overspeed Protection is
enforced (engine speed
restricted to 2250RPM)

• FFCM J2-K4 Anti-Stall Valve

prevented
• FFCM J2-D3 Anti-Stall Valve
prevented
• Anti-Stall Valve Command is
0mA GEN3 HP Management configured;
ANTI-STALL VALVE
33427 5000mS • Anti-Stall Valve Actual is 0mA open-circuit is detected on FFCM J2-D3 / Power cycled
– OPEN CIRCUIT
FFCM J2-K4
If Machine Setup’s MODEL is TL943 and
ENGINE CONTROL is CAT C36 S5 55KW:
• Engine De-Rate for Pump
Overspeed Protection is
enforced (engine speed
restricted to 2250RPM)

• FFCM J2-K4 Anti-Stall Valve

prevented
• FFCM J2-D3 Anti-Stall Valve
prevented
• Anti-Stall Valve Command is
ANTI-STALL VALVE 0mA GEN3 HP Management configured;
– SHORT TO 33428 5000mS • Anti-Stall Valve Actual is 0mA short to ground is detected on FFCM J2- Power cycled
GROUND D3 / FFCM J2-K4
If Machine Setup’s MODEL is TL943 and
ENGINE CONTROL is CAT C36 S5 55KW:
• Engine De-Rate for Pump
Overspeed Protection is
enforced (engine speed
restricted to 2250RPM)

BACKLIGHTING –
CCM J1-G4 Backlighting digital output is Short to ground detected on CCM J1-G4
SHORT TO 33488 5000mS Power cycled
prevented Backlighting
GROUND

• FFCM J3-G2 Left Marker Light

FRONT MARKER prevented Short to ground detected on FFCM J3-
LIGHT – SHORT TO 33489 5000mS G2 Power cycled
GROUND • FFCM J3-H1 Right Marker Light or FFCM J3-H1
prevented

FOG LIGHTS –
• RFCM J2-M4 Fog Lights digital Short to ground on RFCM J2-M4 Fog
SHORT TO 33491 5000mS Power cycled
output is prevented Lights
GROUND

3614RS, 4017RS 31211337 9-115

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Throttle Position is 0%
• Outrigger Left Joystick is 0%
• Outrigger Right Joystick is 0% Current limit detected on protected FET
CCM ANALOG for CCM analog ground
• Rear Auxiliary 1 Joystick is 0%
GROUND – SHORT 33493 5000mS Power cycled
TO BATTERY • Rear Auxiliary 2 Joystick is 0% Note: Check that CCM J1-B1, J2-G1, and
J2-L3 Analog Ground are 0+/-0.1V.
• Proportional Travel Speed is
0%
• Brake Pedal Position is 0%

• Hydraulic Oil Temperature is

+150°C
• Intercooler Air Temperature is
+150°C
• Transmission Oil Temperature
is +150°C
• Intercooler Air Temperature is
+150°C
• Outrigger Left Extend Pressure
is 0 PSI / BAR
• Outrigger Left Retract Pressure Current limit detected on protected FET
FFCM ANALOG is 0 PSI / BAR for FFCM analog ground
GROUND – SHORT 33494 5000mS • Outrigger Left Not Set Note: Check that FFCM J2-G3, J2-H3, J2- Power cycled
TO BATTERY J3, J2-K3, J3-A3, J3-B3, and J3-C3 Analog
• Outrigger Right Extend Pres-
Ground are 0+/-0.1V.
sure is 0 PSI / BAR
• Outrigger Right Retract Pres-
sure is 0 PSI / BAR
• Outrigger Right Not Set
• Fuel Level assumed to be
Empty (0.0%)
• Brake Pedal Pressure is 3000PSI
• De-Clutch prevented
• Service Brake Relay Pressure is
3000 PSI (max)

• Boom Angle Sensor is +99°

• Lift Up speed de-rated
• Load Stability assumed to be
100%
• HIRAS Mode is forced to ERROR
Current limit detected on protected FET
• Start HIRAS Integrity Checks is for RFCM analog ground
RFCM ANALOG
prevented
GROUND – SHORT 33495 5000mS Note: Check that RFCM J2-G3, J2-H3, J2- Power cycled
TO BATTERY • HIRAS Pressure PT1 is assumed J3, J2-K3, J3-A3, J3-B3, and J3-C3 Analog
to be 600.0 BAR Ground are 0+/-0.1V.
• HIRAS Pressure PT2 is assumed
to be 600.0 BAR
• HIRAS Pressure PT3 is assumed
to be 600.0 BAR
• Boom Damping prevented

9-116 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• LMIS / Weigh Load Predicted
Load is 32,767
• Lift Cylinder Head Pressure 1 is
600.0 BAR
• Lift Cylinder Head Pressure 2 is
600.0 BAR
• Lift Cylinder Rod Pressure 1 is Machine Setup’s LOAD MOMENT IND
600.0 BAR SYSTEM is YES, PLATFORM OPTION is
• Lift Cylinder Rod Pressure 2 is YES, or WEIGH LOAD is YES;
LCM ANALOG 600.0 BAR current limit detected on protected FET
GROUND – SHORT 33496 5000mS for LCM analog ground Power cycled
TO BATTERY • Compensation Cylinder Head
Pressure 1 is 600.0 BAR Note: Check that LCM J2-G3, J2-H3, J2-
• Compensation Cylinder Head J3, J2-K3, J3-A3, J3-B3, and J3-C3 Analog
Pressure 2 is 600.0 BAR Ground are 0+/-0.1V.
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR
• Boom Length Measurement is
maximum (Lmax)

OUTRIGGER LEFT • Outriggers prevented Machine Setup’s OUTRIGGERS is YES;

UP VALVE – SHORT 33500 5000mS short to battery is detected on FFCM J1- Power cycled
TO BATTERY • Frame Level prevented B4

OUTRIGGER LEFT Machine Setup’s OUTRIGGERS is YES;

UP VALVE – SHORT 33501 5000mS • Outrigger Left Up prevented short to ground is detected on FFCM J1- Power cycled
TO GROUND B4

OUTRIGGER LEFT
Machine Setup’s OUTRIGGERS is YES;
UP VALVE – OPEN 33502 5000mS • Outrigger Left Up prevented Power cycled
open circuit is detected on FFCM J1-B4
CIRCUIT

OUTRIGGER LEFT
• Outriggers prevented Machine Setup’s OUTRIGGERS is YES;
DOWN VALVE –
33503 5000mS short to battery is detected on FFCM J1- Power cycled
SHORT TO • Frame Level prevented C4
BATTERY

OUTRIGGER LEFT
Machine Setup’s OUTRIGGERS is YES;
DOWN VALVE – • Outrigger Left Down pre-
33504 5000mS short to ground is detected on FFCM J1- Power cycled
SHORT TO vented
C4
GROUND

OUTRIGGER LEFT
• Outrigger Left Down pre- Machine Setup’s OUTRIGGERS is YES;
DOWN VALVE – 33505 5000mS Power cycled
vented open circuit is detected on FFCM J1-C4
OPEN CIRCUIT

OUTRIGGER RIGHT • Outriggers prevented Machine Setup’s OUTRIGGERS is YES;

UP VALVE – SHORT 33506 5000mS short to battery is detected on FFCM J1- Power cycled
TO BATTERY • Frame Level prevented D3

OUTRIGGER RIGHT Machine Setup’s OUTRIGGERS is YES;

UP VALVE – SHORT 33507 5000mS • Outrigger Right Up prevented short to ground is detected on FFCM J1- Power cycled
TO GROUND D3

OUTRIGGER RIGHT
Machine Setup’s OUTRIGGERS is YES;
UP VALVE – OPEN 33508 5000mS • Outrigger Right Up prevented Power cycled
open circuit is detected on FFCM J1-D3
CIRCUIT

3614RS, 4017RS 31211337 9-117

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
OUTRIGGER RIGHT
• Outriggers prevented Machine Setup’s OUTRIGGERS is YES;
DOWN VALVE –
33509 5000mS short to battery is detected on FFCM J1- Power cycled
SHORT TO • Frame Level prevented F4
BATTERY

OUTRIGGER RIGHT
Machine Setup’s OUTRIGGERS is YES;
DOWN VALVE – • Outrigger Right Down pre-
33510 5000mS short to ground is detected on FFCM J1- Power cycled
SHORT TO vented
F4
GROUND

OUTRIGGER RIGHT
• Outrigger Right Down pre- Machine Setup’s OUTRIGGERS is YES;
DOWN VALVE – 33511 5000mS Power cycled
vented open circuit is detected on FFCM J1-F4
OPEN CIRCUIT

LOW BEAM –
• Low Beam digital output pre- Short to ground detected on FFCM J3-
SHORT TO 33512 5000mS Power cycled
vented G3 or FFCM J3-H4
GROUND

HIGH BEAM –
• High Beam digital output pre- Short to ground detected on FFCM J3-
SHORT TO 33513 5000mS Power cycled
vented G1 or FFCM J3-H2
GROUND

• FFCM J2-K4 Anti-Stall Valve

GEN3 HP Management configured,
prevented
Current Feedback Faults are enabled,
• FFCM J2-D3 Anti-Stall Valve and one of the following conditions
prevented exist:
ANTI-STALL VALVE • Anti-Stall Valve Command is • FFCM J2-K4 / FFCM J2-D3 Anti-
– CURRENT 0mA Stall Valve measured current is
FEEDBACK 33514 5000mS • Anti-Stall Valve Actual is 0mA 250mA less than command Power cycled
READING TOO when command is greater
If Machine Setup’s MODEL is TL943 and
LOW than 500mA for 1000mS
ENGINE CONTROL is CAT C36 S5 55KW:
• FFCM J2-K4 / FFCM J2-D3 Anti-
• Engine De-Rate for Pump
Stall Valve measured current is
Overspeed Protection is
less than 255mA when PWM is
enforced (engine speed
greater than 40% for 500mS
restricted to 2250RPM)

OUTRIGGER/
FRAME LEVEL • Outriggers prevented Machine Setup’s OUTRIGGERS is YES;
SPEED VALVE – 33515 5000mS short to battery is detected on FFCM J2- Power cycled
SHORT TO • Frame Level prevented F3 / FFCM J2-F4
BATTERY

OUTRIGGER/
FRAME LEVEL • Outriggers prevented Machine Setup’s OUTRIGGERS is YES;
SPEED VALVE – 33516 5000mS short to ground is detected on FFCM J2- Power cycled
SHORT TO • Frame Level prevented F3 / FFCM J2-F4
GROUND

OUTRIGGER/
• Outriggers prevented Machine Setup’s OUTRIGGERS is YES;
FRAME LEVEL
33517 5000mS open-circuit is detected on FFCM J2-F3 / Power cycled
SPEED VALVE – • Frame Level prevented FFCM J2-F4
OPEN CIRCUIT

9-118 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
Machine Setup’s OUTRIGGERS is YES,
Current Feedback Faults are enabled,
and one of the following occur:
OUTRIGGER/
FFCM J2-F4 / FFCM J2-F3 Outrigger /
FRAME LEVEL
Frame Level Speed Valve measured
SPEED VALVE – • Outriggers prevented current is 250mA less than command
CURRENT 33518 5000mS Power cycled
• Frame Level prevented when command is greater than 500mA
FEEDBACK
for 1000mS
READING TOO
LOW FFCM J2-F4 / FFCM J2-F3 Outrigger /
Frame Level Speed Valve measured
current is less than 255mA when PWM is
greater than 40% for 500mS

FRONT LEFT TURN

• Left Turn Indicator flashes at
LIGHT – SHORT TO 33645 5000mS Short to battery detected on FFCM J3-H3 Power cycled
increased rate
BATTERY

• Left Turn Light digital output

FRONT LEFT TURN prevented (FFCM) Short to ground detected on FFCM J3-
LIGHT – SHORT TO 33519 5000mS Power cycled
• Left Turn Indicator flashes at H3
GROUND
increased rate

FRONT LEFT TURN

• Left Turn Indicator flashes at Machine Setup’s ROAD LIGHTING is YES;
LIGHT – OPEN 33646 5000mS Power cycled
increased rate open circuit detected on FFCM J3-H3
CIRCUIT

FRONT RIGHT
TURN LIGHT – • Right Turn Indicator flashes at
33647 5000mS Short to battery detected on FFCM J2-L3 Power cycled
SHORT TO increased rate
BATTERY

FRONT RIGHT • Right Turn Light digital output

TURN LIGHT – prevented (FFCM)
33520 5000mS Short to ground detected on FFCM J2-L3 Power cycled
SHORT TO • Right Turn Indicator flashes at
GROUND increased rate

FRONT RIGHT
• Right Turn Indicator flashes at Machine Setup’s ROAD LIGHTING is YES;
TURN LIGHT – 33648 5000mS Power cycled
increased rate open circuit detected on FFCM J2-L3
OPEN CIRCUIT

REAR LEFT TURN

• Left Turn Indicator flashes at Short to battery detected on RFCM J3-
LIGHT – SHORT TO 33649 5000mS Power cycled
increased rate H3
BATTERY

• Left Turn Light digital output

REAR LEFT TURN prevented (RFCM) Short to ground detected on RFCM J3-
LIGHT – SHORT TO 33527 5000mS Power cycled
• Left Turn Indicator flashes at H3
GROUND
increased rate
REAR LEFT TURN Machine Setup’s ROAD LIGHTING is YES
• Left Turn Indicator flashes at
LIGHT – OPEN 33650 5000mS and LED TAILLIGHT is NO; open circuit Power cycled
increased rate
CIRCUIT detected on RFCM J3-H3

REAR RIGHT TURN

• Right Turn Indicator flashes at
LIGHT – SHORT TO 33651 5000mS Short to battery detected on RFCM J2-L3 Power cycled
increased rate
BATTERY

• Right Turn Light digital output

REAR RIGHT TURN prevented (RFCM)
LIGHT – SHORT TO 33528 5000mS Short to ground detected on RFCM J2-L3 Power cycled
GROUND • Right Turn Indicator flashes at
increased rate

3614RS, 4017RS 31211337 9-119

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
REAR RIGHT TURN Machine Setup’s ROAD LIGHTING is YES
• Right Turn Indicator flashes at
LIGHT – OPEN 33652 5000mS and LED TAILLIGHT is NO; open circuit Power cycled
increased rate
CIRCUIT detected on RFCM J2-L3

REAR MARKER
• Marker Light digital output Short to ground detected on RFCM J3-
LIGHT – SHORT TO 33529 5000mS Power cycled
prevented (RFCM) G2 or RFCM J3-H1
GROUND

• RFCM J3-G1 Left Brake Light

BRAKE LIGHTS – digital output prevented Short to ground detected on RFCM J3-
SHORT TO 33530 5000mS Power cycled
• RFCM J3-H2 Right Brake Light G1 or RFCM J3-H2
GROUND
digital output prevented

• RFCM J3-G3 Left Reverse Light

REVERSE LIGHTS – digital output prevented Short to ground detected on RFCM J3-
SHORT TO 33531 5000mS Power cycled
• RFCM J3-H4 Right Reverse G3 or RFCM J3-H4
GROUND
Light digital output prevented

REVERSE ALARM –
• RFCM J2-L4 Reverse Alarm dig-
SHORT TO 33532 5000mS Short to ground detected on RFCM J2-L4 Power cycled
ital output prevented
GROUND

• RFCM J1-C4 / RFCM J2-D4 RAS Machine Setup’s REAR AXLE STAB is G-
REAR AXLE STAB 1 Float 1 Valve prevented SERIES;
VALVE – SHORT TO 33521 5000mS short to battery is detected on RFCM J1- Power cycled
BATTERY • RFCM J1-D3 / RFCM J2-C4 RAS C4 /
Float 2 Valve prevented RFCM J2-D4 RAS Float 1 Valve

• RFCM J1-C4 / RFCM J2-D4 RAS Machine Setup’s REAR AXLE STAB is G-
REAR AXLE STAB 1 Float 1 Valve prevented SERIES;
VALVE – SHORT TO 33522 5000mS short to ground is detected on RFCM J1- Power cycled
GROUND • RFCM J1-D3 / RFCM J2-C4 RAS C4 /
Float 2 Valve prevented RFCM J2-D4 RAS Float 1 Valve

• RFCM J1-C4 / RFCM J2-D4 RAS Machine Setup’s REAR AXLE STAB is G-
REAR AXLE STAB 1 Float 1 Valve prevented SERIES;
VALVE – OPEN 33523 5000mS Power cycled
• RFCM J1-D3 / RFCM J2-C4 RAS open-circuit is detected on RFCM J1-C4 /
CIRCUIT
Float 2 Valve prevented RFCM J2-D4 RAS Float 1 Valve

• RFCM J1-C4 / RFCM J2-D4 RAS Machine Setup’s REAR AXLE STAB is G-
REAR AXLE STAB 2 Float 1 Valve prevented SERIES;
VALVE – SHORT TO 33524 5000mS short to battery is detected on RFCM J1- Power cycled
BATTERY • RFCM J1-D3 / RFCM J2-C4 RAS D3 /
Float 2 Valve prevented RFCM J2-C4 RAS Float 2 Valve

• RFCM J1-C4 / RFCM J2-D4 RAS Machine Setup’s REAR AXLE STAB is G-
REAR AXLE STAB 2 Float 1 Valve prevented SERIES;
VALVE – SHORT TO 33525 5000mS short to ground is detected on RFCM J1- Power cycled
GROUND • RFCM J1-D3 / RFCM J2-C4 RAS D3 /
Float 2 Valve prevented RFCM J2-C4 RAS Float 2 Valve

• RFCM J1-C4 / RFCM J2-D4 RAS Machine Setup’s REAR AXLE STAB is G-
REAR AXLE STAB 2 Float 1 Valve prevented SERIES;
VALVE – OPEN 33526 5000mS Power cycled
• RFCM J1-D3 / RFCM J2-C4 RAS open-circuit is detected on RFCM J1-D3 /
CIRCUIT
Float 2 Valve prevented RFCM J2-C4 RAS Float 2 Valve

IGNITION RELAY – • Hydraulic functions are pre-

vented Short to battery detected on CCM J1-H3
SHORT TO 33533 Continuously Power cycled
Ignition Relay at power-up
BATTERY • Engine start prevented

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 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• Hydraulic functions are pre-
vented
BLOCKING VALVE • Blocking Valve prevented Machine Setup’s BLOCKING VALVE is
– SHORT TO 33534 Continuously YES; Power cycled
• Boom Ride prevented
BATTERY Short to battery detected on FFCM J2-E4
• Boom Float prevented
• Boom Damping prevented

• Hydraulic functions are pre-

vented
BLOCKING VALVE • Blocking Valve prevented Machine Setup’s BLOCKING VALVE is
– SHORT TO 33535 Continuously YES; Power cycled
• Boom Ride prevented
GROUND Short to ground detected on FFCM J2-E4
• Boom Float prevented
• Boom Damping prevented

• Hydraulic functions are pre-

vented
• Blocking Valve prevented Machine Setup’s BLOCKING VALVE is
BLOCKING VALVE
33536 Continuously YES; Power cycled
– OPEN CIRCUIT • Boom Ride prevented
Open-circuit detected on FFCM J2-E4
• Boom Float prevented
• Boom Damping prevented

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
Valve prevented Machine Setup’s AUXILIARY F/R SELECT
AUXILIARY FRONT
is YES;
/ REAR SELECT – 33569 5000mS • RFCM J1-D4 Auxiliary Rear 1/2 Power cycled
open-circuit is detected on RFCM J1-B4
OPEN CIRCUIT Valve prevented
Auxiliary Front / Rear Valve
• RFCM J1-B4 Auxiliary Front /
Rear Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

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 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J3-D1 Auxiliary A pre-
vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY FRONT Valve prevented Machine Setup’s AUXILIARY F/R SELECT
/ REAR SELECT – is YES;
33570 5000mS • RFCM J1-D4 Auxiliary Rear 1/2 Power cycled
SHORT TO short to battery is detected on RFCM J1-
Valve prevented
BATTERY B4 Auxiliary Front / Rear Valve
• RFCM J1-B4 Auxiliary Front /
Rear Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
AUXILIARY FRONT Valve prevented Machine Setup’s AUXILIARY F/R SELECT
/ REAR SELECT – is YES;
33571 5000mS • RFCM J1-D4 Auxiliary Rear 1/2 Power cycled
SHORT TO short to ground is detected on RFCM J1-
Valve prevented
GROUND B4 Auxiliary Front / Rear Valve
• RFCM J1-B4 Auxiliary Front /
Rear Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

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 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J3-D1 Auxiliary A pre-
vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
Valve prevented Machine Setup’s AUXILIARY REAR
AUXILIARY REAR
SELECT is YES;
SELECT – OPEN 33572 5000mS • RFCM J1-D4 Auxiliary Rear 1/2 Power cycled
open-circuit is detected on RFCM J1-D4
CIRCUIT Valve prevented
Auxiliary Rear 1/2 Valve
• RFCM J1-B4 Auxiliary Front /
Rear Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

• RFCM J3-D1 Auxiliary A pre-

vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
Valve prevented Machine Setup’s AUXILIARY REAR
AUXILIARY REAR
SELECT is YES;
SELECT – SHORT 33573 5000mS • RFCM J1-D4 Auxiliary Rear 1/2 Power cycled
short to battery is detected on RFCM J1-
TO BATTERY Valve prevented
D4 Auxiliary Rear 1/2 Valve
• RFCM J1-B4 Auxiliary Front /
Rear Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

3614RS, 4017RS 31211337 9-123

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RFCM J3-D1 Auxiliary A pre-
vented
• RFCM J3-E1 Auxiliary B pre-
vented
• RFCM J2-A4 / RFCM J2-B4 Aux-
iliary A / Auxiliary B Valve pre-
vented
• RFCM J1-E4 Auxiliary Front 1/2
Valve prevented Machine Setup’s AUXILIARY REAR
AUXILIARY REAR
SELECT is YES;
SELECT – SHORT 33574 5000mS • RFCM J1-D4 Auxiliary Rear 1/2 Power cycled
short to ground is detected on RFCM J1-
TO GROUND Valve prevented
D4 Auxiliary Rear 1/2 Valve
• RFCM J1-B4 Auxiliary Front /
Rear Valve prevented
• Auxiliary De-Compression pre-
vented
• Continuous Auxiliary Hydrau-
lics prevented
• Hydraulic Quick Connect pre-
vented

Machine Setup’s LOAD MOMENT IND

LIGHT TOWER
SYSTEM is YES;
GREEN – SHORT 33581 5000mS LCM J2-H4 Light Tower Green prevented Power cycled
short to battery is detected on LCM J2-
TO BATTERY
H4

Machine Setup’s LOAD MOMENT IND

LIGHT TOWER
SYSTEM is YES;
GREEN – SHORT 33582 5000mS LCM J2-H4 Light Tower Green prevented Power cycled
short to ground is detected on LCM J2-
TO GROUND
H4

Machine Setup’s LOAD MOMENT IND

LIGHT TOWER
SYSTEM is YES;
YELLOW – SHORT 33583 5000mS LCM J2-E4 Light Tower Yellow prevented Power cycled
short to battery is detected on LCM J2-
TO BATTERY
E4

Machine Setup’s LOAD MOMENT IND

LIGHT TOWER
SYSTEM is YES;
YELLOW – SHORT 33584 5000mS LCM J2-E4 Light Tower Yellow prevented Power cycled
short to ground is detected on LCM J2-
TO GROUND
E4

Machine Setup’s LOAD MOMENT IND

LIGHT TOWER RED
SYSTEM is YES;
– SHORT TO 33585 5000mS LCM J2-F4 Light Tower Red prevented Power cycled
short to battery is detected on LCM J2-
BATTERY
F4

Machine Setup’s LOAD MOMENT IND

LIGHT TOWER RED
SYSTEM is YES;
– SHORT TO 33586 5000mS LCM J2-F4 Light Tower Red prevented Power cycled
short to ground is detected on LCM J2-
GROUND
F4

PLATFORM • LCM J2-K4 Platform Pressure

Reducing Valve prevented Machine Setup’s PLATFORM OPTION is
PRESSURE
33587 5000mS YES; MARKET is ANSI or ANSI EXPORT; Power cycled
REDUCING VALVE • Transition to Platform Mode open circuit detected on LCM J2-K4
– OPEN CIRCUIT prevented

PLATFORM • LCM J2-K4 Platform Pressure

PRESSURE Reducing Valve prevented Machine Setup’s PLATFORM OPTION is
REDUCING VALVE 33588 5000mS YES; MARKET is ANSI or ANSI EXPORT; Power cycled
– SHORT TO • Transition to Platform Mode short to battery detected on LCM J2-K4
BATTERY prevented

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 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
PLATFORM • LCM J2-K4 Platform Pressure
PRESSURE Reducing Valve prevented Machine Setup’s PLATFORM OPTION is
REDUCING VALVE 33589 5000mS YES; MARKET is ANSI or ANSI EXPORT; Power cycled
– SHORT TO • Transition to Platform Mode short to ground detected on LCM J2-K4
GROUND prevented

• RAS Mode is forced to RAS

Lock
• RFCM J1-B4 / RFCM J2-C4 RAS Machine Setup’s REAR AXLE STAB is
REAR AXLE RATE 1 Rate 1 Valve prevented SKYTRAK;
VALVE – SHORT TO 33590 5000mS short to battery is detected on RFCM J1- Power cycled
BATTERY • RFCM J1-D4 / RFCM J2-D4 RAS B4 /
Rate 2 Valve prevented RFCM J2-C4 RAS Rate 1 Valve
• Frame Level Left / Right pre-
vented

• RAS Mode is forced to RAS

Lock
• RFCM J1-B4 / RFCM J2-C4 RAS Machine Setup’s REAR AXLE STAB is
REAR AXLE RATE 1 Rate 1 Valve prevented SKYTRAK;
VALVE – SHORT TO 33591 5000mS short to ground is detected on RFCM J1- Power cycled
GROUND • RFCM J1-D4 / RFCM J2-D4 RAS B4 /
Rate 2 Valve prevented RFCM J2-C4 RAS Rate 1 Valve
• Frame Level Left / Right pre-
vented

• RAS Mode is forced to RAS

Lock
• RFCM J1-B4 / RFCM J2-C4 RAS Machine Setup’s REAR AXLE STAB is
REAR AXLE RATE 1 Rate 1 Valve prevented SKYTRAK;
VALVE – OPEN 33592 5000mS open-circuit is detected on RFCM J1-B4 / Power cycled
CIRCUIT • RFCM J1-D4 / RFCM J2-D4 RAS RFCM J2-C4 RAS Rate 1 Valve
Rate 2 Valve prevented (only detected at power-up)
• Frame Level Left / Right pre-
vented

• RAS Mode is forced to RAS

Lock
• RFCM J1-B4 / RFCM J2-C4 RAS Machine Setup’s REAR AXLE STAB is
REAR AXLE RATE 2 Rate 1 Valve prevented SKYTRAK;
VALVE – SHORT TO 33593 5000mS short to battery is detected on RFCM J1- Power cycled
BATTERY • RFCM J1-D4 / RFCM J2-D4 RAS D4 /
Rate 2 Valve prevented RFCM J2-D4 RAS Rate 2 Valve
• Frame Level Left / Right pre-
vented

• RAS Mode is forced to RAS

Lock
• RFCM J1-B4 / RFCM J2-C4 RAS Machine Setup’s REAR AXLE STAB is
REAR AXLE RATE 2 Rate 1 Valve prevented SKYTRAK;
VALVE – SHORT TO 33594 5000mS short to ground is detected on RFCM J1- Power cycled
GROUND • RFCM J1-D4 / RFCM J2-D4 RAS D4 /
Rate 2 Valve prevented RFCM J2-D4 RAS Rate 2 Valve
• Frame Level Left / Right pre-
vented

3614RS, 4017RS 31211337 9-125

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• RAS Mode is forced to RAS
Lock
• RFCM J1-B4 / RFCM J2-C4 RAS Machine Setup’s REAR AXLE STAB is
REAR AXLE RATE 2 Rate 1 Valve prevented SKYTRAK;
VALVE – OPEN 33595 5000mS open-circuit is detected on RFCM J1-D4 / Power cycled
CIRCUIT • RFCM J1-D4 / RFCM J2-D4 RAS RFCM J2-D4 RAS Rate 2 Valve
Rate 2 Valve prevented (only detected at power-up)
• Frame Level Left / Right pre-
vented

• RFCM J1-C4 / RFCM J2-D4

Hitch Up Valve prevented Hitch Configured; open circuit detected
HITCH UP VALVE –
33599 5000mS on Power cycled
OPEN CIRCUIT • RFCM J1-D3 / RFCM J2-C4 RFCM J1-C4 / RFCM J2-D4 Hitch Up Valve
Hitch Down Valve prevented

• RFCM J1-C4 / RFCM J2-D4

HITCH UP VALVE – Hitch Up Valve prevented Hitch Configured; short to battery
SHORT TO 33600 5000mS detected on Power cycled
BATTERY • RFCM J1-D3 / RFCM J2-C4 RFCM J1-C4 / RFCM J2-D4 Hitch Up Valve
Hitch Down Valve prevented

• RFCM J1-C4 / RFCM J2-D4

HITCH UP VALVE – Hitch Up Valve prevented Hitch Configured; short to ground
SHORT TO 33601 5000mS detected on Power cycled
GROUND • RFCM J1-D3 / RFCM J2-C4 RFCM J1-C4 / RFCM J2-D4 Hitch Up Valve
Hitch Down Valve prevented

• RFCM J1-C4 / RFCM J2-D4 Hitch Configured; open circuit detected

HITCH DOWN Hitch Up Valve prevented on
VALVE – OPEN 33602 5000mS Power cycled
• RFCM J1-D3 / RFCM J2-C4 RFCM J1-D3 / RFCM J2-C4 Hitch Down
CIRCUIT
Hitch Down Valve prevented Valve

• RFCM J1-C4 / RFCM J2-D4 Hitch Configured; short to battery

HITCH DOWN Hitch Up Valve prevented detected on
VALVE – SHORT TO 33603 5000mS Power cycled
• RFCM J1-D3 / RFCM J2-C4 RFCM J1-D3 / RFCM J2-C4 Hitch Down
BATTERY
Hitch Down Valve prevented Valve

• RFCM J1-C4 / RFCM J2-D4 Hitch Configured; short to ground

HITCH DOWN Hitch Up Valve prevented detected on
VALVE – SHORT TO 33604 5000mS Power cycled
• RFCM J1-D3 / RFCM J2-C4 RFCM J1-D3 / RFCM J2-C4 Hitch Down
GROUND
Hitch Down Valve prevented Valve

• FFCM J1-H3 HIRAS Lock Con-

trol Valve 1 is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE LOCK prevented Machine Setup’s REAR AXLE STAB is
CONTROL VALVE 1 • Rear Axle Stabilization Indica- HIGH INTEGRITY;
33612 5000mS Power cycled
– SHORT TO tor flashes (fast) on Parker short to battery is detected on FFCM J1-
BATTERY Cabin Display H3 HIRAS Lock Control Valve 1
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

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 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• FFCM J1-H3 HIRAS Lock Con-
trol Valve 2 is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE LOCK prevented Machine Setup’s REAR AXLE STAB is
CONTROL VALVE 1 • Rear Axle Stabilization Indica- HIGH INTEGRITY;
33613 5000mS Power cycled
– SHORT TO tor flashes (fast) on Parker short to ground is detected on FFCM J1-
GROUND Cabin Display H3 HIRAS Lock Control Valve 1
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

• FFCM J1-H3 HIRAS Lock Con-

trol Valve 2 is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
prevented Machine Setup’s REAR AXLE STAB is
REAR AXLE LOCK
• Rear Axle Stabilization Indica- HIGH INTEGRITY;
CONTROL VALVE 1 33614 5000mS Power cycled
tor flashes (fast) on Parker open circuit is detected on FFCM J1-H3
– OPEN CIRCUIT
Cabin Display HIRAS Lock Control Valve 1
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

Machine Setup’s REAR AXLE STAB is

RALP and one of the following occur:
LCM J2-J4 / LCM J2-A3 RALP Lock
REAR AXLE LOCK
• LCM J2-J4 / LCM J2-A3 RALP Control Valve 1 measured current is
CONTROL VALVE 1
Lock Control Valve 1 prevented 250mA less than command when
– CURRENT
33615 5000mS command is greater than 500mA for Power cycled
FEEDBACK • LCM J3-D1 / LCM J2-C3 RALP 1000mS
READING TOO Lock Control Valve 2 prevented
LOW LCM J2-J4 / LCM J2-A3 RALP Lock
Control Valve 1 measured current is less
than 255mA when PWM is greater than
40% for 500mS

• FFCM J1-H4 HIRAS Lock Con-

trol Valve 2 is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE LOCK prevented Machine Setup’s REAR AXLE STAB is
CONTROL VALVE 2 • Rear Axle Stabilization Indica- HIGH INTEGRITY;
33616 5000mS Power cycled
– SHORT TO tor flashes (fast) on Parker short to battery is detected on FFCM J1-
BATTERY Cabin Display H4 HIRAS Lock Control Valve 2
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

3614RS, 4017RS 31211337 9-127

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• FFCM J1-H4 HIRAS Lock Con-
trol Valve 2 is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE LOCK prevented Machine Setup’s REAR AXLE STAB is
CONTROL VALVE 2 • Rear Axle Stabilization Indica- HIGH INTEGRITY;
33617 5000mS Power cycled
– SHORT TO tor flashes (fast) on Parker short to ground is detected on FFCM J1-
GROUND Cabin Display H4 HIRAS Lock Control Valve 2
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

• FFCM J1-H4 HIRAS Lock Con-

trol Valve 2 is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
prevented Machine Setup’s REAR AXLE STAB is
REAR AXLE LOCK
• Rear Axle Stabilization Indica- HIGH INTEGRITY;
CONTROL VALVE 2 33618 5000mS Power cycled
tor flashes (fast) on Parker open circuit is detected on FFCM J1-H4
– OPEN CIRCUIT
Cabin Display HIRAS Lock Control Valve 2
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

Machine Setup’s REAR AXLE STAB is

RALP and one of the following occur:
LCM J3-D1 / LCM J2-C3 RALP Lock
REAR AXLE LOCK
• LCM J2-J4 / LCM J2-A3 RALP Control Valve 2 measured current is
CONTROL VALVE 2
Lock Control Valve 1 prevented 250mA less than command when
– CURRENT
33619 5000mS command is greater than 500mA for Power cycled
FEEDBACK • LCM J3-D1 / LCM J2-C3 RALP 1000mS
READING TOO Lock Control Valve 2 prevented
LOW LCM J3-D1 / LCM J2-C3 RALP Lock
Control Valve 2 measured current is less
than 255mA when PWM is greater than
40% for 500mS

• LCM J2-J4 / LCM J2-A3 RALP

Lock Control Valve 1 prevented Machine Setup’s REAR AXLE STAB is
REAR AXLE TANK RALP;
• LCM J3-D1 / LCM J2-C3 RALP
VALVE – SHORT TO 33620 5000mS short to battery is detected on LCM J3- Power cycled
Lock Control Valve 2 prevented
BATTERY E1 /
• LCM J3-E1 / LCM J2-E3 RALP LCM J2-E3 RALP Tank Valve
Tank Valve prevented

• LCM J2-J4 / LCM J2-A3 RALP

Lock Control Valve 1 prevented Machine Setup’s REAR AXLE STAB is
REAR AXLE TANK RALP;
• LCM J3-D1 / LCM J2-C3 RALP
VALVE – SHORT TO 33621 5000mS short to ground is detected on LCM J3- Power cycled
Lock Control Valve 2 prevented
GROUND E1 /
• LCM J3-E1 / LCM J2-E3 RALP LCM J2-E3 RALP Tank Valve
Tank Valve prevented

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 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• LCM J2-J4 / LCM J2-A3 RALP
Lock Control Valve 1 prevented Machine Setup’s REAR AXLE STAB is
REAR AXLE TANK
• LCM J3-D1 / LCM J2-C3 RALP RALP;
VALVE – OPEN 33622 5000mS Power cycled
Lock Control Valve 2 prevented open-circuit is detected on LCM J3-E1 /
CIRCUIT
• LCM J3-E1 / LCM J2-E3 RALP LCM J2-E3 RALP Tank Valve
Tank Valve prevented

Machine Setup’s REAR AXLE STAB is

RALP and one of the following occur:
• LCM J2-J4 / LCM J2-A3 RALP • LCM J3-E1 / LCM J2-E3 RALP
REAR AXLE TANK Lock Control Valve 1 prevented Tank Valve measured current
VALVE – CURRENT is 250mA less than command
• LCM J3-D1 / LCM J2-C3 RALP
FEEDBACK 33623 5000mS when command is greater Power cycled
Lock Control Valve 2 prevented
READING TOO than 500mA for 1000mS
LOW • LCM J3-E1 / LCM J2-E3 RALP
• LCM J3-E1 / LCM J2-E3 RALP
Tank Valve prevented
Tank Valve measured current
is less than 255mA when PWM
is greater than 40% for 500mS

Machine Setup’s TRAILER BRAKE is

TRAILER BRAKE
ITALIAN;
VALVE – SHORT TO 33630 5000mS Trailer Brake Valve prevented Power cycled
short to battery is detected on RFCM J1-
BATTERY
C3

Machine Setup’s TRAILER BRAKE is

TRAILER BRAKE
ITALIAN;
VALVE – SHORT TO 33631 5000mS Trailer Brake Valve prevented Power cycled
short to ground is detected on RFCM J1-
GROUND
C3

TRAILER BRAKE Machine Setup’s TRAILER BRAKE is

VALVE – OPEN 33632 5000mS Trailer Brake Valve prevented ITALIAN; Power cycled
CIRCUIT open-circuit is detected on RFCM J1-C3

TRAILER LEFT
Machine Setup’s VEHICLE is LBP-AG;
TURN LIGHT – Trailer Turn Indicator flashes at increased
33659 5000mS short to battery detected on RFCM J1-G3 Power cycled
SHORT TO rate
Trailer Left Turn Light
BATTERY

TRAILER LEFT • RFCM J1-G3 Trailer Left Turn

Light digital output prevented Machine Setup’s VEHICLE is LBP-AG;
TURN LIGHT –
33660 5000mS short to ground detected on RFCM J1- Power cycled
SHORT TO • Trailer Turn Indicator flashes at G3 Trailer Left Turn Light
GROUND increased rate

Machine Setup’s VEHICLE is LBP-AG;

TRAILER LEFT
Trailer Turn Indicator flashes at increased trailer connected;
TURN LIGHT – 33661 5000mS Power cycled
rate open circuit detected on RFCM J1-G3
OPEN CIRCUIT
Trailer Left Turn Light for 3000mS

TRAILER RIGHT
Machine Setup’s VEHICLE is LBP-AG;
TURN LIGHT – Trailer Turn Indicator flashes at increased
33662 5000mS short to battery detected on RFCM J1-H3 Power cycled
SHORT TO rate
Trailer Right Turn Light
BATTERY

TRAILER RIGHT • RFCM J1-H3 Trailer Right Turn

Light digital output prevented Machine Setup’s VEHICLE is LBP-AG;
TURN LIGHT –
33663 5000mS short to ground detected on RFCM J1- Power cycled
SHORT TO • Trailer Turn Indicator flashes at H3 Trailer Right Turn Light
GROUND increased rate

Machine Setup’s VEHICLE is LBP-AG;

TRAILER RIGHT
Trailer Turn Indicator flashes at increased trailer connected;
TURN LIGHT – 33664 5000mS Power cycled
rate open circuit detected on RFCM J1-H3
OPEN CIRCUIT
Trailer Right Turn Light for 3000mS

3614RS, 4017RS 31211337 9-129

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
TRAILER MARKER Machine Setup’s VEHICLE is LBP-AG;
RFCM J2-M3 Trailer Marker Lights digital
LIGHTS – SHORT 33666 5000mS short to ground detected on RFCM J2- Power cycled
output prevented
TO GROUND M3 Trailer Marker Lights

TRAILER BRAKE Machine Setup’s VEHICLE is LBP-AG;

RFCM J1-G4 Trailer Brake Lights digital
LIGHTS – SHORT 33669 5000mS short to ground detected on RFCM J1- Power cycled
output prevented
TO GROUND G4 Trailer Brake Lights

TRAILER FOG Machine Setup’s VEHICLE is LBP-AG;

RFCM J1-H4 Trailer Fog Lights digital
LIGHTS – SHORT 33672 5000mS short to ground detected on RFCM J1- Power cycled
output prevented
TO GROUND H4 Trailer Fog Lights

AGRICULTURAL Machine Setup’s TRAILER BRAKE is

TRAILER BRAKE RFCM J3-A1 Agricultural Trailer Brake AGRICULTURAL;
33742 5000mS Power cycled
VALVE – OPEN Valve digital output prevented open circuit detected on RFCM J3-A1
CIRCUIT Agricultural Trailer Brake Valve

AGRICULTURAL Machine Setup’s TRAILER BRAKE is

TRAILER BRAKE RFCM J3-A1 Agricultural Trailer Brake AGRICULTURAL;
33743 5000mS Power cycled
VALVE – SHORT TO Valve digital output prevented short to battery detected on RFCM J3-A1
BATTERY Agricultural Trailer Brake Valve

AGRICULTURAL Machine Setup’s TRAILER BRAKE is

TRAILER BRAKE RFCM J3-A1 Agricultural Trailer Brake AGRICULTURAL;
33744 5000mS Power cycled
VALVE – SHORT TO Valve digital output prevented short to ground detected on RFCM J3-A1
GROUND Agricultural Trailer Brake Valve

CONTINUOUS
Machine Setup’s VEHICLE is LBP-RS,
AUXILIARY
AUXILIARY HYDRAULICS is YES; short to
HYDRAULICS CCM J2-M3 RS Continuous Auxiliary
33760 5000mS battery detected on CCM J2-M3 RS Power cycled
INDICATOR – Hydraulics Indicator prevented
Continuous Auxiliary Hydraulics
SHORT TO
Indicator
BATTERY

CONTINUOUS
Machine Setup’s VEHICLE is LBP-RS,
AUXILIARY
AUXILIARY HYDRAULICS is YES; short to
HYDRAULICS CCM J2-M3 RS Continuous Auxiliary
33761 5000mS ground detected on CCM J2-M3 RS Power cycled
INDICATOR – Hydraulics Indicator prevented
Continuous Auxiliary Hydraulics
SHORT TO
Indicator
GROUND

OUTRIGGERS Machine Setup’s VEHICLE is LBP-RS, O/R

DEPLOYED FFCM J1-H3 Outriggers Deployed DETECTION is PRESS or PRESS & PROX,
33762 5000mS Power cycled
INDICATOR – Indicator is prevented open circuit detected on FFCM J1-H3
OPEN CIRCUIT Outriggers Deployed Indicator

OUTRIGGERS
Machine Setup’s VEHICLE is LBP-RS, O/R
DEPLOYED
FFCM J1-H3 Outriggers Deployed DETECTION is PRESS or PRESS & PROX,
INDICATOR – 33763 5000mS Power cycled
Indicator is prevented short to battery detected on FFCM J1-H3
SHORT TO
Outriggers Deployed Indicator
BATTERY

OUTRIGGERS
Machine Setup’s VEHICLE is LBP-RS, O/R
DEPLOYED
FFCM J1-H3 Outriggers Deployed DETECTION is PRESS or PRESS & PROX,
INDICATOR – 33764 5000mS Power cycled
Indicator is prevented short to ground detected on FFCM J1-H3
SHORT TO
Outriggers Deployed Indicator
GROUND

OUTRIGGERS Machine Setup’s VEHICLE is LBP-RS, O/R

STOWED FFCM J1-H4 Outriggers Stowed Indicator DETECTION is PRESS or PRESS & PROX,
33765 5000mS Power cycled
INDICATOR – is prevented open circuit detected on FFCM J1-H4
OPEN CIRCUIT Outriggers Stowed Indicator

9-130 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
OUTRIGGERS
Machine Setup’s VEHICLE is LBP-RS, O/R
STOWED
FFCM J1-H4 Outriggers Stowed Indicator DETECTION is PRESS or PRESS & PROX,
INDICATOR – 33766 5000mS Power cycled
is prevented short to battery detected on FFCM J1-H4
SHORT TO
Outriggers Stowed Indicator
BATTERY

OUTRIGGERS
Machine Setup’s VEHICLE is LBP-RS, O/R
STOWED
FFCM J1-H4 Outriggers Stowed Indicator DETECTION is PRESS or PRESS & PROX,
INDICATOR – 33767 5000mS Power cycled
is prevented short to ground detected on FFCM J1-H4
SHORT TO
Outriggers Stowed Indicator
GROUND

EMISSIONS
SYSTEM Machine Setup’s ENGINE CONTROL is
MALFUNCTION CCM J2-M4 Emissions System DEUTZ 55KWS5 HRC, short to battery
33769 5000mS Power cycled
INDICATOR – Malfunction Indicator is prevented detected on CCM J2-M4 Emissions
SHORT TO System Malfunction Indicator
BATTERY

EMISSIONS
SYSTEM Machine Setup’s ENGINE CONTROL is
MALFUNCTION CCM J2-M4 Emissions System DEUTZ 55KWS5 HRC, short to ground
33770 5000mS Power cycled
INDICATOR – Malfunction Indicator is prevented detected on CCM J2-M4 Emissions
SHORT TO System Malfunction Indicator
GROUND

Machine Setup’s TRANSMISSION is

LINDE HYSTAT;
• Pump Pressure A is assumed as current limit detected on protected FET
TCM ANALOG 600.0 BAR for TCM analog ground
GROUND – SHORT 33771 5000mS Power Cycled
TO BATTERY • Pump Pressure B is assumed as
600.0 BAR Note: Check that TCM J2-G3, J2-H3, J2-
J3, J2-K3, J3-A3, J3-B3, and J3-C3 Analog
Ground are 0+/-0.1V.

The following actions shall occur when

Calibration’s TRANS SERVICE is NO:
• Direction Selection is forced to
Neutral (drive prevented)
WATCHDOG Machine Setup’s TRANSMISSION is
• TCM J1-A4 Watchdog Valve is
VALVE – OPEN 33798 5000mS LINDE HYSTAT, open circuit detected on Power Cycled
prevented
CIRCUIT TCM J1-A4 Watchdog Valve
• TCM J2-F4 / J2-F3 Drive For-
ward Valve is prevented
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

The following actions shall occur when

Calibration’s TRANS SERVICE is NO:
• Direction Selection is forced to
Neutral (drive prevented)
WATCHDOG Machine Setup’s TRANSMISSION is
• TCM J1-A4 Watchdog Valve is
VALVE – SHORT TO 33799 5000mS LINDE HYSTAT, short to battery detected Power Cycled
prevented
BATTERY on TCM J1-A4 Watchdog Valve
• TCM J2-F4 / J2-F3 Drive For-
ward Valve is prevented
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

3614RS, 4017RS 31211337 9-131

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
The following actions shall occur when
Calibration’s TRANS SERVICE is NO:
• Direction Selection is forced to
Neutral (drive prevented)
WATCHDOG Machine Setup’s TRANSMISSION is
• TCM J1-A4 Watchdog Valve is
VALVE – SHORT TO 33800 5000mS LINDE HYSTAT, short to ground detected Power Cycled
prevented
GROUND on TCM J1-A4 Watchdog Valve
• TCM J2-F4 / J2-F3 Drive For-
ward Valve is prevented
• TCM J2-H4 / J2-B3 Drive
Reverse Valve is prevented

• Direction Selection is forced to Machine Setup’s TRANSMISSION is

Neutral (drive prevented) LINDE HYSTAT and one of the following
• TCM J1-A4 Watchdog Valve is occur:
prevented • TCM J2-F4 / J2-F3 Drive For-
DRIVE FORWARD • TCM J2-F4 / J2-F3 Drive For- ward Valve measured current
VALVE – CURRENT ward Valve is prevented is 250mA less than command
33801 5000mS Power Cycled
FEEDBACK TOO when command is greater
• TCM J2-H4 / J2-B3 Drive
LOW than 500mA for 1000mS
Reverse Valve is prevented
• TCM J2-F4 / J2-F3 Drive For-
ward Valve measured current
is less than 255mA when PWM
is greater than 40% for 500mS

• Direction Selection is forced to Machine Setup’s TRANSMISSION is

Neutral (drive prevented) LINDE HYSTAT and one of the following
• TCM J1-A4 Watchdog Valve is occur:
prevented • TCM J2-H4 / J2-B3 Drive
• TCM J2-F4 / J2-F3 Drive For- Reverse Valve measured cur-
DRIVE REVERSE ward Valve is prevented rent is 250mA less than com-
VALVE – CURRENT mand when command is
33802 5000mS • TCM J2-H4 / J2-B3 Drive Power Cycled
FEEDBACK TOO greater than 500mA for
Reverse Valve is prevented
LOW 1000mS
• TCM J2-H4 / J2-B3 Drive
Reverse Valve measured cur-
rent is less than 255mA when
PWM is greater than 40% for
500mS

• FFCM J1-G3 / J2-C4 HIRAS Pres-

sure Control Valve is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE prevented Machine Setup’s REAR AXLE STAB is
PRESSURE
• Rear Axle Stabilization Indica- HIGH INTEGRITY;
CONTROL VALVE – 33806 5000mS Power cycled
tor flashes (fast) on Parker short to battery is detected on FFCM J1-
SHORT TO
Cabin Display G3 / J2-C4 HIRAS Pressure Control Valve
BATTERY
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

9-132 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• FFCM J1-G3 / J2-C4 HIRAS Pres-
sure Control Valve is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE prevented Machine Setup’s REAR AXLE STAB is
PRESSURE
• Rear Axle Stabilization Indica- HIGH INTEGRITY;
CONTROL VALVE – 33807 5000mS Power cycled
tor flashes (fast) on Parker short to ground is detected on FFCM J1-
SHORT TO
Cabin Display G3 / J2-C4 HIRAS Pressure Control Valve
GROUND
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

• FFCM J1-G3 / J2-C4 HIRAS Pres-

sure Control Valve is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE prevented Machine Setup’s REAR AXLE STAB is
PRESSURE • Rear Axle Stabilization Indica- HIGH INTEGRITY;
33808 5000mS Power cycled
CONTROL VALVE – tor flashes (fast) on Parker open circuit is detected on FFCM J1-G3 /
OPEN CIRCUIT Cabin Display J2-C4 HIRAS Pressure Control Valve
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

• FFCM J2-H4 / J2-A3 HIRAS Rate

Control Valve is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE RATE prevented Machine Setup’s REAR AXLE STAB is
CONTROL VALVE – • Rear Axle Stabilization Indica- HIGH INTEGRITY;
33809 5000mS Power cycled
SHORT TO tor flashes (fast) on Parker short to battery is detected on FFCM J2-
BATTERY Cabin Display H4 / J2-A3 HIRAS Rate Control Valve
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

3614RS, 4017RS 31211337 9-133

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• FFCM J2-H4 / J2-A3 HIRAS Rate
Control Valve is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
REAR AXLE RATE prevented Machine Setup’s REAR AXLE STAB is
CONTROL VALVE – • Rear Axle Stabilization Indica- HIGH INTEGRITY;
33810 5000mS Power cycled
SHORT TO tor flashes (fast) on Parker short to ground is detected on FFCM J2-
GROUND Cabin Display H4 / J2-A3 HIRAS Rate Control Valve
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

• FFCM J2-H4 / J2-A3 HIRAS Rate

Control Valve is prevented
• Main Lift Up is prevented when
Boom Angle is greater than 40°
• Frame Leveling Left/Right are
prevented Machine Setup’s REAR AXLE STAB is
REAR AXLE RATE
• Rear Axle Stabilization Indica- HIGH INTEGRITY;
CONTROL VALVE – 33811 5000mS Power cycled
tor flashes (fast) on Parker open circuit is detected on FFCM J2-H4 /
OPEN CIRCUIT
Cabin Display J2-A3 HIRAS Rate Control Valve
• HIRAS Mode is forced to ERROR
• Drive Speed Restriction for RAS
Error is forced
• Start HIRAS Integrity Checks is
prevented

• FFCM J2-H4 / J2-A3 HIRAS Rate Machine Setup’s REAR AXLE STAB is
Control Valve is prevented HIGH INTEGRITY; Current Feedback
• Main Lift Up is prevented when Faults are enabled and any of the
Boom Angle is greater than 40° following conditions are present:
• Frame Leveling Left/Right are • FFCM J2-H4 / J2-A3 HIRAS
REAR AXLE RATE
prevented Rate Control Valve measured
CONTROL VALVE –
current is 250mA less than
CURRENT • Rear Axle Stabilization Indica-
33812 5000mS command when command is Power cycled
FEEDBACK tor flashes (fast) on Parker
greater than 500mA for
READING TOO Cabin Display
1000mS
LOW • HIRAS Mode is forced to ERROR
• FFCM J2-H4 / J2-A3 HIRAS
• Drive Speed Restriction for RAS Rate Control Valve measured
Error is forced current is less than 255mA
• Start HIRAS Integrity Checks is when PWM is greater than
prevented 40% for 500mS

9-134 31211337 3614RS, 4017RS

 Electrical System

Cabin Latch
Help Message DTC Actions Trigger
Alarm Condition
• FFCM J1-G3 / J2-C4 HIRAS Pres- Machine Setup’s REAR AXLE STAB is
sure Control Valve is prevented HIGH INTEGRITY; Current Feedback
• Main Lift Up is prevented when Faults are enabled and any of the
Boom Angle is greater than 40° following conditions are present:
REAR AXLE • Frame Leveling Left/Right are • FFCM J1-G3 / J2-C4 HIRAS
PRESSURE prevented Pressure Control Valve mea-
CONTROL VALVE – sured current is 250mA less
• Rear Axle Stabilization Indica-
CURRENT 33813 5000mS than command when com- Power cycled
tor flashes (fast) on Parker
FEEDBACK mand is greater than 500mA
Cabin Display
READING TOO for 1000mS
LOW • HIRAS Mode is forced to ERROR
• FFCM J1-G3 / J2-C4 HIRAS
• Drive Speed Restriction for RAS Pressure Control Valve mea-
Error is forced sured current is less than
• Start HIRAS Integrity Checks is 255mA when PWM is greater
prevented than 40% for 500mS

3614RS, 4017RS 31211337 9-135

 Electrical System

9.16.10 Engine (43x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
FUEL SENSOR –
Fuel Level assumed to be Empty FFCM J1-E1 Fuel Sensor Signal
SHORT TO BATTERY 431 5000mS Power cycled
(0.0%) measures >4.77V for 1,000mS
OR OPEN CIRCUIT

FUEL SENSOR – Fuel Level assumed to be Empty FFCM J1-E1 Fuel Sensor Signal
432 5000mS Power cycled
SHORT TO GROUND (0.0%) measures <0.05V for 1,000mS

ENGINE TROUBLE ECM annunciates a fault using J1939’s J1939 DM1 request
437 5000mS –
CODE: SPN:FMI DM1 terminates

HIGH ENGINE
High Engine Temperature
COOLANT ECM annunciates High Engine High Engine Coolant
4316 Continuously Indicator is shown on Parker Cabin
TEMPERATURE Coolant Warning via DM1 Warning not active
Display
WARNING

• Engine De-Rate is acti-

HIGH ENGINE vated (engine speed
COOLANT restricted) ECM annunciates High Engine High Engine Coolant
4317 Continuously
TEMPERATURE • High Engine Tempera- Coolant Critical via DM1 Critical not active
CRITICAL ture Indicator is shown
on Parker Cabin Display

LOW ENGINE OIL Low Engine Oil Pressure Indicator ECM annunciates Low Engine Oil
4318 Continuously Power cycled
PRESSURE WARNING is shown on Parker Cabin Display Pressure Warning via DM1

• Engine De-Rate is acti-

vated (engine speed
LOW ENGINE OIL restricted) ECM annunciates Low Engine Oil
4319 Continuously Power cycled
PRESSURE CRITICAL • Low Engine Oil Pressure Pressure Critical via DM1
Indicator is shown on
Parker Cabin Display

Machine Setup’s ENGINE CONTROL is

not CUMMINS, Engine Running for
AIR FILTER Air Filter Restriction icon is shown
4321 5000mS 10,000mS, and FFCM J3-F2 Air Filter Power cycled
RESTRICTION on Parker Cabin Display
Pressure Switch is closed (grounded)
for 3,000mS

Machine Setup’s ENGINE CONTROL is

CUMMINS, and either of the following
conditions is present:
• ECM indicates differential
AIR FILTER Air Filter Restriction icon is shown
4321 5000mS pressure exceeds 25” of Power cycled
RESTRICTION on Parker Cabin Display
water column (DM1 107:15)
• ECM indicates differential
pressure exceeds 45” of
water column (DM1 107:16)

9-136 31211337 3614RS, 4017RS

 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s VEHICLE is not LBP-
RS, and any of the following
conditions are present:
• CCM J1-A1 Throttle Pedal
Position (Primary) or CCM
THROTTLE PEDAL – J1-A2 Throttle Pedal Posi-
Throttle Engine Speed is set to
VOLTAGE OUT OF 4337 5000mS tion (Backup) is less than Power cycled
Closed Throttle RPM
RANGE 0.25V for 500mS
• CCM J1-A1 Throttle Pedal
Position (Primary) or CCM
J1-A2 Throttle Pedal Posi-
tion (Backup) is greater than
4.75V for 500mS

Machine Setup’s VEHICLE is not LBP-

RS, and all of the following conditions
are present:
THROTTLE PEDAL – • DTC 4337 not active
Throttle Engine Speed is set to
VOLTAGE 4338 5000mS • Scaled Throttle Pedal Posi- Power cycled
Closed Throttle RPM
DISAGREEMENT tion (Primary) and Scaled
Throttle Pedal Position (Sec-
ondary) differ more than
10% for 500mS

• Fan Speed Valve pre- Machine Setup’s FAN CONTROL is

vented HYDRAULIC, HYD W/ REV, or DUAL
FAN SPEED VALVE –
4339 5000mS HYD; short to battery detected on Power cycled
SHORT TO BATTERY • Fan Reverse Valve pre- FFCM J3-D1 / FFCM J2-B4 Fan Speed
vented Valve

• Fan Speed Valve pre- Machine Setup’s FAN CONTROL is

vented HYDRAULIC, HYD W/ REV, or DUAL
FAN SPEED VALVE –
4340 5000mS HYD; short to ground detected on Power cycled
SHORT TO GROUND • Fan Reverse Valve pre- FFCM J3-D1 / FFCM J2-B4 Fan Speed
vented Valve

• Fan Speed Valve pre- Machine Setup’s FAN CONTROL is

FAN SPEED VALVE – vented HYDRAULIC, HYD W/ REV, or DUAL
4341 5000mS Power cycled
OPEN CIRCUIT • Fan Reverse Valve pre- HYD; open-circuit detected on FFCM
vented J3-D1 / FFCM J2-B4 Fan Speed Valve

Machine Setup’s FAN CONTROL is

HYDRAULIC, HYD W/ REV, or DUAL
HYD; Current Feedback Faults are
enabled; and one the following occur:
• FFCM J3-D1 / FFCM J2-B4
• Fan Speed Valve pre- Fan Speed Valve measured
FAN SPEED VALVE – vented current is 250mA less than
CURRENT FEEDBACK 4342 5000mS command when command Power cycled
READING TOO LOW • Fan Reverse Valve pre- is greater than 500mA for
vented 1000mS
• FFCM J3-D1 / FFCM J2-B4
Fan Speed Valve measured
current is less than 255mA
when PWM is greater than
40% for 500mS

3614RS, 4017RS 31211337 9-137

 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
• Fan Speed Valve pre-
vented Machine Setup’s FAN CONTROL is
FAN REVERSE VALVE
• Fan Speed 2 Valve pre- HYD W/ REV, or DUAL HYD; short to
– SHORT TO 4343 5000mS Power cycled
vented battery detected on FFCM J3-E1 Fan
BATTERY
• Fan Reverse Valve pre- Reversing Valve
vented

Machine Setup’s FAN CONTROL is

FAN REVERSE VALVE
• Fan Reverse Valve pre- HYD W/ REV, or DUAL HYD; short to
– SHORT TO 4344 5000mS Power cycled
vented ground detected on FFCM J3-E1 Fan
GROUND
Reversing Valve

Machine Setup’s FAN CONTROL is

FAN REVERSE VALVE • Fan Reverse Valve pre- HYD W/ REV, or DUAL HYD; open-
4345 5000mS Power cycled
– OPEN CIRCUIT vented circuit detected on FFCM J3-E1 Fan
Reversing Valve

• Drivetrain Neutral pre- Machine Setup’s ENGINE CONTROL is

DRIVETRAIN vented DEUTZ;
NEUTRAL – SHORT 4346 5000mS Power cycled
• Engine Start is pre- short to battery detected on FFCM J2-
TO BATTERY
vented J4

• Drivetrain Neutral pre- Machine Setup’s ENGINE CONTROL is

DRIVETRAIN vented DEUTZ;
NEUTRAL – SHORT 4347 5000mS Power cycled
• Engine Start is pre- short to ground detected on FFCM J2-
TO GROUND
vented J4

• Drivetrain Neutral pre-

DRIVETRAIN vented Machine Setup’s ENGINE CONTROL is
NEUTRAL – OPEN 4348 5000mS DEUTZ; Power cycled
CIRCUIT • Engine Start is pre- open-circuit detected on FFCM J2-J4
vented

Machine Setup’s AIR CONDITION is

A/C COMMAND – • A/C Command pre- YES;
4349 5000mS Power cycled
SHORT TO BATTERY vented short to battery detected on CCM J2-
L4

Machine Setup’s AIR CONDITION is

A/C COMMAND – • A/C Command pre- YES;
4350 5000mS Power cycled
SHORT TO GROUND vented short to ground detected on CCM J2-
L4

Machine Setup’s AIR CONDITION is

A/C COMMAND – • A/C Command pre-
4351 5000mS YES; Power cycled
OPEN-CIRCUIT vented
open-circuit detected on CCM J2-L4
• Fan Speed 2 Valve pre- Machine Setup’s FAN CONTROL is
FAN SPEED 2 VALVE vented DUAL HYD; short to battery detected
– SHORT TO 4354 5000mS Power cycled
• Fan Reverse Valve pre- on FFCM J1-G3 / FFCM J2-C4 Fan
BATTERY
vented Speed 2 Valve

• Fan Speed 2 Valve pre- Machine Setup’s FAN CONTROL is

FAN SPEED 2 VALVE vented DUAL HYD; short to ground detected
– SHORT TO 4355 5000mS Power cycled
• Fan Reverse Valve pre- on FFCM J1-G3 / FFCM J2-C4 Fan
GROUND
vented Speed 2 Valve

• Fan Speed 2 Valve pre- Machine Setup’s FAN CONTROL is

FAN SPEED 2 VALVE vented DUAL HYD; open-circuit detected on
4356 5000mS Power cycled
– OPEN CIRCUIT • Fan Reverse Valve pre- FFCM J1-G3 / FFCM J2-C4 Fan Speed 2
vented Valve

9-138 31211337 3614RS, 4017RS

 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s FAN CONTROL is
DUAL HYD; Current Feedback Faults
are enabled; and one the following
occur:
• FFCM J1-G3 / FFCM J2-C4
• Fan Speed 2 Valve pre- Fan Speed 2 Valve mea-
FAN SPEED 2 VALVE
vented sured current is 250mA less
– CURRENT
4357 5000mS than command when com- Power cycled
FEEDBACK READING • Fan Reverse Valve pre- mand is greater than
TOO LOW vented 500mA for 1000mS
• FFCM J1-G3 / FFCM J2-C4
Fan Speed 2 Valve mea-
sured current is less than
255mA when PWM is
greater than 40% for 500mS

Machine Setup’s ENGINE CONTROL is

SCR CLEAN ENABLE CAT34 Engine Configured or CAT44
– SHORT TO 4361 5000ms SCR Clean Enable prevented Engine Configured; Power cycled
BATTERY short to battery detected on FFCM J2-
J4

Machine Setup’s ENGINE CONTROL is

SCR CLEAN ENABLE CAT34 Engine Configured or CAT44
– SHORT TO 4362 5000mS SCR Clean Enable prevented Engine Configured; Power cycled
GROUND short to ground detected on FFCM J2-
J4

Machine Setup’s ENGINE CONTROL is

CUMMINS 55KW, DEUTZ 55KW HRC,
WRONG ENGINE Throttle Engine Speed is set to or DEUTZ 55KWS5 HRC;
4367 5000mS Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <53KW
or >57KW

Machine Setup’s ENGINE CONTROL is

WRONG ENGINE Throttle Engine Speed is set to DEUTZ 75KWRS LRC
4367 5000mS Power cycled
SELECTED Closed Throttle RPM SPN166 Engine Rated Power <73KW
or >77KW

Machine Setup’s VEHICLE is LBP-AG;

ENGINE CONTROL is CAT C36 S5
WRONG ENGINE Throttle Engine Speed is set to 100KW and TRANSMISSION is not
4367 5000mS Power cycled
SELECTED Closed Throttle RPM TURNER 6SPD L/U (only one
transmission selection is permitted
with this vehicle/engine)

Machine Setup’s VEHICLE is LBP-AG;

ENGINE CONTROL is CAT C36 S5 90KW
WRONG ENGINE Throttle Engine Speed is set to and TRANSMISSION is not TURNER
4367 5000mS Power cycled
SELECTED Closed Throttle RPM 6SPD AUTO (only one transmission
selection is permitted with this
vehicle/engine)

Machine Setup’s VEHICLE is LBP-AG;

ENGINE CONTROL is CAT C36 S3A
WRONG ENGINE Throttle Engine Speed is set to 90KW and TRANSMISSION is not
4367 5000mS Power cycled
SELECTED Closed Throttle RPM TURNER 6SPD (only one transmission
selection is permitted with this
vehicle/engine)

3614RS, 4017RS 31211337 9-139

 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s ENGINE CONTROL is
WRONG ENGINE Throttle Engine Speed is set to CUMMINS 119KWHRC;
4367 5000mS Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <124KW

Machine Setup’s ENGINE CONTROL is

WRONG ENGINE Throttle Engine Speed is set to CUMMINS 119KWLRC;
4367 5000mS Power cycled
SELECTED Closed Throttle RPM SPN166 Engine Rated Power <118KW
or >124KW

Machine Setup’s VEHICLE is HBP;

Machine Setup’s ENGINE CONTROL is
WRONG ENGINE Throttle Engine Speed is set to CAT34 75KW HRC;
4367 5000mS Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <75.0KW
or >76.0KW

Machine Setup’s VEHICLE is HBP;

Machine Setup’s ENGINE CONTROL is
WRONG ENGINE Throttle Engine Speed is set to CAT34 83KW HRC;
4367 5000mS Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <82.5KW
or >84KW

Machine Setup’s VEHICLE is HBP;

Machine Setup’s ENGINE CONTROL is
WRONG ENGINE Throttle Engine Speed is set to CAT C36 S5 55KW;
4367 5000mS Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <54KW
or >56KW

Machine Setup’s VEHICLE is HBP;

Machine Setup’s ENGINE CONTROL is
WRONG ENGINE Throttle Engine Speed is set to CAT C36 S5 100KW or CAT C36 S5
4367 5000mS 83KW; Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <98KW
or >102KW

Machine Setup’s VEHICLE is HBP;

Machine Setup’s ENGINE CONTROL is
WRONG ENGINE Throttle Engine Speed is set to CAT44 74.5KW LRC;
4367 5000mS Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <74.0KW
or >74.5KW

Machine Setup’s VEHICLE is HBP;

Machine Setup’s ENGINE CONTROL is
WRONG ENGINE Throttle Engine Speed is set to CAT44 82.1KW LRC;
4367 5000mS Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <81KW
or >82.5KW

Machine Setup’s VEHICLE is HBP;

Machine Setup’s ENGINE CONTROL is
WRONG ENGINE Throttle Engine Speed is set to CAT44 106KW HRC or CAT44 106KW
4367 5000mS LRC Power cycled
SELECTED Closed Throttle RPM
SPN166 Engine Rated Power <102KW
or >107KW

Machine Setup’s FAN CONTROL is

REVERSING FAN – CLEANFIX, VEHICLE is not LBP-SC;
4369 5000mS Cleanfix Reversing Fan prevented Power cycled
OPEN CIRCUIT open-circuit detected on FFCM J3-E1
Reversing Fan digital output

9-140 31211337 3614RS, 4017RS

 Electrical System

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s FAN CONTROL is
REVERSING FAN – CLEANFIX, VEHICLE is LBP-SC; open-
4369 5000mS Cleanfix Reversing Fan prevented Power cycled
OPEN CIRCUIT circuit detected on FFCM J1-G4
Reversing Fan digital output

Machine Setup’s FAN CONTROL is

REVERSING FAN – CLEANFIX, VEHICLE is not LBP-SC;
4370 5000mS Cleanfix Reversing Fan prevented Power cycled
SHORT TO BATTERY short to battery detected on FFCM J3-
E1 Reversing Fan digital output

Machine Setup’s FAN CONTROL is

REVERSING FAN – CLEANFIX, VEHICLE is LBP-SC; short to
4370 5000mS Cleanfix Reversing Fan prevented Power cycled
SHORT TO BATTERY battery detected on FFCM J1-G4
Reversing Fan digital output

Machine Setup’s FAN CONTROL is

REVERSING FAN – CLEANFIX, VEHICLE is not LBP-SC;
4371 5000mS Cleanfix Reversing Fan prevented Power cycled
SHORT TO GROUND short to ground detected on FFCM J3-
E1 Reversing Fan digital output

Machine Setup’s FAN CONTROL is

REVERSING FAN – CLEANFIX, VEHICLE is not LBP-SC;
4371 5000mS Cleanfix Reversing Fan prevented Power cycled
SHORT TO GROUND short to ground detected on FFCM J1-
G4 Reversing Fan digital output

Machine Setup’s ENGINE CONTROL is

DEUTZ 100KW LRC or DEUTZ 115KW
LRC; Water In Fuel Issue not
WATER IN FUEL 4375 Continuously –
active
ECM annunciates Water In Fuel Issue
via DM1 (SPN 97, any FMI)

Machine Setup’s ENGINE CONTROL is

DPF EXCHANGE
DEUTZ 55KWS5 HRC and DPF Status is
REQUIRED – HIGH 4383 5000mS – Power cycled
EXCHANGE REQD (Engine requesting
ASH LOAD
exchange of Diesel Particulate Filter)

Machine Setup’s ENGINE CONTROL is

DPF EXCHANGE DEUTZ 55KWS5 HRC and DPF Status is
REQUIRED – 4384 Continuously – EXCH REQD WL1 (Engine requesting Power cycled
WARNING LEVEL 1 urgent exchange of Diesel Particulate
Filter)

Machine Setup’s ENGINE CONTROL is

DPF EXCHANGE Note: The engine will derate itself DEUTZ 55KWS5 HRC and DPF Status is
REQUIRED –ENGINE 4385 Continuously during this situation, exchange the EXCH REQD WL2 (Engine derates Power cycled
DERATED DPF immediately! itself, immediate exchange of Diesel
Particulate Filter is required)

3614RS, 4017RS 31211337 9-141

 Electrical System

9.16.11 Battery Supply (44x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Either of the following
conditions are presen for
10,000mS:
BATTERY VOLTAGE Battery Voltage Low icon is shown on Engine running; CCM battery
445 5000mS Engine Operating State is
LOW Parker Cabin Display voltage < 11.00V for 3,000mS
not ENGINE RUNNING
CCM battery voltage
>11.25V
Machine Setup’s PLATFORM
REFERENCE
OPTION is YES;
VOLTAGE OUT OF
448 5000mS Platform functions prevented keyswitch platform; PLT detects Power cycled
RANGE –
reference voltage is out of range
PLATFORM
(>5.4V or <4.6V) for 1,000mS
CCM BATTERY • Hydraulic functions are pre- Engine not cranking; CCM J1-H3
VOLTAGE TOO vented Ignition Relay has been energized
4435 5000mS Power cycled
LOW – SYSTEM • Power State is ERROR for for >140mS; CCM battery voltage <
SHUTDOWN power-up or SAFE for run-time 9.0V for 500mS

CCM BATTERY • Hydraulic functions are pre-

vented CCM battery voltage exceeds
VOLTAGE TOO
4436 5000mS Maximum Supply Voltage for Power cycled
HIGH – SYSTEM • Power State is ERROR for 250mS
SHUTDOWN power-up or SAFE for run-time
FFCM BATTERY • Hydraulic functions are pre-
VOLTAGE TOO vented Engine not cranking; FFCM battery
4438 5000mS Power cycled
LOW – SYSTEM • Power State is ERROR for voltage < 9.0V for 500mS
SHUTDOWN power-up or SAFE for run-time
FFCM BATTERY • Hydraulic functions are pre-
vented FFCM battery voltage exceeds
VOLTAGE TOO
4439 5000mS Maximum Supply Voltage for Power cycled
HIGH – SYSTEM • Power State is ERROR for 250mS
SHUTDOWN power-up or SAFE for run-time
RFCM BATTERY • Hydraulic functions are pre-
VOLTAGE TOO vented Engine not cranking; RFCM battery
4441 5000mS Power cycled
LOW – SYSTEM • Power State is ERROR for voltage < 9.0V for 500mS
SHUTDOWN power-up or SAFE for run-time
RFCM BATTERY • Hydraulic functions are pre-
vented RFCM battery voltage exceeds
VOLTAGE TOO
4442 5000mS Maximum Supply Voltage for Power cycled
HIGH – SYSTEM • Power State is ERROR for 250mS
SHUTDOWN power-up or SAFE for run-time
TCM BATTERY • Hydraulic functions are pre-
VOLTAGE TOO vented Engine not cranking; TCM battery
4449 5000mS Power cycled
LOW – SYSTEM • Power State is ERROR for voltage < 9.0V for 500mS
SHUTDOWN power-up or SAFE for run-time
TCM BATTERY • Hydraulic functions are pre-
vented TCM battery voltage exceeds
VOLTAGE TOO
4450 5000mS Maximum Supply Voltage for Power cycled
HIGH – SYSTEM • Power State is ERROR for 250mS
SHUTDOWN power-up or SAFE for run-time
LCM BATTERY
VOLTAGE TOO Engine not cranking; LCM battery
4469 5000mS Hydraulic functions are prevented Power cycled
LOW – SYSTEM voltage < 9.0V for 500mS
SHUTDOWN
LCM BATTERY
LCM battery voltage exceeds
VOLTAGE TOO
4470 5000mS Hydraulic functions are prevented Maximum Supply Voltage for Power cycled
HIGH – SYSTEM
250mS
SHUTDOWN

9-142 31211337 3614RS, 4017RS

 Electrical System

9.16.12 Transmission & Drive System (46x)

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
Machine Setup’s TRANS TEMP is
SWITCH, SENSOR, or BOSCH HYSTAT
and one of the following situations • Machine Setup’s
occur: TRANSMISSION is HC
HIGH HYSTAT and Transmis-
TRANSMISSIO Transmission Temperature • Machine Setup’s TRANSMIS- sion Oil
N OIL 461 Continuously Critical icon is shown on Parker ISON is HC HYSTAT and Trans- Temperature < 100ºC
TEMPERATUR Cabin Display mission Oil Temperature >
E CRITICAL • (Default) Transmission
102ºC for 250mS
Oil Temperature <
• (Default) Transmission Oil 110ºC
Temperature >120ºC for
250mS
One of the following occur:
Machine Setup’s TRANS TEMP is • Drive Selection is For-
HIGH ward or Reverse; Trans-
HYSTAT SENSOR;
TRANSMISSIO Transmission Temperature mission Oil Temp <
Direction Selection is Forward or
N OIL 461 Continuously Critical icon is shown on Parker 73ºC
Reverse;
TEMPERATUR Cabin Display
Transmission Oil Temperature >75ºC for • Drive Selection is Neu-
E CRITICAL
250mS tral for 5 minutes
• Power cycled

• Column Direction Machine Setup’s COLUMN SELECTOR is

CONFLICTING Switch position is YES; Drive Forward Switch (CCM J1-D3),
DRIVE regarded as neutral
462 5000mS Drive Neutral Switch (CCM J1-E3), or Power cycled
DIRECTION
• Engine Start pre- Drive Reverse Switch (CCM J1-E4) are
SIGNALS
vented energized simultaneously for 500mS

• Column Direction Cabin Mode; Machine Setup’s COLUMN

DRIVE Switch position is SELECTOR is YES; Drive Forward Switch
DIRECTION 463 5000mS regarded as neutral (CCM J1-D3), Drive Neutral Switch (CCM Power cycled
SIGNAL LOST • Engine Start pre- J1-E3), and Drive Reverse Switch (CCM
vented J1-E4) are de-energized for 500mS

Cabin Mode; Machine Setup’s COLUMN

SELECTOR is YES; Machine Setup’s
JOYSTICK FNR is NO; and one of the
following occur:
• Machine Setup’s TRANSMIS-
SION is HC HYSTAT, BOSCH
HYSTAT or LINDE HYSTAT;
CONFLICTING Gear Select 1 Switch (CCM J2-
GEAR Last valid gear selection is G3) and Gear Select 2 Switch
464 5000mS Power cycled
SELECTION maintained (CCM J2-F4) are energized
SIGNALS simultaneously for 500mS
• Default; Gear Select 1 Switch
(CCM J2-G3), Gear Select 2
Switch (CCM J2-F4), Gear
Select 3 Switch (CCM J2-E3),
or Gear Select 4 Switch (CCM
J2-K3) are energized simulta-
neously for 500mS

3614RS, 4017RS 31211337 9-143

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
Cabin Mode; Machine Setup’s COLUMN
SELECTOR is YES; Machine Setup’s
JOYSTICK FNR is NO; and one of the
following occur:
• Machine Setup’s TRANSMIS-
SION is HC HYSTAT, BOSCH
HYSTAT or LINDE HYSTAT;
Gear Select 1 Switch (CCM J2-
GEAR
Last valid gear selection is G3) and Gear Select 2 Switch
SELECTION 465 5000mS Power cycled
maintained (CCM J2-F4) are de-energized
SIGNAL LOST
for 500mS
• Default; Gear Select 1 Switch
(CCM J2-G3), Gear Select 2
Switch (CCM J2-F4), Gear
Select 3 Switch (CCM J2-E3),
and Gear Select 4 Switch
(CCM J2-K3) are de-energized
for 500mS

TRANSMISSIO Machine Setup’s TRANSMISSION is

N TROUBLE BOSCH HYSTAT; J1939 DM1 request
467 5000mS –
CODE: DRC annunciates a fault using J1939’s terminates
SPN:FMI DM1

The following restrictions apply

continuously:
• Vehicle Speed is “99” Machine Setup’s VEHICLE is not HBP
Machine Setup’s TRANSMISSION is
TURNER 4SPD2 or TURNER 4SPD3, and
The following restrictions apply
all of the following conditions are
until power cycle:
present:
• Gear selection
VEHICLE • Direction Selection is Forward
restricted to present
or Reverse Retained through power cycle;
SPEED state
468 5000mS Vehicle Speed counts
SENSOR – NOT • Park Brake is released
• Direction selection detected for 5,000mS
RESPONDING restricted to present • Service Brake Status is
state and neutral Released
• Engine RPM >1200 RPM
The following restrictions apply • FFCM J1-F3 Vehicle Speed
after power cycle: counts not detected for
40,000mS
• Gear and Direction
Selection restricted to
F2, N2, and R2

9-144 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
Machine Setup’s VEHICLE is not HBP;
Machine Setup’s TRANSMISSION is
Turner 6 Speed Transmission
Configured, all of the following
conditions are present:
The following restrictions apply
• Direction Selection is Forward
continuously:
or Reverse
• Vehicle Speed is “99” • Park Brake is released
• Lock-Up Convertor • Service Brake Status is
prevented Released
• Engine RPM >1200 RPM
The following restrictions apply
until power cycle:
AND any of the following conditions are
VEHICLE • Gear selection present: Retained through power cycle;
SPEED restricted to last valid
468 5000mS Vehicle Speed counts
SENSOR – NOT state • Manual Transmission Mode is
detected for 5,000mS
RESPONDING selected and FFCM J1-F3
• Direction selection Vehicle Speed counts not
restricted to present detected for 40,000mS
state and neutral
• Automatic Transmission
Mode is selected, Gear Selec-
The following restrictions apply tion is st, 2nd or 3rd gear, and
after power cycle: FFCM J1-F3 Vehicle Speed
• Gear and Direction counts not detected for
Selection restricted to 40,000mS
F3, N3, and R2 • Automatic Transmission
Mode is selected, Gear Selec-
tion is 4th, 5th, or 6th gear, and
FFCM J1-F3 Vehicle Speed
counts not detected for
3000mS

The following restrictions apply

continuously:
• Vehicle Speed is “99”
Machine Setup’s TRANSMISSION is ZF
4SPD AUTO and all of the following
The following restrictions apply
conditions are present:
until power cycle:
• Direction Selection is Forward
• Gear selection
VEHICLE or Reverse
restricted to last valid
Retained through power cycle;
SPEED state • Park Brake is released
468 5000mS Vehicle Speed counts
SENSOR – NOT • Direction selection • Service Brake Status is detected for 5,000mS
RESPONDING restricted to present Released
state and neutral • Engine RPM >1200 RPM
• FFCM J1-F3 Vehicle Speed
The following restrictions apply counts not detected for
after power cycle: 3000mS

• Gear and Direction

Selection restricted to
F2, N2, and R2

3614RS, 4017RS 31211337 9-145

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
Machine Setup’s TRANSMISSION is HC
The following restrictions apply HYSTAT or LINDE HYSTAT and all of the
continuously: following conditions are present:
• Vehicle Speed is “99” • Direction Selection is Forward
or Reverse
• Park Brake is released
VEHICLE The following restrictions apply
if Engine Speed > 1050 RPM or • Service Brake Status is Retained through power cycle;
SPEED
468 5000mS Service Brake Status is Released: Released Vehicle Speed counts
SENSOR – NOT
• Engine RPM >1400 RPM detected for 5,000mS
RESPONDING • Gear selection
restricted to present • FFCM J1-F3 Vehicle Speed
state counts not detected for
• Direction selection 5000mS
restricted to present • FFCM J2-H1 Transmission
state and neutral Gear Switch is energized
(gearbox engaged in drive)

The following restrictions apply

continuously:
• Vehicle Speed is “99”
Machine Setup’s TRANSMISSION is
DANA 3SPD and all of the following
The following restrictions apply
conditions are present:
until power cycle:
• Direction Selection is Forward
• Gear selection
VEHICLE or Reverse
restricted to present
Retained through power cycle;
SPEED state • Park Brake is released
468 5000mS Vehicle Speed counts
SENSOR – NOT • Direction selection • Service Brake Status is detected for 5,000mS
RESPONDING restricted to present Released
state and neutral • Engine RPM >1400 RPM
• FFCM J1-H1 Vehicle Speed
The following restrictions apply counts not detected for
after power cycle: 40,000mS

• Gear and Direction

Selection restricted to
F3, N3, and R3

Machine Setup’s TRANSMISSION is

BOSCH HYSTAT, TURNER 4SPD2,
TURNER 4SPD3, or Turner 6 Speed Engine Speed < 2700RPM
VEHICLE Flash Vehicle Speed (1Hz) on Transmission Configured
469 Continuously and Vehicle Speed < 43KPH for
OVERSPEED Parker Cabin Display and either of the following occur: 1000mS
• Engine Speed > 2,700 RPM
• Vehicle Speed > 43 KPH

Machine Setup’s TRANSMISSION is ZF

4SPD AUTO
and either of the following occur: Engine Speed < 3250 RPM
VEHICLE Flash Vehicle Speed (1Hz) on
469 Continuously and FFCM J1-F3 Vehicle Speed
OVERSPEED Parker Cabin Display • Engine Speed > 3250 RPM
Frequency < 3270Hz
• FFCM J1-F3 Vehicle Speed
Frequency > 3270Hz

9-146 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
Machine Setup’s TRANSMISSION is HC
HYSTAT and either of the following
occur: Engine Speed < 2700RPM and
VEHICLE Flash Vehicle Speed (1Hz) on FFCM J1-F3 Vehicle Speed
469 Continuously • Engine Speed > 2,700RPM
OVERSPEED Parker Cabin Display Frequency < 1498Hz
• FFCM J1-F3 Vehicle Speed fre- for 1000mS
quency
• > 1498Hz
Machine Setup’s TRANSMISSION is
LINDE HYSTAT and any of the following
occur:
• Engine Speed > 2,900RPM
• Gear Selection is 1st Gear and
FFCM J1-F3 Vehicle Speed fre-
quency > 785Hz for 2000mS .
VEHICLE Flash Vehicle Speed (1Hz) on Note: this corresponds to a All trigger conditions are
469 Continuously
OVERSPEED Parker Cabin Display motor speed of 3700 RPM and removed for 1000mS
vehicle speed of 6.8 MPH.
• Gear Selection is 2nd Gear
FFCM J1-F3 Vehicle Speed fre-
quency > 2208Hz for 2,000mS
. Note: this corresponds to a
motor speed of 3575 RPM and
vehicle speed of 19.3 MPH.

HYD FLUID
Machine Setup’s FAN CONTROL is
TEMP SENSOR
Hydraulic Fluid Temperature is HYDRAULIC, HYD W/ REV or DUAL HYD
– SHORT TO 4640 5000mS Power cycled
+150°C and FFCM J1-B1 Hydraulic Fluid
BATTERY OR
Temperature is >4.73V for 500mS
OPEN CIRCUIT

HYD FLUID
TEMP SENSOR Machine Setup’s HYD TEMP MGMT is
Hydraulic Fluid Temperature is
– SHORT TO 4640 5000mS YES and FFCM J1-B1 Hydraulic Fluid Power cycled
+150°C
BATTERY OR Temperature is >4.73V for 500mS
OPEN CIRCUIT

TRANS FLUID
TEMP SENSOR Machine Setup’s TRANS TEMP is
Transmission Oil Temperature is
– SHORT TO 4641 5000mS SENSOR; Power cycled
+150°C
BATTERY OR FFCM J1-C1 is >4.73V for 500mS
OPEN CIRCUIT

INTERCOOLER
Machine Setup’s FAN CONTROL is
AIR TEMP
HYDRAULIC, HYD W/ REV or DUAL HYD;
SENSOR – Intercooler Air Temperature is
4642 5000mS Machine Setup’s ENGINE CONTROL is Power cycled
SHORT TO +150°C
not CAT C36 Engine Configured; and
BATTERY OR
FFCM J1-F1 is >4.73V for 500mS
OPEN CIRCUIT

HYD FLUID Machine Setup’s FAN CONTROL is

TEMP SENSOR Hydraulic Fluid Temperature is HYDRAULIC, HYD W/ REV or DUAL HYD;
4643 5000mS Power cycled
– SHORT TO +150°C and FFCM J1-B1 Hydraulic Fluid
GROUND Temperature is <0.1V for 500mS

HYD FLUID
TEMP SENSOR Hydraulic Fluid Temperature is Machine Setup’s HYD TEMP MGMT is
4643 5000mS Power cycled
– SHORT TO +150°C YES and FFCM J1-B1 is <0.1V for 500mS
GROUND

3614RS, 4017RS 31211337 9-147

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
TRANS FLUID
Machine Setup’s TRANS TEMP is
TEMP SENSOR Transmission Oil Temperature is
4644 5000mS SENSOR; Power cycled
– SHORT TO +150°C
FFCM J1-C1 is <0.1V for 500mS
GROUND

INTERCOOLER Machine Setup’s FAN CONTROL is

AIR TEMP HYDRAULIC, HYD W/ REV or DUAL HYD;
Intercooler Air Temperature is
SENSOR – 4645 5000mS Machine Setup’s ENGINE CONTROL is Power cycled
+150°C
SHORT TO not CAT C36 Engine Configured; and
GROUND FFCM J1-F1 is <0.1V for 500mS

• Direction Selection is
Neutral Machine Setup’s VEHICLE is HBP or LBP-
PARK BRAKE SC;
• Park Brake Valve pre-
VALVE – short to battery detected on FFCM J3-
4646 5000mS vented Power cycled
SHORT TO D1 Park Brake Valve, FFCM J2-B4 Park
BATTERY • Energize Park Brake Brake Valve Return, or FFCM J3-E1 Park
Indicator on Parker Brake 2 Valve
Cabin Display

• Direction Selection is
Neutral Machine Setup’s VEHICLE is HBP or LBP-
PARK BRAKE SC;
• Park Brake Valve pre-
VALVE – short to ground detected on FFCM J3-
4647 5000mS vented Power cycled
SHORT TO D1 Park Brake Valve, FFCM J2-B4 Park
GROUND • Energize Park Brake Brake Valve Return, or FFCM J3-E1 Park
Indicator on Parker Brake 2 Valve
Cabin Display

• Direction Selection is
Neutral Machine Setup’s VEHICLE is HBP or LBP-
SC;
PARK BRAKE • Park Brake Valve pre-
open-circuit detected on FFCM J3-D1
VALVE – OPEN 4648 5000mS vented Power cycled
Park Brake Valve, FFCM J2-B4 Park Brake
CIRCUIT • Energize Park Brake Valve Return, or FFCM J3-E1 Park Brake
Indicator on Parker 2 Valve
Cabin Display

The following actions shall occur

when Calibration’s TRANS
SERVICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS FWD noid prevented
LOW COIL – Turner Transmission Configured;
4649 Continuously • FFCM J1-E4 Transmis- Power cycled
SHORT TO short to battery detected on FFCM J2-
BATTERY sion Reverse Solenoid H4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

9-148 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
The following actions shall occur
when Calibration’s TRANS
SERVICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS FWD noid prevented
LOW COIL – Turner Transmission Configured;
4650 5000mS • FFCM J1-E4 Transmis- Power cycled
SHORT TO short to ground detected on FFCM J2-
GROUND sion Reverse Solenoid H4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

The following actions shall occur

when Calibration’s TRANS
SERVICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS FWD noid prevented
LOW COIL – 4651 5000mS • FFCM J1-E4 Transmis- Turner Transmission Configured; Power cycled
OPEN CIRCUIT sion Reverse Solenoid open-circuit detected on FFCM J2-H4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-149

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
The following actions shall occur
when Calibration’s TRANS
SERVICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS FWD noid prevented
HIGH COIL – Turner Transmission Configured;
4652 Continuously • FFCM J1-E4 Transmis- Power cycled
SHORT TO short to battery detected on FFCM J2-
BATTERY sion Reverse Solenoid G4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

The following actions shall occur

when Calibration’s TRANS
SERVICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS FWD noid prevented
HIGH COIL – Turner Transmission Configured;
4653 5000mS • FFCM J1-E4 Transmis- Power cycled
SHORT TO short to ground detected on FFCM J2-
GROUND sion Reverse Solenoid G4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

9-150 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS FWD noid prevented
HIGH COIL – 4654 5000mS Turner Transmission Configured; Power cycled
OPEN CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J2-G4
sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS sion Fwd High Sole-
noid prevented Turner Transmission Configured;
REVERSE COIL
4655 Continuously short to battery detected on FFCM J1- Power cycled
– SHORT TO • FFCM J1-E4 Transmis- E4
BATTERY sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-151

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is
REVERSE COIL noid prevented DANA 3SPD;
4655 Continuously Power cycled
– SHORT TO • FFCM J1-E4 Transmis- short to battery detected on FFCM J1-
BATTERY sion Reverse Solenoid E4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is HC
REVERSE COIL noid prevented HYSTAT;
4655 Continuously Power cycled
– SHORT TO • FFCM J1-E4 Transmis- short to battery detected on FFCM J1-
BATTERY sion Reverse Solenoid E4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

9-152 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS sion Fwd High Sole-
noid prevented Turner Transmission Configured;
REVERSE COIL
4656 5000mS short to ground detected on FFCM J1- Power cycled
– SHORT TO • FFCM J1-E4 Transmis- E4
GROUND sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is
REVERSE COIL noid prevented DANA 3SPD;
4656 5000mS Power cycled
– SHORT TO • FFCM J1-E4 Transmis- short to ground detected on FFCM J1-
GROUND sion Reverse Solenoid E4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-153

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is HC
REVERSE COIL noid prevented HYSTAT;
4656 5000mS Power cycled
– SHORT TO • FFCM J1-E4 Transmis- short to ground detected on FFCM J1-
GROUND sion Reverse Solenoid E4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS sion Fwd High Sole-
REVERSE COIL noid prevented Turner Transmission Configured;
4657 5000mS Power cycled
– OPEN • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-E4
CIRCUIT sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

9-154 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS sion Forward Sole-
noid prevented Machine Setup’s TRANSMISSION is
REVERSE COIL
4657 5000mS DANA 3SPD; Power cycled
– OPEN • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-E4
CIRCUIT sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS sion Forward Sole-
noid prevented Machine Setup’s TRANSMISSION is HC
REVERSE COIL
4657 5000mS HYSTAT; Power cycled
– OPEN • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-E4
CIRCUIT sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-155

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS 1ST sion Fwd High Sole-
noid prevented Turner Transmission Configured;
GEAR COIL –
4658 Continuously short to battery detected on FFCM J1- Power cycled
SHORT TO • FFCM J1-E4 Transmis- D4
BATTERY sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS 1ST sion Forward Sole- Machine Setup’s TRANSMISSION is
GEAR COIL – noid prevented DANA 3SPD;
4658 Continuously Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to battery detected on FFCM J1-
BATTERY sion Reverse Solenoid D4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

9-156 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS 1ST sion Forward Sole- Machine Setup’s TRANSMISSION is HC
GEAR COIL – noid prevented HYSTAT;
4658 Continuously Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to battery detected on FFCM J1-
BATTERY sion Reverse Solenoid D4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
TRANS 1ST • Direction Selection Machine Setup’s TRANSMISSION is
GEAR COIL – forced to Neutral LINDE HYSTAT;
4658 Continuously Power cycled
SHORT TO • FFCM J1-D4 Transmis- short to battery detected on FFCM J1-
BATTERY sion 1ST Gear Sole- D4
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS 1ST sion Fwd High Sole-
noid prevented Turner Transmission Configured;
GEAR COIL –
4659 5000mS short to ground detected on FFCM J1- Power cycled
SHORT TO • FFCM J1-E4 Transmis- D4
GROUND sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-157

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS 1ST sion Forward Sole- Machine Setup’s TRANSMISSION is
GEAR COIL – noid prevented DANA 3SPD;
4659 5000mS Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to ground detected on FFCM J1-
GROUND sion Reverse Solenoid D4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS 1ST sion Forward Sole- Machine Setup’s TRANSMISSION is HC
GEAR COIL – noid prevented HYSTAT;
4659 5000mS Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to ground detected on FFCM J1-
GROUND sion Reverse Solenoid D4
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
TRANS 1ST • Direction Selection Machine Setup’s TRANSMISSION is
GEAR COIL – forced to Neutral LINDE HYSTAT;
4659 5000mS Power cycled
SHORT TO • FFCM J1-D4 Transmis- short to ground detected on FFCM J1-
GROUND sion 1ST Gear Sole- D4
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

9-158 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS 1ST noid prevented Turner Transmission Configured;
GEAR COIL – 4660 5000mS Power cycled
• FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-D4
OPEN CIRCUIT
sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Forward Sole-
TRANS 1ST noid prevented Machine Setup’s TRANSMISSION is
GEAR COIL – 4660 5000mS DANA 3SPD; Power cycled
OPEN CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-D4
sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-159

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
sion Forward Sole-
TRANS 1ST noid prevented Machine Setup’s TRANSMISSION is HC
GEAR COIL – 4660 5000mS HYSTAT; Power cycled
OPEN CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-D4
sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
TRANS 1ST forced to Neutral Machine Setup’s TRANSMISSION is
GEAR COIL – 4660 5000mS LINDE HYSTAT; Power cycled
OPEN CIRCUIT • FFCM J1-D4 Transmis- open-circuit detected on FFCM J1-D4
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS 2ND sion Fwd High Sole-
noid prevented Turner Transmission Configured;
GEAR COIL –
4661 Continuously short to battery detected on FFCM J3- Power cycled
SHORT TO • FFCM J1-E4 Transmis- C1
BATTERY sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

9-160 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS 2ND sion Forward Sole- Machine Setup’s TRANSMISSION is
GEAR COIL – noid prevented DANA 3SPD;
4661 Continuously Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to battery detected on FFCM J3-
BATTERY sion Reverse Solenoid C1
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS 2ND sion Forward Sole- Machine Setup’s TRANSMISSION is HC
GEAR COIL – noid prevented HYSTAT;
4661 Continuously Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to battery detected on FFCM J3-
BATTERY sion Reverse Solenoid C1
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
TRANS 2ND • Direction Selection Machine Setup’s TRANSMISSION is
GEAR COIL – forced to Neutral LINDE HYSTAT;
4661 Continuously Power cycled
SHORT TO • FFCM J1-D4 Transmis- short to battery detected on FFCM J3-
BATTERY sion 1ST Gear Sole- C1
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-161

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS 2ND sion Fwd High Sole-
noid prevented Turner Transmission Configured;
GEAR COIL –
4662 5000mS short to ground detected on FFCM J3- Power cycled
SHORT TO • FFCM J1-E4 Transmis- C1
GROUND sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS 2ND sion Forward Sole- Machine Setup’s TRANSMISSION is
GEAR COIL – noid prevented DANA 3SPD;
4662 5000mS Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to ground detected on FFCM J3-
GROUND sion Reverse Solenoid C1
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

9-162 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS 2ND sion Forward Sole- Machine Setup’s TRANSMISSION is HC
GEAR COIL – noid prevented HYSTAT;
4662 5000mS Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to ground detected on FFCM J3-
GROUND sion Reverse Solenoid C1
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
TRANS 2ND • Direction Selection Machine Setup’s TRANSMISSION is
GEAR COIL – forced to Neutral LINDE HYSTAT;
4662 5000mS Power cycled
SHORT TO • FFCM J1-D4 Transmis- short to ground detected on FFCM J3-
GROUND sion 1ST Gear Sole- C1
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS 2ND noid prevented Turner Transmission Configured;
GEAR COIL – 4663 5000mS Power cycled
• FFCM J1-E4 Transmis- open-circuit detected on FFCM J3-C1
OPEN CIRCUIT
sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-163

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Forward Sole-
TRANS 2ND noid prevented Machine Setup’s TRANSMISSION is
GEAR COIL – 4663 5000mS DANA 3SPD; Power cycled
OPEN CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J3-C1
sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
sion Forward Sole-
TRANS 2ND noid prevented Machine Setup’s TRANSMISSION is HC
GEAR COIL – 4663 5000mS HYSTAT; Power cycled
OPEN CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J3-C1
sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
TRANS 2ND forced to Neutral Machine Setup’s TRANSMISSION is
GEAR COIL – 4663 5000mS LINDE HYSTAT; Power cycled
OPEN CIRCUIT • FFCM J1-D4 Transmis- open-circuit detected on FFCM J3-C1
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

9-164 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS 3RD sion Fwd High Sole-
GEAR COIL – noid prevented Turner Transmission Configured;
4664 Continuously Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to battery detected on FFCM J1-
BATTERY sion Reverse Solenoid A3
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
TRANS 3RD sion Fwd High Sole-
GEAR COIL – noid prevented Turner Transmission Configured;
4665 5000mS Power cycled
SHORT TO • FFCM J1-E4 Transmis- short to ground detected on FFCM J1-
GROUND sion Reverse Solenoid A3
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-165

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANS 3RD noid prevented
GEAR COIL – 4666 5000mS Turner Transmission Configured; Power cycled
OPEN CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-A3
sion Reverse Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y1 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4667 Continuously Transmission Configured; Power cycled
TO BATTERY • FFCM J1-E4 Transmis- short to battery detected on FFCM J2-
sion Y3 Solenoid pre- H4 Transmission Y1 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

9-166 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y1 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4668 5000mS Transmission Configured; Power cycled
TO GROUND • FFCM J1-E4 Transmis- short to ground detected on FFCM J2-
sion Y3 Solenoid pre- H4 Transmission Y1 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y1 vented Machine Setup’s TRANSMISSION is ZF
COIL – OPEN 4669 5000mS Transmission Configured; Power cycled
CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J2-H4
sion Y3 Solenoid pre- Transmission Y1 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

3614RS, 4017RS 31211337 9-167

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y2 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4670 Continuously Transmission Configured; Power cycled
TO BATTERY • FFCM J1-E4 Transmis- short to battery detected on FFCM J2-
sion Y3 Solenoid pre- G4 Transmission Y2 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y2 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4671 5000mS Transmission Configured; Power cycled
TO GROUND • FFCM J1-E4 Transmis- short to ground detected on FFCM J2-
sion Y3 Solenoid pre- G4 Transmission Y2 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

9-168 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y2 vented Machine Setup’s TRANSMISSION is ZF
COIL – OPEN 4672 5000mS Transmission Configured; Power cycled
CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J2-G4
sion Y3 Solenoid pre- Transmission Y2 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y3 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4673 Continuously Transmission Configured; Power cycled
TO BATTERY • FFCM J1-E4 Transmis- short to battery detected on FFCM J1-
sion Y3 Solenoid pre- E4 Transmission Y3 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

3614RS, 4017RS 31211337 9-169

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y3 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4674 5000mS Transmission Configured; Power cycled
TO GROUND • FFCM J1-E4 Transmis- short to ground detected on FFCM J1-
sion Y3 Solenoid pre- E4 Transmission Y3 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y3 vented Machine Setup’s TRANSMISSION is ZF
COIL – OPEN 4675 5000mS Transmission Configured; Power cycled
CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-E4
sion Y3 Solenoid pre- Transmission Y3 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

9-170 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y4 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4676 Continuously Transmission Configured; Power cycled
TO BATTERY • FFCM J1-E4 Transmis- short to battery detected on FFCM J1-
sion Y3 Solenoid pre- D4 Transmission Y4 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y4 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4677 5000mS Transmission Configured; Power cycled
TO GROUND • FFCM J1-E4 Transmis- short to ground detected on FFCM J1-
sion Y3 Solenoid pre- D4 Transmission Y4 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

3614RS, 4017RS 31211337 9-171

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y4 vented Machine Setup’s TRANSMISSION is ZF
COIL – OPEN 4678 5000mS Transmission Configured; Power cycled
CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-D4
sion Y3 Solenoid pre- Transmission Y4 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y5 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4679 Continuously Transmission Configured; Power cycled
TO BATTERY • FFCM J1-E4 Transmis- short to battery detected on FFCM J3-
sion Y3 Solenoid pre- C1 Transmission Y5 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

9-172 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y5 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4680 5000mS Transmission Configured; Power cycled
TO GROUND • FFCM J1-E4 Transmis- short to ground detected on FFCM J3-
sion Y3 Solenoid pre- C1 Transmission Y5 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y5 vented Machine Setup’s TRANSMISSION is ZF
COIL – OPEN 4681 5000mS Transmission Configured; Power cycled
CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J3-C1
sion Y3 Solenoid pre- Transmission Y5 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

3614RS, 4017RS 31211337 9-173

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y6 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4682 Continuously Transmission Configured; Power cycled
TO BATTERY • FFCM J1-E4 Transmis- short to battery detected on FFCM J1-
sion Y3 Solenoid pre- A3 Transmission Y6 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y6 vented Machine Setup’s TRANSMISSION is ZF
COIL – SHORT 4683 5000mS Transmission Configured; Power cycled
TO GROUND • FFCM J1-E4 Transmis- short to ground detected on FFCM J1-
sion Y3 Solenoid pre- A3 Transmission Y6 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

9-174 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Y1 Solenoid pre-
vented
• FFCM J2-G4 Transmis-
sion Y2 Solenoid pre-
TRANS Y6 vented Machine Setup’s TRANSMISSION is ZF
COIL – OPEN 4684 5000mS Transmission Configured; Power cycled
CIRCUIT • FFCM J1-E4 Transmis- open-circuit detected on FFCM J1-A3
sion Y3 Solenoid pre- Transmission Y6 Solenoid
vented
• FFCM J1-D4 Transmis-
sion Y4 Solenoid pre-
vented
• FFCM J3-C1 Transmis-
sion Y5 Solenoid pre-
vented
• FFCM J1-A3 Transmis-
sion Y6 Solenoid pre-
vented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is
FORWARD noid prevented DANA 3SPD;
4685 Continuously Power cycled
COIL – SHORT • FFCM J1-E4 Transmis- short to battery detected on FFCM J2-
TO BATTERY sion Reverse Solenoid H4 Transmission Forward Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-175

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is HC
FORWARD noid prevented HYSTAT;
4685 Continuously Power cycled
COIL – SHORT • FFCM J1-E4 Transmis- short to battery detected on FFCM J2-
TO BATTERY sion Reverse Solenoid G4 Transmission Forward Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is
FORWARD noid prevented DANA 3SPD;
4686 5000mS Power cycled
COIL – SHORT • FFCM J1-E4 Transmis- short to ground detected on FFCM J2-
TO GROUND sion Reverse Solenoid H4 Transmission Forward Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is HC
FORWARD noid prevented HYSTAT;
4686 5000mS Power cycled
COIL – SHORT • FFCM J1-E4 Transmis- short to ground detected on FFCM J2-
TO GROUND sion Reverse Solenoid G4 Transmission Forward Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

9-176 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following actions
shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is
FORWARD noid prevented DANA 3SPD;
4687 5000mS Power cycled
COIL – OPEN • FFCM J1-E4 Transmis- open-circuit detected on FFCM J2-H4
CIRCUIT sion Reverse Solenoid Transmission Forward Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following actions

shall occur when Cali-
bration’s TRANS SER-
VICE is NO:
• Direction Selection
forced to Neutral
• FFCM J2-G4 Transmis-
TRANS sion Forward Sole- Machine Setup’s TRANSMISSION is HC
FORWARD noid prevented HYSTAT;
4687 5000mS Power cycled
COIL – OPEN • FFCM J1-E4 Transmis- open-circuit detected on FFCM J2-G4
CIRCUIT sion Reverse Solenoid Transmission Forward Solenoid
prevented
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented

• The following condi-

tions apply when Cali-
bration’s TRANS
SERVICE is NO:
TRANSMISSIO • Direction Selection is Machine Setup’s TRANSMISSION is
N HWFS1 – Neutral BOSCH HYSTAT; short to battery
46114 5000mS Power cycled
SHORT TO • FFCM J2-H4 Transmis- detected on FFCM J2-H4 Transmission
BATTERY sion HWFS1 de-ener- HWFS1
gized
• FFCM J2-A3 Transmis-
sion HWFS2 de-ener-
gized

3614RS, 4017RS 31211337 9-177

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following condi-
tions apply when Cali-
bration’s TRANS
SERVICE is NO:
TRANSMISSIO • Direction Selection is Machine Setup’s TRANSMISSION is
N HWFS1 – Neutral BOSCH HYSTAT; short to ground
46115 5000mS Power cycled
SHORT TO • FFCM J2-H4 Transmis- detected on FFCM J2-H4 Transmission
GROUND sion HWFS1 de-ener- HWFS1
gized
• FFCM J2-A3 Transmis-
sion HWFS2 de-ener-
gized

• The following condi-

tions apply when Cali-
bration’s TRANS
SERVICE is NO:
• Direction Selection is Machine Setup’s TRANSMISSION is
TRANSMISSIO Neutral BOSCH HYSTAT;
N HWFS1 – 46116 5000mS Power cycled
• FFCM J2-H4 Transmis- open-circuit detected on FFCM J2-H4
OPEN CIRCUIT
sion HWFS1 de-ener- Transmission HWFS1
gized
• FFCM J2-A3 Transmis-
sion HWFS2 de-ener-
gized

• The following condi-

tions apply when Cali-
bration’s TRANS
SERVICE is NO:
TRANSMISSIO • Direction Selection is Machine Setup’s TRANSMISSION is
N HWFS2 – Neutral BOSCH HYSTAT; short to battery
46117 5000mS Power cycled
SHORT TO • FFCM J2-H4 Transmis- detected on FFCM J2-A3 Transmission
BATTERY sion HWFS1 de-ener- HWFS2
gized
• FFCM J2-A3 Transmis-
sion HWFS2 de-ener-
gized

• The following condi-

tions apply when Cali-
bration’s TRANS
SERVICE is NO:
• Direction Selection is
TRANSMISSIO Neutral
Machine Setup’s TRANSMISSION is
N LOGIC • FFCM J2-G4 Transmis-
BOSCH HYSTAT; short to battery
SUPPLY – 46127 5000mS sion Logic Supply de- Power cycled
detected on FFCM J2-G4 Transmission
SHORT TO energized
Logic Supply
BATTERY • FFCM J2-H4 Transmis-
sion HWFS1 de-ener-
gized
• FFCM J2-A3 Transmis-
sion HWFS2 de-ener-
gized

9-178 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• The following condi-
tions apply when Cali-
bration’s TRANS
SERVICE is NO:
• Direction Selection is
TRANSMISSIO Neutral
Machine Setup’s TRANSMISSION is
N LOGIC • FFCM J2-G4 Transmis-
BOSCH HYSTAT; short to ground
SUPPLY – 46128 5000mS sion Logic Supply de- Power cycled
detected on FFCM J2-G4 Transmission
SHORT TO energized
Logic Supply
GROUND • FFCM J2-H4 Transmis-
sion HWFS1 de-ener-
gized
• FFCM J2-A3 Transmis-
sion HWFS2 de-ener-
gized

• The following condi-

tions apply when Cali-
bration’s TRANS
SERVICE is NO:
• Direction Selection is
Neutral
TRANSMISSIO Machine Setup’s TRANSMISSION is
• FFCM J2-G4 Transmis-
N LOGIC BOSCH HYSTAT; open-circuit detected
46129 5000mS sion Logic Supply de- Power cycled
SUPPLY – on FFCM J2-G4 Transmission Logic
energized
OPEN CIRCUIT Supply
• FFCM J2-H4 Transmis-
sion HWFS1 de-ener-
gized
• FFCM J2-A3 Transmis-
sion HWFS2 de-ener-
gized

• FFCM J3-B1 Lock-Up

Convertor prevented
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANSMISSIO noid prevented Machine Setup’s TRANSMISSION is
N LOCK-UP
• FFCM J1-E4 Transmis- TURNER 6SPD L/U; short to battery
CONVERTOR – 46131 5000mS Power cycled
sion Reverse Solenoid detected on FFCM J3-B1 Lock-Up
SHORT TO
prevented Convertor
BATTERY
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

3614RS, 4017RS 31211337 9-179

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• FFCM J3-B1 Lock-Up
Convertor prevented
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANSMISSIO noid prevented Machine Setup’s TRANSMISSION is
N LOCK-UP
• FFCM J1-E4 Transmis- TURNER 6SPD L/U; short to ground
CONVERTOR – 46132 5000mS Power cycled
sion Reverse Solenoid detected on FFCM J3-B1 Lock-Up
SHORT TO
prevented Convertor
GROUND
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

• FFCM J3-B1 Lock-Up

Convertor prevented
• Direction Selection
forced to Neutral
• FFCM J2-H4 Transmis-
sion Fwd Low Sole-
noid prevented
• FFCM J2-G4 Transmis-
sion Fwd High Sole-
TRANSMISSIO noid prevented Machine Setup’s TRANSMISSION is
N LOCK-UP • FFCM J1-E4 Transmis- TURNER 6SPD L/U; open-circuit
46133 5000mS Power cycled
CONVERTOR – sion Reverse Solenoid detected on FFCM J3-B1 Lock-Up
OPEN CIRCUIT prevented Convertor
• FFCM J1-D4 Transmis-
sion 1ST Gear Sole-
noid prevented
• FFCM J3-C1 Transmis-
sion 2ND Gear Sole-
noid prevented
• FFCM J1-A3 Transmis-
sion 3RD Gear Sole-
noid prevented

SAHR BRAKE • FFCM J1-G4 SAHR

Brake Valve prevented Machine Setup’s SAHR BRAKE is AUTO;
VALVE –
46138 5000mS short to battery detected on FFCM J1- Power cycled
SHORT TO • Direction Selection is G4 SAHR Brake Valve
BATTERY Neutral

SAHR BRAKE • FFCM J1-G4 SAHR

Brake Valve prevented Machine Setup’s SAHR BRAKE is AUTO;
VALVE –
46139 5000mS short to ground detected on FFCM J1- Power cycled
SHORT TO • Direction Selection is G4 SAHR Brake Valve
GROUND Neutral

9-180 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• FFCM J1-G4 SAHR
SAHR BRAKE Brake Valve prevented Machine Setup’s SAHR BRAKE is AUTO;
VALVE – OPEN 46140 5000mS open-circuit detected on FFCM J1-G4 Power cycled
CIRCUIT • Direction Selection is SAHR Brake Valve
Neutral

• FFCM J1-G4 SAHR Machine Setup’s SAHR BRAKE is

SAHR
Brake Valve prevented MANUAL or AUTO;
PRESSURE
46141 5000mS engine running; park brake released; Power cycled
SWITCH – • Direction Selection is CCM J3-E2 SAHR Pressure Switch de-
OPEN CIRCUIT Neutral energized for 5000mS

• Transmission Tem-
perature Critical icon
HIGH is shown on Parker Machine Setup’s TRANS TEMP is
TRANSMISSIO Cabin Display SENSOR or HYSTAT SENSOR; Transmission Oil Temperature
N OIL
46142 Continuously • Engine De-Rate is acti- Transmission Oil Temperature >125ºC < 110ºC for 250mS (both
TEMPERATUR
vated (engine speed for ConstantData)
E – ENGINE
restricted) while Direc- 3000mS (both ConstantData)
DERATED
tion Selection is For-
ward or Reverse
INCHING
Machine Setup’s TRANSMISSION is HC
VALVE – FFCM J1-G3 / FFCM J2-C4
46143 5000mS HYSTAT; short to battery detected on Power cycled
SHORT TO Inching Valve prevented
FFCM J1-G3 / FFCM J2-C4 Inching Valve
BATTERY

INCHING
Machine Setup’s TRANSMISSION is HC
VALVE – FFCM J1-G3 / FFCM J2-C4
46144 5000mS HYSTAT ; short to ground detected on Power cycled
SHORT TO Inching Valve prevented
FFCM J1-G3 / FFCM J2-C4 Inching Valve
GROUND

INCHING Machine Setup’s TRANSMISSION is HC

FFCM J1-G3 / FFCM J2-C4
VALVE – OPEN 46145 5000mS HYSTAT; open-circuit detected on FFCM Power cycled
Inching Valve prevented
CIRCUIT J1-G3 / FFCM J2-C4 Inching Valve

Machine Setup’s TRANSMISSION is HC

HYSTAT; Current Feedback Faults are
enabled; and one of the following
occur:
• FFCM J1-G3 / FFCM J2-C4
INCHING
Inching Valve measured cur-
VALVE –
rent is 250mA less than com-
CURRENT FFCM J1-G3 / FFCM J2-C4
46146 5000mS mand when command is Power cycled
FEEDBACK Inching Valve prevented
greater than 500mA for
READING TOO
1000mS
LOW
• FFCM J1-G3 / FFCM J2-C4
Inching Valve measured cur-
rent is less than 255mA when
PWM is greater than 40% for
500mS

PARK BRAKE • FFCM J1-G4 Park Brake Machine Setup’s TRANSMISSION is HC

RELEASE Release Valve pre- HYSTAT;
VALVE – 46156 5000mS vented HC Park Brake Release configured; Power cycled
SHORT TO • Direction Selection is short to battery detected on FFCM J1-
BATTERY Neutral G4 Park Brake Release Valve

PARK BRAKE • FFCM J1-G4 Park Brake Machine Setup’s TRANSMISSION is HC

RELEASE Release Valve pre- HYSTAT;
VALVE – 46157 5000mS vented HC Park Brake Release configured; Power cycled
SHORT TO • Direction Selection is short to ground detected on FFCM J1-
GROUND Neutral G4 Park Brake Release Valve

3614RS, 4017RS 31211337 9-181

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• FFCM J1-G4 Park Brake Machine Setup’s TRANSMISSION is HC
PARK BRAKE Release Valve pre- HYSTAT;
RELEASE vented
46158 5000mS HC Park Brake Release configured; Power cycled
VALVE – OPEN
• Direction Selection is open-circuit detected on FFCM J1-G4
CIRCUIT
Neutral Park Brake Release Valve

PUMP
PRESSURE Machine Setup’s TRANSMISSION is
Pump Pressure A is assumed as
SENSOR A – 46159 5000mS LINDE HYSTAT; TCM J1-C1 Pump Power cycled
600.0 BAR
OUT OF Pressure A is >4.73V for 500mS
RANGE HIGH

PUMP
PRESSURE Machine Setup’s TRANSMISSION is
Pump Pressure A is assumed as
SENSOR A – 46160 5000mS LINDE HYSTAT; TCM J1-C1 Pump Power cycled
600.0 BAR
OUT OF Pressure A is <0.10V for 500mS
RANGE LOW

PUMP
PRESSURE Machine Setup’s TRANSMISSION is
Pump Pressure B is assumed as
SENSOR B – 46161 5000mS LINDE HYSTAT; TCM J1-B1 Pump Power cycled
600.0 BAR
OUT OF Pressure B is >4.73V for 500mS
RANGE HIGH

PUMP
PRESSURE Machine Setup’s TRANSMISSION is
Pump Pressure B is assumed as
SENSOR B – 46162 5000mS LINDE HYSTAT; TCM J1-B1 Pump Power cycled
600.0 BAR
OUT OF Pressure B is <0.10V for 500mS
RANGE LOW

Machine Setup’s VEHICLE is LBP-SC and

one of the following occur:
• Direction Selection is • FFCM J3-D1/J2-B4 Park Brake
PARK BRAKE Neutral Valve measured current is
VALVE – • Park Brake Valve pre- 250mA less than command
CURRENT 46165 5000mS vented when command is greater Power Cycled
FEEDBACK • Energize Park Brake than 500mA for 1000mS
TOO LOW Indicator on Parker • FFCM J3-D1/J2-B4 Park Brake
Cabin Display Valve measured current is less
than 255mA when PWM is
greater than 40% for 500mS

9-182 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
Machine setup’s TRANSMISSION is
LINDE HYSTAT and all of the following
conditions are present for >30,000mS :
• Engine Operating State is
ENGINE RUNNING
• Direction Selection is Neutral
(transmission disengaged)
• Pump Pressure A is • Vehicle Speed is 0 KPH (vehi-
PUMP assumed as 600.0 BAR cle not moving)
PRESSURE
• Pump Pressure B is • Park Brake is Applied
SENSORS – 46206 5000mS Power Cycled
assumed as 600.0 BAR
INVALID • Hystat Gear Change Status is
READING • Hydrostatic Speed IDLE (no gear change)
Limit is set to 14.0 KPH

AND THEN any of the following

conditions are present for >5,000mS :
• Pump Pressure A and Pump
Pressure B disagree by >25bar
• Pump Pressure A or Pump
Pressure B is >65bar

SERVICE Machine Setup’s MODEL is 12010H /

BRAKE RELAY 2733, Brake Relay Pressure Flag is
PRESSURE Service Brake Relay Pressure is ENABLED, and
46207 5000mS Power Cycled
SENSOR - OUT assumed as 3000 PSI (max)
OF RANGE FFCM J1-C1 Service Brake Relay
LOW Pressure < 0.25V for 500mS

SERVICE Machine Setup’s MODEL is 12010H /

BRAKE RELAY 2733, Brake Relay Pressure Flag is
PRESSURE Service Brake Relay Pressure is ENABLED, and
5000mS Power Cycled
SENSOR - OUT 46208 assumed as 3000 PSI (max)
OF RANGE FFCM J1-C1 Service Brake Relay
HIGH Pressure > 4.75V for 500mS

Machine Setup’s MODEL is 12010H /

Maintain through Power Cycle;
2733, and all of the following
all of the following conditions
conditions are present for 2500mS:
are present for 2500mS:
SERVICE • Engine is running
BRAKE RELAY • Engine is Running
VALVE - Fast flash Service Brake Fault • Brake Pedal Pressure & Ser-
46209 5000mS • Brake Pedal Positon
PRESSURE Indicator vice Brake Relay Pressure are
>85.0%
DISAGREEME both <700 PSI (ConstantData,
sensors are healthy) • Brake Pedal Pressure &
NT
Service Brake Relay
• Brake Pedal Pressure & Ser-
Pressure agree within
vice Brake Relay Pressure dis-
+/-58 PSI
agree greater than +/-58 PSI

3614RS, 4017RS 31211337 9-183

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
Machine Setup’s MODEL is 12010H /
2733, and all of the following conditions Maintain through Power Cycle;
are present for 2500mS: all of the following conditions
are present for 2500mS:
• Engine is running
SERVICE
• Brake Pedal Position is • Engine is Running
BRAKE RELAY
Fast flash Service Brake Fault >85.0% (ConstantData, pedal • Brake Pedal Position
VALVE – 46210 5000mS
Indicator is depressed) >85.0%
PRESSURE
TOO LOW • Brake Pedal Pressure OR Ser- • Brake Pedal Pressure &
vice Brake Relay Pressure is Service Brake Relay
<290 PSI (ConstantData, Pressure are both >290
insufficient pressure, cannot PSI
apply brakes)

Machine Setup's MODEL is 12010H / Maintain through Power Cycle;

2733, and all of the following all of the following conditions
conditions are present for 2500mS: are present for 2500mS:
SERVICE • Engine is running • Engine is Running
BRAKE RELAY
Fast flash Service Brake Fault • Service Brake Relay Pressure • Brake Pedal Position
VALVE – 46211 5000mS
Indicator is <3000 PSI (healthy sensor) >99.0%
PRESSURE
TOO HIGH • Service Brake Relay Pressure • Brake Pedal Pressure &
is >1160 PSI (ConstantData, Service Brake Relay
excessive brake pressure, can- Pressure are both
not release brakes) <1160 PSI

9-184 31211337 3614RS, 4017RS

 Electrical System

9.16.13 Communications (66x)

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
Platform Mode; Machine Setup’s
CANBUS
PLATFORM OPTION is YES;
FAILURE – • Function Enable Switch disen-
662 Continuously Engine Running or Stopped for 1000mS; Power cycled
PLATFORM gaged
PLT messages not detected within
MODULE
CANbus Timeout Interval

• Hydraulic functions prevented

• Engine Start prevented
• Lock-Up Convertor prevented
• Fan Speed Valve prevented
CANBUS Cabin or Platform Mode;
FAILURE – • Fan Speed 2 Valve prevented Engine Running or Stopped;
666 Continuously Power cycled
ENGINE • Fan Reverse Valve prevented ECM messages not detected
CONTROLLER • Engine Hours assumed to be within CANbus Timeout Interval
9999.9 hours
ECM defaults to Closed Throttle RPM on
loss of J1939 TSC1 without interaction
from the System Modules

CANBUS • CCM detects 500 Bus-Off condi-

FAILURE – tions since power-up
EXCESSIVE 6613 Continuously – Power cycled
CANBUS • CCM detects 22 Bus-Off condi-
ERRORS tions within 1,000mS

CANBUS • Direction Selection is Neutral

Machine Setup’s TRANSMISSION is BOSCH
FAILURE – • FFCM J2-H4 Transmission
HYSTAT;
TRANSMISSIO 6616 5000mS HWFS1 de-energized Power cycled
DRC messages not detected within
N • FFCM J2-A3 Transmission HWFS2 CANbus Timeout Interval
CONTROLLER de-energized

• Pump Pressure A is assumed as

600.0 BAR
CANBUS
• Pump Pressure B is assumed as Machine Setup’s TRANSMISSION is LINDE
FAILURE –
600.0 BAR HYSTAT;
TRANSMISSIO 6616 5000mS Power cycled
TCM messages not detected within
N • Direction Selection is Neutral CANbus Timeout Interval
CONTROLLER
• Power State is ERROR for power-
up or SAFE for run-time

CANBUS
Cabin Mode; Engine Running or Stopped;
FAILURE –
6617 Continuously Hydraulic functions are prevented Cabin Joystick CANbus not detected Power cycled
CABIN
within CANbus Timeout Interval
JOYSTICK

CANBUS Machine Setup’s VEHICLE is not LBP-RS;

FAILURE – Cabin Mode; Engine Running or Stopped;
6618 Continuously – Power cycled
CABIN Parker Cabin Display messages not
DISPLAY detected within CANbus Timeout Interval

CANBUS Machine Setup’s VEHICLE is LBP-RS; Cabin

FAILURE – Mode; Stoneridge Cabin Display
6618 Continuously – Power cycled
CABIN messages not detected within CANbus
DISPLAY Timeout Interval

3614RS, 4017RS 31211337 9-185

 Electrical System

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
• Boom angle sensor assumed to
be +99°
• HIRAS Mode is forced to ERROR
• Start HIRAS Integrity Checks is
prevented
Machine Setup’s CAN BOOM ANGLE is
CANBUS • LMIS / Weigh Load Predicted YES;
FAILURE – Load is 32,767 Engine Running or Stopped for 1000mS;
6621 Continuously Power cycled
BOOM ANGLE • Lift Up prevented in Platform CANbus Boom Angle Sensor (BMA)
SENSOR Mode messages not detected
within CANbus Timeout Interval
• Lift Up prevented while platform
attached
• Lift Up and Down de-rated in
Cabin Mode
• Boom Damping prevented

Machine Setup’s AUTO FORK LEVEL is YES

and all of the following conditions are
CANBUS present:
• Fork Tilt Angle is assumed to be
FAILURE – 6625 5000mS • Powerup Delay has expired Power Cycled
worst case (+99.99°)
FORK SENSOR • Fork Tilt Sensor messages not
detected within CANbus Time-
out Interval

Machine Setup’s CHASSIS TILT is YES;

CANBUS
Worst case tilt readings (+25.00°, +25.00°) Engine Running or Stopped;
FAILURE – 6635 5000mS Power cycled
assumed TILT1 or TILT2 messages not detected
CHASSIS TILT
within CANbus Timeout Interval

CANBUS Machine Setup’s REMOTE CONTROL is

FAILURE – • Remote controls prevented YES; Remote Control Mode Switch is
REMOTE 6642 5000mS closed and powerup delay expired; RCM Power Cycled
INPUT • Remote engine start prevented messages not detected within CANbus
MODULE Timeout Interval

• Hydraulic functions prevented

• Engine Start prevented
• Throttle Engine Speed set to
Closed Throttle RPM
CANBUS • Direction Selection Neutral
FAILURE – • Transmission Solenoids pre- FFCM messages not detected
FRONT FRAME 6647 Continuously vented Power cycled
within CANbus Timeout Interval
CONTROL
• Fuel Level assumed to be Empty
MODULE
(0.0%)
• Auxiliary De-Compression pre-
vented
• Power State is ERROR for power-
up or SAFE for run-time

9-186 31211337 3614RS, 4017RS

 Electrical System

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
• Hydraulics functions prevented
• Engine Start prevented
• Throttle Engine Speed set to
CANBUS Closed Throttle RPM
FAILURE –
• Load Stability Reading assumed RFCM messages not detected
REAR FRAME 6648 Continuously Power cycled
100% within CANbus Timeout Interval
CONTROL
MODULE • Auxiliary De-Compression pre-
vented
• Power State is ERROR for power-
up or SAFE for run-time

• Hydraulics functions prevented

• Engine Start prevented
• Throttle Engine Speed set to
Closed Throttle RPM
• LMIS / Weigh Load Predicted
Load is 32,767
• Lift Cylinder Head Pressure 1 is
600.0 BAR
• Lift Cylinder Head Pressure 2 is
600.0 BAR
• Lift Cylinder Rod Pressure 1 is
600.0 BAR Machine Setup’s LOAD MOMENT IND
SYSTEM is YES, PLATFORM OPTION is YES,
CANBUS • Lift Cylinder Rod Pressure 2 is
WEIGH LOAD is YES, or BOOM DAMPING is
FAILURE – 6649 Continuously 600.0 BAR Power cycled
YES;
LCM MODULE • Compensation Cylinder Head LCM messages not detected within
Pressure 1 is 600.0 BAR CANbus Timeout Interval
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR
• Boom Length Measurement is
maximum (Lmax)
• Lift Accumulator Pressure is
600.0 BAR
• Boom Damping is Prevented

Cabin Mode; Engine Running or Stopped

CANBUS for 1000mS;
FAILURE – • Reverse Obstacle Detection Sen- Machine Setup’s REVERSE OBSTACLE
REVERSE 6658 5000mS sor is Unhealthy DETECTION is YES; ROD message not Power cycled
OBSTACLE • Detection Zone 1 is assumed detected within 350mS CANbus Timeout
SENSOR Interval
when Direction Selection is Reverse

Machine Setup’s PREMIUM DISPLAY is YES

CANBUS
or
FAILURE – • LMIS Attachment Selection
6659 5000mS YES W/ ANTI-THEFT; PRM messages not Power cycled
PREMIUM Change is prevented
detected within
DISPLAY
CANbus Timeout Interval

3614RS, 4017RS 31211337 9-187

 Electrical System

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
CANBUS • Hydraulics functions prevented
FAILURE – CCM messages to FFCM, RFCM, LCM, or
• Engine Start prevented
CABIN 6662 Continuously TCM not detected Power cycled
CONTROL • Throttle Engine Speed set to within CANbus Timeout Interval
MODULE Closed Throttle RPM

Machine Setup’s ATTACH RECOG is YES;

Powerup delay has expired and either of
the following conditions is present for
5000mS :
RS232 Attachment Recognition functionality is
• RFID reader does not respond
FAILURE – prevented, operator must manually select
6670 5000mS to new Inventory requests on Power Cycled
ATTACHMENT attachment to reenable boom functions
RS232.
RECOGNITION after attachment change.
• Inventory Sessions are not suc-
cessful (STATUS byte is not
0x00/OK or 0x01/NO TAGS
DETECTED).

Machine Setup’s AUTO FORK LEVEL is YES

CANBUS and all of the following conditions are
• Tilt Cylinder Stroke is assumed to present:
FAILURE – TILT be 999.9mm
CYLINDER 6684 5000mS • Powerup Delay has expired Power Cycled
STROKE • Tilt Cylinder Status is assumed to
be ERROR • Tilt Cylinder Stroke Sensor mes-
SENSOR sages not detected within CAN-
bus Timeout Interval

9-188 31211337 3614RS, 4017RS

 Electrical System

9.16.14 Envelope Control (84x)

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition

• Boom Length Measure- Boom Length Configured; Boom Length

BOOM LENGTH ment is maximum Calibrated;
SWITCH / (Lmax) Boom Retract Switch Closed;
843 5000mS Power cycled
SENSOR LCM J1-E1 Boom Length Signal is not within
DISAGREEMENT • LMIS / Weigh Load Pre- +0.45V of the Boom Length Minimum Calibration
dicted Load is 32,767 for 500mS

Boom Length Configured, Debug’s BOOM NR is

NO, Main Lift Up Command <900mA, Main Lift
Down Command <900mA, LCM J1-E1 Boom
Length (Signal) is not changing more than +/-
0.05V over 5,000mS and either of the following
BOOM LENGTH • Boom Length Measure- conditions are present:
SENSOR NOT ment is maximum
(Lmax) • Telescope In Command > 950mA and
DETECTING 844 5000mS Power cycled
LCM J1-E1 Boom Length (Signal) >
LENGTH • LMIS / Weigh Load Pre- Boom Length Minimum Calibration +
CHANGE dicted Load is 32,767 0.25V
• Telescope Out Command >950mA and
LCM J1-E1 Boom Length (Signal) <
Boom Length Maximum Calibration –
0.25V

• Boom Length Measure-

BOOM LENGTH ment is maximum
Boom Length Configured;
SENSOR – OUT 845 5000mS (Lmax) Power cycled
OF RANGE HIGH LCM J1-E1 Boom Length Signal > 4.9V for 500mS
• LMIS / Weigh Load Pre-
dicted Load is 32,767

• Boom Length Measure-

BOOM LENGTH ment is maximum
Boom Length Configured;
SENSOR – OUT 846 5000mS (Lmax) Power cycled
OF RANGE LOW LCM J1-E1 Boom Length Signal < 0.1V for 500mS
• LMIS / Weigh Load Pre-
dicted Load is 32,767

• Boom Length Measure-

BOOM LENGTH ment is maximum
(Lmax) Boom Length Configured and Boom Length Not Boom Length
SENSOR – NOT 8464 5000mS
Calibrated Calibrated
CALIBRATED • LMIS / Weigh Load Pre-
dicted Load is 32,767

3614RS, 4017RS 31211337 9-189

 Electrical System

9.16.15 Tilt Sensor (81x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
CHASSIS TILT
Worst case tilt readings Machine Setup’s CHASSIS TILT is YES;
SENSOR NOT 813 5000mS Power cycled
(+25.00°, +25.00°) assumed TILT1 and TILT2 not calibrated
CALIBRATED

Machine Setup’s CHASSIS TILT is YES;

CHASSIS TILT
Worst case tilt readings TILT1 and TILT2 calibrated; TILT1 and
SENSOR 815 5000mS Power cycled
(+25.00°, +25.00°) assumed TILT2 disagree more than +/- 2.0 Degrees
DISAGREEMENT
for 1000mS while Park Brake is applied

9-190 31211337 3614RS, 4017RS

 Electrical System

9.16.16 Load Moment (85x)

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm

Machine Setup’s LOAD STABILITY is YES;

LSI NOT
8514 5000mS Load Stability assumed to be 100% Load Stability has not been calibrated or LSI calibrated
CALIBRATED
calibration factors out of range

Machine Setup’s LOAD STABILITY is YES;

LSI LOAD CELL Power cycled for short to
RFCM J3-E4 LSI Sensor Signal 1 reading
A – OUT OF 8516 5000mS Load Stability assumed to be 100% battery; LSI Sensor Signal 1 in
out of range
RANGE range for 3000mS
or short to battery

Machine Setup’s LOAD STABILITY is YES;

LSI LOAD CELL Power cycled for short to
RFCM J3-F4 LSI Sensor Signal 2 reading
B – OUT OF 8517 5000mS Load Stability assumed to be 100% battery; LSI Sensor Signal 2 in
out of range
RANGE range for 3000mS
or short to battery

LSI Verification Passed

LSI OUT OF Machine Setup’s LOAD STABILITY is YES;
8519 5000mS Load Stability assumed to be 100% (Retained through power
CALIBRATION LSI Verification Failed
cycles)

LSI LOAD CELL

Machine Setup’s LOAD STABILITY is YES;
A&B– Difference in tolerance for
8520 5000mS Load Stability assumed to be 100% Load Stability Primary % & Backup %
DISAGREEMEN 3000mS
difference excessive
T

• LMIS / Weigh Load Predicted

Load is 32,767
• LCM V
• LOW protected FET disabled
• Lift Cylinder Head Pressure 1
is 600.0 BAR
• Lift Cylinder Head Pressure 2
is 600.0 BAR
LIFT CYLINDER • Lift Cylinder Rod Pressure 1 is Machine Setup’s LOAD MOMENT IND
HEAD 600.0 BAR SYSTEM is YES or WEIGH LOAD is YES or
PRESSURE 1 – 8523 5000mS • Lift Cylinder Rod Pressure 2 is BOOM DAMPING is YES; LCM J1-C1 Lift Power cycled
OUT OF RANGE 600.0 BAR Cylinder Head Pressure 1
HIGH > 20mA for 500mS
• Compensation Cylinder Head
Pressure 1 is 600.0 BAR
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR
• Boom Damping prevented

LIFT CYLINDER • LMIS / Weigh Load Predicted Machine Setup’s LOAD MOMENT IND
HEAD Load is 32,767 SYSTEM is YES or WEIGH LOAD is YES or
PRESSURE 1 – 8524 5000mS • Lift Cylinder Head Pressure 1 BOOM DAMPING is YES; LCM J1-C1 Lift Power cycled
OUT OF RANGE is 600.0 BAR Cylinder Head Pressure 1
LOW • Boom Damping prevented < 2mA for 500mS

3614RS, 4017RS 31211337 9-191

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• LMIS / Weigh Load Predicted
Load is 32,767
• LCM V
• LOW protected FET disabled
• Lift Cylinder Head Pressure 1
is 600.0 BAR
• Lift Cylinder Head Pressure 2
is 600.0 BAR
LIFT CYLINDER • Lift Cylinder Rod Pressure 1 is Machine Setup’s LOAD MOMENT IND
HEAD 600.0 BAR SYSTEM is YES or WEIGH LOAD is YES or
PRESSURE 2 – 8525 5000mS • Lift Cylinder Rod Pressure 2 is BOOM DAMPING is YES; LCM J1-B1 Lift Power cycled
OUT OF RANGE 600.0 BAR Cylinder Head Pressure 2
HIGH > 20mA for 500mS
• Compensation Cylinder Head
Pressure 1 is 600.0 BAR
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR
• Boom Damping prevented

LIFT CYLINDER • LMIS / Weigh Load Predicted Machine Setup’s LOAD MOMENT IND
HEAD Load is 32,767 SYSTEM is YES or WEIGH LOAD is YES or
PRESSURE 2 – 8526 5000mS • Lift Cylinder Head Pressure 2 BOOM DAMPING is YES; LCM J1-B1 Lift Power cycled
OUT OF RANGE is 600.0 BAR Cylinder Head Pressure 2
LOW • Boom Damping prevented < 2mA for 500mS

Machine Setup’s LOAD MOMENT IND

LIFT CYLINDER • LMIS / Weigh Load Predicted SYSTEM is YES or WEIGH LOAD is YES or
HEAD Load is 32,767 BOOM DAMPING is YES; LCM J1-C1 Lift
PRESSURE – 8527 5000mS • Lift Cylinder Head Pressure 1 & Cylinder Head Pressure 1 and LCM J1-B1 Power cycled
DISAGREEMEN 2 are 600.0 BAR Lift Cylinder Cylinder Head Pressure 2
T • Boom Damping prevented disagree by more than +/- 50BAR for
500mS

9-192 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• LMIS / Weigh Load Predicted
Load is 32,767
• LCM V
• LOW protected FET disabled
• Lift Cylinder Head Pressure 1
is 600.0 BAR
• Lift Cylinder Head Pressure 2
is 600.0 BAR
• Lift Cylinder Rod Pressure 1 is Machine Setup’s LOAD MOMENT IND
LIFT CYLINDER 600.0 BAR SYSTEM is YES or WEIGH LOAD is YES or
ROD PRESSURE
8528 5000mS • Lift Cylinder Rod Pressure 2 is BOOM DAMPING is YES; LCM J1-A1 Lift Power cycled
1 – OUT OF
600.0 BAR Cylinder Rod Pressure 1
RANGE HIGH
> 20mA for 500mS
• Compensation Cylinder Head
Pressure 1 is 600.0 BAR
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR
• Boom Damping prevented

• LMIS / Weigh Load Predicted Machine Setup’s LOAD MOMENT IND

LIFT CYLINDER Load is 32,767 SYSTEM is YES or WEIGH LOAD is YES or
ROD PRESSURE
8529 5000mS • Lift Cylinder Rod Pressure 1 is BOOM DAMPING is YES; LCM J1-A1 Lift Power cycled
1 – OUT OF
600.0 BAR Cylinder Rod Pressure 1
RANGE LOW
• Boom Damping prevented < 2mA for 500mS

• LMIS / Weigh Load Predicted

Load is 32,767
• LCM V
• LOW protected FET disabled
• Lift Cylinder Head Pressure 1
is 600.0 BAR
• Lift Cylinder Head Pressure 2
is 600.0 BAR
• Lift Cylinder Rod Pressure 1 is Machine Setup’s LOAD MOMENT IND
LIFT CYLINDER 600.0 BAR SYSTEM is YES or WEIGH LOAD is YES or
ROD PRESSURE
8530 5000mS • Lift Cylinder Rod Pressure 2 is BOOM DAMPING is YES; LCM J1-D1 Lift Power cycled
2 – OUT OF
600.0 BAR Cylinder Rod Pressure 2
RANGE HIGH
> 20mA for 500mS
• Compensation Cylinder Head
Pressure 1 is 600.0 BAR
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR
• Boom Damping prevented

3614RS, 4017RS 31211337 9-193

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• LMIS / Weigh Load Predicted Machine Setup’s LOAD MOMENT IND
LIFT CYLINDER Load is 32,767 SYSTEM is YES or WEIGH LOAD is YES or
ROD PRESSURE
8531 5000mS • Lift Cylinder Rod Pressure 2 is BOOM DAMPING is YES; LCM J1-D1 Lift Power cycled
2 – OUT OF
600.0 BAR Cylinder Rod Pressure 2
RANGE LOW
• Boom Damping prevented < 2mA for 500mA

• LMIS / Weigh Load Predicted Machine Setup’s LOAD MOMENT IND

LIFT CYLINDER
Load is 32,767 SYSTEM is YES or WEIGH LOAD is YES or
ROD PRESSURE
BOOM DAMPING is YES; LCM J1-A1 Lift
– 8532 5000mS • Lift Cylinder Rod Pressure 1 & Power cycled
Cylinder Rod Pressure 1 and LCM J1-D1
DISAGREEMEN 2 are 600.0 BAR
Lift Cylinder Rod Pressure 2 disagree by
T • Boom Damping prevented more than +/- 50BAR for 500mS

• LMIS / Weigh Load Predicted

Load is 32,767
• LCM V
• LOW protected FET disabled
• Lift Cylinder Head Pressure 1
is 600.0 BAR
• Lift Cylinder Head Pressure 2
COMP is 600.0 BAR
Machine Setup’s VEHICLE is not LBP-SC;
CYLINDER • Lift Cylinder Rod Pressure 1 is
Machine Setup’s LOAD MOMENT IND
HEAD 600.0 BAR
8533 5000mS SYSTEM is YES or WEIGH LOAD is YES; Power cycled
PRESSURE 1 – • Lift Cylinder Rod Pressure 2 is LCM J1-F2 Compensation Cylinder Head
OUT OF RANGE 600.0 BAR Pressure 1 > 20mA for 500mS
HIGH
• Compensation Cylinder Head
Pressure 1 is 600.0 BAR
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR

COMP
CYLINDER • LMIS / Weigh Load Predicted Machine Setup’s LOAD MOMENT IND
HEAD Load is 32,767 SYSTEM is YES or WEIGH LOAD is YES;
8534 5000mS Power cycled
PRESSURE 1 – • Compensation Cylinder Head LCM J1-F2 Compensation Cylinder Head
OUT OF RANGE Pressure 1 is 600.0 BAR Pressure 1 < 2mA for 500mS
LOW

9-194 31211337 3614RS, 4017RS

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
• LMIS / Weigh Load Predicted
Load is 32,767
• LCM V
• LOW protected FET disabled
• Lift Cylinder Head Pressure 1
is 600.0 BAR
• Lift Cylinder Head Pressure 2
COMP is 600.0 BAR
Machine Setup’s VEHICLE is not LBP-SC;
CYLINDER • Lift Cylinder Rod Pressure 1 is
Machine Setup’s LOAD MOMENT IND
HEAD 600.0 BAR
8535 5000mS SYSTEM is YES or WEIGH LOAD is YES; Power cycled
PRESSURE 2 – • Lift Cylinder Rod Pressure 2 is LCM J1-F1 Compensation Cylinder Head
OUT OF RANGE 600.0 BAR Pressure 2 > 20mA for 500mS
HIGH
• Compensation Cylinder Head
Pressure 1 is 600.0 BAR
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR

COMP
• LMIS / Weigh Load Predicted Machine Setup’s VEHICLE is not LBP-SC;
CYLINDER
Load is 32,767 Machine Setup’s LOAD MOMENT IND
HEAD
8536 5000mS SYSTEM is YES or WEIGH LOAD is YES; Power cycled
PRESSURE 2 – • Compensation Cylinder Head LCM J1-F1 Compensation Cylinder Head
OUT OF RANGE Pressure 2 is 600.0 BAR Pressure 2 < 2mA for 500mS
LOW

Machine Setup’s VEHICLE is not LBP-SC;

COMP
• LMIS / Weigh Load Predicted Machine Setup’s LOAD MOMENT IND
CYLINDER
Load is 32,767 SYSTEM is YES or WEIGH LOAD is YES;
HEAD
8537 5000mS LCM J1-F2 Compensation Cylinder Head Power cycled
PRESSURE – • Compensation Cylinder Head Pressure 1 and LCM J1-F1 Compensation
DISAGREEMEN Pressure 1 & 2 are 600.0 BAR Cylinder Head Pressure 2 disagree by
T
more than +/- 50BAR for 500mS

• LMIS / Weigh Load Predicted

Load is 32,767
• LCM V
• LOW protected FET disabled
• Lift Cylinder Head Pressure 1
is 600.0 BAR
• Lift Cylinder Head Pressure 2
is 600.0 BAR
COMP Machine Setup’s VEHICLE is not LBP-SC;
• Lift Cylinder Rod Pressure 1 is
CYLINDER ROD Machine Setup’s LOAD MOMENT IND
600.0 BAR
PRESSURE 1 – 8538 5000mS SYSTEM is YES or WEIGH LOAD is YES; Power cycled
OUT OF RANGE • Lift Cylinder Rod Pressure 2 is LCM J3-E4 Compensation Cylinder Rod
HIGH 600.0 BAR Pressure 1 > 20mA for 500mS
• Compensation Cylinder Head
Pressure 1 is 600.0 BAR
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR

3614RS, 4017RS 31211337 9-195

 Electrical System

Help Cabin
DTC Actions Trigger Latch Condition
Message Alarm
COMP • LMIS / Weigh Load Predicted Machine Setup’s VEHICLE is not LBP-SC;
CYLINDER ROD Load is 32,767 Machine Setup’s LOAD MOMENT IND
PRESSURE 1 – 8539 5000mS SYSTEM is YES or WEIGH LOAD is YES; Power cycled
OUT OF RANGE • Compensation Cylinder Rod LCM J3-E4 Compensation Cylinder Rod
LOW Pressure 1 is 600.0 BAR Pressure 1 < 2mA for 500mS

• LMIS / Weigh Load Predicted

Load is 32,767
• LCM V
• LOW protected FET disabled
• Lift Cylinder Head Pressure 1
is 600.0 BAR
• Lift Cylinder Head Pressure 2
is 600.0 BAR
COMP Machine Setup’s VEHICLE is not LBP-SC;
• Lift Cylinder Rod Pressure 1 is
CYLINDER ROD Machine Setup’s LOAD MOMENT IND
600.0 BAR
PRESSURE 2 – 8540 5000mS SYSTEM is YES or WEIGH LOAD is YES; Power cycled
OUT OF RANGE • Lift Cylinder Rod Pressure 2 is LCM J3-F4 Compensation Cylinder Rod
HIGH 600.0 BAR Pressure 2 > 20mA for 500mS
• Compensation Cylinder Head
Pressure 1 is 600.0 BAR
• Compensation Cylinder Head
Pressure 2 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 1 is 600.0 BAR
• Compensation Cylinder Rod
Pressure 2 is 600.0 BAR

COMP • LMIS / Weigh Load Predicted Machine Setup’s VEHICLE is not LBP-SC;
CYLINDER ROD Load is 32,767 Machine Setup’s LOAD MOMENT IND
PRESSURE 2 – 8541 5000mS SYSTEM is YES or WEIGH LOAD is YES; Power cycled
OUT OF RANGE • Compensation Cylinder Rod LCM J3-F4 Compensation Cylinder Rod
LOW Pressure 2 is 600.0 BAR Pressure 2 < 2mA for 500mS

Machine Setup’s VEHICLE is not LBP-SC;

COMP • LMIS / Weigh Load Predicted Machine Setup’s LOAD MOMENT IND
CYLINDER ROD Load is 32,767 SYSTEM is YES or WEIGH LOAD is YES;
PRESSURE – 8542 5000mS LCM J3-E4 Compensation Cylinder Rod Power cycled
DISAGREEMEN • Compensation Cylinder Rod Pressure 1 and LCM J3-F4 Compensation
T Pressure 1 & 2 are 600.0 BAR Cylinder Rod Pressure 2 disagreed by
more than +/- 50BAR for 500mS

LMIS / WEIGH
LOAD Machine Setup’s LOAD MOMENT IND
ATTACHMENT • LMIS / Weigh Load Predicted SYSTEM is YES or WEIGH LOAD is YES;
8543 5000mS Power cycled
SELECTION – Load is 32,767 LCM and PRM Attachment Selected do
DISAGREEMEN not agree for 3000mS
T

Machine Setup’s LOAD MOMENT IND

All calibration offsets are in
SYSTEM is YES or WEIGH LOAD is YES;
range for selected
LMIS NOT • LMIS / Weigh Load Predicted LMIS Passive Mode is DISABLE; LMIS
8544 5000mS attachment (LMIS calibration
CALIBRATED Load is 32,767 Calibration Mode is MANUAL; At least
must be successfully
one LMIS calibration offset is out of
completed)
range for the selected attachment

9-196 31211337 3614RS, 4017RS

 Electrical System

9.16.17 Steering (86x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s STEER PRESSURE is YES;
Low Steering Pressure Machine Setup’s VEHICLE is not LBP-RS; Steering Pressure Switch
LOW STEERING
8638 Continuously Indicator is shown on Engine running >5,000mS; CCM J3-C3 energized (closed) for
PRESSURE
Parker Cabin Display Steering Pressure Switch is de-energized 3,000mS
(open) for 3,000mS

Machine Setup’s STEER PRESSURE is YES;

Low Steering Pressure Machine Setup’s VEHICLE is LBP-RS; Steering Pressure Switch
LOW STEERING
8638 Continuously Indicator is shown on Engine running >5,000mS; CCM J3-C3 energized (closed) for
PRESSURE
Stoneridge Cabin Display Steering Pressure Switch is de-energized 3,000mS
(open) for 3,000mS

3614RS, 4017RS 31211337 9-197

 Electrical System

9.16.18 Service Required (87x)

Cabin
Help Message DTC Actions Trigger Latch Condition
Alarm
Machine Setup’s PREMIUM DISPLAY is NO; Operator Maintenance Interval reset by
MAINTENANCE user
874 5000mS – Tools’ ENABLE MAINT INTERVAL is YES; Maintenance
INTERVAL
Interval has been reached 10 Minutes elapses

Machine Setup’s ENGINE CONTROL is Deutz Engine

OIL CHANGE Configured and any one of the following occur:
REQUIRED DUE TO All of trigger conditions
875 5000mS – • DM1 (524194:8) active
STANDSTILL removed
REFRESH • DM1 (524193:2) active
• Oil Exchange Request active

9-198 31211337 3614RS, 4017RS

 Electrical System

9.16.19 Hardware (99x)

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
• Hydraulic functions are pre-
EEPROM vented EEPROM checksum issue detected Configure and
FAILURE – calibrate vehicle
998 Continuously • Engine Start is prevented EEPROM cannot be synchronized at power-
CHECK ALL
SETTINGS • Engine speed set to closed up Power cycled
throttle RPM

FUNCTION
LOCKED OUT –
PLATFORM Machine Setup’s PLATFORM OPTION is YES;
• Platform functions pre-
MODULE 9910 Continuously keyswitch platform; PLT Software Major is Power cycled
vented
SOFTWARE not 0x04
VERSION
IMPROPER

• Hydraulic functions are pre-

vented
FUNCTIONS Adjust Machine
LOCKED OUT – • Engine Start is prevented
9924 5000mS Machine Setup’s MODEL is UNKNOWN Setup’s MODEL
MACHINE NOT • Engine speed set to closed
CONFIGURED Power cycled
throttle RPM
• All other faults are masked
PLATFORM
Machine Setup’s PLATFORM OPTION is YES;
MODULE • Platform functions pre-
9948 Continuously keyswitch platform; PLT reports Low Side FET Power cycled
HARDWARE vented
failure
FAILURE

MACHINE • Hydraulic functions are pre- CCM, FFCM, RFCM, LCM or TCM detects one
CONFIGURATIO vented Configure Machine
of these issues:
N OUT OF 9949 Continuously • Engine Start is prevented Setup
Machine Setup parameter out of range
RANGE – CHECK • Engine speed set to closed Power cycled
ALL SETTINGS Machine Setup checksum improper
throttle RPM

• Hydraulic functions are pre- CABIN JOYSTICK DM1 (520193:12) active

vented
CABIN JOYSTICK DM1 (520194:12) active
• Engine Start is prevented
CABIN JOYSTICK CABIN JOYSTICK DM1 (520197:12) active
- INTERNAL 9976 Continuously • Engine speed set to closed Power cycled
throttle RPM CABIN JOYSTICK provides undocumented
FAILURE
DM1
• Direction Selection is Neu-
tral when Machine Setup’s CABIN JOYSTICK Main and Supervisor
JOYSTICK FNR is YES feedback improper

• Hydraulic functions are pre- CCM, FFCM, or RFCM detects one of these
EEPROM VALUE vented Configure
issues:
– OUT OF 9978 Continuously • Engine Start is prevented Personalities
Personality parameter out of range
RANGE • Engine speed set to closed Power cycled
Personality checksum improper
throttle RPM

FUNCTIONS • Hydraulic functions are pre-

LOCKED OUT – vented Machine Setup’s SAFETY JOYSTICK is YES;
CAB JOYSTICK
9985 Continuously • Engine Start is prevented CCM Software Type is Production; Power cycled
SOFTWARE
• Engine speed set to closed Cabin Mode; JoystickSWMajor is not 0x02
VERSION
IMPROPER throttle RPM

3614RS, 4017RS 31211337 9-199

 Electrical System

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
FUNCTIONS • Hydraulic functions are pre-
LOCKED OUT – vented Machine Setup’s VEHICLE is LBP-RS, SAFETY
CAB JOYSTICK JOYSTICK is NO; CCM Software Type is
9985 Continuously • Engine Start is prevented Power cycled
SOFTWARE Production;
VERSION • Engine speed set to closed Cabin Mode; JoystickSWMajor is not 0x01
IMPROPER throttle RPM

FUNCTIONS • Hydraulic functions are pre-

LOCKED OUT – vented
TCM Type, Major, & Minor Software Versions
TCM SOFTWARE 99163 Continuously • Engine Start is prevented Power cycled
do not match CCM
VERSION • Engine speed set to closed
IMPROPER throttle RPM

FUNCTIONS • Hydraulic functions are pre-

LOCKED OUT – vented
FFCM FFCM Type, Major, & Minor Software Versions
99173 Continuously • Engine Start is prevented Power cycled
SOFTWARE do not match CCM
VERSION • Engine speed set to closed
IMPROPER throttle RPM

FUNCTIONS • Hydraulic functions are pre-

LOCKED OUT – vented
RFCM RFCM Type, Major, & Minor Software Versions
99174 Continuously • Engine Start is prevented Power cycled
SOFTWARE do not match CCM
VERSION • Engine speed set to closed
IMPROPER throttle RPM

FUNCTIONS • Hydraulic functions are pre-

LOCKED OUT – vented
LCM Type, Major, & Minor Software Versions
LCM SOFTWARE 99175 Continuously • Engine Start is prevented Power cycled
do not match CCM
VERSION • Engine speed set to closed
IMPROPER throttle RPM

Machine Setup’s VEHICLE is not LBP-RS; CCM

FUNCTIONS • Hydraulic functions are pre- Software Type is Production and one of the
LOCKED OUT – vented following occurred:
CABIN DISPLAY
99176 Continuously • Engine Start is prevented Power cycled
SOFTWARE CabinDisplaySWType is not 0x50
VERSION • Engine speed set to closed (Production)
IMPROPER throttle RPM
CabinDisplaySWMajor is not 0x01

• Hydraulic functions are pre-

FFCM CURRENT vented
FEEDBACK FFCM current feedback calibration is out of
99177 Continuously • Engine Start is prevented Power cycled
GAINS OUT OF range
RANGE • Engine speed set to closed
throttle RPM

• Hydraulic functions are pre-

RFCM CURRENT vented
FEEDBACK RFCM current feedback calibration is out of
99178 Continuously • Engine Start is prevented Power cycled
GAINS OUT OF range
RANGE • Engine speed set to closed
throttle RPM

FFCM CURRENT • Hydraulic functions are pre-

FEEDBACK vented
FFCM current feedback calibration checksum
CALIBRATION 99179 Continuously • Engine Start is prevented Power cycled
is improper
CHECKSUM • Engine speed set to closed
INCORRECT throttle RPM

9-200 31211337 3614RS, 4017RS

 Electrical System

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
RFCM CURRENT • Hydraulic functions are pre-
FEEDBACK vented
RFCM current feedback calibration checksum
CALIBRATION 99180 Continuously • Engine Start is prevented Power cycled
is improper
CHECKSUM • Engine speed set to closed
INCORRECT throttle RPM

• Hydraulic functions are pre-

vented
• Engine Start is prevented
• Engine speed set to closed
throttle RPM
• Throttle Position is 0% CCM detects one of these issues for 1,000mS:

• Outrigger Left Joystick is +5V analog reference is >5.1V or <4.9V

CCM ANALOG 0% +3.3V analog reference is >3.4V or <3.2V
REFERENCE OUT 99181 Continuously • Outrigger Right Joystick is Power cycled
OF RANGE 0%
Note: Check that pins CCM J1-H2, J2-F1, and
• Rear Auxiliary 1 Joystick is J2-F2 Analog Reference Voltage are +5+/-
0% 0.1V.
• Rear Auxiliary 2 Joystick is
0%
• Proportional Travel Speed is
0%
• Brake Pedal Position is 0%

• Hydraulic Fluid Tempera-

ture is +150°C
• If Machine Setup’s TRANS
TEMP is SENSOR or HYSTAT
SENSOR; Transmission Oil
Temperature is +150°C
• Intercooler Air Tempera-
ture is +150°C
• Outrigger Left Extend Pres- FFCM detects one of these issues for
sure is 0 PSI / BAR 1,000mS:
• Outrigger Left Retract Pres- +5V analog reference is >5.1V or <4.9V
sure is 0 PSI / BAR
FFCM ANALOG +3.3V analog reference is >3.4V or <3.2V
REFERENCE OUT 99182 Continuously • Outrigger Left Not Set Power cycled
OF RANGE • Outrigger Right Extend
Pressure is 0 PSI / BAR Note: Check that pins FFCM J1-H2, J2-F1, J2-
F2, J2-L2, J3-A2, J3-B2, J3-C2, J3-D2, J3-D3,
• Outrigger Right Retract
and J3-E3 Analog Reference Voltage are +5+/
Pressure is 0 PSI / BAR
-0.1V.
• Outrigger Right Not Set
• Fuel Level assumed to be
Empty (0.0%)
• Brake Pedal Pressure is
3000PSI
• De-Clutch prevented
• Service Brake Relay Pres-
sure is 3000 PSI (max)

3614RS, 4017RS 31211337 9-201

 Electrical System

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
• Boom Angle Sensor is +99° RFCM detects one of these issues for
• HIRAS Mode is forced to 1,000mS:
ERROR +5V analog reference is >5.1V or <4.9V
RFCM ANALOG • Start HIRAS Integrity Checks +3.3V analog reference is >3.4V or <3.2V
REFERENCE OUT 99183 Continuously is prevented Power cycled
OF RANGE • Lift Up de-rated
Note: Check that pins RFCM J1-H2, J2-F1, J2-
• Load Stability assumed to F2, J2-L2, J3-A2, J3-B2, J3-C2, J3-D2, J3-D3,
be 100% and J3-E3 Analog Reference Voltage are +5+/
• Boom Damping prevented -0.1V.

• LMIS / Weigh Load Pre-

dicted Load is 32,767
• Lift Cylinder Head Pressure
1 is 600.0 BAR
• Lift Cylinder Head Pressure
2 is 600.0 BAR
Machine Setup’s LOAD MOMENT IND
• Lift Cylinder Rod Pressure 1 SYSTEM is YES, PLATFORM OPTION is YES, or
is 600.0 BAR WEIGH LOAD is YES; LCM detects one of
• Lift Cylinder Rod Pressure 2 these issues for 1,000mS:
is 600.0 BAR +5V analog reference is >5.1V or <4.9V
LCM ANALOG
REFERENCE OUT 99184 Continuously • Compensation Cylinder +3.3V analog reference is >3.4V or <3.2V Power cycled
OF RANGE Head Pressure 1 is 600.0
BAR
• Compensation Cylinder Note: Check that pins LCM J1-H2, J2-F1, J2-
Head Pressure 2 is 600.0 F2, J2-L2, J3-A2, J3-B2, J3-C2, J3-D2, J3-D3,
BAR and J3-E3 Analog Reference Voltage are +5+/
-0.1V.
• Compensation Cylinder
Rod Pressure 1 is 600.0 BAR
• Compensation Cylinder
Rod Pressure 2 is 600.0 BAR
• Boom Length Measurement
is maximum (Lmax)

• Hydraulic functions are pre-

vented
• Engine Start is prevented
CCM INTERNAL • Engine speed set to closed CCM failed integrity tests at power-up or run-
99203 Continuously Power cycled
ERROR throttle RPM time
• Power State is ERROR for
power-up or SAFE for run-
time

• Hydraulic functions are pre-

vented
• Engine Start is prevented
FFCM INTERNAL • Engine speed set to closed FFCM failed integrity tests at power-up or
99204 Continuously Power cycled
ERROR throttle RPM run-time
• Power State is ERROR for
power-up or SAFE for run-
time

9-202 31211337 3614RS, 4017RS

 Electrical System

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
• Hydraulic functions are pre-
vented
• Engine Start is prevented
RFCM INTERNAL • Engine speed set to closed RFCM failed integrity tests at power-up or
99205 Continuously Power cycled
ERROR throttle RPM run-time
• Power State is ERROR for
power-up or SAFE for run-
time

• Hydraulic functions are pre-

vented
• Engine Start is prevented
• Engine speed set to closed
throttle RPM
• Load Moment assumed to
LCM INTERNAL be 100% LCM failed integrity tests at power-up or run-
99278 Continuously Power cycled
ERROR • Power State is ERROR for time
power-up or SAFE for run-
time
• LMIS / Weigh Load Pre-
dicted Load is 32,767
• Boom Length Measurement
is maximum (Lmax)

• Hydraulic functions are pre-

LCM CURRENT vented
FEEDBACK LCM current feedback calibration is out of
99279 Continuously • Engine Start is prevented Power cycled
GAINS OUT OF range
RANGE • Engine speed set to closed
throttle RPM

LCM CURRENT • Hydraulic functions are pre-

FEEDBACK vented
LCM current feedback calibration checksum
CALIBRATION 99280 Continuously • Engine Start is prevented Power cycled
is improper
CHECKSUM • Engine speed set to closed
INCORRECT throttle RPM

Machine Setup’s LOAD STABILITY is YES;

RFCM ANALOG
• Load Stability assumed to RFCM’s Q4 and Q5 current sampling switches
ENABLE OUTPUT 99283 Continuously Power cycled
be 100% (Analog Input Type 2) are enabled but do not
NOT ON
respond

Machine Setup’s LOAD MOMENT IND

SYSTEM is YES or WEIGH LOAD is YES and
• Hydraulic functions are pre-
either of the following conditions are
vented
LCM LOAD present:
• Engine Start is prevented
CHART • Calculated and embedded Data
99284 Continuously • Engine speed set to closed Power cycled
CHECKSUM Load Charts checksums do not
INCORRECT throttle RPM match
• LMIS / Weigh Load Pre- • Calculated and Premium Display’s
dicted Load is 32,767 Data Load Charts checksums do
not match

Machine Setup’s VEHICLE is not LBP-SC or

LBP-HC; Machine Setup’s SAHR BRAKE is NO
SAHR BRAKE
or MANUAL; CCM’s Power Management
CONFIGURATIO 99287 5000mS – Power cycled
State is Normal; normal valve impedance
N INCORRECT
detected on FFCM J1-G4 SAHR Brake Valve
for 2000mS

3614RS, 4017RS 31211337 9-203

 Electrical System

Help Cabin Latch

DTC Actions Trigger
Message Alarm Condition
FUNCTIONS
LOCKED OUT –
99294 Continuously – CCM’s Power Management State is Safe Power cycled
SYSTEM IN SAFE
MODE

TRANSMISSION
TEMPERATURE Machine Setup’s FAN CONTROL is
Transmission Oil Temperature is
SENSOR 99295 5000mS HYDRAULIC, HYD W/ REV, or DUAL HYD and Power cycled
+150°C
CONFIGURATIO Machine Setup’s TRANS TEMP is SWITCH
N INCORRECT

Machine Setup’s VEHICLE is HBP, TRANS

TRANSMISSION TEMP is SWITCH; FFCM J1-C1 Transmission
TEMPERATURE Oil Temperature (Sensor) is greater than 0.1V
Transmission Oil Temperature is
SENSOR 99295 5000mS and less than 4.73V for 1,000mS. Power cycled
+150°C
CONFIGURATIO
N INCORRECT Note: Change TRANS TEMP to SENSOR and
cycle power to clear faults.

TRANSMISSION Machine Setup’s TRANSMISSION is BOSCH

MACHINE TYPE Engine speed set to closed throttle HYSTAT;
99297 5000mS Power cycled
CONFIGURATIO RPM reported Machine Type does not match
N INCORRECT configuration

ATTACHMENT Attachment Recognition functionality

Machine Setup’s ATTACH RECOG is YES;
RECOGNITION is prevented, operator must manually
99317 5000mS Reader Configuration was not successful Power Cycled
CONFIGURATIO select attachment to reenable boom
after engine start.
N INCORRECT functions after attachment change.

Machine Setup’s TRANSMISSION is LINDE

HYSTAT; TCM detects one of these issues for
1,000mS:
• +5V analog reference is >5.1V or
• Pump Pressure A is <4.9V
TCM ANALOG assumed as 600.0 BAR • +3.3V analog reference is >3.4V or
REFERENCE OUT 99334 Continuously Power Cycled
• Pump Pressure B is <3.2V
OF RANGE
assumed as 600.0 BAR
Note: Check that pins TCM J1-H2, J2-F1, J2-
F2, J2-L2, J3-A2, J3-B2, J3-C2, J3-D2, J3-D3,
and J3-E3 Analog Reference Voltage are +5+/
-0.1V.

• Hydraulic functions are pre-

vented
• Engine Start is prevented
Machine Setup’s TRANSMISSION is LINDE
• Engine speed set to closed HYSTAT and any of the following conditions
throttle RPM exist:
• Direction Selection is Neu- • TCM failed integrity tests at power-
TCM INTERNAL tral
99335 Continuously up or run-time Power cycled
ERROR • Pump Pressure A is • TCM current feedback calibration is
assumed as 600.0 BAR out of range
• Pump Pressure B is • TCM current feedback calibration
assumed as 600.0 BAR checksum is improper
• Power State is ERROR for
power-up or SAFE for run-
time

9-204 31211337 3614RS, 4017RS

 Electrical System

9.17 ENGINE DIAGNOSTIC

Note: For more information, contact your local authorized engine service distributor

SPN FMI Description

98 2 Oil level sensor internal error. Sensor reports error (open/short (transducer))

Oil level out of range.

1) Level below measuring range
98 31
2) Level above measuring range
Strong signal noise (e.g., oil foaming)

98 31 Oil sensor voltage out of range. Sensor reports voltage out of range (<8,5V ±0,5V; >16,5V ±0,5V).

98 2 Oil sensor invalid sensor status. Sensor status can not be read correctly.

98 31 Oil sensor temperature out of range (-48°C > temp. > 168°C).

98 14 Oil sensor is broken or disconnected. PWM input signal from sensor is not available or not correct.

100 3 Sensor error oil pressure; signal range check high.

100 4 Sensor error oil pressure sensor; signal range check low.

100 1 Low oil pressure; warning threshold exceeded.

100 1 Low oil pressure; shut off threshold exceeded.

107 0 Air filter differential pressure; air filter cologged.

411 2 PEGRdiff_p value stuck check failed. Pressure does not change between engine operating points.

411 3 Signal value above maximum limit.

411 4 Signal value below minimum limit.

108 0 Ambient air pressure sensor range check max-error.

108 1 Ambient air pressure sensor range check min-error

108 15 Fault check max signal range violated for ambient air pressure sensor

108 17 Fault check min signal range violated for ambient air pressure sensor

108 2 Ambient air pressure sensor sensor error by component self diagnosis

3720 0 DPF ash load exceeded shut off level.

3734 0 DPF soot load exceeded remove filter level.

4781 14 DPF soot load exceeded shut off level.

1209 15 Pressure turbine upstream above upper limit.

1176 1 Pressure turbine upstream below lower limit.

1209 2 Pressure turbine upstream stuck check failed. Pressure does not change between engine operating points.

1209 3 Diagnostic fault check for SRC high for outlet-valve downstream pressure.

1209 4 Diagnostic fault check for SRC low for outlet-valve downstream pressure.

3614RS, 4017RS 31211337 9-205

 Electrical System

SPN FMI Description

3251 3 DFC to report an error in case of signal line Short circuitrd to battery.

3251 4 DFC to report an error in case of signal line Short circuitrd to ground.

3251 14 DFC for reporting communication error.

3251 14 DFC for reporting data error.

3251 14 DFC for reporting fast channel1 error.

3251 14 DFC for reporting fast channel 2 signal range error.

3251 2 Particle filter difference pressure value not plausible.

3251 0 Particle filter difference pressure above shut off threshold.

3251 16 Particle filter difference pressure above warning threshold.

3251 1 Particle filter difference pressure below shut off threshold.

3251 18 Particle filter difference pressure below warning threshold.

5571 16 The pressure relief valve (PRV) has reached the number of allowed activations.

5571 2 Pressure relief valve is forced to open, perform pressure increase.

5571 2 Pressure Relief Valve (PRV) forced to open. Performed by pressure increase.

5571 16 Pressure Relief Valve (PRV) forced to open. Shutoff conditions.

5571 15 Pressure Relief Valve (PRV) forced to open. Warning conditions.

5571 0 Open Pressure Relief Valve (PRV) was detected.

5571 2 Unexpected opening of the pressure relief valve.

5571 2 Successful PRV opening cannot be ensured.

5571 13 Averaged rail pressure after PRV opening is outside the expected tolerance range.

5571 16 Open time of Pressure Relief Valve (PRV) for wear out monitoring had exceeded.

94 1 Fuel pressure build up during engine start not successful.

1347 5 Electrical fuel pre - supply pump; open load.

1347 3 Electrical fuel pre - supply pump; short circuit to battery.

1347 4 Electrical fuel pre - supply pump. Short circuit to ground.

1231 14 Errror generated from DemEvent ComCILBusOffNode_APPL_CAN: CAN Busoff Error for Application CAN.

7103 13 Rail pressure below setpoint, speed-dependent threshold exceeded.

7103 13 Railpressure metering unit: Fuel quantity balance is disrupted.

7103 13 Negative rail pressure governor deviation at zero delivery by metering unit.

7103 1 Rail pressure value is below minimum rail pressure threshold.

7103 0 Maximum rail pressure exceeded.

7103 2 Setpoint of metering unit in overrun mode not plausible.

9-206 31211337 3614RS, 4017RS

 Electrical System

SPN FMI Description

639 14 Error generated from DemEvent ComCILBusOffNode_PT_CAN: CAN Busoff Error for Powertrain CAN.

5357 14 Shut-off due to undershoot of minimum rail pressure.

157 0 Maximum rail pressure exceeded in limp home mode.

Sensor error rail pressure.

157 3
Sensor voltage above upper limit.

157 4 Sensor error rail pressure. Sensor voltage below lower limit.

520252 2 Wrong checksum in the CAN message EAT Control.

Error generated from DemEvent RBA_IOEXTLIB_KEEPALIVE_DRV: KeepAlive error during runtime at an external
629 12
device.

Error generated from DemEvent RBA_IOEXTLIB_KEEPALIVE_INI: KeepAlive error during initialisation phase at an
629 12
external device.

629 12 DFC generated from DemEvent rba_MemDiag_MemReadErr: Read diagnosis error for non volatile memory.

629 12 DFC generated from DemEvent rba_MemDiag_MemWrErr: Write diagnosis error for non volatile memory.

629 12 DFC generated from DemEvent rba_MultiStackTrace_Threshold: Stack memory threshold overrun.

DFC generated from DemEvent rba_SyC_IrrSwOffTrigEngRun_Event: Observation Counter Irregular Switch Off
629 12
Counter Triggered by Engine Running.

4207 2 Checksum fault.

4207 2 Checksum fault.

5826 15 NCD Inducement level 1 for EU.

5826 0 NCD Inducement level 2 for EU.

5826 14 NCD Pretrigger for inducement level 2.

4207 2 Checksum fault.

4207 2 Checksum fault.

91 3 Sensor error accelerator pedal (channel 1), short circuit to battery.

2623 3 Sensor error accelerator pedal (channel 2), short circuit to battery.

29 3 Signal Range Check High for remote APP signal 1.

2625 3 Short circuit to battery of remote accelerator pedal signal 2.

91 4 Sensor error accelerator pedal (channel 1), short circuit to ground.

2623 4 Sensor error accelerator pedal (channel 2), short circuit to ground.

29 4 Signal Range Check Low for remote APP signal 1.

2625 4 Short circuit to ground of remote accelerator pedal signal 2.

3509 14 Failure of sensor supply voltage 1.

3509 0 DFC generated from DemEvent SSpMon1OV: Overvoltage error at sensor supply 1 .

3614RS, 4017RS 31211337 9-207

 Electrical System

SPN FMI Description

3509 6 DFC generated from DemEvent SSpMon1SCG: Short circuit to ground error at sensor supply 1.

3509 1 DFC generated from DemEvent SSpMon1UV: Undervoltage error at sensor supply 1 .

3510 14 Failure of sensor supply voltage 2.

3510 0 DFC generated from DemEvent SSpMon2OV: Overvoltage error at sensor supply 2.

3510 6 DFC generated from DemEvent SSpMon2SCG: Short circuit to ground error at sensor supply 2.

3510 1 DFC generated from DemEvent SSpMon2UV: Undervoltage error at sensor supply 2.

677 3 Starter relay high side. Short circuit to battery.

677 4 Starter relay high side. Short circuit to ground.

677 5 Starter relay low side no load error.

677 3 Starter relay low side short circuit to battery.

677 4 Starter relay low side short circuit to ground.

91 11 Plausibility error between APP1 and APP2 or APP1 and idle switch.

In case of dual analog accelerator pedal, it is the plausibility check between RmtAPP1 and RmtAPP2 and in case
29 11
of potentiometer switch accelerator pedal, it is the plausibility check between APP1 and idle switch.

1041 14 Terminal 50 was operated too long.

105 0 High charged air cooler temperature. Warning threshold exceeded.

105 0 High charged air cooler temperature. Shut off threshold exceeded.

1136 0 Physical range check high for ECU temperature.

1136 1 Physikal range check low for ECU temperature.

1136 15 Signal Range Check Maximum for ECU temperature sensor.

1136 17 Signal Range Check Minimum for ECU temperature sensor.

1136 2 Diagnostic Fault Check for TECU sensor plausibility.

412 15 Physical Range Check high for EGR cooler downstream temperature.

412 17 Physical Range Check low for EGR cooler downstream temperature.

412 3 Electrical error EGR cooler downstream temperature. Signal range check high.

412 4 Electrical error EGR cooler downstream temperature. Signal range check low.

51 5 Throtte valve, open load.

51 3 Throtte valve, short circuit to battery1.

51 3 Throtte valve, short circuit to battery2.

51 4 Throtte valve, short circuit to ground1.

51 4 Throtte valve, short circuit to ground2.

51 6 Throttle valve, over load.

9-208 31211337 3614RS, 4017RS

 Electrical System

SPN FMI Description

51 7 Status of diagnostic fault check valve jammed closed.

51 7 Status of diagnostic fault check valve jammed opened.

51 3 Throtte valve, short circuit to battery.

51 4 Throtte valve, short circuit to ground.

105 0 TIntkVUs_t above upper limit.

105 1 TIntkVUs_t below lower limit.

Dynamic plausibility check for TOxiCatDs_t failed. Temperature difference between ToxiCatUs_t and ToxiCatDs_t
4766 2
too high.

4766 2 Plausibility check for TOxiCatDs_t failed. Temperature is too low.

4766 15 Temperature downstream DOC, temperature above upper warning threshold.

4766 3 Sensor error exhaust gas temperature downstream (DOC); signal range check high.

4766 4 Sensor error exhaust gas temperature downstream (DOC); signal range check low.

4765 2 Temperature upstream DOC, plausibility error.

4765 15 Temperature upstream DOC, temperature above upper warning threshold .

4765 3 Sensor error exhaust gas temperature upstream (DOC); signal range check high.

4765 4 Sensor error exhaust gas temperature upstream (DOC); signal range check low.

4765 2 Stuck check for TOxiCatUs_t failed. Temperature does not change anymore.

520256 9 Timeout of EAT Control Receive Message. The message is not received.

523211 9 Timeout error of CAN-Receive-Frame EBC1.

523212 9 Timeout error of CAN-Receive-Frame ComEngPrt. Engine Protection.

520254 8 The standstill-regeneration mode time exceeds the long limit threshold.

520255 2 Hoses connected to the dp DPF SENT sensor inverted. Swap the hoses.

523741 14 Engine shut off request through CAN.

97 0 Water in fuel level prefilter; maximum value exceeded.

523240 9 Timeout CAN-message FunModCtl. Function Mode Control.

520253 2 Rolling counter fault CAN message EAT Control.

4206 2 Fault check for Rolling Counter of TSC1AE

4206 2 Fault check for Rolling Counter of TSC1AR

4206 2 Fault check for Rolling Counter of TSC1TE

4206 2 Fault check for Rolling Counter of TSC1TR

3349 0 Timeout error of CAN-Receive-Frame Active TSC1AE.

3349 0 Timeout error of CAN-Receive-Frame Passive TSC1AE.

3614RS, 4017RS 31211337 9-209

 Electrical System

SPN FMI Description

3349 0 Timeout error of CAN-Receive-Frame Active TSC1AR.

3349 0 Timeout error of CAN-Receive-Frame Passive TSC1AR.

3349 0 Timeout error of CAN-Receive-Frame TSC1TE - active.

3349 0 Short circuit to ground error.

3349 0 Timeout error of CAN-Receive-Frame TSC1TR.

3349 0 Passive timeout error of CAN-Receive-Frame TSC1TR.

3349 0 Timeout error of CAN-Receive-Frame TSC1AE. Traction Control.

3349 0 Timeout error of CAN-Receive-Frame TSC1AR. Retarder.

3349 0 Timeout error of CAN-Receive-Frame TSC1TE. Setpoint.

3349 0 Timeout Error of CAN-Receive-Frame TSC1TR; control signal.

1485 3 Short circuit to battery error.

1485 3 Short circuit to battery error of actuator relay 2.

1485 3 Short circuit to battery of actuator relay 3.

1485 4 Short circuit to ground error.

1485 4 Short circuit to ground of actuator relay 2.

1485 4 Short circuit to ground of actuator relay 3.

168 0 Physical range check high for battery voltage.

168 1 Physical range check low for battery voltage.

168 3 Sensor battery voltage error; signal range check is high.

168 4 Sensor battery voltage error; signal range check is low.

523982 0 Powerstage diagnosis disabled. High battery voltage.

523982 1 Powerstage diagnosis disabled. Low battery voltage.

168 0 High battery voltage; warning threshold is exceeded.

27 5 EGR valve, open load.

27 3 EGR valve, short circuit to battery1.

27 3 EGR valve, short circuit to battery2.

27 4 EGR valve, short circuit to ground1.

27 4 EGR valve, short circuit to ground2.

27 6 EGR valve, over load.

27 7 Status of diagnostic fault check valve jammed closed.

27 7 Status of diagnostic fault check valve jammed opened.

5763 3 EGR valve, short circuit to battery.

9-210 31211337 3614RS, 4017RS

 Electrical System

SPN FMI Description

5763 4 EGR valve, short circuit to ground.

3055 14 Internal software error ECU. Injection cut off.

Engine speed above warning threshold.

190 0
Overspeed detection in component engine protection.

190 0 Engine speed above warning threshold (FOC-Level 1).

190 0 Engine speed above warning threshold (FOC-Level 2).

190 0 Engine speed above warning threshold (Overrun Mode).

171 15 Environment temperature sensor, temperature above upper physical threshold.

Sensor error SCR-System environment temperature.

171 3
DPF-System air inlet temperature, signal range check high.

Sensor error SCR-System environment temperature.

171 4
DPF-System air inlet temperature, signal range check low.

723 8 Sensor camshaft speed, disturbed signal.

Sensor camshaft detection.

723 14
Out of range, signal disrupted, no signal.

723 13 Offset angle between crank- and camshaft-sensor is too large.

Sensor crankshaft detection.

4201 8
Out of range, signal disrupted or no signal.

4201 14 Speed detection, out of range, signal disrupted or no signal.

Error generated from DemEvent CAN_E_TIMEOUT: CAN Hardware registers are not updated within the expected
1669 14
time.

110 2 Defect fault check for dynamic plausibility test.

97 3 DFC SAE J1939 error.

97 4 Sensor error water in fuel, signal range check low.

94 15 Low fuel pressure system, max. physical range exceeded.

94 3 Sensor error low fuel pressure, signal range check high.

94 4 Sensor error low fuel pressure, signal range check low.

94 1 Low fuel pressure system, warning threshold exceeded.

94 1 Low fuel pressure, shut off threshold exceeded.

110 3 Sensor error coolant temperature; Signal range check high.

110 4 Sensor error coolant temperature; Signal range check low.

110 0 High coolant temperature; Warning threshold exceeded.

3614RS, 4017RS 31211337 9-211

 Electrical System

SPN FMI Description

110 0 Coolant temperature; System reaction initiated.

676 12 Cold start aid relay error.

676 5 Cold start aid relay: Open load.

676 5 Cold start aid relay: Open load.

411 2 Intake air massflow not in expected range.

676 3 Intake Air Heater Device: Short circuit to battery.

676 4 Powerstage on CJ945, short circuit to ground.

2797 14 Number of possible injections limited by the injection valve.

2797 4 Booster voltage too low.

5358 5 Open load on the power stage of injection valve 0.

5359 5 Open load on the power stage of injection valve 1.

5360 5 Open load on the power stage of injection valve 2.

5361 5 Open load on the power stage of injection valve 3.

5362 5 Open load on the power stage of injection valve 4.

5363 5 Open load on the power stage of injection valve 5.

2797 6 Short circuit of the HDEV power stage high-side (bank0 error).

2798 6 Short circuit of the HDEV power stage high-side (bank1 error).

5358 6 Short circuit of the power stage low-side (cylinder error 0).

5359 6 Short circuit of the power stage low-side (cylinder error 1).

5360 6 Short circuit of the power stage low-side (cylinder error 2).

5361 6 Short circuit of the power stage low-side (cylinder error 3).

5362 6 Short circuit of the power stage low-side (cylinder error 4).

5363 6 Short circuit of the power stage low-side (cylinder error 5).

111 1 Coolant level too low.

5358 6 Short circuit between high-side and low-side of the power stage (high-side non plausible error).

5359 6 Short circuit between high-side and low-side of the power stage (high-side non plausible error).

5360 6 Short circuit between high-side and low-side of the power stage (high-side non plausible error).

5361 6 Short circuit between high-side and low-side of the power stage (high-side non plausible error).

5362 6 Short circuit between high-side and low-side of the power stage (high-side non plausible error).

5363 6 Short circuit between high-side and low-side of the power stage (high-side non plausible error).

105 3 Signal Range Check high for intake valve upstream temperature.

105 4 Signal Range Check Low for intake valve upstream temperature.

9-212 31211337 3614RS, 4017RS

 Electrical System

SPN FMI Description

2797 14 Check of missing injector adjustment value programming (IMA) injector 1.

2798 14 Check of missing injector adjustment value programming (IMA) injector 2.

4257 14 Check of missing injector adjustment value programming (IMA) injector 3.

4258 14 Check of missing injector adjustment value programming (IMA) injector 4.

0 0

7103 5 Open load diagnosis of MeUn power stage.

7103 3 Short circuit to battery on the high side power stage of MeUn.

7103 3 Short circuit to battery on the low side power stage of MeUn.

7103 4 Short circuit to ground on the high side power stage of MeUn.

7103 4 Short circuit to ground on the low side power stage of MeUn.

7103 6 Short circuit between high side and low side power stage of MeUn.

629 12 Function monitoring: fault of ECU ADC - Null Load Test Pulse.

629 12 Function monitoring: fault of ECU ADC - test voltage.

629 12 DFC to indicate ICO request from MoCSOP module.

91 14 Function monitoring: Monitoring of accelerator pedal position.

190 2 Function monitoring: fault of engine speed check.

5357 2 Diagnostic fault check to report the plausibility error between level 1 energizing time and level 2 information.

5441 2 Diagnostic fault check to report the error due to plausibility between the injection begin v/s injection type.

5357 2 Diagnostic fault check to report the error due to non plausibility in ZFC

523612 12 Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off.

598 10 No clutch edge within calibrated time.

523612 12 Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor.

523612 12 Diagnosis fault check to report the error to demand for an ICO due to an error in change of EOM.

5357 2 Diagnosis fault check to report the error to demand for an ICO due to an error in total toruque relevant quantity.

5357 2 Diagnostic fault check to report the error due to injection quantity correction.

5442 2 Diagnostic fault check to report the plausibility error in rail pressure monitoring.

29 2 DFC to report the fault in Remote APP plausibility check.

677 2 Function monitoring: fault of ECU powertrain active.

513 2 DFC to report the fault in energizing time comparison.

513 2 DFC to report fault in torque comparison error.

520250 2 Function monitoring: error in the post-build selectable monitoring.

3614RS, 4017RS 31211337 9-213

 Electrical System

SPN FMI Description

629 12 Status of the EMM alarm FCCU0 which is read out of the FCCU hardware module.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

1109 2 Engine shut off demand ignored.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

1109 14 Shut off request from supervisory monitoring function.

9-214 31211337 3614RS, 4017RS

 Electrical System

SPN FMI Description

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Internal ECU error.

629 12 Diagnostic fault check to report ABE active state.

629 12 Function monitoring: fault of ECU, WDA active by inquiry/response communication.

629 12 Function monitoring: fault of ECU, Error Pin active suspicion of HW fault.

629 12 Function monitoring: fault of ECU, WDA active by overvoltage detection.

3614RS, 4017RS 31211337 9-215

 Electrical System

9-216 31211337 3614RS, 4017RS

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