JLG 1850SJ Service And Maintenance Manual
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JLG 1850SJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
1850SJ
3121619
June 29, 2018 - Rev J
AS/NZS

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Summary of Contents for JLG 1850SJ

  • Page 1 Service and Maintenance Manual Model 1850SJ 3121619 June 29, 2018 - Rev J AS/NZS...

  • Page 3: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - June 18, 2014 Revised B - September 25, 2014 Revised C - May 15, 2015 Revised D - November 5, 2015 Revised E - January 27, 2016 Revised F - June 8, 2016 Revised G - November 8, 2016 Revised...

  • Page 5: Table Of Contents

    Do NOT Do the Following When Welding on JLG Equipment .......
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Axle Extension System................3-2 Drive Orientation System .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Slow Down System................4-3 Dual Capacity System .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections..5-6 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections... . 5-7 Assembly Instructions for 37°...
  • Page 9 To Connect the JLG Control System Analyzer........
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 6.12 LSS System ..................6-94 Diagnostic Menu .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram ............. 1-4 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-38. Swing Bearing Torquing Sequence..............3-40 3-39.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-24. Jib Hydraulics - Sheet 1 of 7............... . . 4-43 4-25.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-16. Hydraulic Hose Installation - Sheet 1 of 8 ............5-51 5-17.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-59. Tapered Bushing Installation ............... 5-74 5-60.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-102. Piston and Spacer Disassembly ..............5-97 5-103.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-1. Hand Held Analyzer ................6-1 6-2.
  • Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-7. Connector Assembly Figure 1 ............... 7-7 7-8.
  • Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-52. Chassis Harness - Sheet 1 of 6............... 7-48 7-53.
  • Page 20 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-98. Battery Jump-Start Hookup ............... . . 7-94 7-99.
  • Page 21 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. This page left blank intentionally 3121619 xvii...
  • Page 22 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Dimensional Data .
  • Page 23 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-31 Flange Code (FL61 & FL62) -Inch Fasteners ............5-45 5-32 Flange Code (FL61 &...
  • Page 24 LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally. 3121619...

  • Page 25: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Table 1-2. Dimensional Data Horizontal Reach over end Table 1-1. Operating Specifications Unrestricted Capacity 70 ft. 6 in. (21.59 m) Restricted Capacity 59 ft. 6 in. (18.13 m) Capacity - ANSI Unrestricted 500 lbs (227 kg) Horizontal Reach over side...

  • Page 26: Engine Data

    Up to 5% BioDiesel NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- 1.6 MAJOR COMPONENT WEIGHTS tain the same required additives or be of comparable vis- cosities.
  • Page 27 SECTION 1 - SPECIFICATIONS Table 1-9. Mobil DTE 10 Excel 32 Specs Table 1-12. Exxon Univis HVI 26 Specs ISO Viscosity Grade Specific Gravity 32.1 Specific Gravity 0.877 Pour Point -76°F (-60°C) Pour Point, Max Flash Point 217°F (103°C) -40°F (-40°C) Viscosity Flash Point, Min.
  • Page 28 SECTION 1 - SPECIFICATIONS Figure 1-1. Maintenance and Lubrication Diagram 3121619...

  • Page 29: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.8 MAINTENANCE AND LUBRICATION 2. Swing Gearbox NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-14. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 30 SECTION 1 - SPECIFICATIONS 4. Hydraulic Return Filter 6. Hydraulic Charge Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 6 months Lube Point(s) - Replaceable Element or 300 hours thereafter. Interval - Change after first 50 hours and every 6 months 7.
  • Page 31 SECTION 1 - SPECIFICATIONS 8. Hydraulic Oil 10. Oil Change w/Filter - Deutz Lube Point(s) - Fill Cap Capacity - 75 Gallons (208 liters) Tank to Full Mark Lube Point(s) - Fill Cap/Spin-on Element 82 Gallons (310.4 L) System Capacity - 9.6 Quarts (9.1 L) Lube - HO Lube - EO Interval - Check level daily.
  • Page 32 SECTION 1 - SPECIFICATIONS 13. Air Filter 11. Fuel Filter - Deutz Lube Point(s) - Replaceable Element Interval - Every year or 500 hours of operation 12. Fuel Pre-Filter Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator Comments - Check dust valve for dirt daily 14.
  • Page 33 SECTION 1 - SPECIFICATIONS 16. Diesel Exhaust Fluid (DEF) (If Equipped) 18. Optional Fuel Filter/Water Separator Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 600 hours of operation Lube Point - Fill Cap Lube - DEF Capacity - 5.7 gal.
  • Page 34 SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 1-10 3121619...
  • Page 35 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121619 1-11...
  • Page 36 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-12 3121619...
  • Page 37 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121619 1-13...
  • Page 38 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-14 3121619...

  • Page 39: General

    Service Technician as a person who has successfully com- this product will be fit for continued use. pleted the JLG Service Training School for the subject JLG product model. Reference the machine Service and Mainte- Preparation, Inspection, and Maintenance nance Manual and appropriate JLG inspection form for perfor- mance of this inspection.

  • Page 40: Service And Guidelines

    Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual rental delivery. and applicable JLG inspection form. Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual comes first;...

  • Page 41: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING or assemble one part, then start on another. Always recheck LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.

  • Page 42: Lubrication

    SECTION 2 - GENERAL Lubrication Hydraulic Oil 1. Refer to Section 1 for recommendations for viscosity Service applicable components with the amount, type, and ranges. grade of lubricant recommended in this manual, at the speci- fied intervals. When recommended lubricants are not avail- Changing Hydraulic Oil able, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

  • Page 43: Cylinder Drift

    SECTION 2 - GENERAL CYLINDER DRIFT Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature Theory before beginning this test. When a hydraulic cylinder is supporting a load, cylinder drift Measure drift at cylinder rod with a calibrated dial indicator. may occur as a result of any of the circumstances below: In an area free of obstructions, cylinder must have load •...

  • Page 44: Pins And Composite Bearing Repair Guidelines

    • Ground only to structure being welded. 2. Filament wound bearings should be replaced if any of the following is observed: Do NOT Do the Following When Welding on JLG a. Frayed or separated fibers on the liner surface. Equipment b.
  • Page 45 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields...
  • Page 46 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Capacity Indicator Drive Brakes Swing Brakes...
  • Page 47 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...
  • Page 48 SECTION 2 - GENERAL 1001159163 A Figure 2-1. Engine Operating Temperature Specifications - Deutz 2-10 3121619...
  • Page 49 SECTION 2 - GENERAL HYDRAULIC FLUID OPERATION CHART MACHINE OPERAT ION USING NON-JLG APPROVED HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF T HE T EMPERATURE BOUNDARIES OUT LINED IN T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY RESULT IN PREMAT URE WEAR OR DAMAGE TO COMPONENT S OF T HE HYDRAULIC SYST EM.
  • Page 50 SECTION 2 - GENERAL NOTES: 2-12 3121619...

  • Page 51: Chassis & Turntable

    For polyurethane foam filled tires, JLG Industries, Inc. recom- mends that when any of the following are discovered, mea- sures must be taken to remove the JLG product from service immediately and arrangements must be made for replace- ment of the tire or tire assembly.

  • Page 52: Axle Extension System

    SECTION 3 - CHASSIS & TURNTABLE 3.2 AXLE EXTENSION SYSTEM 3.3 DRIVE ORIENTATION SYSTEM The Drive Orientation System (DOS) is intended to indicate to NOTE: The boom must be oriented between the rear wheels to the operator conditions that could make the direction of extend or retract the axles.

  • Page 53: Steering Control System

    SECTION 3 - CHASSIS & TURNTABLE 3.4 STEERING CONTROL SYSTEM There are three different modes of steering selectable by the position of the steer select switch on the platform control panel: crab, coordinated, and conventional two wheel steer- ing. These are shown below. Figure 3-3.

  • Page 54: Drive/Steering Speed Control

    SECTION 3 - CHASSIS & TURNTABLE will be driven based on the information available from the 3.6 TRACTION CONTROL SYSTEM other sensors. This axle will not track perfectly and will The traction control system uses the steering sensors from the become farther out of position over time.
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally. 3121619...

  • Page 56: Axle Hose Routing - Sheet 1 Of 2

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-4. Axle Hose Routing - Sheet 1 of 2 3121619...
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE Figure 3-5. Axle Hose Routing - Sheet 2 of 2 3121619...
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE 3121619...
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 3121619...
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 3-10 3121619...
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-11...

  • Page 62: Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE ASSEMBLY 1. Drive Hub 3. Drive motor 5. Bolt 7. Bolt 2. O-Ring 4. Washer 6. Washer Figure 3-10. Drive Assembly 3-12 3121619...

  • Page 63: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.8 DRIVE HUB 1001149921 1. Ring 9. Pin 17. Pinion 25. Flange 33. Seal 41. Plastic Plug 49. O-Ring 2. Screw 10. O-Ring 18. Hub Housing 26. O-Ring 34. Coupling 42. Input Shaft 50. Brake Piston 3.

  • Page 64: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly 4. Remove, Ring (1), Cover (6), O-Ring (7), Spacer (8) and O-Ring (10). Do not damage O-Rings. Check and remove 1. Remove plugs (5) and pour lubricant in a container. Gasket (4) if damaged. Reinstall plugs.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 6. Remove two Screws (19), Planetary Ring (18) and O-Ring 8. Remove three snap rings (22) and planetary gears (24) (26). Do not damage O-Ring. from spindles on Flange (25). 7. Remove Coupling (34) and Spring (35). 9.
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 10. Remove Hub Support (30), Bearing (29), O-Ring (31), 12. Remove Snap Ring (53), Spacer (52), Seal (48), O-Ring Bearing (32), and two Seals (33) from Axle (38). (49), and Brake Piston (50) from Axle (38). Remove five Brake Springs (51) from Brake Piston (50).

  • Page 67: Assembly

    SECTION 3 - CHASSIS & TURNTABLE 14. Remove Split Ring (36), Input Shaft (42), and Bearing (37) 3. Install Seal (46), O-Ring (47), Seal (48), and O-Ring (49) in from Axle (38). Axle (38). Starting with Brake Disk (43) alternate with Iron Disk (44) until a total of eight Brake Disks and nine Iron Discs are installed on Input Shaft (42 - not shown) in Axle.
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 5. Install Flange (25) on Axle (38), with Plug (21) and six NOTE: Install Ring Nut with convex part facing bearing. screws (20). 7. Install Ring Nut (27) on Flange (25). Prevent Flange from turning and torque Ring Nut to 295 ft-lb (400 Nm).
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 9. Install Spring (35) and Coupling (34). 11. Install Gear Reduction Assembly (16), Gear Reduction Assembly (13), and Pinion (11) in Planetary Housing. Lubricate all bearings. 10. Install O-Ring (26). Install Planetary Ring (18) with two 12.
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 13. Install O-Ring (54) and Motor Flange (55). Apply Loctite 15. Install Pin (4) and Cover (3). Secure with two Screws (2). 243 or equivalent to six Screws (56). Install and torque Torque to 7 ft-lb (10 Nm). Screws to 177 ft-lb (240 Nm).

  • Page 71: Free Wheeling Option

    SECTION 3 - CHASSIS & TURNTABLE 3.9 FREE WHEELING OPTION 3.10 GEAR HUB OIL SERVICE Disengage Drive Motors & Brakes for Towing, etc. Check Oil Level (Free Wheel) 1. Position hub as shown in Figure 3-13. 1. Chock wheels. 2. Remove Level Plug (3) and check oil is level with plug opening.
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE 3160339 1. Bolt 7. Needle Bearing 13. Cylinder Block 19. O-Ring 25. Gasket 31. Shaft 2. Motor End cap 8. Valve Plate 14. Slipper Pin 20. Servo Piston 26. Plug 32. Bearing 3. Locating Pin 9.

  • Page 73: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.11 DRIVE MOTOR Shaft Seal Replacement NOTE: Drive motor servicing is similar for all Series 45 hydraulic REMOVAL motors. The physical appearance of your motor may be 1. Remove snap ring (1) retaining shaft seal, and support slightly different than shown.

  • Page 74: Loop Flushing Valve

    SECTION 3 - CHASSIS & TURNTABLE INSPECTION 2. Using a 1/4 in hex wrench remove plug (3). Inspect new seal, motor housing seal bore, and sealing area on 3. Remove O-rings (4, 5, and 6). shaft for rust, wear, and contamination. Polish shaft and clean 4.

  • Page 75: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-2. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill reservoir to proper level. Ensure oil supply to motor is adequate and supply to motor.

  • Page 76: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This ensures parts will be lubricated during start-up. Replace all O-Rings and gaskets. It is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.

  • Page 77: End Cap

    SECTION 3 - CHASSIS & TURNTABLE 25. Valve Plate 28. O-ring 26. End Cap 29. Angle Stop 27. O-ring 30. Servo Spring 22. Screw 23. End Cap Figure 3-21. Valve Plate & Rear Shaft Bearing 24. O-ring Figure 3-20. End Cap DO NOT SCRATCH VALVE PLATE SURFACE.

  • Page 78: Cylinder Kit

    SECTION 3 - CHASSIS & TURNTABLE 32. Snap Ring 33. Support Washer 31. Cylinder Kit Assembly 34. Shaft Seal Figure 3-22. Cylinder Kit Figure 3-23. Shaft Seal 18. Turn housing on its side and remove cylinder kit assem- bly (31). Set assembly aside. Do not to scratch running surface.

  • Page 79: Swash Plate & Servo Piston

    SECTION 3 - CHASSIS & TURNTABLE Lift Here 35. Inner Snap Ring 37. Bearing 36. Snap Ring 38. Shaft Figure 3-24. Shaft & Front Bearing 20. Remove inner snap ring (35) and shaft/bearing assembly. 21. Remove snap-ring (36) retaining shaft front bearing. Pull 39.

  • Page 80: Inspection

    SECTION 3 - CHASSIS & TURNTABLE 27. Turn block over. Using a press, apply pressure on block spring washer (50) to compress block spring. Compress spring enough to safely remove spiral retaining ring (51). While maintaining pressure, unwind spiral retaining ring (51).
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE CYLINDER BLOCK Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface. Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing will not reduce block height below minimum specification.

  • Page 82: Assembly

    SECTION 3 - CHASSIS & TURNTABLE SHAFT BEARINGS Assembly Inspect bearings for excessive wear or contamination. Rotate 1. Install new O-ring (1) and piston seal (2) to servo piston bearings while feeling for uneven movement. Bearings should (3). Install piston seal over O-ring. spin smoothly and freely.

  • Page 83: Swash Plate And Journal Bearing

    SECTION 3 - CHASSIS & TURNTABLE 6. Install journal bearings (13) in housing seats. Use assem- bly grease to keep bearings seated during assembly. RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES Ensure locating nubs drop into seat cavities. If reusing bearings, install in original location and orientation.

  • Page 84: Shaft And Front Bearing

    SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) on shaft (16). Press bearing 11. Lubricate and install servo spring (20) and minimum on shaft with lettering facing out. Lubricate bearing roll- angle stop (21) in housing bore. ers.

  • Page 85: Valve Plate And Rear Bearing

    SECTION 3 - CHASSIS & TURNTABLE 12. Press rear shaft bearing (22) in endcap. Install bearing 15. Install endcap (25) on housing with endcap screws (26). with letters facing out. Press until bearing surface is 0.08 Ensure endcap will properly seat to housing without ±0.01 in (2 ±0.25 mm) above endcap surface.

  • Page 86: Shaft Seal

    SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install a 20. Install orifice poppet (30). new shaft seal (27) with cup side facing motor. Press seal in housing until it bottoms out. Press evenly to avoid binding and damaging seal.

  • Page 87: Initial Start-Up

    5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres- sure gauge port of pump to monitor system pressure 3. Apply JLG Thread locking compound P/N 0100019 to during start up. bolt. Torque pivot spacer screw to 340 ft-lb (47 kgm).

  • Page 88: Turntable Bearing Mounting Bolt Condition Check

    SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.

  • Page 89: Swing Bearing Torque Values

    Lower the boom to horizontal and fully extend the boom. Figure 3-37. Swing Bolt Feeler Gauge Check 3.13 SWING BEARING TORQUE VALUES 1. Outer Race - 708 ft.lbs. (960 Nm) w/ JLG Threadlocker P/N 0100019. 2. Inner Race - 708 ft.lbs. (960 Nm) w/ JLG Threadlocker P/N 0100019.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE Figure 3-38. Swing Bearing Torquing Sequence 3-40 3121619...

  • Page 91: Swing Bearing Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING BEARING WEAR TOLERANCE 5. Position the machine as follows and as seen in Figure 3- 30., Swing Bearing Wear Tolerance, Position 2: See Figure 3-39., Swing Bearing Wear Tolerance. a. Do not rotate the turntable 1.
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE Figure 3-39. Swing Bearing Wear Tolerance 3-42 3121619...
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-43...
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE 3-44 3121619...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-45...
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE 3-46 3121619...

  • Page 97: Swing Control System

    SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING CONTROL SYSTEM main boom length is less than 1477.7 inches in the 500 lb mode or 1442.8 inches in the 1000 lb mode. The swing control system uses the turntable swing angle sen- The 8.0º...

  • Page 98: Water In Fuel Sensing System (Optional)

    • The engine will shut down automatically. If the engine has been inactive for some time or the air tem- • The JLG Control System will set DTC 4375 - Water in Fuel perature is very low, crank the engine first and then run at idle.

  • Page 99: Diesel Exhaust Fluid (Def) Tank

    SECTION 3 - CHASSIS & TURNTABLE 3.20 DIESEL EXHAUST FLUID (DEF) TANK Cleaning and Flushing the Tank Refer to Figure 3-44. and Figure 3-45. If contaminated fluid or foreign material is found in the tank, the tank must be cleaned. Use the following procedure for Diesel exhaust fluid (DEF) is a urea solution consisting of 32.5% cleaning.
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE Figure 3-44. Diesel Exhaust Fluid (DEF) Tank - Sheet 1 of 2 3-50 3121619...
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE 1. Coolant Tube 13. Header 2. Level Tube 14. Metallic Flange 3. DEF Filter 15. Cover 4. Tie-Wrap 16. Screw 5. Rubber Bushing 17. Spring Tube 6. Float Assembly 18. Urea Quality Sensor 7. Suction Tube 19.
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE 3-52 3121619...
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-53...
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE 3-54 3121619...
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-55...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 3-56 3121619...
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-57...
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE 3-58 3121619...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-59...
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE 3-60 3121619...

  • Page 111: Deutz Engine With Diesel Exhaust Fluid (Def)

    SECTION 3 - CHASSIS & TURNTABLE 3.21 DEUTZ ENGINE WITH DIESEL EXHAUST FLUID WINTER OPERATION WITH DIESEL FUEL Special demands are placed on the cold behavior (tempera- (DEF) ture limit value of the filtrability) for winter operation. Suitable fuels are available in winter. Engine Oil Mixing with petrol is not permissible for safety and technical reasons (cavitation in the injection system).

  • Page 112: Selective Catalytic Reduction (Scr) - Machines Using Diesel Exhaust Fluid (Def)

    SECTION 3 - CHASSIS & TURNTABLE 3.22 SELECTIVE CATALYTIC REDUCTION (SCR) - 2. Move the machine to an area free of flammables and personnel that could be exposed to hot exhaust. Launch MACHINES USING DIESEL EXHAUST FLUID (DEF) the cleaning process by pressing the SCR button on the Ground Console for 3 seconds.

  • Page 113: Maintenance Standstill Cleaning Initiation Methods

    SECTION 3 - CHASSIS & TURNTABLE 4. After the cleaning process is complete, the engine will Unsuccessful Cleaning Event run for approximately 5 minutes to allow the Engine and If there is an unsuccessful cleaning event, The SCR icon will Exhaust After Treatment (EAT) to cool down.
  • Page 114 Derate Comments Levels Light Light Cleaning 0-500 Between 500 and 1000 hours, clean- Normal None ing cycle can be initiated with JLG Operation 500-1000 analyzer. Standstill 1000-1100 None Required Engine coolant temperature muxt 0.5 Hz be >40° C and DEF should be thawed before cleaning can be initiated.
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523925 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on 2. Components on Pin A88, K57 cannot be 1- Lamps K57: Warn Ash Charge, Diagnostic, pins A88, K57.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 7-2-2 523912 @ engines < 4l: The sensed raw voltage value is below the mini- The sensed raw voltage value Throttle valve error, Open Load or Short cut mum threshold.
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code Coolant temperature: the coolant tempera- Coolant temperature above shut off threshold. Clean radiator, check fan drive, check coolant ture calculated by ECU is above the target level, check cooling system in general, range.
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523941 Timeout Error (BAM to packet) for CAN- Timeout Error (Missing CAN Bus message) NOX downstream sensor and sensor connection Receive-Frame AT1OGCVol2 information; check factors &...
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code Internal hardware monitoring: the ECU finds Section could not be erased Threshold for error detection is an internal ECU an error during the access to its EEPROM threshold.
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code Camshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU signal and uses the signal from camshaft threshold, occurs by disturbed or no speed sensor as alternative to calculate the camshaft signal.
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code The cold start aid relay is according to wiring Relay defect or wire harness problem Threshold for error detection is an internal ECU faulty.
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code Injector cyl. 1: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU nection cyl.
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code Injector cyl. 6: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU ECU is above the target range injector cylinder 6 threshold.
  • Page 124 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523612 Internal hardware monitoring: the CPU of Error report due to an interrupted SPI communi- Threshold for error detection is an internal ECU the ECU is reset and the cause is logged inter- cation (ECU internal error) threshold.
  • Page 125 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523612 Impermissible offset between the engine Calculated engine speed in level 1/2 implausi- Threshold for error detection is an internal ECU speed of level 2 and level 1 ble (->...
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523612 supply voltage too low not used Threshold for error detection is an internal ECU threshold. 523612 Error report "WDA wire is active" due to a Error detection by monitoring module Threshold for error detection is an internal ECU defect query/response communication...
  • Page 127 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code Air filter differential pressure: the pressure Pressure loss above target range with system Check airfilter and if necessary clean or renew it, difference of the intake air between the filter reaction, air filter clogged or defective, check cabling, check sensor and if...
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code DFC is stored in EEPROM and status kept until deviation between desired O2 concentration in Threshold for error detection is an internal ECU check is allowed intake air manifold threshold.
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523470 Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal ECU threshold. Only after ECU reset. Check PRV opening counter and if necessary replace it, check rail-pressure sensor for plausibility and if...
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523613 Rail pressure: the fuel pressure in rail calcu- Rail pressure falls below the limiting value Threshold for error detection is an internal ECU lated by ECU is below the target range based on the engine speed.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523722 Supply module heater: Faulty PWM signal PWM Signal for temperature readout from sup- Threshold for error detection is an internal ECU from supply module.
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 2-2-6 Analog accelerator pedal sensor 1 or double Short circuit to ground. Check cabling, check accelerator pedal sensor accelerator pedal sensor: the voltage mea- and if necessary replace it, check sured by ECU is out of the target range or the connection cable and if necessary repair or...
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code Start relay (high side power stage): Shortcut HighSide-output to ground. Threshold for error detection is an internal ECU the current drain measured by ECU is above threshold.
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1-2-6 Diagnostic fault check of synchronism of Plausibility error between sensor and idle Threshold for error detection is an internal ECU hand throttle and Low idle switch(LIS).
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1012 523960 Physical range check low for EGR cooler sensor voltage > lower limit EGR-Valve blocked open downstream temperature. EGR-Valve actuator defect EGR-cooler defect (check for coolant water) Reed Valve defect Intake throttle blocked in closed position...
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1036 4768 Static plausibility check: Static plausibility check: Check ambient temperature => value plausi- The exhaust temperature value from the The exhaust temperature value from the sensor ble? sensor before DOC, the exhaust temperature before DOC, the exhaust temperature...
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1069 4360 The filtered urea cat upstream temperature Sensed temperature upstream SCR > physical Check temperature difference across DOC is greater than an applicable maximum tem- high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at higher perature threshold...
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1092 4345 Urea backflow line heater: the current drain Shortcut to battery Threshold for error detection is an internal ECU measured by ECU is above the target range If this error detected during the heating phase is threshold a result error: KWP 1089...
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1106 523719 Urea supply module heater: the current Open load Threshold for error detection is an internal ECU drain measured by ECU is above the target If this error detected during the heating phase is threshold range...
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1121 4375 Urea supply module pump: the current drain Shortcut to ground Threshold for error detection is an internal ECU measured by ECU is above the target range If this error detected during the heating phase is threshold a result error: KWP 1089...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1135 3031 The urea tank temperature sensor detects a Sensed urea tank temperature > physical range Case "CANBUS sensor": value above the maximum allowed thresh- high limit Check urea tank temperature: really hot? Check CANBus-message of DEF sensor urea tank...
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1180 Battery voltage: the voltage measured by Battery voltage over limit Check alternator, regulator of alternator and if ECU is out of the target range necessary replace it, check wiring and voltage of alternator 1181...
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1239 523984 Actuator relay 5: the voltage measured by Short-Circuit to battery to component Threshold for error detection is an internal ECU ECU is out of the target range threshold.
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1455 3711 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC DPF temperature < Threshold 1 temperature, is below or above Exh_tSensOxiCatUs within Stand-still: >...
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1535 524076 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU downstream SCR downstream SCR threshold.
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1538 524079 sensed lambda value of NOx-sensor down- sensed lambda value of NOx-sensor down- Compare to ComRxSCR_rCanLamUs_mp. stream SCR catalyst is < physical low limit stream SCR catalyst is <...
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1544 524085 sensed Nox-value of Nox-sensor upstream sensed Nox-value of Nox-sensor upstream SCR Check CANBus of NOx-sensor upstream SCR cat- SCR catalyst < Threshold catalyst <...
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1565 524065 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check for crystallisation in exhaust line from the urea cat upstream cal high range limit f(exhaust volume upstream SCR and dwnstream of urea injector...
  • Page 149 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1570 524065 voltage of pressure sensor upstream SCR < voltage of pressure sensor upstream SCR < volt- Check wiring of pressure sensor upstream SCR voltage low limit age low limit catalyst.
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1586 524067 Filtered urea supply module temperature sensed temperature of urea within supply mod- Check ambient temperature EnvT_t < thresh- (SCR_tSMT) value is below an applicable ule <...
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1639 524147 No proper urea pressure level could be build This error shows up, if no proper urea pressure Make sure that frozen lines, pump or tank can be up within the SCR system state "Fill Lines"...
  • Page 152 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1655 1761 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea threshold of <5% below applicable threshold 5% Check DEF level sensor.
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1754 2791 EGR actuator can not learn stop positions. Error detection during the learning process. Threshold for error detection is an internal ECU Possibly only second failure if other EGRTV threshold.
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1858 524141 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector: urea or other deposits.
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1864 524178 The urea pump is not able to control the urea The urea pump controller is not able to control Make sure that DEF lines, pump and tank are not pressure between 9bar and 11 bar.
  • Page 156 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1866 4334 absolute difference of sensed urea pump absolute difference of sensed urea pump pres- Check environment pressure sensor (EnvP_p) pressure (SCR_pAbsSensUPmpP) and ambi- sure (SCR_pAbsSensUPmpP) and =>...
  • Page 157 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1880 1761 The DEF tank level is below the threshold. actual DEF tank level SCRUTnk_rVol_mp [%] is Check DEF level => if empty, refill below the threshold Check DEF level sensor.
  • Page 158 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1893 524193 The total time in standstill-regeneration Stand-still mode is very often aborted by the Read out stand-still statistics => see service mode exceeds the long-limit threshold operator.
  • Page 159 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1894 524194 The total time in standstill-regeneration Stand-still mode is aborted / interrupted too Read out stand-still statistics => see service mode exceeds the long-limit threshold: 2,5h often by the operator manual:...
  • Page 160 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1897 3520 The integrated diagnostic of the Urea Quality wiring harness to the suction unit in the DEF Threshold for error detection is an internal ECU Sensor recognized a short circuit to ground.
  • Page 161 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1900 524195 The standstill request of detected crystalli- Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line and zation is ignored for more than reached a level which indicates inspect visually the injector and the...
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1904 2-7-8 3520 Measured DEF Quality from UQS is too low. Suspected components: Check that there is liquid urea of known quality Quality value received from UQS is <...

  • Page 163: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM SYSTEMS Beyond Transport - Drive Speed Cutback System When boom is positioned beyond the Transport Position, the drive motors are automatically restricted to their maximum Broken Cable Indicator System displacement position (slow speed).

  • Page 164: Envelope Control System

    BCS indicator Control System, reduced function speeds, and BCS warning will illuminate indicating the machine requires service by JLG light illumination. The unit will be restricted from leaving the authorized service personnel before the system is used. Failure transport position until the failure is resolved.

  • Page 165: Controlled Boom Angle System

    SECTION 4 - BOOM & PLATFORM end of manual telescope commands when using multiple Slow Down System functions with lift. The telescope command can be used inde- When the main boom approaches the edges of the working pendently or in combination with other functions. Manual envelope, all functions (except jib and platform functions, tele- introduction of telescope will override the controlled arc sys- scope in or out on the rearward edge and telescope in on the...

  • Page 166: Platform Load Sensing System

    SECTION 4 - BOOM & PLATFORM Platform Load Sensing System Boom Control Select The Platform Load Sensing System consists of 4 load cells, The boom control select switch is mounted on the platform mounted between the platform and platform support, and a control panel and allows the operator the ability to select dedicated electronic interface module (LSS) located below the between two different modes of boom control functionality:...

  • Page 167: Boom Recovery Mode

    SECTION 4 - BOOM & PLATFORM Boom Recovery Mode Boom Recovery Mode allows the boom to be lifted down and Press ENTER , the screen should read: telescoped in, in the event CAN bus communication is lost to both the Jib Control Module and the Platform Module. Boom Recovery Override is only available in the event the ground module loses CAN communication with both the Jib Control Module and the Platform module, in the case of a sev-...

  • Page 168: Boom Removal And Installation

    SECTION 4 - BOOM & PLATFORM 4.2 BOOM REMOVAL AND INSTALLATION Use the Left or Right arrow key until you see: Removal 1. If necessary, remove the platform. 2. If necessary, remove the jib. 3. Tag and disconnect hoses T2 T3, 7, 8, and Pressure Filter lines from the main valve.
  • Page 169 SECTION 4 - BOOM & PLATFORM 3121619...

  • Page 170: Installation

    SECTION 4 - BOOM & PLATFORM 4. Tag and disconnect all electrical lines from the limit 9. Carefully lift the boom from the machine, taking care to switches and generator that go to from the turntable to feed the hydraulic and electrical lines up alongside the the powertrack.

  • Page 171: Boom Assembly

    1-5. Boom Section 1 is at the base, Boom Sec- tion 5 is the fly. NOTE: During Assembly, Super Lube® lubricant (JLG p/n 3020042) is to be moderately applied to all four inner surfaces of both ends of each boom section to a minimum depth of three to four feet and also to the end of section 5 that is inserted into section 4.
  • Page 172 Torque the bolts to 40.5 ft.lbs. (55 Nm). 3. Install the top and bottom rear wear pads and shims. Coat the retaining bolts with JLG threadlocking com- pound P/N 0100011 and secure the wear pads with the bolts and washers. Torque the bolts to 40.5 ft.lbs. (55 Nm).
  • Page 173 SECTION 4 - BOOM & PLATFORM 3121619 4-11...
  • Page 174 SECTION 4 - BOOM & PLATFORM 4-12 3121619...
  • Page 175 SECTION 4 - BOOM & PLATFORM 3121619 4-13...
  • Page 176 SECTION 4 - BOOM & PLATFORM 4-14 3121619...
  • Page 177 SECTION 4 - BOOM & PLATFORM 3121619 4-15...
  • Page 178 SECTION 4 - BOOM & PLATFORM 4-16 3121619...
  • Page 179 SECTION 4 - BOOM & PLATFORM 3121619 4-17...
  • Page 180 SECTION 4 - BOOM & PLATFORM 4-18 3121619...
  • Page 181 SECTION 4 - BOOM & PLATFORM 3121619 4-19...
  • Page 182 SECTION 4 - BOOM & PLATFORM 4-20 3121619...
  • Page 183 SECTION 4 - BOOM & PLATFORM 3121619 4-21...
  • Page 184 SECTION 4 - BOOM & PLATFORM 4-22 3121619...
  • Page 185 SECTION 4 - BOOM & PLATFORM 3121619 4-23...
  • Page 186 SECTION 4 - BOOM & PLATFORM 4-24 3121619...
  • Page 187 SECTION 4 - BOOM & PLATFORM 3121619 4-25...
  • Page 188 SECTION 4 - BOOM & PLATFORM 4-26 3121619...
  • Page 189 SECTION 4 - BOOM & PLATFORM 3121619 4-27...
  • Page 190 SECTION 4 - BOOM & PLATFORM 4-28 3121619...
  • Page 191 15. Install the rear top wear pads and shims to section 4. Coat the retaining bolts with JLG threadlocking com- NOTE: Apply a thin coat of moly paste (JLG P/N 3020039) on the pound P/N 0100011 and secure the wear pads with the inside diameter of the sheave bearing before installation of bolts and washers.
  • Page 192 4 using the retaining bolts. Torque the sheave retaining bolts to 178 ft.lbs. (241 Nm). Torque the sheave 24. Apply Super Lube® lubricant (JLG p/n 3020042) to all 4 plate/retainer block bolts to 40.5 ft.lbs. (55 Nm) sides of the boom approximately 3 to 4 feet on both ends.
  • Page 193 SECTION 4 - BOOM & PLATFORM 25. Install the fixed sheave shields, and deflector sheaves 27. Coat the bolts with JLG Threadlocker P/N 0100011 and using the retaining bolts and washers. Coat the bolts install the section 5 extend ropes to section 3 using nuts, with JLG Threadlocker P/N 0100011 before installation.
  • Page 194 29. Apply a thin coat of moly paste on I.D. of sheave bear- washers, bolts, and shims. Torque the bolts to 28 ft.lbs. ings. Coat the bolts with JLG Threadlocker P/N 0100011 (38 Nm)) and install the sheaves to the front of section 3 using the pin, keeper, bolt, and washer.
  • Page 195 NOTE: Boom section 2 weighs approximately 3755 lbs. (1703 kg). 40. Place boom section 2 on a proper supporting device. 41. Apply Super Lube® lubricant (JLG p/n 3020042) to all 4 sides of the boom approximately 3 to 4 feet on both ends.
  • Page 196 63. Route cables and hose’s out thru the power track. 55. Apply Super Lube® lubricant (JLG p/n 3020042) to all 4 sides of the boom approximately 3 to 4 feet on both ends. Apply Super Lube® to section 2 on the end that will go into section 1 only.

  • Page 197: Telescope Cylinder

    SECTION 4 - BOOM & PLATFORM 4.4 TELESCOPE CYLINDER 4. Remove the bolts securing the adjustment mount and disconnect the adjustment mount from boom section 1. Removal 1. Remove the boom from the machine. Refer to Section - Boom Recovery Mode. 2.

  • Page 198: Boom Shimming Procedure

    SECTION 4 - BOOM & PLATFORM 6. Remove the bolts securing the extend rope support and 4.5 BOOM SHIMMING PROCEDURE disconnect the support from boom section 3. NOTE: Throughout this procedure, boom sections are identified numerically, 1-5. Boom Section 1 is at the base, Boom Sec- tion 5 is the fly.

  • Page 199: Boom Lubrication Application

    Section 2. 1. JLG recommends the use of the JLG Hostile Environment 11. Repeat steps 1-7 above to assemble the Section 5/4/3/2 Package if available to keep the internal portions of a assembly into Section 1.

  • Page 200: Hose Adjustment Procedure

    SECTION 4 - BOOM & PLATFORM 4.8 HOSE ADJUSTMENT PROCEDURE 5. With clamp D set, pull the hoses and cables until they are resting against the flat bars on the outside radius of the power track. Force additional hydraulic hose slack 1.
  • Page 201 SECTION 4 - BOOM & PLATFORM Figure 4-20. Hose Adjustment 3121619 4-39...
  • Page 202 SECTION 4 - BOOM & PLATFORM 4-40 3121619...
  • Page 203 SECTION 4 - BOOM & PLATFORM 3121619 4-41...
  • Page 204 SECTION 4 - BOOM & PLATFORM 4-42 3121619...
  • Page 205 SECTION 4 - BOOM & PLATFORM 3121619 4-43...
  • Page 206 SECTION 4 - BOOM & PLATFORM 4-44 3121619...
  • Page 207 SECTION 4 - BOOM & PLATFORM 3121619 4-45...
  • Page 208 SECTION 4 - BOOM & PLATFORM 4-46 3121619...
  • Page 209 SECTION 4 - BOOM & PLATFORM 3121619 4-47...
  • Page 210 SECTION 4 - BOOM & PLATFORM 4-48 3121619...
  • Page 211 SECTION 4 - BOOM & PLATFORM 3121619 4-49...

  • Page 212: Jib

    SECTION 4 - BOOM & PLATFORM 4.9 JIB 8. Remove the bolt and keeper pin securing the jib level pivot pin and remove the pin. Place blocking under the cylinder rod or a soft material under the cylinder rod to Removal protect the rod from being scratched.

  • Page 213: Installation

    4. Attach a lifting device to the front of the jib and align WITH JIB ASSEMBLY AS SHOWN the jib level cylinder attachment fittings. Install the pivot pin. Apply JLG Threadlocker P/N 0100019 to the bolt 3121619 4-51...
  • Page 214 PLATFORM LEVEL CYLINDER PLATFORM ROTATOR BAR CLAMP COVER SCREW RUBBER PAD Adhesive PN# 0100081 BOLT JLG Threadlocker PN# 0100011 KEEPER JLG Threadlocker PN# 0100019 TORQUE 25 FT.LBS. (34 Nm) Figure 4-31. Jib Assembly - Sheet 1 of 4 4-52 3121619...
  • Page 215 JIB LIFT CYLINDER JIB PIVOT BOLT KEEPER TORQUE 120 FT.LBS. (163 Nm) JIB ROTATE ACTUATOR SHIMS BOLT TORQUE 340 FT.LBS. (460 Nm) JLG Threadlocker PN# 0100011 JLG Threadlocker PN# 0100019 Figure 4-32. Jib Assembly - Sheet 2 of 4 3121619 4-53...
  • Page 216 SECTION 4 - BOOM & PLATFORM BOLT LOCKPIN CYLINDER CAP ALIGN CUTOUT IN CAP INWARD AS SHOWN ALIGN LOCK CYL WITH (SEE SECTION A-A BELOW) PROTRUSIONS CAP (SEE SECTION A-A BELOW) JIB LOCK CYLINDER LOCKNUT TORQUE 180 FT.LBS. (245 Nm) LOCK PIN ALIGN CUTOUT IN CAP CYLINDER...
  • Page 217 PIVOT PAD MOUNT JIB ROTATOR BEARING BOTTOM PLATE JIB PIVOT BEARING BEARING WEAR PADS SHIMS BOLT TORQUE BOLTS TO 20 FT-LBS Loctite RC 609 Threadlocker JLG Threadlocker PN# 0100011 Figure 4-34. Jib Assembly - Sheet 4 of 4 3121619 4-55...

  • Page 218: Stowed Jib Shimming Procedure

    SECTION 4 - BOOM & PLATFORM Stowed Jib Shimming Procedure 2. Insert a shim between the wear pad and pivot pad mount. 1. Rotate the jib to the appropriate position as shown below. 3. Add shims as required to fill the gap between the wear pad and the edge of the side plate of the jib rotator.

  • Page 219: Wire Rope

    SECTION 4 - BOOM & PLATFORM 4.11 WIRE ROPE Three Month Inspection 1. Remove boom covers and visually (with flashlight) Inspection inspect the ropes for rust, broken wires, frays, abuse, or any signs of abnormalities. NOTE: The pictures in this paragraph are just samples to show the 2.

  • Page 220: Wire Rope Tensioning Adjustment

    SECTION 4 - BOOM & PLATFORM 4.12 WIRE ROPE TENSIONING ADJUSTMENT 2. Take preliminary measurements of the position of each boom section with the boom in the fully retracted posi- tion and compare them to Figure 4-36., Fully Retracted If new wire ropes are installed, there is a general starting point Boom Section Positions.
  • Page 221 SECTION 4 - BOOM & PLATFORM 3121619 4-59...
  • Page 222 SECTION 4 - BOOM & PLATFORM BOOM SECTION #3 REPOSITIONING: needs to move to be within tolerance (for example, if the section must move 0.5 inches to fall within the 1. If Boom Section #3 falls within the dimension and toler- dimension shown, tighten the nut so it moves 0.5 ance shown in Figure 4-36.
  • Page 223 SECTION 4 - BOOM & PLATFORM 6. Verify that the exposed boom section dimensions meet the dimension and tolerance of Figure 4-36.. a. If Section #3 still does not fall within the dimension and tolerance of Figure 4-36., repeat the steps out- lined in 3.
  • Page 224 SECTION 4 - BOOM & PLATFORM g. To remove slack resulting from the adjustment in c, f. Tighten the Section #4 Extend Adjustment Nuts tighten the Section #4 Extend Adjustment Nuts shown below, moving them a distance equal to shown below until they contact the rope mount what the section needs to move to be within toler- plate.
  • Page 225 SECTION 4 - BOOM & PLATFORM BOOM SECTION #5 REPOSITIONING: If Boom Section #5 falls within the dimension and toler- ance shown in Figure 4-36. with the boom fully retracted, proceed to Wire Rope Tensioning procedure in Section 6 of this document. 2.

  • Page 226: Wire Rope Tensioning Procedure

    If the boom sections have been properly positioned but there is not enough adjustment travel remaining on a wire 5. Using tool, JLG p/n 1001162217, torque Section #3 rope to achieve proper torque, the service life of the rope Retract Adjustment Nuts to 38 ft-lb (51.5 Nm), alternat-...
  • Page 227 SECTION 4 - BOOM & PLATFORM ing between the two ropes until both maintain the 10. Using tool, JLG p/n 1001162216, torque Section #4 required torque. Extend Adjustment Nuts to 17 ft-lb (23 Newton meters), alternating between the two ropes until both maintain the required torque.

  • Page 228: Confirm Proper Boom Deployment Function

    SECTION 4 - BOOM & PLATFORM 14. Retract the boom 2-3 feet (.6m – 1.0m) Do NOT fully Re-Assembly retract the boom or bottom out any section. 1. Install nylon collar locknuts on Section #4 extend wire 15. Verify wire rope torque values for extend ropes. rope fittings.

  • Page 229: Broken Boom Cable Proximity Switch

    SECTION 4 - BOOM & PLATFORM 4.13 BROKEN BOOM CABLE PROXIMITY SWITCH 3. Tighten the jam nut. This system uses a proximity switch to detect excessive move- ment of the cable block. If movement is detected the Cable Break indicator will illuminate in the platform control panel. No restrictions are made to the functionality of the control sys- tem.
  • Page 230 SECTION 4 - BOOM & PLATFORM 4-68 3121619...
  • Page 231 SECTION 4 - BOOM & PLATFORM 3121619 4-69...
  • Page 232 SECTION 4 - BOOM & PLATFORM 4-70 3121619...
  • Page 233 SECTION 4 - BOOM & PLATFORM 3121619 4-71...
  • Page 234 SECTION 4 - BOOM & PLATFORM 4-72 3121619...
  • Page 235 SECTION 4 - BOOM & PLATFORM 3121619 4-73...
  • Page 236 SECTION 4 - BOOM & PLATFORM 4-74 3121619...
  • Page 237 SECTION 4 - BOOM & PLATFORM 3121619 4-75...
  • Page 238 SECTION 4 - BOOM & PLATFORM 4-76 3121619...
  • Page 239 SECTION 4 - BOOM & PLATFORM 3121619 4-77...
  • Page 240 SECTION 4 - BOOM & PLATFORM 4-78 3121619...
  • Page 241 SECTION 4 - BOOM & PLATFORM 3121619 4-79...
  • Page 242 SECTION 4 - BOOM & PLATFORM 4-80 3121619...

  • Page 243: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.14 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of the powertrack. One Piece Bracket Maintenance 1. Place the powertrack on a workbench. 4. Pull up on the loose side of the round bar to allow the poly roller to slide off.
  • Page 244 SECTION 4 - BOOM & PLATFORM 5. Slide the poly roller off of the round bar. 7. Slide the flat bar out. 6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket. 9.

  • Page 245: Two Piece Bracket Maintenance

    SECTION 4 - BOOM & PLATFORM 10. Push down with slight pressure on the link and slide the Two Piece Bracket Maintenance bracket side up and over the extrusion on the link. 1. Loosen the screw. 11. Repeat the previous step on the other side. 2.

  • Page 246: Snap Rings And Screws

    SECTION 4 - BOOM & PLATFORM 4. Hold the flat bar and remove the screws. 7. Slide the link out. 5. Remove the snap rings and pins. Snap Rings and Screws WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO DISCARD AND REPLACE ALL OLD SCREWS.
  • Page 247 SECTION 4 - BOOM & PLATFORM Make sure that all snap rings are closed and seated. A seated and closed snap ring is shown below. CLOSED OPEN 10-24 x 0.812 button torx socket head with blue locking patch: • Tighten to 45-50 in.lbs. (5-5.6 Nm). An open snap ring is shown below.
  • Page 248 SECTION 4 - BOOM & PLATFORM Torque to 40 ft.lbs. (55 Nm) Loctite #242 Torque to 586ft. lbs. (795 Nm) Check torque every 150 hours of operation Torque to 85 ft. lbs. (116 Nm) Figure 4-53. Platform Support Torque Values 4-86 3121619...

  • Page 249: Bolt-On External Fall Arrest

    SECTION 4 - BOOM & PLATFORM 4.15 BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands, kinks, or any signs of corrosion. The bolt-on external fall arrest system is designed to provide a GAP SHOWING: GAP SHOWING: lanyard attach point while allowing the operator to access INCORRECT INCORRECT...

  • Page 250: Installation

    SECTION 4 - BOOM & PLATFORM Installation nuts onto the cable finger tight so the mark on the cable does not move. 1. Install the retaining hardware (bolts, nuts, and washers) and secure the brackets to the platform rail. Tighten the WASHER BELLEVILLE nuts but do not torque them yet.
  • Page 251 SECTION 4 - BOOM & PLATFORM 1,2,3,4 1. Belleville Washer 2. Washer 3. Hex Nut 4. Jam Nut 5. LH Bracket 6. Attachment Ring 7. Cable 8. RH Bracket 9. Decal Figure 4-55. Bolt-On External Fall Arrest System 3121619 4-89...
  • Page 252 SECTION 4 - BOOM & PLATFORM NOTES: 4-90 3121619...

  • Page 253: Basic Hydraulic Information & Hydraulic Schematics

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the SYSTEM fitting, making sure the entire o-ring is completely satu- rated.

  • Page 254: Dip Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Dip Method Spray Method This method requires a pump or trigger spray bottle. NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- 2.

  • Page 255: Hydraulic Connection Assembly And Torque Specification

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512 TORQUE SPECIFICATION Tapered Thread Types NPTF = national tapered fuel (Dry Seal) per SAE J476/J512 Figure 5-4. SAE Thread ORFS = o-ring face seal per SAE J1453 Figure 5-1.

  • Page 256: Straight Thread Types, Port Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Straight Thread Types, Port Connections Flange Connection Types ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162 MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162 6149, DIN 3852 Figure 5-10.

  • Page 257: Assembly And Torque Specifications

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the correct torque values. Prior to selecting the appropriate torque from the tables a. Verify the material designation in the table head- within this section, it is necessary to properly identify the con- ings.

  • Page 258: Assembly Instructions For American Standard Pipe Thread Tapered (Nptf) Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST Thread Tapered (NPTF) Connections. TURN FOR ALIGNMENT. 1.

  • Page 259: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for British Standard Pipe 5. Rotate male fitting the number of turns per Table 5-2, BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT Thread Tapered (BSPT) Connections procedure requirements.

  • Page 260: Assembly Instructions For 37° (Jic) Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table Table 5-3, 37° Flare (JIC)Thread - Steel or Table 5-4, 37° Flare 1. Inspect the flare for obvious visual squareness and con- (JIC)Thread - Aluminum/Brass while using the Double centricity issues with the tube OD.
  • Page 261 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-3. 37° Flare (JIC)Thread - Steel Type/Fitting Identification Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
  • Page 262 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass TYPE/FITTING IDENTIFICATION Torque Flats from Wrench Thread ØA* ØB* [Ft-Lb] [N-m] Resistance Size Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...

  • Page 263: Assembly Instructions For 45° Sae Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using 1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section.
  • Page 264 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-5. 45° Flare (SAE) - Steel TYPE/FITTING IDENTIFICATION Torque Thread ØA* ØB* [Ft-Lb] [N-m] Size Dash Size (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 5/8-18 0.56 14.30 0.63 15.90 3/4-16...

  • Page 265: Assembly Instructions For O-Ring Face Seal (Orfs) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal (ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu- Fittings minum/Brass while using the Double Wrench Method.
  • Page 266 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass Flats from Wrench TYPE/FITTING IDENTIFICATION Torque Resistance (F.F.W.R)** Thread Swivel & ØA* ØB* [Ft-Lb] [N-m] Dash Tube Size Hose Size Nuts Ends (UNF) (in) (mm) (in)

  • Page 267: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND LEAKAGE. 1. Inspect the components to ensure free of contamina- tion, external damage, rust, splits, dirt, foreign matter, or burrs.
  • Page 268 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-9. DIN 24°Cone (MBTL & MBTS) DIN 24° CONE FLARELESS BITE FITTING TYPE/FITTING IDENTIFICATION (With or Without O-Ring) Torque Flats from Tube Thread M ØA* ØB* ØD* Wrench O.D. Size [Ft-Lb] [N-m] Resistance...

  • Page 269: Assembly Instructions For Bulkhead (Bh) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Bulkhead (BH) Fittings 1. Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter. 2.
  • Page 270 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-10. Bulkhead Fittings (BH) - INCH FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Thread Size Dash Size [Ft-Lb] [N-m] (UNF) 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 5/16-12 1 7/16-12 1 11/16-12 2-12...
  • Page 271 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-11. Bulkhead Fittings (BH) - METRIC FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Connecting Thread M Size Tube O.D. MATERIAL TYPE [Ft-Lb] [N-m] (mm) (metric) M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5...
  • Page 272 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru Table 5-17 while using the Double Wrench Method. Fittings a. The table headings identify the straight thread O- ring port and the type on the other side of the fit- 1.
  • Page 273 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-12. O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size...
  • Page 274 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24...
  • Page 275 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
  • Page 276 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
  • Page 277 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33) 3/8-24 0.37 9.52...
  • Page 278 1.19 30.10 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on 1 5/8-12 1.63 41.30 JLG applications. Consult specific service procedure if encountered. 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 ZERO LEAK GOLD® TYPE/FITTING IDENTIFICATION...

  • Page 279: Assembly Instructions For Adjustable Port End Metric (Mff) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18, Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5- Metric (MFF) Fittings 23 while using the Double Wrench Method.
  • Page 280 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 281 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-19. Metric Flat Face Port (MFF) - L Series - Table 2 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 282 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS Torque...
  • Page 283 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque...
  • Page 284 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3 FORM E (EOLASTIC SEALING RING) FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end...
  • Page 285 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-23. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...

  • Page 286: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24 while using the Double Wrench Method. Port Assembly Stud Ends a. The table headings identify the Metric port and the type on the other side of the fitting.
  • Page 287 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...
  • Page 288 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...

  • Page 289: Assembly Instructions For Adjustable Port End (Bspp) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25, Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5- (BSPP) Fittings 30 while using the Double Wrench Method.
  • Page 290 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 5-38 3121619...
  • Page 291 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 3121619 5-39...
  • Page 292 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 5-40 3121619...
  • Page 293 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 3121619 5-41...
  • Page 294 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 5-42 3121619...
  • Page 295 Service Manual. G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 3121619 5-43...

  • Page 296: Assembly Instructions For Flange Connections: (Fl61 And Fl62)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Flange Connections: (FL61 and FL62) 1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs. 2. See Figure for O-ring installation instructions. 3.
  • Page 297 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch GRADE 5 Screws GRADE 8 Screws...
  • Page 298 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch CLASS 8.8 Screws...

  • Page 299: Double Wrench Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually indicates the hose To prevent undesired hose or connector rotation, two is twisted.

  • Page 300: Ffwr And Tfft Methods

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS FFWR and TFFT Methods Adjustable Stud End Assembly For Adjustable Stud End Connections; the following assembly FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed: 1. Lubricate the o-ring with a light coat of hydraulic oil. 1.

  • Page 301: O-Ring Installation (Replacement)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-14. Adjustable Stud End Assembly O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On straight threads, ensure O-ring is seated all the way past the threads prior to installation. Care must be taken when installing O-rings over threads dur- ing replacement or installation.
  • Page 302 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5-50 3121619...
  • Page 303 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3121619 5-51...
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  • Page 311: Hydraulic Cylinders

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.3 HYDRAULIC CYLINDERS 5. Mark cylinder head and barrel with center punch marks for later realignment. Remove the capscrews (4). Axle Extend Cylinder Refer to Figure 5-27. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 312 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1. Bushing 6. Wiper Seal 10. O-Ring 14. O-Ring 18. Tapered Bushing 2. Barrel 7. Seal 11. Wear Ring 15. Piston 19. Bolt 3. Counterbalance Valve 8. Cylinder Head 12. Spacer 16.
  • Page 313 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 9. Loosen and remove bolts from tapered bushing and pis- CLEANING AND INSPECTION ton. 1. Clean parts thoroughly with approved cleaning solvent. 10. Insert bolts in threaded holes in outer piece of tapered 2.
  • Page 314 NOTE: Use proper cylinder seal kit for cylinder assembly. See your grooves of piston. JLG Parts Manual. 7. Install hydrolock seals and guidelock rings in outer Apply a light film of hydraulic oil to all components before grooves of piston.
  • Page 315 O-ring and seal ring. 15. Continue pushing rod in barrel until cylinder head can be inserted into barrel cylinder. NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011) to capscrews. 16. Secure cylinder head and washer ring with eight cap- screws.

  • Page 316: Jib Level (Slave) Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Level (Slave) Cylinder 5. Mark cylinder head and barrel with center punch marks (3) for later realignment. Remove eight cylinder head Refer to Figure 5-38. capscrews DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 317 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 17** 13 14 *Torque to 50-55 ft-lb (67-75 Nm) **Torque to 30 ft-lb (41 Nm) 1001155834 1. Bushing 5. Washer Ring 9. Wear Ring 13. Back-Up Ring 17. Bolt 2. Barrel 6.
  • Page 318 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8. Using suitable protection, clamp cylinder rod in a vise or Remove and discard two lock rings (18) and seals (19) similar holding fixture as close to piston as possible. from outside grooves of piston. 9.
  • Page 319 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS CLEANING AND INSPECTION d. Press bushing in barrel or rod bushing with correct size arbor. 1. Clean parts thoroughly with approved cleaning solvent. 2. Inspect cylinder rod for scoring, tapering, ovality, or Composite Barrel or other damage.
  • Page 320 CYLINDER OPERATION. NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Install backup ring (10) and O-ring (11) in outside diame- ter grooves of cylinder head (8).
  • Page 321 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS NOTE: Apply JLG Threadlocker (P/N 0100011) to tapered bushing bolts. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, 10. Assemble the tapered bushing loosely into the piston AND PISTON.

  • Page 322: Platform Level Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Platform Level Cylinder Remove cylinder length sensor assembly (6) from barrel (3). Refer to Figure 5-51. DISASSEMBLY CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
  • Page 323 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 11** 13*** 24**** *Torque to 30-35 ft-lb (41-47 Nm) **Torque to 4 in-lb (.4 Nm) ***Torque to 9 ft-lb (12 Nm) ****Torque to 200 ft-lb (271 Nm) 1001139999 1. Screw 6. Length Sensor 11.
  • Page 324 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON. SHARP OBJECT, OR SCREW DRIVER.
  • Page 325 NOTE: Use proper cylinder seal kit for cylinder assembly. See your threads as necessary. JLG Parts Manual. 8. Inspect seal and O-ring grooves in piston for burrs and Apply a light film of hydraulic oil to all components before sharp edges. Dress surfaces as necessary.
  • Page 326 8. Thread piston on rod until it aligns with spacer end and install tapered bushing. 9. Apply JLG Threadlocker (P/N 0100011) or equivalent to tapered bushing capscrews and assemble the tapered bushing loosely into the piston. Insert capscrews Figure 5-60.
  • Page 327 SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. 15. Clamp barrel securely and support rod. NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011) to cylinder head threads. 16. Insert piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.

  • Page 328: Boom Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Boom Lift Cylinder 5. Mark cylinder head and barrel with center punch marks for later realignment. Remove cylinder head cap screws. Refer to Figure 5-66. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 329 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1. Bearing 6. Capscrew 11. Wiper Seal 16. Backup Ring 21. Bushing 2. Counterbalance Valve 7. Washer Ring 12. Rod Seal 17. Piston 22. Bolt 3. Counterbalance Valve 8. Wear Ring 13.
  • Page 330 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8. Remove three bolts attaching tapered bushing to pis- 12. Remove rod from holding fixture. Remove cylinder head (13) and washer ring (7) from rod. ton. 13. Remove and discard wiper seal (11), rod seal (12), wear 9.
  • Page 331 Dress applicable surfaces as necessary. NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. 12. Inspect cylinder head outside diameter for scoring, damage, ovality, and tapering. Replace as necessary. Apply a light film of hydraulic oil to all components before 13.
  • Page 332 NOTE: When installing the tapered bushing, piston and mating rotation to 60 ft-lb (81 Nm). end of rod must be free of oil. 6. Apply JLG Threadlocker (P/N 0100011) to tapered bush- ing capscrews. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston.
  • Page 333 10. Remove cylinder rod from holding fixture. 15. Apply primer and medium-strength locking compound JLG P/N 0100011or equivalent to eight capscrews (6). 11. Position cylinder barrel in a suitable holding fixture. Secure cylinder head assembly (13) and washer ring (7) to barrel (5)with capscrews.

  • Page 334: Jib Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Lift Cylinder 5. If necessary, remove eight capscrews (11) and retainer cap (10). Remove O-Ring plug (5) and setscrew (4). Remove cylinder length sensor assembly (9) from barrel Refer to Figure 5-79. (1).
  • Page 335 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12*** *Torque to 50-55 ft-lb (67-75 Nm) **Torque to 4 in-lb (.4 Nm) ***Torque to 9 ft-lb (12 Nm) 1001140104 1. Barrel 7. Sensor Magnet 13. Tapered Bushing 19. O-Ring 25. Seal 2.
  • Page 336 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND SHARP OBJECT, OR SCREW DRIVER.
  • Page 337 Use proper cylinder seal kit for cylinder assembly. See your 8. Inspect seal and O-ring grooves in piston for burrs and JLG Parts Manual. sharp edges. Dress surfaces as necessary. Apply a light film of hydraulic oil to all components before 9.
  • Page 338 NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 9. Apply JLG Threadlocker (P/N 0100011) to tapered bush- ing bolts. Assemble the tapered bushing loosely into the Figure 5-88. Seating the Tapered Bearing 12.
  • Page 339 O-ring and seal ring. 14. Continue pushing rod into barrel until cylinder head gland can be inserted into barrel cylinder. NOTE: Apply JLG Threadlocker (P/N 0100011) or equivalent to capscrews. Figure 5-89. Rod Assembly Installation 16. Install two counterbalance valves (3) with new O-rings in valve block.

  • Page 340: Jib Lock Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Lock Cylinder 5. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. Refer to Figure 5-91. 6. Protect cylinder rod from damage and clamp in a vise or holding fixture.
  • Page 341 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1001119313 1. Rod 4. Barrel 7. O-Ring 10. Seal 2. Seal 5. O-Ring 8. Head 11. Rod Wiper 3. Wear Ring 6. Backup Ring 9. Wear Ring Figure 5-91. Jib Lock Cylinder Assembly 3121619 5-89...
  • Page 342 Repair as necessary. ASSEMBLY NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. Figure 5-92. Cylinder Head Installation 1. Position cylinder barrel in a suitable holding fixture.

  • Page 343: Steer Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Steer Cylinder 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Refer to Figure 5-95. ROD SUPPORT DISASSEMBLY SUPPORT TABLE CCONTAMINATION MAY DAMAGE EQUIPMENT.
  • Page 344 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1001155986 1. Bushing 4. Seal 7. Backup Ring 10. Wear Ring 13. Setscrew 16. Bushing 2. Barrel 5. Head 8. O-Ring 11. O-Ring 14. Wear Ring 17. Rod 3. Wiper Seal 6.
  • Page 345 8. Apply medium-high strength (red) thread-locking com- 4. Inspect inner surface of cylinder barrel tube for scoring pound JLG P/N 0100071 or equivalent to rod threads. or other damage. Check inside diameter for tapering or 9. Thread piston assembly on rod. Do not dislodge or dam- ovality.
  • Page 346 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Install setscrew (13) in piston. Torque to 90 in-lb (10 Nm). 15. Adjust cylinder head until screw hole aligns with barrel. Install screw (9). Figure 5-97. Cylinder Head and Piston Assembly Figure 5-98.

  • Page 347: Jib Telescope Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Telescope Cylinder PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL Refer to Figure 5-101. SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON. DISASSEMBLY 8. Clamp barrel securely. Pull rod assembly out until piston bottoms to cylinder head.
  • Page 348 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 20*** *Torque to 20 ft-lb (27 Nm) **Torque to 25-30 ft-lb (33-40 Nm) ***Torque to 100 ft-lb (135 Nm) 1001158991 1. Shuttle Valve 5. Washer 9. Washer 13. Cylinder Head 17. Spacer 21.
  • Page 349 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS CLEANING AND INSPECTION REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, SHARP OBJECT, OR SCREW DRIVER. MAKE NOTE OF SEAL ORIENTATION CLEAN PARTS THOROUGHLY WITH WATER AND A RUST PREVENTATIVE ONLY. BEFORE REMOVING FOR PROPER INSTALLATION.
  • Page 350 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 9. Apply medium-strength locking compound JLG P/N 0100011or equivalent to rod threads. 10. Install piston on cylinder rod. Do not damage or dis- lodge O-ring.
  • Page 351 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011) 17. Install shuttle valve (1) with new O-ring in valve block. or equivalent to capscrew threads. Torque to 20 ft-lb (27 Nm).

  • Page 352: Boom Telescope Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Boom Telescope Cylinder Tap around outside of Cylinder Head with a suitable hammer to break thread-locking compound. Unscrew Refer to Figure 5-112. Cylinder Head (23). DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 353 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1001178592 1. Capscrew 6. O-Ring 11. Wear Ring 16. Spacer 21. Wiper Seal 26. Bracket 2. Valve Block 7. Rod 12. Seal 17. Wear Ring 22. Retaining Ring 27. Capscrew 3. Check Cartridge 8.
  • Page 354 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Remove three bolts attaching tapered bushing to pis- 14. Remove capscrew (15) and spacer (16) from rod (7). ton. 15. Remove rod from holding fixture. 11. Insert bolts in threaded holes in outer piece of tapered NOTE: Record orientation of rings for reassembly.
  • Page 355 NOTE: Use proper cylinder seal kit for cylinder assembly. See your 1. Clean parts thoroughly with approved cleaning solvent. JLG Parts Manual. 2. Inspect cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite Apply a light film of hydraulic oil to all components before or equivalent.
  • Page 356 JLG P/N 0100011 or equivalent to socket install tapered bushing. head capscrew (10). Install capscrew. 11. Apply JLG Threadlocker (P/N 0100011) to tapered bush- ing bolts. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston.
  • Page 357 3 times as there are 3 spaces between made during disassembly. the capscrews. NOTE: Apply locking primer and JLG Threadlocker (P/N 0100011 to capscrews. 20. Install bracket (26) with two capscrews (27). 21. Install six washers (24) and capscrews (25). Tighten all capscrews.

  • Page 358: Cylinder Length Sensor

    5. Remove the plug that is over the setscrew that secures the sensor in place. Both the jib lift cylinder and the platform level cylinder utilize a cylinder length sensor which communicates with the JLG control system. These sensors can be removed from without the cylinder being disassembled.
  • Page 359 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 7. Using an allen wrench, remove the bolts securing the 8. Pull sensor out of the cylinder. DO NOT use the wiring retaining cap and remove the cap. harness to pull the sensor out as this will cause damage to the wiring.

  • Page 360: Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Installation 3. Apply lubricant JLG P/N 3020039 to the setscrew and install the setscrew. Torque the setscrew to 4 in. lbs. (0.45 1. Carefully insert the sensor into the cylinder. It may be Nm).

  • Page 361: Oil Sampling

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.5 OIL SAMPLING 4. Unscrew the knurled end which is attached to the chain. See Figure 5-123., Oil Sampling Valve Location. This machine is equipped with an oil sampling valve to allow for verification of hydraulic oil condition.
  • Page 362 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS OIL TEMP SENSOR MAIN DUMP REDUCED PRESSURE RELIEF PRESSURE REDUCING VALVE MAIN TELE OUT PORT 7 MAIN LIFT UP PORT 8 TELE OUT RELIEF PORT 4 SWING RIGHT PORT 5 LIFT DOWN AUX LIFT UP RELIEF LIFT PILOT SWING LEFT RELIEF...
  • Page 363 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS CHASSIS ENABLE WARM-UP MAIN DUMP TELE CNTL TELE OUT RELIEF MAIN TELE IN LIFT CNTL LIFT DOWN RELIEF MAIN LIFT DOWN SWING CNTL SWING LEFT LIFT PILOT LIFT DOWN AUX SWING RIGHT RELIEF Figure 5-125.
  • Page 364 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Item Ft.Lbs. 60-70 81-95 25-30 34-40.5 40-49 54-66 2.2-3 30-35 40.5-47 122-133 165-180 3.7-5.2 28.8-37.6 39-51 30-37 40.5-50 17.5 Figure 5-126. Main Valve Torque Values - Sheet 1 of 2 5-112 3121619...
  • Page 365 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-127. Main Valve Torque Values - Sheet 2 of 2 3121619 5-113...

  • Page 366: Pressure Setting Procedure

    Cold temperatures have a significant impact on pressure read- rear pump. The high pressure relief adjustment is the ings. JLG Industries Inc. recommends operating the machine adjustment closest to the pump case. until the hydraulic system has warmed to normal operating temperatures prior to checking pressures.

  • Page 367: Adjustments Made At The Main Valve Bank

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 4. The stand by adjustment is the outside adjustment. 2. Remove deutsch connector from lift down coil. Using the same procedure as in the (PC) setting above adjust (LS) to 300psi (21bar). LIFT DOWN COIL 3.
  • Page 368 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Plug and cap the hose on port 5. Activate lift up. The gauge should read 3700 psi. (255 bar). 4. Reconnect lift down coil. 5. Retighten locknuts. 3. The adjustment cartridge is located to the right of port 5.
  • Page 369 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS LIFT DOWN SWING 1. Install a high pressure gauge at the “M4” port of the 1. Install a high pressure gauge at port “MS2”. main valve block. 2. Install the Turntable lock pin. 2.
  • Page 370 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 4. Install gauge at MS3, Activate swing left, the gauge TELESCOPE OUT should read 2000 psi. (138 bar), The adjustment is NOTE: NEVER increase telescope out pressure to achieve desired located at 9 o’clock beside port 3, Turn clockwise to telescope length.
  • Page 371 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Plug the telescope in hose either at the valve bank (port #7) or at the inlet of the telescope cylinder (V2). TELESCOPE IN 3. Activate telescope in. The gauge should read 3300 psi. 1.

  • Page 372: Adjustments Made At The Frame Valve Bank

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3. Adjustments Made at the Frame Valve Bank 3. Turn clockwise to increase, counterclockwise to decrease. AXLE EXTEND AND RETRACT, FRONT AND REAR 1. To extend the axles drive the machine back and forth until extended.

  • Page 373: Adjustments Made At The Platform Valve Bank

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS STEERING, FRONT AND REAR 4. Adjustments Made at the Platform Valve Bank 1. The axles must be extended to set the steer pressures. PLATFORM LEVEL UP 2. Install a high pressure gauge at “MS2” and “MS4” gauge 1.

  • Page 374: Adjustments Made At Jib Valve

    Turn clockwise to JIB LEVEL UP increase, counterclockwise to decrease. NOTE: To check or adjust the jib level up pressure setting the JLG Analyzer must be used to override the automatic jib level function.
  • Page 375 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 6. Using the arrow keys scroll until MENU: SERVICE MODE is 8. Enter code 58237 and Press ENTER . The screen reached. Press ENTER should read SERVICE MODE: JIB & SWING AND JIB LEVEL. 7.
  • Page 376 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 11. When the function bottoms out, pressure should read 6. Using the arrow keys scroll until MENU: SERVICE MODE is 2600 psi.(180bar). 12. If necessary to adjust pressure, CW increases and CCW reached.
  • Page 377 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Once turned on, operate the Jib Lift Down function. This will activate the Jib Level Down function. 8. Enter code 58237 and Press ENTER . The screen should read SERVICE MODE: JIB & SWING AND JIB LEVEL. 11.
  • Page 378 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 15. Adjust the jib level using the JIB TELESCOPE IN Jib Lift function switch until 1. Install high pressure gauge at MTA. the jib level control angle reads zero (0). 16. After the control angle is set, use the UP or DOWN arrow keys to toggle the override from On to Off.
  • Page 379 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS JIB LIFT UP JIB LIFT DOWN 1. Install high pressure gauge at port MJB. 1. Install high pressure gauge at port MJA. 2. Fully extend jib lift cylinder or cap port JB. 2.

  • Page 380: Adjustments Made In Traction Circuit

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 6. Adjustments Made in Traction Circuit 3. Adjust the charge relief valve to obtain reading of 400psi (28bar). The charge relief is located on the turntable side of the pump above M3. Clockwise increases pressure, CHARGE PRESSURE RELIEF Counterclockwise decreases pressure.

  • Page 381: Drive Pumps

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.7 DRIVE PUMPS Electric displacement control Electric displacement control Servo piston Servo piston Swashplate feedback pin Swashplate feedback pin Valve plates Piston Piston Slipper Front shaft bearing Slipper Rear shaft bearin g Shaft seal Rear shaft Front shaf t...
  • Page 382 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Servo gauge port M5 Charge inlet port E ISO 11926-1 - 7/16-20 ISO 11926-1 - 1 5/16-12 Case drain port L3 Servo gauge port M4 ISO 11926-1 - 1 1/16-12 ISO 11926-1 - 7/16-20 Case drain port L1 ISO 11926-1 - 1 1/16-12 System port B...
  • Page 383 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS System gauge port MB System gauge port MC ISO 11926-1 - 9/16-18 ISO 11926-1 - 9/16-18 Brake gage port X7 Charge constr port M3 ISO 11926-1 - 9/16-18 ISO 11926-1 - 9/16-18 Se rvo gauge port M4 Servo gauge port M5 ISO 11926-1 - 7/16-20...

  • Page 384: Initial Startup Procedures

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Initial Startup Procedures tions and listen for cavitation. Check for proper fluid level in reservoir. Follow this procedure when starting-up a new pump or when 9. When adequate charge pressure is established (as restarting a pump that has been removed.
  • Page 385 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-34. Electrical troubleshooting Item Description Action Control operates pump in one direction only Control coil failure. Measure resistance at coil pins. Resistance should be 14.2W (24V) or 3.66W (12V) at 20° C [70°...
  • Page 386 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-37. System will not operate Item Description Action Oil level in reservoir Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level. Control orifices Control orifices are blocked. Clean control orifices.
  • Page 387 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-39. Sluggish system response Item Description Action Oil level in reservoir Low oil level will cause sluggish response. Fill reservoir. Charge check / HPRVs Incorrect pressure settings will affect system Replace charge check / HPRVs.

  • Page 388: Adjustments

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Adjustments pump speeds or higher charge flows the charge pressure will rise over the rated setting. 3. Loosen the locknut and rotate the adjusting screw CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR clockwise to increase the setting;...
  • Page 389 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 4. After establishing the desired maximum displacement 3. Observe pressure gauges. If necessary, turn adjusting screw to reduce any pressure differential. setting, hold adjusting screw in place and tighten the locknut. Torque to 23 Nm [17 lbft]. C NOTE: Adjustment of the EDC is very sensitive.
  • Page 390 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5. Rotate the neutral adjusting screw clockwise half the PUMP SETUP distance between the wrench positions noted above. 1. Attach a 50 bar [1000 psi] gauge to each servo pressure The gauges should read the same pressure, indicating port M4 and M5.
  • Page 391 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS System gauge port MB System gauge port MC ISO 11926-1 - 9/16-18 ISO 11926-1 - 9/16-18 Front servo gauge port M4 Rear servo gauge port M5 Servo cylinder (4 pl.) ISO 11926-1 - 7/16-20 ISO 11926-1 - 7/16-20 E300 Se r vo cylinder locking clip...

  • Page 392: Removing The Pump

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SERVO ADJUSTMENT Removing The Pump Before working on the pump, thoroughly clean the outside. If 6. Run prime mover at 1800 min (rpm). the pump has an auxiliary pump attached, remove both 7.

  • Page 393: Electric Control Module

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Electric Control Module REASSEMBLY NOTE: Ensure you install dowel pins (D300) in housing before REMOVAL installing control. Refer to exploded diagram, next page. 1. Install a new gasket (D150). 1. Using a 5 mm internal hex wrench, remove the six cap 2.

  • Page 394: Shaft, Seal, And Bearing

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS CONTROL SOLENOIDS REMOVAL Shaft, Seal, and Bearing 1. Disconnect electrical connection and remove the three The front pump input shaft assembly is serviceable without cap screws (D050) using a 4.mm internal hex wrench. disassembling the pump, the rear shaft is not.

  • Page 395: Charge Pump

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS INSPECTION Charge Pump Position pump with front shaft pointing downward. Attach 1. Inspect the shaft journals for wear, scratching, and pits. securely to a proper work stand. If an auxiliary pump is Check the splines for fretting;...
  • Page 396 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-136. Charge Pump 5-144 3121619...

  • Page 397: Charge Check / Hprv

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS REPLACING CHARGE PUMP JOURNAL BEARINGS 10. Install screws (K351) and brackets (K975). Torque screws per listing in the table. Use a suitable press to remove and replace the journal bear- ings. Refer to the drawings below for installation dimensions. Charge Check / HPRV The high pressure relief and charge check valve assembly may be removed for cleaning and replacement of the O-rings.

  • Page 398: Charge Pressure Relief Valve

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-138. Charge Check / HPRV Charge Pressure Relief Valve REASSEMBLY 1. Lubricate and install new O-rings (V10A). Replace the charge pressure relief valve (V10-1) or (V10-2) as a complete unit. Do not attempt to repair the internal compo- 2.

  • Page 399: Control Cutoff Valve

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-139. Charge Pressure Relief Valve Control Cutoff Valve REASSEMBLY 1. Lubricate and install new O-rings (G10A) onto the valve. Replace the control cutoff valve as a complete unit. Do not attempt to repair the internal components of the valve.
  • Page 400 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-140. Control Cutoff Valve Table 5-41. Fastener Size and Torque Chart Item Fastener Wrench size Torque D015 Neutral adjust screw 4 mm internal hex D050 Control coil mounting screw 4 mm internal hex 8 Nm [5.9 lbft] D060 Neutral adjust locking nut...
  • Page 401 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-141. Fastener and Plug Locations 3121619 5-149...

  • Page 402: Function Pump

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS FUNCTION PUMP 6. Remove the bearing cup (B010), bearing cone (B020) and housing O-ring (K060). Discard the O-ring. Disassembly 7. Tilt the housing on its side to allow fluid to drain. 8.
  • Page 403 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 14. Remove the servo piston (P020) and bias spring (B025) rings. Remove the 2 set screws (C102). Remove the from the swashplate by removing the clevis pin (B043) spools (C112, C132). Note which bore each spool came and snap ring (B044).

  • Page 404: Inspection

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS NOTE: The pistons are not selectively fitted, however units with pressed air. Conduct inspection in a clean area and keep all high hourly usage may develop wear patterns. Number the parts free from contamination. Clean and dry parts again after pistons and bores for reassembly if they are to be reused.
  • Page 405 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS BLOCK SPRING, AND WASHERS for scratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating of hydraulic oil. If cylinder kit was fully dissembled, visual inspection of the cyl- inder block, spring, and washers should indicate minimal wear.
  • Page 406 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SWASHPLATE recommended to detect cracks. The valve plate must be replaced if any cracks exist. Carefully inspect each surface of the swashplate for wear. All swashplate surfaces should be smooth. Inspect the swash- 3.88 mm [0.153 in] min.

  • Page 407: Assembly

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS HOUSING NOTE: If journal bearings are reused, reinstall them in their origi- nal orientation and position. Inspect the housing to ensure that it is clean and free of for- eign material. Inspect the swashplate bearing surfaces, and endcap mating surfaces.
  • Page 408 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3. Reinstall the swashplate/servo piston/bias spring them to the original block bores. Lubricate the pistons, assembly in its original orientation in the housing. slippers, retainer, and ball guide before assembly. Set Rotate the servo piston perpendicular to the swash- the cylinder kit aside on a clean surface until needed.
  • Page 409 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS NOTE: To insure proper pump operation, it is extremely important install the seal retaining ring (K010). Remove the instal- to ensure that there is no contamination between the end- lation sleeve. cap and valve plate.
  • Page 410 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 15. Hold the control in a horizontal position. Install the using a criss cross pattern and retorque the first screw to spherical end of the LS spool (C112) into the LS bore (see ensure proper torque retention.

  • Page 411: Gear Pump

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.9 GEAR PUMP PROCEDURE 1. Clamp the unit. Disassembly Clamp the unit in a vice from the flange side. Prior to proceeding it may be necessary to prepare some sub- assemblies separately. Make sure the vice jaws are clean and have smooth sur- The details for preparing each subassembly are given in the faces to prevent damage to the pump.
  • Page 412 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3. Remove socket head capscrews. (03 Flange or Multiple 4. Remove front flange. Pump Stages Only). Place the pump on the table and slowly remove the Using a 4 mm internal hex wrench, loosen and remove front flange.
  • Page 413 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 6. Remove bearing blocks and gears. 8. Remove Outer O-Ring Seal Check the quality of this seal. If necessary, replace it. Fol- Place the pump on its side and carefully remove the low the same removal recommenda?tions given in step bearing block and gear set.

  • Page 414: Assembly

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Remove the shaft seal. Prepare the flange and shaft seal by lightly lubricating with grease. Check the shaft seal quality and remove if necessary. Seat the seal in the flange by hand. Then, using the shaft To remove, pry the bottom of the shaft seal and force it seal installation tool, press the seal until the tool stops out while rotating the flange to lift it out evenly.
  • Page 415 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 4. Install pressure seals. 6. Install outer seal. Prepare the pressure seals by lightly lubricating them Prepare the outer seal by lightly lubricating with grease. with grease. Install outer seals in the grooves on both sides of the Install pressure seals into the grooves on the front flange body.
  • Page 416 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 7. Prepare the gears. 8. Prepare the bearing blocks. Clean the two bearing blocks. THE GEAR SURFACES ARE SUPER-FINISHED. RESIDUE ON HANDS AND FIN- Inspect the flat surfaces of the bearing blocks for burrs GERS MAY BE CORROSIVE TO THIS SURFACE.
  • Page 417 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 9. Assemble the bearing blocks and gears. 11. Clean the mating surfaces. Lubricate the journals and the gear faces. Remove any excess lubrication and grease from the mat- ing surfaces of the pump body. Ensure that these sur- Assemble the bearing blocks and gears.
  • Page 418 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Install the dowel pins. 13. Clean the mating surfaces. Install four 5 mm dowel pins into the proper cavities on Remove any excess lubrication and grease from the mat- both sides of the body (refer to the illustration). Swab ing surfaces of the front flange and rear cover.
  • Page 419 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 15. Prepare pump for front flange assembly. Ensure that the seals remain seated in their grooves dur- ing this operation. Place the pump with the rear cover downwards. Ensure that the assembly marks on the bearing block / body are properly aligned.
  • Page 420 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 18. Install socket head capscrews. (03 flange and first stage 20. Prepare the unit for shipment or storage. of multiple). Clean the exterior of the pump and install the following: Using a 4 mm internal hex wrench, install the socket a.

  • Page 421: Trouble Shooting

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Trouble Shooting Table 5-43. Troubleshooting Low or No Flow From Gear Pump Item Description Action 1. Check oil level in reservoir. Description Insufficient oil to supply gear pump. Fill reservoir to proper level. 2.

  • Page 422: Start-Up Procedure

    1. Insure all electrical checks have been performed & the 3. The third or rear pump is the function pump. It is cou- machine is set up correctly with the JLG Analyzer. pled to the back of the middle pump and provides oil flow to operate the boom, axle, steer and platform func- 2.
  • Page 423 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Operate the drive system in the "turtle mode", forward 17. Check oil level & temperature. and reverse. 18. Remove and inspect charge pressure oil filter, replace with new element. 11. De-aerate the system by bleeding fluid from the Ma & Mb ports.
  • Page 424 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS TELE CYL LIFT CYL T E L E S C O P E BORE: 5.5 IN ROD: 4.5 IN STROKE 333.15 BORE: 8.0 IN ROD: 7.0 IN STROKE 84.9 L I F T 3 0 0 0 p s i 3 3 0 0 p s i (227.5BAR)
  • Page 425 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SWING DRIVES SWING SWING BRAKES SWING 2000PSI (138BAR) 2000PSI (138BAR) SWING DIRECTIONAL P TO JIB VALVE P L A T F O R M F I L T E R SWING R E L I E F B10>=1000 3 5 5 0 p s i...
  • Page 426 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SWIVEL SWIVEL FRONT DEPLOY CYLS PORT# 1 PORT#2 2 5 0 0 p s i ( 1 7 2 .4 b a r ) 2 5 0 0 p s i ( 1 7 2 .4 b a r ) 2 6 0 0 p s i ( 1 7 9 .3 b a r )
  • Page 427 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SWIVEL SWIVEL PORT#2 PORT#1 REAR DEPLOY CYLS 2 5 0 0 p s i M A 1 ( 1 7 2 . 4 b a r ) A 1 4 2 5 0 0 p s i ( 1 7 2 .4 b a r ) M A 2 2 6 0 0 p s i...
  • Page 428 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS FRONT DRIVE PUMP MB MC F00A F00B TO PORT P3, MAIN TO PORT T4, MAIN CONTROL CONTROL VALVE PAGE 1 VALVE PAGE 1 PORT PORT PORT PORT PORT PORT PORT SWIVEL PORTS REAR AXLE 300 PSI...
  • Page 429 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS REAR CHARGE PUMP FILTER DRIVE B6>=200 PUMP BYPASS 50PSI CHARGE PUMP 1.025 IN3 OIL COOLER OPTION PORT L3 OF THE PUMP TO THE INLET OF THE COOLER. COOLER OUTLET FCOB FCOA BACK TO TANK.
  • Page 430 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS JIB ROTATOR SPRING 3300 PSI JIB LIFT CYLINDER JIB LEVEL CYLINDERS BORE: 5” BORE: 5.5” ROD: 2.5” ROD: 2.5” STROKE: 25.15” STROKE: 16.59” V 1 T JIB TELESCOPE CYLINDER BORE: 2.5” ROD: 1.5”...
  • Page 431 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PLATFORM ROTATOR SPRING 3000 PSI PLATFORM LEVEL CYLINDER BORE: 3.55” ROD: 1.5” STROKE: 14.79” JIB LOCK CYLINDER BORE: 2.5” ROD: 1.75” STROKE: 13.375” M L 1 M L 2 2 5 0 0 p s i 2 5 0 0 p s i 2 0 0 0 p s i ( 1 7 2 .4 B A R )
  • Page 432 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS NOTES: 5-180 3121619...

  • Page 433: Jlg Control System

    IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH The JLG Control System controller has a built in LED to indicate AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- any faults. The system stores recent faults which may be TRIES, INC.

  • Page 434: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer Using the Analyzer 1. Connect the four pin end of the cable supplied with the With the machine power on and the analyzer connected prop- analyzer, to the motor controller module located in the...

  • Page 435: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP DIAGNOSTICS DRIVE ACTIVATE TEST BOOM ACCESS LEVEL SYSTEM...

  • Page 436: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Press ENTER to select the ACCESS LEVEL menu. Analyzer Once you have gained access to level 1, and a personality item Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

  • Page 437: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK When a machine digit item is selected, press the UP DOWN...

  • Page 438: Ground Control Console Display Gauge - Machines Using Diesel Exhaust Fluid (Def)

    Figure 6-2. Splash Screen The Diagnostic Screen will show active and inactive faults from the JLG Control System on the screen. An asterisk (*) will be displayed to show active faults. D IAG N O S TIC C O D E S Figure 6-3.
  • Page 439 SECTION 6 - JLG CONTROL SYSTEM INDICATOR LAMP FUEL LEVEL ENGINE HOURS NAVIGATE BACK ARROW NAVIGATE FORWARD ARROW NAVIGATION BUTTONS Figure 6-5. Ground Control Console Display Gauge 3121619...
  • Page 440 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING GROUND ACCEL ACCELERATE GREEN ACTIVE GROUND MODULE ANALOG DIGITAL CONVERTER COUNT HOURS AMB. AMBIENT HARDWARE ANGLE HWFS HARDWARE FAILSAFE AUXILIARY IN or CURRENT...
  • Page 441 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING SHORT CIRCUIT SELECTOR SERIAL NUMBER SPEED STOW STOWED STOWD STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ. TORQUE TRANSPORT TURNTABLE TOWER TURNTBL TURNTABLE TOWER UPPER or UP...
  • Page 442 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal- ity settings first and then changing the model number of the machine configuration will cause the personality settings to return to default The items marked in BOLD bold text on this sheet represent a new board that has never been configured.
  • Page 443 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number GLOW PLUG: NO GLOW PLUGS: No glow plugs installed. AIR INTAKE: Glow plugs installed in the air intake on the manifold. IN-CYLINDER: Glow plugs installed in each cylinder.
  • Page 444 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number JIB: NO: No Jib installed. YES: Jib installed. SIDESWING: Jib with Sideswing installed. 4WS: NO: 2WS mode enabled. YES: 4WS mode enabled.
  • Page 445 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number LOAD SYSTEM: NO: No load sensor installed. WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
  • Page 446 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number LEVELING MODE: LIFT: Platform leveling during lift only. ALL: Platform leveling during all functions. CLEARSKY: NO: ClearSky Telematics system not installed. YES: ClearSky Telematics system installed.
  • Page 447 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings 1850SJ 1850SJ Gen Set / Welder Model Number Envelope Height Market Gen Set Cutout Engine Head & Taillights Load System Glow Plug...
  • Page 448 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings 1850SJ Language Platform Cutout Temp Cutout BOLD TEXT indicates the default setting. Plain text indicates another available selec- tion. ITALIC TEXT indicates the default when option is factory installed. SHADED CELLS indicate hidden menu or selection.
  • Page 449 SECTION 6 - JLG CONTROL SYSTEM 6.2 MACHINE PERSONALITY SETTINGS AND NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. FUNCTION SPEEDS Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU...
  • Page 450 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU DEFAULT TIME RANGE (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 VALUES (SEC) ANALYZER 1ST LINE) LINE) SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec DECEL X.Xs...
  • Page 451 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU DEFAULT TIME RANGE (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 VALUES (SEC) ANALYZER 1ST LINE) LINE) PLATFORM ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec...
  • Page 452 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU DEFAULT TIME RANGE (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 VALUES (SEC) ANALYZER 1ST LINE) LINE) JIB LEVEL: ACCEL X.Xs Displays/adjusts jib level acceleration 0.1 to 5.0 sec...

  • Page 453: Test Notes

    SECTION 6 - JLG CONTROL SYSTEM DRIVE REVERSE (Creep Max), high torque - low 6.3 MACHINE ORIENTATION WHEN SETTING speed setting, platform speed knob at full creep, FUNCTION SPEEDS drive reverse 50 ft. LIFT UP, from platform control, lowest elevation...

  • Page 454: Canbus Communications

    SECTION 6 - JLG CONTROL SYSTEM 6.4 CANBUS COMMUNICATIONS The GROUND MODULE (UGM) is the master system controller. Most functions are dispatched and coordinated from this module, all other system modules (PLATFORM, JIB, BLAM, CANbus: CAN (Control Area Network) is a two wire differential CHASSIS) handle sub-tasks.
  • Page 455 SECTION 6 - JLG CONTROL SYSTEM MS83 3X4 B us s Bar Be low U GM LSS Module C hassi s U GM Shie ld Groun d X468 YEL Ca n Hig h GRN C an Lo C an 2 Buss Bar...
  • Page 456 SECTION 6 - JLG CONTROL SYSTEM MS83 3X4 Buss Bar Below UGM MS1000-3 A B C UGM MODULE YEL Can High Deutz ECM GRN Can Lo J12-4 J1 Connector J12-7 Shield from Can J12-6 1 Bus Bar Sheet White 5 Zone H3...

  • Page 457: Calibration Instructions

    SECTION 6 - JLG CONTROL SYSTEM 6.5 CALIBRATION INSTRUCTIONS Table 6-5. Calibration Instructions This machine incorporates a variety of sensors and a high Telescope Crack Point Cali- Ground module replacement degree of function interaction. For safety and proper machine bration...
  • Page 458 SECTION 6 - JLG CONTROL SYSTEM 6-26 3121619...
  • Page 459 SECTION 6 - JLG CONTROL SYSTEM 3121619 6-27...
  • Page 460 SECTION 6 - JLG CONTROL SYSTEM 6-28 3121619...
  • Page 461 SECTION 6 - JLG CONTROL SYSTEM 3121619 6-29...
  • Page 462 SECTION 6 - JLG CONTROL SYSTEM 6-30 3121619...
  • Page 463 SECTION 6 - JLG CONTROL SYSTEM 3121619 6-31...
  • Page 464 SECTION 6 - JLG CONTROL SYSTEM 6-32 3121619...
  • Page 465 SECTION 6 - JLG CONTROL SYSTEM 3121619 6-33...
  • Page 466 SECTION 6 - JLG CONTROL SYSTEM 6-34 3121619...
  • Page 467 SECTION 6 - JLG CONTROL SYSTEM 3121619 6-35...
  • Page 468 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type THROTTLE ACTUATOR (DIESEL ONLY) DIGITAL OUTPUT SPARE (LP NOT USED) DIGITAL OUTPUT TOWER BOOM LIFT POWER DIGITAL OUTPUT GROUND GROUND INPUT GROUND GROUND INPUT TOWER TELESCOPE ENABLE DIGITAL OUTPUT SPARE (LP NOT USED)
  • Page 469 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type PLATFORM EMS DIGITAL INPUT PLATFORM MODE DIGITAL INPUT GROUND MODE DIGITAL INPUT TOWER CYLINDER PRESSURE ANALOG INPUT REFERENCE VOLTAGE VOLTAGE OUTPUT CAN TERMINATION TERM SPARE ANALOG INPUT SPARE ANALOG INPUT 2...
  • Page 470 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type GROUND FROM BATTERY GROUND INPUT GROUND EMS GROUND INPUT (Black) GROUND TO PLATFORM GROUND OUTPUT GROUND EMS OUT TO PLATFORM GROUND OUTPUT Connector Function Type AXLES SET LAMP DIGITAL OUTPUT 500# CAPACITY LAMP...
  • Page 471 SECTION 6 - JLG CONTROL SYSTEM Connector Type FUNCTION FUNCTION Connector Type Power Feed Thru to J1-1 Power Power Feed Thru to J2-1 Power Power Feed Thru to J1-2 Power Connector FUNCTION Type Power Feed Thru to J2-2 Power Ground...
  • Page 472 SECTION 6 - JLG CONTROL SYSTEM Connector Type FUNCTION FUNCTION Connector Type Power Feed Thru to J1-1 Power Power Feed Thru to J2-1 Power Power Feed Thru to J1-2 Power Connector FUNCTION Type Power Feed Thru to J2-2 Power Ground...
  • Page 473 SECTION 6 - JLG CONTROL SYSTEM Connector FUNCTION Type Connector Pin FUNCTION Type Power Feed Thru to J2-1 Power Power Feed Thru to J1-1 Power Connector Pin FUNCTION Type Power Feed Thru to J2-2 Power Power Feed Thru to J1-2...
  • Page 474 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-24. Analyzer Connecting Points 6-42 3121619...

  • Page 475: Control System Boom Sensors

    SECTION 6 - JLG CONTROL SYSTEM 6.6 CONTROL SYSTEM BOOM SENSORS Sensor #3 - Main Boom Length Sensor (1) The Boom Control System (BCS) requires the use of multiple sensors to measure the position of the boom. The sensors used to determine main boom and jib boom position are shown in the following figures.
  • Page 476 SECTION 6 - JLG CONTROL SYSTEM SENSOR ORIENTATION LEFT SIDE VIEW SENSOR ORIENTATION RIGHT SIDE VIEW SENSOR INSTALLATION ON LEFT & RIGHT SIDES OF PLATE (LEFT SIDE, SENSOR #2, SHOWN) ANGLE SENSOR #1 (RIGHT) PIN # DESC SENSOR HARNESS PIN #1...

  • Page 477: Sensor #4 - Main Boom Cylinder Angle Sensor (1)

    SECTION 6 - JLG CONTROL SYSTEM Sensor #4 - Main Boom Cylinder Angle Sensor (1) table and attached to the Main Lift cylinder of the base boom. It is a dual output sensor in a single mechanical body with See (See Figure 6-26.) electrically opposing signals.
  • Page 478 SECTION 6 - JLG CONTROL SYSTEM TRANSPORT LIMIT SWITCH WIRING TOP OF SENSOR LIMIT SWITCH BLACK +1° 90° -10° WHITE SECTION LIMIT SWITCH ADJUSTMENT LIMIT SWITCH COVER RUBBER PAD, BOLT, WASHER, ADHESIVE LIMIT SWITCH THREADLOCKER P/N-0100081 P/N-0100011 T orque 25ft.lbs. (34 Nm)

  • Page 479: Sensor #6 - Jib Level Angle Sensor (1)

    SECTION 6 - JLG CONTROL SYSTEM Sensor #6 - Jib Level Angle Sensor (1) ing bracket. The LED on the sensor will light when power is applied and the sensor is within range. See (See Figure 6-29.) This sensor is used to measure Jib Level angle relative to the Main Boom.
  • Page 480 SECTION 6 - JLG CONTROL SYSTEM SPACER SCREW, WASHER, BOLT ANGLE THREADLOCKER SENSOR P/N-0100035 SCREW, THREADLOCKER P/N-0100011 ANGLE SENSOR WASHER INSTALL BETWEEN LINK AND ARM DETAIL B BOLT, WASHER, SCREW, NUT THREADLOCKER TORQUE UNTIL SNUG P/N-0100011 5 NM MAX SENSOR...

  • Page 481: Sensor #8 - Jib Stow Angle Sensor (1)

    SECTION 6 - JLG CONTROL SYSTEM Sensor #8 - Jib Stow Angle Sensor (1) See (See Figure 6-30.) This sensor is used to measure Jib swing angle. This is a rotary sensor mounted to the underside of the Jib Pivot weldment. It is a dual output sensor in a single mechanical body with elec- trically opposing signals.

  • Page 482: Sensor #10 - Dual Capacity / Jib Transport Length Switches (2)

    SECTION 6 - JLG CONTROL SYSTEM Sensor #10 - Dual Capacity / Jib Transport Length Sensor #11 - Platform Level Angle Sensor (1) Switches (2) This sensor is used to measure Platform angle relative to the Jib. A linear position sensor is located inside the Platform Level See (See Figure 6-31.)

  • Page 483: Sensor #12 - Platform Level Angle Gravity Sensors (2)

    SECTION 6 - JLG CONTROL SYSTEM Sensor #12 - Platform Level Angle Gravity Sensors Sensor #17 - Chassis Tilt Sensor (Externally mounted) (1) This sensor is the primary tilt sensor and measures the tilted See (See Figure 6-32.) angle of the turntable relative to gravity. It is mounted on a...

  • Page 484: Sensor #21 - Main Lift Cylinder Pressure Transducer (1)

    SECTION 6 - JLG CONTROL SYSTEM Sensor #21 - Main Lift Cylinder Pressure Transducer 3. Plug the analyzer into the connector at the base of the platform control box. This pressure transducer is located on the port block of the main boom lift cylinder.
  • Page 485 SECTION 6 - JLG CONTROL SYSTEM 5. Pull out the Emergency Stop switch and Start the 7. Use the arrow button to reach SYSTEM TEST. Hit Enter. engine. The analyzer will prompt you asking if you want to acti- vate the system test; hit Enter again to activate.
  • Page 486 SECTION 6 - JLG CONTROL SYSTEM Figure 6-33. System Test Flow Chart - Platform Tests - Sheet 1 of 2 6-54 3121619...
  • Page 487 SECTION 6 - JLG CONTROL SYSTEM Figure 6-34. System Test Flow Chart - Platform Tests - Sheet 2 of 2 3121619 6-55...

  • Page 488: Test From The Ground Station

    SECTION 6 - JLG CONTROL SYSTEM Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the engine. 1. Position the Platform/Ground select switch to the Ground position. 4. The analyzer screen should read: 2. Plug the analyzer into the connector inside the Ground control box.
  • Page 489 SECTION 6 - JLG CONTROL SYSTEM Figure 6-35. System Test Flow Chart - Ground Station Tests 3121619 6-57...
  • Page 490 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer RUNNING Initial display when system test is run; certain “critical” checks are made. Problems that can be reported include below messages.
  • Page 491 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “nor- mal”...
  • Page 492 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends.

  • Page 493: Calibration Procedures

    SECTION 6 - JLG CONTROL SYSTEM 6.8 CALIBRATION PROCEDURES General notes: During all controller lag times the controller should display Axle Calibration “CALIBRATING…” The axle angle sensors need to be calibrated to ensure that the After each operator “ENTER” input preceding the recording of axle angle can be accurately calculated.
  • Page 494 SECTION 6 - JLG CONTROL SYSTEM 3. If the initial conditions are not met, the controller will 6. The controller shall display “LIFT UP TO STOP”. After the operator presses the ENTER key, the controller shall dis- prompt the operator with analyzer messages “BLAM play “CAL POSITION 3”...
  • Page 495 SECTION 6 - JLG CONTROL SYSTEM 11. The controller will disable telescope out, enable tele- 17. The controller shall display “CAL POSITION 9” on the first scope in and display “CAL POSITION 6” on the first line line and “JIB OUT TO STOP” on the second. When the and “TELE IN TO STOP”.

  • Page 496: Jib Sensor Calibrations

    SECTION 6 - JLG CONTROL SYSTEM 6.9 JIB SENSOR CALIBRATIONS 4. The analyzer screen should read: To calibrate the jib sensors, the analyzer must be in access level 1. All jib sensors can be calibrated at one time or each cal- ibration can be performed on an individual basis.
  • Page 497 SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach the JIB SENSORS. The screen 10. Press ENTER. The screen should read as shown below. should read: When it does, activate boom lift until the control system stops it at 20 degrees boom angle.
  • Page 498 SECTION 6 - JLG CONTROL SYSTEM 11. Press ENTER. The screen should read as shown below. 12. If the operator presses enter at the jib lift sensor calibra- When it does, the operator can either press enter to tion prompt, the screen shown below will be displayed.
  • Page 499 SECTION 6 - JLG CONTROL SYSTEM 14. Once the jib is stopped the screen shown below will be 16. Hitting the ENTER key at this point will take the operator displayed. to the next jib sensor calibration. The screen will show: 15.
  • Page 500 SECTION 6 - JLG CONTROL SYSTEM 18. Operate jib lift down until the jib stops. When the jib is 20. Press ENTER. The screen should read: at the mechanical stop the operator must hit ENTER again. The screen will show: 21.
  • Page 501 SECTION 6 - JLG CONTROL SYSTEM 22. When the system completes this step, the next screen 24. When the system completes the previous step, the will show: screen will read: 23. Press ENTER. The screen should read as shown below.
  • Page 502 SECTION 6 - JLG CONTROL SYSTEM 26. Hitting the ENTER key at this point will take the operator 28. When the jib reaches the mechanical stop, press ENTER. to the next jib sensor calibration. The screen will show: The screen will show: 27.
  • Page 503 SECTION 6 - JLG CONTROL SYSTEM 30. Press Enter. The screen shown below will be displayed. 32. At the finish of the jib swing lift calibration the jib lock At this point, use the platform rotate left function switch pin will be locked by the control system. The screen will to swing the jib left.
  • Page 504 SECTION 6 - JLG CONTROL SYSTEM NOTE: At this point the left or right arrow key may be used to skip 37. When the platform level up is at mechanical stop, Press to any of the other jib sensor calibrations.

  • Page 505: Calibrating The Jib Level Up And Down Valve Crackpoints

    SECTION 6 - JLG CONTROL SYSTEM 39. Press ENTER. The display will then show: 40. The control system will stop the platform level and the screen will show: 41. Pressing ENTER will take you back to the beginning and escape (ESC) will take you to the initial screen.
  • Page 506 SECTION 6 - JLG CONTROL SYSTEM 2. Plug the analyzer into the connector inside the Ground 5. Use the arrow button to reach OPERATOR ACCESS. Hit control box. Enter. 6. Enter the Access Code, 33271. 7. Go to the CALIBRATIONS menu and hit ENTER.

  • Page 507: Boom Unlock Procedure

    SECTION 6 - JLG CONTROL SYSTEM 6.10 BOOM UNLOCK PROCEDURE 2. Once the operator selects the UNLOCK BOOM option, the screen will read: If the fault “LIFT CYLINDER OVER PRESSURE” or “WRONG TELE RESPONSE” is active, then the boom will be trapped in trans- port.
  • Page 508 SECTION 6 - JLG CONTROL SYSTEM 3. If all of the initial conditions are passed, the analyzer will 4. After the machine has reached the set point in step 3, display: Lift up and down functionality will be cut out and Tele- scope in and out functionality will be restored.
  • Page 509 SECTION 6 - JLG CONTROL SYSTEM 5. As soon as the machine had reached the set point in analyzer will display “CHECK FAILED PRESS ENTER”. If the step 4, Telescope in and out functionality will be cut out. check passes the analyzer will display “CHECK PASSED The analyzer menu will display: PRESS ENTER”.
  • Page 510 SECTION 6 - JLG CONTROL SYSTEM 8. Regardless if the check passed or failed in Step 7, after 9. After the boom is retracted, the analyzer menu will advance to: the status of the test has been reported, press menu will advance to:...

  • Page 511: Setting Crackpoints

    • Main Lift Up and Down, • Main Telescope Out and In. THE JLG ANALYZER WILL PROMPT USERS FOR A CODE UPON REACHING MENU: OPERATOR ACCESS. THIS FIVE-DIGIT CODE (33271) WILL DISABLE THE BOOM ENVELOPE CONTROL. WHEN THE BOOM ENVELOPE CONTROL IS DISABLED, THE MACHINE MAY TIP IF USED INCORRECTLY.
  • Page 512 SECTION 6 - JLG CONTROL SYSTEM 4. Scroll to MENU: CALIBRATIONS and press ENTER 6. Press ENTER to calibrate Platform Level Up crack- point. NOTE: Have an assistant help verify that movement occurs. 5. Scroll to LEVEL UP CRKPT and press ENTER 7.
  • Page 513 SECTION 6 - JLG CONTROL SYSTEM 8. This completes the Platform Level Up crackpoint pro- 10. Press ENTER to calibrate Platform Level Down cedure. Press ESC to return to the calibrations crackpoint. menu. NOTE: Have an assistant help verify that movement occurs.

  • Page 514: Jib Level Up And Down Crackpoints

    14. Push in Power/Emergency stop switch to save the cali- bration changes. Jib Level Up and Down Crackpoints NOTE: To set crackpoints for the Jib Level Up and Down, a JLG analyzer is needed. Have an assistant on hand to help ver- ify that movement occurs.
  • Page 515 SECTION 6 - JLG CONTROL SYSTEM 4. Scroll to MENU: CALIBRATIONS and press ENTER 6. Press ENTER to calibrate Jib Level Up crackpoint. NOTE: Have an assistant help verify that movement occurs. 5. Scroll to JIB LVL UP CRKPT and press ENTER 7.
  • Page 516 SECTION 6 - JLG CONTROL SYSTEM 8. This completes the Jib Level Up crackpoint procedure. 10. Press ENTER to calibrate Jib Level Down crack- Press ESC to return to the calibrations menu. point. NOTE: Have an assistant help verify that movement occurs.

  • Page 517: Main Lift Up And Down Crackpoints

    14. Push in Power/Emergency Stop switch to save the calibration changes. Main Lift Up and Down Crackpoints NOTE: To set crackpoints for the Main Lift Up and Down, a JLG analyzer is needed. Have an assistant on hand to help ver- ify that movement occurs.
  • Page 518 SECTION 6 - JLG CONTROL SYSTEM 4. Scroll to MENU: CALIBRATIONS and press ENTER 6. Press ENTER 5. Scroll to MAIN LIFT CRKPT and press ENTER 7. Press ENTER to calibrate Main Lift Up crackpoint. 6-86 3121619...
  • Page 519 SECTION 6 - JLG CONTROL SYSTEM NOTE: Have an assistant help verify that movement occurs. 9. This completes the Main Lift Up crackpoint procedure. 8. At the Ground Controls, press Press ENTER and hold the Lift Up toggle switch until the function starts...
  • Page 520 SECTION 6 - JLG CONTROL SYSTEM NOTE: Have an assistant help verify that movement occurs. 12. This completes the Main Lift Down crackpoint proce- 11. At the Ground Controls, press dure. Press ENTER and hold the Lift Down toggle switch until the function starts moving, then press ENTER .
  • Page 521 SECTION 6 - JLG CONTROL SYSTEM 15. At the Ground Controls, press and hold the Lift Down toggle FOR THE FOLLOWING STEP, ELEVATE THE BOOM UNTIL IT STOPS IN ORDER TO switch until the function starts CORRECTLY CALIBRATE THE MAIN LIFT ENABLE CRACKPOINT.

  • Page 522: Main Telescope Out And In Crackpoints

    THE BOOM MUST BE FULLY RETRACTED AND HORIZONTAL BEFORE STARTING THE MAIN TELESCOPE OUT AND IN CRACKPOINT PROCEDURE. NOTE: To set crackpoints for the Main Telescope Out and In, a JLG analyzer is needed. Have an assistant on hand to help ver- ify that movement occurs.
  • Page 523 SECTION 6 - JLG CONTROL SYSTEM 5. Scroll to MAIN TELE CRKPT and press ENTER 7. Press ENTER to calibrate Main Telescope Out crackpoint. 6. Press ENTER 3121619 6-91...
  • Page 524 SECTION 6 - JLG CONTROL SYSTEM NOTE: Have an assistant help verify that movement occurs. 9. This completes the Main Telescope Out crackpoint pro- 8. At the Ground Controls, press cedure. Press ENTER and hold the Telescope Out toggle switch until the func-...
  • Page 525 SECTION 6 - JLG CONTROL SYSTEM NOTE: Have an assistant help verify that movement occurs. 12. The crackpoint setting procedure for Main Telescope 11. At the Ground Controls, press Out and In is complete. Press ESC to exit calibra- and hold the Telescope In tions.

  • Page 526: Lss System

    SECTION 6 - JLG CONTROL SYSTEM 6.12 LSS SYSTEM The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF form load via a sensor mounted in the platform support struc- THE FOLLOWING CONDITIONS OCCUR: ture.
  • Page 527 SECTION 6 - JLG CONTROL SYSTEM Figure 6-36. LSS Installation - Sheet 1 of 4 3121619 6-95...
  • Page 528 SECTION 6 - JLG CONTROL SYSTEM Figure 6-37. LSS Installation - Sheet 2 of 4 6-96 3121619...
  • Page 529 SECTION 6 - JLG CONTROL SYSTEM Figure 6-38. LSS Installation - Sheet 3 of 4 3121619 6-97...
  • Page 530 SECTION 6 - JLG CONTROL SYSTEM Figure 6-39. LSS Installation - Sheet 4 of 4 6-98 3121619...

  • Page 531: Diagnostic Menu

    SECTION 6 - JLG CONTROL SYSTEM Diagnostic Menu Press the LEFT and RIGHT Arrow keys to view the displays and select the various sub-menus. To access a sub-menu, press the The Diagnostic Menu is another troubleshooting tool for the ENTER key. Once in a sub-menu, press the LEFT and RIGHT Load Sensing System.

  • Page 532: Calibration Procedure

    System to record its’ weight during calibration. This includes all tools, debris, and customer-installed devices. 2. Plug the JLG Analyzer into the Machine at the Ground Station and enter Service Access Password 33271. 3. The platform should be approximately level for calibra- tion.
  • Page 533 80 lb (36 kg) Work Surface 20 lb (9 kg) NOTE: Not all Accessories are available on every JLG model. Some Accessory combinations are prohibited due to excessive weight and/or load restriction. If any installed JLG Accessories are labeled with weight decals but are not listed in the table above, include their weight when entering the ACC WEIGHT value.
  • Page 534 SECTION 6 - JLG CONTROL SYSTEM 9. The control system will calculate the load cell readings 11. Use the analyzer keys to select N for no or Y for yes. Press and ensure it is greater than 130 lbs. (59 kg), but less than 575 lbs.(261 kg).
  • Page 535 SECTION 6 - JLG CONTROL SYSTEM 12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-10. Pipe Rack Capacity Reductions PLATFORM OVRLD ENTER . The control system will default to an esti- Capacity...
  • Page 536 SECTION 6 - JLG CONTROL SYSTEM 14. Press ENTER . If calibration is successful, the screen will read: 6-104 3121619...

  • Page 537: Testing & Evaluation

    (fully functional and the Load Sensing System’s Overload stowed) for safety. Plug the JLG Analyzer into the control Visual and Audible Warnings are not active. Simulate an system connection and proceed to the DIAGNOSTICS, Overload by unplugging the Shear Beam Load Cell.

  • Page 538: Troubleshooting

    Inspect wiring where damage to the channel is apparent. out the influence of vibration or wind). 3. The Load Cell was not assembled properly during installation. Examine the sensor’ s reading using the JLG Analyzer. Proceed to the DIAG- There are large variations in Platform Load NOSTICS, CELL, LOAD displays and determine if the readings are reasonable.

  • Page 539: Resetting The Msso System

    SECTION 6 - JLG CONTROL SYSTEM 6.13 RESETTING THE MSSO SYSTEM 9. Use the arrow keys to reach the LOAD SENSING menu. The screen should read: 1. Use the following procedure to reset the MSSO system. 2. Position the Platform/Ground select switch to the desired position.
  • Page 540 SECTION 6 - JLG CONTROL SYSTEM 12. Press Enter . The screen will read: 13. Press Enter . The JLG Control System will reset an active 873 DTC and the MSSO System will be reset. Press Escape to return to the CALIBRATIONS menu.

  • Page 541: Electronic Platform Leveling

    Platform Leveling Fault Warning 1. In the case of a short to ground or an open circuit, the The JLG Control System takes a snapshot of the two sensor val- platform valve cannot be turned on and the following ues and records the difference once on each power up. The will occur: Control system allows a ±5 degree difference from those val-...
  • Page 542 SECTION 6 - JLG CONTROL SYSTEM TILT SENSOR ERRORS In each of the cases above it will be necessary to re-cycle the EMS to clear the fault. Operable functions shall be in the creep If the secondary tilt sensor is faulty, the control system will mode except while below elevation.
  • Page 543 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ EVERYTHING OK ✔ ✔ ✔ ✔ ✔ RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION ✔...
  • Page 544 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM ✔ ✔ ✔ ✔ ✔ FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER ✔...
  • Page 545 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ REAR LEFT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE HIGH ✔ REAR RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW ✔...
  • Page 546 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ ELECTRIC PUMP - SHORT TO BATTERY 3351 ✔ ✔ ✔ ✔ ✔...
  • Page 547 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ JIB LIFT UP VALVE - OPEN CIRCUIT 33101 ✔ ✔ ✔ JIB LIFT UP VALVE - SHORT TO BATTERY 33102 ✔...
  • Page 548 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ LIFT DOWN AUX VALVE - OPEN CIRCUIT 33154 ✔ ✔ ✔ ✔ LIFT DOWN AUX VALVE - SHORT TO BATTERY 33155 ✔...
  • Page 549 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ HORN - SHORT TO BATTERY 33208 ✔ ✔ ✔ ✔ ✔ HORN - SHORT TO GROUND 33209 ✔...
  • Page 550 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ CHASSIS ENABLE VALVE - SHORT TO BATTERY 33465 ✔ CHASSIS ENABLE VALVE - OPEN CIRCUIT 33466 ✔...
  • Page 551 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ JIB TELESCOPE OUT VALVE - SHORT TO GROUND 3515 ✔ ✔ JIB TELESCOPE OUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3516 ✔...
  • Page 552 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ LOSS OF ENGINE SPEED SENSOR 4322 ✔ ✔ ✔ ✔ ✔ SPEED SENSOR READING INVALID SPEED 4323 ✔...
  • Page 553 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ TOWER LIFT PVG VALVE - COMMAND IMPROPER 4523 ✔ TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER 4524 ✔...
  • Page 554 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ CANBUS FAILURE - BLAM 6610 ✔ ✔ ✔ ✔ ✔ CANBUS FAILURE - CHASSIS MODULE 6611 ✔...
  • Page 555 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST 8316 ✔ ✔ ✔ ✔...
  • Page 556 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT 8410 ✔ ✔ ✔ ✔...
  • Page 557 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ TRANSPORT DUAL CAPACITY BAD TRANSITION 8445 ✔ MAIN TRANSPORT LENGTH SWITCH DISAGREEMENT 8446 ✔ MAIN DUAL CAPACITY LENGTH SWITCH DISAGREEMENT 8447 ✔...
  • Page 558 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ WRONG SWING RESPONSE 84109 ✔ ✔ ✔ ✔ MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE ✔...
  • Page 559 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ FRONT RIGHT STEER SENSOR - DECOUPLED 8622 ✔ ✔ ✔ ✔ ✔...
  • Page 560 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ REAR RIGHT AXLE - MOVEMENT WITHOUT COMMAND 8688 ✔ REAR LEFT AXLE - MOVEMENT WITHOUT COMMAND 8689 ✔...
  • Page 561 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Diagnostic Fault Code Chart Fault Text Flash 1 Flash 2 1350 1200 1250 1500 1850 ✔ ✔ ✔ ✔ ✔ LENGTH SENSOR REF VOLTAGE LOW 9938 ✔ ✔ ✔ ✔ ✔ BLAM HIGH RES A/D FAILURE 9939 ✔...
  • Page 562 SCR CLEANING REQUIRED SCR Cleaning for regular maintenance (engine controlled) BOOM UNLOCK REQUIRED Triggers if machine is 1850SJ and DTC 23127 and DTC 8413 become active <<< HELP COMMENT >>> FSW OPEN A drive / boom function was selected with the Footswitch open.
  • Page 563 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code KEYSWITCH FAULTY Both Platform and Ground modes are selected simultaneously. FSW FAULTY Both Footswitches are closed for more then one second.
  • Page 564 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 23128 REDUCTION CHECK PRESSURE SENSOR - Pressure sensor voltage output < 0.4V for Check sensor hardware and wiring OUT OF RANGE LOW...
  • Page 565 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code FRONT RIGHT AXLE SWING SENSOR - VOLT- Sensor output < 0.1V Check sensor hardware and wiring AGE OUT OF RANGE LOW FRONT RIGHT AXLE SWING SENSOR - VOLT- Sensor output >4.9V...
  • Page 566 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 3328 LEFT REVERSE DRIVE PUMP - SHORT TO There is a Short to Ground to the - Chassis Module equipped vehicles only.
  • Page 567 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 3369 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the Two Speed Valve. 3370 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the Two Speed Valve.
  • Page 568 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 3399 PLATFORM ROTATE RIGHT VALVE - SHORT TO There is a Short to Battery to the Platform BATTERY Rotate Right Valve.
  • Page 569 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 33207 HORN - OPEN CIRCUIT There is an Open Circuit to the Horn. 33208 HORN - SHORT TO BATTERY There is a Short to Battery to the Horn.
  • Page 570 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 33456 MAIN LIFT FLOW CONTROL VALVE - CUR- Current feedback into controller not Check wiring and coil RENT FEEDBACK READING LOST...
  • Page 571 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 3429 JIB LOCK VALVE - SHORT TO GROUND 3430 JIB UNLOCK VALVE - OPEN CIRCUIT 3431 JIB UNLOCK VALVE - SHORT TO BATTERY...
  • Page 572 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code <<<Chassis Output Driver >>> FRONT AXLE EXTEND VALVE - SHORT TO BAT- Short to Battery detected Check wiring TERY FRONT AXLE EXTEND VALVE - SHORT TO...
  • Page 573 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code HIGH ENGINE TEMP (Ford engine only) The engine temperature - Ford / Deutz engine only. is > 117 C. (Deutz engine only) The engine tempera- ture is >...
  • Page 574 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code <<< BATTERY SUPPLY >>> BATTERY VOLTAGE TOO LOW - SYSTEM Battery voltage is < 9V. SHUTDOWN BATTERY VOLTAGE TOO HIGH - SYSTEM Battery voltage is >...
  • Page 575 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 6622 CANBUS FAILURE - TCU MODULE Machine Setup/ Telematics=YES, No device heartbeat for 30 sec 6623 CANBUS FAILURE - GATEWAY MODULE...
  • Page 576 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8218 LSS SENSOR DISAGREEMENT The control system has determined that the Attempt to re-calibrate the load sensing system. difference between the calculated load for sensor 1 and sensor 2 differ by more than Possible sensor hardware issue.
  • Page 577 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8224 LSS STRAIN GAUGE 1 - OUT OF RANGE LOW The shear beam is reporting an out of range Possible sensor hardware issue.
  • Page 578 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8228 LSS STRAIN GAUGE 1 - INITIALIZATION The shear beam is reporting an initializa- Possible sensor hardware issue. ERROR tion issue with the strain gauge 1 sensor.
  • Page 579 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8232 LSS STRAIN GAUGE 1 - SENSOR DEFECT The shear beam is reporting a sensor defect Possible sensor hardware issue.
  • Page 580 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8237 LSS STRAIN GAUGE 1 - A/D DEFECT The shear beam is reporting an internal Possible sensor hardware issue. issue with the strain gauge 1 sensor.
  • Page 581 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code PLATFORM LEVEL DOWN CRACKPOINT - NOT The Platform Level Down Valve Crackpoint - Electronic leveling system equipped vehicles only. CALIBRATED has not been calibrated.
  • Page 582 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8335 JIB LEVEL UP CRACKPOINT - NOT CALI- BRATED 8336 JIB LEVEL DOWN CRACKPOINT - NOT CALI- BRATED 8337 JIB LEVELING SYSTEM TIMEOUT...
  • Page 583 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8495 TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE LOW 8496 TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE HIGH...
  • Page 584 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 84151 TOWER LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) that these Check Hardware, Wiring faults can be set: If the length sensor voltage changes more than 0.0168 volts within 40 milliseconds a...
  • Page 585 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 84152 TOWER LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) that these Check Hardware, Wiring faults can be set: If the length sensor voltage changes more than 0.0168 volts within 40 milliseconds a...
  • Page 586 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 84153 BOOM LENGTH SENSOR 1 FAULTY There are three ways (a, b, c) that these Check wiring and hardware faults can be set: If the length sensor voltage changes more than 0.0168 volts within 40 milliseconds a...
  • Page 587 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 84154 BOOM LENGTH SENSOR 2 FAULTY There are three ways (a, b, c) that these Check wiring and hardware faults can be set: If the length sensor voltage changes more than 0.0168 volts within 40 milliseconds a...
  • Page 588 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code <<< STEERING / AXLE >>> RESTRICTED TO TRANSPORT - OSCILLATING The Oscillating Axle Pressure Switch indi- - Electrically released Oscillated...
  • Page 589 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8623 FRONT LEFT STEER SENSOR - DECOUPLED The Front Left Steer Sensor has become decoupled. 8624 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has become decoupled.
  • Page 590 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 8670 RIGHT FRONT STEER RIGHT VALVE  - OPEN Open Circuit detected Check wiring CIRCUIT 8671 RIGHT FRONT STEER RIGHT VALVE  - SHORT...
  • Page 591 Envelope Control has been disabled by the - Envelope Control equipped vehicles only. user from Access Level 0. 99282 GROUND DISPLAY SOFTWARE VERSION IS 1850SJ T4F machines with Ground Display IMPROPER must have software version P1.1 or greater to work. 3121619...
  • Page 592 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code 99285 LSS - FACTORY CALIBRATION ERROR The load sensor is reporting a factor calibra- Possible sensor hardware issue. tion issue (internal error) The machine will assume the platform is overloaded.

  • Page 593: Basic Electrical Information & Electrical Schematics

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GENERAL that the leads are connected to the device under test correctly. Also check that the lead on the "COM" port goes to the Ground This section contains basic electrical information and sche- or negative side of the signal and the lead on the other port matics to be used for locating and correcting most of the oper-...

  • Page 594: Resistance Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing conti- Figure 7-2.

  • Page 595: Current Measurement

    TO ELECTRICAL CONNECTIONS NOTE: This section is not applicable for battery terminals. JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- RIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connec- tions: •...

  • Page 596: Installation Of Dielectric Grease

    3. Leave a thin layer of dielectric grease on the face of the prevents the connector from latching, pierce one of the connector unused wire seals. After assembly, install a seal plug (JLG #4460905) in that location to prevent moisture ingress. 4. Assemble the connector system immediately to prevent...

  • Page 597: Amp Mate-N-Lok

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Figure 7-6. Use of Seal Plugs Exclusions AMP Mate-N-Lok A limited number of connectors do not benefit from dielectric grease, or may be permanently damaged by application.
  • Page 598 The EMR2 engine control the dielectric grease (replacement of female contacts module from Deutz employs this connector system (for exam- required). The JLG Load Sensing System and 1250AJP Rotary ple). Angle Sensors are examples of components with the M12 con- nector system.

  • Page 599: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Figure 7-9.). Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-7.).
  • Page 600 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-9. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).

  • Page 601: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. 2.
  • Page 602 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-13. Connector Installation 7-10 3121619...

  • Page 603: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-15. DT/DTP Contact Removal Figure 7-14. DT/DTP Contact Installation 1. Remove wedgelock using needlenose pliers or a hook 1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.

  • Page 604: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact crimp 1. With rear insert toward you, snap appropriate size barrel.

  • Page 605: Telematics Gateway

    DEF Tank Level (If Equipped) Percentage (%) • 100% = Full • 00 - No Machine Faults • 01 - Active Machine Fault JLG Machine Faults: Active / Not-Active • 10 - Error • 11 - Not available Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions.
  • Page 606 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-14 3121619...
  • Page 607 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1609 ( MS1620-3 (CAN-T 2) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1-0 BAT 16 AWG X1606 (B) CANH2 18 AWG CO1613-J2 (10) 0-0 GND 16 AWG S1615 (1)
  • Page 608 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS FROM REFERENCE WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE MS1620-2 CAN L2 18 AWG 1151 MS1619-3 CAN L2 18 AWG X1609 MS1619-2 CAN L1 18 AWG MS1618-2 CO1613-J1 CAN L2 18 AWG MS1620-3 CO1613-J2...

  • Page 609: Wiring Harness Connector Labels

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.7 WIRING HARNESS CONNECTOR LABELS Table 7-1. Wiring Harness Connector Labels Component Category Label Connector Labels Audible Alarms Connectors between harnesses are identified by the prefix "X" Horns and a sequentially assigned number. An optional suffix (letters Battery Batteries &...
  • Page 610 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Table 7-1. Wiring Harness Connector Labels Component Category Label Other Switches Disconnect Foot HVAC Park brake Pump pot Push Shifter Turn signal Relay 5 Pin 4 Pin Contactor Power module Rocker Switch Sensor Angle Fuel...
  • Page 611 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-19...
  • Page 612 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CONN W IRE W IRE GAUGE JACKET COLOR LABEL W HT 52-4 GEN 18 AWG CO01-J7 (9) SW16 18 AWG CO01-J2 (33) STEER MODE W HT 49-24 SFTCH 18 AWG CO01-J7 (18) W HT 49-27 18 AWG...
  • Page 613 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CO01-J1 X33A CONN WIRE WIRE CONN WIRE WIRE GAUGE JACKET COLOR LABEL GAUGE JACKET COLOR LABEL 49-20 PROX NC 18 AWG X33A (15) SHLD CAN SHIELD 20 AWG J1939 CABLE MS41 (5) CAN LOW 20 AWG J1939 CABLE...
  • Page 614 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-22 3121619...
  • Page 615 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HV343 X36B JLOCK OUT CONN WIRE WIRE GA UGE JA CK E T P OS COLOR LA B E L CONN WIRE WIRE RE D CA B LE 18 AWG CA B LE S N274 (1) GA UGE JA CK E T...
  • Page 616 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-24 3121619...
  • Page 617 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HV256 SN246 JIB LVL UP CONN WIRE WIRE GAUGE JACKET COLOR LABEL CONN WIRE WIRE GAUGE JACKET GROUND 18 AWG CABLE CO245-J3 (12) COLOR LABEL 5V PWR 18 AWG CABLE CO245-J3 (10) 55-20 JLVL UP 18 AWG CO245-J2 (11)
  • Page 618 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CO245-J3 CONN WIRE WIRE CO245-J5 GAUGE JACKET COLOR LABEL 5V PWR 18 AWG CABLE SN247 (F) CONN WIRE WIRE SIGNAL 18 AWG CABLE SN247 (C) GAUGE JACKET COLOR LABEL GROUND 18 AWG CABLE SN247 (E) 27-5-1...
  • Page 619 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-27...
  • Page 620 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X404B MS148-1 CONN WIRE WIRE GAUGE JACKET COLOR LABEL CONN WIRE WIRE GAUGE JACKET B LNGTH 18 AWG CABLE CO128-J3 (7) COLOR LABEL B LNGTH 18 AWG CABLE CO128-J3 (8) CAN HIGH 18 AWG CO128-J1 (6) B LNGTH...
  • Page 621 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CO128-J4 CONN WIRE WIRE GAUGE JACKET COLOR LABEL +B PWR SUP -B GND SUP CAN HI CAN LO SHLD SHIELD CONN WIRE WIRE GAUGE JACKET COLOR LABEL +B PWR SUP -B GND SUP CAN HI CAN LO 001157646-A...
  • Page 622 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X406B CONN WIRE WIRE GAUGE JACKET COLOR LABEL #1 ANGLE PWR 18 AWG CABLE BLUE #1 ANGLE SIG 18 AWG CABLE BLACK #1 ANGLE GND 18 AWG CABLE RED/BLACK 18 AWG CABLE YELLOW #2 ANGLE PWR...
  • Page 623 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X404A CONN WIRE WIRE GAUGE J ACKET COLOR LABEL B LNTH PWR 18 AWG CABLE BLUE B LNTH SIG 18 AWG CABLE BLACK B LNTH GND 18 AWG CABLE RED/BLACK 18 AWG CABLE YELLOW BRKN CBL PWR...
  • Page 624 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SN221 CONN WIRE WIRE GAUGE JACKET COLOR LABEL BROWN BRKN CBL PWR 22 AWG CABLE WHITE 22 AWG CABLE BLUE BRKN CBL GND 1 22 AWG CABLE S409 BLACK BRKN CBL SIG 1 22 AWG CABLE CONN...
  • Page 625 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-33...
  • Page 626 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BEACON SIDE CONNECTION CONN WIRE WIRE GAUGE JACKET COLOR LABEL B E A CON P WR 16 AWG CA B LE HA RNE S S S I DE CONNE CTI ON B LK B E A CON GND 16 AWG...
  • Page 627 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-35...
  • Page 628 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-36 3121619...
  • Page 629 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS RL360-85 X457 CONN WIRE WIRE CONN WIRE WIRE GAUGE JACKET GAUGE JACKET COLOR LABEL COLOR LABEL 55-35 AUX B+ DISC 18 AWG CO02-J1 (2) 1-15 18 AWG IP414 (2) 16 AWG IP415 (2) RL360-86 IP415...
  • Page 630 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS RL235-R CONN WI RE WI RE CONN WI RE WI RE GA UGE J A CK E T GA UGE J A CK E T P OS COLOR LA B E L P OS COLOR LA B E L...
  • Page 631 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CONN WIRE WIRE GAUGE JACKET COLOR LABEL 27-3 JIB DN O/R 18 AWG X81 (15) 25-6 PLVL UP O/R 18 AWG X81 (9) 25-5 PLVL DN O/R 18 AWG X81 (7) 50-2 PLTFM DUMP 16 AWG X341A (4)
  • Page 632 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-40 3121619...
  • Page 633 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CONN WIRE WIRE CONN WIRE WIRE GAUGE JACKET COLOR LABEL GAUGE JACKET COLOR LABEL SHLD CAN SHLD 20 AWG J1939 CABLE M S82 (5) 1-7-2 WK LT PWR 16 AWG IP379 (2) CAN LO 20 AWG J1939 CABLE...
  • Page 634 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CO02-J1 CONN WIRE WIRE GAUGE JACKET CONN WIRE WIRE COLOR LABEL GAUGE JACKET COLOR LABEL 16 AWG IP415 (1) 55-30 LFT ENABLE 18 AWG X440B (1) 1-4-1 18 AWG CO02-J7 (3) 55-35 AUX B+ DISC 18 AWG RL360-85 (1)
  • Page 635 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X467 CONN WIRE WIRE GAUGE JACKET COLOR LABEL CONN WIRE WIRE GAUGE JACKET COLOR LABEL 2-4-4 18 AWG S89 (2) UGM TO CHASSIS GND 4 AWG BRAID CO02-J8 (3) 2-4-3 18 AWG S89 (2) 1-4-1 18 AWG...
  • Page 636 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-44 3121619...
  • Page 637 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-45...
  • Page 638 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS LB69 CONN WIRE W IRE CONN W IRE WIRE GAUGE JACKET GAUGE JACKET COLOR LABEL COLOR LABEL W HT 39-4 AXLE 18 AWG LB68 (1) 48-5 GLOW 18 AWG CO02-J4 (15) W HT 54-4 500# 18 AWG...
  • Page 639 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SW56-1 CONN WIRE WIRE CONN WIRE WIRE GAUGE JACKET GAUGE JACKET COLOR LABEL COLOR LABEL 48-4 STRT 18 AWG CO02-J4 (4) 1-4-3 18 AWG X327 (3) 2-9-9 18 AWG SW64 (2) 53-2 AUX 18 AWG CO02-J4 (16)
  • Page 640 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-48 3121619...
  • Page 641 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HV164 - REAR AXLE SWG RET. CONN WIRE WIRE GAUGE JACKET COLOR LABEL S195 38-6 RAXS RET 18 AWG CO03-J2 (7) 60-5-2 RAXS RT N 18 AWG S168 (2) CONN WIRE WIRE GAUGE JACKET...
  • Page 642 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HV174 - RIGHT REAR STR RHT X340A CONN WIRE WIRE CONN WIRE WIRE GAUGE JACKET GAUGE JACKET COLOR LABEL COLOR LABEL 9-5 RREAR ST RR 18 AWG CO03-J2 (8) RHT F RNT ST R 18 AWG CABLE CO03-J7 (9)
  • Page 643 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CO03-J4 CO03-J3 CONN WI RE WI RE CONN WI RE WI RE GA UGE JA CK E T GA UGE JA CK E T P OS COLOR LA B E L P OS COLOR LA B E L...
  • Page 644 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CO03-J1 CONN WIRE WIRE GAUGE JACKET COLOR LABEL 00-9 18 AWG SN243 (E) 00-8 18 AWG S195 (1) 38-10 FAXS LFT 18 AWG X449B (2) 38-9 RAXS RHT 18 AWG X448B (2) 55-15 TTABLE ANG 18 AWG SN243 (C)
  • Page 645 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-57. Chassis Harness - Sheet 6 of 6 3121619 7-53...
  • Page 646 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-54 3121619...
  • Page 647 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HV102 LIFT DN AUX LIFT FLOW CNTRL CONN WIRE WIRE CONN WIRE WIRE GAUGE JACKET GAUGE JACKET COLOR LABEL COLOR LABEL 55-10 LFT DN AUX 18 AWG CO02-J2 (12) 55-9 LFT FCNTRL 18 AWG CO02-J2 (19) 0-6-3...
  • Page 648 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS S153 CONNECT OR PART NUM BER: SPLICE CONN WIRE WIRE T ERM INAL CONN WIRE WIRE GAUGE JACKET GAUGE JACKET COLOR LABEL COLOR LABEL 50-3 JIB DUM P 16 AWG X159A (5) 0-30 18 AWG CO02-J2 (18)
  • Page 649 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HV142 HV144 RHT DRV PUMP FWD LFT DRV PUMP REV X222A S146 HV143 RHT DRV PUMP REV HV145 LFT DRV PUMP FWD 001149970-B CONN WIRE WIRE GAUGE JACKET COLOR LABEL 7-4 RDRV PFWD 18 AWG HV142 (1) 7-3 RDRV PREV...
  • Page 650 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-58 3121619...
  • Page 651 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CONN WIRE WIRE GAUGE JACKET COLOR LABEL 148-1 ECM PWR 2.5 mm² FLRYW S944 (2) 148-2 ECM GND 2.5 mm² FLRYW S945 (2) 148-3 ECM PWR 2.5 mm² FLRYW S944 (2) 148-4 ECM GND 2.5 mm²...
  • Page 652 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CONN WIRE WIRE GAUGE JACKET COLOR LABEL SHLD 248-38ENGINE SPEED CRANKSHAFT 0.75 mm² SHLD ECM-J2 (38) 148-70 STRT GND 0.75 mm² FLRYW ECM-J1 (28) 148-71 STRT SIG 0.75 mm² FLRYW ECM-J1 (73) SHLD 248-53ENGINE SPEED CAMSHAFT 0.75 mm²...
  • Page 653 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CONN WIRE WIRE GAUGE JACKET COLOR LABEL 248-2 INJECTOR 3 1.5 mm² FLRYW EIC (61) 248-3 INJECTOR 2 1.5 mm² FLRYW EIC (41) 248-4MPROP ACTUATOR 1.5 mm² FLRYW EIC (19) 248-5MPROP ACTUATOR 1.5 mm²...
  • Page 654 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-62 3121619...
  • Page 655 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-63...
  • Page 656 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-64 3121619...
  • Page 657 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-69. Generator Enable Harness - Sheet 1 of 2 3121619 7-65...
  • Page 658 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-66 3121619...
  • Page 659 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-67...
  • Page 660 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-72. T4F Engine Harness - Sheet 3 of 14 7-68 3121619...
  • Page 661 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-73. T4F Engine Harness - Sheet 4 of 14 3121619 7-69...
  • Page 662 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-74. T4F Engine Harness - Sheet 5 of 14 7-70 3121619...
  • Page 663 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-75. T4F Engine Harness - Sheet 6 of 14 3121619 7-71...
  • Page 664 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-72 3121619...
  • Page 665 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-77. T4F Engine Harness - Sheet 8 of 14 3121619 7-73...
  • Page 666 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-78. T4F Engine Harness - Sheet 9 of 14 7-74 3121619...
  • Page 667 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-79. T4F Engine Harness - Sheet 10 of 14 3121619 7-75...
  • Page 668 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-80. T4F Engine Harness - Sheet 11 of 14 7-76 3121619...
  • Page 669 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-77...
  • Page 670 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-82. T4F Engine Harness - Sheet 13 of 14 7-78 3121619...
  • Page 671 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-79...
  • Page 672 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-80 3121619...
  • Page 673 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X253 X436B UREA SUP MOD TO ENG HARN CONN WIRE WIRE GAUGE JACKET CONN WIRE WIRE LABEL GAUGE JACKET COLOR LABEL COLOR 19-X253 UREA PRS 0.75 mm² FLRYW X734B (5) 57-X253 UREA PRS 0.75 mm²...
  • Page 674 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-82 3121619...
  • Page 675 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-83...
  • Page 676 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X404B CONNECTS TO BASE BOOM SENSORS CABLE CO128-J2 X406A CONNECTS TO BASE BOOM ANGLE SENSORS CABLE CO128-J5 CO02-J8 CO128-J1 CO02-J1 SN123 CONNECTS TO TRANSPORT SWITCH CABLE CO02-J7 CONNECTS TO MAIN BOOM CABLE X341A CO02-J12 CONNECTS TO 16/4 MAIN...
  • Page 677 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SN416 HYD OIL TEMP HV314 CHASSIS ENABLE HV316 HV104 WARM UP VLV MAIN DUMP HV108 HV109 TELE FLOW CNTRL MAIN TELE IN HV102 HV101 LIFT FLOW CNTRL MAIN LIFT DN HV103 HV100 MAIN TELE OUT SWG LFT...
  • Page 678 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS RL234-85 RL234-86 RL127-85 RL127-86 RL360-85 RL360-86 RL236-R RL236-Y RL235-Y RL235-R X237 X362 X353 X373 X375 X376 X377 X378 X418 X419 X406A X404B X395 SN123 CONNECTS TO TILT SENSOR X341A SN959 LB417 MS82 X412 X411...
  • Page 679 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS LB71 LO OIL LB70 HI TEMP LB73 MOMNT CNTRL LB72 LB74 NO ALT BOOM CNTRL LB69 GLOW PLUG LB75 PLATF OVRLD LB68 AXLE SET LB67 SW66-2 500 CAP SW66-1 LB76 SW61 1000 CAP JIB TELE SW60...
  • Page 680 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SW55-1B BAT B+ SW55-2B E-STOP B+t SW56-1 GND MODE SW56-B E-STOP B+ SW56-3 PLATF MODE EMERGENCY STOP AND KEY SWITCH IP379 IP414 IP415 BATTERY AND RELAYS 1001156522-H Figure 7-92. Electrical Installation - Sheet 5 of 10 7-88 3121619...
  • Page 681 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X339A X337A CONNECTS TO STEER CABLE CONNECTS TO STEER CABLE 3 OF 4 4 OF 4 449B CONNECTS TO SEQ #22 CONNECTS TO X147B 445A HV179 X160 SN423 SN243 HV178 X147B 448B 442A CONNECTS TO LINEAR AXLE SENSOR...
  • Page 682 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HV162 HV161 FRONT AXLE SWG RET. FRONT AXLE SWG EXT. HV170 HV171 RIGHT FRONT STR LFT RIGHT FRONT STR RHT HV175 HV174 RIGHT REAR STR LFT RIGHT REAR STR RHT SECTION E-E HV177 HV176 LEFT REAR STR LFT...
  • Page 683 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001156522-H Figure 7-95. Electrical Installation - Sheet 8 of 10 3121619 7-91...
  • Page 684 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-92 3121619...
  • Page 685 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121619 7-93...
  • Page 686 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS THIS MACHINE UTILIZES A 12-VOLT ELECTRICAL SYSTEM. TO PREVENT DAMAGE WHEN JUMP-STARTING THE MACHINE, CONNECT THE JUMP-START EQUIPMENT ONLY TO THE BATTERY SHOWN TO PREVENT DAMAGE TO THE MACHINE'S ELEC- TRICAL SYSTEM. Figure 7-98.
  • Page 687 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-99. Battery Installation - Sheet 1 of 2 3121619 7-95...
  • Page 688 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-100. Battery Installation - Sheet 2 of 2 7-96 3121619...
  • Page 689 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-101. Electrical Schematic - Sheet 1 of 21 3121619 7-97...
  • Page 690 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS JIB LOCK PIN LIGHT AXLE EXTEND/RETRACT TOGGLE SWITCH WHT 59-1 JSWG RT [5,G] JIB SWING RIGHT WHT 59-2 JSWG LT JIB SWING LEFT [5,G] WHT 55-6 DOS WHT 55-6 DOS DRIVE ORIENTATION [8,G] WHT 49-21 SFTCH LT SOFT TOUCH...
  • Page 691 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BOOM CONTROL SELECT START/AUX POWER CAPACITY SELECT DRIVE ORIENTATION TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH JIB LOCK PIN SOFT TOUCH OVERRIDE HEAD/TAIL LIGHT TOGGLE SWITCH PUSH BUTTON LIGHT JIB SWING JIB LIFT MAIN BOOM TELESCOPE TOGGLE SWITCH...
  • Page 692 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN SENSOR #2 (LH) SENSOR #1 (RH) ANGLE SENSOR PROXIMITY SENSOR PROXIMITY SENSOR PROXIMITY SENSOR PLATFORM LEVEL SENSOR PLATFORM LEVEL SENSOR JIB LIFT IGNITION/GROUND JIB LOCK JIB LOCK PLATF LVL PLATF LVL...
  • Page 693 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN JIB LEVEL JIB LEVEL JIB LIFT JIB LIFT JIB TELE JIB TELE JIB SWING JIB SWING ANGLE SENSOR PROXIMITY SENSOR PROXIMITY SENSOR PROXIMITY SENSOR DOWN DOWN RIGHT...
  • Page 694 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BROKEN CABLE BROKEN CABLE PROXIMITY SENSOR #1 PROXIMITY SENSOR #2 S409 BLK PROX SIG (22) BRN PROX PWR (22) BLK BRKN CBL SIG (22) BLU BRKN CBL GND2 (22) SHIELD B LNGTH BLU BRKN CBL PROX MS148-2 MS148-1...
  • Page 695 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS STROBE LIGHT WHT B LNTH CBL 1001145974_5-[3,C] BLK B LNTH CBL 1001145974_5-[3,C] RED B LNTH CBL 1001145974_5-[3,D] SHLD 1001145974_5-[3,F] 1001145974_5-[3,F] 1001145974_5-[3,F] X411 BLK 0-22 (14) BLK 0-22 (14) YEL 2-10 (14) YEL 2-10 (14) BLU BRKN CBL PROX BLU CABLE...
  • Page 696 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS TURNTABLE MAIN MAIN SWITCH EMERGENCY SWING LIFT TELESCOPE TELESCOPE LIFT MSSO ENGINE MOMNT CNTRL CAN CHANNEL #1 SWITCH REGENERATION PUSH BUTTON 3 x 4 Buss Bar WHT 49-28 MNT CNTRL WHT 49-29 BCS WHT 49-30 OVERLOAD WHT 54-5 1000# SHLD CAN SHLD...
  • Page 697 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 500# CAP. GLOW PLUG LOW OIL MOMENT CNTRL PLATFORM OVERLOAD LIGHT LIGHT PRES. LIGHT TEST LIGHT LIGHT MAIN MAIN PLATFORM PLATFORM START/ TURNTABLE SWING LIFT TELESCOPE TELESCOPE LIFT ROTATE LEVEL AUX PWR MOMNT CNTRL AXLE SET HIGH COOLANT...
  • Page 698 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS MTS LINEAR SENSOR DEUTSCH REAR LFT AXLE SWG 1 x 8 Buss Bar FRNT AXLE SWG EXT. TWO SPEED FRNT AXLE SWG RET. REAR AXLE SWG EXT. BRAKE FRNT RHT AXLE SWG OPEN HYD.
  • Page 699 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS MTS LINEAR SENSOR MTS LINEAR SENSOR DEUTSCH REAR LFT AXLE SWG FRNT RHT AXLE SWG 1 x 8 Buss Bar FRNT AXLE SWG EXT. TWO SPEED FRNT AXLE SWG RET. REAR AXLE SWG EXT. BLK 00-1 WHT 55-14 BRAKE BRAKE...
  • Page 700 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HYDRAULIC OIL TEMP. WARM UP LIFT CHASSIS VALVE ENABLE ENABLE WHT 7-4 RDRV PFWD RIGHT DRV BLK 0-15-1 PUMP FWD HV142 WHT 7-4 RDRV PFWD WHT 7-3 RDRV PREV WHT 7-3 RDRV PREV RIGHT DRV BLK 0-15 BLK 0-15...
  • Page 701 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HYDRAULIC OIL TEMP. WARM UP LIFT CHASSIS SWING MOTION ALARM/ VALVE ENABLE ENABLE FLOW CONTROL HORN BRN 49-77 P C PWR (20) BLK 49-76 P C GND (20) BLU 49-75 PRS CHK (20) SHLD RTN (20) S455 BRN 49-73 L P PWR (20)
  • Page 702 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GLOW PLUG SENSOR IGNITION FUSE FUSE BLK 148-70 STRT RTN SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm² BLK 148-71 STRT SIG BLK 148-15-68 CLUTCH SWITCH BLK 148-70 STRT RTN BLK 148-35-3 STRT REQ BLK 148-71 STRT SIG MS1000-3 120 OHM...
  • Page 703 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GLOW GLOW PLUG SENSOR IGNITION PLUGS FUSE FUSE 150 A EC971-B+ RED EPDM 2/0AWG EC971 EC971-B- X1008 BLK 000-148-2 1.5 K OHM BLK 148-35-4 STRT REQ BLK 148-35-3 STRT REQ BLK 148-35-2 STRT REQ BLK 148-35-2 STRT REQ S1007 YEL CAN HIGH...
  • Page 704 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-116. Electrical Schematic - Sheet 16 of 21 7-112 3121619...
  • Page 705 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-117. Electrical Schematic - Sheet 17 of 21 3121619 7-113...
  • Page 706 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS DEUTZ EMR4 91 WAY CONNECTOR (D2.2) TIER 4 FINAL DEUTZ TD3.6L CYLINDER 1 WHT 64-35 INJCTR RTN (1.5mm²) INJECTOR WHT 45-40 INJCTR (1.5mm²) CYLINDER 2 WHT 24-41 INJCTR RTN (1.5mm²) INJECTOR WHT 44-38 INJCTR (1.5mm²) CYLINDER 3 WHT 23-61 INJCTR RTN (1.5mm²)
  • Page 707 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS FUEL PUMP AUXILIARY AUXILIARY RELAY RELAY PUMP DEUTZ EMR4 91 WAY CONNECTOR (D2.2) ENGINE/AUX PUMP BATTERY FUEL PUMP DPF PRESSURE DS DPF AMBIENT AIR TEMP. SENSOR WATER IN FUEL SWITCH EMR4 IGNITION GROUND GENERATOR ENABLE GLOW...
  • Page 708 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS ENGINE HARNESS ENGINE HARNESS SHEET #10 SHEET #10 ZONE A-2/3 ZONE A-4/5 AFTERTREATMENT SECTION UREA TANK/ SUPPLY MODULE LOCATED ON LEFT SIDE OF MACHINE UREA QUALITY, N6 CONNECTION SUCTION LINE PRESSURELINE LEVEL AND TEMP.
  • Page 709 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS RED - BEACON PWR RED - BEACON PWR BLK - GROUND BLK - GROUND WHT - IGNITION S208 BLK - GROUND X207 UREA TANK MODULE & CRIBBING Figure 7-121. Electrical Schematic - Sheet 21 of 21 3121619 7-117...
  • Page 710 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS NOTES: 7-118 3121619...
  • Page 712 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations www.jlg.com...

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