A 800s Hc3 860sj Hc3 JLG Service English

Service & Maintenance Manual
Model
800S HC3, 860SJ HC3
PVC 2307
31222415
July 10, 2023 - Rev A
ANSI ©
Copyright
AS/NZS MOL70 GB
EFFECTIVITY PAGE
DATE REVISION DESCRIPTION

July 10, 2023 A Original Issue
800S HC3, 860SJ HC3 31222415 3

This Page is intentionally left blank
4
READ THIS FIRST
Modifications
Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations.
Any modification must be approved by JLG.
800S HC3, 860SJ HC3 31222415 5

6
SECTION CONTENTS
Section Subject Page
EFFECTIVITY PAGE........................................................................................................................................ 3
READ THIS FIRST........................................................................................................................................... 5

SECTION 1
SAFETY ......................................................................................................................................................... 11
1.1 General ............................................................................................................................. 11
1.2 Safety Information .............................................................................................................. 11
1.3 Safety Hazards.................................................................................................................... 12
1.4 Safety Decals...................................................................................................................... 13
1.5 Machine Verification............................................................................................................ 13
SECTION 2
GENERAL MACHINE INFORMATION AND SPECIFICATIONS ................................................................. 15
2.1 Specifications ..................................................................................................................... 15
2.2 Machine Temperature Chart ................................................................................................. 20
2.3 Serial Number Location........................................................................................................ 21
2.4 Fluids and Lubrication ......................................................................................................... 21
2.5 Machine Characteristics ....................................................................................................... 24
2.6 ClearSky Smart Fleet™ (If Equipped) ...................................................................................... 33
SECTION 3
MAINTENANCE AND INSPECTION SCHEDULES...................................................................................... 35
3.1 Machine Preparation, Inspection, and Maintenance ................................................................. 35
3.2 Service and Guidelines......................................................................................................... 36
3.3 Preventive Maintenance and Inspection Schedule ................................................................... 38
3.4 Pins and Composite Bearing Repair Guidelines........................................................................ 42
3.5 Tires and Wheels................................................................................................................. 43
3.6 Fuel Tank Inspection ........................................................................................................... 43
3.7 Boom Inspection and Maintenance ....................................................................................... 44
3.8 Hydraulic Filter Replacement ................................................................................................ 48
3.9 Turntable Bearing Inspection ................................................................................................ 49
3.10 Engine General Inspection.................................................................................................... 54
3.11 Bio Fuel In Deutz Engines..................................................................................................... 67
3.12 Deutz EMR2 ....................................................................................................................... 69
3.13 Deutz EMR5 ....................................................................................................................... 72
3.14 Generator Inspection ........................................................................................................... 75
SECTION 4
TESTING, CALIBRATIONS AND SPECIAL PROCEDURES......................................................................... 83
4.1 Special Tools ...................................................................................................................... 83
4.2 Testing Procedures.............................................................................................................. 87
800S HC3, 860SJ HC3 31222415 7

Section Contents
4.3 Calibration Procedures......................................................................................................... 94

4.4 Special Procedures ............................................................................................................ 109
4.5 Wheel Drive Hub............................................................................................................... 113
4.6 Swing Drive. ..................................................................................................................... 115
SECTION 5
SYSTEM SOFTWARE..................................................................................................................................117
5.1 Load Sensing System (LSS) ................................................................................................. 117
5.2 JLG Analyzer .................................................................................................................... 121
5.3 Analyzer Software Accessibility ........................................................................................... 136
5.4 Function Test ................................................................................................................... 155
5.5 CANBUS Communications .................................................................................................. 157
5.6 Service Mode ................................................................................................................... 157
5.7 Electronic Platform Leveling ............................................................................................... 159
SECTION 6
FAULT CODES ............................................................................................................................................169
6.1 Fault Codes Introduction.................................................................................................... 169
6.2 Engine Diagnostic ............................................................................................................. 169
6.3 Machine Fault Codes ......................................................................................................... 245
SECTION 7
HYDRAULICS..............................................................................................................................................259
7.1 General Information and Safety........................................................................................... 259
7.2 Theories of Operation ........................................................................................................ 260
7.3 Hydraulic Components ...................................................................................................... 261
7.4 Torque Values .................................................................................................................. 270
7.5 Hydraulic Diagram - Chassis. ............................................................................................... 274
SECTION 8
ELECTRICALS .............................................................................................................................................283
8.1 General Information .......................................................................................................... 283
8.2 Electrical Connectors ......................................................................................................... 286
8.3 Electrical Component Terminology...................................................................................... 290
8.4 Harness Layouts................................................................................................................ 290
8.5 Board Layouts .................................................................................................................. 291
8.6 AMP Connector ................................................................................................................ 303
8.7 Telematics Gateway .......................................................................................................... 307
SECTION 9
REMOVAL AND INSTALLATION ..............................................................................................................313
9.1 Wheel and Tire ................................................................................................................. 313
9.2 Chassis/Frame Assembly .................................................................................................... 315
9.3 Boom .............................................................................................................................. 323
9.4 Platform .......................................................................................................................... 337
9.5 Engine............................................................................................................................. 344
9.6 Transmission .................................................................................................................... 400
8 31222415 800S HC3, 860SJ HC3

Section Contents
9.7 Hydraulic Cylinders ........................................................................................................... 400

9.8 Hydraulic Valves ............................................................................................................... 413
9.9 Hydraulic Pumps............................................................................................................... 419
9.10 Electrical Components ....................................................................................................... 422
9.11 Turntable......................................................................................................................... 425
9.12 Generator Pulley ............................................................................................................... 431
SECTION 10
DISASSEMBLY AND ASSEMBLY ..............................................................................................................439
10.1 Drive Assembly................................................................................................................. 439
10.2 Boom and Jib Assembly ..................................................................................................... 471
10.3 Hydraulic Cylinders ........................................................................................................... 507
10.4 Turntable......................................................................................................................... 569
10.5 Generator Disassembly and Assembly.................................................................................. 622
10.6 Powertrack Maintenance.................................................................................................... 625
SECTION 11
TORQUE/CONNECTION INFORMATION .................................................................................................633
11.1 Hydraulic Fittings .............................................................................................................. 633
11.2 Torque Charts................................................................................................................... 690
SECTION 12
SCHEMATICS..............................................................................................................................................707
12.1 Hydraulic Schematics. ........................................................................................................ 707
12.2 Electrical Schematics ......................................................................................................... 711
12.3 Deutz EMR2 Schematics..................................................................................................... 724
12.4 Deutz EMR5 Schematics..................................................................................................... 729
12.5 7500W Generator Schematic............................................................................................... 741
12.6 4000W Generator Schematic............................................................................................... 747
800S HC3, 860SJ HC3 31222415 9

10
SECTION 1
SAFETY
1.1 GENERAL
This Service Manual provides general directions for service and repair procedures. Following the procedures in this manual will help
assure safety and equipment reliability.
This section contains general safety precautions that must be observed during maintenance of this machine. It is of utmost importance
that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must be followed to ensure the machine is safe to operate.
Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes,
regulations and laws.
WARNING
Modification or alteration of this machine shall be made only with written permis-
sion from the manufacturer.
These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for
meeting every possible contingency during operation, maintenance, or testing. Supplementary information may be available from JLG
Industries, Inc. or your local authorized servicing entity.
WARNING
Since the machine manufacturer has no direct control over the field inspection and
maintenance, safety in this area is the responsibility of the owner/user.
1.1.1 Disclaimer
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specific changes without prior notification.
Contact JLG Industries, Inc. for updated information.
Refer to www.JLG.com for Warranty, Product Registration, and other machine-related documentation.
1.1.2 Operation & Safety Manual

The machine must not be operated until the Operation & Safety manual has been read and understood, training has been accomplished,
and operation of the machine has been completed under the supervision of an experienced and qualified operator.
1.1.3 Do Not Operate Tags

Place Do Not Operate tags on the ignition key switch and the steering wheel/joystick before attempting to perform any service or
maintenance. Remove key and disconnect battery power.
1.2 SAFETY INFORMATION
The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are
generally those that apply when servicing electric, hydraulic, and larger machine component parts.
To avoid possible death or injury, carefully read, understand and comply with all safety messages on the machine and in the Service
Manual.
800S HC3, 860SJ HC3 31222415 11

Safety
1.2.1 Safety Alert System and Signal Words
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will re-
sult in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may re-
sult in minor or moderate injury.
1.3 SAFETY HAZARDS
WARNING
Failure to comply with safety precautions listed in this section could result in ma-
chine damage, personnel injury or death, and is a safety violation.
1.3.1 Personal Hazards

• Wear eye protection at all times during maintenance procedures.
• Wear all personal protective equipment necessary to perform the job safely.
• Remove all rings, watches, and jewelry when performing any maintenance.
• Do not wear unrestrained long hair or loose fitting clothing which could become caught on or entangled in equipment.
• Do not smoke while servicing the machine.
• Never refuel during electrical storms.
1.3.2 Equipment Hazards

• Unless required by the service activity, if the machine is supporting a load it should be removed prior to any maintenance being
conducted.
• Never work under an elevated boom or scissor stack until it has been safely restrained by blocking or overhead sling, or the safety
prop has been engaged.
• Be conscious of equipment weight. Do not move heavy parts without the aid of a mechanical device. Do not allow heavy objects to
rest in an unstable position. When raising or supporting a portion of the equipment, make sure an adequate lifting capacity device is
provided.
1.3.3 General Hazards

• Make sure the fuel cap is closed and secure during maintenance.
• Only use approved, nonflammable cleaning solvents.
• Keep oil, grease, water, etc. from all work areas, standing surfaces, and hand holds.
12 31222415 800S HC3, 860SJ HC3

Safety
• Keep all support equipment and attachments stowed in the proper location.
• Avoid pressure-washing electrical/electronic components. In the event pressure-washing the machine is needed, make sure the
machine is powered off before pressure-washing. If pressure-washing areas containing electrical/electronic components, it is
recommended a maximum pressure of 750 psi (52 bar) at a minimum distance of 12 in. (30.5 cm) away from these components. If
electrical/electronic components are sprayed, spraying must not be direct and spray for brief time periods to avoid heavy saturation.
• Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.
1.3.4 Operational Hazards
• Before making adjustments, lubricating, or performing any other maintenance, shut off all power controls. Never work on a machine
when the engine, cooling, or hydraulic systems are hot. Allow systems to cool before proceeding.
• Use only replacement parts or components which are approved by JLG. To be considered approved, the replacement parts or
components must be identical or equivalent to the original parts or components. Never alter, remove, or substitute any items such as
counterweights, tires, batteries, or other items that may reduce or affect the overall weight or stability of the machine.
• On certain hybrid/electric machines, the electrical system operates at high, potentially dangerous voltages. Do not attempt repairs
unless specific training has been completed.
• The fuel and hydraulic systems operate at extremely high, potentially dangerous pressures. Do not attempt repairs unless specific
training has been completed.
• Never check for leaks using any part of your body.
• Relieve all pressure before disconnecting any component, part, line or hose.
• Never remove the radiator cap while the cooling system is hot.
• Do not service the fuel or hydraulic systems near an open flame, sparks, or smoking materials.
• Disconnect batteries prior to replacing of electrical components and prior to servicing fuel or hydraulic systems.
• Do not charge a frozen battery. Allow the battery to thaw before jump-starting or connecting a battery charger.
• Lithium ion batteries should never be opened or tampered with.
1.4 SAFETY DECALS
Check that all safety decals are present and legible on the machine. Refer to the Operation & Safety Manual supplied with machine for
information.
1.5 MACHINE VERIFICATION
Verify the machine operates properly after all maintenance or services have been performed.
800S HC3, 860SJ HC3 31222415 13

14
SECTION 2
GENERAL MACHINE INFORMATION AND SPECIFICATIONS
2.1 SPECIFICATIONS
2.1.1 Machine Specifications

Maximum Work Load (Capacity)
All Markets
Unrestricted 500 lb (227 kg)
Restricted 750 lb (340 kg)
Restricted 1000 lb (454 kg)
Maximum Operating Slope 4°
Maximum Travel Grade (Gradeability)*
800S
2WD 25%
4WD 45%
860SJ
4WD 45%
Maximum Travel Grade (Side Slope)* 4°
Maximum Vertical Platform Height

800S 80 ft. (24.38 m)
860SJ 86 ft. (26.21 m)
Maximum Horizontal Platform Reach
800S 71 ft. 3 in. (21.72 m)
860SJ 74 ft. 8.9 in. (22.78 m)
Turning Radius- 2WS (800S/860SJ)
Outside 21.7 ft. (6.6 m)

Inside 14.77 ft. (4.5 m)
Max. Hydraulic System Pressure 4500 psi (310 Bar)
Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 400 N
Electrical System Voltage 12 Volts
Gross Machine Weight (Platform Empty)
800S 33,030 lb (14,982 kg)

860SJ 38,040 lb (17,255 kg)
* With boom in stowed position
800S HC3, 860SJ HC3 31222415 15

General Machine Information and Specifications
2.1.2 Machine Dimensional Data

Swing 360°
Tail Swing 4 ft. 8.14 in. (1.43 m)
Platforms 36 in. x 96 in. (0.91 m x 2.44 m)

Overall Width 8 ft. 1.52 in. (2.48 m)
Stowed Height 9 ft. 8.1 in. (2.95 m)
Stowed Length
800S 37 ft. 6 in. (11.43 m)
860SJ 40 ft. 0.4 in. (12.20 m)
Wheel base 10 ft. 0.9 in. (3.07 m)
Ground Clearance 11.1 in. (0.28 m)
Drive Speed 2WD and 4WD 3.6 mph (5.8 kmph)
Ground Bearing Pressure - 800S 72 psi (5.06 kgm/cm2)
Ground Bearing Pressure - 860SJ 81 psi (5.7 kgm/cm2)
Occupied Floor Area 107.17 ft.² (9.96 m2)
2.1.3 Engine Data

Table 1. Deutz D2011LO40 Specs
Fuel Diesel (10,000 ppm Max Sulfur Content)

Max Output (Power) 46 kW (61.6 hp) @ 2600 rpm
Max Output (Torque) 140 ft. lbs. (190 Nm) @ 1700 rpm
Oil Capacity 11 Quarts (10.5 L)
Low RPM 1000 ± 50 rpm

High RPM 2600 ± 50 rpm
Alternator 12 V, 55 Amp
Battery 950 Cold Cranking Amps,
205 Minutes Reserve Capacity, 12 VDC
Average Fuel Consumption

0.88 GPH (3.33 lph)
(may vary with application)
Table 2. Deutz TD 2.9 L4 T4F Specs
Fuel Ultra Low Sulfur Diesel (15 ppm)

Max Output (Power) 50 kW (67 hp) @ 2600 rpm
Oil Capacity 9.4 Quarts (8.9 L)
Cooling System Capacity 3.3 Gallon (12.5 L)
16 31222415 800S HC3, 860SJ HC3

Table 2. Deutz TD 2.9 L4 T4F Specs (continued)


1.06 GPH (4.0 LPH)
may vary with application)
Table 3. Ford 2.5L DF, MSG-425 Specs

Fuel Unleaded Gasoline: 87 -89 Octane
Ethanol/Gasoline Mix: 10% Ethanol max
Propane: HD-SLPG
Max Output (Power)
Gasoline 62 kW (84 hp) @ 3200 rpm
LP 59 kW (80 hp) @ 3200 rpm
Max Output (Torque)

Gasoline 142 ft. lbs. (192 Nm) @ 2400 RPM
LP 145 ft. lbs. (197 Nm) @ 2400 RPM
Oil Capacity 7 qt (6.6 L)
Coolant System Capacity 2 Gallon (7.5 L)

Alternator 12V, 150 Amp

Gasoline 0.99 GPH (3.74 LPH)

LP 0.68 GPH (2.57 LPH)
Table 4. Deutz TD2.9L4 Stage V Specs
Fuel Ultra Low Sulfur Diesel (15 ppm)

No. of Cylinders 4
Max Output (Power) 50 kW (67 hp) @ 2600 rpm

Displacement 177 cu. in. (2.9 L)

Oil Capacity 2.35 Gallons (8.9 L)
800S HC3, 860SJ HC3 31222415 17

Table 4. Deutz TD2.9L4 Stage V Specs (continued)

Cooling System 0.92 Gallons (3.5 L)

Average Fuel Consumption 1.32 GPH (5.0 lph)
Table 5. Deutz TD2.9L4 China III Specifications
Fuel China Low Sulfur Diesel (500 ppm)

No. of Cylinders 4
Output 50 kW (67 hp)

Torque 173 ft. lbs. (234 Nm) @ 1800 rpm
Displacement 177 cu. in. (2.9 L, 2900 cc)
Oil Capacity (Crankcase) 2.11 Gallon (8.0 L) w/Filter

Average Fuel Consumption 0.91 GPH (3.44 lph)
(May vary with applications)
Table 6. Deutz TD2.9L4 China IV Specifications

No. of Cylinders 4
Output 36 kW (48 hp)
Displacement 177 cu.in. (2.9 L)

Oil Capacity (Crankcase) 2.11 Gallons (8.0 L) w/Filter

Starter 12 V, 3.2 kW
Glow Plug 12 V, 80 Amp
18 31222415 800S HC3, 860SJ HC3

2.1.4 Tires
Size Type Ply Rating Load Range Pressure
15 - 625 Foam-Filled 16 H N/A
18 - 625 Foam-Filled 16 H N/A
41/18-22.5 Foam-Filled 14 - N/A
2.1.5 Critical Stability Weights
WARNING
Do not replace items critical to stability with items of different weight or specifica-
tion (for example: batteries, filled tires, platform). Do not modify unit in any way to
affect stability.
Component Pounds Kilograms
Turntable (bare) (860SJ) 3272 1484

Turntable (bare) (800S) 3302 1498
Counterweight (860SJ) 8750 3969
Counterweight (800S) 7000 3175
Upright 1127 511
Tower (860SJ) 697 316

Tower (800S) 489 222
Fly Boom (860SJ) 484 220
Fly Boom (800S) 488 221
Mid Boom (860SJ) 338 153

Mid Boom (800S) 726 330
Base Boom (860SJ) 1480 672
Base Boom (800S) 1497 680
Boom Assembly (860SJ) 3488 1582
Boom Assembly (800S) 3505 1590
Telescope Cylinder (860SJ) 589 267
Telescope Cylinder (800S) 606 275
Slave Cylinder (860SJ) 99 45
Slave Cylinder (800S) 63 29
Torque Hub 223 101
Tire & Wheel (FF) (15-625) 544 247

Tire & Wheel (FF) (18-625) 601 273
Lift Cylinder (860SJ) 620 281
Lift Cylinder (800S) 692 314
800S HC3, 860SJ HC3 31222415 19

Component Pounds Kilograms

Deutz TD2.9L 1433 650
Deutz D2011L04 983 445
Deutz TD 2.9L4 1511 686
Ford MSG425-DF 353 160
2.1.6 Torque Requirements

Torque Value
Description Interval Hours
(Dry)
Wheel Lugs 300 ft. lbs. 150
(407 Nm)
Swing Bearing Bolts 190 ft. lbs. 50/600*
(258 Nm)
Starter Solenoid
Contacts 95 in. lbs. (9.5 Nm)
Coil 40 in. lbs. (4 Nm) As required
*Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter (Refer to Section – Turntable Bearing Inspection, page 49).
Note: When maintenance becomes necessary or a fastener has loosened, refer to Section – Torque Chart, page 690 to determine proper torque value.
2.1.7 Pressure Settings
Telescope In 2600 psi (179 Bar)
Swing, Left & Right 1575 psi (109 Bar)

Steer 2500 psi (172 Bar)
Platform Level Up 2600 psi (179 Bar)
Platform Level Down 1800 psi (124 Bar)

Jib Down 1900 psi (131 Bar)
2.1.8 Battery
Voltage 12 Volt
Type 31-950
Cold Cranking Amps 950 CCA @ 0 °F (-18 °C)

Reserve Capacity 205 Minutes @ 80 °F (27 °C)
2.2 MACHINE TEMPERATURE CHART
Note: Service information not available at time of publication.
20 31222415 800S HC3, 860SJ HC3

2.3 SERIAL NUMBER LOCATION
Figure 1. Serial Number Location

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate is located
on the frame.
Note: The replacement of any part on this machine with any other than factory authorized replacement parts can adversely affect the
performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages,
whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.
A warranty registration form must be filled out by the local JLG distributor, signed by the purchaser, and returned to JLG when the
machine is sold and/or put into use.
Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty
service, verify the distributor has returned the business reply card of the warranty registration form to JLG.
2.4 FLUIDS AND LUBRICATION
NOTICE
Fuel represents a major portion of machine operating costs and therefore must be
used efficiently. Always use a premium brand of high quality, clean diesel fuel. Low
cost, inferior fuel can lead to poor performance and expensive engine repair.
2.4.1 General Information

1. The primary enemy of a hydraulic system is contamination. Contaminants can enter the system by using inadequate hydraulic oil;
allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance; or allowing the pump to
cavitate due to insufficient system warm-up or leaks in pump supply (suction) lines.
2. Design and manufacturing tolerances of component working parts are very close. The smallest amount of dirt or other
contamination entering a system can cause wear or damage to components and faulty operation. Take every precaution to keep
hydraulic oil clean - including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as
necessary, at the specified intervals required in the Section – Preventive Maintenance and Inspection Schedules, page 38. Always
examine filters for evidence of metal particles.
3. Cloudy oils indicate high moisture content which permits organic growth and causes oxidation or corrosion. If this condition
occurs, the system must be drained, flushed, and refilled with clean oil.
800S HC3, 860SJ HC3 31222415 21

4. It is not advisable to mix oils of different brands or types. They may not contain required additives or be of comparable viscosities.
Good grade mineral oils, with viscosities suited to ambient temperatures in which the machine is operating, are recommended for
use.
Note: Metal particles may appear in oil or filters of new machines due to wear-in of meshing components.
2.4.2 Hydraulic Oil
Hydraulic System S.A.E. Viscosity
Operating Temperature Range Grade

+0 °F to + 180 °F (-18 °C to +83 °C) 10W
+0 °F to + 210 °F (-18 °C to +99 °C) 10W-20, 10W-30
+50 °F to + 210 °F (+10 °C to +99 °C) 20W-20
Note: Refer to Section – Fluids, page 22 for recommended fluid type and classifications.
Note: Hydraulic oils require anti-wear qualities of at least API Service Classification GL-3, and sufficient chemical stability for mobile hy-
draulic system service.
Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types. They may not contain required addi-
tives or be of comparable viscosities.
Note: When temperatures remain consistently below 20 °F (-7 °C), JLG Industries recommends the use of Premium Hydraulic Fluid.
2.4.3 Changing Hydraulic Oil

1. Filter elements must be changed as instructed in Section – Preventive Maintenance and Inspection Schedules, page 38. If it is
necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to
obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent.
Avoid mixing petroleum and synthetic base oils.
2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to
clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge
any time the system oil is changed.
3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic
components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.
2.4.4 Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multipurpose greases
usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of
greases in maintenance stock, consult your local supplier for evaluation. Refer to Section – Preventive Maintenance and Inspection
Schedules, page 38 for the components and assemblies requiring lubrication.
2.4.5 Fluids
Compartment or System Type and Classification Viscosities Ambient Temperature Range
°F °C
Min. Max. Min. Max.
API Classification: CK-4 and CK-4/CJ-4
Deutz Specification: DQC 11-10 LA and DQC 111-10 LA
Engine Crankcase SAE 15W-40 15 120 -9 49
Recommended: Shell Rotella T3 Fleet (US) and Rimula R4 L
(CE/UKCA)
22 31222415 800S HC3, 860SJ HC3

Compartment or System Type and Classification Viscosities Ambient Temperature Range

°F °C
Min. Max. Min. Max.
Optional: Mobil Delvac 1300 Super (US), Delvac MX ESP (CE/
UKCA)
API Classification: CK-4
Deutz Specification: DQC IV-18 LA SAE 5W-40 -20 120 -29 49
Recommended: Mobil Delvac I ESP (US)
API Classification: SN PLUS
Ford Specification: WSS-M2C946-A, WSS-M2C929-A SAE 5W-30 -40 120 -40 49
Recommended: Formula Shell (US)
API Classification: GL-4 and GL-5
Drive Hub Recommended: Shell Spirax S4 AX SAE 80W-90 -4 115 -20 46
Optional: Mobil Mobilube GX
Recommended: ISO Viscosity Grade Viscosity Index
Shell Spirax S4 TXM 68 146

Shell Tellus S2 VX 32 32 142
Shell Tellus S4 VX 32 32 296/258
Shell Naturelle HF - E46 46 193
Ucon Hydrolube HP - 5046D 46 192
Hydraulic System
Optional: ISO Viscosity Grade Viscosity Index
Mobilfluid 424 68 134

Premium Hydraulic Fluid 32 161
Mobil DTE 10 Excel 32 32 161
Univis HVI 26 26 352/304
Mobil EAL Envirosyn H46 46 147
NLGI Grade 2 EP
or
Grease Fittings Extreme Pressure Grease 5 155 -15 46
NLGI Grade 3 EP
with Moly Additive
50% Ethylene Glycol

Standard
50% Water
Engine Coolant Ethylene Glycol and Water
60% Ethylene Glycol
Cold Weather
40% Water
EN 590
Fuel ASTM D 975 Grade 2-D Ultra Low Sulfur Diesel (15 ppm)
Deutz 0199-99-01218/2 (Maximum 5% Biodiesel)
800S HC3, 860SJ HC3 31222415 23

2.4.6 Capacities
Fuel Tank (Diesel)
Approx. 31 gallons (117.3 L)
Fuel Tank (Optional) (Gas)
Drive Hub 58 ounces (1.7 L)
Hydraulic Tank (to Full Line on Sight Gauge) Approx. 48 gallons (181.7 L)
Engine Oil Capacity

Deutz D2011L04 11 Quarts (10.5 L)
Deutz TD 2.9L4 9.4 Quarts (8.9 L)
Ford MSG425-DF 7 Quarts (6.6 L)
2.4.7 Lubrication Schedule

Note: Refer to Section – Preventive Maintenance and Inspection Schedules, page 38.
2.5 MACHINE CHARACTERISTICS
2.5.1 Ground Control Keyswitch System

The ground control keyswitch is used for selecting the active control of the machine between the platform or ground control stations
and as another shut off switch for machine power.
The key is removable only in the off position, which allows the ground control station to have ultimate priority over the platform control.
2.5.2 Platform Control Enable System

The platform controls make use of a time dependent enable circuit to limit the time availability of "live" or enabled controls.
To operate any directional function, the footswitch must be depressed before activation of the function. When the footswitch is
depressed, the controls are enabled, and the operator has 7 seconds to operate any function.
The controls will remain enabled as long as the operator continues to use any function and will remain enabled 7 seconds after the last
function has been used. While the controls are "live", the enabled light will be illuminated in the platform display panel.
When the time limit has been reached, the enabled light will turn off and the controls will be disabled.
To continue use of the machine the controls must be re-enabled to start the timer system over again. Do this by releasing all functions,
then releasing and re-depressing the footswitch. Releasing the foot switch during function commands will stop the function movement.
2.5.3 Main Boom End of Stroke Damping

When main boom lift is activated, end of stroke damping is achieved through the electronic control system. This system slows the main
boom speed within the last 5 degree before minimum and maximum main boom elevations. This reduction in speed occurs only while
approaching the end of stroke limits. Speeds in the opposite direction are not altered.
2.5.4 Diesel Particulate Filter (If Equipped)

Note:
• If machine is equipped with digital display (1) follow below procedure for standstill cleaning.
• If machine is equipped with mechanical hour meter (2) use JLG analyzer to perform standstill cleaning.
24 31222415 800S HC3, 860SJ HC3

1 2
BM111454A
Diesel Particulate Filter (DPF) is an emissions control system used in diesel engines and requires operator interaction to make sure
proper operation of the system.
For peak operation, the DPF system must be cleaned using one of two methods, Standstill Cleaning and Maintenance Standstill
Cleaning. Standstill Cleaning is any cleaning requested by the engine outside of the regular maintenance window (for example, if the
system detects excessive soot in the DPF canister). Maintenance Standstill Cleaning is cleaning requested by the engine on the regular
maintenance interval.
Note: The system will reset the maintenance interval back to zero hours after Standstill or Maintenance Standstill Cleaning events are
performed.
Table 7. DPF Operational Indicators
Indicator / Switch Meaning / Use Platform Control LED Module Ground Control LED Module Ground Control LCD
The DPF Time Since Last Regen

Regen Required Clock, or Soot Loading, is calling -
for a Standstill Regeneration. BM100272A BM100272A
The engine is producing High

Emission Temperature - -
Exhaust System Temperatures.
BM100273A
The DPF Ash Loading has

Ash Overload reached levels that require DPF - - DPF Filter Exchange
Replacement.
BM100274A
The Engine's monitoring systems

have detected an issue requiring
Engine Distress service. Fault Fault Codes
Codes will be displayed on the BM100271A BM100271A
LCD.
The Emission Controls'
monitoring systems have
Emission System Malfunction detected an issue requiring - Fault Codes
service. Fault Codes will be BM100272A
displayed on the LCD.
Actuated by the Operator to

Standstill Regen Initiation initiate a Standstill - -
Switch Regeneration. BM100272A
Standstill Cleaning
The following conditions must be met to perform Standstill Cleaning.
• Machine must be stationary.
• Boom in the stowed position.
800S HC3, 860SJ HC3 31222415 25

• No personnel in platform.
• Engine must be idling.
• Coolant temperature must be above 104°F (40°C).
• Machine in Ground Station mode.
1. The Diesel Particulate Filter (DPF) Indicator on the Platform Control Panel will flash when standstill cleaning is required.
2. Move the machine to an suitable area free of flammables and personnel that could be exposed to hot exhaust.
3. Launch the cleaning process by pressing the DPF button on the Ground Console for 3 seconds. The Indicator Gauge will display
the following screen.
4. The Main Cleaning process will begin and last for approximately 30 to 60 minutes. The following screen will show that the process
has begun and includes a status bar that indicates the progress of the cleaning process.
26 31222415 800S HC3, 860SJ HC3

5. After the cleaning process is complete, the engine will run for approximately 5 minutes to allow the Engine and Exhaust After
Treatment (EAT) to cool down. The Indicator Gauge will display the “Regen Complete” screen as shown and the Emissions
Temperature indicator will no longer be illuminated.
Maintenance Standstill Cleaning Initiation Methods

Maintenance Standstill Cleaning can be started by one of two methods, by using the Analyzer or the DPF button on the Ground Console.
All the same conditions as outlined under Standstill Cleaning must be met.
Canceling Maintenance Standstill
Maintenance Standstill Cleaning will be stopped immediately if:
• The Platform/Ground Select switch is switched from Ground to Platform mode.
• Any function switch is enabled to perform a boom function.
• The Engine is powered down.
If Maintenance Standstill Cleaning is interrupted, it must be reinitiated and the Indicator Gauge will display the “Regen Failed” screen as
shown.
BM100265A
Unsuccessful Cleaning Event

If there is an unsuccessful cleaning event, the DPF icon will show on the display gauge. Possible causes of an Unsuccessful Cleaning
Event are:
• Engine is not warmed up.
• DEF tank is frozen.
• Machine functions operated during cleaning event in progress.
• Other engine faults are active.
The Gauge will display “Regen Failed” screen as shown. If the cleaning event has failed, the process must be repeated.
800S HC3, 860SJ HC3 31222415 27

BM100266A
DPF Filter Replacement due to Ash Load

The DPF collects non-burnable particulates which cannot be removed by the Standstill Cleaning process. Build up of the ash load
requires filter maintenance and/or exchange. DPF filter maintenance or exchange requirement is indicated by the DPF Exchange icon
shown on the display gauge.
Table 8. Maintenance Standstill Cleaning

Machine Hours DPF Regenera- Emissions
Standstill Cleaning Levels Since Last Engine Error
tion Initiation DPF Indicator Temperature Derate Comments
Cleaning Indicator
Methods Indicator*
Serdia Tool Between 500
(Level 2) + and 650 hours,
0–500 (Switch in JLG cleaning cycle
machine or JLG can be initiated
Analyzer) with a JLG
analyzer or
Switch in
machine.
Normal
0 - - None (Deutz ECM will
Operation
BM100272A
generate DPF
Switch in JLG cleaning
500–650 Machine OR JLG required lamp
Analyzer at 500 hours.
JLG will mask
this lamp until
500–650 650
hours.)
Exhaust gas
temperature will
Switch in JLG be around 600°C
Standstill
1 650–750 Machine OR JLG - None during standstill
Required
Analyzer BM100272A BM100273A
DPF
regeneration
.
Switch in JLG Continuous
Derating Step 1 Machine placed
Machine OR JLG
2 Warning Level 750–775 (25% Power in Creep and
Analyzer
BM100272A BM100273A
derate) DTC active
BM100271A
28 31222415 800S HC3, 860SJ HC3

Table 8. Maintenance Standstill Cleaning (continued)

Machine Hours DPF Regenera- Emissions
Standstill Cleaning Levels Since Last Engine Error
tion Initiation DPF Indicator Temperature Derate Comments
Cleaning Indicator
Methods Indicator*
Must have Ser-
dia Level 3
access Blinking Idle Lock. Boom
Functions
+ Derating Step 2
3 Shut Off Level >775 Locked Out and
(Idle Lock)
trapped in
Switch in JLG BM100271A
BM100272A BM100273A
Transport.
machine or JLG
analyzer)
Blinking Idle Lock. Boom

Functions
DPF Regeneration NOT POSSIBLE Derating Step 2
4 Filter Exchange Locked Out and
DPF Filter exchange required (Idle Lock
BM100272A BM100273A
trapped in
BM100271A
Transport.
*Emissions Temperature indicator continuously ON during Standstill Cleaning
Table 9. Standstill Cleaning: DPF Filled with Soot

HEST Lamp
DPF (Possible),
Time in Heat Regenera Check DPF Cleaning Continuously
Standstill Escalation Steps Soot Load Mode tion Derate Comments
Engine Lamp Lamp on during
(Hours) Initiation standstill
Methods cleaning
Normal
0 <70% -
Operation
If soot load
reaches 56%
in 50 hours of
Heat Mode 1,
1 Heat Mode 1 71% to 85% 50 System will
automatically
take it to
normal
- - - None operation.
BM100272A
If soot load
reaches 56%
in 250 hours
of Heat Mode
2 Heat Mode 2 86% to 100% 250 2, System will
automatically
take it to
normal
operation.
Will remain in
0.5 Hz Standstill
Switch in JLG
Standstill 101% to mode for 100
3 100 Machine or - None
Required 115% hours or until
JLG Analyzer
BM100272A
BM100273A
the soot load

reaches 115%.
Continuous 0.5 Hz Will remain in
Switch in JLG Derating Step
Warning Level 116% to Machine or Warning level
4 25 1 (25% Power
130% JLG Analyzer (Derate) for
derate)
BM100271A BM100272A
BM100273A
25 hours or
800S HC3, 860SJ HC3 31222415 29

Table 9. Standstill Cleaning: DPF Filled with Soot (continued)

HEST Lamp
DPF (Possible),
Time in Heat Regenera Check DPF Cleaning Continuously
Standstill Escalation Steps Soot Load Mode tion Derate Comments
Engine Lamp Lamp on during
(Hours) Initiation standstill
Methods cleaning
until the soot

load reaches
130%.
Machine
placed in
Creep and DTC
active.
Must have Idle Lock.
Serdia Level 3 Blinking 3 Hz Boom
131% to access + Derating Step Functions
5 Shut Off Level (switch in JLG Locked Out
145% 2 (Idle Lock)
machine or BM100271A
BM100272A
BM100273A
and Trapped
JLG Analyzer) in Transport.
DPF Idle Lock.
Regeneration Blinking 3 Hz Boom
Filter NOT POSSIBLE. Derating Step Functions
6 Exchange >145% DPF Filter Locked Out
2 (Idle Lock)
exchange BM100271A
BM100272A
BM100273A
and Trapped
required. in Transport.
*Emissions Temperature indicator continuously ON during Standstill Cleaning
Ash Load
• During the lifetime of the EAT system the DPF collects also particulates that cannot be removed by regeneration process. All non‐
burnable particles stored in the filter are here summarized as ash load. This ash load leads to shortened regeneration intervals and
finally a filter maintenance or exchange is required.
• When 100'% of the rated ash load is reached, a filter exchange is required. The maintenance request is indicated by the ash lamp
(solid on) and/or by the respective CAN‐message.
• In case of continuously ignored maintenance requests the available filter volume is reduced and the need for standstill regenerations
becomes more probable.
• Therefore, at higher ash loads an error paths is set and engine protection functionalities are activated. At this state the ash lamp is
flashing with 1 Hz.
• After exchanging the filter, the soot and ash load stored in the ECU must be reset with the Service Tool (SERDIA).
Table 10. Ash Load DPF Filter Replacement
AT1S DPF Test Monitor DM1 Byte 1.3‐6 System reaction
Ash Load Byte 2 Byte 3.3‐4 Ash Lamp Warning Lamp EU and EPA
[%] Symbol
xx0000xx
Normal Operation <100% 00 Off - No Derating
-
xx0000xx
Filter Exchange Required ≥100% 01 On No Derating
-
30 31222415 800S HC3, 860SJ HC3

Table 10. Ash Load DPF Filter Replacement (continued)
AT1S DPF Test Monitor DM1 Byte 1.3‐6 System reaction
Ash Load Byte 2 Byte 3.3‐4 Ash Lamp Warning Lamp EU and EPA
[%] Symbol
DPF Filter Exchange

-
BM100274A
Blinking xx0000xx
Warning Level ≥105% 10 - No Derating

DPF Filter Exchange
BM100274A
-
xx0000xx
Blinking On
Continuous Derating
Warning Level ≥110% 11 DPF Filter Exchange
Step 1 Active.
BM100274A
BM100275A
2.5.5 Drive System

The four-wheel drive system consists of one variable displacement closed loop pump, four variable displacement piston motors, gear
reduction hubs, and a traction control manifold that includes three flow dividers/combiners.
Drive speed is varied by a combination of drive pump displacement, engine speed, and motor displacement. Traction control is full time
and is present in all drive modes. There are three drive modes that can be selected at the platform console.
The functionality of the drive system is dependent on the position of the boom (In Transport or Out of Transport), using the Section —
Beyond Transport — Drive Speed Cutback System, page 33.
The following chart describes how the system works in each drive mode. Actual RPM may vary according to selected engine. See
commanded engine RPM for specific Engine Speed value.
Table 11. Drive Mode Speeds

Drive Selection (Toggle Switch Location on the Platform Engine Speed when Drive
Boom Position Approx. Max. Speed (MPH)
Console) Control is Activated
Max Speed High – 2600 RPM 3.6
In Transport Mid-Engine Mid – 1800 RPM 0.9
Max Torque High – 2600 RPM 1.3
Max Speed High – 2600 RPM 0.74
Out of Transport Mid-Engine Mid – 1800 RPM 0.74
Max Torque High – 2600 RPM 0.74
800S HC3, 860SJ HC3 31222415 31

2.5.6 Drive Orientation System

This is intended to indicate to the operator conditions that could make the direction of movement of the chassis different than the
direction of movement of the drive/steer control handle.
The system indicates to the operator the need to match the black and white directional arrows on the platform control panel to the
arrows on the chassis. The system uses a proximity switch mounted on the hydraulic swivel, an indicator light and a spring return
override switch on the platform display panel. The proximity switch trips when the turntable is swing +/- 45 degrees off center of the
normal driving position. This occurs roughly when the main boom is swing past a rear tire.
When the turntable is in the normal drive position with the boom between the rear tires, no indications or interlocks are made. When
the machine is actively driving when the turntable is swing past the switch point, the system is ignored until drive/steer is released.
When drive is initiated with the boom swing past the switch point, the DOS indicator will flash, and the drive/steer functions will be
disabled. The operator must engage the DOS override switch to enable Drive/steer (high drive will remain disabled).
When the DOS is enabled, the DOS indicator will be illuminated continuously, and a 3 second enable timer will be started and will
continue for 3 seconds after the end of the last drive/steer command. If the timer expires, the DOS override switch must be re-engaged
to enable drive/steer.
2.5.7 Function Speed Control System

The platform controls for the jib, lift, and main telescope functions are controlled through a common variable speed control knob.
This knob feeds the valve driver of each control circuit allowing a smooth ramp up, controlled maximum output speed, and ramp down.
Each function has its own personality settings allowing the characteristics of each function to be modified using the standard analyzer.
Not all functions will respond the same to the changes in the function speed knob position.
The variable speed control knob when turned counterclockwise and into the detent position (shown with a snail on the control panel
decal), will place all functions, including proportional functions, in creep.
2.5.8 Oscillating Axle System

The oscillating front axle is attached to the frame by a pivot pin, which allows all four wheels to remain on the ground when traveling on
rough terrain.
The oscillating axle also incorporates two lockout cylinders connected between the frame and the axle. The lockout cylinders permit axle
oscillation when the main boom is in transport position as described in the Section — Transport Position Sensing System, page 33 and
when the boom is oriented between the rear tires as described in the Section — Drive Orientation System, page 32.
2.5.9 Chassis Tilt Indicator System

The Chassis Tilt Indicator System measures the turntable angle with respect to ground level. The control system compares the reading to
a preset turntable tilt angle value.
When machine is in transport position, it can travel at up to maximum speed until it tilts more than 8 degree, then the system will limit
the drive speed to maximum displacement mode (slow drive speed).
When machine is out of transport position and the turntable tilts more than the preset value, the boom functions can only operate in
creep speed mode and the drive function is disabled. The operator must return the machine into transport mode in order to continue
drive the machine.
Default tilt sensor preset value is 4 degree, but it can be selected between 4 degree and 3 degree by JLG hand held analyzer.
2.5.10 Platform Load Sensing System

The Platform Load Sensing System consists of a single load cell mounted within the platform support. This system provides the platform
load to the Dual Capacity System or the Triple Capacity System. The control system will light the applicable capacity light in both the
platform control box and the ground control station based on the value observed by the LSS system.
When there is a fault in the system, the platform and ground overload indicator will flash, the platform alarm will sound at the rate of 5
sec on / 2 sec off and all platform function controls (except auxiliary power) will be disabled. The ground controls are unaffected unless
configured otherwise in the machine setup selection.
If the LSS system senses an overload condition, boom functions will be disabled, the overload alarm will sound at the platform. If power
is cycled under this condition, the machine will only allow the boom telescope function to retract and will only allow the boom lift
function to lift up, since these actions will bring the platform towards a condition improved stability.
32 31222415 800S HC3, 860SJ HC3

2.5.11 Transport Position Sensing System

The transport position sensing system consists of a boom angle sensor (this sensor is a hall effect sensor) mounted at the pivot point
between the main boom and upright and two proximity switches mounted at the bottom of the base boom.
The system uses these sensor/switches in combination to sense if the boom is in the position associated with high speed travel. The
control circuit reads two redundant angular sensor signals from the boom angle sensor.
Above transport angle is recognized when one angular sensor signal from the boom angle sensor reads more than 12 degree greater
than horizontal (with respect to the turntable), and resets to within transport position when both angular sensor signals read less than 2
degree greater than horizontal (with respect to the turntable).
Transport length is recognized when any one of two length switches reads more than 18 in. extension of fly boom.
During failures of either of two length switches, the system will sense a disagreement. It will presume the boom is extended out past the
limit. The position of the articulated jib is not considered.
This system is used to control the following systems:
1. Beyond Transport Position - Drive Speed Cutback System
2. Drive/Steer - Boom Function Interlock System
3. Oscillating Axle System.
2.5.12 Beyond Transport - Drive Speed Cutback System

When the boom is positioned beyond the transport position as described in Section — Transport Position Sensing System, page 33, the
drive motors are automatically restricted to their maximum displacement position (slow speed).
Refer the Section — Chassis Tilt Indicator System, page 32 for interaction with the tilt sensor.
2.5.13 Drive/Steer - Boom Function Interlock System

The Drive/Steer - Boom Function Interlock System uses the Section — Transport Position Sensing System, page 33 to sense when the
boom is out of the transport position. All controls are simultaneously functional when the booms are within the transport position as on
the standard machine.
When the boom is beyond the transport position, the control functions are interlocked to prevent simultaneous operation of any boom
function with drive/steer. The first function set to be operated while in this mode, becomes the master function set. In other words,
while operating drive/steer functions the boom functions are disable. Similarly, while operating boom functions drive/steer.
2.5.14 Machine Safety System Override (CE/UKCA only)

The MSSO (Machine Safety System Override) is fitted to the ground console and is standard only for the CE/UKCA market.
The MSSO is only used to retrieve an operator who is pinned, trapped, or unable to operate the machine from the platform controls and
function controls are locked out from platform due to a platform overload situation.
Platform overload fault is logged like any other fault, it remains active and is displayed until it is removed using the JLG Analyzer. No
functional checks of the MSSO system are necessary. The JLG control system will set a Diagnostic Code if the MSSO enable switch is
faulty.
2.6 CLEARSKY SMART FLEET™ (IF EQUIPPED)
2.6.1 General
ClearSky Smart Fleet™ integrates on-machine hardware (CS550) and app or web-based software to provide data, tools and analytics to
aid in asset and fleet management. Personnel with the appropriate permissions can access these features using the ClearSky Smart Fleet
web portal or the ClearSky Smart Fleet mobile app. Features include telematics data reporting (such as fuel level and battery charge),
remote troubleshooting tools (including diagnostic trouble codes or system alerts), and access control (if available) restrictions.
800S HC3, 860SJ HC3 31222415 33

Figure 2. CS550 (LED Motion / Amber Beacon)
2.6.2 ClearSky Smart Fleet™ — Access Control

This machine may be equipped with ClearSky Smart Fleet™ Access Control. Using the ClearSky Smart Fleet mobile app or web portal
(remotely or locally), the machine can be placed into restricted states that limit machine functionality for all operators. Only authorized
personnel can make changes from within the web portal or app.
WARNING
Before placing the machine into a restricted state ensure the machine can be safely
locked out or function speeds reduced. This includes verifying that it is the correct
machine, the machine is not in use, and there are no personnel in the work plat-
form. JLG Industries, Inc. assumes no responsibility or liability for any and all inci-
dents involving personal injury, property damage, or equipment damage that may
occur from the improper utilization of JLG products.
Restricted states may include:
1. Speed Restricted — Machine is in Creep mode. See Operation & Safety Manual for more information on machine mode.
2. Speed and Function Restricted — Machine is in Creep mode and boom movement is restricted to transport position. In this state,
once the boom reaches the transport position, it is not permitted to leave that defined position.
3. Locked Out — Machine has been locked out and will not operate (including engine start and auxiliary power, if applicable).
CAUTION
The Locked Out state will override the machine capability to use auxiliary power.
NOTICE
The Access Control function has the capability to place the machine into a restricted
state remotely. Account for Access Control functionality, including restricted states,
in a safe use plan.
Note: Restricted functionality may occur if the CS550 (ClearSky® LED Motion / Amber Beacon) is damaged or removed. A protective
cage is available through JLG.
Machines equipped with ClearSky Smart Fleet Access Control are also equipped with the ClearSky CS550.
34 31222415 800S HC3, 860SJ HC3

SECTION 3
MAINTENANCE AND INSPECTION SCHEDULES
3.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
3.1.1 General
This section provides the necessary information needed by those personnel that are responsible to place the machine in operation
readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary
inspections and maintenance have been completed before placing the machine into service. With proper care, maintenance, and
inspections performed per JLG's recommendations, and with any and all discrepancies corrected, this product will be fit for continued
use.
3.1.2 Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table
outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or
local regulations for further requirements. The frequency of inspections and maintenance must be increased as environment, severity
and frequency of usage requires.
3.1.3 Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use daily or at each change
of operator. Reference the Operation and Safety Manual for completion procedures for the Pre-Start Inspection. The Operation and
Safety Manual must be read in its entirety and understood prior to performing the Pre-Start Inspection.
3.1.4 Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc.
recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive
knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject
JLG product model.
The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-
Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for
each machine in service for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventive Maintenance Schedule for items
requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and
maintenance procedures.
3.1.5 Annual Machine Inspection

The Annual Machine Inspection must be performed on an annual basis, no later than thirteen (13) months from the date of the prior
Annual Machine Inspection. JLG Industries recommends this task be performed by a Factory-Trained Service Technician. JLG Industries,
Inc. recognizes a Factory-Trained Service Technician as a person who has successfully completed the JLG Service Training School for the
subject JLG product model. Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for
performance of this inspection.
Reference the JLG Annual Machine Inspection Form and the Inspection and Preventive Maintenance Schedule for items requiring
inspection during the performance of this inspection. Reference the appropriate areas of this manual for servicing and maintenance
procedures.
For the purpose of receiving safety-related bulletins, it is important that JLG Industries, Inc. has updated ownership information for each
machine. When performing each Annual Machine Inspection, notify JLG Industries, Inc. of the current machine ownership.
800S HC3, 860SJ HC3 31222415 35

Maintenance and Inspection Schedules
3.1.6 Preventive Maintenance

In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries,
Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive
JLG product model.
Reference the Preventive Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures.
The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.
Table 12. Inspection and Maintenance

Type Frequency Primary Responsibility Service Qualification Reference
Prior to use each day; or At

Pre-Start Inspection User or Operator User or Operator Operation and Safety Manual
each Operator change.
Service and Maintenance

Prior to each sale, lease, or
Pre-Delivery Inspection Owner, Dealer, or User Qualified JLG Mechanic Manual and applicable JLG
rental delivery.
inspection form.
In service for 3 months or 150

hours, whichever comes first; or Service and Maintenance
Frequent Inspection Out of service for a period of Owner, Dealer, or User Qualified JLG Mechanic Manual and applicable JLG
more than 3 months; or inspection form.
purchased used.
Annually, no later than 13 Service and Maintenance
Factory-Trained Service
Annual Machine Inspection months from the date of the Owner, Dealer, or User Manual and applicable JLG
Technician (Recommended)
prior inspection. inspection form.
At intervals as specified in the

Owner, Dealer, or User Service and Maintenance
Preventive Maintenance Service and Maintenance Qualified JLG Mechanic
Manual
Manual.
3.2 SERVICE AND GUIDELINES
3.2.1 General
The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this
manual.
3.2.2 Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of
weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable
position. When raising a portion of the equipment, ensure that adequate support is provided.
3.2.3 Cleanliness
The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital
components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and
oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.
At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a
line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.
Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts
to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready
to be used.
3.2.4 Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be
parallel to each other and as near perpendicular as possible to top of part being lifted.
36 31222415 800S HC3, 860SJ HC3

2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket
lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.
3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent
parts are interfering.
3.2.5 Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or
assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any
adjustments, other than those recommended, without obtaining proper approval.
3.2.6 Pressure-Fit Parts

When assembling pressure-fit parts, use a molybdenum disulfide base compound or equivalent to lubricate the mating surface.
3.2.7 Bearings
1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to
drip dry. Compressed air can be used but do not spin the bearing.
2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.
3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new
bearings until they are ready to install.
4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to
the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.
3.2.8 Gaskets
Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket
material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious
system damage.
3.2.9 Bolt Usage and Torque Application

Note: Self locking fasteners, such as nylon insert and thread deforming locknuts, are not intended to be reinstalled after removal.
1. Always use new replacement hardware when installing locking fasteners. Use bolts of proper length. A bolt which is too long will
bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and
hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is
equivalent.
2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs,
and steel nuts, in accordance with recommended shop practices. Refer to Section – Torque Charts, page 690.
3.2.10 Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit.
This will assure that they are correctly reinstalled.
3.2.11 Hydraulic System

1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.
2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate
components, as required, to aid assembly.
3.2.12 Lubrication
Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals.
800S HC3, 860SJ HC3 31222415 37

3.2.13 Battery
Clean battery using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry
battery and coat terminals with an anti corrosion compound.
3.2.14 Welding on JLG Equipment

Note: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on an external
structure, or component.
Do the Following When Welding on JLG Equipment
• Disconnect the battery.
• Disconnect the moment pin connection (if applicable).
• Ground only to structure being welded.
Do Not Do the Following When Welding on JLG Equipment
• Do NOT ground on frame and weld on any other area than chassis.
• Do NOT ground on turntable and weld on any other area than turntable.
• Do NOT ground on platform/support and weld on any other area than platform/support.
• Do NOT ground on a specific boom section and weld on any other area than that specific boom section.
• Do NOT allow pins, wear pads, wire ropes, bearings, gearing, seals, valves, electrical wiring, or hoses to be between grounding
position and welded area.
CAUTION
Failure to comply with the above requirements may result in component damage (i.
e. Electronic modules, swing bearing, collector ring, boom wire ropes etc.).
3.3 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE
In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries,
Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive
JLG product model.
Reference the Preventive Maintenance and Inspection Schedules and the appropriate areas of this service manual and/or operation and
safety manual for servicing and maintenance procedures. The frequency of service and maintenance must be increased as environment,
severity and frequency of usage requires.
Note: If hour and year intervals are listed, perform maintenance at interval which occurs first.
Table 13. Inspection and Preventive Maintenance Schedule

Inspection
AREA Pre-Delivery1 or Frequent2 (Quar-
Annual3 (Yearly) Inspection
terly) Inspection
Boom Assembly
Hose/Cable Carrier Installations 1, 2 1, 2

Hose/Cable Carrier Installations 1, 2 1, 2
Sheaves, Sheave Pins 1, 2 1, 2
38 31222415 800S HC3, 860SJ HC3

Table 13. Inspection and Preventive Maintenance Schedule (continued)

Inspection
terly) Inspection
Bearings 1, 2 1, 2
Wear Pads 1, 2 1, 2
Covers or Shields 1, 2 1, 2
Extend/Retract Chain or Cable Systems4 1, 2 1, 2
Platform Assembly
Railing 2 2
Gate 1, 2, 3 1, 2, 3
Floor 2 2
Rotator 1, 2, 3, 4 1, 2, 3, 4
Lanyard Anchorage Point 1, 2, 6 1, 2, 6
Turntable Assembly
Swing Bearing or Worm Gear 150, 2 150, 2
Oil Coupling 4 4
Swing Drive System 1, 4 1, 4
Turntable Lock 1, 2, 3 1, 2, 3
Hood, Hood Props, Hood Latches 3 3
Chassis Assembly
Tires 1, 2 1, 2
Wheel Nuts/Bolts 150 150
Wheel Bearings 1, 2, 4, 5 1, 2, 4, 5
Oscillating Axle/Lockout Cylinder Systems 1, 2, 4, 5 1, 2, 4, 5
Steer Components 1, 2 1, 2
Spindle Thrust Bearing/Washers 1, 2 1, 2
Drive Hubs 1, 4 1, 4
Functions/Controls
Platform Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9
Platform Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9
Function Control Locks, Guards, or Detents 1, 3, 9 1, 3, 9
Footswitch (shuts off function when released) 1, 3, 9 1, 3, 9
Function Limit or Cutout Switch Systems 1, 3, 9 1, 3, 9
Capacity Indicator 1, 3, 9 1, 3, 9
Drive Brakes 1, 3, 9 1, 3, 9
Swing Brakes 1, 3, 9 1, 3, 9
800S HC3, 860SJ HC3 31222415 39


Inspection
terly) Inspection
Auxiliary Power 1, 3, 9 1, 3, 9
Load Sensing System (LSS) 3, 9 3, 9
Power System
Engine Idle, Throttle, and RPM 1, 3, 7 1, 3, 7
Engine Fluids: Oil 4 4
Engine Fluids: Coolant 1, 4, 7 1, 4, 7
Air Filter 1, 4 1, 4
Fuel Filter(s) 1, 5 1, 5
Drain Oil Build Up in 2-Stage Vaporizer (LP Only) 1, 4 1, 4
Exhaust System 1, 4 1, 4
Batteries 1, 4 1, 4
Battery Fluid 4 4
Battery Charger 1, 3 1, 3
Intake System 1, 2 1, 2
Glow Plug (Diesel Only) 1, 2, 3 1, 2, 3
Serpentine Belt, Tensioner, Pulleys 1, 2, 3 1, 2, 3
Fuel Reservoir, Cap, and Breather 1, 2, 4 1, 2, 4
Hydraulic/Electric System
Hydraulic/Electric System 1, 2, 4 1, 2, 4
Hydraulic Cylinders 1, 2, 4, 5 1, 2, 4, 5
Cylinder Attachment Pins and Pin Retainers 1, 2 1, 2
Hydraulic Hoses, Lines, and Fittings 1, 2, 4 3
Hydraulic Reservoir, Cap, and Breather 1, 2, 3, 4, 5 1, 2, 3, 4, 5
Hydraulic Filter(s) 1, 4, 5 1, 4, 5
Hydraulic Fluid 4, 5 4, 5
Electrical Connections 1, 2 1, 2
Instruments, Gauges, Switches, Lights, Horn 1, 3 1, 3
General
All Decals/Placards Installed, Secure, Legible 9 9
Annual Machine Inspection Due - 9
No Unauthorized Modifications or Additions 9 9

All Relevant Safety Publications Incorporated 9 9
40 31222415 800S HC3, 860SJ HC3


Inspection
terly) Inspection
General Structural Condition and Welds 2 2

All Fasteners, Pins, Shields, and Covers 1, 2 1, 2
Grease and Lubricate to Specifications 9 9
Function Test of All Systems 9 9
Paint and Appearance 5 5
Stamp Inspection Date on Frame - 9
Notify JLG of Machine Ownership - 9
Footnotes:
1 Prior to each sale, lease, or delivery
2 In service for 3 months; Out of service for 3 months or more; Purchased used
3 Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating body
4 Replace every 12 years or 7,000 hours
50 Indicates a 50 hour interval required to perform task after initial use of machine. This only occurs once in machine life
250 Indicates a 250 hour interval required to perform task after initial use of machine. This only occurs once in machine life
Performance Codes:
1 - Check for proper and secure: installation, adjustment, or torque
2 - Visual inspection for damage: (cracks, corrosion, abrasions, distortion, excessive wear, broken welds, gouges, chafing and threads showing)
3 - Proper operation
4 - Check for proper sealing, signs of leakage and fluid level
5 - Clean and free of debris

6 - Decals installed and legible
7 - Check for proper tolerances, routing, and lubrication
8 - Fully Charged
9 - Verify/Perform
Maintenance Schedules
Note: If hour and year intervals are listed, perform maintenance at interval that occurs first.
3.3.1 Daily
Check Hydraulic Tank Level Change Oil Level w/Filter – All Engines Check Engine Coolant – Deutz TD2.9L4/Ford MSG425
3.3.2 First 50 Hours

Change Hydraulic Charge Filter Change Hydraulic Return Filter
800S HC3, 860SJ HC3 31222415 41

3.3.3 Every 150 Hours or 3 Months
Swing Bearing – Grease Fittings Check Wheel Drive Hub – Level/Fill Plug Change Fuel Filter (Propane) – Ford 2.5L Engine
3.3.4 First 300 Hours or 6 Months

Change Hydraulic Charge Filter Change Hydraulic Return Filter Air Filter – Replaceable Element for all Engines
3.3.5 First 300 Hours or 1 Year

Oil Change w/Filter – Ford 2.5L Engine
3.3.6 Every 600 Hours or 1 Year
Change Fuel Filter – For All Engines Oil Change w/Filter – Deutz TD2.9L Engines Change Fuel/Water Separator – Deutz TD2.9L4 China III/
D2011LO40 Engines
Oil Change w/Filter – Deutz
Change Engine Coolant – Deutz TD2.9L4/Ford MSG425
3.3.9 Every 1200 Hours or 2 Years
Wheel Bearings Change Wheel Drive Hub Change fluid in Hydraulic Tank
3.4 PINS AND COMPOSITE BEARING REPAIR GUIDELINES
Filament Wound Bearings

1. Pinned joints should be disassembled and inspected if the following occurs:
a. Excessive sloppiness in joints.
b. Noise originating from the joint during operation.
2. Filament wound bearings should be replaced if any of the following is observed:

a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their housing.
d. Debris embedded in liner surface.
3. Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to inspection):
a. Detectable wear in the bearing area.
b. Flaking, pealing, scoring, or scratches on the pin surface.
c. Rusting of the pin in the bearing area.
42 31222415 800S HC3, 860SJ HC3

4. Re-assembly of pinned joints using filament wound bearings:

a. Blow out housing using compressed air to remove all dirt and debris. Bearings and bearing housings must be free of all
contamination.
b. Clean bearings and pins with solvent to remove all grease and oil.
Note: Filament wound bearings are a dry joint and should not be lubricated unless otherwise instructed (i.e. sheave pins).
c. Inspect pin to ensure it is free of burrs, nicks, and scratches which can damage bearing during installation and operation.
3.5 TIRES AND WHEELS
WARNING
Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply
tires) may compromise machine stability and may cause machine to tip over.
3.5.1 Tire Inflation

JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts
Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we
recommend that replacement tires have the following characteristics:
• Equal or greater ply/load rating and size of original.
• Tire tread contact width equal or greater than original.
• Wheel diameter, width, and offset dimensions equal to the original.
• Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load).
Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When
selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations
between tire brands, both tires on the same axle should be the same.
The rims installed on each product model have been designed for stability requirements which consist of track width and load capacity.
Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may
result in an unsafe condition regarding stability.
3.5.2 Tire Damage

For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be
taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly.
• A smooth, even cut through the cord plies which exceeds 3 in. (7.5 cm) in total length.
• Any tears or rips (ragged edges) in the cord plies which exceeds 1 in. (2.5 cm) in any direction.
• Any punctures which exceed 1 in. in diameter.
• Any damage to the bead area cords of the tire.
If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to insure the damage hasn’t
propagated beyond the allowable criteria.
3.6 FUEL TANK INSPECTION
1. For cleaning of tank, refer to Section – Fuel Tank Cleaning and Drying, page 109 procedure.
2. For replacement of tank, refer to Section – Fuel Tank, page 392 for Removal/Installation of fuel tank.
3. Inspect the fuel tank thoroughly for any cracks, slices, leaks or other damage.
800S HC3, 860SJ HC3 31222415 43

4. Dispose of damaged fuel tank according to local regulations concerning hazardous materials disposal.
3.7 BOOM INSPECTION AND MAINTENANCE
3.7.1 Wire Rope Tensioning Procedure

1. Position boom in fully down and retracted position.
Model 800S HC3 860SJ HC3

Dim. A 14.8 in. (37.5 cm) 16.7 in. (42.5 cm)
Dim. B 9.2 in. (23.5 cm) 9.2 in. (23.5 cm)
800S800S
HC3
A
B A
860SJ
860SJ HC3
A
BB A
BM110871B
BM110871A
44 31222415 800S HC3, 860SJ HC3

2. Clamp both threaded ends of wire rope to prevent rotation.
Note: Do not clamp on threads.
Figure 3. Clamping Wire Ropes
3. Install adjusting nuts (or remove nylon collar locknuts if re-adjusting) to both retract and extend wire ropes.
4. Torque retract adjusting nuts (platform end) to 15 ft. lbs. (20 Nm) alternating between the two wire ropes and keeping
approximately the same amount of thread beyond the adjusting nut.
Note: Do not allow wire rope to rotate. This may damage the wire rope.
5. Repeat the torque procedure in step #4 to the extend wire ropes (turntable end).
6. Extend the boom 2 – 3 ft. using the telescope function. Repeat step #4.
7. Retract the boom 1 – 2 ft. using the telescope function. Do not bottom out telescope cylinder. Repeat step #5.
8. Extend the boom approximately 2 – 3 ft. again and check torque on the retract wire ropes.
9. Retract the boom without bottoming out telescope cylinder and check torque on the extend wire ropes.
Note: Step #8 and #9 may need to be repeated to equalize the torque on all 4 wire ropes.
10. After all wire ropes have been properly torqued, install nylon collar locknuts. Remove all clamping devices and install all covers
and guards. Check the boom for proper function.
3.7.2 Wire Rope
CAUTION
Wire rope can have sharp edges and cause serious injury. Never handle wire rope
with bare hands.
Each day before using machine:
1. Raise main boom approximately horizontal.
2. Extend and retract the boom sections.
3. Check for delayed movement of fly section which indicates loose wire ropes.
WARNING
If delayed movement is detected in wire rope operation, lower platform to stowed
position, shut down machine, and have wire ropes inspected/serviced by a qualified
JLG mechanic. Loose or misadjusted wire ropes could result in serious injury or
death.
800S HC3, 860SJ HC3 31222415 45

Inspection
Note: Pictures in this paragraph are samples to show rope replacement criteria.
1. Inspect ropes for broken wires, particularly valley wire breaks and breaks at end terminations.
Note: Flexing a wire rope can often expose broken wires hidden in valleys between strands.
Figure 4. Wire Rope Wire Breaks
2. Inspect ropes for corrosion.
3. Inspect ropes for kinks or abuse.
Note: A kink is caused by pulling down a loop in a slack line during improper handling, installation, or operation.
Figure 5. Wire Rope Kink
4. Inspect sheaves for condition of bearings/pins. (See Dimension Of Sheaves for proper dimension.)
5. Inspect sheaves for condition of flanges. (See Dimension Of Sheaves for proper dimension.)
6. Inspect sheaves with a groove wear-out gauge for excessive wear.
Note: Check groove so that it may be clearly seen if gauge contour matches sheave groove contour.
Figure 6. Sheave Groove Wear
7. Ropes passing inspection should be lubricated with wire rope lubricant before reassembly.
Three Month Inspection

1. Remove boom covers and visually (with flashlight) inspect the ropes for rust, broken wires, frays, abuse, or any signs of
abnormalities.
2. Check rope tension by deflecting the ropes by hand. Properly tensioned ropes should have little or no movement.
Note: Delayed movement of the fly boom indicates loose wire ropes.
Additional Inspection Required If:

1. Machine is exposed to hostile environment or conditions.
2. Erratic boom operation or unusual noise exists.
46 31222415 800S HC3, 860SJ HC3

3. Machine is idle for an extended period.
4. Boom is overloaded or sustained a shock load.
5. Boom exposed to electrical arc. Wires may be fused internally.
12 Year or 7000 Hour Replacement

1. Mandatory wire rope and sheave replacement.
Additional Replacement Criteria
Note: Sheaves and wire rope must be replaced as sets.
1. Rusted or corroded wire ropes.
2. Kinked, “bird caged”, or crushed ropes.
3. Ropes at end of adjustment range.
4. Sheaves failing wear-out gauge inspection.
5. Ropes with 6 total broken wires in one rope lay, 3 in one strand in one rope lay, 1 valley break, or 1 break at any end termination.
3.7.3 Boom Cleanliness Guidelines

The following are guidelines for internal boom cleanliness for machines used in excessively dirty environments.
1. JLG recommends use of JLG Hostile Environment Package to keep internal portions of a boom cleaner and help prevent dirt and
debris from entering the boom. This package reduces the amount of contamination which can enter the boom, but does not
eliminate the need for more frequent inspections and maintenance when used in these types of environments.
2. JLG recommends you follow all guidelines for servicing your equipment in accordance with instruction in the JLG Service &
Maintenance Manual for your machine. Periodic maintenance and inspection is vital to proper operation of the machine.
Frequency of service and maintenance must be increased as environment, severity, and frequency of usage requires.
3. Debris and contamination inside the boom can cause premature failure of components and should be removed. Methods to
remove debris should always be done using all applicable safety precautions outlined in the JLG Operation & Safety Manual and
the JLG Service & Maintenance Manuals.
4. The first attempt to remove debris from inside the boom must be to utilize pressurized air to blow the debris toward the nearest
exiting point from the boom. Make sure that all debris is removed before operating the machine.
5. If pressurized air cannot dislodge debris, then water with mild solvents applied with a pressure washer can be used. Wash debris
toward the nearest exiting point from the boom. Make sure all debris is removed, no “puddling” of water has occurred, and boom
internal components are dry before operating machine. Make sure you comply with all federal and local laws for disposing of wash
water and debris.
6. If pressurized air or washing boom does not dislodge and remove debris, disassemble boom following instructions outlined in the
JLG Service & Maintenance Manual to remove debris.
3.7.4 Boom Wear Pad Inspection

1. Visual inspection for damage, cracks, distortion or excessive wear.
2. Check for proper adjustment and correct as needed.
3. Check for contaminated, corroded or rusted wear pad sliding surfaces.
4. If Operating in extremely dusty/abrasive conditions. Wear pads should be cleaned frequently.
800S HC3, 860SJ HC3 31222415 47

3.8 HYDRAULIC FILTER REPLACEMENT
3.8.1 Hydraulic Filter Removal

1. Park machine on a firm level surface, fully retract boom, lower boom until on machine's boom rest stop.
2. Turn key Select switch to (center) OFF position, push in power/ emergency stop switch (down) to OFF and remove the key.
3. Open both the side hoods and allow the system fluids to cool.
4. Properly relieve any pressure in the hydraulic system.
5. Disconnect battery power from the machine.
6. Place a Do Not Operate tag on the key select switch.
7. Disconnect electrical and hydraulic connections from the hydraulic oil reservoir (7).
8. Remove nuts (1) and washers (2) securing filter cover (3).
9. Remove the filter cover (3) and gasket (4) from hydraulic oil filter (5).
10. Remove hydraulic oil filter (5) from hydraulic oil reservoir (7).
11. Cover the filter opening to keep dirt and debris from entering the hydraulic system.
12. Loosen the breather assembly (6) from the hydraulic oil reservoir (7).
13. Transfer the used hydraulic oil filter into a suitable covered container, and label as “Used Oil”. Dispose of used filter at an approved
recycling facility.
1
2
MAF43960
Figure 7. Hydraulic Filter Replacement
3.8.2 Hydraulic Filter Installation

1. Apply a light coating of clean hydraulic oil to the new hydraulic filter O-ring seal near the base.
48 31222415 800S HC3, 860SJ HC3

2. Put the hydraulic oil filter (5) on the hydraulic oil reservoir. Verify filter is seated in hydraulic oil reservoir (7).
3. Put gasket (4) and filter cover (3) onto hydraulic oil filter (5).
4. Secure hydraulic filter assembly to hydraulic reservoir using previously removed nuts (1) and washers (2). Torque nuts to 8.1 ft. lbs.
(11 Nm).
5. Tighten breather assembly (6) onto reservoir with your hand.
6. Connect electrical and hydraulic connections to hydraulic oil reservoir (7).
7. Reconnect battery power to the machine.
8. Close both the side hoods.
9. Reinsert the key pull out power/emergency stop switch (up) to ON and turn key select switch to Ground position.
10. Start machine and check all hydraulic functions for proper operation. Check for any hydraulic oil leaks.
11. Shut machine OFF and check hydraulic oil level. If oil is warm, oil level should be visible in the gauge window.
12. Add hydraulic oil if necessary. Refer to Section – Capacities, page 24.
13. Remove Do Not Operate tag from key select switch.
3.9 TURNTABLE BEARING INSPECTION
3.9.1 Turntable Bearing Mounting Bolt Condition Check

Note: This check must be performed after first 50 hours of machine operation and every 600 hours of machine operation thereafter. If
during this check any bolts are found to be missing or loose, replace missing or loose bolts with new bolts and torque to the val-
ue specified in the torque chart, after lubricating the bolt threads with High Strength Threadlocking Compound. After replacing
and re-torquing the bolt recheck all existing bolts for looseness.
1. Check the bolts attaching the swing bearing to the frame as follows, Refer to Figure — Swing Bearing Attaching Bolt Configuration,
page 50.
Note: These bolts engage the swing bearing from underneath
a. Position boom as Boom Fully Elevated. Refer to Figure — Swing Bearing Tolerance Boom Placement, page 53, Position 2.
b. Check the quadrant of bolts that are toward the turntable counterweight by inserting a 0.0015 in. (0.0381 mm) feeler gauge
between the bolts and hardened washers. Refer to Figure — Frame Side Bearing Bolt Feeler Gauge Check, page 50.
c. Ensure that the feeler gauge will not penetrate under the bolt head to the bolt shank.
d. Rotate the turntable 90 degrees, and check the next quadrant of bolts.
e. Continue rotating the turntable at 90 degree intervals until all bolts have been checked.
2. Check the bolts attaching the swing bearing to the turntable as follows, Refer to Figure — Swing Bearing Attaching Bolt
Configuration, page 50.
a. Position boom as Boom Fully Elevated. Refer to Figure — Swing Bearing Tolerance Boom Placement, page 53, Position 2.
b. Check the semi-circle of bolts that are toward the turntable counterweight by inserting a 0.0015 in. (0.0381 mm) feeler gauge
between the bolts and hardened washers. Refer to Figure — Turntable Side Bearing Bolt Feeler Gauge Check, page 50.
c. Ensure that the feeler gauge will not penetrate under the bolt head to the bolt shank.
d. Reposition boom. Refer to Figure — Swing Bearing Tolerance Boom Placement, page 53, Position 1.
e. Check the remaining semi-circle of bolts.
800S HC3, 860SJ HC3 31222415 49

Figure 8. Swing Bearing Attaching Bolt Configuration
1. Turntable Side Bearing Bolt 4. Turntable Bearing Inner Race
2. Turntable Bearing Outer Race 5. Turntable

3. Frame Side Bearing Bolt 6. Frame
Figure 9. Frame Side Bearing Bolt Feeler Gauge Check
7. Feeler Gauge, 0.0015 in. (0.0381 mm)
BM109394A
Figure 10. Turntable Side Bearing Bolt Feeler Gauge Check
8. Feeler Gauge, 0.0015 in. (0.0381 mm)
50 31222415 800S HC3, 860SJ HC3

Wear Tolerance
NOTICE
The swing bearing is one of the most critical points on a mobile elevating work plat-
form. It is here that the stresses of lifting are concentrated, at the center of rotation.
Because of this, proper maintenance of the swing bearing is a must for safe
operation.
1. Position machine as shown in Figure — Swing Bearing Tolerance Boom Placement, page 53, Position 1.
2. Set up a dial indicator as follows:

a. Dial indicator is to be located next to the swing bearing, in-line with the boom's center line, opposite the turntable
counterweight. Refer to Figure — Dial Indicator Setup, page 52. and Figure — Dial Indicator Pointer Location, page 52.
b. Position the magnetic base of the dial indicator on the frame.
c. Position the indicator point to touch the underside of the turntable base plate 6 in. (152.4 mm) from root of gear tooth.
3. Zero the dial indicator.
4. Check dial indicator accuracy using a feeler gauge. Ensure dial indicator reading is same as thickness of feeler gauge.
5. Do not swing the turntable. Reposition boom as shown in Refer to Figure — Swing Bearing Tolerance Boom Placement, page 53,
Position 2.
6. Verify that the dial indicator has not shifted, & then record the indicator value for bearing play.
7. Return the boom to Position 1. The dial indicator should return to zero. If dial indicator does not return to zero, take corrective
action and repeat the test.
8. If the measurement is more than 0.117 in. (3.0 mm), replace the bearing. If the measurement is less, and any of the following
conditions exist, the bearing should be removed, disassembled, and inspected:
a. Metal particles in the grease
b. Increased drive power required
c. Noise
d. Rough rotation.
9. If bearing inspection shows no defects, reassemble and return to service.
800S HC3, 860SJ HC3 31222415 51

Figure 11. Dial Indicator Setup
BM109539A
Figure 12. Dial Indicator Pointer Location
9. Dial Indicator Point
52 31222415 800S HC3, 860SJ HC3

11
10
POSITION 1
LEVEL SURFACE
12
10
POSITION 2
BM109538A
Figure 13. Swing Bearing Tolerance Boom Placement
800S HC3, 860SJ HC3 31222415 53

Note: Refer to Figure — Swing Bearing Tolerance Boom Placement, page 53 for below table.
10. Dial Indicator Gauge Measuring Point
11. Boom Fully Extended Horizontal
12. Main Boom Fully Raised and Fully Retracted
3.10 ENGINE GENERAL INSPECTION
3.10.1 General Maintenance

Note: Refer to engine manufacturer's manual for detailed operating and maintenance instructions. Limited engine maintenance items
are presented here for convenience but detailed engine maintenance items and schedule are included in the engine manufactur-
er's manual.
3.10.2 Checking Oil Level

1. Make sure machine and engine are level and switch engine OFF before checking oil level.
2. Remove oil dipstick and wipe with clean cloth.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level as shown in figure below with an approved grade and type of oil outlined in engine manufacturer’s
operator’s manual.
Figure 14. Deutz Engines Dipstick Markings
Figure 15. Deutz D2011LO40 Dipstick Markings
5. Replace dipstick until fully seated.
3.10.3 Changing Engine Oil

1. Allow engine to warm up. Engine oil should reach approximately 176° F (80° C).
2. Make sure machine and engine are level.
54 31222415 800S HC3, 860SJ HC3

3. Switch off engine
4. Place oil tray under engine.
WARNING
Hot engine oil can cause burns. Avoid contact with hot oil when draining.
CAUTION
Do Not let used oil run into soil.
Collect used oil in a container suitable for disposal or recycling. Dispose off used en-
gine oil in accordance with environmental regulations.
5. Open oil drain valve and drain oil.
6. Close oil drain valve.
7. Pour in new engine oil.

Refer to Section — Capacities, Figure — Engine Operating Temperature Specifications - Ford, page 56, and Figure — Engine Operating
Temperature Specifications - Deutz, page 58.
800S HC3, 860SJ HC3 31222415 55

Figure 16. Engine Operating Temperature Specifications - Ford
56 31222415 800S HC3, 860SJ HC3

Figure 17. Engine Operating Temperature Specifications - Deutz TD2.9L4
800S HC3, 860SJ HC3 31222415 57

Figure 18. Engine Operating Temperature Specifications - Deutz D2011L04
3.10.4 Replacing the Oil Filter

Note: Engine oil filters are mounted horizontally or vertically onto engine. Removal and installation is always same.
MAF44070
Figure 19. Oil Filter Location — For Deutz TD2.9L4 (T4F, Stage V, China III and IV) Engines
58 31222415 800S HC3, 860SJ HC3

MAF44090
Figure 20. Oil Filter Location — For Deutz D2011LO40 (T4I)
BM110622A
Figure 21. Oil Filter Location — For Ford MSG425-DF
1. Wipe area around filter to remove dirt and other contaminants.
800S HC3, 860SJ HC3 31222415 59

2. Using a suitable oil filter removal tool, loosen the lube oil filter cartridge and spin off.
3. Catch any escaping oil.
4. Clean any dirt from filter carrier sealing surface.
5. Lightly oil rubber gasket on new oil filter.
6. Manually screw in new filter until gasket is flush.
7. Tighten filter another half-turn.
8. Check oil level.
9. Check oil pressure.
10. Check oil filter cartridge for leaks.
3.10.5 Replacing the Primary Fuel Filters
MAF44040
Figure 22. Filter Location — For Deutz TD2.9L4 (T4F, Stage V, China III and IV) Engines
60 31222415 800S HC3, 860SJ HC3

MAF44060
Figure 23. Filter Location — For Deutz D2011LO40 (T4I)
WARNING
Fuel is flammable and can cause death or serious injury. Make sure no open flames
or sparks are in the area when working on fuel system.
Do Not smoke when working on the fuel systems.
1. Wipe area around filter to clean any dirt from area.
2. Fuel supply from the fuel tank may need to be blocked to prevent flow from the fuel tank.
3. Remove fuel filter cartridge.
4. Catch any escaping fuel.
MAF44250
5. Clean dirt from filter carrier sealing surface.
6. Apply light film of oil or diesel fuel to rubber gasket of new filter cartridge.
800S HC3, 860SJ HC3 31222415 61

7. Screw in new filter by hand until gasket is flush. Hand tighten filter another 3/4 turn.
MAF44260
8. Check for leaks.
62 31222415 800S HC3, 860SJ HC3

3.10.6 Replacing the Fuel Pre-Filter
Figure 24. Location of Fuel Pre-Filter
Note: Refer to Figure – Components of Fuel Pre-Filter, page 63.
Figure 25. Components of Fuel Pre-Filter
1. Fuel Supply Flow to the Pump 4. Drain Plug
2. Venting Screw 5. Filter Element
3. Electrical Connection for Water Level Sensor 6. Fuel Inlet from the Fuel Tank
WARNING
When working on the fuel system, make sure there are no open flames or sparks in
the area. Do not smoke when working on the fuel system.
1. Switch off the engine.
2. Fuel supply from the fuel tank may need to be blocked to prevent fuel flow from the tank.
3. Place suitable collecting container under drain plug.
4. Disconnect electrical connections from water sensor.
5. Loosen drain plug and drain liquid.
800S HC3, 860SJ HC3 31222415 63

6. Remove filter element.
7. Catch any escaping fuel.
8. Clean any dirt of the sealing surfaces of the new filter element and opposite side of filter head.
9. Wet the sealing surfaces of new filter element slightly with fuel.
10. Install new filter onto the filter head in clockwise direction. Torque to 12.5-13.3 ft. lbs. (17-18 Nm).
11. Install the drain plug and tighten to torque 1-1.4 ft. lbs. (1.3-1.9 Nm).
12. Connect electrical connection to water sensor.
13. Check for leaks after starting engine.
3.10.7 Water in Fuel Sensing System (Optional)

The Water in Fuel Sensing System detects when there is an excessive amount of water in the fuel and sets a DTC code in the JLG Control
System to alert the operator and/or service technician.
When Water in Fuel condition occurs, the machine will respond in the following way:
• The engine will shut down automatically.
• The JLG Control System will set DTC 4375 - Water in Fuel.
• An alarm will sound from the active control station (ground or platform).
• If in platform mode, the Low Fuel Indicator will flash.
• Engine Restart will be permitted after the machine senses the Water in Fuel condition, but will only run for 2 minutes and the engine
will shut down again. This restart process will continue until the Water in Fuel condition is corrected.
3.10.8 Draining Water

Frequency of water draining is determined by the contamination level of the fuel. Inspect or drain the collection bowl of water daily or
as necessary. The collection bowl must be drained before contaminants reach the top of the turbine or when the Water Detection
Module (optional) indicates it’s time to drain water.
Pressure Applications / Installations:
1. Open the drain plug on the bottom of the bowl to evacuate water and contaminants with a suitable collection container in place.
2. Close the drain after all the water and contaminants have been evacuated.
Note: Do not leave the drain open too long as it may completely drain the entire filter assembly of water and fuel.
64 31222415 800S HC3, 860SJ HC3

3.10.9 Auxiliary Fuel Filter
Figure 26. Components of Auxiliary Fuel Filter
1. T-handle 3. Lid
2. Filter Element 4. Drain Plug
WARNING
When working on the fuel system, make sure there are no open flames or sparks in
the area. Do not smoke when working on the fuel system.
ELEMENT REPLACEMENT
Frequency of element replacement is determined by the contamination level of the fuel. Replace the elements every 500 hours, if power
loss is noticed or annually, which ever comes first.
1. Switch off the engine.
2. Fuel supply from the fuel tank may need to be blocked to prevent fuel flow from the tank.
3. Wipe the area around the filter to clean any dirt from the area.
4. Remove the T-handle and lid.
5. Remove the element by holding the bail handles and slowly pulling upward with a twisting motion. Dispose of properly.
6. Replace old lid gasket and T-handle O-ring with new seals (supplied with new element). Lubricate both seals with motor oil or
diesel fuel before installation.
7. Refer to Priming of auxiliary fuel filter or fill the unit with clean fuel, then replace the lid and T-handle then tighten snugly by hand
only.
Note: Do not use any tool for removal and installation of T-handle.
PRIMING OF AUXILIARY FUEL FILTER

1. Remove the T-handle and lid from the top of the filter assembly.
2. Fill the filter assembly with clean fuel.
3. Lubricate lid gasket and T-handle O-ring with clean fuel or motor oil.
800S HC3, 860SJ HC3 31222415 65

4. Replace the lid and T-handle and tighten snugly by hand only.
Note: Do not use any tool for removal and installation of T-handle.
5. Start engine and check for fuel system leaks.
6. Correct as necessary with engine off and pressure relieved from filter assembly.
DRAINING WATER
Frequency of water draining is determined by the contamination level of the fuel. Inspect or drain the collection bowl of water daily or
as necessary. The collection bowl must be drained before contaminants reach the top of the turbine or when the Water Detection
Module (optional) indicates it’s time to drain water.
Pressure Applications / Installations:
1. Open the self-venting drain plug on the bottom of the bowl to evacuate water and contaminants with a suitable collection
container in place. Head pressure will push any water and contaminants out of the drain while keeping the filter primed.
2. Close the drain after all the water and contaminants have been evacuated.
3. If necessary, follow priming of auxiliary fuel filter.
Note: Do not leave the drain open too long as it may completely drain the entire filter assembly of water and fuel.
3.10.10 Clean Fuel Strainer for Deutz D2011LO40 (only)
WARNING
or sparks are in the area when working on fuel system. Do not smoke when working
on fuel system.
1. Unscrew hexagonal nut (1).
2. Remove fuel strainer cover (2).
3. Clean fuel strainer with diesel fuel and replace as needed.
4. Place seal (3) in position.
5. Install fuel strainer cover (2). Tighten screw (1).
6. Check for leaks.
3.10.11 Spark Arrester Cleaning Instructions for Deutz D2011LO40 (only)

1. Remove cleanout plug in bottom of spark arrester (muffler).
66 31222415 800S HC3, 860SJ HC3

2. Without causing deformation (or any type of damage to spark arrester) repeatedly tap on arrester near cleanout plug. This may be
enough to begin spark trap drainage.
3. An industrial vacuum cleaner can do a complete job at this point.

a. Or, IN A SAFE AREA, start engine. Alternate between low idle and high idle for two to three minutes.
b. Or, operate engine as required by application for two to three minutes.
4. Install cleanout plug.
3.10.12 Glow Plugs

If glow plug option is enabled in the JLG Control System, glow plug and indicator lamp will be energized when Power/Emergency Stop
switch is pulled on if ambient air temperature is less than 50° F (10° C) and engine coolant temperature is less than 140° F (60° C).
This determination occurs one second after the Power/Emergency Stop switch has been pulled on. Lamp and glow plugs remain
energized for period of time specified by setting in the JLG Control System. Engine start is disabled during this period.
On Deutz engines, glow plugs continue (post glow) after engine has started three times the machine digit setting.
3.11 BIO FUEL IN DEUTZ ENGINES
3.11.1 General
Use of bio fuels is permitted for the compact engines made by DEUTZ.
Distillate fuels with residue oil percentages or mixed fuels may not be used in DEUTZ compact engines.
The DEUTZ vehicle engines are designed for diesel fuels in accordance with EN 590 with a cetane number of at least 51. DEUTZ engines
for mobile machinery are designed for a cetane number of at least 45. When using fuels of a low cetane number, disturbing white smoke
and ignition misfires are to be expected under some circumstances.
A cetane number of at least 40 is permissible for the US market, therefore special engine models have been developed to avoid starting
difficulties, extreme white smoke or increased hydrocarbon emissions (EPA specification - US EPA REGULATIONS FOR LARGE NONROAD
COMPRESSION-IGNITION ENGINES).
If the white smoke behavior is unacceptable when using a very low cetane number, the use of ignition improvers is to be reco
mendedas a later remedial measure.
The certification measurements for compliance with the legal emission limits are carried out with the test fuels prescribed by law. These
correspond to the diesel fuels in accordance with EN 590 and ASTM D 975. No emission values are guaranteed with the other fuels
described. It is the obligation of the owner to check the permission for use of the fuels in accordance with regional regulations.
3.11.2 Bio Fuel

Permitted Bio-Diesel Fuels
Originally only rape seed oil methylester (RME) was sold as a biodiesel fuel in Europe but fatty acid methylester (FAME) based on other
oils have come onto the market increasingly in recent years. However, with the latter there is a risk that the limit values of EN 14214 are
not kept in the field. Anyone who uses bio-diesel fuel in DEUTZ engines must therefore choose his supplier very carefully and have him
guarantee compliance with the EN 14214 limit values. Since experience has shown that rape seed oil methylester (RME) exceeds the limit
values less often that other esters, it is expressly recommended to use only rape seed oil methyester. DEUTZ customers in Germany can
additionally ensure the quality by buying bio-diesel fuel with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Management Biodiesel
e.V.).
The use of US bio-diesel based on soy oil methylester is only permissible in mixtures with diesel fuel with a bio-diesel part of a max. 20
weight-%. The US bio-diesel used for the mixture must comply with the ASTM D6751-07a (B100) standard.
Approved Engines
Refer to respective engine manufacturer's manual for detailed instructions on approved bio-diesel fuel. Some basic conditions specified
below.
Basic Conditions to be Observed
• A power loss of 5-9% in relation to diesel fuel in accordance with EN 590 is possible due to the lower heating value. Blocking of the
fuel injector is not allowed.
800S HC3, 860SJ HC3 31222415 67

• The lubricating oil quality must correspond to TR 0199- 99- 3002. The lubricating oil change interval must be halved in relation to
operation with diesel fuel in accordance with EN 590.
• Standstills of longer than 4 to 6 weeks must be avoided with bio-diesel. Otherwise the engine must be started and stopped with
diesel fuel.
• Bio-diesels can be mixed with normal diesel fuel but the basic conditions described in this subsection apply for mixtures. Mixtures
with up to 5% (m/m) bio-diesel (B5) which have recently been on sale at European fuel stations are excepted. These fuels must be
treated like normal diesel fuels because EN 590 expressly permits adding up to 5% (m/m) bio-diesel in accordance with EN 14214.
• Approx. 30-50 hours after changing over from diesel fuel to bio-diesel, the fuel filter should be changed as a preventive measure to
avoid a drop in performance due to clogged fuel filters. Deposited fuel ageing products are dissolved by biodiesel and transported
into the fuel filter. They should not be changed immediately but after approx. 30 to 50 hours because the dissolving of dirt takes a
certain amount of time.
Plant Oil
NOTICE
Pure plant oils (E.g. Rape seed oil, Soy oil, Palm oil) are not classified as bio-diesel
and exhibit problematical properties for diesel engine operation (Strong tendency
to coke, risk of piston seizure, Extremely high viscosity, poor evaporation behavior).
Conversion of DEUTZ engines to rape seed oil fuel operation with conversion kits and modified tanks systems of various manufacturers
is not allowed and leads to loss of warranty rights.
3.11.3 Biological Contamination In Fuels

Symptoms
The following symptoms may indicate a fuel tank is contaminated by micro-organisms:
• Internal tank corrosion.
• Filter blockage and the associated loss of power due to gellike deposits on the fuel filter (especially after long standstills).
Cause
Micro-organisms (bacteria, yeasts, funguses) can form bio sludge under unfavorable conditions (favored particularly by heat and water).
Penetration by water is usually caused by condensation of the water in the air. Water does not dissolve in fuel so that the penetrating
water collects at the bottom of the tank. The bacteria and funguses grow in the watery phase, at the phase boundary to the fuel phase,
from which they draw their nutrition. There is an increased risk especially with bio-diesel (FAME).
Preventive Measures
• Keep storage tank clean, regular cleaning of the tank by specialist companies.
• Installation of fuel pre-filters with water traps, especially in countries with frequently fluctuating fuel qualities and high percentage of
water.
If the fuel system and storage tank have already been attacked by micro-organisms. The biocide must be dosed according to the
manufacturer's specifications.
• Avoid direct exposure of the storage tank to sunlight.
• Use smaller storage tanks with corresponding low dwell times of the stored fuel.
Fuel Additives
Use of fuel additives is not permitted. The flow improvers mentioned above are an exception. Use of unsuitable additives will result in
loss of warranty.
68 31222415 800S HC3, 860SJ HC3

3.12 DEUTZ EMR2
The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control System are
connected by means of separate cable harnesses to the EMR control unit.
The sensors attached to the engine provide the electronics in the control unit with all the relevant physical parameters In accordance
with the information of the current condition of the engine and the preconditions (throttle position etc.), the EMR2 controls an actuator
that operates the control rod of the injection pump and thus doses the fuel quantity in accordance with the performance requirements.
The exact position of the regulating rod is reported back and, if necessary, is corrected, by means of the control rod travel sensor,
situated together with the rotation magnets in a housing of the actuator.
The EMR2 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running (Limp
home) functions.
In order to switch the engine off, the EMR2 is switched in a de energized fashion over the ignition switch. A strong spring in the actuator
presses the control rod in the de-energized condition into the zero position. As a redundancy measure, an additional solenoid serves for
switching off and this, independently of the actuator, also moves the control rod in the de-energized condition into the zero position.
After the programming, that is carried out over the ISO9141 interface, the EMR2 possesses a motor-specific data set and this is then
fixedly assigned to the engine. Included in this are the various application cases as well as the customer’s wishes regarding a particular
scope of function.
Each EMR2 module is matched by serial number to the engine. Modules cannot be swapped between engines.
800S HC3, 860SJ HC3 31222415 69

Figure 27. EMR2 Engine Side Equipment
70 31222415 800S HC3, 860SJ HC3

BM110455A
Figure 28. Deutz EMR2 Troubleshooting Flow Chart
800S HC3, 860SJ HC3 31222415 71

3.13 DEUTZ EMR5
The EMR5 consists of the sensors, the control unit and the common rail injection system. Engine-side controls as well as the JLG Control
System are connected by means of separate cable harnesses to the EMR control unit.
The sensors attached to the engine provide the electronics in the control unit with all the relevant physical parameters In accordance
with the information of the current condition of the engine and the preconditions (throttle position etc.), the EMR5 controls the injection
pump and thus doses the fuel quantity in accordance with the performance requirements.
The EMR5 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running (Limp
home) functions.
In order to switch the engine off, the EMR5 is switched in a de-energized fashion over the ignition switch.
After the programming, that is carried out over the interface, the EMR5 possesses a motor-specific data set and this is then fixedly
assigned to the engine. Included in this are the various application cases as well as the customer’s wishes regarding a particular scope of
function.
Each EMR5 module is matched by serial number to the engine. Modules cannot be swapped between engines.
72 31222415 800S HC3, 860SJ HC3

Figure 29. EMR5 Engine Side Equipment
1. Injector 5. Crankshaft Speed Sensor 9. MPROP
2. Glow Plugs 6. EGR Actuator 10. Oil Pressure Sensor
3. Coolant Temperature Sensor 7. Starter Relay 11. Fuel Low Pressure Sensor
4. Charge Air Pressure and Temperature Sensor 8. Rail Pressure Sensor 12. Camshaft Speed Sensor
800S HC3, 860SJ HC3 31222415 73

Figure 30. Deutz EMR5 Troubleshooting Flow Chart
74 31222415 800S HC3, 860SJ HC3

3.14 GENERATOR INSPECTION
3.14.1 2500W Generator

Maintenance Schedule
Every 250 hours
Every 250 hours of operation, check the drive belt for proper tension.
Figure 31. Generator Belt Tension

Every 1000 Hours
Every 1000 hours of service, blow out the inside of the generator. If operating in a hostile environment, clean monthly.
MAF52460

Every 250 hours
800S HC3, 860SJ HC3 31222415 75

Every 1000 Hours

MAF44320
Overload Protection
CAUTION
Stop the engine whenever Checking or Inspecting the circuit breaker.
The circuit breaker protects the generator windings from overload. If the circuit breaker opens, generator output stops. If the circuit
breaker continues to open, check for faulty equipment connected to the platform receptacles.
MAF44330
Figure 33. Generator Circuit Breaker Location
1. Circuit Breaker
Field Flashing
1. Disconnect plug on wiring enclosure cover.
2. Loosen strain relief bushing.
3. Remove wiring enclosure cover.
4. Make sure that the CB1 is ON.
5. Flash the field by connecting negative of battery to 2T. With the generator running, momentarily connect the battery positive to
1T.
6. Check for output voltage. If output voltage is not present, repeat field flashing procedure.
76 31222415 800S HC3, 860SJ HC3

7. When output voltage is available, stop generator and reinstall cover.
Note: Refer to Table – Troubleshooting, page 78 and replace components as described.
CR1
7 C1
5 6
RC2C RC2
D
PLG2 PLG2
4 5 6
NORMAL VOLTAGE: (81-84)
PLG4 PLG4
1 RC43 4
RC4
50 HZ 230V
60 HZ 240V
5 6
60 HZ - CONNECT 90 TO 3T
50 HZ - SLEEVE END & SECURE
DO NOT CONNECT - FIELD OPTION
1 90 4
5
CR
1
8 9
CB1
B +12V TO ENABLE
TOOLS NEEDED: RC4
C -ENABLE
81 84
3T
1T 2T
MAF44340
Figure 34. Field Flashing
1. 12 Volt Battery 3. Terminal 2T 5. Battery Positive (+) Lead
2. Terminal 1T 4. Battery Negative (-) Lead 6. Circuit Breaker CB1
Troubleshooting
Inspect generator and repair or replace components or wiring that shown signs of physical damage. Inspect stator winding for evidence
of overheating. Do not return the generator unless indicated by the troubleshooting guide and factory authorized service agent. Do not
return the control box.
Note: For details related to generator circuit diagram refer to Section – 4000W Generator Schematic, page 747 .
800S HC3, 860SJ HC3 31222415 77

Table 14. Troubleshooting

Trouble Remedy
No generator output at platform receptacles. Be sure generator control switch is turned on at platform.
Check and secure electrical connections at platform, generator, and control box.
Be sure all equipment is turned off when starting unit.
Check circuit breaker CB1 for loose terminals. Check continuity across poles of CB1. Reset or replace CB1 (Refer to
Section – Overload Protection, page 76 ).
Check connections at receptacle RC4 Be sure battery voltage is present (12 volts DC) to enable control relay CR1.
Check control relay CR1: Check all connections, check coil continuity, check for proper coil voltage, and check contact
voltage (input to common and output to common) to ensure contacts are operating. Replace CR1 if indicated.
Disconnect stator leads 1, 4, and 90 (if applicable) from circuit breaker CB1, and check continuity between leads.
Replace generator if indicated.
Check capacitor C1 and replace if indicated.
Excitation of field lost. Flash field according to Figure – Field Flashing, page 77 .
Low generator output at platform receptacles. Verify generator is running at 3600 rpm for 60 Hz, 3000 rpm for 50 Hz.
Disconnect stator leads 1, 4, and 90 (if applicable) from circuit breaker CB1, and check continuity between leads.
Replace generator if indicated.
Check capacitor C1 and replace if indicated.
High generator output at platform receptacles. Verify generator is running at 3600 rpm. for 60 Hz, 3000 rpm for 50 Hz.
Erratic generator output at platform receptacles. Check and secure electrical connections at platform, generator, and control box.
Verify generator is running at 3600 rpm. for 60 Hz, 3000 rpm for 50 Hz.
Check circuit breaker CB1 for loose terminals. Check continuity across poles of CB1. Reset or replace CB1 (Refer to
Section – Overload Protection, page 76 ).

Every 250 Hours

Every 1000 hours
Every 1000 hours of operation, service the generator brushes and slip rings. Hostile environments may require more frequent service.
78 31222415 800S HC3, 860SJ HC3

Figure 36. Generator Brushes and Slip Rings

Figure 37. Generator Cleaning

Overload Protection
CAUTION
Stop the engine whenever checking or inspecting the circuit breaker.
The circuit breaker protects the generator windings from overload. If the circuit breaker opens, generator output stops. If the circuit
breaker continues to open, check for faulty equipment connected to the platform receptacles.
BM108097A
Figure 38. Generator Circuit Breaker Location
1. Circuit Breaker
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings

Refer to Figure – Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings, page 80 .
Inspecting Brush Position
Inspect brush alignment with slip rings. View alignment through the air vents in the stator barrel. The brushes must ride completely on
the slip rings.
Inspecting Brushes
Remove the end panel. Inspect the wires. Remove the brush holder assembly. Pull the brushes from the holders.
Replace the brushes if damaged, or if the brush is at or near minimum length.
800S HC3, 860SJ HC3 31222415 79

Cleaning Slip Rings

Visually inspect the slip rings. Under normal use, the rings turn dark brown.
If the slip rings are corroded or their surface is uneven, remove the belt to turn the shaft by hand for cleaning.
Clean the rings with 220 grit emery paper. Remove as little material as possible. If the rings are deeply pitted and do not clean up,
consult generator factory service.
Reinstall the belt, brush holder assembly, and end panel.
Figure 39. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
1. Brush Holder Assembly
2. Brushes
3. Slip Rings
Troubleshooting
Note: For details related to generator circuit diagram refer to Section – 7500W Generator Schematic, page 741 .
80 31222415 800S HC3, 860SJ HC3


Trouble Remedy
No generator output at platform AC receptacles. Be sure generator control switch is turned on at platform.
Check and secure electrical connections at platform, generator, and control box.
Be sure all equipment is turned off when starting unit.
Reset circuit breaker CB1.

Check plug PLG3 connection and/or connections at receptacles RC3 and RC5.
Be sure + 12 volts DC input voltage is being supplied to control box.
Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes if necessary.
Disconnect leads 12 and 13 from brushes, and check continuity across slip rings (nominal reading is 26 ohms). Replace
generator if rotor is open.
Disconnect stator weld leads 1, 2, and 3 from circuit breaker CB1 , and check continuity between leads. Replace
generator if necessary.
Disconnect plug PLG4 and check continuity between exciter leads 5 and 6. Replace generator if necessary.
Check power board PC1 and connections, and replace if necessary.
Check control board PC2 and connections, and replace if necessary.
Low generator output at platform AC receptacles. Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
Disconnect leads 12 and 13 from brushes, and check continuity across slip rings nominal reading is 26 ohms). Replace
Disconnect stator weld leads 1, 2, and 3 from circuit breaker CB1, and check continuity between leads. Replace
generator if necessary.
Disconnect plug PLG4 and check continuity between exciter leads 5 and 6. Replace generator if necessary.
High generator output at platform AC receptacles. Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
Erratic generator output at platform AC receptacles. Check and secure electrical connections at platform, generator, and control box.
Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes n necessary.
Disconnect leads 12 and 13 from brushes, and check continuity across slip rings nominal reading is 26 ohms). Replace
800S HC3, 860SJ HC3 31222415 81

82
SECTION 4
TESTING, CALIBRATIONS AND SPECIAL PROCEDURES
4.1 SPECIAL TOOLS
4.1.1 Multimeter Basics

A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. This section shows diagrams
of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary. Please consult the
meter operator’s manual for more information.
Grounding
“Grounding the meter” means to take the black lead (which is connected to the COM (common) or negative port) and touch it to a good
path to the negative side of the Voltage source.
Backprobing
To “backprobe” means to take the measurement by accessing a connector’s contact on the same side as the wires, the back of the
connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type, great care must be
taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specifically designed for this technique,
especially on sealed connectors. Whenever possible insert probes into the side of the connector such that the test also checks both
terminals of the connection. It is possible to inspect a connection within a closed connector by backprobing both sides of a connector
terminal and measuring resistance. Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector.
Min/Max
Use of the “Min/Max” recording feature of some meters can help when taking measurements of intermittent conditions while alone. For
example, you can read voltage applied to a solenoid when it is only operational while a switch, far from the solenoid and meter, is held
down.
Polarity
Getting a negative Voltage or current reading when expecting a positive reading frequently means the leads are reversed. Check what
reading is expected, location of the signal and leads are correctly connected to the device under test. Also check the lead on the “COM”
port goes to the ground or negative side of the signal and lead on the other port goes to the positive side of the signal.
Scale
M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
m = milli = (Displayed Number) / 1,000
µ = micro = (Displayed Number) / 1,000,000
Example: 1.2 kW = 1200 W
Example: 50 mA = 0.05 A
800S HC3, 860SJ HC3 31222415 83

Testing, Calibrations and Special Procedures
Voltage Measurement
• If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual).
• Use firm contact with meter leads.
Resistance Measurement
• First test meter and leads by touching leads together. Resistance should read a short circuit (very low resistance).
• Circuit power must be turned OFF before testing resistance.
• Disconnect component from circuit before testing.
• If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual).
84 31222415 800S HC3, 860SJ HC3

Continuity Measurement
• Some meters require a separate button press to enable audible continuity testing.
• Circuit power must be turned OFF before testing continuity.
• Disconnect component from circuit before testing.
• First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity.
Current Measurement
• Set up meter for expected current range.
• Be sure to connect meter leads to correct jacks for selected current range.
• If meter is not auto ranging, set it to correct range (See multi meter’s operation manual).
800S HC3, 860SJ HC3 31222415 85

4.1.2 Threadlocking Compound
JLG PN Loctite® ND Industries Description

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

For additional special tools required, refer to the Tools Catalog.
The Tools Catalog can be found on JLG Online Express www.onlineexpress.jlg.com; JLG Catalog Part Number 401002.
86 31222415 800S HC3, 860SJ HC3

4.2 TESTING PROCEDURES
4.2.1 Starter
C BM110620A
Figure 40. Location of Starter
A. For Deutz TD2.9L4 (T4F, Stage V, China III and IV) Engines B. For Deutz D2011LO40 (T4I)
C. For Ford MSG425-DF 1. Starter
Testing Starter on Engine

If starter (1) does not engage when ignition key switch is turned, check following:
1. Main fuse may be blown, requiring replacement. Check for cause of blown fuse.
800S HC3, 860SJ HC3 31222415 87

2. There may be a defect in ignition key switch, ignition wiring or starter solenoid.
3. Check battery condition. Clean battery posts and connectors at each end of battery cables.
4. Check for broken wiring and damaged insulation on wiring. Replace all broken or damaged wiring.
5. Check all connections at starter solenoid, key switch and wiring harness plugs. Clean and tighten all connections.
6. If starter still does not operate after these checks have been performed, check starting circuit.
7. Refer to Section – Starter, page 388 for removal and installation.
Starter Circuit Checks

1. Check wires and connections for looseness, corrosion, damage, etc.
2. If a “whirring” no ise is heard but engine do es no t turn o ver, starter is spinning but no t engaging flywheel. The starter drive or
solenoid that pushes drive forward to engage flywheel may be defective. Missing or damaged teeth on flywheel can also prevent
starter from cranking engine.
3. If starter only “clicks” it may indicate that battery is discharged, or that there is a loose or corroded battery cable connection. Check
battery state of charge and battery condition first, then check cables and cable connections.
4. For additional information on starting circuit, Refer to Section – Electrical Schematics, page 711.
88 31222415 800S HC3, 860SJ HC3

Charging Circuit
C
BM110621A
Figure 41. Location of Alternator
A. For Deutz TD2.9L4 (T4F, Stage V, China III and IV) Engines B. For Deutz D2011LO40 (T4I)
C. For Ford MSG425-DF 2. Alternator
Before using a battery charger, an attempt can be made to recharge battery by jump-starting machine (refer to the appropriate
Operation and Safety Manual). Allow engine to run, which will enable alternator (2) to charge the battery.
If engine alternator charging warning indicator illuminates, perform following checks:
1. Check all battery cable connections at battery, and verify that they are clean and tight.
2. Check external alternator wiring and connections, and verify that they are in good condition.
800S HC3, 860SJ HC3 31222415 89

3. Check fan belt condition and tension.
4. Run engine and check alternator for noise. A loose drive pulley, loose mounting hardware, worn or dirty internal alternator
bearings, a defective stator or defective diodes can cause noise. Replace a worn or defective alternator.
Note: Refer to Section – Alternator, page 390 for removal and installation of alternator.
4.2.2 SkyGuard®
Operation
SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actuation
will reverse or cutout. The SkyGuard Function Table provides more details on these functions.
Consult the following illustrations to determine which type of SkyGuard the machine is equipped with. Regardless of the type, SkyGuard
function according to the SkyGuard Function Table does not change.
WARNING
The machine operator is required to perform a daily function test to ensure proper
operation of the SkyGuard system.
Function Test
SKYGUARD ONLY
Perform this function test if SkyGuard only is selected in machine setup (refer to Table — Machine Configuration Programming
Information (Software Version P6.40), page 141).
From the Platform Control Console in an area free from obstructions:
1. Operate the telescope out function, then activate SkyGuard sensor.
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2. Once sensor has been activated, ensure telescope out function stops then telescope in function operates for a short duration.
Additionally, verify Soft Touch/SkyGuard indicator light flashes and horn sounds. If machine is equipped with SkyGuard beacon,
ensure it flashes when sensor activates.
3. With SkyGuard sensor still engaged, press and hold yellow Soft Touch/SkyGuard override button. Operate a function to verify
operation can be resumed.
4. Disengage SkyGuard sensor, release controls, and recycle footswitch. Ensure normal operation available.
In Ground Mode:
1. Operation is allowed regardless of SkyGuard activation.
BOTH SKYGUARD AND SOFT TOUCH

Perform this procedure if both SkyGuard and Soft Touch are selected in machine setup (refer to Table — Machine Configuration
Programming Information (Software Version P6.40), page 141).
From the Platform Control Console in an area free from obstructions:
Note: Machine will treat Soft Touch/SkyGuard override switch as if it is a Soft Touch and SkyGuard switch.
1. Operate the telescope out function, then activate Sky-Guard sensor.
2. Once sensor has been activated, ensure telescope out function stops. Additionally, verify Soft Touch/SkyGuard indicator light
flashes and horn sounds. If machine is equipped with SkyGuard beacon, ensure it flashes when sensor activates.
3. With SkyGuard sensor still engaged, press and hold yellow Soft Touch/SkyGuard override button. Operate a function to verify
operation can be resumed.
4. Disengage SkyGuard sensor, release controls, and recycle footswitch. Ensure sure normal operation is available.
In Ground Mode:
1. Operation is allowed regardless of SkyGuard activation.
SOFT TOUCH ONLY

If Soft Touch only is selected in machine setup (refer to Table — Machine Configuration Programming Information (Software Version
P6.40), page 141), machine will treat the Soft Touch/SkyGuard override switch as if it is a Soft Touch switch.
SKYGUARD NOT SELECTED IN MACHINE SETUP

If the SkyGuard system is installed on the machine, but no option is selected in the machine setup (refer to Table — Machine
Configuration Programming Information (Software Version P6.40), page 141), SkyGuard sensor status will be ignored. No function cutout or
reversal will be implemented.
Diagnostics and Troubleshooting
If SkyGuard does not function when the sensor is engaged, first verify the configuration under the MACHINE SETUP: SKYGUARD OPTION
menu using the handheld Analyzer. Ensure the selected configuration matches the actual system installed on the machine. If not, select
the correct configuration, then verify operation.
Additionally, use the handheld analyzer to navigate to the DIAGNOSTICS: FEATURES → SKYGUARD INPUTS menu to determine additional
SkyGuard fault information.
Engage the SkyGuard sensor and observe the Analyzer to determine if the switch/relay closes.
If the status of the switch/relay remains OPEN while the SkyGuard sensor is actively engaged, it is possible the sensor has failed and
should be replaced immediately.
If the status of the switch/relay remains CLOSED while the SkyGuard sensor is actively engaged, a power or ground wire may not be
making good contact or may be loose or broken. Additionally, there is a low probability that both relays may have failed.
If the switch/relay status is in disagreement, then one may have failed or is not installed correctly. In this case, the machine will be
inoperable.
FAULT CODES
Refer to Table – Diagnostic Trouble Code Chart (DTC), page 245 for more fault code information.
800S HC3, 860SJ HC3 31222415 91

• 0039 – SkyGuard switch activation fault
• 2563 – switch disagreement fault
Table 16. SkyGuard Function Table
Drive Drive Boom Lift Boom Lift Boom Tele Boom Tele Basket Basket
Steer Swing Jib Lift
Forward Reverse Up Down Out In Level Rotate
R*/C** R C R R R R C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
*DOS (Drive Orientation System) Enabled
**DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active
Note: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing.
4.2.3 LSS Testing and Evaluation

Preparation
Refer to Section – Troubleshooting, page 93 if the Load Sensing System (LSS) fails to meet these guidelines.
1. Connect the JLG Analyzer.
2. Remove all items from the platform, except permanently fixed JLG Accessories. This includes all tools, debris, and customer-
installed devices.
3. Gently shake or move the platform to settle the platform LSS components. (Generally, the technician stepping into and out of the
platform is sufficient).
4. Level the Platform: The platform should be approximately level for accurate evaluation, or the testing, calibration and other
guidelines will not be applicable.
Level the platform from Ground Control (if necessary) to within ±5 degrees.
5. Observe Empty Platform Weight:

a. Remove all tools, debris, and customer installed devices if not already completed.
b. Proceed to the DIAGNOSTICS, FEATURES, LOAD sub-menu.
c. Observe and record the measured platform load.
Ideally, the LOAD should be zero but can vary ±15 lb. (± 7 kg). The reading should be stable and should not vary by more
than ±2 lb. (±1 kg) (unless there is heavy influence from wind or vibration).
Testing LSS Control System Warnings and Interlocks:
Platform Mode
1. Using the keyswitch, select Platform Mode and power-up.
2. Start the machine’s engine and ensure that all controls are functional and the Load Sensing System’s Overload Visual and Audible
Warnings are not active.
3. Simulate an Overload by unplugging the Shear Beam Load Cell. The Overload Visual Warning should flash, and the Audible
Warning (at Platform and Ground) should sound for 5 seconds On, and 2 seconds Off. With the engine running, all control should
be prevented.
4. Cycle the Platform EMS to stop the engine and then power-up again. The Overload Visual and Audible Warnings should continue.
5. Verify that platform controls are now responsive when using the Auxiliary Power Unit (for emergency movement).
6. Reconnect the Load Cell. The Overload Visual and Audible Warnings should cease and normal control function should return.
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Ground Mode
1. Using the keyswitch, select Ground Mode and power-up.
2. Start the machine’s engine and ensure that all controls are functional and the Load Sensing System’s Overload Visual and Audible
Warnings are not active.
3. Simulate an Overload by unplugging the Shear Beam Load Cell. The Overload Visual Warning should flash, and the Audible
Warning (at Platform and Ground) should sound for 5 seconds On, and 2 seconds Off. Controls will remain functional.
Note: The Ground Mode default software settings will allow controls to remain functional when using the engine or the Auxiliary
Power Unit. (2=CUTOUT PLT software setting).
In Ground Mode, to prevent control in an Overload state during engine power:
a. Proceed to the MACHINE SETUP, LOAD SYSTEM sub-menu.
b. Using the arrow keys, set to 3=CUTOUTALL.
4. Reconnect the Load Cell. The Overload Visual and Audible Warnings should cease.
Testing LSS Platform Load Reading with Calibrated Weights:

This test confirms the LSS is accurately reporting platform load. An accurate empty platform weight must be observed prior to executing
this procedure.
1. From Ground Control, place the boom in the transport position (fully stowed).
2. Plug the JLG Analyzer into the control system connection and proceed to the DIAGNOSTICS, FEATURES, LOAD display.
3. Place calibrated weight (Example: 500 lbs. [230 kg]) in the platform and ensure that LOAD is within ±5% of the actual weight.
For machines with multiple capacities, repeat steps above for each alternate capacity (unrestricted or restricted zones) with weights
corresponding to the zone.
If test is not successful, the LSS should be re-calibrated. Refer to Section – Calibration Procedures, page 94.
Testing LSS Platform Load Reading with a Known Weight:
This test confirms the LSS is accurately reporting platform load when calibrated weights are not available. If other known weights are
also not available, the technician weight may be used to evaluate (as described in the procedure). An accurate empty platform weight
must be observed prior to executing this procedure.
1. From Ground Control, place the boom in the transport position (fully stowed).
2. Plug the JLG Analyzer into the control system connection and proceed to the DIAGNOSTICS, FEATURES, LOAD display.
3. The technician should enter and stand in the center of the platform and record the LOAD reading. Ensure the LOAD is within ±5%
of the technician’s actual weight.
If test is not successful, the LSS should be re-calibrated. Refer to Section – Calibration Procedures, page 94.
4.2.4 Troubleshooting
The following tables are furnished to provide possible resolutions for common difficulties. Difficulties are classified as General,
Calibration, Measurement Performance, and Host System Functionality.
Table 17. LSS Troubleshooting Chart

Difficulty Possible Resolution
Empty Platform Weight (DIAGNOSTICS, The LSS System is unable to properly measure the platform weight.
PLATFORM LOAD) is not within ±15 lb. (±7 1. The Load Cell is not properly plugged into the LSS Harness. It is possible poor electrical contact is made.
kg) of zero.
or 2. Wiring leading to the Load Cell is damaged. Carefully inspect sensor wiring where it passes through cable clamps for signs of
damage. Inspect wiring where damage to the channel is apparent.
Platform Load readings (DIAGNOSTICS, 3. The Load Cell was not assembled properly during installation. Examine the sensor’s reading using the JLG Analyzer. Proceed to
PLTLOAD) are unstable by more than ±2 lb. the DIAGNOSTICS, CELL, LOAD displays and determine if the readings are reasonable. It is often helpful to apply slight downward
800S HC3, 860SJ HC3 31222415 93

Table 17. LSS Troubleshooting Chart (continued)

Difficulty Possible Resolution
(±1 kg) (without the influence of vibration pressure above the sensor and observe that its output increases (increasing force measurement; decreasing means the sensor is
or wind). mounted upside-down).
or 4. The Load Cell is contaminated by debris or moisture. Examine the sensor’s reading using the JLG Analyzer. Proceed to the
DIAGNOSTICS, CELL, LOAD displays and determine if the readings are reasonable and stable (not changing by more than ±2 lb.
(±1 kg) (without the influence of vibration or wind). Lack of measurement stability is a key indication of contamination. Unplug
the connector and inspect for dirt or moisture. Look carefully into the female connector on the sensor’s cordset for evidence of
contamination. Debris should be brushed away with a soft bristle brush (do not introduce any cleaners as they will leave
conductive residue). Moisture should be allowed to evaporate or accelerated with a heat-gun (use low heat and be carefully to
not melt connector materials). Moisture intrusion into the molded portion of the connector (capillary action into the wire bundle)
or the Shear Beam Load Cell itself will require replacement of the sensor.
There are large variations in Platform Load 5. The Load Cell has been mechanically damaged. If the Load Cell is physically deformed or has damage to the cover it should be
(DIAGNOSTICS, PLTLOAD) based on the replaced immediately. It is also possible to have invisible mechanical damage resulting from an extreme overload (>6000 lb.
location of the load. Tolerance to variations [>2722 kg]).
is 20 lb. (9 kg) for an evaluation using the
technician's weight, and +5% of Rated
Load when using calibrated weights.
The Visual and Audible Overload Warnings The Control System is failing to regard the overload signal from the LSS System, or the signal is shorted.
fail to sound when platform is loaded 1. The Load Sensing System must be enabled within the Control System. Plug the JLG Analyzer into the Control System, enter
beyond Rated Load, or when simulated by the Access Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu. The selection “2=CUTOUT PLT” should
unplugging the Load Cell. Controls remain be displayed (platform controls prevented during overload, ground controls remain operational). In country- or customer-specific
functional at Platform and Ground Control circumstance, the selection “3=CUTOUT ALL” is used (platform and ground controls prevented during overload).
positions.
The Ground Audible Warning fails to sound, The Ground Alarm is missing or improperly installed. Verify that the device is mounted. Verify wiring from the Main Terminal
but the Platform Audible Warning sounds Box and Ground Module.
properly.
Controls remain functional at the Ground The JLG Control System is configured to prevent platform controls only in the event of overload. Alternately, the Host Control
Control position during an overload, or System can be configured to prevent ground and platform controls for country- or customer-specific circumstances.
when simulated by unplugging the Load Using the JLG Analyzer, enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this
Cell. The Controls at the Platform Control parameter to “2=CUTOUT PLT” to prevent platform controls in the event of overload. Set this parameter to “3=CUTOUT ALL” to
position are prevented when using the prevent platform and ground controls in the event of overload.
engine, but not when using the Auxiliary
Power Unit.
4.3 CALIBRATION PROCEDURES
4.3.1 JLG Analyzer

Calibration procedures are performed using the JLG Analyzer. For usage and functions of the JLG Analyzer refer to Section – JLG Analyzer,
page 121.
This machine incorporates a variety of sensors and a high degree of function interaction. To maintain proper machine functionality, the
calibration procedures must be repeated for any control module replacement, system calibration related fault, or removal or
replacement of any sensors, valves, coils, motors, or pumps.
4.3.2 Calibration Preparation

Check and execute the following to prepare for calibration and verification.
1. Park the machine on a level surface with a slope less than or equal to 0.5 degrees.
2. Fully retract the boom and lower the platform. Ensure the platform is level within ± 5 degrees in both directions.
3. Ensure wind speed is less than or equal to 20 mph (32 kph).
4. Ensure the batteries are fully charged and hydraulic fluid level is acceptable.
94 31222415 800S HC3, 860SJ HC3

5. Resolve any active control system faults.
6. Remove all foreign materials from the platform. This includes all tools, debris, and non-permanent customer-installed devices.
7. Install any JLG Accessories that will be permanently attached (Pipe Racks, SkyGlazier, etc.).
8. If using weights to calibrate, center and evenly distribute known or calibrated weight in the platform.
9. Gently shake or move the platform to settle the platform LSS components. (Generally, the technician stepping into and out of the
platform is sufficient).
4.3.3 Load Sensing System Calibration
Note: All calibration preparation steps must be completed prior to executing calibration procedures.
1. Using the keyswitch, select Ground Mode. LSS Calibration must be performed in Ground Mode.
2. Pull out the Emergency Stop switch and start the engine.
3. Plug the JLG Analyzer into the machine at the Ground Station. The JLG Analyzer enters Operator Access
(Level 2) by default. The Calibration Menu is not available in Operator Access.
4. Go to Service Access (Level 1) by entering password 33271 at the prompt.
5. Use the arrow keys to reach the CALIBRATIONS menu. Press Enter.
Upon entry to the Calibration Menu, the JLG Control System will link to the Analyzer.
6. Use the arrow keys to reach LOAD SENSING menu. The screen will read “CALIBRATION: LOAD SENSING”.
7. Press Enter, the screen will read “LOAD SENSING: CALIBRATE?”.
Note: Calibration will automatically fail if LSS DTC's are active (443, 444, 4479, 4480, 663, 821, 822, 823, 824, 8218, 8222 -> 8238, 991,
992, 993, 994 or 99285).
Pressing the ESC key after starting calibration and before calibration is complete will display the CAL FAILED message. This will not disturb
the prior calibration information.
8. Press Enter, the screen will read “LOAD SENSING: PLATFORM EMPTY?”.
9. Universal Ground Module (UGM) will set the Accessory Weight default value. Press Enter. The screen will read “LOAD SENSING: ACCESSORY
XXX”. (lb. or kg)
Calculate the total weight of all installed accessories using the Accessory Weights Table. Use the arrow keys to enter the total additional
accessory weight at the prompt.
EXAMPLE: The machine has the SkyCutter/SkyWelder Combo, Fire Extinguisher and Work Surface installed. The technician enters 205 lb.
(93 kg) at the accessory weight prompt.
SkyCutter/SkyWelder Combo 140 lb. (64 kg)
800S HC3, 860SJ HC3 31222415 95

Fire Extinguisher 45 lb. (20 kg)

Work Surface 20 lb. (9 kg)
205 lb. (93
Total kg)
Note: Accessory weight will reset to 0 lb. (0 kg) each time the machine is re-calibrated and will need to be re-entered.
Note: The Accessory weight will be temporarily stored in the Control System until calibration has been completed successfully. Refer to
Table — Accessory Weights, page 96.
Table 18. Accessory Weights

ACCESSORY WEIGHT
SkyWelder (Stick welder) 70 lb. (32 kg)
Prep only = 15 lb. (7 kg)

SkyWelder Prep
Full install = 70 lb. (32 kg)
SkyCutter (Plasma cutter) 70 lb. (32 kg)
SkyCutter / SkyWelder Combo 140 lb. (64 kg)
Fire Extinguisher 45 lb. (20 kg)
Overhead SoftTouch 80 lb. (36 kg)
Work Surface 20 lb. (9 kg)
Note: Not all Accessories are available on every JLG model. Some Accessory combinations are prohibited due to excessive weight and/or load restriction.
If any installed JLG Accessories are labeled with weight decals but are not listed in the table above, include their weight when entering the ACC WEIGHT value.
10. Press Enter, the screen will read “LOAD SENSING: CALIBRATING”.
11. UGM will set the Glazier default value. Press Enter. The screen will read “LOAD SENSING: SKY GLAZIER? X”.
Use the analyzer keys to select N for no or Y for yes.
12. UGM will set the Pipe Racks default value. Press Enter. The screen will read: “LOAD SENSING: PIPE RACKS? X”.
Use the analyzer keys to select N for no or Y for yes.
Note: If both SkyGlazier and Pipe Racks are configured, capacity will be the lower of the two values.
Table 19. SkyGlazier and Pipe Rack Capacity Reductions

SKYGLAZIER CAPACITY REDUCTIONS PIPE RACK CAPACITY REDUCTIONS
CAPACITY
PLATFORM OVRLD PLATFORM OVRLD RESTRICT PLATFORM OVRLD PLATFORM OVRLD RESTRICT
500 lb. (227 kg) 400 lb. (181 kg) N/A 400 lb. (181 kg) N/A
750 lb. (340 kg) N/A 590 lb. (268 kg) N/A 650 lb. (295 kg)
1000 lb. (454 kg) N/A 750 lb. (340 kg) N/A 900 lb. (408 kg)
96 31222415 800S HC3, 860SJ HC3

13. UGM will set the Unrestricted Rated Load. Press Enter. The screen will read “LOAD SENSING UNRSTRICT XXXLBS”.
14. UGM will set the Restricted Rated Load. Press Enter. The screen will read “LOAD SENSING: RSTRICT XXXXLBS”.
15. After a few seconds, the screen will read “LOAD SENSING: CAL COMPLETE”.
16. Press ESC twice to return to CALIBRATIONS menu.
4.3.4 Tilt Sensor Calibration
WARNING
Do not calibrate the tilt sensor except on a level surface.
1. Place the machine on a firm, level surface.
2. Using the analyzer, go to Service Access level. Refer to Changing the Access Level of the Hand Held Analyzer in this section.
3. Using the arrow keys, navigate to Calibrations Menu as shown below and press ENTER .
800S HC3, 860SJ HC3 31222415 97

4. Using the arrow keys, navigate to Calibrations Menu as shown below and press ENTER .
5. The screen will then read:
6. When the sensor is calibrated in that position, the screen will read:
98 31222415 800S HC3, 860SJ HC3

7. Swing the machine 180 degrees, making sure the boom is centered and in the transport position, and ENTER . The screen will
read:
8. When the calibration is complete the screen will read as shown below. Return the machine to the travel position.
800S HC3, 860SJ HC3 31222415 99

4.3.5 Boom Angle Calibration

1. To access the Calibration Menu, use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu. The screen
will read:
2. Press the ENTER key to view the menu. Upon entry to the Calibration Menu, the JLG Control System will link to the Analyzer
and the screen will read:
100 31222415 800S HC3, 860SJ HC3

3. Hit Enter. The screen will read.
4. UGM will confirm the tilt sensor calibration. The screen will read.
5. Hit Enter. The screen will read.
800S HC3, 860SJ HC3 31222415 101

6. UGM will confirm the Boom In-Line position. The screen will read:
7. Hit Enter. The Screen will read:
8. When the sensor is calibrated at lower position of the boom. The screen will read:
102 31222415 800S HC3, 860SJ HC3

11. UGM will confirm the position of the boom. Press Enter. The screen will read:
800S HC3, 860SJ HC3 31222415 103

12. When the sensor is calibrated at upper position of the boom. The screen will read:
13. UGM will confirm the position of the boom. Press Enter. The screen will read:
104 31222415 800S HC3, 860SJ HC3

15. After few seconds. The screen will read:
16. Hit ESC twice to go back to CALIBRATIONS.
4.3.6 Resetting The MSSO System (CE/UKCA Only)

1. Use the following procedure to reset the MSSO system.
2. Position the Platform/Ground select switch to the desired position.
3. Plug the analyzer into the connector coming from the ground control module or from the platform console.
Note: If performing the procedure from the platform console, the Emergency Stop switch on the ground console must also be
pulled out.
4. Pull out the Emergency Stop switch.
5. The analyzer screen should read:
6. Use the arrow button to reach OPERATOR ACCESS. Press Enter .
7. Enter the Access Code, 33271.
800S HC3, 860SJ HC3 31222415 105

8. Use the right Arrow key to reach MENU: CALIBRATIONS. Press Enter .
9. Use the arrow keys to reach the MSSO menu. The screen should read:
10. Press ENTER .
11. Use the Down arrow to reach MSSO RESET.
106 31222415 800S HC3, 860SJ HC3

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.
4.3.7 Calibrating the Load Sensor

1. Place the boom in the following position.
a. Boom - Stowed
b. Telescope - In
c. Jib - 0 Degrees
d. Swing - 0 Degrees
e. Basket Level - 0 Degrees
f. Basket Rotate - 0 Degrees
g. Weight in Basket - 0
h. Machine parked on firm, level surface
2. Activate both emergency stop switches and turn the key switch to the platform position.
3. Remove all loads from the platform, including the operator.
4. Turn P1 clockwise (in) until the potentiometer begins to click.
5. Plug the analyzer into the port in the platform.
6. Select Access Level from Main Menu.
7. Enter 33271.
8. Select Machine Set-Up>Load Cell>1 Warn Only.
9. Select Machine Diagnostics>System Load Cell on the Analyzer.
10. Adjust P2 until the Load = 0%.
11. Place 525 lb. (238 kg) in the center of the basket.
13. Verify that the overload indicator lights continuously and the alarm sounds continuously during an overload condition.
800S HC3, 860SJ HC3 31222415 107

14. Remove the weight from the platform.
16. Place 525 lb. (238 kg) in the center of the basket.
18. Remove the weight from the basket.
19. Seal the potentiometers with fingernail polish.
Figure 42. Load Sensing Device
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4.4 SPECIAL PROCEDURES
4.4.1 Drive Cutout Override Service Mode
WARNING
The service modes in this section should be used with extreme caution as they
override the normal boom envelope control system. Improper use can result in
component interference/damage or machine instability, personnel injury or death.
The Drive Cutout Override Mode provides a qualified service technician a means to move the machine to a safe area for troubleshooting
and repair.
1. Plug the analyzer into the connector at the base of the platform control box.
2. Pull out the emergency stop switch.
3. The analyzer screen should read: HELP-PRESS ENTER.
4. Use the arrow button to reach ACCESS LEVEL 2. Press the enter key.
5. Enter the Access Code 33271 to get into ACCESS LEVEL 1 mode.
Note: The service mode will only be displayed on the analyzer when in access level 1 and be hidden while in access level 2.
NOTICE
The service mode menu will be selectable at the top level of the analyzer menu
structure. “Service Mode” will be displayed on the top line of the analyzer with the
current sub-menu selection on the bottom line. The sub-menus will scroll with the
left and right arrow keys.
6. Scroll the analyzer menu until “SERVICE MODE” is displayed. Press the ENTER key.
7. Scroll the menu until “DRIVE CUTOUT” is displayed on the analyzer screen.
8. Enter code 23732, which allows operator to enable drive cutout override.
Note: This mode will be canceled in the event of a power cycle, disconnect of analyzer or pressing ESC on the analyzer.
4.4.2 Fuel Tank Cleaning and Drying

If contaminated fuel or foreign material is in the tank, clean the tank.
To clean the fuel tank:
1. Have a dry chemical (Class B) fire extinguisher near work area.
2. Remove tank drain plug and safely drain any fuel into a suitable container. Dispose of fuel properly.
WARNING
or sparks are in the area when working on fuel system. Do Not smoke when work-
ing on the fuel systems.
3. Clean fuel tank with a high pressure washer, or flush tank with hot water for five minutes and drain water. Dispose of
contaminated water properly.
800S HC3, 860SJ HC3 31222415 109

4. Add a diesel fuel emulsifying agent to tank. Refer to manufacturer’s instructions for correct emulsifying agent-to water mixture
ratio. Refill tank with water and agitate mixture for 10 minutes. Drain tank completely. Dispose of contaminated water properly.
5. Refill fuel tank with water until it overflows. Completely flush tank with water. Empty fuel tank and allow it to dry completely.
4.4.3 Cylinder Checking Procedure

Checking Cylinder Pressure
Attach a digital or an analog 4000 psi (276 bar) gauge to test port on hydraulic pump to check system pressure.
Adjusting Cylinder Pressure
If a hydraulic cylinder pressure is greater than main control valve pressure, increase main control valve pressure by adjusting the main
relief.
Note: Generally, one half turn clockwise will be adequate to check an individual circuit. Activate circuit and if pressure is obtained turn
main relief counter clockwise one half turn. Re-check main relief setting and adjust if necessary.
4.4.4 Cylinder Drift

Theory
When a hydraulic cylinder is supporting a load, cylinder drift may occur as a result of any of the circumstances below:
• Normal leakage of load holding valves or malfunction of load holding valves. Refer to Section — Cylinder Leakage Test, page 110 and
Table — Cylinder Drift, page 110 below for evaluation.
• Damaged or worn piston seals.
• Normal thermal expansion or contraction of the hydraulic oil within cylinders (Refer to Section — Cylinder Thermal Drift below).
The first two circumstances may result in cylinder movement due to oil leaking out of the cylinder externally or by leaking back to tank
or due to oil leaking internally from one cylinder chamber to the other.
Thermal expansion or contraction of oil in hydraulic cylinders is a normal occurrence and does not result in oil leaking out of the cylinder
or leaking internally from one cylinder chamber to the other. Thermal expansion or contraction is the tendency for materials to change
size in response to a change in temperature.
Cylinder Leakage Test
IMPORTANT
Cylinder oil must be at stabilized ambient temperature before beginning this test.
Measure drift at cylinder rod with a calibrated dial indicator.

In an area free of obstructions, cylinder must have load applied and appropriately positioned to detect drift.
Cylinder leakage is acceptable if it passes this test.
Table 20. Cylinder Drift

Cylinder Bore Diameter Max. Acceptable Drift in 10 Minutes
inches mm inches mm
3 76.2 0.026 0.66
3.5 89 0.019 0.48
4 101.6 0.015 0.38
5 127 0.009 0.22
6 152.4 0.006 0.15
7 177.8 0.005 0.13
110 31222415 800S HC3, 860SJ HC3

Table 20. Cylinder Drift (continued)

Cylinder Bore Diameter Max. Acceptable Drift in 10 Minutes
inches mm inches mm
8 203.2 0.004 0.10
9 228.6 0.003 0.08
Note: This information is based on 6 drops per minute cylinder leakage.
Cylinder Thermal Drift

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

This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, where and how to check those
pressures and a hydraulic schematic.
Electrical and hydraulic functions are often related. Verify that the electrical components of the circuit are functioning properly whenever
troubleshooting the hydraulic circuit.
Always check the following before beginning to troubleshoot a circuit that is not functioning correctly.
1. Check the hydraulic oil level in the reservoir. If oil is cold, oil level should be visible in the lower gauge window with all cylinders
retracted.
2. Check hoses, tubes, fittings and other hydraulic components for leaks, bends, kinks, interference, etc.
3. Check for air in the hydraulic system. Erratic machine performance and/or spongy cylinder operation are signs of air in the
hydraulic system. If air in the hydraulic system is suspected, you will hear air leakage when hydraulic fittings are loosened and see
air bubbles in the hydraulic fluid. Loose fittings, faulty O-rings or seals, trapped oil, leaks, system opened for service, etc., can cause
air in the system. Determine what is causing air to enter the system and correct it. Bleed air from the system.
4.4.6 Lockout Cylinder Bleeding

1. Start the engine.
2. Position the turntable to the normal stowed position.
3. Attach clear tubing to bleeder valve nipple.
4. Position a small bucket/bottle in front of the lockout cylinder bleeder valve and insert clear tubing.
5. Using a 3/8 in. wrench, loosen the bleeder valve, turning counterclockwise slowly. Bleed air from the top of lockout cylinder.
Capture hydraulic oil until a steady unbroken stream of hydraulic oil is viewed. Tighten/close the bleeder valve while stream of
hydraulic oil is running.
6. Locate the bleeder valve on the opposite side lockout cylinder. Repeat the process.
Bleeder Valve
BM110098A
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4.4.7 Oscillating Axle Lockout Test
NOTICE
Lockout system test must be performed quarterly, any time a system component is
replaced, or when improper system operation is suspected.
Note: Ensure boom is fully retracted, lowered and centered between drive wheels prior to beginning lockout cylinder test.
1. Place a 6 in. (15.2 cm) high block with ascension ramp in front of left front wheel.
2. From platform control console, start engine.
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/TORQUE SELECT control switches to their respective LOW positions.
4. Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of
block.
5. Carefully activate SWING control lever and position boom over right side of machine.
6. With boom over right side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp.
7. Have an assistant check to see that left front wheel or right rear wheel remains elevated in position off of ground.
8. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches
center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate DRIVE to
release cylinders.
9. Place the 6 in. (15.2 cm) high block with ascension ramp in front of right front wheel.
10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block.
11. Carefully activate SWING control lever and position boom over left side of machine.
12. With boom over left side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp.
13. Have an assistant check to see that right front wheel remains locked in position off of ground.
14. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches
center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate DRIVE to
release cylinders.
15. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.
4.4.8 Free Wheeling Option

To Disengage Drive Motors and Brakes (Free Wheel) for Emergency Towing
1. Chock wheels securely if not on flat level surface.
2. Disconnect both drive hubs by reversing the disconnect caps in the center of the hubs.
3. If equipped, move steer/tow selector valve to float (tow) position by pulling control knob out.
112 31222415 800S HC3, 860SJ HC3

To Engage Drive Motors and Brakes (Normal Operation)

1. If equipped, move steer/tow valve to steer position by pushing valve knob in.
2. Connect both drive hubs by inverting disconnect cap in center of hub.
3. Remove chocks from wheels as required.
4.5 WHEEL DRIVE HUB
4.5.1 Roll and Leak Test

Torque-Hub® units should always be roll and leak tested before disassembly (if possible) and after assembly to make sure the unit’s
gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests.
THE ROLL TEST
The purpose of the roll test is to determine if the unit’s gears are rotating consistently, easily and properly. Release the brake by applying
400 psi (27.5 bar) to the brake port. To perform a roll test, use the recommended tool from table below (or something equivalent) to
apply constant rotational force to the input of the gearbox. If more drag is felt in the gears only at certain points, then the gears are not
rolling consistently and easily and should be examined for improper installation or defects. Some gear packages roll with more difficulty
than others. Do not be concerned if the gears in the unit seem to roll hard as long as they roll with consistency. Rotate the gearbox both
clockwise and counterclockwise the same number of turns as the ratio of the unit. The gearbox ratio is the same number as the last
three numbers on the ID tag.
THE LEAK TEST
The purpose of a leak test is to make sure the unit is airtight. To perform a leak test use the leak test fixture from the table below. If the
tool is not available, the gearbox must be sealed to perform the test. This can be accomplished by assembling the sealed input device
onto the gearbox at the input end and replace one of the oil plugs with an air chuck. Do not exceed 10 psi (0.7 bar) pressure during the
leak test. Higher pressure will create a false sealing effect in assemblies with lip-seals. The unit has a leak if the pressure gauge reading
on your leak check fitting starts to fall after the gearbox has been pressurized and allowed to equalize. Leaks will most likely occur at the
pipe plugs, the main seal or wherever O-rings or gaskets are located. The exact location of a leak can usually be detected by brushing a
soap and water solution around the main seal and where the O-rings or gaskets meet on the exterior of the unit and then checking for
air bubbles. If a leak is detected in a seal, O-ring, or gasket, the part must be replaced and the unit rechecked. Leak test at 10 psi (0.7 bar)
for 20 minutes.
TIGHTENING AND TORQUING BOLTS
If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure the bolts are not tightened beyond their
specified torque. The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle.
800S HC3, 860SJ HC3 31222415 113

1. Tighten (but do not torque) bolt “A” until snug.
2. Go to the opposite side of the bolt circle and tighten bolt “B” until equally snug.
3. Crisscross around the bolt circle and tighten the remaining bolts.
4. Use a torque wrench to apply the specified torque to bolt “A”.
5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts.
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4.6 SWING DRIVE
4.6.1 Roll, Leak and Brake Testing

Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit's gears,
bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests.
Note: The brake must be released before performing the roll test. This can be accomplished by either pressure testing using the Brake
Leak Test procedure below or by tightening the 12 bolts into the piston through the end plate (refer to Section — Motor and
Brake Disassembly, page 570).
Note: Bolts must be removed while performing brake release test.
Roll Test
The purpose of the roll test is to determine if the unit’s gears are rotating freely and properly. Remove Motor and release the brake by
applying 400 psi to the brake port.
To perform a roll test, use a tool capable of applying constant rotational force to the input of the gearbox.
If more drag is felt in the gears only at certain points, then the gears are not rolling consistently and easily and should be examined for
improper installation or defects.
Some gear packages roll with more difficulty than others.
Do not be concerned if the gears in the unit seem to roll hard as long as they roll with consistency.
Rotate the gearbox 36 revolutions both clockwise and counterclockwise.
Leak Test (Main Unit)
The purpose of a leak test is to make sure the unit is airtight. Use tool T201476 refer to Figure — Leak Test Adapter Plate (T201476), page
583 for details to perform the leak test. If the tool is not available, the gearbox must be sealed to perform the test. This can be
accomplished by assembling the sealed input device onto the gearbox at the input end and replace one of the oil plugs with an air
chuck.
Note: Do not exceed 10 psi (0.7 Bar) pressure during the leak test.
Higher pressure will create a false sealing effect in assemblies with lip-seals. The unit has a leak if the pressure gauge reading on your
leak check fitting starts to fall after the gearbox has been pressurized and allowed to equalize. Leaks will most likely occur at the pipe
plugs, the main seal or wherever O-rings or gaskets are located.
The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the O-rings
or gaskets meet on the exterior of the unit and then checking for air bubbles.
If a leak is detected in a seal, O-ring, or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20
minutes.
Brake Test
Prior to brake check remove Motor, Tubing and Elbow as per Motor disassembly instruction. To perform a brake check, use a 7/16-20
thread fitting. Install a hydraulic hand pump with pressure gauge into brake port in Brake Housing using thread fitting.
Place ROLL TEST Tool previously used or equivalent into Sun Gear (8). Apply 25 in.lbs. (2.7 Nm) torque.
While trying to rotate tool, pump the handle on the hydraulic hand pump and increase the pressure until the brake releases. The brake is
released when you are able to rotate the tool.
Record the release pressure. If brake does not release within 197 to 210 psi, check to see if it has the proper number of springs using the
SPRING CHECKING PROCEDURE.
Increase to maximum pressure to 2000 psi and hold at that pressure for one minute. If the brake does not leak or lose pressure, the unit
has passed the brake test. If brake loses pressure, contact JLG service department.
While brake is still released, roll check the unit for one revolution of the output member by rotating the tool. Bleed off pressure slowly
while rotating the ROLL TEST Tool previously used.
Record the pressure at which the brake locks up. Using a clean rag, wipe off excess fluid from around brake port and install the pipe
plug.
800S HC3, 860SJ HC3 31222415 115

Spring Checking Procedure

Install two Flat Socket Head Cap screws 0.250-20 UNC, 1/2 in. length into holes in brake piston. Tighten bolts evenly to ensure that brake
piston remains straight while being compressed into brake cavity of brake housing.
Carefully remove retaining ring from brake housing. Slowly remove bolts evenly from the input brake. Remove the pressure plate from
the end of the input brake and count the number of springs in brake.
If number of springs matches the number 14, go to the next step. If number of springs does not matches the number 14, install the
correct number of springs.
4.6.2 Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their
specified torque.
The following steps describe how to tighten and torque bolts or socket head Cap screws in a bolt circle.
1. Tighten (but do not torque) bolt “A" until snug.
2. Go to the opposite side of the bolt circle and tighten bolt “B” until equally snug.
3. Crisscross around the bolt circle and tighten remaining bolts.
4. Now use a torque wrench to apply the specified torque to bolt “A”.
5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts.
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SECTION 5
SYSTEM SOFTWARE
5.1 LOAD SENSING SYSTEM (LSS)
5.1.1 Theory of Operation

The Platform Load Sensing System (LSS) measures platform load from a sensor in the platform support.
If the LSS senses an overload condition (platform load exceeds rated load), the overload alarm will sound and the overload indicator will
flash at both the platform control and the ground control stations.
In the overloaded condition, all normal movement is prevented from the platform control position (As an option, ground control
functions can also be prevented). To regain boom movement, actual platform load must be reduced until it is less than Rated Load (as
indicated on the capacity decal). If unable to resolve an overload condition, authorized personnel may use the emergency override
system (Auxiliary Power) to return the platform to a safe working condition.
Calibration
Calibrate the LSS when one or more of the following conditions occur:
1. Removal or replacement of LSS sensor.
2. Removal or addition of certain platform-mounted accessories. Refer to Section – Calibration Procedures (LSS), page 94.
3. Removal, replacement, or repair of platform.
4. Platform shows evidence of impact.
Note: For detailed LSS calibration instruction refer to Section – Calibration Procedures (LSS), page 94.
NOTICE
The LSS requires periodic function verification not to exceed 6 months from pre-
vious verification. Refer to Section – LSS Testing And Evaluation, page 92.
Capacity Zones (Triple Capacity)

This machine is equipped with a Triple Capacity System with one unrestricted and two restricted capacity zones. The control system will
light the applicable capacity zone indicator in both the platform control and the ground control stations based on the location of and
load on the platform.
When platform load is equal to or less than 500 lb. (227 kg), the platform position is unrestricted within the full machine envelope
boundary. When platform load is between 500 lb. (227 kg) and 750 lb. (340 kg) the platform position is restricted within a smaller
working envelope boundary. When platform load is between 750 lb. (340 kg) and 1000 lb. (454 kg) the platform position is further
restricted to the smallest working envelope.
If the operator attempts to cross a boundary into a zone of lesser or no restriction with a greater load than allowed, the machine will
stop at the boundary.
Capacity Limits with Accessories
Accessories mounted to the platform have an impact on the LSS capacity limit.
Accessories like SkyWelder reduce the LSS capacity limit according to their weight, and the load setting must be set to account for their
total weight. Accessories like SkyGlazier or Pipe Racks, which are attached to the platform exterior or extend (or hold materials that
extend) outside of the platform, reduce the LSS capacity limit by more than the weight of equipment. The farther the material or
equipment weight is from the center of the platform, the greater the platform’s capacity is affected and must be reduced. Platform
capacity is based on an evenly distributed load in the platform.
JLG accessories display a decal with their effective contribution (weight) toward rated load. If this decal is missing or if fitting more than
one accessory to a machine, follow the documentation furnished with factory-provided accessories or consult JLG.
800S HC3, 860SJ HC3 31222415 117

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5.1.2 Load Sensing Gauge Removal/ Installation

Note: Refer to Figure – Load Sensing Gauge Removal/ Installation, page 119 for removal and Installation procedure.
Removal
1. Park machine on a firm level surface, fully retract boom, lower boom until on machine's boom rest stop.
5. Disconnect the load sensing gauge (4) electrical connection from connecting point at bottom of Platform console box.
6. Remove nut (10), bolt (13), washer (11) and clamp (12) attaching sensor cable (5) on side plate of rotator support weldment (8) as
shown in Figure – Load Sensing Gauge Removal/ Installation, page 119.
Note: If necessary, refer Removal/Installation instructions on Section – Platform Support, page 337.
7. Loosen the nut (14) at mounting plate (7) of platform support weldment (6).
8. Remove nuts (2), bolts (1) and washer (3) attaching load sensing gauge (4) to the mounting plate (9) of rotator support weldment
(8).
9. Carefully remove the load sensing gauge (4) from rotator support weldment (8).
Installation
CAUTION
Make sure that the platform and rotator assembly are free from any dirt and debris.
Properly clean the mounting and adjacent areas.
Note: Apply medium strength threadlocking compound to hardware before installation.
Note: Make sure that the screw head is centrally aligned with the round head of the carriage bolt located above as shown in Figure —
Load Sensing Gauge Removal/ Installation, page 119.
1. Position load sensing gauge (4) on the mounting plate (9) of rotator support weldment (8).
2. Attach load sensing gauge (4) on the mounting plate (9) of rotator support weldment (8) using bolts (1), washer (3) and nuts (2).
Torque nuts to 49 ft. lbs. (67 Nm).
3. Tighten the nut (14) at mounting plate (7) of platform support weldment (6) to make sure that sensing gauge are tightly fit.
Torque the nut to 71.5 ft. lbs. (97 Nm).
Note: Make sure that the engrave arrow on body of sensor should face away from the head of the bolt (1).
4. Route and attach sensor cable (5) at side plate of rotator support weldment (8) using clamp (12), washer (11), bolt (13) and nut
(10).
5. Connect electrical connector of the load sensing gauge (4) with electrical connector at bottom of platform console box.
6. Connect battery power to the machine.
8. Insert the key, pull out power/emergency stop switch (up) to ON and turn key select switch to ground position.
9. Calibrate the load sensing gauge (4). Refer to Figure — Load Sensing Gauge Removal/Installation, page 119.
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System Software
1 13
11
11
12
10
5
4
3 8
14
7 9
SECTIONAL VIEW OF LOAD SENSING GAUGE

BM111636A
Figure 43. Load Sensing Gauge Removal/Installation
800S HC3, 860SJ HC3 31222415 119

System Software
Note: Refer to Figure – Load Sensing Gauge Removal/Installation, page 119, for below callout table.
1. Bolt 6. Platform Support Weldment 11. Washer

2. Nut 7. Mounting Plate 12. Clamp
3. washer 8. Rotator Support Weldment 13. Bolt

4. Load Sensing Gauge 9. Mounting Plate 14. Nut
5. Sensor Cable 10. Nut
Diagnostic Menu
The Diagnostic Menu is another troubleshooting tool for the Load Sensing System. Sensor and status information is presented in real
time for the technician. Several sub-menus exist to organize the data.
Refer to Table – Diagnostic Menu Descriptions, page 120, for the structure of the Diagnostic Menu and the meaning of each piece of
information.
Table 21. Diagnostic Menu Descriptions
Parameter Parameter Value
Diagnostics Menu
(Displayed on Analyzer 2nd (Displayed on Analyzer 2nd Description
(Displayed on Analyzer 1st Line)
Line) Line)
PLATFORM LOAD STATE: OK / OVERLOAD LSS Status.
PLATFORM LOAD ACTUAL: XXX.X KG Calibrated weight of the platform.
??? if Platform Load is Unhealthy**.
PLATFORM LOAD (service*) GROSS: XXX.X KG Gross weight of the platform.

??? if both Cells are Unhealthy**.
PLATFORM LOAD (service*) OFFSET 1: XXX.X KG Stored offset weight of Cell 1.

??? if LSS is not calibrated.
PLATFORM LOAD (service*) OFFSET 2: XXX.X KG Stored offset weight of Cell 1.
PLATFORM LOAD (service*) ACCESSORY XXX.X KG Stored accessory weight.
PLATFORM LOAD (service*) UNRESTRICT XXX.X KG UGM will set Unrestricted Rated Load as defined by Machine
Configuration.
PLATFORM LOAD (service*) RESTRICT XXX.X KG UGM will set Restricted Rated Load as defined by Machine
Configuration.
PLATFORM LOAD (service*) RAW 1: XXX.X KG Gross value from Cell 1.

??? if Unhealthy**.
PLATFORM LOAD (service*) RAW 2: XXX.X KG Gross value from Cell 2.

??? if Unhealthy**.
* Indicates only visible in service view mode

** Typically indicates a DTC is active
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System Software
5.2 JLG ANALYZER
5.2.1 Introduction
NOTICE
When installing a new power module controller on the machine, it will be necessary
to program the controller for the proper machine configuration, including options.
NOTICE
It is a good practice to avoid pressure-washing electrical/electronic components.
Should pressure-washing be utilized to wash areas containing electrical/electronic
components, jlg industries, inc. Recommends a maximum pressure of 750 psi (52
bar) at a minimum distance of 12 in. (30.5 cm) away from these components. If elec-
trical/electronic components are sprayed, spraying must not be direct and be for
brief time periods to avoid heavy saturation.
The JLG designed Control System is a 12 volt based control unit installed on the boom lift.
The JLG Control System has reduced the need for exposed terminal strips, diodes and trimpots and provides simplicity in viewing and
adjusting the various personality settings for smooth control of: acceleration, deceleration, creep, min. speed, and max. speed for all
boom, drive, and steering functions.
The main lift, swing, and drive are controlled by individual joysticks, with steering being controlled by a rocker switch built into the top
the drive joystick. To activate Drive, Lift, and Swing simply pull up on the slide lock location on the joystick and move the handle into the
direction desired.
The control system will control the voltage output to the valves and pump, as programmed for smooth operation and maximum cycle
time. Ground control speeds for all boom functions can also be programmed into the control system.
The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which may be accessed for
troubleshooting. Optional equipment includes a soft touch system, head and tail lights, and ground alarm. These options may be added
later but must be programmed into the control system when installed.
The Control System may be accessed utilizing a custom designed, hand held analyzer (Analyzer Kit, JLG part no. 1001249695) which will
display two lines of information at a time, by scrolling through the program.
Figure 44. Hand Held Analyzer
800S HC3, 860SJ HC3 31222415 121

System Software
5.2.2 To Connect the JLG Control System Analyzer

1. Connect one end of the cable, supplied with the analyzer, to the correct four pin connector on the motor control unit; there will be
only one connector which correctly fits the cable.
2. Connect the other end of the cable to the analyzer.
Note: The ends of the cable are identical and can be reversed; the cable end can only be inserted one way into the matching
connector.
3. Power up the vehicle by turning the key to the platform or ground position and pulling the emergency stop buttons on; this will
power the SMART System and the analyzer.
5.2.3 Using the Analyzer

The analyzer will display the current top level menu item, for example:
MENU:
DIAGNOSTICS
Press LEFT & RIGHT (g, e) to move between menu items; press ENTER to select the displayed menu item.
When a top level menu item is selected, a new set of menu items may be offered; press LEFT RIGHT arrows then ENTER
again to select the required item.
To cancel a selected menu item, press ESCAPE ; then a different menu item can be chosen.
The available menu items will vary depending on the vehicle; check the vehicle manual for more information.
5.2.4 Changing the Access Level of the Hand Held Analyzer

When the analyzer is first connected, its access level ensures that most configurations cannot be changed; this ensures that a setting
cannot be accidentally altered.
To change the access level, a PASSWORD must be entered; the password must be known.
To enter a password, first find the appropriate top level menu item:
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System Software
MENU:
ACCESS LEVEL 3
Press ENTER to select the ACCESS LEVEL item; then press UP & DOWN arrows and LEFT & RIGHT arrows to
enter the correct five digit password:
ACCESS LEVEL:
CODE 33271
When the correct password is displayed, press ENTER to confirm it; the access level will change to match the password (if not, press
ENTER to check and correct the password).

The correct passwords will vary depending on the vehicle; check the vehicle manual for more information.
5.2.5 Adjusting Configuration Using the Hand Held Analyzer
When a personality item is selected, press UP & DOWN arrows to adjust its value, for example:
800S HC3, 860SJ HC3 31222415 123

System Software
PERSONALITIES:
DRIVE ACCEL 1.0s
There will be a maximum and minimum for the value to ensure safe, operation; the value will not increase if UP is pressed when at
the maximum, or if DOWN is pressed when at the minimum.
If the value does not change when UP or DOWN is pressed, check the access level.
5.2.6 Machine Setup
When a machine digit item is selected, press UP & DOWN (e, e) to adjust its value, for example:
GROUND ALARM:
2 = DRIVE
The effect of the machine digit value is displayed along with its value; there will only be certain settings allowed to ensure safe
operation.
If the value does not change when UP or DOWN is pressed, check the access level.
The available personality and machine digit items will vary depending on the vehicle; check the vehicle manual for more information.
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5.2.7 Level Vehicle Description

A new tilt module will act as if it is tilted all of the time until the following procedure is performed.
WARNING
Do not calibrate the level sensor except on a level surface.
Place machine in stowed position with the boom between the rear wheels.
To level machine chose:
CALIBRATION:
TILT SENSOR
Press ENTER .
When prompted, swing machine 180°
Press ENTER .
Table 22. Analyzer Abbreviations
ABBREVIATION MEANING
ACCEL ACCELERATE
ACT ACTIVE
A/D ANALOG DIGITAL CONVERTER COUNT
AMB. AMBIENT
ANG ANGLE
AUX AUXILIARY
BCS BOOM CONTROL SYSTEM
BM BOOM LENGTH ANGLE MODULE
BLAM BOOM LENGTH ANGLE MODULE
BR BROKEN
BSK BASKET
CAL CALIBRATION
CL CLOSED
800S HC3, 860SJ HC3 31222415 125

System Software
Table 22. Analyzer Abbreviations (continued)

CM CHASSIS MODULE
CNTL CONTROL
CNTRL CONTROL
C/O CUT OUT
CONT(S) CONTRACTOR(S)
COOR COORDINATED
CRK PT CRACK POINT
CRP CREEP
CUT CUTOUT
CYL CYLINDER
DECEL DECELERATE
D DOWN
DN DOWN
DWN DOWN
DEG. DEGREE
DOS DRIVE ORIENTATION SYSTEM
DRV DRIVE
E ERROR
E&T ELEVATED & TILTED
ELEV ELEVATION
ENG ENGINE
EXT EXTEND
F FRONT
FL FLOW
FNT FRONT
FOR FORWARD
FWD FORWARD
FSW FOOT SWITCH
FUNC FUNCTION
G GROUND
GND GROUND
GRN GREEN
GM GROUND MODULE
H HOURS
HW HARDWARE
HWFS HARDWARE FAILSAFE
I IN or CURRENT
JOY JOYSTICK
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System Software

L LEFT
LB POUND
LEN LENGTH
LIM LIMIT
LT LEFT
LVL LEVEL
M MINUTES
MIN MINIMUM
MAX MAXIMUM
M MAIN
MN MAIN
NO NORMALLY OPEN or NO
NC NORMALLY CLOSED
O OUT
O/C OPEN CIRCUIT
OP OPEN
O/R OVERRIDE or OUTRIGGER
O//R OVERRIDE
OSC OSCILLATING
OVRD OVERRIDE
P PLATFORM
P PRESSURE
PCV PROPORTIONAL CONTROL VALVE
PLAT PLATFORM
PLT PLATFORM
PM PLATFORM MODULE
POT POTENTIOMETER
PRES PRESSURE
PRS PRESSURE
PT POINT
R REAR or RIGHT
REV REVERSE or REVISION
RET RETRACT
ROT. ROTATE
RT RIGHT
S/C SHORT CIRCUIT
SEL SELECTOR
SN SERIAL NUMBER
800S HC3, 860SJ HC3 31222415 127

System Software

SPD SPEED
STOW STOWED
STOWD STOWED
SW SWITCH or SOFTWARE
TELE TELESCOPE
TEMP TEMPERATURE
TORQ. TORQUE
TRN TRANSPORT
T/T TURNTABLE
T TOWER
TURNTBL TURNTABLE
TWR TOWER
U main or UP
V VOLT
VER VERSION
VLV VALVE
WIT WITNESS
YEL YELLOW
128 31222415 800S HC3, 860SJ HC3

System Software
Function Switch
Inputs
Function
Speed Knob
Lift/Swing Platform Module

Lamp Inputs
Joystick
Drive/Steer Valve Inputs

Joystick Analyzer Connection
Option Switch
Inputs
Load Cell Input

Boom Cable
Proximity Switch
Inputs Valve Inputs
Ground Module
Limit Switch Tilt

Sensor Lamp Inputs
Inputs
Analyzer Connection Rs485

Port
Throttle Output
Engine Inputs
(Deutz Only)
MAF36450
Figure 45. ADE Block Diagram
800S HC3, 860SJ HC3 31222415 129

System Software
5.2.8 Analyzer Software Version P6.40

Sheet 1 of 7
130 31222415 800S HC3, 860SJ HC3

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Sheet 2 of 7
800S HC3, 860SJ HC3 31222415 131

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Sheet 3 of 7
132 31222415 800S HC3, 860SJ HC3

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Sheet 4 of 7
800S HC3, 860SJ HC3 31222415 133

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Sheet 5 of 7
134 31222415 800S HC3, 860SJ HC3

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Sheet 6 of 7
800S HC3, 860SJ HC3 31222415 135

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Sheet 7 of 7
5.3 ANALYZER SOFTWARE ACCESSIBILITY
5.3.1 Analyzer Diagnostics Menu Structure
In the following structure descriptions, an intended item is selected by pressing ENTER; pressing ESC steps back to the next outer
level. The LEFT /RIGHT arrow keys move between items in the same level. The UP /DOWN arrow keys alter a value if
allowed.
136 31222415 800S HC3, 860SJ HC3

System Software
Table 23. Adjustments - Personality Descriptions

DRIVE
ACCEL Displays/adjusts drive acceleration
DECEL Displays/adjusts drive deceleration
MIN FORWARD Displays/adjusts minimum forward drive speed
MAX FORWARD Displays/adjusts maximum forward drive speed
MIN REVERSE Displays/adjusts minimum reverse drive speed
MAX REVERSE Displays/adjusts maximum reverse drive speed
ELEVATED MAX Displays/adjusts maximum drive speed
Note: used when elevation cutout switches are limiting maximum speed
CREEP MAX Displays/adjusts maximum drive speed
Note: used when elevation cutout switches are limiting maximum speed
STEER MAX Displays/adjusts the maximum steer speed
LIFT
ACCEL Displays/adjusts upper lift acceleration
DECEL Displays/adjusts upper lift deceleration
MIN UP Displays/adjusts minimum upper lift up speed
MAX UP Displays/adjusts maximum upper lift up speed
CREEP UP Displays/adjusts maximum upper lift up speed
Note: used when creep switch on pump pot is active
MIN DOWN Displays/adjusts minimum upper lift down speed
MAX DOWN Displays/adjusts maximum upper lift down speed
CREEP DOWN Displays/adjusts maximum upper lift down speed
SWING
ACCEL Displays/adjusts swing acceleration
DECEL Displays/adjusts swing deceleration
MIN LEFT Displays/adjusts minimum swing left speed

MAX LEFT Displays/adjusts maximum swing left speed
CREEP LEFT Displays/adjusts maximum swing left speed
MIN RIGHT Displays/adjusts minimum swing right speed
MAX RIGHT Displays/adjusts maximum swing right speed
CREEP RIGHT Displays/adjusts maximum swing right speed
800S HC3, 860SJ HC3 31222415 137

System Software
Table 23. Adjustments - Personality Descriptions (continued)

DRIVE
MAIN TELESCOPE
ACCEL Displays/adjusts telescope acceleration
DECEL Displays/adjusts telescope deceleration
MIN IN Displays/adjusts minimum telescope in speed
MAX IN Displays/adjusts maximum telescope in speed
MIN OUT Displays/adjusts minimum telescope out speed
MAX OUT Displays/adjusts maximum telescope out speed
BASKET LEVEL
ACCEL Displays/adjusts basket level acceleration
DECEL Displays/adjusts basket level deceleration
MIN UP Displays/adjusts minimum basket level up speed

MAX UP Displays/adjusts maximum basket level up speed
MIN DOWN Displays/adjusts minimum basket level down speed
MAX DOWN Displays/adjusts maximum basket level down speed
BASKET ROTATE
ACCEL Displays/adjusts basket rotate acceleration
DECEL Displays/adjusts basket rotate deceleration
MIN LEFT Displays/adjusts minimum basket rotate left speed

MAX LEFT Displays/adjusts maximum basket rotate left speed
MIN RIGHT Displays/adjusts minimum basket rotate right speed
MAX RIGHT Displays/adjusts maximum basket rotate right speed
JIB LIFT Not displayed if JIB = NO
ACCEL Displays/adjusts jib acceleration
DECEL Displays/adjusts jib deceleration
MIN UP Displays/adjusts minimum jib up speed

MAX UP Displays/adjusts maximum jib up speed
MIN DOWN Displays/adjusts minimum jib down speed
MAX DOWN Displays/adjusts maximum jib down speed
MIN LEFT Displays/adjusts minimum jib left speed

MAX LEFT Displays/adjusts maximum jib left speed
MIN RIGHT Displays/adjusts minimum jib right speed
MAX RIGHT Displays/adjusts maximum jib right speed
138 31222415 800S HC3, 860SJ HC3

System Software
Table 23. Adjustments - Personality Descriptions (continued)

DRIVE
STEER
MAX SPEED Displays/adjusts maximum steer speed, which applies when vehicle speed is at
minimum
GROUND MODE
LIFT UP Displays/adjusts fixed lift up speed
LIFT DOWN Displays/adjusts fixed lift down speed

SWING Displays/adjusts fixed swing speed
TELE Displays/adjusts fixed telescope speed
BASKETLEVEL Displays/adjusts fixed basket level speed
BASKETROTATE Displays/adjusts fixed basket rotate speed
JIB (U/D) Displays/adjusts jib lift speed

Not displayed if JIB = NO
JIB (L/R) Displays/adjusts jib swing speed

Table 24. Diagnostic Menu Descriptions

DRIVE
DRIVE FOR … Displays drive joystick direction & demand
STEER … Displays steer switch direction & demand
Note: steer demand is inversely proportional to vehicle speed
BRAKES … Displays brake control system status
CREEP … Displays pump pot creep switch status
TWO SPEED... Displays two speed switch status
2 SPEED MODE Displays status of two speed valve
HIGH ENGINE Displays high engine switch status
BOOM
U LIFT UP … Displays lift joystick direction & demand
SWING LEFT … Displays swing joystick direction & demand
LEVEL UP … Displays basket level switch direction & demand

NOTE: demand is controlled by the pump pot
ROT. LEFT … Displays basket rotate switch direction & demand
Note: demand is controlled by the pump pot
U TELE IN … Displays telescope switch direction & demand
JIB UP … Displays jib lift switch direction & demand
800S HC3, 860SJ HC3 31222415 139

System Software
Table 24. Diagnostic Menu Descriptions (continued)

JIB LEFT … Displays jib swing switch direction & demand
PUMP POT … Displays pump pot demand
ENGINE
START … Displays start switch status
AIR FILTER … Displays air filter status

BATTERY … Displays measured battery voltage
COOLANT … Displays coolant temperature
OIL PRS … Displays oil pressure status
FUEL SELECT … Displays selected fuel (Dual Fuel only)

FUEL LEVEL … Displays fuel level status
RPM Displays Engine RPM
GM BATTERY Displays battery voltage at ground module
PM BATTERY … Displays battery voltage at platform module

TEMP... Displays ground module temperature
ELEV. CUTOUT … Displays elevation cutout switch status
FUNC. CUTOUT … Displays function cutout switch status
CREEP… Displays creep switch status
TILT … Displays measured vehicle tilt
AUX POWER … Displays status of auxiliary power switch
HORN … Displays status of horn switch
R FILTER … Displays status of return filter switch
C FILTER … Displays status of charge pump filter
LOAD LENGTH … Displays length switch status
ANGLE … Displays angle switch status
LOAD … Displays load sensor value
Note: Not displayed if load = 0.
DATALOG
ON … Displays total controller on (EMS) time
ENGINE … Displays engine run time
140 31222415 800S HC3, 860SJ HC3

System Software
Table 24. Diagnostic Menu Descriptions (continued)

DRIVE … Displays total controller drive operation time
LIFT … Displays total controller lift operation time
SWING … Displays total controller swing operation time
TELE … Displays total controller tele operation time

MAX.TEMP … Displays maximum measured heatsink temp.
MIN.TEMP … Displays minimum measured heatsink temp.
MAX.VOLTS … Displays maximum measured battery voltage
RENTAL … Displays total controller operation time
Note: can be reset
ERASE RENTAL Not available at password level 2

YES:ENTER, NO:ESC ENTER resets rental datalog time to zero
VERSIONS
GROUND … Displays ground module software version
PLATFORM … Displays platform module software version
ANALYSER … Displays Analyzer software version
5.3.2 Machine Set-Up

Table 25. Machine Configuration Programming Information (Software Version P6.40)
Configuration Default
Number Description
Label/Digit Number
Note: 1. The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model
number of the machine configuration will cause the personality settings to return to default values.
2. Select Market as CE for UKCA specification machine on Analyzer.
MODEL NUMBER: 1 600A 1

1
2 800A
3 800S
4 H800A
MARKET: 1 ANSI USA 1

2*
2 ANSI EXPORT
3 CSA
4 CE
5 AUSTRALIA
6 MOL70
7 GB
8 EAC
* Certain model selections will limit market options.
800S HC3, 860SJ HC3 31222415 141

System Software
Table 25. Machine Configuration Programming Information (Software Version P6.40) (continued)
Number Description
Label/Digit Number
ENGINE: 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1)

3*
2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1)
4 CAT. 3044C: CAT 3044C Diesel (Tier 2)
5 DEUTZ F4 TIER2: Deutz F4M2011 Diesel (Tier 2)
6 FORD GAS TIER2: Ford LRG425 EFI Gas (Tier 2)
7 FORD D/F TIER2: Ford LRG425 EFI Dual Fuel (Tier 2)
8 DEUTZ ECM: Engine Control Module - ECM (Tier 2 and Tier 3) 8
9 DUAL FUEL ECM: GM/PSI 3.0L Dual Fuel (Tier 2)

10 CAT ECM T4I
11 DEUTZ EMR4: Deutz Engine Control Module (Tier 4 Final)
12 FORD DUAL FUEL
13 KUBOTA D1305
14 DZTD22 E5 X-36: Deutz TD22 Stage V 36 KW)
15 DZTD29 E5 X-50: Deutz TD29 Stage V 50 KW
* Certain model selections will limit engine options.

* Certain market selections will limit engine options.
GLOW PLUG: 1 NO GLOW PLUGS: No glow plugs installed.

4*
2 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
3 IN-CYLINDER: Glow plugs installed in each cylinder. 3
* Only visible for diesel engine selections.
STARTER LOCKOUT: 1 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be at- 1
5* tempted at any time during pre-glow.
2 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre-
glow is finished.
ENGINE SHUTDOWN: 1 DISABLED: No engine shutdown.

6
2 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is 2
less than 8 PSI.
FUEL CUTOUT: 1 RESTART: Engine allowed to be restarted multiple times when very low fuel level is reached 1
7*
2 ONE RESTART: Engine allowed to be restarted once for 2 minutes when very low fuel level is reached
142 31222415 800S HC3, 860SJ HC3

System Software
Number Description
Label/Digit Number
3 ENGINE STOP: Engine not able to restart when very low fuel level is reached

JIB: 1 NO: No jib installed. 1
8*
2 YES: Jib installed which has up and down movements only.
* Only visible under certain model selections.
CAPACITY 1 SINGLE: Single Capacity system installed. 1

9*
2 DUAL: Dual Capacity system installed.
3 TRIPLE: Triple Capacity system installed.
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above
10* elevation; also reduces drive speed to creep.
2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees and above
elevation; also reduces drive speed to creep.
3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees and above
elevation; also reduces drive speed to creep.
4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees and
above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out and main lift up.
7 5 DEGREES + DRV CUT Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees
and above elevation; also reduces drive speed to creep when drive reversal is allowed, drive is disallowed otherwise.
8 4 DEGREES + DRV CUT Reduces the maximum speed of all boom functions to creep when tilted more than 8
4 degrees and above elevation; also reduces drive speed to creep when drive reversal is allowed, drive is
disallowed otherwise.
9 3 DEGREES + DRV CUT Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees
and above elevation; also reduces drive speed to creep when drive reversal is allowed, drive is disallowed otherwise.
* Certain market selections will limit tilt options and alter default setting.
4 WHEEL STEER: 1 NO: No four-wheel steer installed. 1

11*
2 YES: Four-wheel steer installed.
SOFT TOUCH: 1 NO: No soft touch installed. 1

12*
2 YES: Soft touch installed
800S HC3, 860SJ HC3 31222415 143

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Number Description
Label/Digit Number
SKYGUARD: 1 NO: No SkyGuard installed.

13
2 BAR/SKYLINE: SkyGuard system installed. 2
3 SKYEYE: SkyGuard system installed.
GEN SET/WELDER: 1 NO: No generator installed. 1

14
2 BELT DRIVE: Belt driven setup.
GEN SET CUTOUT: 1 MOTION ENABLED: Motion enabled when generator is ON. 1
15*
2 MOTION CUTOUT: Motion cutout in platform mode only.
* Only visible if gen set / welder selection is not NO.
H & T LIGHTS: 1 NO: No head and tail lights installed. 1

16
2 YES: Head and tail lights installed.
CABLE SWITCH: 1 NO: No broken cable switch installed. 1

17*
2 YES: Broken cable switch installed.
LOAD SYSTEM: 1 NO: No load sensor installed.

18*
2 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
3 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF). 3
4 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5 sec ON, 2 sec
OFF).
* Certain market selections will limit load system options or alter default setting.
FUNCTION CUTOUT: 1 NO: No drive cutout. 1

19*
2 BOOM CUTOUT: Boom function cutout while driving above elevation.
3 DRIVE CUTOUT: Drive & steer cutout above elevation.
* Certain market selections will limit function cutout options or alter default setting.
GROUND ALARM: 1 NO: No ground alarm installed.

20
2 DRIVE: Travel alarm sounds when the drive function is active (Option).
3 DESCENT: Descent alarm sounds when lift down is active (Option).
4 MOTION: Motion alarm sounds when any function is active (Option). 4
144 31222415 800S HC3, 860SJ HC3

System Software
Number Description
Label/Digit Number
DRIVE: 1 4WD: Four wheel drive. 1
21
2 2DW: Two wheel drive
3 2WD W/ 2-SPEED: Two wheel drive with 2-speed valve.
DISPLAY UNITS: 1 IMPERIAL: DEG F, PSI, LBS 1

22*
2 METRIC: DEG C, KPA, KGS
* Certain market selections will alter default setting.
LEVELING MODE: 1 ALL FUNCTIONS: Platform level with all functions. 1

23*
2 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
DRIVE CONTROL: 1 NORMAL: Drive coils are energized from the Ground Module.
24*
2 PROPULSION: Drive coils are energized from the Propulsion Module.
3 ENHANCED: Drive coils are energized from the Ground Module and the ground side of the drive coils are 3
brought back to current feedback returns.
DRIVE PUMP: 1 SAUER DANFOSS: Machine equipped with Sauer Danfoss drive pump. 1
25*
2 EATON: Machine equipped with Eaton drive pump.
3 M46-XXXX: Machine equipped with M46-XXXX drive pump.
4 830XXXXX: Machine equipped with 830XXXXX: drive pump.
BOOM CONTROL: 1 NORMAL: Boom function coils are energized from the Ground Module
26*
2 ENHANCED: Boom function are energized from the Ground Module and the ground side of the drive coils 2
are brought back to current feedback returns

CLEARSKY: 1 NO: ClearSky (telematics) options is disabled. 1
27
2 YES: ClearSky (telematics) option is enabled.
CRIBBING OPTION: 1 NO: Cribbing Option is disabled. 1

28*
2 YES: Cribbing Option is enabled.
800S HC3, 860SJ HC3 31222415 145

System Software
Number Description
Label/Digit Number
FUEL TANK SIZE: 1 31 Gallon Tank 1
29*
2 52 Gallon Tank
ALARM / HORN: 1 SEPARATE: Separate alarm and horn.

30
2 COMBINED: Combination alarm / horn. 2
ALERT BEACON: 1 OFF FOR CREEP: Alert beacon will not flash while in Creep 1
31
2 20FPS FOR CREEP: Alert beacon will flash at 20FPS while in Creep
TEMP CUTOUT: 1 NO: Temp Cutout is Disabled 1

32*
2 YES: Temp Cutout is Enabled
* Certain model selections will limit temp cutout options.
PLAT LVL OVR CUT 1 NO: Platform Level Override will always be functional 1
33
2 YES: Platform Level Override will only be functional when In Transport
WATER IN FUEL 1 NO: Water in Fuel Sensor Disabled 1

SENSOR:
34* 2 YES: Water in Fuel Sensor Enabled
* Only visible if engine selection is Deutz EMR4.
GROUND DISPLAY 1 NO: No Ground Display installed. 1

35*
2 MDI: MDI display installed.
3 MONO LCD DISP: Kongsburg Ground Display installed.

1001249237-F
Table 26. 800S HC3 Machine Configuration Programming Settings (Software Version P6.40)
800S HC3 ANSI USA ANSI Export CSA CE Australia MOL70 GB EAC
Model Number 3 3 3 3 3 3 3 3
Market 1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2
Engine
3 3 3 3 3 3 3 3
4 4 4 4 4 4 4 4
146 31222415 800S HC3, 860SJ HC3

System Software
Table 26. 800S HC3 Machine Configuration Programming Settings (Software Version P6.40) (continued)
5 5 5 5 5 5 5 5
6 6 6 6 6 6 6 6
7 7 7 7 7 7 7 7
8 8 8 8 8 8 8 8
9 9 9 9 9 9 9 9
10 10 10 10 10 10 10 10
11 11 11 11 11 11 11 11
12 12 12 12 12 12 12 12
X X X X X X X X
X X X X X X X X
X X X 15 X X X X
1 1 1 1 1 1 1 1
Glow Plug 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1
Starter Lockout
2 2 2 2 2 2 2 2
Engine 1 1 1 1 1 1 1 1
Shutdown 2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Fuel Cutout 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1
JIB
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Capacity 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
X X X X X X X X
X X X X X 2 X X
X X X X X 3 X X
4 4 4 4 4 4 4 4
Tilt 5 5 5 5 5 5 5 5
X X X X X X X X
X X X X X X X X
8 8 8 8 8 8 8 8
9 9 9 9 9 9 9 9
1 1 1 1 1 1 1 1
4 Wheel Steer
2 2 2 2 2 2 2 2
Soft Touch 1 1 1 1 1 1 1 1
800S HC3, 860SJ HC3 31222415 147

System Software
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
SkyGuard 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
Gen Set / 1 1 1 1 1 1 1 1
Welder 2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Gen Set Cutout
2 2 2 2 2 2 2 2
Head & 1 1 1 1 1 1 1 1
Taillights 2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Cable Switch
2 2 2 2 2 2 2 2
X X X X X X X X
X X X X X X X X
Load System
3 3 3 X 3 3 3 X
4 4 4 4 X 4 4 4
1 1 1 1 1 1 1 1
Function Cutout X 2 2 2 2 2 2 2
3 3 3 X 3 3 3 X
1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2
Ground Alarm
3 3 3 3 3 3 3 3
4 4 4 4 4 4 4 4
1 1 1 1 1 1 1 1
Drive 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1
Display Units
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Leveling Mode
2 2 2 2 2 2 2 2
X X X X X X X X
Drive Control X X X X X X X X
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2
Drive Pump
X X X X X X X X
X X X X X X X X
Boom Control X X X X X X X X
148 31222415 800S HC3, 860SJ HC3

System Software
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
ClearSky
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Cribbing Option
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Fuel Tank Size
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Alarm / Horn
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Alert Beacon
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Temp Cutout
X 2 X 2 X X 2 2
1 1 1 1 1 1 1 1
Plat Lvl Ovr Cut
2 2 2 2 2 2 2 2
Water In Fuel 1 1 1 1 1 1 1 1
Sensor 2 2 2 2 2 2 2 2
1 1 1 X 1 1 1 1
Ground Display X X X 2 X X X X
3 3 3 3 3 3 3 3
BOLD TEXT indicates the default setting. Plain text indicates another available selection. RED ITALIC text indicates the required selection for machine model. SHADED CELLS indi-
cate hidden menus or selections.
1001249237-F
Table 27. 860SJ HC3 Machine Configuration Programming Settings (Software Version P6.40)
860SJ HC3 ANSI USA ANSI Export CSA CE Australia MOL70 GB EAC
Model Number 3 3 3 3 3 3 3 3
Market 1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
4 4 4 4 4 4 4 4
5 5 5 5 5 5 5 5
Engine 6 6 6 6 6 6 6 6
7 7 7 7 7 7 7 7
8 8 8 8 8 8 8 8
9 9 9 9 9 9 9 9
10 10 10 10 10 10 10 10
11 11 11 11 11 11 11 11
800S HC3, 860SJ HC3 31222415 149

System Software
Table 27. 860SJ HC3 Machine Configuration Programming Settings (Software Version P6.40) (continued)
12 12 12 12 12 12 12 12
X X X X X X X X
X X X X X X X X
X X X 15 X X X X
1 1 1 1 1 1 1 1
Glow Plug 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1
Starter Lockout
2 2 2 2 2 2 2 2
Engine 1 1 1 1 1 1 1 1
Shutdown 2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Fuel Cutout 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1
Jib
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Capacity 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
X X X X X X X X
X X X X X 2 X X
X X X X X 3 X X
4 4 4 4 4 4 4 4
Tilt 5 5 5 5 5 5 5 5
X X X X X X X X
X X X X X X X X
8 8 8 8 8 8 8 8
9 9 9 9 9 9 9 9
1 1 1 1 1 1 1 1
4 Wheel Steer
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Soft Touch
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
SkyGuard 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
Gen Set / 1 1 1 1 1 1 1 1
Welder 2 2 2 2 2 2 2 2
Gen Set Cutout 1 1 1 1 1 1 1 1
150 31222415 800S HC3, 860SJ HC3

System Software
2 2 2 2 2 2 2 2
Head & 1 1 1 1 1 1 1 1
Taillights 2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Cable Switch
2 2 2 2 2 2 2 2
X X X X X X X X
X X X X X X X X
Load System
3 3 3 X 3 3 3 X
4 4 4 4 X 4 4 4
1 1 1 1 1 1 1 1
Function Cutout X 2 2 2 2 2 2 2
3 3 3 X 3 3 3 X
1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2
Ground Alarm
3 3 3 3 3 3 3 3
4 4 4 4 4 4 4 4
1 1 1 1 1 1 1 1
Drive 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1
Display Units
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Leveling Mode
2 2 2 2 2 2 2 2
X X X X X X X X
Drive Control X X X X X X X X
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2
Drive Pump
X X X X X X X X
X X X X X X X X
X X X X X X X X
Boom Control
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
ClearSky
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Cribbing Option
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Fuel Tank Size
2 2 2 2 2 2 2 2
800S HC3, 860SJ HC3 31222415 151

System Software
1 1 1 1 1 1 1 1
Alarm / Horn
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Alert Beacon
2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1
Temp Cutout
X 2 X 2 X X 2 2
1 1 1 1 1 1 1 1
Plat Lvl Ovr Cut
2 2 2 2 2 2 2 2
Water In Fuel 1 1 1 1 1 1 1 1
Sensor 2 2 2 2 2 2 2 2
1 1 1 X 1 1 1 1
GROUND
X X X 2 X X X X
DISPLAY
3 3 3 3 3 3 3 3
BOLD TEXT indicates the default setting. Plain text indicates another available selection. RED ITALIC text indicates the required selection for machine model. SHADED CELLS indi-
cate hidden menus or selections.
1001249237-F
5.3.3 Personalities
Note: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance.
Note: GROUND MODE speeds are automatically limited to being lower than platform speed for a given function.
Note: Set personalities in the following order: creep speeds, platform speeds, and then ground speeds.
Table 28. Machine Personality Settings and Function Speeds (Software Version P6.40)
DANFOSS EATON
FUNCTION PERSONALITY RANGE DEFAULTS-800S DEFAULTS-860SJ DEFAULTS-800S DEFAULTS-860SJ
HC3 HC3 HC3 HC3
DRIVE Acceleration 0.0-5.0 sec 2.0 2.0 2.0 2.0
Deceleration 0.0-3.0 sec 2.0 2.0 2.0 2.0
Forward Minimum speed 1-35% 4 4 15 15
Forward Maximum speed 1-100% 30 30 53 53
Reverse Minimum speed 1-35% 4 4 15 15
Reverse Maximum speed 1-100% 30 30 53 53
Elevated Maximum speed 1-100% 20 20 28 28
Creep Maximum speed 1-90% 20 20 30 30
STEER Maximum speed 1 to 100% 100 100 100 100
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Table 28. Machine Personality Settings and Function Speeds (Software Version P6.40) (continued)
DANFOSS EATON
HC3 HC3 HC3 HC3
MAIN LIFT Acceleration 0.0-5.0 sec 2.5 2.5 2.5 2.5
Minimum Up speed 1-60% 15 15 15 15
Maximum Up speed 1-100% 80 80 80 80
Creep maximum Up speed 1-65% 30 30 30 30
Minimum Down speed 1-60% 15 15 15 15
Maximum down speed 1-100% 80 80 80 80
Creep Maximum down speed 1-75% 30 30 30 30
Soft Up 1-75% 35 35 35 35
Soft Down 1-75% 30 30 30 30
SWING Acceleration 0.0-5.0 sec 2.8 2.8 2.8 2.8

Minimum Left speed 1-50% 14 14 14 14
Maximum Left speed 1-100% 65 65 65 65
Creep Maximum Left speed 1-65% 43 43 43 43
Minimum Right speed 1-50% 14 14 14 14
Maximum Right speed 1-100% 68 68 68 68
Creep Maximum Right speed 1-65% 49 49 49 49
MAIN TELESCOPE Acceleration 0.0-5.0 sec 3.5 3.5 3.5 3.5

Minimum IN speed 1-65% 24 24 24 24
Maximum IN speed 1-100% 63 63 63 63
Minimum OUT speed 1-65% 26 26 26 26
Maximum OUT speed 1-100% 65 65 65 65
PLATFORM LEVEL Acceleration 0.0-5.0 sec 0.1 0.1 0.1 0.1

Maximum Up speed 1-100% 100 100 100 100
Minimum Down speed 1-65% 48 48 48 48
Maximum Down speed 1-100% 100 100 100 100
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Table 28. Machine Personality Settings and Function Speeds (Software Version P6.40) (continued)
DANFOSS EATON
HC3 HC3 HC3 HC3
PLATFORM Acceleration 0.0-5.0 sec 0.1 0.1 0.1 0.1
ROTATE
Minimum Left speed 1-100% 69 69 69 69
Maximum Left speed 1-100% 90 90 90 90
Minimum Right speed 1-100% 69 69 69 69
Maximum Right speed 1-100% 90 90 90 90
JIB LIFT Acceleration 0.0-5.0 sec 3.3 3.3 3.3 3.3

Maximum Up speed 1-100% 80 80 80 80
Minimum Down 1-65% 40 40 40 40

Maximum Down 1-100% 75 75 75 75
GROUND MODE Main Lift Up speed 1-100% 63 63 63 63
Main Lift down speed 1-100% 63 63 63 63
Swing speed 1-100% 64 64 64 64
Main Telescope speed 1-100% 62 62 62 62
Platform Rotate speed 1-100% 89 89 89 89
Platform Level speed 1-100% 99 99 99 99
Jib Lift speed 1-100% 79 79 79 79
1001245447-E
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5.4 FUNCTION TEST
Main Lift
• Tower lift fully elevated, tower telescope fully extended, Main Telescope fully retracted.
• Main Lift Up, record time.
• Main Lift Down, record time.
• Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode; Creep light on Panel must be energized.
• Verify that machine will Lift Up and Down. Return Knob to fully clockwise.
Swing
• Boom at full elevation, Telescope retracted. Swing Right until over rear axle or end stop (if equipped).
Note: To eliminate effect of controller ramp-up/down, record time starting, while swinging, as turntable is centered.
• Swing Left 360° or end stop (if equipped), record time.
• Swing Right 360° or end stop (if equipped), record time.
• Verify that machine will swing left and right. Return Knob to fully clockwise.
Main Telescope
• Main Lift at full elevation, Telescope Retracted.
• Telescope Out, record time.
• Telescope In, record time.
• Verify that machine will Telescope In and Out. Return Knob to fully clockwise.
Drive (Below Elevation)

• Test should be done on a smooth, level surface. The Drive Select Switch should be in the "Max Speed" position.
• Start approximately 7.6 m (25 ft.) from starting point so the unit is at a maximum speed when starting the test. Results should be
recorded for a 61 m (200 ft.) course. Drive forward, "High Speed", record time.
Drive (Above Elevation)

• Test should be done on a smooth, level surface. The Drive Select Switch should be in the "Max Speed" position, the boom should be
10° above horizontal to ensure the drive is operating in Max Torque mode.
• Results should be recorded for a 15.2 m (50 ft.) course.
• Drive forward, record time.
• Drive reverse, record time.
• Verify that machine will Drive Forward and Reverse. Return Knob to fully clockwise.
Platform Rotate
• Platform level, Rotate Platform Right until stop.
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• Platform Left, record time.
• Platform Right, record time.
• Verify that machine will Platform Rotate Left and Right. Return Knob to fully clockwise.
Note: The platform rotate may not work, when the platform speed control knob is turned fully counterclockwise. This is acceptable.
Jib Lift
• Platform level and centered with the boom. Jib Lift Down until stop.
• Jib Lift Up, record time.
• Jib Lift Down, record time.
• Verify that machine will Jib Lift Up and Down. Return Knob to fully clockwise.
Test Notes
1. Stop watch should be started with the function movement, not with actuation of joystick or switch.
2. All speed tests are run from the platform. These speeds do not reflect the ground control operation.
3. The platform speed knob control must be at full speed (turned clockwise completely) unless noted.
4. Function speeds may vary due to cold, thick hydraulic oil. Test should be run with the oil temperature above 100° F (38° C).
5. Some flow control functions may not work with the platform speed control knob clicked into the creep position.
6. Drive speeds should be set to the values below regardless of the tire size.
Table 29. Function Speeds (In Seconds)

Function 800S HC3 860SJ HC3
Main Lift Up 59-75 56-73
Main Lift Down 57-75 56-75

Swing Right & Left* 110-135 110-135
Note: No more than 10% difference between swing left and swing right.
Main Telescope Out 59-65 56-65
Main Telescope In 45-57 44-60
Platform Rotate Right & Left** 18-30 18-30
Note: No more than 15% difference between rotate left and rotate right.
Jib Up N/A 33-47
Jib Down N/A 29-39

Drive (Forward) 33-45 33-45
Drive (Elevated) 46-75 46-75
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5.5 CANBUS COMMUNICATIONS
CANbus
CAN (Control Area Network) is a two wire differential serial link between the Platform and Ground Modules providing bi-directional
communications.
Two-wire
One wire (red) is driven high (5v) and the other low (black) (0v) to send a signal. Both wires “float” (2.5 V) when no signal is being sent.
Differential
Any electrical line noise can affect the high or the low wires but never both, so communications is not corrupted.
Serial Link
Messages are being sent bit by bit along the wires; the high bus speed allow all modules to be constantly updated around 20 times per
second. Typical traffic is 300 - 500 messages per second.
A complete CANbus circuit is approximately 60 ohms, which can be verified at the “T” fitting inside the ground station. Individual circuits
are approximately 120 ohms.
The GROUND MODULE (UGM) is the master system controller. Most functions are dispatched and coordinated from this module. The
PLATFORM MODULE handles sub-tasks. All characterized information (values) are stored in the ground module (i. e., Personalities or
Calibrations).
Interlocks
Any device that sends an electrical input. (For an example a limit switch, proximity switch, etc).
Platform Level
The GROUND MODULE stores default values and handles interlocks. The PLATFORM MODULE reads sensors mounted on the platform
assembly and controls Level Up / Down valves to maintain setpoint sent from the GROUND MODULE.
Steer
The GROUND MODULE stores crack points, and sends desired drive direction, steering mode, and axle extend/retract commands. The
PLATFORM MODULE reports steering switch position to the GROUND MODULE.
Drive
The GROUND MODULE stores crack points and sends commands for each drive pump. (Command is computed from drive joystick input,
interlocks, wheel angle, etc).
Lift, Tele, & Swing
The GROUND MODULE stores default values, and handles interlocks and calibration information. Lift, Telescope, and Swing commands
depend on interlocks through out the machine. Boom angle, length, and swing are controlled by the GROUND MODULE.
5.6 SERVICE MODE
To facilitate the servicing and enabling of functions due to component faults, there is a need to override the normal operation of the
machine. Service Mode shall become visible only after entering Service Access Level.
WARNING
The service modes in this section should be used with extreme caution as they
override the normal boom envelope control system. Improper use can result in
component interference/damage or machine instability, personnel injury or death.
Service Mode Event Log

The Service Mode events listed below shall be stored in the Service Mode event log (DIAGNOSTICS –> DATALOG –> SERVICE LOG) if their
corresponding conditions are met.
• SERVICE LSS – Logged when the LSS Service mode transitions from OFF to ON.
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• SERVICE DRV CUT – Logged when the LSS Service mode transitions from OFF to ON.
5.6.1 Load Sensing System

The Load Sensing System provides a qualified service technician a means to move the machine to a safe area for troubleshooting and
repair.
1. Plug the analyzer into the connector at the base of the platform control box.
2. Pull out the emergency stop switch.
3. The analyzer screen should read: “HELP PRESS ENTER”.
4. Use the arrow button to reach ACCESS LEVEL 2. Press the enter key.
5. Enter the Access Code 33271 to get into ACCESS LEVEL 1 mode.
Note: The service mode will only be displayed on the analyzer when in access level 1 and be hidden while in access level 2.
NOTICE
The service mode menu will be selectable at the top level of the analyzer menu
structure. “Service Mode” will be displayed on the top line of the analyzer with the
current sub-menu selection on the bottom line. The sub-menus will scroll with the
left and right arrow keys.
6. Scroll the analyzer menu until “SERVICE MODE” is displayed. Press the ENTER key.
7. Scroll the menu until “LSS” is displayed on the analyzer screen.
8. Enter code "18171", which allows operator to enable LSS.
Note: This mode will be canceled in the event of a power cycle, disconnect of analyzer or pressing ESC on the analyzer.
Service Mode Submenu (Dis- Parameter (Displayed on Ana- Parameter Value (Displayed on Transition and Software Checks
played on Analyzer 2nd lyzer 1st Line) Analyzer 2nd Line)
Line)
LSS: CODE: XXXXX Operator uses Up and Down Arrow keys on Analyzer to input
Service Mode Code;
On ENTER, UGM to confirm code of 18171. If correct advance
to next menu. If incorrect or on ESC, go to SERVICE MODE
menu.
LSS? (NOT VISIBLE IF MACHINE LSS: SERVICE ON The UGM shall treat MACHINE SETUP –> LOAD SYSTEM as if
SETUP? LOAD SYSTEM = NO) it is set to WARN ONLY until:
- Power is Cycled
- Analyzer is disconnected
- ESC is pressed
On ESC, go to SERVICE MODE menu.
5.6.2 Drive Cutout Override

Note: Refer to Section — Drive Cutout Override Service Mode, page 109 for detailed instructions.
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5.7 ELECTRONIC PLATFORM LEVELING
5.7.1 Description
Electronic platform leveling replaces the conventional hydraulic method of platform leveling. The term “platform leveling” does not refer
to the system maintaining the platform at level (or 0°) with respect to gravity, but instead refers to the controls automatically
maintaining the platform within several degrees of a preset angle.
To control electronic platform leveling the platform is equipped with a pair of tilt sensors, one primary and one secondary, mounted to
the non-rotating portion of the platform rotator, level up and level down valves that are used to provide proportional hydraulic flow for
each directional function, and a control module that interprets the sensor readings and actuates the leveling valves.
PRIMARY AND SECONDARY TILT SENSOR INTERACTION
Two tilt sensors, mounted on each side of the platform support, are used to measure the incline of the platform with respect to gravity
and control the automatic platform angle control function. The right one (as viewed from standing in the platform) is used as the
primary sensor and the left one as a secondary backup sensor.
If a fault occurs with the primary sensor, control will revert to the secondary sensor. (Refer to Section — ERROR RESPONSE).
Because of the mounting orientation of the tilt sensors, the primary tilt sensor will output ascending voltage values with increases in
positive platform tilt angle. The backup or secondary tilt sensor will output descending voltage values with increases in positive platform
angle.
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Figure 46. Level Switches - 800S
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Figure 47. Level Switches - 860SJ

PLATFORM VALVES
The platform specific valves are located in a manifold at the platform.
There are six valves that control various platform functions. Two control Platform Level up and down for the leveling function, two are
used to rotate the platform, and two to control jib up and down.
All platform valves are Pulse Width Modulated (PWM’d). PWM is a method of setting the voltage across a valve, and therefore the flow
through it, by varying the On/Off duty cycle of the control module output. PWM permits proportional flow control.
There is also a Platform Dump Valve, located in the platform valve manifold, which is used to hydraulically isolate the control valves and
to improve hydraulic response.
The Ground Module controls this valve to enable automatic platform leveling and to provide manual platform leveling in the event that
the Platform Module is inoperable.
In ground mode, the platform dump valve is turned on whenever any platform or jib valve output is turned on. Whenever all platform
and jib valves are turned off, the platform dump valve is turned off.
In platform mode, the platform dump valve is turned on whenever the footswitch is depressed.
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5.7.2 Normal Operation

AUTOMATIC PLATFORM ANGLE CONTROL
The level system will assume a new fixed set point (fixed incline of the platform with respect to gravity) each time the control system is
powered up (cycling of the EMS) and each time the footswitch is engaged.
Automatic platform angle control only functions while operating drive, telescope, lift or swing. It does not adjust the platform angle
while operating any other function (e. g. rotate, jib, or steer). Furthermore, machines equipped with control system software P5.0 and
later, automatic platform angle control for drive and swing may be disabled by using the analyzer. For this case, the platform angle
setpoint is taken when the joystick moves from a non-leveling function (drive/swing) to a leveling function (lift/tele).
The machine controls attempt to maintain the angle of the platform to setpoint by providing a command proportional to the angular
error from setpoint. Since the sensors used to measure the platform angle are fluid-filled, gravity-based sensors, reading the sensors in
real time would cause constant correction of the platform position due to machine vibration and inertial changes of the boom.
Therefore, the sensor readings are averaged over time, or filtered, in order to achieve a more uniform reading. This filtering has the
advantage of providing smoother operation, but has the disadvantage of causing a lag (or sluggishness) in the system response. This lag
may cause the platform to be several degrees from setpoint.
In order to provide a better system response, the controls also compute the rate of angular change of the platform position and set the
leveling valve positions to achieve a matching velocity. The measured velocity is the average platform speed over the last 0.5 seconds.
The desired valve command is computed by comparing the measured velocity to the desired velocity and setting the valve opening to
correspond to the required amount of make-up angle. The amount the valve opens when making an automatic correction is
proportional to and directly affected by:
• Crackpoint setting
• Velocity error (proportional factor)
• Sum of velocity errors over time (integral factor)
These three factors are summed together with appropriate gain factors to compute the resulting current to the valves. The operator
does not have control over the latter two factors, but can affect the resulting current by adjusting the crackpoint. Increasing the
crackpoint makes the valve current higher, resulting in quicker more aggressive control and larger amounts of overshoot. Decreasing the
crackpoint will result in smoother operation but may not permit enough platform velocity to keep up with the boom (i. e., may get
platform timeout alarms) in some multi-function operations. The platform controls are set up to provide smooth leveling operations for
the majority of conditions and will perform best for steady operator command, as opposed to command values for function, that change
frequently.
In order to obtain acceptable performance while performing all hydraulic functions, five sets of parameters are used. These “zones” allow
compensation for differences in how the basket level changes when doing different functions. These zones are as follows:
1. Lift up
2. Lift down
3. Other boom functions
4. Drive
5. Auxiliary
The other boom functions zone includes Swing, Telescope, Jib swing (It is not necessary to level with jib lift, since the mechanical linkage
keeps the basket level).
These zones are prioritized when multiple functions are active.
The priorities are as follows.
1. Auxiliary power and any other function, zone = auxiliary power
2. Drive and any other function, zone = Drive
3. Lift up and any other function, zone = Lift up
4. Lift down and any other function, zone = Lift down
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5. Other boom functions, zone = Other boom functions
During the power-up procedure, function enable, in both Platform and Ground Mode, is delayed during the 1.5 second startup lamp
test. During this 1.5 second startup period, the basket level up valve will be energized at 100% duty cycle for 0.5 second, and then the
basket level down valve energized at 100% duty cycle for 0.5 second. This will help to keep the valves from sticking.
PLATFORM LEVEL MANUAL OVERRIDE
In addition to automatic platform angle control, the operator is able to manually adjust the platform level position by means of the level
override switches located at the platform and ground control positions (similar to a Master/Slave hydraulic system).
If a command from the Platform Level Up and Down toggle switch on either the platform or the ground is received, automatic platform
angle control will cease and the appropriate output will be commanded to turn on.
The duty cycle of the output shall be scaled from the pump potentiometer. When the toggle switch is released, after one second, the
current filtered value of tilt angle will be taken as the new set point.
In other words the operator can chose a platform level incline other than level with gravity and the system will maintain the chosen
platform angle within several degrees of setpoint.
5.7.3 Platform Leveling Fault

The JLG Control System takes a snapshot of the two sensor values and records the difference once on each power up. The Control
system allows a ±5 degrees difference from those values. For example, if Sensor 1 is at 5 degrees and Sensor 2 is at 11 degrees, the
difference is 6 degrees and the DTC is triggered when the sensors are 1 degree (or less) apart or 11 degrees (or more) apart.
If a fault occurs in the platform leveling system the following will occur:
1. Automatic platform angle control will stop and the platform dump valve will be disabled (level, rotate, and jib functions disabled).
The exception is when there is a fault in only one sensor automatic platform angle control will remain active as the control system
will use the other sensor to control leveling.
2. The level system fault lamp will flash (to indicate that the leveling function has been lost).
3. The platform alarm will sound.
4. A system fault will be logged.
5. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the transport
position see below).
To reset the fault the emergency stop switch should be recycled.
NOTICE
If the level system fault indicator remains illuminated, return the platform to the
stowed position, shut down the machine, and repair the leveling system.
ERROR RESPONSE
If basket level varies from the current setpoint by ± 5.5° for more than 2 seconds for large variations from setpoint when the platform is
not in the transport position, the controls assume the system is not properly set up or has degraded and initiate a fault.
When the unit is in the transport position and driving and the current setpoint varies by ± 5.5° for more than 10 seconds the events 1,2,3
& 4 above will occur. (note function speeds will operate normally). Since the control system can not anticipate all conditions under which
a machine is to be operated, these parameters have been chosen to provide reasonable performance and safe operation. If an error
occurs, cycling the EMS will clear the fault. The operator should evaluate the operating situation and assess his machine to determine
the source of the fault.
VALVE DRIVER ERRORS
There are three possible level valve driver errors, short to battery, short to ground, and open circuit.
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1. In the case of a short to ground or an open circuit, the platform valve cannot be turned on and the following will occur:
a. All interactions with platform leveling shall cease
b. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost).
c. The platform alarm will sound.
d. A system fault will be logged.
e. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the
transport position).
2. In the case of a short to battery on one of the platform leveling valves, the valve cannot be turned off and the following will
occur:
a. The platform dump valve will be turned off to prevent unintended tilting of the platform.
b. All interactions with platform leveling shall cease.
c. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost).
d. The platform alarm will sound.
e. A system fault will be logged.
f. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the
transport position)
3. In the case of a short to battery on the platform dump valve, the valve cannot be turned off. The controllability of the platform
leveling function will be impaired and the following will occur:
a. All interactions with platform leveling shall cease.
b. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost).
c. The platform alarm will sound.
d. A system fault will be logged.
e. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the
transport position).
Lift, swing, drive and telescope will continue to operate

In each of the cases above it shall be necessary to re-cycle the EMS to clear the fault. Operable functions shall be in the creep mode
except while below elevation.
TILT SENSOR ERRORS
If the secondary tilt sensor is faulty, the control system will continue to utilize information from the primary sensor.
If the primary sensor is faulty, the control system will switch to the backup sensor for control.
In both cases above the following will occur:
1. The Electronic Leveling System Fault Lamp will flash (to indicate that there is a leveling fault).
4. All function speeds (lift, swing, telescope, jib and drive) will be placed in creep mode (except when the platform is in the transport
position).
5. Automatic platform angle control remains active.
Lift, swing, drive and telescope will continue to operate.

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 mode
except while below elevation.
When both sensors appear to be working but have measurements that disagree by ±5.5º The following will occur:
1. All interactions with platform leveling shall cease.
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2. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost).
5. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the transport
position)
At this point, the operator must use the level up and down toggle switch to manually level during descent. It shall be necessary to re-
cycle the EMS to clear the fault.
5.7.4 CAN Errors

The Ground Module has two direct outputs dedicated to overriding the Platform Module’s control of the leveling valves. The EPBC
Ground Module “Platform Level Up/Down” outputs are used to control the platform level up and down valves.
When in ground mode, if the Ground Module reads a platform leveling switch command, the switch command is communicated over
CAN to the Platform Module where it is handled normally.
If Ground Module determines that CAN communication is inoperable, it turns on the platform control valve and the appropriate platform
leveling override outputs while the switch is engaged.
If the Platform Module is still running when CAN is down nothing will operate when in platform mode. When the operator switches to
ground mode, the platform will not control any of its valve outputs and a CAN error message is signaled.
5.7.5 Replacing the Level Sensors

Earlier generations of this machine had three different generations of level sensors that were used on this machine. JLG PN 4360503, PN
4360528, and PN 4360544. PN 4360528 and 4360544 supersede PN 4360503. If one of the 4360503 sensors fail, BOTH sensors must be
replaced with two PN 4360544 sensors. 4360503 Sensors can be identified by the code SSY0185-13 which is printed on the sensor.
Otherwise, single 4360528 or 4360544 9999 sensors may be replaced.
5.7.6 Additional Platform and Jib Valves

The high side drivers for the platform left and right and the jib up and down valves are be located in the Platform Module and are
PWM’d. The control for these functions are the same as currently implemented for the EPBC except that the flow through the valves is
individually controllable instead of controlled by single the flow control valve. The individually controlled duty cycle will be the same as
would otherwise have been commanded to the flow control valve.
Only one platform or jib function is allowed at one time to limit the amount of current draw, minimizing the voltage drop on the supply
to the PM.
The function is enabled first shall remain active until it is released. Any other function commanded while another function is active is
ignored.
If only one other function is commanded when the active function is released, the other function will be activated.
If more than one function is commanded when the active function is released, only one function shall be activated.
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5.7.7 Platform Leveling Calibration Procedure

STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
1. Put machine into “Ground Mode”.
2. Start machine and plug in Analyzer.
3. Go to the “Access Level 2” screen.
4. Enter “33271” to get into Access Level 1 mode.
5. Go to the “Personalities” menu and adjust the following personalities. Refer to the Personality Ranges/Defaults table in Section –
Analyzer Software Accessibility, page 136 for proper setting values.
Basket Level Up Min
Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
6. Recycle EMS.
STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS (FOR PLATFORM SOFTWARE PRIOR TO VERSION P3.4)
3. Manually level the platform with the switch on the MTB.
6. Go to the “Calibrations” menu and hit ENTER.
7. Use RIGHT ARROW go to “Plat. Leveling” screen.
8. Hit ENTER. “Calibrate?” prompt should appear.
9. Hit ENTER again to calibrate level sensors.
10. When calibration has been successful “Cal Complete” should appear.
11. Cycle power to the machine.
STEP 3: BLEEDING THE PLATFORM VALVES

Start up the machine and exercise the following platform functions (from the ground) eight (8) to ten (10) times for 5 seconds in each
direction.
Basket Rotate
Basket Level
Jib U/D (if configured)
STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS
Note: Since the valve position which allows minimum oil flow (crackpoint) is dependent on the oil pressure, verify the proper stand-by
pressure as outlined in Section – Hydraulic Components, page 261 prior to setting the crackpoints.
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5. Go to the “Calibrations” menu and hit ENTER.
6. Go to the “Basket U Crkpt” Screen. Hit ENTER.
7. “Calibrate?” prompt should appear. Hit ENTER again.
8. You will hear engine go to 1800 rpm.
9. Using UP ARROW, increase the value until you see the basket up movement. (Typically from 275 – 425).
10. Hit ENTER again. “Cal Complete” message should appear
11. Engine should again return to idle.
12. Hit ESC should return to “Basket U Crkpt” screen.
13. Hit RIGHT ARROW to get to the “Basket D Crkpt” screen. Hit ENTER.
14. “Calibrate?” prompt should appear. Hit ENTER again.
15. You will hear engine go to 1800 rpm.
16. Using UP ARROW, increase the value until you see the basket down movement. (Typically from 275 – 425).
17. Hit ENTER again. “Cal Complete” message should appear.
18. Engine should again return to idle.
19. Hit ESC to exit.
20. Cycle power to the machine.
21. The preceding steps will provide acceptable crackpoint settings for the majority of machines. However, there exists the possibility
certain machines could still have too high or too low a crackpoint setting.
If the operator can feel small jolts in the platform from the valve opening during a leveling operation, the crackpoint is likely too
high. A high crackpoint may also lead to over-leveling, causing the platform to drift beyond the set point. An example of this
would be the platform tilting too far backwards during a Lift Up operation. Use the following guidelines to evaluate whether
further crackpoint adjustment is required.
a. Telescope the boom halfway.
b. Perform a continued Lift Up command (do not cycle the joystick on/off repeatedly). If the basket leans backward (over
compensates), the Level Down crackpoint is too high. If the basket leans forward or a BASKET LEVELING SYSTEM TIMEOUT
fault occurs, the Level Down crackpoint is too low.
c. Perform a continued Lift Down command (do not cycle the joystick on/off repeatedly). If the basket leans forward (over
compensates), the Level Up crackpoint is too high. If the basket leans backwards or the Tilt Cutout Alarm comes on, the Level
Up crackpoint is too low.
If Platform Level is slow to respond during Lift commands, causing PLATFORM LEVEL TIMED OUT faults, it may be necessary to
increase the crackpoint settings. Use the following guidelines to evaluate whether further crackpoint adjustment is required.
a. Perform a continued Lift Up command (do not cycle the joystick on/off repeatedly). If the PLATFORM LEVEL TIMED OUT fault
sets or if Platform Level Down seems slow to respond, an increase in the Platform Level Down crackpoint may be necessary.
b. Perform a continued Lift Down command (do not cycle the joystick on/off repeatedly). If the PLATFORM LEVEL TIMED OUT
fault sets or if Platform Level Up seems slow to respond an increase in the Platform Level Up crackpoint may be necessary.
800S HC3, 860SJ HC3 31222415 167

168
SECTION 6
FAULT CODES
6.1 FAULT CODES INTRODUCTION
Faults are detected while key switch is in RUN position, during operation of machine itself. If a fault becomes active (currently detected)
at this time, a fault is logged in memory and a snapshot of DTC parameters is logged.
The list of machine, engine or specific system fault codes are detailed further in this section.
6.2 ENGINE DIAGNOSTIC
6.2.1 Deutz TD2.9L4 (EMR4 or T4F) Engine

Table 30. Engine Fault Codes (Deutz EMR4 or T4F)
Deutz Description
SPN FMI Blink Code Possible Cause Action
Code
29 2 978 1-2-6 Diagnostic fault check of Plausibility error between sensor Threshold for error detection is an
synchronism of hand throttle and and idle switch internal ECU threshold.
Low idle switch (LIS). The accelerator pedal must have
detected full load and idle
plausibility at least once.
29 3 932 1-2-6 Diagnostic fault check of short circuit The signal exceeds the applicable If the signal is below the applicable
to supply voltage (signal range threshold; signal range violation threshold APP_uRawSRCHiHTLIS_C,
check high) of acceleration pedal the signal range violation is reset
signal. after the healing debouncing. In
case when the CCP is active (CCP_
stActive = 1)and the reading from
the EEPROM memory is successful,
the signal is below the threshold
APP_uHTLISCCPHi[1], a signal range
violation is reset after debouncing.
29 4 937 1-2-6 Diagnostic fault check of short circuit The signal is below the applicable If the signal exceeds the applicable
to ground (signal range check low) threshold; signal range violation threshold APP_uRawSRCLoHTLIS_C,
of acceleration pedal signal the signal range violation is reset
after the healing debouncing. In
case when the CCP is active (CCP_
stActive = 1)and the reading from
the EEPROM memory is successful,
the signal exceeds the threshold
APP_uHTLISCCPLo[1], a signal range
violation is reset after debouncing.
91 3 935 2-2-6 Analog accelerator pedal sensor 1 or Sensor defect. Short cut to battery Check cabling, check accelerator
double accelerator pedal sensor: the or open loop. pedal sensor and if necessary
voltage measured by ECU is out of replace it, check connection cable
the target range or the calculated and if necessary repair or replace it.
pedal position is implausible If the signal is below the applicable
compared with the position of the threshold APP_uRaw1SRCHigh_C,
second pedal the signal Range violation is reset
after The healing debouncing.
91 4 940 2-2-6 Analog accelerator pedal sensor 1 or Short circuit to ground. Check cabling, check accelerator
double accelerator pedal sensor: the pedal sensor and if necessary
voltage measured by ECU is out of replace it, check Connection cable
the target range or the calculated and if necessary repair or replace it
pedal position is implausible If the signal exceeds the applicable
threshold APP_uRaw1SRCLow_C,
800S HC3, 860SJ HC3 31222415 169

Fault Codes
Table 30. Engine Fault Codes (Deutz EMR4 or T4F) (continued)

Deutz Description
Code
Compared with the position of the the signal Range violation is reset
second pedal after the Healing
91 11 976 2-2-6 Diagnostic fault check of Measured voltage of accelerator Threshold for error detection is an
synchronism of single potentiometer pedal 1 is out of plausible range. internal ECU threshold.
and Low idle switch (LIS). Check cabling, check accelerator
pedal and pedal sensor and if
necessary replace it,
Check connection cable and if
necessary repair or replace it.
When the PWM period APP_
tiPWMPer is in between APP_
tiSRCLoPWMPer_C and APP_
tiSRCHiPWMPer_C .
94 1 474 216 Low fuel pressure: the low fuel Fuel pressure below warning Check low fuel pressure system (fuel
pressure calculated by ECU is threshold feed pump, relay , fuse, wiring,
underneath the target range; the sensor) and if Necessary repair or
ECU activates a system reaction replace it.
94 3 472 216 Low fuel pressure sensor: the Cable break or short circuit, sensor Check cabling, if sensor not working,
voltage of sensor measured by ECU defective, connection cable check sensor and if necessary
is out of the target range damaged, Short cut to battery or replace it, check Connection cable
open loop and if necessary repair or replace it
94 4 473 216 Low fuel pressure sensor: the Cable break or short circuit, sensor Check cabling, if sensor not working,
voltage of sensor measured by ECU defective, connection cable check sensor and if necessary
is out of the target range damaged Short cut to ground replace it, check Connection cable
and if necessary repair or replace it
97 3 464 228 Fuel filter water level sensor: the Sensor not connected or sensor Check of wiring and water in fuel
voltage of sensor measured by ECU defect. sensor. Check cabling, if charge
is out of the target range Water in Fuel sensor is not working,
check sensor and if Necessary
replace it, Check connection cable
and if necessary repair or replace it.
97 4 465 228 Fuel filter water level sensor: the Cable break or short circuit, sensor Check sensor and if necessary
voltage of sensor measured by ECU defective, connection cable replace it, check connection cable
is out of the target range. damaged. Short cut to ground. And if necessary repair or replace it.
97 12 1157 228 Fuel filter water level sensor: the Water level in fuel pre-filter Measure Voltage at Water in Fuel
maximum level is exceeded reservoir over limit (bad fuel Sensor and renew harness if needed.
quality)
100 1 736 231 Oil pressure is below the target Oil pressure too low (pressure Threshold for error detection is an
range (warning threshold) below warning threshold) internal ECU threshold.
Check oil level, check engine for oil
leakage, measure oil pressure
external to evaluate Sensor value
100 1 737 231 Oil pressure is below the target Oil pressure too low (pressure Threshold for error detection is an
range (shut off threshold) below shut off threshold). internal ECU threshold.
Check oil level, check engine for oil
leakage, measure oil pressure
external to evaluate Sensor value.
100 3 732 224 Oil pressure sensor: the voltage of Short circuit to battery or cable Check battery and wiring
sensor measured by ECU is out of break Check cabling. If sensor not working,
the target range check sensor and if necessary
replace it,
170 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
Check connection cable and if
100 4 733 224 Oil pressure sensor: the voltage of Short circuit to ground The sensed raw voltage value Oil_
sensor measured by ECU is out of uRawPSwmp is above Oil_
the target range SRCPSwmp.uMin_C
Check cabling, if sensor not working,
check sensor and if necessary
replace it, check
Connection cable and if necessary
repair or replace it
No detail information!
102 1 774 223 Charge air pressure below lower Measured charge air pressure below Check complete air system of engine
limit the threshold. for massive leakage, especially from
compressor to intake air manifold.
Check air filter.
Exchange charge air pressure sensor.
102 2 88 223 Charge air pressure measured by Charged air cooler pressure below Check waste gate system if
sensor is above the shut off threshold. necessary replace TC,
threshold. check CAC if all channels are clean,
check charge air piping if necessary.
102 2 89 223 Charge air pressure measured by Charge air pressure above shut off Check waste gate system if
sensor is above the warning threshold necessary replace TC, check CAC if all
threshold channels are clean,
Check charge air piping if necessary.
102 2 772 223 Deviation between sensed intake Deviation between ambient 1) Exchange boost pressure sensor
manifold pressure is not possible pressure sensor and charge air 2) Exchange ECU
compared to environment pressure. pressure sensor at not Running
Which sensor is not okay can not be engine to high
said.
102 3 776 223 Charge air pressure sensor: the The Sensor Voltage is above the Check cabling, if charge air pressure/
measured voltage of sensor by ECU Threshold. temperature sensor is not working,
is out of the target range check sensor and if necessary
replace it, check connection cable
102 4 777 223 Charge air pressure sensor: the The Sensor Voltage is below the Check cabling, if charge air pressure/
measured voltage of sensor by ECU Threshold. temperature sensor is not working,
is out of the target range check sensor and if necessary
105 0 996 233 Charge air temperature downstream Charge air temperature Check CAC system and clean it.
calculated by ECU is above the (downstream) over warning Check fan functionality.
target range. threshold. Check cooling performance with
The ECU activates a system reaction. temperature measurement.
105 0 997 233 Charge air temperature downstream Charge air temperature Check CAC system and clean it.
calculated by ECU is under the shut (downstream) over the low Check fan functionality. Check
down threshold. threshold. cooling performance with
The ECU activates a system reaction. temperature measurement.
105 1 992 128 Charged Air cooler down stream Sensed temperature within intake actual temperature below -40°C?
temperature. air manifold < threshold. exchange sensor
Temperature below lower physical
threshold.
800S HC3, 860SJ HC3 31222415 171

Fault Codes

Deutz Description
Code
105 3 994 128 Charge air temperature sensor: the Short circuit to battery. The sensor raw signal Air_
voltage of sensor measured by ECU sensor voltage > limit uRawTCACDs (voltage) > Air_
is out of the target range. SRCTCACDs.uMin_C.
Check CAC-sensor and if necessary
105 4 995 128 Charge air temperature sensor: the Short circuit to ground or open The sensor raw signal Air_
voltage of sensor measured by ECU load. uRawTCACDs (voltage) is below Air_
is out of the target range. sensor voltage < limit. SRCTCACDs.uMin_C.
Check CAC-sensor and if necessary
107 0 752 136 Air filter differential pressure: the Pressure loss above target range Check air filter and if necessary
pressure difference of the intake air with system reaction, air filter clean or renew it, check cabling,
between the filter inlet and outlet clogged or defective, sensor not check sensor and if necessary
calculated by ECU is above the working, connection cable damaged replace it, check connection cable
target range and the ECU activates a Pressure value above warning and if necessary repair or replace it
system reaction threshold
110 0 98 232 Coolant temperature: the coolant Cooling temperature too high. Clean radiator, check fan drive,
temperature calculated by ECU is Coolant temperature above warning check coolant level, check cooling
above the target range; the ECU threshold system in general, check thermostat
activates a system reaction function, check water pump
110 0 99 232 Coolant temperature: the coolant Coolant temperature above shut off Clean radiator, check fan drive,
temperature calculated by ECU is threshold. check coolant level, check cooling
above the target range. system in general, check thermostat
The ECU activates a system reaction function, check water pump
110 1 93 225 Coolant temperature sensor: the Suspected components: wiring Check wiring harness and connected
voltage of the sensor measured by harness, coolant temperature Coolant Temp Sens.
ECU is out of the target range. sensor.
110 3 96 225 Coolant temperature sensor: the Short cut to battery or open load. Check sensor and if necessary
voltage of the sensor measured by replace it, check connection cable
ECU is out of the target range and if necessary repair or replace it.
110 4 97 225 Coolant temperature sensor: the Voltage Surveillance has found Check sensor and if necessary
voltage of the sensor measured by shortcut to Ground at Coolant replace it, check connection cable
ECU is out of the target range Temperature Sensor. and if necessary repair or replace it
Measure Voltage at Coolant
Temperature Sensor and renew
harness if needed.
111 1 101 235 Coolant level: the coolant level Coolant level too low, leakage in Check coolant level, inspect cooling
calculated by ECU is underneath the cooling system, sensor defective, system for leakage and if necessary
allowed minimum. wiring damaged. repair it, check sensor and wiring
157 3 877 147 Rail pressure sensor: the voltage of Short cut to battery. Check cabling, check rail pressure
sensor measured by ECU is out of Damaged rail pressure sensor. sensor and if necessary replace it,
the target range. check connection cable and if
157 4 878 147 Rail pressure sensor: the voltage of Check cabling, check rail pressure Check cabling, check rail pressure
sensor measured by ECU is out of sensor and if necessary replace it, sensor and if necessary replace it,
the target range. check connection cable and if check connection cable and if
necessary repair or replace it. necessary repair or replace it.
164 2 1381 839 Rail pressure safety function is not Rail pressure is still above Threshold for error detection is an
executed correctly threshold. internal ECU threshold.
172 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
Reset the fault and at reappearance
check ECU and injection system
168 0 1180 318 Battery voltage: the voltage Battery voltage over limit Check alternator, regulator of
measured by ECU is out of the alternator and if necessary replace
target range it, check wiring and voltage of
alternator
168 1 1181 318 Battery voltage: the voltage Battery voltage below limit Check alternator, cabling, contact
measured by ECU is out of the resistance, safety fuses, too high
target range load in energy system, check battery
and if necessary replace it
168 2 47 318 Battery voltage: the voltage If Battery voltage (Ubatt_U) > 17V Check wiring harness and connected
measured by ECU is out of the or 31V for more than =0.5 sec a alternator.
target range, system reaction is warning is generated
initiated Battery voltage above warning
threshold
168 3 45 318 Battery voltage: the voltage Battery voltage above warning Check wiring harness and connected
measured by ECU is out of the threshold (~38,9Volt), Short cut to alternator.
target range, system reaction is battery possible.
initiated
168 4 46 318 Battery voltage: the voltage Battery voltage below warning Check wiring harness and connected
measured by ECU is out of the threshold, Short cut to ground alternator.
target range, system reaction is
initiated
171 3 417 312 Sensor error SCR-System open loop to sensor Check cabling, if environment
environment temperature; DPF- temperature sensor is not working,
System air inlet temperature; signal check sensor and if necessary
range check high replace it, check connection cable
171 4 418 312 Sensor error SCR-System short circuit to Ground Check cabling, if environment
environment temperature; DPF- temperature sensor is not working,
System air inlet temperature; signal check sensor and if necessary
range check low replace it, check connection cable
172 0 1425 226 sensed intake air temperature at air sensed intake air temperature at air Check outside conditions:
filter > physical high limit filter > physical high limit Temperature > Threshold within the
intake air system of the engine?
E.G: engine sucks in air from hot
asphalt out of paver bucket
Sensor positioned within black air
filter housing above engine lid at
hot environmental conditions and
idling or similar?
=> if yes check with application
team to adapt limits
if not check sensor and wiring
harness exchange sensor
172 1 1183 226 sensed air temperature within air sensed air temperature within air Cold start and ambient temperature
intake path of engine below intake path of engine below < threshold
physical low limit physical low limit Check wiring harness to AFST-sensor
Exchange AFST-sensor
190 0 389 214 Engine speed: the engine speed Overspeed monitoring during 1 check powertrain settings regarding
calculated by ECU is above the level of FOC (Failure overrun overspeed
800S HC3, 860SJ HC3 31222415 173

Fault Codes

Deutz Description
Code
target range; the ECU activates a condition) if engine speed was over
system reaction Limit.
190 2 421 213 ECU measures a deviation between Offset error between crankshaft and Threshold for error detection is an
camshaft and crankshaft angle to camshaft. internal ECU threshold, occurs by
target. offset between crankshaft and
camshaft.
Check increment wheel position,
clean and adjust if necessary, check
sensor position.
Check Camshaft and Crankshaft
senor or wiring.
190 8 419 212 Camshaft speed sensor: the ECU When disturbed camshaft signal Threshold for error detection is an
receives no signal and uses the detected. internal ECU threshold, occurs by
signal from crankshaft speed sensor Error in sensor or wiring. disturbed camshaft signal.
as alternative to calculate the Check increment wheel position,
engine speed clean and adjust if necessary, check
sensor position.
Check Camshaft Sensor or wiring.
190 8 422 212 Sensor crankshaft speed; disturbed Error in sensor or wiring. Threshold for error detection is an
signal Crankshaft sensor defect. internal ECU threshold, occurs by
disturbed crankshaft signal.
Check increment wheel position,
clean and adjust if necessary, check
sensor position.
Check Crankshaft Sensor or wiring.
190 11 390 214 Engine speed: the engine speed Overspeed monitoring during 2 check powertrain settings regarding
calculated by ECU is above the level of FOC (Failure overrun overspeed
target range; the ECU activates a condition) if engine speed was over
system reaction limit.
190 12 420 212 Camshaft speed sensor: the ECU Error in sensor or wiring. Threshold for error detection is an
receives no signal and uses the internal ECU threshold, occurs by
signal from camshaft speed sensor disturbed or no camshaft signal.
engine speed Threshold: clean and adjust if necessary, check
sensor position.
Check Camshaft Sensor or wiring.
190 12 423 212 Crankshaft speed sensor: the ECU Error in sensor or wiring. Threshold for error detection is an
receives no signal and uses the internal ECU threshold, occurs by
signal from camshaft speed sensor disturbed or no crankshaft signal.
engine speed. clean and adjust if necessary, check
Crankshaft sensor position or wiring.
190 14 391 214 Engine speed: the engine speed Overspeed monitoring during ORC check powertrain settings regarding
calculated by ECU is above the (Override conditions) if engine overspeed
target range; the ECU activates a speed was over 2900 rpm
system reaction
190 14 1222 2-1-2 Camshaft- and Crankshaft speed Sensors for engine speed are defect. Threshold for error detection is an
sensor signal not available on CAN internal ECU threshold.
or defect. Check wiring, check cables and
repair or replace if necessary.
411 0 791 693 delta pressure across venturi in EGR sensed value of venturi difference Threshold for error detection is an
line above physical high limit pressure > high limit internal ECU threshold.
EGR-Valve blocked open
174 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
EGR-Valve actuator defect
EGR-cooler defect (check for coolant
water)
Reed Valve defect
Intake throttle blocked in closed
position => Check intake throttle
Exhaust pressure too high => Check
Exhaust pressure
Check NOx-sensor upstream SCR
catalyst
dp venturi sensor defect
411 1 792 693 delta pressure across venturi in EGR sensed value of venturi difference Threshold for error detection is an
line below physical low limit pressure < low limit internal ECU threshold.
Check correct mounting of difference
pressure sensor at venturi tube
Exchange difference pressure sensor
broken
411 3 795 693 The sensed raw voltage Air_ EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta
uRawPEGRDeltaP is above the pressure sensor is not working,
maximum threshold. check sensor and
if necessary replace it, check
connection cable and if necessary
repair or replace it.
411 4 381 693 Range check cannot be done or EGR or wiring defect Check wiring harness and connected
interrupted. EGR.
411 4 796 693 The sensed raw voltage value Air_ EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta
uRawPEGRDeltaP is above the pressure sensor is not working,
minimum threshold. check sensor and
if necessary replace it, check
411 11 793 693 DFC is stored in EEPROM and status deviation between desired O2 Threshold for error detection is an
kept until check is allowed concentration in intake air manifold internal ECU threshold.
to be carried out again and the real O2-concentration EGR-Valve mechanically blocked
DFC can be reset by service routine within intake air manifold > limit open or closed
216 EGR-pipe blocked with metal plate
instead sealing downstream EGR-
Valve
EGR-Valve actuator defect
water)
Reed Valve defect
position => Check intake throttle
Exhaust pressure too high => Check
Exhaust pressure
catalyst
412 3 1007 682 EGR downstream temperature Short circuit to battery. Check wiring harness to TEGR-
sensor: the voltage of sensor sensor voltage > limit sensor.
measured by ECU is out of the Exchange TEGR-sensor.
target range.
412 4 1008 682 EGR downstream temperature Short circuit to ground or open Check wiring harness to TEGR-
sensor: the voltage of sensor load. sensor.
800S HC3, 860SJ HC3 31222415 175

Fault Codes

Deutz Description
Code
measured by ECU is out of the sensor voltage < limit Exchange TEGR-sensor.
target range.
630 12 376 281 Internal hardware monitoring: the Section could not be erased Threshold for error detection is an
ECU finds an error during the access internal ECU threshold.
to its EEPROM memory or works There is no healing possible for the
with an alternative value error. In the every new initialization
phase, the debounce level is set to
zero.
If not programmed, EEPROM is
defect –> ECU is defect, reprogram
ECU and if necessary replace it.
630 12 377 281 Internal hardware monitoring: the Minimum 3 blocks could not be There is no healing possible for the
ECU finds an error during the access read, EEPROM has Checksum Error error. In the every new initialization
to its EEPROM memory or works phase, the debounce level is set to
with an alternative value zero.
If not programmed, EEPROM is
defect –>ECU is defect, reprogram
ECU and if necessary replace it
630 12 378 281 Internal hardware monitoring: the Block could not be written for Threshold for error detection is an
ECU finds an error during the access minimum 3 times internal ECU threshold.
to it's EEPROM memory or works If not programmed, EEPROM is
with an alternative value defect –> ECU is defect, reprogram
ECU and if necessary replace it.
639 14 84 271 CAN bus 0: the ECU is not allowed CAN BusOff error; CAN 0 (Customer Threshold for error detection is an
to send messages, because the CAN) internal ECU threshold.
status "BusOff" is detected. BusOff bit for CAN A node is set.
Check wiring of CAN bus and if
necessary repair it, check connection
cable and if necessary repair or
replace it, check resistance in CAN
lines (120 Ohm)
651 3 580 154 Injector cyl. 1: the current drop Suspected Components: Threshold for error detection is an
measured by ECU is above the injector cylinder 1 internal ECU threshold.
target range wiring harness, cable break or short Check wiring harness, injectors and
circuit, sensor defective, connection if necessary repair/replace it. Use
cable damaged SerDia Injector test for diagnosis.
651 5 568 154 Injector cyl. 1: interruption of Interruption of electronic connection Threshold for error detection is an
electrical connection Injector cyl. 1 internal ECU threshold.
Check wiring harness, injectors and
if necessary repair/replace it.
cable SerDia Injector test for diagnosis.
damaged
target range
176 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
wiring harness, cable break or short Check wiring harness, injectors and
cable damaged SerDia Injector test for diagnosis.
676 11 543 263 Cold start aid relay error. Relay defect or wire harness Threshold for error detection is an
problem internal ECU threshold.
check wire harness, replace relay
676 11 544 263 Cold start aid relay open load Relay or wire harness Threshold for error detection is an
internal threshold.
check wire harness, replace relay
677 3 956 512 Start relay (high side power stage): Short cut HighSide-output to Threshold for error detection is an
the current drop measured by ECU is battery. internal ECU threshold.
above the target range. Check cabling and start relay and if
check connection cable and if
677 3 960 512 Start relay (low side power stage): Shortcut LowSide-Output to battery. Threshold for error detection is an
the current drain measured by ECU internal ECU threshold.
is above the target range. Check cabling and start relay and if
800S HC3, 860SJ HC3 31222415 177

Fault Codes

Deutz Description
Code
677 4 957 512 Start relay (high side power stage): Shortcut HighSide-output to Threshold for error detection is an
the current drain measured by ECU ground. internal ECU threshold.
is above the target range. Check cabling and start relay and if
677 4 961 512 Start relay (low side power stage): Shortcut LowSide-Output to ground. Threshold for error detection is an
the current drop measured by ECU is internal ECU threshold.
check connection cable of terminal
50 and if necessary repair or replace
it.
677 5 958 512 Start relay (low side power stage): Open circuit/disconnection LowSide- Threshold for error detection is an
the current drop measured by ECU is Output. internal ECU threshold.
above the target range Check cabling and start relay and if
677 12 959 512 Start relay (low side power stage): Temperature over limit. Threshold for error detection is an
the current drop measured by ECU is internal ECU threshold.
691 8 928 928 Supply module heater: PWM time PWM signal for temperature The Time period of the received
period out of valid range. readout from supply module to the PWM signal SCR_tiSMPerPwm is
control unit is out of range. within the specified range of 150 ms
Supply module defect, fault in the to 250 ms
wiring. Supply module check and replace if
necessary.
Check the wiring.
729 3 549 263 wiring to the intake air heater Intake Air Heater Device: overload, Threshold for error detection is an
device is faulty. short-circuit internal ECU threshold.
Electrical error, Check wiring to the
intake air heater device.
729 4 551 263 wiring to the air intake heater is Relay (for cold start aid) cable break Threshold for error detection is an
faulty or short to ground: internal ECU threshold.
Electrical error, check wiring to the
air intake heater.
729 5 545 263 The cold start aid relay is according Relay defect or wire harness Threshold for error detection is an
to wiring faulty. problem internal ECU threshold.
Electrical error, check wires
729 12 547 263 The cold start aid relay is High temperature around the cold Check the functionality of relay and
overheated, which causes this error start relay. replace it if needed.
Check the temperature around the
cold start relay during worst case
operation.
178 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
898 9 305 118 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus Check CAN Bus cabling (Bus
TSC1TE - active message) scheduling, polarity, short circuit,
power interrupt), test
protocol of receiver, check CAN
functional range.
1079 13 946 282 Internal hardware monitoring: the Suspected components EDC17cv52 Check cabling of external
ECU detects a deviation of the target Pin A19: DEF press / components, check working voltage
range of the power supply voltage Exh.PressBeforeTurb (P3) / Air Pump and if necessary correct it.
of sensor output 1. Press Check connection cable and if
/BrnFuelPressAfterDV2 Pin K19: Fan necessary repair or replace it.
Speed Sensor If error is not removable, change
Pin A21: LDF6T / OilPress / ECU.
LowFuelPress Pin A17: Rail Pressure
Sensor
Suspected components EDC17cv54
Pin A21: CAM speed Pin K44: Delta
Press Venturi / Poti EGR or Inlet
Throttle
Pin A24: LDF6T / OilPress /
LowFuelPressPin K43: Reserve 5V
Sensor Supply
Pin A09: second footpedal
Pin A21: Cam speed Pin K44: DEF
press / Air FilterDiffPress
Pin A24: LDF6T / OilPress /
LowFuelPress Pin K43: second
footpedal
Pin A09: Delta Press Venturi
ECU detects a deviation of the target Pin K16: second footpedal components, check working voltage
range of the power supply voltage Pin A20: Exh.PressAfterTurb/ and if necessary correct it, check
of sensor output 2. DPFDiffPress/BrnDV1Press/ connection cable and if necessary
HCIPressDV1DV2 repair or replace it, if error is not
Suspected components EDC17cv54 removable, change ECU.
Pin K45: DPF Diff Press / Exh. Press
After Turb / Fan Speed Sensor
Pin A46: first footpedal
Pin A22: Fan Speed Sensor
Pin K45: Position EGR or Intake
throttle flap
Pin K46: First footpedal
1109 2 121 341 Request of engine shut off: the Engine Shut Off demand has been Depending on error requested a shut
operator ignores the engine shut off ignored by the user off.
request within an allowed period.
1136 0 1398 681 ECU internal temperature; Short-Circuit in ECU, ECU heated by Close warm air circuits, replace ECU
temperature measured by ECU is out hot air
of the target range
1231 14 85 271 CAN bus 1: the ECU is not allowed CAN BusOff error; CAN 1 (Diagnostic Threshold for error detection is an
status "BusOff" is detected BusOff bit for CAN B node is set.
Warning, no diagnostic with Check wiring of CAN bus and if
SERDIA2010 possible necessary repair it, check connection
800S HC3, 860SJ HC3 31222415 179

Fault Codes

Deutz Description
Code
lines (120 Ohm)
1235 14 86 271 CAN bus 2: the ECU is not allowed CAN BusOff error; CAN 2 (Engine Threshold for error detection is an
status "BusOff" is detected. BusOff bit for CAN C node is set.
Warning, depends on engine, EAT. Check wiring of CAN bus and if
necessary repair it, check connection
lines (120 Ohm)
1237 2 747 145 Override switch: the ECU receives a Switch is blocked, taster locked, If the Block Button is pressed
permanent signal. connection cable damaged shorter than the Maximum Plausible
plausibility error "override switch > pressing Time.
250 ms pressed". Check cabling, if sensor is not
working, check switch and if
necessary replace it, check
1761 0 1593 129 The urea tank level sensor detects a Suspected components: Check level sensor and float gauge
value higher than the maximum Urea Quality Sensor defect
allowed threshold mechanical defect at the float
gauge
1761 1 1594 129 The DEF tank level sensor detects a Suspected components: Check level sensor and float gauge
value lower than the minimum Urea Quality Sensor defect
allowed threshold mechanical defect at the float
gauge
1761 14 1655 138 The urea tank volume ratio is below actual urea tank level SCRUTnk_ Check urea level => if empty, then
the threshold of <5% rVol_mp [%] is below applicable fill in urea
threshold 5% Check DEF level sensor.
If there is urea in the tank, then
move the floater of the level sensor.
The floater must be free. If you lift
the sensor body, then SCRUTnk_
rVol_mp must change.
Exchange DEF level sensor, if no
change of value or it's implausible.
1761 14 1656 138 The urea tank volume ratio is below actual urea tank level SCRUTnk_ Check urea level => if empty, then
the threshold of <2.5% rVol_mp [%] is below 2.5% fill in urea
Check DEF level sensor.
If there is urea in the tank, then
move the floater of the level sensor.
The floater must be free. If you lift
the sensor body, then SCRUTnk_
rVol_mp must change.
Exchange DEF level sensor, if no
change of value or it's implausible.
1761 14 1880 138 The DEF tank level is below the actual DEF tank level SCRUTnk_ Check DEF level => if empty, refill
threshold. rVol_mp [%] is below the threshold Check DEF level sensor.
If there is urea in the tank loose the
sensor and move it. The floater
must be free and move if you lift
the sensor body.
SCRUTnk_rVol_mp must change.
Compare SCRUTnk_rVol_mp to:
1 = SCR_rawUTnkLvl
180 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
2 = SCR_rAdapUtnkLvl
3 = SCRUTnk_rActTnkVol
*SCRUTnk_facVolPer_mp
In case of malfunction, exchange
DEF level sensor.
2791 0 1763 415 Internal actuator temperature is Overheating of EGR actuator during Let EGR actuator cool down and
above threshold. operation. check heat accumulation during
worst case operation.
2791 2 1753 415 corrupted CAN communication with CAN bus error or faulty EGR Threshold for error detection is an
actuator. actuator. internal ECU threshold.
Check other CAN bus components. If
no message is sent, fix the wiring.
If OK exchange EGR actuator.
2791 3 1758 415 Overvoltage at EGR actuator. High voltage from the battery Check battery voltage.
2791 4 1759 415 Undervoltage at EGR actuator. Low voltage from the battery. Check battery voltage.
2791 6 1757 415 Overcurrent to EGR actuator. High voltage from battery. Check battery voltage. Check if EGR
EGR actuator is blocked or moving is blocked or not running smoothly.
very hard. If everything is OK change EGR
actuator.
2791 7 1752 415 EGR actuator is mechanically EGR actuator faulty or blocked. Threshold for error detection is an
blocked. internal ECU threshold.
Check the EGR actuator and EGR
valve to mechanical blockage /
clean.
Check for free movement of the
valve. If it'S blocked, then exchange
the EGR valve.
2791 7 1761 415 EGR actuator spring broken. mechanical damage of spring due Threshold for error detection is an
to overstress. internal ECU threshold.
Exchange EGR actuator.
2791 12 1755 415 Internal electrical fault of EGR Internal damage of EGR actuator Threshold for error detection is an
actuator. due to high temperature or internal ECU threshold.
electrical wiring issue. Exchange EGR actuator.
2791 13 1754 415 EGR actuator can not learn stop Error detection during the learning Threshold for error detection is an
positions. process. internal ECU threshold.
Possibly only second failure if other Start Serdia Usecase to reset EGR
EGRTV failures occurs. actuator.
Check EGR valve and mounting
situation. If OK change EGR actuator.
2791 13 1756 415 EGR actuator can not learn stop Interruption of learning process due Threshold for error detection is an
positions because procedure was to mechanical damage. internal ECU threshold.
interrupted. Start Serdia Usecase to reset EGR
actuator.
2791 13 1760 415 Stop positions of EGR valve not OK Mechanical damage of EGR Threshold for error detection is an
actuator. internal ECU threshold.
EGR valve is blocked or moving very Start Serdia Usecase to reset EGR
hard. actuator.
2791 16 1762 415 Internal actuator temperature above overheating of EGR actuator Let EGR actuator cool down, check
threshold. heat accumulation during worst case
operation.
800S HC3, 860SJ HC3 31222415 181

Fault Codes

Deutz Description
Code
2797 4 1337 565 Injector diagnosis: Timeout of Short-Circuit to ground on Threshold for error detection is an
Injector detection cylinder bank 0 component wiring internal ECU threshold.
Check wiring, component, ECU
Note: affected injector has to be
evaluated according to firing order
2797 4 1339 565 Injector test: Short cut to ground on Short-Circuit to ground on Check wiring, component, ECU
cylinder bank 0 component wiring Note: affected injector has to be
2798 4 1338 566 Injector diagnosis: Timeout of Short-Circuit to ground on Threshold for error detection is an
Injector detection cylinder bank 1 component wiring internal ECU threshold.
Note: affected injector has to be
2798 4 1340 566 Injector test: Short cut to ground on Short-Circuit to ground on Check wiring, component, ECU
cylinder bank 1 component wiring Note: affected injector has to be
3031 0 1135 669 The urea tank temperature sensor Sensed urea tank temperature > Case "CANBUS sensor":
detects a value above the maximum physical range high limit Check urea tank temperature: really
allowed threshold hot?
Check CANBus-message of DEF
sensor urea tank temperature Com_
dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1
(urea temperature at quality sensor)
identical?
Tank heater permanently on?
Check wiring of DEF-quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really
hot?
Check urea tank temperature SCR_
tSensUTnkT
Compare urea tank temperature to
EnvT_t or to SCR_tSMT (the urea
temperature
inside the supply module) identical?
Tank heater permanently on?
Check wiring of analog DEF T &
Level sensor
3031 1 1136 669 The urea tank temperature sensor sensed urea tank temperature < Case "CANBUS sensor":
detects a value lower than the physical range low limit Check ambient temperature EnvT_t
minimum allowed threshold. => About -40 °C? If yes Error could
be plausible
Check CANBus-message of DEF
sensor urea tank temperature Com_
dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1
(urea temperature at quality sensor)
identical?
Check wiring of DEF-quality sensor
Check quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really
that cold? Check ambient
temperature EnvT_t =>
182 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
About -40 °C? If yes Error could be
plausible
Check urea tank temperature SCR_
tSensUTnkT
Check wiring of analog DEF T &
Level sensor
Check analog DEF T & Level sensor
3224 2 129 596 DLC Error of CAN-Receive-Frame Not Used Threshold for error detection is an
AT1IG1Vol NOx Sensor (SCR-system internal ECU threshold.
upstream cat; DPF-system Check NOx-Sensor and the wiring
downstream cat); length of frame from CAN-BUS.
incorrect
3224 9 130 597 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOx sensor and sensor connection
AT1IG1Vol; NOx sensor (SCR-system check
upstream cat; DPF-system
downstream cat)
3234 2 138 114 DLC Error of CAN-Receive-Frame Failure of the CAN Bus message NOx downstream sensor and sensor
AT1O1Vol NOx Sensor (SCR-system connection check
downstream cat; DPF-system
downstream cat); length of frame
incorrect
3234 9 139 117 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOx downstream sensor and sensor
AT1OG1Vol; NOx sensor (SCR-system connection check
downstream cat; DPF-system
downstream cat)
3361 3 1077 677 Urea dosing valve (low side power Fault in the wiring Threshold for error detection is an
stage): the current drain measured internal ECU threshold
by ECU is above the target range See substitute function
Check the wiring
3361 3 1078 677 Urea dosing valve (high side power Fault in the wiring Threshold for error detection is an
by ECU is above the target range Check the wiring
3361 4 1079 677 Urea dosing valve (low side power Fault in the wiring Check the wiring
stage): the current drain measured
by ECU is above the target range
3361 4 1080 677 Urea dosing valve (high side power Fault in the wiring Threshold for error detection is an
by ECU is above the target range Check the wiring
3361 6 1075 677 Urea dosing valve: the current Fault in the wiring Check wiring
measured value by ECU at the end Defect urea dosing injection valve Check the urea dosing injection
of the injection is too high valve
3519 3 1898 277 The integrated diagnostic of the Wrong diagnostic of the short Check the wiring to the suction unit
temperature sensor of the Urea circuits logic inside the temperature in the DEF tank.
Quality Sensor recognized a short sensor of the UQS Check the CAN bus communication
circuit to battery. CAN Communication corrupted of the suction unit. In case the
The UQS Sensor is an combined communication is corrupt, exchange
sensor of tank temperature, filling the suction unit.
grade and DEF quality and it is also
an CAN sensor –> no PIN
3519 4 1899 277 The integrated diagnostic of the DEF quality sensor in the suction Check the wiring to the suction unit
temperature sensor of the Urea unit of the DEF tank is defect of the DEF tank.
CAN Communication corrupted
800S HC3, 860SJ HC3 31222415 183

Fault Codes

Deutz Description
Code
Quality Sensor recognized a short Check the CAN bus communication
circuit to ground from the suction unit. In case the
signal is corrupt, exchange the
suction unit in the DEF tank.
3519 12 1895 277 The integrated temperature sensor Temperature sensor inside the UQS Check the temperature sensor signal
of the Urea Quality Sensor measures defect. for plausibility. In case of improper
higher temperature than threshold CAN Communication corrupted. signal,
Overheating of the DEF tank due to exchange the suction unit in the
malfunction of the heating valve. tank.
Flow direction is of coolant is Check CAN bus communication for
wrong due to mixed up the hoses proper signal. In case of improper
routed to the heating valve. signal, exchange the suction unit in
Overheating of the DEF tank due to the tank.
heat transfer from neighbor parts. Check the function of heating valve
and routing of the hoses. The
coolant flow through the heating
valve must be observed according to
the shown arrow.
In case all actions above are OK,
check the real temperature in the
DEF tank during worst case
condition and improve the
installation of the DEF tank.
3519 13 1908 277 Temperature at UQS out of range Suspected Components Check temperature system and/or
the specified thresholds; invalid Tank heater DEF quality sensor
quality of the temperature DEF sensor
3520 2 1904 2-7-8 Measured DEF Quality from UQS is Suspected components: Check that there is liquid urea of
too low. Urea quality sensor defect known quality in the tank first
Quality value received from UQS is Wrong installation (measuring air) Check urea tank level. Add urea
< 22 % for a certain time and a Urea level sensor defect until level is at least 10 cm above
certain number or for measuring Non urea filled in tank sensor.
conditions not observed for a certain CANBUS problems Ensure that urea is not frozen /
time. Evaluation conditions for new sufficient urea is liquid
quality check not fulfilled after Check Sensor: Are urea tank
previous maldetection temperature and level displayed?
Changes the level if you refill urea?
Check electrical connection
Check CANBus
New quality detection is carried out
if urea refill is detected or if an
quality evaluation was triggered and
was not finished successfully: To
provoke a quality measurement:
refill urea, at least 10 % of tank
volume
Wait until quality evaluation was
carried out, can take up to 30
minutes => check value.
It should be about 33 %
Exchange quality sensor
3520 3 1896 278 The integrated diagnostic of the wiring harness of UQS corrupted Threshold for error detection is an
Urea Quality Sensor recognized a CAN Communication corrupted internal ECU threshold.
short circuit to battery Check the wiring harness from the
ECU to the suction unit of the DEF
tank
184 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
Check the CAN bus communication.
If the signal is corrupt, then
exchange the suction unit.
3520 4 1897 278 The integrated diagnostic of the wiring harness to the suction unit Threshold for error detection is an
Urea Quality Sensor recognized a in the DEF tank is corrupted internal ECU threshold.
short circuit to ground. CAN Communication corrupted Check the wiring to the suction unit
in the DEF tank.
Check the CAN bus communication.
In case the communication is
corrupt, exchange the suction unit in
the DEF tank.
3520 13 1907 278 Urea quality at UQS out of range the Suspected components Check DEF quality and/or DEF quality
specified thresholds; invalid quality DEF quality sensor sensor
of the urea DEF
3532 3 1911 127 The urea quality value from the Suspected Components: Check DEF quality and/or sensor.
sensor is greater than the maximum UQS defect
physical range threshold
Comment: tank temperature is
measured by the UQS sensor
3532 4 1912 127 The urea quality value from the Suspected Components: Check DEF quality and/or Sensor.
sensor is lower than the minimum UQS defect
physical range threshold.
3711 12 1455 711 Temperature Phy_tPfWgh, the temperature Phy_tPfWgh, the Check temperature upstream DOC
weighted DPF temperature < weighted DPF temperature, is Exh_tSensOxiCatUs within Stand-
Threshold 1 below or above the target still: > 450 °C? If not:
Temperature Phy_tPfWgh, the temperature towards the end of the => Check air path of engine: EGR-
weighted DPF temperature > stand-still main phase. Valve, Intake-Throttle, Turbocharger
Threshold 2 towards the end of the and Piping each for leakage and
stand-still main phase. correct function
Check temperature difference across
DOC by Exh_tSensOxiCatDs -
Exh_tSensOxiCatUs within Stand-
still: < 100°C? If not:
Check exhaust pipe downstream
turbo charger for oil?
check injectors: is an injector got
stuck?
Too many hydrocarbons in exhaust?
White smoke (at hot EAT system,
not at cold start)?
Check air path of engine: EGR-Valve,
Intake-Throttle, Turbocharger and
Piping each for leakage and correct
function
Check exhaust gas temperature
sensors within EAT-system: T
upstream DOCC, T downstream DOC
& T upstream SCR catalyst all three
of them can influence Phy_tPfWgh
3936 14 1917 2-8-6 Standstill escalation by time. In case Stand-still request ignored by the Perform Stand-still. If soot load level
the standstill request will not be operator. of DPF has increased too high
released within 50 h by the driver Display / stand-still request lamp already call service to perform
this fault code will be set. broken. stand-still.
In case the DPF soot load level
remove DPF => Exchange DPF.
800S HC3, 860SJ HC3 31222415 185

Fault Codes

Deutz Description
Code
4334 0 1122 665 The absolute pressure value of the Suspected Components: Check the urea pump
urea pump is greater than an Urea pump defect Check the supply module pressur
applicable maximal filtered pressure Supply module pressure sensor sensor
threshold defect Clean the urea pump (filter)
Pump contains dirty parts
4334 1 1123 665 Urea supply module pressure sensor: Check the urea pump Check the urea pump
The absolute pressure value of the Check the supply module pressure Check the supply module pressure
urea pump is less than an applicable sensor sensor
minimal filtered pressure threshold Clean the urea pump (filter) Clean the urea pump (filter)
4334 2 1866 665 absolute difference of sensed urea absolute difference of sensed urea Check environment pressure sensor
pump pressure (SCR_ pump pressure (SCR_ (EnvP_p) => plausible value?
pAbsSensUPmpP) and ambient pAbsSensUPmpP) and Engine shut-off and immediately re-
pressure (EnvP_p) > limit ambient pressure (EnvP_p) > limit started? => Shut-off again. Wait
abs(UPmpP_pDiffPmpEnv_mp) > abs(UPmpP_pDiffPmpEnv_mp) > until afterun of ECU has finished, re-
UPmpP_pDiffPmpEnv_C (250 hPa) UPmpP_pDiffPmpEnv_C Start engine
Back-flow line free? Does the urea
pump pressure show values < 1000
hPa in SCR state emptying (64)?
Check revision valve => Does the
urea pump pressure show values <
1000 hPa in SCR state emptying
(64)? => exchange supply module
Supply module pressure sensor
defect => exchange supply module
4341 3 1104 675 Urea heater supply line: the current Electrical error Threshold for error detection is an
drain measured by ECU is above the internal ECU threshold
target range Check wire harness
Check supply line
Check supply line
Check supply line
4343 3 1096 673 Urea pressure line heater: the shortcut to battery Threshold for error detection is an
current drain measured by ECU is If this error detected during the internal ECU threshold
above the target range heating phase is a result error: KWP Check wiring
1089 Check heating element
broken heating element in pressure
line
4343 4 1097 673 Urea pressure line heater: the Shortcut to ground Threshold for error detection is an
Short cut to ground or broken
wiring, broken heating element in
pressure line
4343 5 1094 673 Urea pressure line heater: the Open load Threshold for error detection is an
186 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
Broken wiring, broken heating
element in pressure line
4345 3 1092 674 Urea backflow line heater: the Shortcut to battery Threshold for error detection is an
Short cut to battery or broken
backflow line
4345 4 1093 674 Urea backflow line heater: the Shortcut to ground Threshold for error detection is an
Short cut to ground or broken
backflow line
4345 5 1090 674 Urea backflow line heater: the Open load Threshold for error detection is an
Broken wiring, broken heating
element in backflow line
4360 0 1069 668 The filtered urea cat upstream Sensed temperature upstream SCR Check temperature difference across
temperature is greater than an > physical high limit DOC (Exh_tOxiCatDs-Exh_TOxiCatUs)
applicable maximum temperature at higher engine load =>high
threshold difference > 100 K?
If yes, the engine emits too many
Hydrocarbons => check injectors: is
an injector got stuck?
=> Check EGR Valve
If difference normal the exhaust out
of the engine itself is too hot:
=> Check air path of engine: EGR-
Valve, Intake-Throttle, Turbocharger
and Piping each for leakage and
correct function
If that error was set while stand-still
operation the error source could be
exothermal
soot burn off in DPF (which should
not happen) => Dismount DPF and
check it visually exchange
temperature sensor upstream SCR
4360 1 1070 668 The filtered temperature before urea Sensed temperature upstream SCR Cold start and ambient temperature
cat is less than an applicable catalyst < than physical low limit < Threshold? Missdetection?
minimum temperature threshold Check wiring harness to UCatUsT-
sensor
Exchange UCatUsT-sensor
4360 2 1865 668 Error at static plausibility check: Error at static plausibility check: Check whether temperature sensor
absolute temperature difference of absolute temperature difference of upstream of SCR catalyst is
sensed temperature upstream SCR sensed temperature upstream SCR physically mounted within exhaust
catalyst and ambient temperature > catalyst and ambient temperature pipe
as static plausibility limit at engine > as static plausibility limit at If cold start condition can be made
cold start (engine was off for at engine cold start (engine was off sure (engine was off for at least 8
least 8 h), temperature upstream of for at least 8 h), temperature h) compare values of EnvT_t,
SCR catalyst is expected to be upstream of SCR catalyst is EngDa_tEng, Exh_TOxiCatUs, Exh_
800S HC3, 860SJ HC3 31222415 187

Fault Codes

Deutz Description
Code
identical to ambient temperature expected to be identical to ambient tOxiCatDs and SCR_tSensUCatUsT at
=> see enable conditions for temperature => see enable ignition on, without starting the
details. conditions for details. engine. All identical?
Error at dynamic plausibility check: Error at dynamic plausibility check: Compare values of Exh_TOxiCatUs,
temperature difference of sensed temperature difference of sensed Exh_tOxiCatDs and SCR_
temperature upstream SCR catalyst temperature upstream SCR catalyst tSensUCatUsT after 15 min in
and ambient temperature < as and ambient temperature < as constant operation point: show all
dynamic plausibility limit dynamic dynamic plausibility limit dynamic similar values (30 K tolerance
check is blocked if static plausibility check is blocked if static plausibility width). Are ambient temperature
check is already faulty => check is already faulty => and (EnvT_t), cooling water
Temperature upstream SCR catalyst Temperature upstream SCR catalyst temperature (EngDa_tEng)
must be by 40°C higher than must be by 40°C higher than plausible?
ambient temperature if engine runs ambient temperature if engine runs Sensor coated with urea crystals?
and a certain delay time has and a certain delay time has Dismount urea injector and inspect
expired. expired. temperature sensor upstream SCR
catalyst visually
Check wiring of sensor
Replace sensor
4361 3 1072 668 Urea catalyst upstream temperature Voltage of temperature sensor Check sensor
sensor: the voltage of sensor upstream SCR catalyst > maximum Check wiring
measured by ECU is out of the limit Replace UCatUsT-sensor
target range Short circuit to battery
4361 4 1073 668 Urea catalyst upstream temperature Voltage of temperature sensor Check sensor
sensor: the voltage of sensor upstream SCR catalyst < minimum Check wiring
measured by ECU is out of the limit Replace UCatUsT-sensor
target range Short circuit to ground
4365 2 1137 6-6-9 Signal error in case of Urea tank CAN message is not send properly. Check sensor connector
temperature transmitted via CAN- Check CANbus
signal Com_tUTnkT.
4365 3 1138 6-6-9 Urea tank temperature sensor: he Shortcut or open load. Threshold for error detection is an
current drain measured by ECU is internal ECU threshold.
above the target range. The Sensed raw voltage value SCR_
uRawUTnkT is below SCR_
SRCUTnkT.uMax_C.
Check wiring.
4365 3 1914 669 Internal error of DEF quality sensor. Suspected components: Check wiring harness and DEF
DEF quality sensor quality sensor
Wiring harness
4365 4 1139 6-6-9 Urea tank temperature sensor: he Shortcut or open load. Threshold for error detection is an
current drain measured by ECU is internal ECU threshold.
above the target range. The sensed raw voltage value SCR_
uRawUTnkT is above SCR_
SRCUTnkT.uMin_C.
Check wiring.
4365 4 1915 6-6-9 Internal error of DEF quality sensor. Suspected components: Check wiring harness and DEF
DEF quality sensor quality sensor
Wiring harness
4366 3 1112 671 Urea tank heating valve: the current Shortcut to battery Threshold for error detection is an
drain measured by ECU is above the If this error detected during the internal ECU threshold
target range heating phase is a result error: KWP Check wiring
1089 Check urea tank heating valve
Broken wiring
Urea tank heating valve defect
188 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
4366 4 1113 671 Urea tank heating valve: the current Shortcut to ground Threshold for error detection is an
Broken wiring
4366 5 1110 671 Urea tank heating valve: the current Open load Threshold for error detection is an
Broken wiring
4375 3 1120 666 Urea supply module pump: the Shortcut to battery Threshold for error detection is an
above the target range heating phase is a result error: KWP The hardware detects absence of
1089 any short circuit to battery on the
Broken wiring PWM output power stage for the
Pump in urea supply module defect urea pump module actuator
Check wiring
Check pump in the urea supply
module
4375 4 1121 666 Urea supply module pump: the Shortcut to ground Threshold for error detection is an
above the target range heating phase is a result error: KWP The hardware detects a short circuit
1089 to ground error on the PWM output
Broken wiring power stage for the Urea Pump
Pump in urea supply module defect Module Motor Actuator. The error is
updated by setting bit 1 of
measuring point UPmp-Mot_
stPrevTstRslt_mp
Check wiring
module
4375 5 1118 666 Urea supply module pump: the ECU Open load Threshold for error detection is an
can not measure any reaction during Broken wiring internal ECU threshold
pump control Pump in urea supply module defect The hardware detects the presence
of load on the PWM output power
stage for the urea pump module
actuator.
Check wiring
module
4376 3 1131 667 Urea supply module reversal valve: Shortcut to battery Threshold for error detection is an
the current drain measured by ECU Fault in the wiring internal ECU threshold
is above the target range Reversal valve in the urea supply Check wiring
module defect Check urea supply module
4376 4 1132 667 Urea supply module reversal valve: Shortcut to ground Threshold for error detection is an
4376 5 1129 667 Urea supply module reversal valve: Open load Threshold for error detection is an
800S HC3, 860SJ HC3 31222415 189

Fault Codes

Deutz Description
Code
4765 0 1039 683 The exhaust temperature value from sensed temperature upstream DOC Check air path of engine: EGR-Valve,
the sensor before DOC is above an > shut-off limit Intake-Throttle,
applicable upper shutoff threshold Check Turbocharger and Piping each
TOxiCatUs_tShOffThresHiAds_C = for leakage and correct function
Threshold 1 in Normal and Check injectors: is an injector got
Heatmodes (TOxiCatUs_ stuck? Exchange temperature sensor
tShOffThresHiRgn_C = Threshold 2 upstream DOC
in stand-still)
4765 0 1040 683 The exhaust temperature value from Sensed temperature upstream DOC Check air path of engine: EGR-Valve,
the sensor before DOC is above an > warning limit Intake-Throttle, Turbocharger and
applicable upper warning threshold Piping each for leakage and correct
TOxiCatUs_tWarnThresHi_C = function
Threshold Check injectors: is an injector got
stuck? Exchange temperature sensor
upstream DOC
4768 2 1036 683 Static plausibility check: Static plausibility check: Check ambient temperature =>
The exhaust temperature value from The exhaust temperature value value plausible?
the sensor before DOC, the exhaust from the sensor before DOC, the upstream DOC sensor mounted
temperature value from the sensor exhaust temperature value from the within exhaust line?
after DOC, the temperature value sensor after DOC, the temperature T upstream DOC sensor physically
from the sensor before SCR-Cat, the value from the sensor before SCR- mounted in correct position
environment temperature and the Cat, the environment temperature upstream DOC? (not upstream SCR
coolant engine temperature their and the coolant engine temperature or downstream DOC?)
ratios to each other exceed their their ratios to each other exceed Check T upstream DOC sensor
related thresholds. Dynamic their related thresholds. (difference Check other T-sensors within EAT-
plausibility check with environment between temperature after DOC and system (Exh_tOxiCatDs & UCatUsT_
temperature sensor value: The temperature before DOC > tFlt_mp show plausible values? No
exhaust temperature value from the Threshold 1 difference between errors on them?
sensor before DOC is lower than an temperature before DOC and before
applicable environment temperature SCR > Threshold 2 difference
threshold between temperature after DOC and
before SCR < Threshold 3 difference
between temperature after DOC and
ambient temperature < Threshold 4
difference between temperature
ambient temperature and engine
temperature < Threshold 5)
Dynamic plausibility check with
environment temperature sensor
value:
The exhaust temperature value
from the sensor before DOC is lower
than an applicable environment
temperature threshold (<
environmental temperature +
Threshold 6)
4768 2 1881 683 At engine cold start conditions the Difference temperature of exhaust Check whether all exhaust gas
sensed exhaust gas temperature gas temperature downstream DOC temperature sensors within the EAT
downstream DOC (Exh_ and fixed ambient temperature at system are mounted properly:
tSensTOxiCatDs) has exceeded the ignition on exceeds a certain limit Within the exhaust line and at
sum of ambient temperature (EnvT_ earlier than the difference correct positions.
t) + offset (40°C) earlier than the temperature of exhaust gas Check the position of the sensor
sensed exhaust gas temperature temperature upstream DOC and upstream SCR which might be
upstream of DOC (Exh_ fixed ambient temperature at physically mounted in the wrong
tSensTOxiCatUs). ignition on. position.
The check is only performed once If cold start condition can be made
each ignition cycle and only if the sure (engine was off for at least 8
start is judged a cold start. h) compare values of EnvT_t,
190 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
Error status is frozen for that EngDa_tEng, Exh_TOxiCatUs, Exh_
ignition cycle. No healing possible. tOxiCatDs and SCR_tSensUCatUsT at
ignition on, without starting the
engine. All identical? Then the
sensors itself are okay.
Check exhaust piping for leakage.
Check wiring of sensors
Replace sensors
Check DOC => physically intact?
4768 3 1044 683 Oxidation catalyst upstream The sensed raw voltage value Exh_ Check wiring harness to temperature
temperature sensor: the voltage of uRawTOxiCatUs is above Exh_ sensor upstream DOC
sensor measured by ECU is out of SRCTOxiCatUs.uMax_C Shortcut to Exchange temperature sensor
the target range battery upstream DOC
4768 4 1045 683 Oxidation catalyst upstream The sensed raw voltage value Exh_ Check wiring harness to temperature
temperature sensor: the voltage of uRawTOxiCatUs is sensor upstream DOC
sensor measured by ECU is out of below Exh_SRCTOxiCatUs.uMin_C Exchange temperature sensor
the target range Shortcut to ground upstream DOC
5763 3 1024 594 Actuator of the external EGR valve: Short cut to battery or open loop. Check cabling, actuator defect, check
the ECU detects a short circuit to actuator and if necessary replace it,
battery or open load. check connection cable and if
5763 3 1226 594 Actuator EGR-valve: short cut to Short-Circuit to battery on Threshold for error detection is an
battery is detected component wiring internal ECU threshold.
Check repair with SerDia 2010 use
case
5763 3 1227 594 Actuator EGR-valve: short cut to Short-Circuit to battery on Threshold for error detection is an
battery on ECU pin is detected component wiring internal ECU threshold.
case
5763 4 1025 594 Actuator of the external EGR valve: Short cut to ground Check cabling, actuator defect, check
the ECU detects a short circuit to actuator and if necessary replace it,
ground. check connection cable and if
5763 4 1228 594 Actuator EGR-valve: short cut to Short-Circuit to ground on Threshold for error detection is an
ground on ECU pin is detected component wiring internal ECU threshold.
case
5763 4 1229 594 Actuator EGR-valve: short cut to Short-Circuit to ground on Threshold for error detection is an
battery on ECU pin is detected component internal ECU threshold.
case
5763 4 1232 5-9-4 Actuator error EGR-Valve (2.9;3.6) or Monitoring for CY146 Under Threshold for error detection is an
Throttle-Valve (4.1;6.1;7.8); Voltage Voltage. internal ECU threshold.
below threshold Check wiring, component
3.6) Drosselklappe (4.1;6.1;7.8);
Voltage below threshold;
800S HC3, 860SJ HC3 31222415 191

Fault Codes

Deutz Description
Code
5763 5 1023 5-9-4 Actuator error EGR-Valve; signal Short circuit to ground. Check wiring, check cables and
range check low, measured current repair or replace if necessary, check
is below target actuator with
SERDIA 2010 test for EGR and if
necessary replace it.
5763 6 1014 594 Actuator error EGR-Valve. Short cut to battery. Check wiring and repair or replace if
Signal range check high. necessary, check actuator with
SERDIA test for EGR and if necessary
replace it.
5763 6 1022 5-9-4 Actuator error EGR-Valve; signal Short circuit to battery or open Check cabling, actuator defect, check
range check high, measured current circuit. actuator and if necessary replace it,
by ECU is over target check connection cable and if
5763 6 1223 594 Actuator EGR-Valve: Open load on Open circuit on component wiring Threshold for error detection is an
ECU output is detected internal ECU threshold.
case
5763 6 1224 594 Actuator EGR-valve: too high current Overload on component wiring Threshold for error detection is an
is going into the actuator. Output is internal ECU threshold.
switched off Check wiring, component, ECU
case
5763 6 1230 5-9-4 Actuator error EGR-valve; Overload Short Circuit over Load Threshold for error detection is an
by short-circuit internal ECU threshold.
Check wiring, component
5763 7 1016 594 Actuator position for EGR valve is Position error of throttle flap Threshold for error detection is an
not plausible, internal error, angular (deviation > 7%). internal ECU threshold.
misalignment of the flap. Threshold for error detection,
deviation from setpoint > 7%.
Troubleshooting with SERDIA 2010
Use Case "EGR Diagnostic".
5763 11 1231 5-9-4 Power stage over temperature due Temperature dependent Over Threshold for error detection is an
to high current. Current internal ECU threshold.
Check wiring, component
520521 5 1015 594 Actuator error EGR-Valve. Short cut to ground. Check wiring and repair or replace if
Signal range check low. necessary, check actuator with
SERDIA test for EGR and if necessary
replace it.
523009 9 825 253 The pressure relief valve (PRV) has Rail pressure has exceeded the Replace pressure relief valve (PRV)
reached the number of allowed trigger threshold of the pressure and reset fault with Serdia.
activations. limiting valve.
523009 10 833 2-5-3 The pressure relief valve (PRV) has Rail pressure has exceeded the Replace pressure relief valve (PRV)
reached the allowed opening time. trigger threshold of the pressure and reset fault with Serdia.
limiting valve.
523212 9 171 3-3-3 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus Check wiring harness and customer
ComEngPrt; Engine Protection message) devices
523240 9 179 527 Timeout CAN-message FunModCtl; Timeout Error (Missing CAN Bus Check CAN Bus cabling (Bus
Function Mode Control message) scheduling, polarity, short circuit,
power interrupt), test protocol of
receiver, check CAN functional range.
192 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
523350 4 565 151 Injector cylinder bank 1: the current Short circuit injection bank 1 (all Threshold for error detection is an
drop measured by ECU is above the injectors of this bank can be internal ECU threshold.
target range affected) Check wiring harness, injectors and
523352 4 566 152 Injector cylinder bank 2: the current Short circuit injection bank 2 (all Threshold for error detection is an
drop measured by ECU is above the injectors of this bank can be internal ECU threshold.
target range affected) Check wiring harness, injectors and
523354 12 567 153 Internal hardware monitoring: the Defective power stage in ECU Threshold for error detection is an
ECU detects an error of its injector internal ECU threshold.
high current output. Chip of CY33x If error is not removable, change
defect power stage components ECU.
523450 4 839 1-4-3 Diagnostic fault check for min error The sensed raw value is less than Check cabling, check sensor and if
of COM message. the threshold. necessary replace it,
523470 2 826 146 The pressure relief valve (PRV) has Rail pressure has exceeded the Threshold for error detection is an
been opened due to excessive trigger threshold of the pressure internal ECU threshold.
pressure. limiting valve. Reset the fault and at reappearance
check injection system.
523470 2 827 146 The pressure relief valve (PRV) has Rail pressure has exceeded the Threshold for error detection is an
been opened due to excessive trigger threshold of the pressure internal ECU threshold.
pressure. limiting valve. Reset the fault and at reappearance
check injection system.
523470 7 876 146 Rail pressure is out of the expected Rail pressure is out of the expected (A) Check rail pressure relief valve
average range. average range. and replace if necessary.
PRV can not be opened. (B) Check high pressure pumps,
pressure relief valve and metering
unit.
(C) Change components if necessary
523470 11 831 146 Rail pressure relief valve can not be Rail pressure out of tolerance range Threshold for error detection is an
opened due to the rail pressure. (PRV can not be opened by a internal ECU threshold.
pressure peak in this operating Check rail pressure, check rail
point) pressure sensor for plausibility,
check FCU.
523470 11 832 146 Rail pressure is out of the expected Averaged rail pressure is outside the Threshold for error detection is an
average range. expected tolerance range. internal ECU threshold.
The PRV can not be opened at this Check PRV and replace if necessary.
operating point with a pressure
shock.
523470 12 828 146 Rail pressure relief valve: is open. Shut Off after PRV Open Threshold for error detection is an
Shutoff conditions. internal ECU threshold.
Check PRV opening counter and if
necessary replace PRV,
check rail-pressure sensor for
plausibility and if necessary replace
it,
check FCU and if necessary replace
it.
523470 12 829 146 Rail pressure relief valve is open. Warning PRV open Threshold for error detection is an
Warning conditions. internal ECU threshold.
800S HC3, 860SJ HC3 31222415 193

Fault Codes

Deutz Description
Code
necessary replace PRV,
check rail pressure sensor for
it,
it.
523470 14 830 146 Rail pressure relief valve is open. Open PRV Threshold for error detection is an
(PRV) internal ECU threshold.
Only after ECU reset.
check rail-pressure sensor for
it,
it.
523550 12 980 515 Terminal 50 was operated for more Start information to Starter (T50- Threshold for error detection is an
than 2 minutes. This may happen switch) erratic/defect. internal ECU threshold.
due to short to battery or wrong Check cabling, if sensor not working,
usage of Terminal 50. check start switch and if necessary
Starter control is disabled until this replace it,
error is healed. check connection cable and if
ECU detects a deviation of the target Pin A18: DeltaPressVenturi / components, check working voltage
range of the power supply voltage Position intake throttle flap and if necessary correct it,
of sensor output 3. Pin K20: First footpedal check connection cable and if
Pin K21: Air FilterDiffPress necessary repair or replace it,
Suspected components EDC17cv54 if error is not removable, change
and cv56 ECU.
Pin A07: Rail pressure
523612 3 644 555 supply voltage too high not used Threshold for error detection is an
internal ECU threshold.
523612 4 646 555 supply voltage too low not used Threshold for error detection is an
523612 12 387 555 Internal hardware monitoring: the Injector shut off demand for the ICO Threshold for error detection is an
CPU of the ECU is reset and the coordinator internal ECU threshold.
cause is logged internally; no item System responses: not Caution ! Sequence error, check error
will be created in error memory memory for other errors.
523612 12 612 555 Internal hardware monitoring: the Plausibility check failed (MoCADC_ Threshold for error detection is an
CPU of the ECU is reset and the uNTP_mp is higher than MoCADC_ internal ECU threshold.
cause is logged internally; no item uNTPMax_C). If error is still present, exchange
will be created in error memory. ECU.
523612 12 613 555 Internal hardware monitoring: the Analysis of test voltage (Value is Threshold for error detection is an
CPU of the ECU is reset and the out of the target -> ECU internal internal ECU threshold.
cause is logged internally; no item error) Check wiring, check connected
will be created in error memory sensors actuators.
If error is still present, exchange
ECU.
523612 12 614 555 Internal hardware monitoring: the Analysis of the ratiometric Threshold for error detection is an
CPU of the ECU is reset and the correction (Value is out of the internal ECU threshold.
cause is logged internally; target -> ECU internal error) Check wiring, check connected
sensors actuators.
194 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
no item will be created in error If error is still present, exchange
memory ECU.
523612 12 615 555 Internal hardware monitoring: the Error report due to an error in the Threshold for error detection is an
CPU of the ECU is reset and the plausibility of Function Coordination internal ECU threshold.
cause is logged internally; (FC) and If error is still present, exchange
no item will be created in error Monitoring Module(MM)(ECU ECU.
memory internal error)
523612 12 616 555 Internal hardware monitoring: the Error report due to an interrupted Threshold for error detection is an
CPU of the ECU is reset and the SPI communication (ECU internal internal ECU threshold.
cause is logged internally; no item error) If error is still present, exchange
will be created in error memory ECU.
523612 12 617 555 Internal hardware monitoring: the multiple error in complete ROM-test Threshold for error detection is an
CPU of the ECU is reset and the during post drive detected (ECU internal ECU threshold.
cause is logged internally; no item internal error) If error is still present, exchange
523612 12 618 555 Internal hardware monitoring: the Too less bytes received by Threshold for error detection is an
CPU of the ECU is reset and the monitoring memory from CPU as internal ECU threshold.
cause is logged internally; no item response (ECU internal error). Loss If error is still present, exchange
will be created in error memory of synchronization sending bytes to ECU.
the monitoring memory from CPU
523612 12 619 555 Internal hardware monitoring: the Suspected components: Threshold for error detection is an
CPU of the ECU is reset and the Injector ECU internal ECU threshold.
cause is logged internally; no item wiring harness/connector If error is still present, exchange
523612 12 620 555 Internal hardware monitoring: the Error trying to set MM Response Threshold for error detection is an
CPU of the ECU is reset and the time (ECU internal error) internal ECU threshold.
cause is logged internally; no item If error is still present, exchange
523612 12 621 555 Internal hardware monitoring: the Error detected in the internal ECU Threshold for error detection is an
CPU of the ECU is reset and the communication, Too many SPI internal ECU threshold.
cause is logged internally; no item errors during If error is still present, exchange
will be created in error memory MoCSOP execution ECU.
523612 12 623 555 Internal hardware monitoring: the Error in the check of the shut-off Threshold for error detection is an
CPU of the ECU is reset and the path test of the under voltage internal ECU threshold.
cause is logged internally; no item detection (ECU internal error). If error is still present, exchange
will be created in error memory Diagnostic fault check to report the ECU.
error in undervoltage monitoring
CPU of the ECU is reset and the path of the monitoring module internal ECU threshold.
cause is logged internally; no item (ECU internal error). If error is still present, exchange
523612 12 625 555 Internal hardware monitoring: the Time out error trying to set or Threshold for error detection is an
CPU of the ECU is reset and the cancelling the alarm task (ECU internal ECU threshold.
cause is logged internally; no item internal error). Failure setting the If error is still present, exchange
will be created in error memory alarm task period ECU.
523612 12 627 555 Internal hardware monitoring: the Error in time monitoring of the Threshold for error detection is an
CPU of the ECU is reset and the shut-off path test (ECU internal internal ECU threshold.
cause is logged internally; no item error). Diagnostic fault check to If error is still present, exchange
will be created in error memory report the timeout in the shut off ECU.
path test
800S HC3, 860SJ HC3 31222415 195

Fault Codes

Deutz Description
Code
CPU of the ECU is reset and the path test of the over voltage internal ECU threshold.
cause is logged internally; no item detection (ECU internal error). If error is still present, exchange
will be created in error memory Diagnostic fault check to report the ECU.
error in overvoltage monitoring
523612 12 629 555 The two voltage values (ADC_VAL1, Defect pedal or wiring Threshold for error detection is an
ADC_VAL2), detected by the internal ECU threshold.
accelerator pedal, are not plausible Check Pedal, repair or exchange the
to each other. Pedal. Check wiring.
ECU.
523612 12 630 555 Impermissible offset between the Calculated engine speed in level 1/2 Threshold for error detection is an
engine speed of level 2 and level 1 implausible (-> ECU internal error). internal ECU threshold.
ECU.
523612 12 631 555 Diagnostic fault check to report the Implausible injection energizing Threshold for error detection is an
plausibility error between level 1 time for either PiIx or MI1 or PoIx. internal ECU threshold.
energizing time and level 2 If error is still present, exchange
information ECU.
523612 12 632 555 Error in the plausibility of the start Implausible start of energizing of Threshold for error detection is an
of energizing angles either PiIx or MI1 or PoIx. internal ECU threshold.
ECU.
523612 12 633 555 Error in the plausibility of the The energizing times of the zero Threshold for error detection is an
energizing times of the zero fuel fuel quantity calibration ZFC is out internal ECU threshold.
quantity calibration of the target. (-> If error is still present, exchange
ECU internal error) ECU.
523612 12 634 555 Error in the plausibility of PoI2 Error in the plausibility of PoI2 Threshold for error detection is an
efficiency. efficiency. internal ECU threshold.
ECU.
523612 12 635 555 Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an
ECU.
523612 12 636 555 Error in the plausibility of PoI3 Error in the plausibility of PoI3 Threshold for error detection is an
efficiency. efficiency. internal ECU threshold.
ECU.
523612 12 637 555 Engine speed: the engine speed Error in the plausibility of current Threshold for error detection is an
calculated by ECU is above the energizing time with maximum internal ECU threshold.
target range; the ECU activates a permitted energizing If error is still present, exchange
system reaction time. Diagnostic fault check to ECU.
report the error due to Over Run
523612 12 638 555 Error in the plausibility of the wave Error in the plausibility of the wave Threshold for error detection is an
correction parts correction parts internal ECU threshold.
ECU.
523612 12 639 555 Plausibility error of the Rail pressure In case the gradient of rail pressure Threshold for error detection is an
sensor is larger than the max threshold or internal ECU threshold.
lesser than the min threshold. Check metering unit or cable.
Rail metering unit defect.
196 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
Leakage in the Rail System. Check Rail pressure. Check the Rail
System of leakage.
523612 12 640 555 Error in the torque comparison Error in the torque comparison Threshold for error detection is an
between permissible engine torque between the permissible inner internal ECU threshold.
and current actual torque engine torque and the current If error is still present, exchange
plausible actual torque. ECU.
523612 12 641 555 Diagnosis of curr path limitation The torque comparison is not Threshold for error detection is an
forced by ECU monitoring level 2 plausible with the torque internal ECU threshold.
monitoring. If error is still present, exchange
ECU.
523612 12 642 555 Diagnosis of lead path limitation The setpoint path of the air system Threshold for error detection is an
forced by ECU monitoring level 2 is limited by the limitation torque internal ECU threshold.
of the functional control unit If error is still present, exchange
monitoring. ECU.
523612 12 643 555 Diagnosis of set path limitation If the quantity setpoint is exceeds Threshold for error detection is an
forced by ECU monitoring level 2. the limit of the torque function. internal ECU threshold.
ECU.
523612 12 714 555 Error report "WDA wire is active" Error detection by monitoring Threshold for error detection is an
due to a defect query/response module internal ECU threshold.
communication Software reset.
523612 12 715 555 Error report "ABE wire is active" due The reason is that a slow dropping Threshold for error detection is an
to undervoltage detection of the vehicle electrical system internal ECU threshold.
voltage (defective autobattery) Software reset.
should not lead the ECU OCWDA's
diagnose to enter an error in the
fault memory due to an
undervoltage recognition.
523612 12 716 555 Error report "ABE wire is active" due If the ABE/WDA powerstage shut- Threshold for error detection is an
to overvoltage detection off is active due to an overvoltage internal ECU threshold.
detection. software reset.
523612 12 717 555 Error report "ABE/WDA active" due The reason is that a slow dropping Threshold for error detection is an
to an unknown reason of the vehicle electrical system internal ECU threshold.
voltage (defective autobattery) Software reset.
should not lead the ECU OCWDA's
diagnose to enter an error in the
fault memory due to an
undervoltage recognition.
523612 12 1170 555 Internal hardware monitoring: the Error during positive test (ECU Threshold for error detection is an
CPU of the ECU is reset and the internal error). Diagnostic fault internal ECU threshold.
cause is logged internally; no item check to report that the positive Reflash ECU. If error is still active
will be created in error memory test failed replace ECU.
523612 12 1857 555 Fault in the monitoring during the wiring is not according DEUTZ Threshold for error detection is an
engine start. Start requested in level requirements internal ECU threshold.
1, but not released in level 2 which engine start conditions are not check other active errors and fix
leads to no fuel injection. observed them.
low battery voltage during start check all needed engine start
malfunction of starter conditions, e.g. neutral switch.
check the engine speed during
starting of the engine. If it's too
low, then check the
battery voltage and then check the
starter for malfunction.
800S HC3, 860SJ HC3 31222415 197

Fault Codes

Deutz Description
Code
523612 14 973 555 Internal hardware monitoring: the Visibility of Software resets in DSM Threshold for error detection is an
CPU of the ECU is reset and the internal ECU threshold.
cause is logged internally;
no item will be created in error
memory.
523612 14 974 555 Internal hardware monitoring: the Visibility of Software resets in DSM Threshold for error detection is an
cause is logged internally;
no item will be created in error
memory.
523612 14 975 555 Internal hardware monitoring: the Visibility of Software Resets in DSM Threshold for error detection is an
cause is logged internally; If possible the software update has
no item will be created in error to be done. Replace the ECU.
memory
523613 0 856 134 Rail pressure: the fuel pressure in Pressure governor deviation exceeds Threshold for error detection is an
rail calculated by ECU is below the the limiting value based on the internal ECU threshold.
target range which is dependent on engine speed. (A) Check for leakage
the engine speed. (B) Check fuel-primary pressure
(C) Change components, check
sensor and if necessary replace it,
check fuel system and if necessary
repair it
523613 0 857 134 Rail pressure: the fuel pressure in maximum positive deviation of rail Threshold for error detection is an
rail calculated by ECU is below the pressure exceeded concerning set internal ECU threshold.
target range which is dependent on flow of fuel. (A) Check for leakage
the engine speed. (B) Check fuel-primary pressure
(C) Change components, check
sensor and if necessary replace it,
check fuel system and if necessary
repair it
523613 0 858 134 Rail pressure: the fuel pressure in leakage is detected based on fuel Threshold for error detection is an
rail calculated by ECU is above the quantity balance. internal ECU threshold.
target range which is dependent on (A) Check backflow pressure
the engine speed. (B) Check Injector function with
SerDia
(C) Change components (metering
unit, injector) if necessary
523613 0 859 134 Rail pressure: the fuel pressure in Maximum negative rail pressure Threshold for error detection is an
rail calculated by ECU is above the deviation with metering unit on internal ECU threshold.
target range which is dependent on lower limit is exceeded. (A) Check backflow pressure
SerDia
523613 0 862 134 Rail pressure: the fuel pressure in Rail pressure exceeds the limiting (A) Check backflow pressure
rail calculated by ECU is above the value. (B) Check pressure relief valve and
target range. metering unit.
523613 1 861 134 Rail pressure: the fuel pressure in Rail pressure falls below the Threshold for error detection is an
rail calculated by ECU is below the limiting value based on the engine internal ECU threshold.
target range which is dependant on speed. (A) Check backflow pressure
SerDia
198 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
523613 2 864 134 Rail pressure metering unit, Setpoint Pressure pump delivery quantity in Threshold for detection is an
of metering unit in overrun mode overrun exceeds the threshold internal ECU threshold.
not plausible. based on the pressure. (A) Check backflow pressure
(B) Check pressure relief valve and
metering unit.
523615 3 594 135 Fuel metering unit: the current drain short circuit to battery high side Threshold for error detection is an
measured by ECU is above the internal ECU threshold.
target range Check wiring harness and metering
unit if necessary repair/replace it.
523615 3 596 135 Fuel metering unit: the current drain short circuit to battery low side Threshold for error detection is an
523615 4 595 135 Fuel metering unit: the current drain short circuit to ground high side Threshold for error detection is an
523615 4 597 135 Fuel metering unit: the current drain short circuit to ground low side Threshold for error detection is an
523615 5 592 135 Detecting an open load fault in the wiring harness defective, cable Threshold for error detection is an
metering unit break internal ECU threshold.
Check wiring harness and metering
523615 12 593 135 powerstage of metering unit is over temperature Threshold for error detection is an
overheated internal ECU threshold.
Check functionality of metering unit
and replace it if needed.
Check temperature of metering unit
and improve the installation in case
of overheating.
523632 3 1127 665 Urea supply module pressure sensor: Shortcut to battery Check wiring
the current drain measured by ECU Broken wiring Check pressure sensor in urea supply
is above the target range Pressure sensor in urea supply module
module defect
523632 4 1128 665 Urea supply module pressure sensor: Shortcut to ground Check wiring
the current drain measured by ECU Broken wiring Check pressure sensor in urea supply
is above the target range Pressure sensor in urea supply module
The sensed raw voltage value SCR_ module defect
uRawUPmpP is above SCR_
SRCUPmpP.uMin_C
523632 11 1117 666 Urea supply module pump: the When the pump motor does not Threshold for error is an internal
current drain measured by ECU is switch to pump actuation mode ECU threshold
above the target range after temperature measurement has
been carried out.
523698 11 122 591 Shut off request from supervisory Engine Shut Off due to supervisory Threshold for error detection is an
monitoring function function internal ECU threshold.
800S HC3, 860SJ HC3 31222415 199

Fault Codes

Deutz Description
Code
Check error memory for additional
error code to find root cause.
Depending on additional error
follow the documented "Take action
for repair".
523718 3 1100 676 Urea heater relay: the current drain Shortcut to battery Threshold for error detection is an
measured by ECU is above the If this error detected during the internal ECU threshold
target range heating phase it is a result error: Check wiring
KWP 1089 Check SCR main relay
Broken wiring, broken relay
523718 4 1101 676 Urea heater relay: the current drain Shortcut to ground Threshold for error detection is an
target range heating phase it is a result error: Check wiring
KWP 1089 Check SCR main relay
Broken wiring, broken relay
523718 5 1098 676 Urea heater relay: the current drain Open load Threshold for error detection is an
target range heating phase it is a result error: Test SCR main relay
KWP 1089 Check cabling, if necessary replace
Broken wiring relay.
broken relay
523719 4 1109 672 Urea supply module heater: the Shortcut to ground Threshold for error detection is an
above the target range heating phase it is a result error: Check wiring
Broken wiring supply module
Heating element in supply module
defect
523719 5 1106 672 Urea supply module heater: the Open load Threshold for error detection is an
1089 Check cabling, if necessary replace
defect
523720 8 925 148 Supply module heater: Duration of Duty cycle for temperature readout When the received supply module
switch on is too long. from supply module heater to the heater temperature duty cycle SCR_
control unit is out of range; Supply rSMT is out of the failure range
module defect, fault in the wiring. (SCR_rSMFailMax_C < SCR_rSMHtrT
< SCR_rSMFailMin_C)
Supply module check and replace if
necessary.
Check the wiring.
523720 8 926 148 Supply module heater: Duty cycle Duty cycle for temperature readout When the received supply module
timing over error threshold. from supply module heater to the heater duty cycle SCR_rSMHtrT is in
control unit is not valid. the valid range (SCR_r-
Supply module defect, fault in the Supply module check and replace if
wiring. necessary.
Check the wiring.
523721 8 930 689 Supply module heater: Duty cycle Duty cycle for temperature readout Supply module check and replace if
timing over error threshold. from supply module to the control necessary.
unit is out of range. Check the wiring.
Supply module defect, fault in the
wiring.
200 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
523721 8 931 689 Supply module heater: Duty cycle Duty cycle for temperature readout When the received supply module
timing out of valid range. from supply module to the control duty cycle SCR_rSMT is in the valid
unit is not valid. range
Supply module defect, fault in the (SCR_rSMTVld-Min_C <= SCR_
wiring. rSMT <= SCR_rSMTVldMax_C), OR
in the failure range (SCR_
rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C)
necessary.
Check wiring.
523721 11 927 689 Supply module heater: temperature Duty cycle for temperature readout Threshold for detection is an
measurement not available. from supply module heater to the internal ECU threshold.
control unit is not available. No erasing in the current driving
Supply module defect, fault in the cycle.
wiring. Supply module check and replace if
necessary. Check the wiring.
523722 8 929 691 Supply module heater: Faulty PWM PWM Signal for temperature Threshold for error detection is an
signal from supply module. readout from supply module to the internal ECU threshold.
control unit is not valid. When valid Sync followed by
Supply module defect, fault in the temperature information signal is
wiring. received AND valid sync
and temperature signal for both
information is received one after the
other.
necessary.
Check the wiring.
523776 9 291 119 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus Threshold for error detection is an
TSC1TE - active message) internal ECU threshold.
Check CAN Bus cabling (Bus
scheduling, polarity, short circuit,
523777 9 292 119 Message TSC1-TE has been missing Passive timeout Error (Missing CAN Check CAN Bus cabling (Bus
(passive) Bus message) scheduling, polarity, short circuit,
receiver, check CAN functional range,
check actuator
523895 13 559 1-5-8 Missing or wrong injector Missing or wrong injector Threshold for error detection is an
adjustment value programming adjustment value for cyl. 1. internal ECU threshold.
(IMA) injector 1 (in firing order). Check correct injector adjustment
value (IMA). Use SERDIA UseCase to
check it.
adjustment value programming adjustment value for cyl. 2 internal ECU threshold.
(IMA) injector 2 (in firing order). check dataset and flash correct
injector adjustment value (IMA). Use
SERDIA
UseCase to check it.
523897 13 561 1-5-8 Missing or wrong injector Missing or wrong parametrization Threshold for error detection is an
adjustment value programming of injector adjustment cyl. 3. internal ECU threshold.
value (IMA).
800S HC3, 860SJ HC3 31222415 201

Fault Codes

Deutz Description
Code
value (IMA).
value (IMA).
value (IMA).
523912 4 73 7-2-2 @ engines < 4l: The sensed raw voltage value is The sensed raw voltage value DPM_
Throttle valve error, Open Load or below the minimum threshold. uRawBrnDVDsP is above the
Short cut to Battery, blocked valve minimum threshold
or wrong control signal for valve. DPM_SRCBrnDVDsP.uMin_C
@ engines with Burner T4i: @ CRT < 4l: check throttle valve
Pressure Sensor error after valve @ engines with Burner T4i: check
(DV2), lower limit reached back-pressure valve
523924 4 42 167 Overload at Pins O_V_RH2x: A01, Suspected components: Threshold for error detection is an
K74, K91. Components on A01, K74, 1- Pin K91: internal ECU threshold.
K91 cannot be activated. Clutch switch, Brake switch, Engine Check wiring harness and connected
Internal ECU power stage switched brake demand, Regeneration loads on pins A01, K74, K91 and/or
off. activation, Parking reflash ECU.
brake, Gearbox N, Fan control 1 If error is still present, exchange
2- Pin K74: ECU.
Boost air cooler bypass or electrical
fuel pump relay, Fan control 2/fuel
valve for flame
star
523925 3 38 731 Short circuit to battery error of Suspected Components: Check wiring harness and connected
actuator relay 2. Components on Pin 1- Lamps K57: Warn Ash Charge, loads on pins A88, K57.
A88, K57 cannot be activated. Diagnostic, Warn Coolant Temp/
Internal ECU power stage switched Level, Warn Oil,
off. Warn Boost Air, Warn Air Filter,
Warn Water in Fuel, SCR,
Regeneration, Engine Running.
2- Relay Preheat A88
3- Exhaust Flap A88
523925 4 43 731 Short circuit to ground actuator Suspected components: Threshold for error detection is an
relays 3 1- Pin A88: internal ECU threshold.
Overload at Pins O_V_RH3x: A88, Preheat relay, Exhaust flap Check wiring harness and connected
K57 2- Pin K 57: loads on pins A88, K57.
- control lamps: If error is still present, exchange
- OBD, preheat lamp, warning ECU.
temp., warning oil, maintenance
lamp, regeneration
indicator, alternator management,
engine running, diagnostic
523926 4 44 732 Short circuit to ground actuator Suspected components: Fan, Wiring Threshold for error detection is an
relays 4. harness internal ECU threshold.
Overload at Pins O_V_PCV: A90 Check wiring harness and connected
loads on pin A90.
ECU.
202 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
523927 3 40 733 Short circuit to battery error of Suspected Components: Check wiring harness and connected
actuator relay 2. Components on Pin 1- Urea Pump A04 loads on pins A04, A05.
A04, A05 cannot be activated. 2- SCR Heater A05
Internal ECU power stage switched
off.
523935 12 168 763 Timeout Error of CAN-Transmit- Fault is detected if a TimeOut of the Check wiring harness and customer
Frame EEC3VOL1; Engine send EEC3VOL1 frame has occured. nodes
messages
523936 12 169 764 Timeout Error of CAN-Transmit- Timeout Error (Missing CAN Bus Check wiring harness and customer
Frame EEC3VOL2; Engine send message) nodes
messages
523938 9 133 766 Timeout Error (BAM to packet) for Failure of the CAN Bus message NOx sensor and sensor connection
CAN-Receive-Frame AT1IGCVol1 check
information; factors & Sensor
calibration for NOx Sensor (SCR-
system upstream cat; DPF-system
downstream cat)
523939 9 134 766 Broadcast Announce Message of the Defective NOx sensor, faulty NOx sensor and sensor connection
calibration message of the upstream parameterization check
catalytic NOx sensor has failed.
Timeout Error (BAM to BAM) for
CAN-Receive-Frame AT1IGCVol1
information.
factors & Sensor calibration for NOx
Sensor (SCR-system upstream cat,
DPF-system downstream cat).
523940 9 135 766 Timeout Error (PCK2PCK) for CAN- Failure of the CAN Bus message NOx sensor and sensor connection
Receive-Frame AT1IGCVol1 check
system upstream cat; DPF-system
downstream cat)
523941 9 140 767 Timeout Error (BAM to packet) for Timeout Error (Missing CAN Bus NOx downstream sensor and sensor
CAN-Receive-Frame AT1OGCVol2 message) connection check
system downstream cat; DPF-system
downstream cat)
523942 9 141 767 Timeout Error (BAM to BAM) for Defective NOx sensor, faulty NOx downstream sensor and sensor
CAN-Receive-Frame AT1OGCVol2 parameterization. connection check.
information,
Calibration message 1 of the after
catalyst NOx sensor has failed.
Factors & Sensor calibration for NOx
Sensor (SCR-system downstream cat,
DPF-system downstream cat)
523943 9 142 767 Timeout Error (PCK2PCK) for CAN- The fault is detected when a NOx downstream sensor and sensor
Receive-Frame AT1OGCVol2 timeout error in packet 2 of connection check
information; factors & Sensor NOxSenVol2Rx frame occurs.
system downstream cat; DPF-system
downstream cat)
800S HC3, 860SJ HC3 31222415 203

Fault Codes

Deutz Description
Code
523960 0 1011 771 Physical range check high for EGR Sensed temperature downstream EGR-Valve blocked open
cooler downstream temperature. EGR-cooler > limit. EGR-Valve actuator defect
water)
Reed Valve defect
position
Exhaust pressure too high
catalyst
523960 1 1012 771 Physical range check low for EGR sensor voltage > lower limit EGR-Valve blocked open
cooler downstream temperature. EGR-Valve actuator defect
water)
Reed Valve defect
position
Exhaust pressure too high
catalyst
523982 0 360 737 Powerstage diagnosis disabled; Powerstage diagnostic can be Check wiring, check alternator, check
Indicating that battery voltage is not deactivated due to too high battery cables and repair or replace if
high. voltage. necessary.
523982 1 361 737 Powerstage diagnosis disabled; Powerstage diagnostic can be Check wiring, check alternator, check
Indicating that battery voltage is not deactivated due to too low battery cables and repair or replace if
low. voltage. necessary.
523984 3 1239 788 Actuator relay 5: the voltage Short-Circuit to battery to Threshold for error detection is an
measured by ECU is out of the component internal ECU threshold.
target range Check wiring, component, ECU
523986 4 1241 176 Actuator relay 4: the voltage Short-Circuit to ground to Threshold for error detection is an
523987 4 1242 791 Actuator relay 5: the voltage Short-Circuit to ground to Threshold for error detection is an
524050 11 1434 8-3-6 CAN; not used not used not used
524051 11 1435 8-3-7 CAN; not used not used not used
524057 2 1505 8-4-3 Low fuel pressure: the low fuel Fuel pressure below warning Threshold for error detection is an
pressure calculated by ECU is threshold internal ECU threshold.
underneath the target range; the Check low fuel pressure system (fuel
ECU activates a system reaction feed pump, relay , fuse, wiring,
sensor) and if necessary repair or
replace it.
524063 3 1558 869 SCR heater main relay; short circuit Short-Circuit to battery on wiring to Check wiring, component
to battery component
Threshold 1 < SCRHtr_
rUHtrMeasRatio_mp < Threshold 2
204 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
524063 4 1559 869 Connection between heating valve Faulty wiring, faulty heater relay Disconnect plug from heating valve
(Y31) on the control unit Pin A:92 (K27-K31), defective heating valve (Y31) and reset fault.
and (Y31), If fault is still present you have to
Load side SCR heater main relay broken element in heating. look in the wiring of Y31 to the
(K31) is a short cut to ground. control unit Pin A:92.
Threshold 1 < SCRHtr_ If error is no longer present, you
rUHtrMeasRatio_mp < Threshold 2 have to check the wiring of Y31 via
relay K31 and possibly the heating
cables and relay (K27-K30).
524063 5 1555 869 Urea backflow line heater: broken Open Load on wiring to component Check wiring, component
wiring detected
524063 5 1556 869 Urea main relay: broken wiring relay defect Check wiring, component
detected relay not connected
Threshold 1 < SCRHtr_ wiring harness broken
rUHtrMeasRatio_mp < Threshold 2 problems with supply voltage
524063 5 1557 869 Urea pressure line heater: broken Open load on wiring to component Check wiring, component
wiring detected
524063 5 1560 869 SCR relay for suction line not relay defect Check wiring, component
connected relay not connected
Threshold 1 < SCRHtr_ wiring harness broken
rUHtrMeasRatio_mp < Threshold 2 problems with supply voltage
524063 5 1561 869 Open load on wiring to component Open load on wiring to component Check wiring, component
524063 5 1562 869 SCR heater tank; open load Open load on wiring to component Check wiring, component
524063 12 1646 869 SCR supply module temperature is Suspected components: Check:
not reaching a threshold before a Environment temperature sensor Environment temperature sensor
calibrates time is exceeded. defect SCR supply module temperature
Corresponding to the environmental SCR supply module temperature sensor
Temperature a specific defrosting sensor defect SCR supply module electrical heater
time is given. After starting the SCR supply module electrical heater
defrosting a clock counter is defect
starting. Does the counter reach the
given defrosting time limit, an error
will be detected. Is the temperature
reached in time the clock counter
will be reset
Example: by using the calibrated
temperature/time curve –>
environmental temperature 0°C –>
defrosting time limit 6000 s –> if
the clock counter reaches 6000 s the
error will
be detected
524065 0 1565 892 The relative pressure value of the sensed pressure upstream SCR Check for crystallization in exhaust
exhaust gas from the urea cat catalyst > physical high range limit line upstream SCR and downstream
upstream f(exhaust volume flow) of urea injector
sensor is greater than an applicable UCatUsP_pRelFlt_mp > UCatUsP_ Check correct connection from
maximum pressure threshold pMax_mp exhaust line to pressure sensor
upstream SCR catalyst:
800S HC3, 860SJ HC3 31222415 205

Fault Codes

Deutz Description
Code
syphons?, water in tube?, water in
sensor?
Check that exhaust pipe outlet is
free (downstream SCR catalyst)
Check wiring of pressure sensor
upstream SCR catalyst
Check pressure sensor upstream SCR
catalyst:
sensor has no connection to vehicle
body? => Ensure that sensor is free
Does sensor oscillate heavily at
engine low idle / high idle? => try
to suppress the oscillation
Exchange pressure sensor upstream
SCR catalyst
Check calculated exhaust volume
flow of engine within EDC: SCR_
dvolSCRUs
plausible? If not:
Check T sensor upstream SCR
catalyst, check complete engine air
path: EGR-Valve,
Intake throttle, turbocharger, piping
for leakage and function
Check SCR catalyst: Broken?
Exchange SCR-Catalyst
524065 1 1566 892 The relative pressure value of the sensed pressure upstream SCR Check correct connection from
exhaust gas from the urea cat catalyst > physical high range limit exhaust line to pressure sensor
upstream sensor is less than an f(exhaust volume flow) UCatUsP_ upstream SCR catalyst:
applicable minimum pressure pRelFlt_mp < UCatUsP_pMin_mp leakage? Check electric connector:
threshold 4h pin open / new connector type
used? pressure exchange from inside
electrical connector with the
environment possible
Check exhaust line: any leakages
upstream of SCR catalyst?
SCR catalyst
Check calculated exhaust volume
flow of engine within EDC: SCR_
dvolSCRUs
plausible? If not:
Check T sensor upstream SCR
catalyst, check complete engine air
path: EGR-Valve,
Intake throttle, turbocharger, piping
for leakage and function
Check SCR catalyst: Broken?
Exchange SCR-Catalyst
524065 2 1598 892 Comparison of urea cat upstream absolute value of difference Check electric connector: 4h pin
exhaust gas- and environment between sensed pressure upstream open / new connector type used?
pressure, the difference should not SCR catalyst and environmental pressure exchange from inside
exceed a certain limit abs(UCatUsP_ pressure > limit abs(UCatUsP_ electrical connector with the
pDiffEnvCat_mp) > Threshold pDiffEnvCat_mp) > Threshold environment possible?
water in sensor?
sensor frozen?
206 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
SCR catalyst
Check intake manifold pressure
sensor (Air_pCACDs)
Check ambient pressure sensor
(EnvP_p)
524065 3 1569 892 voltage of pressure sensor upstream voltage of pressure sensor upstream Check wiring of pressure sensor
SCR > voltage high limit SCR > voltage high limit upstream SCR catalyst
Check pressure sensor upstream SCR
catalyst
SCR catalyst
524065 4 1570 892 voltage of pressure sensor upstream voltage of pressure sensor upstream Check wiring of pressure sensor
SCR < voltage low limit SCR < voltage low limit upstream SCR catalyst. Check
pressure sensor
upstream SCR catalyst. Exchange
pressure sensor upstream SCR
catalyst
524067 0 1581 894 Filtered urea supply module heater sensed temperature of supply Compare SCR_tSMT with SCR_
temperature value is above an module heater > physical high tSMHtrT. Both show the same
applicable maximum heater range limit value?
temperature threshold of the supply Check urea tank temperature (SCR_
module tAdapUTnkT). Very hot (> 70°C),
The temperature is read out via the urea tank heater
PWM signal of the urea pump. That permanent on?
is only possible in status init of the Does the pump never stop working?
SCR-system short after ignition was Check wiring to supply module
switched on. When that state is left Compare SCR_tSMT with SCR_
the sensed temperature value is tSMHtrT. Both show different values
frozen. or urea tank
temperature (SCR_tAdapUTnkT) is
cold:
exchange urea pump unit
Supply module heater temperature
sensor defect
Supply module heater defect
Supply module defect
524067 0 1585 894 Filtered urea supply module sensed temperature of urea within Compare SCR_tSMT with SCR_
temperature value (SCR_tSMT) is supply module > physical high tSMHtrT. Both show the same
above an applicable maximum range limit value?
temperature threshold of the supply Check urea tank temperature (SCR_
module tAdapUTnkT). Very hot (> 70°C),
The temperature is read out via the urea tank heater
PWM signal of the urea pump. That permanent on?
is only possible in status init of the Does the pump never stop working?
SCR-system short after ignition was Check wiring to supply module
switched on. When that state is Compare SCR_tSMT with SCR_
left the sensed temperature value is tSMHtrT. Both show different values
frozen. or urea tank
temperature (SCR_tAdapUTnkT) is
cold:
exchange urea pump unit
Supply module temperature sensor
defect
Supply module heater defect
800S HC3, 860SJ HC3 31222415 207

Fault Codes

Deutz Description
Code
Supply module defect
524067 1 1582 894 Filtered urea supply module heater sensed temperature of supply Check ambient temperature EnvT_t
temperature value is below an module heater < threshold < Threshold?
applicable minimum heater Compare SCR_tSMT with SCR_
temperature threshold of the supply tSMHtrT
module Check wiring with regard to supply
The temperature is read out via the module heater
PWM signal of the urea pump. That exchange urea pump unit
is only possible in status init of the Supply module heater temperature
SCR-system short after ignition was sensor defect
switched on. When that state is left Supply module defect
the sensed temperature value is
frozen.
524067 1 1586 894 Filtered urea supply module sensed temperature of urea within Check ambient temperature EnvT_t
temperature (SCR_tSMT) value is supply module < physical low < threshold?
below an applicable minimum range limit Compare SCR_tSMT with SCR_
temperature threshold of the supply tSMHtrT
module Check wiring with regard to supply
The temperature is read out via the module heater
PWM signal of the urea pump. That exchange urea pump unit
is only possible in status init of the Supply module temperature sensor
SCR-system short after ignition was defect
switched on. When that state is Supply module defect
left the sensed temperature value is
frozen.
524067 2 1867 894 absolute difference of sensed absolute difference of sensed Compare SCR_tSMT with SCR_
temperature of supply module temperature of supply module tSMHtrT, EnvT_t and CEngTds_t and
heater temperature and ambient heater temperature and ambient SCR_tAdapUTnkT => All identical?
temperature UPmpT_ temperature UPmpT_ If not:
tDiffPmpHtrAmb_mp > threshold tDiffPmpHtrAmb_mp > threshold Has the machine been brought from
cold environment into a warm one
or vice versa without engine
running, e.g. at workshop?
Environment temperature sensor
defect
Coolant temperature sensor defect
defect
Problem at Supply module unit
(broken?) => exchange supply
module
524067 2 1868 894 absolute difference of sensed absolute difference of sensed Compare SCR_tSMT with SCR_
temperature of supply module temperature of supply module tSMHtrT, EnvT_t and CEngTds_t and
temperature and ambient temperature and ambient SCR_tAdapUTnkT => All identical?
temperature > threshold temperature UPmpT_ If not:
tDiffPmpAmb_mp > threshold Has the machine been brought from
cold environment into a warm one
or vice versa without engine
running, e.g. at workshop?
Environment temperature sensor
defect
Coolant temperature sensor defect
defect
Problem at Supply module unit
(broken?) => exchange supply
module
208 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
524074 9 1533 246 Open load sensor internally at NOx- Open load sensor internally at NOx- Threshold for error detection is an
sensor downstream SCR sensor downstream SCR internal ECU threshold.
Check NOx-Sensor downstream SCR
catalyst: water inside? Shake out
sensor after dismounting. => If
water inside, replace sensor.
Check mounting position of sensor
and judge it regarding condense
water formation / agglomeration.
Check wiring harness
Exchange sensor
524075 11 1534 247 Short circuit sensor internally at Short circuit sensor internally at Threshold for error detection is an
NOx-sensor downstream SCR NOx-sensor downstream SCR internal ECU threshold.
Check NOx-Sensor downstream SCR
catalyst: water inside? Shake out
water formation / agglomeration?
Rearrange if critical and possible
Exchange sensor
524076 9 1535 248 Open line sensor internally at NOx- Open line sensor internally at NOx- Threshold for error detection is an
sensor downstream SCR sensor downstream SCR internal ECU threshold.
NOx Sensors are CAN Sensors –> no Check NOx-Sensor upstream SCR
HW Pin on the ECU catalyst: water inside? Shake out
Exchange sensor
524077 11 1536 249 Short circuit sensor internally at Short circuit sensor internally at Threshold for error detection is an
NOx-sensor downstream SCR NOx-sensor downstream SCR internal ECU threshold.
NOx Sensors are CAN Sensors –> no Check NOx-Sensor upstream SCR
HW Pin on the ECU catalyst: water inside? Shake out
Exchange sensor
524078 9 1537 255 Lambda value of NOx-Sensor sensed lambda value of NOx-sensor Check whether NOx-sensor
downstream SCR is out of range. downstream SCR catalyst is > downstream SCR catalyst is
When the filtered Lambda physical high limit ComRxSCR_ physically mounted within the
concentration value at the sensor rCanLamDs_mp > threshold exhaust line
(ComRxSCR_rFltLamDs_mp) is Check Lambda values of NOx-sensor
greater than the physical range downstream SCR catalystat at idle
check max. lambda threshold conditions, ComRxSCR_rCanLamDs_
mp > threshold?
Compare to ComRxSCR_rCanLamUs_
mp. Values must be almost identical
Check CANBus of NOx-sensor
downstream SCR catalyst
800S HC3, 860SJ HC3 31222415 209

Fault Codes

Deutz Description
Code
Check NOx-sensor downstream SCR
catalyst wiring
catalyst itself
Replace NOx-sensor downstream SCR
catalyst
524079 9 1538 256 sensed lambda value of NOx-sensor sensed lambda value of NOx-sensor Compare to ComRxSCR_rCanLamUs_
downstream SCR catalyst is < downstream SCR catalyst is < mp. ComRxSCR_rCanLamDs_mp
physical low limit ComRxSCR_ physical low limit ComRxSCR_ must be almost identical!
rCanLamDs_mp < threshold rCanLamDs_mp < threshold If almost identical,
Check air path of engine: EGR-Valve,
Intake-Throttle, Turbocharger and
Piping each for leakage and correct
function
Check injection system of engine.
Injector stuck?
if sensed lambda upstream SCR
higher (ComRxSCR_rCanLamUs_mp)
: Diesel in Urea-tank?
downstream SCR catalyst
catalyst wiring
catalyst itself
catalyst
524080 9 1539 257 sensed lambda value of NOx-sensor sensed lambda value of NOx-sensor Check whether NOx-sensor upstream
upstream SCR catalyst is > physical upstream SCR catalyst is > physical SCR catalyst is physically mounted
high limit high limit within the exhaust line
ComRxSCR_rCanLamUs_mp > ComRxSCR_rCanLamUs_mp > Check Lambda values of NOx-sensor
Threshold Threshold upstream SCR catalyst at idle
conditions,
ComRxSCR_rCanLamUs_mp <
Threshold?
Compare to ComRxSCR_rCanLamDs_
mp. Must be almost identical
catalyst wiring
catalyst itself
Replace NOx-sensor upstream SCR
catalyst
524081 9 1540 258 sensed lambda value of NOx-sensor sensed lambda value of NOx-sensor Check air path of engine: EGR-Valve,
upstream SCR catalyst is < physical upstream SCR catalyst is < physical Intake-Throttle, Turbocharger and
low limit low limit Piping each for leakage and correct
ComRxSCR_rCanLamUs_mp < ComRxSCR_rCanLamUs_mp < function
Threshold Threshold Check injection system of engine.
Injector stuck?
catalyst wiring
catalyst itself
210 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
catalyst
524083 9 1542 261 sensed NOx-value of NOx-sensor sensed NOx-value of NOx-sensor Check CANBus of NOx-sensor
downstream SCR catalyst < downstream SCR catalyst < physical downstream SCR catalyst
Threshold low limit Check NOx-sensor downstream SCR
catalyst wiring
catalyst itself
catalyst
524085 9 1544 912 sensed NOx-value of NOx-sensor sensed NOx-value of NOx-sensor Check CANBus of NOx-sensor
upstream SCR catalyst < Threshold upstream SCR catalyst < physical upstream SCR catalyst
low limit Check NOx-sensor upstream SCR
catalyst wiring
catalyst itself
catalyst
524100 9 1666 924 Timeout error of CAN-Transmit- Open load on CANBUS wiring. Check wiring, component.
Frame ComDPFHisDat.
524104 9 1676 928 Timeout error of CAN-Receive-Frame Time out of Check CANBUS EAT Threshold for error detection is an
ComRxDPFCtl. CM1 Module Customer Control Receive Message, internal ECU threshold.
Receive Message. PGN65348. Check CANBUS EAT Control Receive
The message is not received. Message, PGN65348.
CM1 Module Customer Receive
Message.
524118 9 1672 9-4-2 Timeout error of CAN-Receive-Frame If the frame CM1 message is not Check CAN Bus cabling (Bus
ComRxCM1 transmitted successfully scheduling, polarity, short circuit,
524121 9 1683 9-4-5 Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus Check CAN Bus cabling (Bus
ComRxTrbChActr message) scheduling, polarity, short circuit,
524125 9 1687 9-4-9 Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus Check CAN Bus cabling (Bus
ComTxTrbChActr message) scheduling, polarity, short circuit,
524141 7 1827 192 DEF dosing valve is blocked with While SCR system is starting up and Check electrical connection of urea
crystallized urea or other deposits. after urea pressure reaches 10000 injector:
hPa, the DEF - wiring harness
dosing module is tested. - connector
Expectation is that urea pressure Conduct SERDIA use-case "injection
drops below 1500 hPa if test". If it is faulty:
injector works properly. The test is - remove urea injector from exhaust
repeated up to 3 times before an line:
error is set. - check for crystallisation direct on
SCRSysPresMon_stPresDropDet_mp injector nozzle / plate
= 0 while SCRCo_stStatus_mp = - rinse it thoroughly in water
16. - remount urea injector and conduct
Suspected component: SERDIA use-case "injection test"
wiring harness If the error is still active, then
DEF dosing valve exchange urea injector.
800S HC3, 860SJ HC3 31222415 211

Fault Codes

Deutz Description
Code
The error is stored into the EEPROM
of the ECU and status at ECU shut
down is
regained at ignition on.
524141 7 1858 192 DEF dosing valve is blocked with While SCR system is starting up and Check electrical connection of urea
crystallized urea or other deposits. after urea pressure reaches 10000 injector:
hPa, the DEF - wiring harness
dosing module is tested. - connector
Expectation is that urea pressure Conduct SERDIA use-case "injection
drops below 1500 hPa if test". If it is faulty:
injector works properly. The test is - remove urea injector from exhaust
repeated up to 3 times before an line:
error is set. - check for crystallization direct on
SCRSysPresMon_stPresDropDet_mp injector nozzle / plate
= 0 while SCRCo_stStatus_mp = - rinse it thoroughly in water
16. - remount urea injector and conduct
Suspected component: SERDIA use-case "injection test"
wiring harness If the error is still active, then
DEF dosing valve exchange urea injector.
The error is stored into the EEPROM
of the ECU and status at ECU shut
down is
regained at ignition on.
524147 13 1639 966 No proper urea pressure level could This error shows up, if no proper Make sure that frozen lines, pump
be build up within the SCR system urea pressure level could be build or tank can be excluded!
state "Fill Lines" => SCRCo_ up within the SCR Check whether there is urea in the
stStatus_mp = 1 within some system state "Fill Lines" => urea tank
minutes SCRCo_stStatus_mp = 1 within Check urea lines:
some minutes All lines connected? The right lines
Once the urea pump pressure has connected to the correct places?
exceeded the threshold the error is Suction line blocked?
declared as okay. No leakage? Not also urea to the
Suspected components: outside but also air into the lines,
Suction line blocked especially in the suction line!
PWM Powerstage has a defect and Perform service routine "pressure
a default value which leads not to a test":
rising pressure Does the urea pump work? =>
Pump Pressure sensor defect check wiring harness & PWM signal
pump filter contains dirty parts for pump
reverting valve continuously open Does the urea pressure rise?
DFC already healed?
If all unsuccessful so far:
Check urea pressure sensor: At
ignition on and SCR system state =
0 ("Init check"),
SCR_pAbsAdapUPmpP shall be
identical to EnvP_p. Fulfilled: Sensor
okay!
Check reverting valve => see DFC_
SCRCoRevVlvBlk
Check pump filter: dirt inside?
Suspected components:
Urea pump broken
Reverting valve continuously open
Urea suction line, backflow line
broken or connection swapped
PWM Powerstage has a defect
Pump Pressure sensor broken
212 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
524152 2 1874 971 CAN message is not received for a CAN message is not received for a Check electrical connection of urea
definite time => error is set. As definite time => error is set. As quality sensor
soon as the message is received the soon as the Check engine CAN bus
error heals. message is received the error heals. Check urea quality sensor itself
Exchange urea quality sensor
524153 2 1875 997 CAN message is not received for a CAN message is not received for a Check electrical connection of
definite time => error is set. As definite time => error is set. As suction unit sensor (combined
soon as the message is received the soon as the message is received the sensor with tank level and tank
error heals. error heals. temperature)
Check engine CAN bus
Check level sensor itself
Exchange suction unit
524156 9 1705 972 Timeout error of CAN-Receive-Frame Timeout Error (Missing CAN Bus Check CAN Bus cabling (Bus
ComRxEBC2 from wheel speed message) scheduling, polarity, short circuit,
sensor. Defect on wheel speed sensor. power interrupt), test protocol of
Replace the wheel speed sensor.
524177 7 1863 995 The error shows up, if no proper This error shows up, if no proper Make sure that DEF lines, pump and
urea pressure could be build up urea pressure could be build up tank are not frozen.
within the SCR system state "Fill within the SCR system state "Fill Check for DEF level in the tank.
Lines" => SCRCo_stStatus_mp = 1. Lines" => SCRCo_stStatus_mp = Check DEF lines:
1. Are all DEF lines connected?
3 cases can lead to the error: Is the suction line blocked?
Case A: increasing pressure is Is there any leakage? Not only urea
detected within 15 s the check has to the outside but also air into the
passed => no error lines, especially in the suction line!
Case B: The pressure threshold was Perform SERDIA usecase "pressure
not reached within the 60 s but test":
case A was not positive. Does the DEF pump work? =>
Case C: The minimum pressure of check wiring harness & PWM signal
3000 hPa was not reached within for pump.
the 60 s. Does the urea pressure increase?
All errors are already healed?
If still unsuccessful so far:
Check urea pressure sensor: At
0 ("Init check"),
okay!
Check DEF pump filter: Is any dirt
inside?
Suction line
PWM Powerstage has a defect and a
default value which leads not to a
rising pressure
DEF pump pressure sensor defect
DEF pump filter contains dirty parts
524178 7 1864 996 The urea pump is not able to control The urea pump controller is not Make sure that DEF lines, pump and
the urea pressure between 9 bar able to control the urea pressure tank are not frozen.
and 11 bar. between 9 bar and 11 Check for DEF level in the tank
bar due to malfunction in the SCR Check DEF lines:
system. All lines connected? The right lines
Suspected components: connected to the correct places?
- DEF pump broken Suction line blocked?
- Reverting valve continuously open
800S HC3, 860SJ HC3 31222415 213

Fault Codes

Deutz Description
Code
- Urea suction line, backflow line Is there any leakage? Not also urea
broken or connection swapped to the outside but also air into the
- PWM Powerstage has a defect lines, especially
- Pump Pressure sensor broken in the suction line!
Perform SERDIA usecase "pressure
test":
Does the DEF pump work properly?
=> check wiring harness & PWM
signal for pump
Does the DEF pressure rise?
Is the error healed?
If still unsuccessful so far:
- Check DEF pressure sensor: At
0 ("Init check"),
okay!
- Check reverting valve
- Check DEF pump filter: dirt inside?
DEF pump broken
Reverting valve continuously open
DEF suction line, backflow line
broken or connection swapped
PWM Powerstage has a defect
DEF pump pressure sensor broken
524190 14 1891 272 Not enough urea in tank or low urea Low DEF tank level Check DEF level in tank. If there is
quality or hardware tampering Low DEF quality no DEF, refill up to volume above
failure is detected or hardware Hardware Tampering is active the warning threshold.
failure is detected Hardware Failure is active Check the DEF quality in the tank. If
wrong fluid is filled, refill with
proper DEF.
Check other errors based on
hardware malfunctions.
524191 14 1892 273 A low DEF tank level or a low DEF Low DEF tank level Threshold for error detection is an
quality is detected or hardware Low DEF quality internal ECU threshold.
tampering(system components are Hardware Tampering is active Check the DEF level in tank. If there
pinched off) or hardware failures as Hardware Failure is active is no DEF, refill up above the
shortcut to battery, shortcut to warning level.
ground etc. are detected. Check DEF quality filled in the tank.
Check other errors based on
hardware tampering or failure.
524193 8 1893 275 The total time in standstill- Stand-still mode is very often Read out stand-still statistics =>
regeneration mode exceeds the aborted by the operator. see service manual:
long-limit threshold within last 500 Stand-still mode does not reach Stand-still operation finished or
h total engine run time. required temperature level and often interrupted by driver / engine
The error is activated if the engine regeneration level is therefore shut-off? => Run stand-still and
runs to many times in Standstill reached after a short time again instruct operator
regeneration. Stand-still operation required often
by soot load => Check dp DPF
pressure sensor
Stand-still mode does not reach
required temperature level:
Check engine air path: Intake
Throttle, EGR-Valve and
turbocharger okay?
214 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
Any leakage in engine air intake
system or exhaust gas system?
Check temperature sensors within
exhaust system: upstream DOC,
downstream DOC
If soot load level of DPf allow it:
Perform Stand-still and check
reached temperature level upstream
and downstream
DOC: T upstream DOC in the range
of 480-550°C? Downstream DOC
after 25 min
stand-still main phase 590°C are
reached?
Temperature traces are steady and
even?
Temperature downstream DOC
higher than upstream DOC but
difference does not exceed 100 K?
Very small difference (< 10 K after
25 min stand-still main phase, 590
°C downstream DOC are not
reached) => exchange DOC
Very big difference (>100 K after 25
min stand-still main phase, 590 °C
downstream DOC exceeded) =>
check injection system of engine &
engine air path
524194 8 1894 276 The total time in standstill- Stand-still mode is aborted / Read out stand-still statistics =>
regeneration mode exceeds the interrupted too often by the see service manual:
long-limit threshold: 2,5h stand-still operator Stand-still operation finished or
operation within 50h total motor Stand-still is required too often due often interrupted by driver / engine
run time. to miscalculation in the soot model shut-off? => Run stand-still and
The error is activated if the engine Stand-still mode does not reach instruct operator
runs to much time in short Standstill temperature level and regeneration Stand-still operation required often
regeneration. level is therefore reached after a by soot load => Check dp DPF
short time again. pressure sensor
Stand-still mode does not reach
required temperature level:
Check engine air path: Intake
Throttle, EGR-Valve and
turbocharger okay?
Any leakage in engine air intake
system or exhaust gas system?
Check temperature sensors within
exhaust system: upstream DOC,
downstream DOC
If soot load level of DPF allows it:
Perform Stand-still and check
reached temperature level upstream
and downstream
DOC: T upstream DOC in the range
of 480-550°C? Downstream DOC
after 25 min
stand-still main phase 590°C are
reached?
Temperature traces are steady and
even?
800S HC3, 860SJ HC3 31222415 215

Fault Codes

Deutz Description
Code
Temperature downstream DOC
higher than upstream DOC but
difference does not exceed 100 K?
Very small difference (< 10 K after
25 min stand-still main phase, 590
°C downstream DOC are not
reached) => exchange DOC
Very big difference (>100 K after 25
min stand-still main phase, 590 °C
downstream DOC exceeded) =>
check injection system of engine &
engine air path
524195 14 1900 279 The standstill request of detected Back pressure upstream SCR catalyst Dismount urea injector from exhaust
crystallization is ignored for more has reached a level which indicates line and inspect visually the injector
than 5h(>300min) crystallization inside of exhaust line. and the exhaust line for urea
This will be activated if there is a The error detection depends on the crystallization upstream of SCR
standstill request activated by sensed pressure upstream of the catalyst:
Crystallization Monitoring. SCR catalyst and the calculated If crystallization can be clearly seen,
exhaust volume flow through the then stand-still must be processed.
mixer pipe. Has the engine been operated in
In case of error is set, but no low load for longer time? If yes,
crystallization can be found in the then it could be the reason for
mixing pipe, a possible reason can crystallization.
be the defect sensors: Does the NOx-Sensors work
- exhaust pressure & temperature properly? Compare ComRxSCR_
upstream of the SCR catalyst, rNOxUs to ComRxSCR_rNOxDs, when
- the ambient pressure ComRxSCR_stNOxRdyUs = 1 &
- the exhaust mass flow => Check ComRxSCR_stNOxRdyDs = 1 (Warm
air path system at the engine. engine and EAT-system, SCRT_
tCatAvrgExhGs_mp > 250°C, SCR_
stStatus = "Dosing" = 8): sensed
NOx upstream of SCR catalyst must
be higher than downstream of SCR
catalyst.
Go to idle and wait until SCR system
enters status "stand-by" (no dosing),
SCRT_tCatAvrgExhGs_mp < 225°C:
ComRxSCR_rNOxUs = ComRxSCR_
rNOxDs
Clean urea injector: rinse it
thoroughly under water
Check EGR-Path: difference pressure
sensor at venturi tube, EGR cooler,
EGR-Valve,
Reed-Valve, Intake throttle
regarding function and leakage.
Does the EGR-cooler leak water in
the exhaust?
Check air path for leakage
Check turbocharger
No crystallization can be seen in the
mixing pipe:
Check exhaust pressure sensor
upstream of SCR catalyst (SCR_
pSensUCatUsP): tube, water in
sensor?
Check environmental pressure sensor
(EnvP_p): plausible?
216 31222415 800S HC3, 860SJ HC3

Fault Codes

Deutz Description
Code
Check exhaust temperature sensor
upstream of SCR-catalyst (SCR_
tSensUCatUsT): plausible compared
to Exh_tOxiCatUs & Exh_tOxiCatDs
e.g. when engine has idled for 20
minutes?
=> Run stand-still to remove
crystallization and to reset the DFC
5232719 3 1108 672 Urea supply module heater: the Short circuit to battery Threshold for error detection is an
above the target range heating phase it is a result error: Check wiring
defect
6.2.2 Deutz TD2.9L4 (Stage V) Engine

Table 31. EMR5 Trouble Codes
DTC-Code FTB SPN FMI Error Identification
1000 0 98 2 Engine Oil Level - Data Erratic, Intermittent or Incorrect
1001 0 98 31 Engine Oil Level - Condition Exists
1003 0 98 2 Engine Oil Level - Data Erratic, Intermittent or Incorrect
1005 0 98 14 Engine Oil Level - Special Instructions
Engine Oil Pressure 1

1021 0 100 3 Voltage Above Normal or Shorted To High Source

1022 0 100 4 -Voltage Below Normal or Shorted To Low Source

1025 0 100 1 - Data Below Normal Operational Range (Most Severe Level)

Engine Air Filter 1 Differential Pressure

1043 0 107 0 - Data Above Normal Operational Range (Most Severe Level)
Engine Exhaust Gas Recirculation 1 Differential Pressure

1071 0 411 2
- Data Erratic, Intermittent or Incorrect


1074 0 411 2
1075 0 411 2 Engine Exhaust Gas Recirculation 1 Differential Pressure
800S HC3, 860SJ HC3 31222415 217

Fault Codes
Table 31. EMR5 Trouble Codes (continued)

1077 0 411 3 - Voltage Above Normal or Shorted To High Source

1078 0 411 4 - Voltage Below Normal or Shorted To Low Source
Barometric Pressure
Barometric Pressure
Barometric Pressure
1081 0 108 15 - Data Above Normal Operational Range (Least Severe Level)
Barometric Pressure
Barometric Pressure
1083 0 108 2 - Data Erratic, Intermittent or Incorrect
After treatment 1 Diesel Particulate Filter Ash Load Percent
After treatment 1 Diesel Particulate Filter Trip Active Regeneration Time

After treatment 1 Diesel Particulate Filter Soot Mass

1087 0 4781 14 - Special Instructions

1089 0 4781 16 - Data Above Normal Operational Range (Moderately Sever Level)
DPF Active Regeneration Time Remaining

After treatment 1 Diesel Particulate Filter Trip Disabled Time

After treatment 1 Diesel Particulate Filter Trip Disabled Time

After treatment 1 Diesel Oxidation Catalyst Outlet Temperature

Ambient Air Temperature

1102 0 171 2
Engine Intake Manifold 1 Pressure



218 31222415 800S HC3, 860SJ HC3

Fault Codes


1121 0 102 2

Engine Exhaust Pressure 1

1124 0 1209 2
Engine Turbocharger 1 Compressor Intake Pressure

1127 0 1209 2

After treatment 1 Diesel Particulate Filter Differential Pressure






1149 0 3251 2



1153 0 3251 18 - Data Below Normal Operational Range (Moderately Severe Level)
High Pressure Common Rail Fuel Pressure Relief Valve

800S HC3, 860SJ HC3 31222415 219

Fault Codes

1162 0 5571 2
1163 0 5571 2



1167 0 5571 2
1168 0 5571 2
1169 0 5571 13
- Out of Calibration
Engine Fuel Delivery Pressure

Engine Fuel Pump Pressurizing Assembly 1

1172 0 1347 5 - Current Below Normal or Open Circuit
CAN Bus 2 / Engine/Diagnose CAN
Engine Fuel Metering Rail Pump
1190 0 7103 13
1191 0 7103 13
1194 0 7103 13


1198 0 7103 2
CAN 1 / Customer CAN (J1939)
Engine Fuel Injection Quantity Error for Multiple Cylinders

220 31222415 800S HC3, 860SJ HC3

Fault Codes

Engine Fuel 1 Injector Metering Rail 1 Pressure


CAN-Receive-Message EAT Control Checksum
Engine Control Unit (Controller 1)
1212 0 629 12 - Bad Intelligent Device or Component



TSC1 Message Checksum

122 0 4207 2
123 0 4207 2
Emission Control System Operator Inducement Severity (NCD Inducement)


125 0 4207 2
Accelerator Pedal Position 1
Accelerator Pedal 1 Channel 2

Accelerator Pedal 2 Position



800S HC3, 860SJ HC3 31222415 221

Fault Codes



Sensor supply voltage 1 from ECU



1291 0 3509 6
- Current Above Normal or Grounded Circuit



1295 0 3510 6
1306 0 677 3 Engine Starter Motor Relay - Voltage Above Normal or Shorted To High Source
1307 0 677 4 Engine Starter Motor Relay - Voltage Below Normal or Shorted To Low Source
1308 0 677 5 Engine Starter Motor Relay - Current Below Normal or Open Circuit
1310 0 677 3 Engine Starter Motor Relay - Voltage Above Normal or Shorted To High Source
1311 0 677 4 Engine Starter Motor Relay - Voltage Below Normal or Shorted To Low Source

1323 0 91 11
- Root Cause Not Known
1326 0 29 11
- Root Cause Not Known
1346 0 1041 14 Start Signal Indicator - Special Instructions
Engine Intake Manifold 1 Temperature


Engine ECU Temperature
222 31222415 800S HC3, 860SJ HC3

Fault Codes

Engine Exhaust Gas Recirculation 1 Temperature



Engine Throttle Valve 1 Position 1




1379 0 51 6
1382 0 51 7 - Mechanical System not Responding or Out of Adjustment






1399 0 4766 2
1400 0 4766 2

800S HC3, 860SJ HC3 31222415 223

Fault Codes

After treatment 1 Diesel Oxidation Catalyst Intake Temperature

1404 0 4765 2



1408 0 4765 2
CAN-Receive-Message EAT Control
142 0 520256 9 - Abnormal Update Rate / Timeout
CAN-Receive-Message EBC1
CAN-Receive-Message Engine Protection
Time in Standstill Mode
1540 0 520254 8 - Abnormal Frequency or Pulse Width or Period
Hoses Connected to dp DPF SENT Sensor Inverted

1541 0 520255 2
Engine Shutdown Request via CAN
Water In Fuel Indicator 1
CAN-Receive-Message Function Mode Control

CAN-Receive-Message EAT Control Message Counter
219 0 520253 2
TSC1 Message Counter
220 0 4206 2
TSC1 Receive Timeout-Error
224 31222415 800S HC3, 860SJ HC3

Fault Codes

ECM Main Relay

ECM Main Relay

ECM Main Relay

ECM Main Relay
ECM Main Relay

ECM Main Relay

Battery voltage
Battery voltage
Battery voltage
Battery voltage
Powerstage Diagnosis disabled, Battery Potential

Powerstage Diagnosis disabled, Battery Potential
Battery voltage
800S HC3, 860SJ HC3 31222415 225

Fault Codes

Engine Exhaust Gas Recirculation 1 Valve Position



574 0 27 6

Engine Exhaust Gas Recirculation 1 Actuator 1

Engine Exhaust Gas Recirculation 1 Actuator 1

Engine Fuel System Monitor (ECU Internal Error)
587 0 190 0 Engine Speed - Data Above Normal Operational Range (Most Severe Level)



Camshaft Speed Sensor


617 0 723 13
Crankshaft Speed Sensor
Crankshaft Speed Sensor

68 0 1669 14 CAN Bus ID-5
226 31222415 800S HC3, 860SJ HC3

Fault Codes

- Special Instructions
Engine Coolant Temperature
70 0 110 2







Engine Cold Start Aid Relay



80 0 411 2

Engine Fuel 1 Injector Group 1

Engine Cylinder 1 Fuel Injection Quantity

800S HC3, 860SJ HC3 31222415 227

Fault Codes

822 0 2797 6
823 0 2798 6
824 0 5358 6
825 0 5359 6
826 0 5360 6
827 0 5361 6
828 0 5362 6
829 0 5363 6
Engine Coolant Level 1

830 0 5358 6
831 0 5359 6
832 0 5360 6
833 0 5361 6
834 0 5362 6
835 0 5363 6


228 31222415 800S HC3, 860SJ HC3

Fault Codes

Not defined





859 0 7103 6


875 0 190 2 Engine Speed - Data Erratic, Intermittent or Incorrect

876 0 5357 2
Engine Fuel Injection Timing Error for Multiple Cylinders
877 0 5441 2
878 0 5357 2
Internal Recovery
88 0 598 10 Clutch Switch - Abnormal Rate of Change
Internal Recovery
Internal Recovery

882 0 5357 2
800S HC3, 860SJ HC3 31222415 229

Fault Codes

883 0 5357 2
Engine Fuel Injection Pressure Error for Multiple Cylinders
884 0 5442 2
885 0 29 2
886 0 677 2 Engine Starter Motor Relay - Data Erratic, Intermittent or Incorrect
Actual Engine Percent Torque

887 0 513 2
Actual Engine Percent Torque
888 0 513 2
Function Monitoring: Error During Subsequent Selectable Monitoring
889 0 520250 2












230 31222415 800S HC3, 860SJ HC3

Fault Codes



Engine Protection System Approaching Shutdown

91 0 1109 2







Engine Protection System Approaching Shutdown





800S HC3, 860SJ HC3 31222415 231

Fault Codes

















232 31222415 800S HC3, 860SJ HC3

Fault Codes


6.2.3 Deutz D2011LO40 Engine

Table 32. EMR2 Trouble Codes
FAULT NO. FAULT LOCALITY/
FAULT GROUP (IN SERDIA) SPN FMI CAUSE REMARKS HELP
FAULT DESCRIPTION
Zero error display 52428 No active faults present

- No faults 31
7
Governor in emergency
operation (if sensor 2
available). Emergency
Sensor failure. Distance switch-off (if sensor 2 not
from gear too far. available or failed). Check distance. Check cable
01 Speed sensor 1 190 8 Additional fault connection. Check sensor and
impulses. Cable joint Governor in emergency replace if required.
interrupted. operation (with sensor 1)
Emergency switch-off (if
sensor 1 not available or
Revolutions/ failed).
speed acquisition
Tacho failed. Additional
Governor in emergency Check cable connection and
3 Speed sensor 84 8 fault impulses. Cable
operation. Tacho. Replace if required.
connection interrupted.
Speed was/is in excess of Check parameter (21). Check

Engine stop.
limit. e. speed settings.
Excess speed switch-
4 190 0 Check PID setting. Check rods. Check actuator and replace if required. Check cable to
off
actuator(impulse on incorrect speed). Check No. of teeth. For vehicles check for possible
thrust mode.
07 Charge air pressure 102 2
08 Oil pressure 100 2
Fault at corresponding With failure of the sensor, Check sensor cable. Check sensor
09 Coolant temperature 110 2
Sensors sensor entry (e.g. short the associated monitoring and replace if required. Check
Charge air circuit or cable break). function is de-activated. fault limits for sensor.
10 temperature 105 2
11 Fuel temperature 174 2

Fault message (disappears Check engine (oil level, oil
Oil pressure below
when oil pressure is again pump). Check oil pressure sensor
Oil pressure warning speed- dependent
30 100 1 above recovery limit).After and cable. Check oil pressure
warning line
a delay time - fill warning line characteristic.
characteristic
Functional fault limitation.
warning Fault message (disappears
when coolant temperature
Coolant temperature Coolant temperature has Check coolant. Check coolant
31 110 0 again drops below
warning exceeded warning level. temperature sensor and cable.
recovery level). After a
delay time - fill limitation.
800S HC3, 860SJ HC3 31222415 233

Fault Codes

FAULT DESCRIPTION
Fault message (disappears
when charge air
Charge air Charge air temperature Check charge air. Check charge
temperature gain drops
32 temperature warning 105 0 has exceeded warning air- temperature sensor and
below recovery level).
level. cable.
After a delay time - fill
limitation.
Coolant level Switch input “Low Check coolant level. Check
34 111 1 Fault message.
warning coolant level” is active. coolant level sensor and cable.
revolutions was/is above
(top) revolution speed Check parameters. Check speed
Speed warning (with limit. “Thrust mode” settings.
35 thrust mode S ID 190 14 function is active.
operation). Check PID setting. Check rods. Check actuator and replace if required. Check cable to
actuator. Check speed sensor (impulses on incorrect speed). Check No. of teeth. For vehicles
check for possible thrust mode.
Fuel temperature Fuel-temperature has when fuel temperature Check fuel. Check fuel
36 warning 174 0 exceeded warning level. again drops below temperature sensor and cable.
recovery level).
Charge air Charge air temperature Check charge air. Check charge
42 temperature switch- 105 0 has exceeded switch-off Emergency stop air- temperature sensor and
Functional fault, off limit. cable. Check switch-off limit.
switch-off
Coolant level switch- Switch input “Low Emergency stop. Start Check coolant level. Check
44 111 1
off coolant level” is active. lock. coolant level sensor and cable.
Check actuator, replace if
50 Feedback S ID 24 12 required. Check cable, check
Actuator not connected. Emergency switch-off. fault limits for “Confirmation”.
Fault in actuator Actuator cannot be Check actuator, replace if
confirmation. operated. required. Check cable, check
52 Reference feedback S ID 24 13
fault limits for “Rifeness
confirmation”.
Injection pump/actuator
jammed or not
connected. Difference Fault message (disappears Check actuator/actuator rods /
Control travel between nominal/actual when difference is < injection pump, replace if
53 DI 23 7
difference control travel is > 10% 10%). required. Check actuator cable.
Actuator of the overall control
path.
Check actuator and replaced if

required. Check feedback cable.
No automatic actuator Check fault limits and reference

Engine stop / start lock. values of the feedback. Program
Auto calibration equalization possible. Governor cannot be taken the fault limits for feedback,
59 BOSCH-EDC pumps S ID 23 13 Incorrect input of the into use. EDC actuator save values. Switch ignition off
faulty operation actuator reference calibration required. and on again. Check again. If
values.
faulty, inform DEUTZ-Service and
carry out automatic equalization
again. Set fault limits again.
Digital output 3 Fault (short circuit /
Hardware inputs/ Driver level is switched Check cable of digital output
60 (Switch-off solenoid, S ID 51 2 cable break) at digital
outputs off. (cable break or short circuit).
pin M 2) output.
234 31222415 800S HC3, 860SJ HC3

Fault Codes

FAULT DESCRIPTION
Digital output 6, pin Fault message.
62 S ID 60 2
M7
Excess voltage
63 S ID 51 6
switch- off solenoid
67 Error Hand Step 1 91 11
68 Error CAN Step 1 898 2
CAN-controller for CAN-
bus is faulty. Fault
70 CAN-Bus controller S ID 231 12 removal despite re-
initializing continuously Check CAN connection,
not possible Application-dependent. terminating resistor (see Chapter
12.4), Check control unit.
Communication Overflow in input buffer
CAN interface SAE or a transmission cannot
71 S ID 231 9
J1939 be placed on the bus.
Check CAN connection, cable
Cable break, short connection. Check sensor and
74 S ID 231 14
circuit or bus-error replace if required.
Fault in parameter
Parameter
programming in the
76 programming (write S ID 253 12 governor fixed value
EEPROM) Switch ignition off and on again.
memory.
Check again. If faulty inform
Constant monitoring of DEUTZ Service
program memory shows Emergency switch-off.
Memory 77 Cyclic program test S ID 240 12
error (so-called “Flash- engine cannot be started.
test”).
Note values of parameters (3895
Constant monitoring of and 3896). Switch ignition off
78 Cyclic RAM test S ID 254 2 working memory shows and on again. Check again. If
error. faulty inform DEUTZ Service.
Power supply for Fault message (disappears Switch ignition off and on again.
Power supply
80 S ID 254 2 actuator not in the when power again in the Check again. If faulty inform
(Actuator)
permissible range. normal range). DEUTZ Service.
83 Reference voltage 1 S ID 254 2 Fault message (disappears Check voltage supply. Switch
Reference voltage for
Reference voltage 2 actuator not in the when power again in the ignition off and on again. Check
84 S ID 254 2
permissible range. normal range). Auxiliary again. If faulty inform DEUTZ
85 Reference voltage 4 S ID 254 2 value 5 V Service.
Control unit
hardware Internal temperature for Fault message (disappears Switch ignition off and on again.
86 Internal temperature 171 12 control unit not in when power again in the Check again. If faulty inform
permissible range. normal range). DEUTZ Service.
when power again in
Atmospheric pressure not normal range).
87 Atmospheric pressure 108 12 in permissible range. Atmospheric pressure
monitoring function de-
activated.
Parameter fault No data found or
Check data for correct settings.
Program logic 90 (EEPROM retrieval or S ID 253 2 checksum of data is Engine cannot be started.
Save parameters. Switch ignition
checksum faulty). faulty (note: fault only
800S HC3, 860SJ HC3 31222415 235

Fault Codes

FAULT DESCRIPTION
occurs during setting of off and on again. Check again. If
parameter / saving or faulty inform DEUTZ Service.
reset.).
Note parameters (3897 and
Internal calculation fault
Emergency switch-off. 3898). Switch ignition off and
93 Stack overflow S ID 240 2 (so-called “Stack over
Engine cannot be started. on again. Check again. If faulty
flow” fault).
inform DEUTZ Service.
94 Internal fault S ID 254 2
Note: SID is equal to 512. To get SPN #, add 512 + number. For example, SID 254 would be 512+254 or an SPN of 766.
6.2.4 Ford Engine

Table 33. CAN to DTC Cross Reference (Ford Engine)
SPN FMI DTC DTC and Description

0 31 1531 Gov1/2/3 interlock failure
0 31 1621 RS-485 Rx inactive
0 31 1622 RS-485 Rx noise
0 31 1623 RS-485 Rx bad packet format
0 31 1624 RS-485 remote shutdown request
29 0 2116 FPP2 higher than IVS

29 1 2140 FPP2 lower than IVS
29 3 2128 FPP2 voltage high
29 4 2127 FPP2 voltage low
51 0 221 TPS1-2 higher than expected
51 1 121 TPS1-2 lower than expected
51 3 123 TPS1 voltage high
51 4 122 TPS1 voltage low

51 7 2111 Unable to reach lower TPS
51 7 2112 Unable to reach higher TPS
TPS1/2 simultaneous voltages out-of-

51 31 2135 range
84 8 502 Roadspeed input loss of signal
91 0 2115 FPP1 higher than IVS

91 1 2139 FPP1 lower than IVS
91 3 2122 FPP1 voltage high
91 4 2123 FPP1 voltage low
J1939 ETC message receipt loss while in-

91 9 1651 gear
236 31222415 800S HC3, 860SJ HC3

Fault Codes
Table 33. CAN to DTC Cross Reference (Ford Engine) (continued)
91 16 2126 FPP1-2 higher than expected
91 18 2121 FPP1-2 lower than expected
91 19 1630 J1939 ETC message receipt loss
FPP1/2 simultaneous voltages out-of-

91 31 1121 range (redundancy lost)
94 0 88 Fuel pressure higher than expected
94 1 87 Fuel pressure lower than expected
94 3 92 FP high voltage
94 4 91 FP low voltage
100 0 521 Oil pressure sender high pressure
100 1 524 Oil pressure low
100 1 524 Oil pressure sender low pressure
100 3 523 Oil pressure sender high voltage
100 4 522 Oil pressure sender low voltage
100 18 520 Oil pressure sender low pressure stage 1

102 0 234 Boost control overboost failure
102 1 299 Boost control underboost failure
102 2 236 TIP active
102 3 238 TIP high voltage
102 4 237 TIP low voltage
105 0 127 IAT higher than expected stage 2
105 3 113 IAT voltage high
105 4 112 IAT voltage low
105 15 111 IAT higher than expected stage 1
106 4 107 MAP voltage low
106 16 108 MAP pressure high
108 0 2229 BP pressure high
108 1 129 BP pressure low
110 0 217 ECT higher than expected stage 2
110 0 1522 CHT higher than expected stage 2
110 3 118 ECT voltage high
110 4 117 ECT voltage low
110 15 116 ECT higher than expected stage 1
110 16 1521 CHT higher than expected stage 1
800S HC3, 860SJ HC3 31222415 237

Fault Codes
168 15 563 Vbat voltage high
168 17 562 Vbat voltage low
173 0 2428 EGT temperature high
174 3 183 FT high voltage
174 4 182 FT low voltage
441 0 1417 EMWT1 higher than expected stage 2
441 3 1411 EMWT1 voltage high
441 4 1413 EMWT1 voltage low
442 3 1412 EMWT2 voltage high
442 4 1414 EMWT2 voltage low
515 0 1112 RPM above spark rev limit level

RPM higher than max allowed govern
515 15 219 speed
515 16 1111 RPM above fuel rev limit level
558 5 2130 IVS stuck at-idle, FPP1/2 match
558 6 2131 IVS stuck off-idle, FPP1/2 match
628 13 601 Microprocessor failure - FLASH
629 31 606 Microprocessor failure - COP
629 31 1612 Microprocessor failure - RTI 1
629 31 1615 Microprocessor failure - A/D
629 31 1616 Microprocessor failure - Interrupt
630 12 604 Microprocessor failure - RAM
632 31 359 Fuel run-out longer than expected
636 2 336 CRANK input signal noise
636 4 337 Crank signal loss
Crank and/or cam could not synchronize

636 8 16 during start
639 12 1626 CAN-J1939 Tx fault
639 12 1627 CAN-J1939 Rx fault
238 31222415 800S HC3, 860SJ HC3

Fault Codes

J1939 CAN address / engine-number
639 13 1628
conflict
645 3 2619 Tach output short to power
645 4 2618 Tach output ground short
651 5 261 Injector 1 open or short to ground
651 6 262 Injector 1 coil shorted
695 9 1629 J1939 TSC1 message receipt loss
697 3 1632 PWM1-Gauge1 short to power
697 5 1631 PWM1-Gauge1 open / ground short
700 3 1638 PWM4 short to power
700 5 1637 PWM4 open / ground short
701 3 1511 AUX analog Pull-Up 1 high voltage
800S HC3, 860SJ HC3 31222415 239

Fault Codes
701 4 1512 AUX analog Pull-Up 1 low voltage
704 3 1541 AUX analog Pull-Up/Down 1 high voltage
704 4 1542 AUX analog Pull-Up/Down 1 low voltage
707 3 1551 AUX digital 1 high voltage
707 4 1552 AUX digital 1 low voltage

709 3 1555 Water Intrusion Detection
710 3 1515 AUX analog Pull-Down 1 high voltage
710 4 1516 AUX analog Pull-Down 1 low voltage
723 2 341 CAM input signal noise
723 4 342 Loss of CAM input signal
731 2 326 Knock1 excessive or erratic signal
731 4 327 Knock1 sensor open or not present
920 3 1643 Buzzer control short to power
920 4 1641 Buzzer control ground short
920 5 1642 Buzzer open
240 31222415 800S HC3, 860SJ HC3

Fault Codes
1079 3 643 Sensor supply voltage 1 high
1079 4 642 Sensor supply voltage 1 low
Sensor supply voltage 1 and 2 out-of-

1079 31 1611 range
1080 3 653 Sensor supply voltage 2 high
1080 4 652 Sensor supply voltage 2 low
1110 31 1625 J1939 shutdown request
1192 3 1131 WGP voltage high
1192 4 1132 WGP voltage low
1213 3 1645 MIL control short to power
1213 4 1644 MIL control ground short
1213 5 650 MIL open

Spark coil 1 primary open or short to
1268 5 2300 ground
1268 6 2301 Spark coil 1 primary shorted

1269 5 2303 ground

1270 5 2306 ground

1271 5 2309 ground

1272 5 2312 ground

1273 5 2315 ground

1274 5 2318 ground
800S HC3, 860SJ HC3 31222415 241

Fault Codes

1275 5 2321 ground

1276 5 2324 ground

1277 5 2327 ground
1321 3 617 Start relay coil short to power
1321 4 616 Start relay ground short
1321 5 615 Start relay coil open
1323 11 1311 Cylinder 1 misfire detected
Cylinder 1 emissions/catalyst damaging

1323 31 301
misfire

1324 31 302
misfire

1325 31 303
misfire

1326 31 304
misfire

1327 31 305
misfire

1328 31 306
misfire

1329 31 307
misfire

1330 31 308
misfire
Fuel-pump high-side open or short to
1347 5 628 ground
1347 6 629 Fuel-pump high-side short to power
242 31222415 800S HC3, 860SJ HC3

Fault Codes
1348 3 629 Fuel pump relay coil short to power
1348 4 628 Fuel pump relay control ground short
1348 5 627 Fuel pump relay coil open
1385 0 1425 ERWT1 higher than expected stage 2
1385 3 1419 ERWT1 voltage high
1385 4 1421 ERWT1 voltage low
1386 3 1420 ERWT2 voltage high
1386 4 1422 ERWT2 voltage low
1485 3 687 Power relay coil short to power
1485 4 686 Power relay ground short
1485 5 685 Power relay coil open
3050 11 420 Catalyst inactive on gasoline (Bank 1)
3050 11 1165 Catalyst inactive on LPG
3050 11 1166 Catalyst inactive on NG
3051 11 430 Catalyst inactive on gasoline (Bank 2)
3056 3 8906 UEGO return voltage shorted high
3056 4 8907 UEGO return voltage shorted low
3217 3 8910 UEGO sense cell voltage high
3217 4 8911 UEGO sense cell voltage low
3217 5 134 EGO1 open / lazy
3218 3 8908 UEGO pump voltage shorted high
3218 4 8909 UEGO pump voltage shorted low
3221 3 8904 UEGO cal resistor voltage high
3221 4 8905 UEGO cal resistor voltage low
3221 31 8901 UEGO microprocessor internal fault
3222 0 8916 UEGO sense cell impedance high
3222 3 8902 UEGO heater supply high voltage
800S HC3, 860SJ HC3 31222415 243

Fault Codes
3222 4 8903 UEGO heater supply low voltage
3222 10 8914 UEGO sense cell slow to warm up
3225 0 8917 UEGO pump cell impedance high
3225 1 8918 UEGO pump cell impedance low
3225 3 8912 UEGO pump voltage at high drive limit
3225 4 8913 UEGO pump voltage at low drive limit
3225 10 8915 UEGO pump cell slow to warm up
Gaseous fuel temperature sender high

3468 3 188 voltage
Gaseous fuel temperature sender low

3468 4 187 voltage
3673 3 223 TPS2 voltage high
3673 4 222 TPS2 voltage low
4236 0 1151 Closed-loop LPG high
4236 0 1153 Closed-loop NG high
4236 0 1155 Closed-loop gasoline bank1 high
4236 1 1152 Closed-loop LPG low
4236 1 1154 Closed-loop NG low
4236 1 1156 Closed-loop gasoline bank1 low
4237 0 171 Adaptive-learn gasoline bank1 high
4237 0 1161 Adaptive-learn LPG high
4237 0 1163 Adaptive-learn NG high
4237 1 172 Adaptive-learn gasoline bank1 low
4237 1 1162 Adaptive-learn LPG low
4237 1 1164 Adaptive-learn NG low
4238 0 1157 Closed-loop gasoline bank2 high
4238 1 1158 Closed-loop gasoline bank2 low
4239 0 174 Adaptive-learn gasoline bank2 high
4239 1 175 Adaptive-learn gasoline bank2 low
520197 2 331 Knock2 excessive or erratic signal
520197 4 332 Knock2 sensor open or not present
244 31222415 800S HC3, 860SJ HC3

Fault Codes

FPP1/2 do not match each other or IVS
520199 11 1122 (redundancy lost)
FPP1 invalid voltage and FPP2 disagrees

520199 11 2120 with IVS (redundancy lost)
FPP1/2 do not match each other or IVS

520199 11 2125 (redundancy lost)
520201 5 509 IAC coil open/short
520201 6 508 IAC ground short
520226 3 916 Shift actuator feedback out-of-range
520226 7 919 Shift unable to reach desired gear

520226 31 920 Shift actuator or drive circuit failed
MegaJector delivery pressure higher than
520260 0 1171 expected
MegaJector delivery pressure lower than
520260 1 1172 expected
520260 3 1174 MegaJector voltage supply high
520260 4 1175 MegaJector voltage supply low
MegaJector internal actuator fault

520260 12 1176
detection
MegaJector internal circuitry fault
520260 12 1177
detection
520260 12 1178 MegaJector internal comm fault detection
520260 31 1173 MegaJector comm lost
520401 0 1182 Fuel impurity level high
520800 7 11 Intake cam / distributor position error
520801 7 24 Exhaust cam position error
520803 31 1183 MegaJector autozero / lockoff failure
Note: For detail Diagnostic Trouble Code of Ford Engine refer DTC manual (PN 3128850).
6.3 MACHINE FAULT CODES
6.3.1 General
Table 34. Diagnostic Trouble Code Chart (DTC)
DTC Flash Code Fault Message Check

001 00 EVERYTHING OK No response required for this DTC.
002 00 GROUND MODE OK No response required for this DTC.
800S HC3, 860SJ HC3 31222415 245

Fault Codes
Table 34. Diagnostic Trouble Code Chart (DTC) (continued)

0010 00 RUNNING AT CUTBACK - OUT OF Response described in Drive Modes
TRANSPORT POSITION section.
000 00 <<< HELP COMMENT >>>
0011 00 FSW OPEN (Foot switch open) The UGM shall not Enable the Machine.
0012 00 RUNNING AT CREEP - CREEP SWITCH The UGM shall limit the machine to
OPEN Creep speed.
0013 00 RUNNING AT CREEP - TILTED AND ABOVE
ELEVATION
0014 00 CHASSIS TILT SENSOR OUT OF RANGE Not reported during power-up.
0015 00 LOAD SENSOR READING UNDER WEIGHT
0031 00 FUEL LEVEL LOW - ENGINE SHUTDOWN Response described in Fuel Shutdown
section.
0035 00 APU ACTIVE Response described in Auxiliary Power/
Emergency Descent Mode section.
0039 00 SKYGUARD ACTIVE - FUNCTIONS CUTOUT Response described in SkyGuard section.
0040 00 RUNNING AT CREEP - CREEP SWITCH
CLOSED
210 21 <<< POWER-UP >>>
211 21 POWER CYCLE
212 21 KEYSWITCH FAULTY The UGM shall assume a station selection
of Ground.
213 21 FSW FAULTY The UGM shall not Enable the Machine.
220 22 <<< PLATFORM CONTROLS >>>
227 22 STEER SWITCHES FAULTY The UGM shall prohibit Steer;
The UGM shall limit Drive to Creep
The Steer Left switch input = Low;
The Steer Right switch input = Low;
Steer and full Drive speed permitted after
controls are initialized.
2211 22 FSW INTERLOCK TRIPPED Can be reported during power-up.
2212 22 DRIVE LOCKED - JOYSTICK MOVED BEFORE Can be reported during power-up.
FOOTSWITCH
2213 22 STEER LOCKED - SELECTED BEFORE The UGM shall not Enable the Machine.
FOOTSWITCH
2214 22 DRIVE/STEER LOCKED - JOYSTICK MOVED
BEFORE ENABLE
2216 22 D/S JOY. OUT OF RANGE HIGH Resistive joysticks.
If the reference voltage is > 7.7 V then
the reference voltage is out of tolerance
of a short to battery has occurred.
2217 22 D/S JOY. CENTER TAP BAD Resistive joysticks.
- There is a +/-.1V range. around these
values due to resistor tolerances.
2219 22 L/S JOY. OUT OF RANGE HIGH Resistive joysticks.
246 31222415 800S HC3, 860SJ HC3

Fault Codes

- If the reference voltage is > 7.7V then
the reference voltage is out of tolerance
of a short to battery has occurred.
2220 22 L/S JOY. CENTER TAP BAD Resistive joysticks.
- There is a +/- .1V range. around these
values due to resistor tolerances.
2221 22 LIFT/SWING LOCKED - JOYSTICK MOVED If triggered by the Lift and/or Swing
BEFORE FOOTSWITCH joystick not being in the neutral position
at Startup, the UGM shall prohibit Lift
and Swing.
If triggered by Lift and/or Swing joystick
is not in the neutral position when
Footswitch becomes active or while DTC
2212, 2213 or 2223 is active, the UGM
shall not Enable the Machine.
2222 22 WAITING FOR FSW TO BE OPEN Can be reported during power- up.
2223 22 FUNCTION SWITCHES LOCKED - SELECTED The UGM shall not Enable the Machine.
BEFORE ENABLE
2224 22 FOOTSWITCH SELECTED BEFORE START The UGM shall prohibit Engine Start.
2269 22 FUNCTION PROBLEM - HIGH SPEED &
CREEP ACTIVE TOGETHER
234 23 FUNCTION SWITCHES FAULTY - CHECK Disable whichever boom functions whose
DIAGNOSTICS/BOOM boom control inputs are triggering the
fault. If Engine Start/Aux at fault, disable
Engine Start but permit Auxiliary Power/
Emergency Descent.
235 23 FUNCTION SWITCHES LOCKED - SELECTED
BEFORE AUX POWER
236 23 FUNCTION SWITCHES LOCKED - SELECTED
BEFORE START SWITCH
237 23 START SWITCH LOCKED - SELECTED The UGM shall prohibit Engine Start.
BEFORE KEYSWITCH
23163 23 FUNCTION PROBLEM - MSSO No response required for this DTC Power
PERMANENTLY SELECTED Cycled.
240 24 <<< OTHER CONTROLS >>>
241 24 AMBIENT TEMPERATURE SENSOR - OUT The UGM shall set Low Temperature
OF RANGE LOW Cutout state = Faulty
If the Machine is in Platform Mode and if
the Boom is Above Elevation; The UGM
shall suspend motion;
If the Machine is in Ground Mode; No
response required for this DTC.
242 24 AMBIENT TEMPERATURE SENSOR - OUT Check Ambient Temperature sensor
OF RANGE HIGH reading < 85C.
250 25 <<< FUNCTION PREVENTED >>>
259 25 MODEL CHANGED - HYDRAULICS Disable all machine and engine functions
SUSPENDED - CYCLE EMS (i.e., command engine shutdown and do
not permit start).
2513 25 GENERATOR MOTION CUTOUT ACTIVE The UGM shall not Enable the Machine.
800S HC3, 860SJ HC3 31222415 247

Fault Codes

2514 25 BOOM PREVENTED - DRIVE SELECTED The UGM shall prohibit all boom
functions.
2516 25 DRIVE PREVENTED - ABOVE ELEVATION The UGM shall prohibit Drive and Steer.
2517 25 DRIVE PREVENTED - TILTED & ABOVE The UGM shall prohibit Drive and Steer.
ELEVATION
2518 25 DRIVE PREVENTED - BOOM SELECTED The UGM shall prohibit Drive and Steer.
2519 25 DRIVE PREVENTED - TILTED & EXTENDED
OR HIGH ANGLE
2520 25 FUNCTIONS LOCKED OUT - CONSTANT
DATA VERSION IMPROPER
2530 25 UMS SENSOR FORWARD LIMIT REACHED
2531 25 UMS SENSOR OUT OF USABLE RANGE
2532 25 UMS SENSOR BACKWARD LIMIT REACHED
2563 25 SKYGUARD SWITCH - DISAGREEMENT Response detailed in SkyGuard section.
2568 25 TEMPERATURE CUTOUT ACTIVE - AMBIENT If the Boom is Above Elevation; The UGM
TEMPERATURE TOO LOW shall suspend motion; The UGM shall
limit the machine to Creep speed after
controls initialized
If the Machine is in Platform Mode and if
the Boom is not Above Elevation.
2576 25 PLATFORM LEVEL PREVENTED - ABOVE The UGM shall suspend Platform Level Up
ELEVATION and Down commands;
The UGM shall prohibit Platform Level Up
and Down
2577 25 DRIVE PREVENTED - START BATTERY Check the battery.
CONNECTED
330 33 <<< GROUND OUTPUT DRIVER >>>
331 33 BRAKE - SHORT TO BATTERY Check Harness for damage.
332 33 BRAKE - OPEN CIRCUIT Check Harness for damage.
3311 33 GROUND ALARM - SHORT TO BATTERY Ground Alarm equipped vehicles only.
3336 33 ALTERNATOR POWER - SHORT TO Check Harness for damage.
GROUND
3340 33 AUX POWER - SHORT TO GROUND Check Harness for damage.
3341 33 AUX POWER - OPEN CIRCUIT Check Harness for damage.
3342 33 AUX POWER - SHORT TO BATTERY Check Harness for damage.
3346 33 ELECTRIC FAN - SHORT TO GROUND Check Harness for damage.
3347 33 ELECTRIC FAN - OPEN CIRCUIT Check Harness for damage.
3348 33 ELECTRIC FAN - SHORT TO BATTERY Check Harness for damage.
3349 33 ELECTRIC PUMP - SHORT TO GROUND Check Harness for damage.
3350 33 ELECTRIC PUMP - OPEN CIRCUIT Check Harness for damage.
3351 33 ELECTRIC PUMP - SHORT TO BATTERY Check Harness for damage.
248 31222415 800S HC3, 860SJ HC3

Fault Codes

3352 33 LP LOCK - SHORT TO GROUND Check Harness for damage.
3353 33 LP LOCK - OPEN CIRCUIT Check Harness for damage.
3354 33 LP LOCK - SHORT TO BATTERY Check Harness for damage.
3355 33 LP START ASSIST - SHORT TO GROUND Check Harness for damage.
3356 33 LP START ASSIST - OPEN CIRCUIT Check Harness for damage.
3357 33 LP START ASSIST - SHORT TO BATTERY Check Harness for damage.
3358 33 MAIN DUMP VALVE - SHORT TO GROUND Check Harness for damage.
3359 33 MAIN DUMP VALVE - OPEN CIRCUIT Check Harness for damage.
3360 33 MAIN DUMP VALVE - SHORT TO BATTERY Check Harness for damage.
3361 33 BRAKE - SHORT TO GROUND Check Harness for damage.
3362 33 START SOLENOID - SHORT TO GROUND Check Harness for damage.
3363 33 START SOLENOID - OPEN CIRCUIT Check Harness for damage.
3364 33 START SOLENOID - SHORT TO BATTERY Check Harness for damage.
3365 33 STEER DUMP VALVE - SHORT TO GROUND Check Harness for damage.
3366 33 STEER DUMP VALVE - OPEN CIRCUIT Check Harness for damage.
3367 33 STEER DUMP VALVE - SHORT TO BATTERY Check Harness for damage.
3368 33 TWO SPEED VALVE - SHORT TO GROUND Check Harness for damage.
3369 33 TWO SPEED VALVE - OPEN CIRCUIT Check Harness for damage.
3370 33 TWO SPEED VALVE - SHORT TO BATTERY Check Harness for damage.
3371 33 GROUND ALARM - SHORT TO GROUND Check Harness for damage.
3372 33 GROUND ALARM - OPEN CIRCUIT Check Harness for damage.
3373 33 GEN SET/WELDER - SHORT TO GROUND Check Harness for damage.
3374 33 GEN SET/WELDER - OPEN CIRCUIT Check Harness for damage.
3375 33 GEN SET/WELDER - SHORT TO BATTERY Check Harness for damage.
3376 33 HEAD TAIL LIGHT - SHORT TO GROUND Check Harness for damage.
3377 33 HEAD TAIL LIGHT - OPEN CIRCUIT Check Harness for damage.
3378 33 HEAD TAIL LIGHT - SHORT TO BATTERY Check Harness for damage.
3379 33 HOUR METER - SHORT TO GROUND Check Harness for damage.
3382 33 PLATFORM LEVEL UP VALVE - SHORT TO Check Harness for damage.
GROUND
3383 33 PLATFORM LEVEL UP VALVE - OPEN Check Harness for damage.
CIRCUIT
BATTERY
3388 33 PLATFORM LEVEL DOWN VALVE - SHORT Check Harness for damage.
TO GROUND
800S HC3, 860SJ HC3 31222415 249

Fault Codes

3389 33 PLATFORM LEVEL DOWN VALVE - OPEN Check Harness for damage.
CIRCUIT
TO BATTERY
3394 33 PLATFORM ROTATE LEFT VALVE - SHORT Check Harness for damage.
TO GROUND
3395 33 PLATFORM ROTATE LEFT VALVE - OPEN Check Harness for damage.
CIRCUIT
TO BATTERY
3397 33 PLATFORM ROTATE RIGHT VALVE - SHORT Check Harness for damage.
TO GROUND
3398 33 PLATFORM ROTATE RIGHT VALVE - OPEN Check Harness for damage.
CIRCUIT
TO BATTERY
33100 33 JIB LIFT UP VALVE - SHORT TO GROUND Check Harness for damage.
33101 33 JIB LIFT UP VALVE - OPEN CIRCUIT Check Harness for damage.
33102 33 JIB LIFT UP VALVE - SHORT TO BATTERY Check Harness for damage.
33103 33 JIB LIFT DOWN VALVE - SHORT TO Check Harness for damage.
GROUND
33104 33 JIB LIFT DOWN VALVE - OPEN CIRCUIT Check Harness for damage.
BATTERY
33106 33 TOWER LIFT UP VALVE - SHORT TO Check Harness for damage.
GROUND
33107 33 TOWER LIFT UP VALVE - OPEN CIRCUIT Check Harness for damage.
33108 33 TOWER LIFT UP VALVE - SHORT TO Check Harness for damage.
BATTERY
33109 33 TOWER LIFT DOWN VALVE - SHORT TO Check Harness for damage.
GROUND
33110 33 TOWER LIFT DOWN VALVE - OPEN CIRCUIT Check Harness for damage.
33111 33 TOWER LIFT DOWN VALVE - SHORT TO Check Harness for damage.
BATTERY
33112 33 TOWER TELESCOPE IN VALVE - SHORT TO Check Harness for damage.
GROUND
33113 33 TOWER TELESCOPE IN VALVE - OPEN Check Harness for damage.
CIRCUIT
33114 33 TOWER TELESCOPE IN VALVE - SHORT TO Check Harness for damage.
BATTERY
33115 33 TOWER TELESCOPE OUT VALVE - SHORT Check Harness for damage.
TO GROUND
33116 33 TOWER TELESCOPE OUT VALVE - OPEN Check Harness for damage.
CIRCUIT
250 31222415 800S HC3, 860SJ HC3

Fault Codes

33117 33 TOWER TELESCOPE OUT VALVE - SHORT Check Harness for damage.
TO BATTERY
33118 33 SWING RIGHT VALVE - SHORT TO GROUND Check Harness for damage.
33119 33 SWING RIGHT VALVE - OPEN CIRCUIT Check Harness for damage.
33120 33 TELESCOPE IN VALVE - SHORT TO Check Harness for damage.
BATTERY
33121 33 SWING RIGHT VALVE - SHORT TO Check Harness for damage.
BATTERY
33122 33 SWING LEFT VALVE - SHORT TO GROUND Check Harness for damage.
33123 33 TELESCOPE OUT VALVE - SHORT TO Check Harness for damage.
BATTERY
33130 33 THROTTLE ACTUATOR - SHORT TO Check Harness for damage.
GROUND
33131 33 THROTTLE ACTUATOR - OPEN CIRCUIT Check Harness for damage.
33132 33 THROTTLE ACTUATOR - SHORT TO Check Harness for damage.
BATTERY
33170 33 LIFT DOWN VALVE - OPEN CIRCUIT Check Harness for damage.
33171 33 LIFT DOWN VALVE - SHORT TO BATTERY Check Harness for damage.
33172 33 LIFT DOWN VALVE - SHORT TO GROUND Check Harness for damage.
33175 33 JIB ROTATE LEFT VALVE - OPEN CIRCUIT Check Harness for damage.
33176 33 JIB ROTATE LEFT VALVE - SHORT TO Check Harness for damage.
BATTERY
GROUND
33178 33 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT Check Harness for damage.
33179 33 JIB ROTATE RIGHT VALVE - SHORT TO Check Harness for damage.
BATTERY
GROUND
33182 33 LIFT VALVES - SHORT TO BATTERY Check Harness for damage.
33186 33 TELESCOPE OUT VALVE - OPEN CIRCUIT Check Harness for damage.
33188 33 TELESCOPE OUT VALVE - SHORT TO Check Harness for damage.
GROUND
33189 33 TELESCOPE IN VALVE - OPEN CIRCUIT Check Harness for damage.
33190 33 TELESCOPE IN VALVE - SHORT TO GROUND Check Harness for damage.
33207 33 HORN - OPEN CIRCUIT Check Harness for damage.
33208 33 HORN - SHORT TO BATTERY Check Harness for damage.
33209 33 HORN - SHORT TO GROUND Check Harness for damage.
33279 33 GLOWPLUG - OPEN CIRCUIT Check Harness for damage.
33280 33 GLOWPLUG - SHORT TO BATTERY Check Harness for damage.
800S HC3, 860SJ HC3 31222415 251

Fault Codes

33281 33 GLOWPLUG - SHORT TO GROUND Check Harness for damage.
33287 33 LIFT - CURRENT FEEDBACK READING TOO The UGM shall suspend Lift Up and Down
LOW command and revert to Open Loop
Current control for Lift;
The UGM shall limit Lift Up and Down to
Creep speed after controls initialized.
33295 33 SWING LEFT VALVE - OPEN CIRCUIT Check Harness for damage.
33306 33 SWING LEFT VALVE - SHORT TO BATTERY Check Harness for damage.
33314 33 FLOW CONTROL VALVE - OPEN CIRCUIT Check Harness for damage.
33315 33 FLOW CONTROL VALVE - SHORT TO Check Harness for damage.
BATTERY
33316 33 FLOW CONTROL VALVE - SHORT TO Check Harness for damage.
GROUND
33317 33 DRIVE FORWARD VALVE - OPEN CIRCUIT Check Harness for damage.
33318 33 DRIVE FORWARD VALVE - SHORT TO Check Harness for damage.
BATTER
33319 33 DRIVE FORWARD VALVE - SHORT TO Check Harness for damage.
GROUND
33320 33 DRIVE REVERSE VALVE - OPEN CIRCUIT Check Harness for damage.
33321 33 DRIVE REVERSE VALVE - SHORT TO Check Harness for damage.
BATTERY
33322 33 DRIVE REVERSE VALVE - SHORT TO Check Harness for damage.
GROUND
33323 33 LIFT UP VALVE - OPEN CIRCUIT Check Harness for damage.
33324 33 LIFT UP VALVE - SHORT TO BATTERY Check Harness for damage.
33325 33 LIFT UP VALVE - SHORT TO GROUND Check Harness for damage.
33331 33 DRIVE - CURRENT FEEDBACK READING The UGM shall suspend Drive Forward
TOO LOW and Reverse command and revert to
Open Current loop control for Drive;
The UGM shall limit Drive Forward and
Reverse to Creep speed after controls
initialized.
33410 33 DRIVE - CURRENT FEEDBACK READING The UGM shall suspend Drive Forward
LOST and Reverse command and revert to
Open Current loop control for Drive;
The UGM shall limit Drive Forward and
Reverse to Creep speed after controls
initialized.
33412 33 SWING VALVES - SHORT TO BATTERY Check Harness for damage.
33414 33 SWING - CURRENT FEEDBACK READING Check wiring and coil.
TOO LOW
33415 33 FLOW CONTROL VALVE - CURRENT The UGM shall suspend Flow Control and
FEEDBACK READING TOO LOW revert to Open Current loop control for
Flow Control.
252 31222415 800S HC3, 860SJ HC3

Fault Codes

33417 33 LIFT - CURRENT FEEDBACK READING LOST The UGM shall suspend Lift Up and Down
command and revert to Open Loop
Current control for Lift;
The UGM shall limit Lift Up and Down to
Creep speed after controls initialized.
33418 33 SWING - CURRENT FEEDBACK READING Check wiring and coil.
LOST
33419 33 FLOW CONTROL VALVE - CURRENT The UGM shall suspend Flow Control and
FEEDBACK READING LOST revert to Open Current loop control for
Flow Control.
33488 33 SWING FLOW CONTROL VALVE - SHORT Check Harness for damage.
TO GROUND
33575 33 ECM PULL DOWN RESISTOR - OPEN Check Harness for damage.
CIRCUIT
340 34 <<< PLATFORM OUTPUT DRIVER
>>>
341 34 PLATFORM LEVEL UP VALVE - OPEN Check Harness for damage.
CIRCUIT
BATTERY
GROUND
BATTERY OR OPEN CIRCUIT
345 34 PLATFORM LEVEL DOWN VALVE - OPEN Check Harness for damage.
CIRCUIT
TO BATTERY
TO GROUND
TO BATTERY OR OPEN CIRCUIT
349 34 PLATFORM ROTATE LEFT VALVE - OPEN Check Harness for damage.
CIRCUIT
TO BATTERY
TO GROUND
3412 34 PLATFORM ROTATE RIGHT VALVE - OPEN Check Harness for damage.
CIRCUIT
TO BATTERY
TO GROUND
3415 34 JIB LIFT UP VALVE - OPEN CIRCUIT Check Harness for damage.
3416 34 JIB LIFT UP VALVE - SHORT TO BATTERY Check Harness for damage.
800S HC3, 860SJ HC3 31222415 253

Fault Codes

3417 34 JIB LIFT UP VALVE - SHORT TO GROUND Check Harness for damage.
3418 34 JIB LIFT DOWN VALVE - OPEN CIRCUIT Check Harness for damage.
BATTERY
GROUND
3421 34 JIB ROTATE LEFT VALVE - OPEN CIRCUIT Check Harness for damage.
BATTERY
GROUND
3424 34 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT Check Harness for damage.
BATTERY
GROUND
430 43 <<< ENGINE >>>
431 43 FUEL SENSOR - SHORT TO BATTERY OR Energize fuel sensor per System
OPEN CIRCUIT Indicators
432 43 FUEL SENSOR - SHORT TO GROUND Energize fuel sensor per System
Indicators
433 43 OIL PRESSURE - SHORT TO BATTERY Deutz engine only.
434 43 OIL PRESSURE - SHORT TO GROUND Deutz engine only.
- Not reported during engine start.
435 43 COOLANT TEMPERATURE - SHORT TO Deutz engine only.
GROUND
436 43 FORD FAULT CODE ##
437 43 ENGINE TROUBLE CODE Report and log in Help
If [(MACHINE SETUP > DEUTZ EMR2) or
(MACHINE SETUP > DEUTZ EMR4) and
SPN:FMI = 535:7], prohibit engine
cranking.
438 43 HIGH ENGINE TEMP Ford / Deutz engine only.
439 43 AIR FILTER BYPASSED Check Air filter for clogging
4310 43 NO ALTERNATOR OUTPUT Activate the No Charge indicator J4-26
per System Indicators.
4311 43 LOW OIL PRESSURE Ford / Deutz engine only.
4312 43 485 COMMUNICATIONS LOST
4313 43 THROTTLE ACTUATOR FAILURE
4314 43 WRONG ENGINE SELECTED - ECM
DETECTED
4322 43 LOSS OF ENGINE SPEED SENSOR Diesel engine only.
254 31222415 800S HC3, 860SJ HC3

Fault Codes

4323 43 SPEED SENSOR READING INVALID SPEED Diesel engine only.
4331 43 SOOT LOAD WARNING - LOW Check Engine.
4332 43 SOOT LOAD WARNING - HIGH Check Engine.
4333 43 SOOT LOAD WARNING - SEVERE Check Engine.
4334 43 ENGINE COOLANT - LOW LEVEL MACHINE SETUP > ENGINE SHUTDOWN =
ENABLED then shutdown the engine;
Activate High Engine Temperature
indicator J4-28.
440 44 <<< BATTERY SUPPLY >>>
441 44 BATTERY VOLTAGE TOO LOW - SYSTEM
SHUTDOWN
442 44 BATTERY VOLTAGE TOO HIGH - SYSTEM
SHUTDOWN
445 44 BATTERY VOLTAGE LOW
660 66 <<< COMMUNICATION >>>
662 66 CANBUS FAILURE - PLATFORM MODULE
664 66 CANBUS FAILURE - ACCESSORY MODULE Check the Wiring.
666 66 CANBUS FAILURE - ENGINE CONTROLLER ECM equipped engine only.
6620 66 CANBUS FAILURE - UMS SENSOR
6622 66 CANBUS FAILURE - TCU MODULE
6623 66 CANBUS FAILURE - GATEWAY MODULE
6629 66 CANBUS FAILURE - TELEMATICS CANBUS
LOADING
TOO HIGH
6657 66 CANBUS FAILURE - TEMPERATURE SENSOR The UGM shall set Low Temperature
Cutout state = Faulty If the Machine is in
Platform Mode and if the Boom is Above
Elevation;
The UGM shall suspend motion;
The UGM shall limit the machine to
Creep speed after controls initialized If
the Machine is in Platform Mode and if
the Boom is not Above Elevation.
671 67 ACCESSORY FAULT
680 68 <<< TELEMATICS >>>
681 68 REMOTE CONTRACT MANAGEMENT
OVERRIDE - ALL FUNCTIONS IN CREEP
66111 Refer to Section – ClearSky CSV3 Smart Fleet DTC Fault Codes, page 257, for details.
682, 683, 684, 685, 686
810 81 <<< TILT SENSOR >>>
813 81 CHASSIS TILT SENSOR NOT CALIBRATED
815 81 CHASSIS TILT SENSOR DISAGREEMENT
800S HC3, 860SJ HC3 31222415 255

Fault Codes

816 81 UMS SENSOR NOT CALIBRATED
817 81 UMS SENSOR FAULT
820 82 <<< PLATFORM LOAD SENSE >>>
825 82 LSS HAS NOT BEEN CALIBRATED UGM to set Platform Load State =
Overloaded
826 82 RUNNING AT CREEP - PLATFORM
OVERLOADED
827 82 DRIVE & BOOM PREVENTED - PLATFORM
OVERLOADED
828 82 LIFT UP & TELE OUT PREVENTED -
PLATFORM OVERLOADED
8639 86 FRONT LEFT STEER VALVE - OPEN CIRCUIT Check Harness for damage.
8640 86 FRONT LEFT STEER VALVE - SHORT TO Check Harness for damage.
BATTERY
8641 86 FRONT LEFT STEER VALVE - SHORT TO Check Harness for damage.
GROUND
8642 86 FRONT RIGHT STEER VALVE - OPEN Check Harness for damage.
CIRCUIT
8643 86 FRONT RIGHT STEER VALVE - SHORT TO Check Harness for damage.
BATTERY
8644 86 FRONT RIGHT STEER VALVE - SHORT TO Check Harness for damage.
GROUND
8645 86 REAR LEFT STEER VALVE - OPEN CIRCUIT Check Harness for damage.
8646 86 REAR LEFT STEER VALVE - SHORT TO Check Harness for damage.
BATTERY
8647 86 REAR LEFT STEER VALVE - SHORT TO Check Harness for damage.
GROUND
8648 86 REAR RIGHT STEER VALVE - OPEN CIRCUIT Check Harness for damage.
8649 86 REAR RIGHT STEER VALVE - SHORT TO Check Harness for damage.
BATTERY
8650 86 REAR RIGHT STEER VALVE - SHORT TO Check Harness for damage.
GROUND
871 87 RETURN FILTER BYPASSED Check Hydraulic Return Filter.
872 87 CHARGE PUMP FILTER BYPASSED Check Charge Pump Filter.
873 87 MACHINE SAFETY SYSTEM OVERRIDE Response described in MSSO
OCCURRED Influence on Machine Operation section.
998 99 EEPROM FAILURE - CHECK ALL SETTINGS Disable all machine and engine functions
(i.e., command engine shutdown and do
not permit start); reset the section of
EEPROM where the failure occurred to
defaults.
9910 99 FUNCTIONS LOCKED OUT - PLATFORM Activate the platform alarm continuously
MODULE SOFTWARE VERSION IMPROPER Creep mode is active
256 31222415 800S HC3, 860SJ HC3

Fault Codes

If Platform Mode is active, disable all
Drive, Steer, and Boom functions and do
not permit Machine Enable.
9914 99 PLATFORM MODULE SOFTWARE UPDATE
REQUIRED
9915 99 CHASSIS TILT SENSOR NOT GAIN
CALIBRATED
9916 99 CHASSIS TILT SENSOR GAIN OUT OF
RANGE
9919 99 GROUND SENSOR REF VOLTAGE OUT OF Not reported during power-up.
RANGE
9920 99 PLATFORM SENSOR REF VOLTAGE OUT OF Not reported during power-up.
RANGE
9921 99 GROUND MODULE FAILURE - HIGH SIDE
DRIVER CUTOUT FAULTY
9922 99 PLATFORM MODULE FAILURE - HWFS
CODE 1
9923 99 GROUND MODULE FAILURE - HWFS CODE
1
9924 99 FUNCTIONS LOCKED OUT - MACHINE NOT Display ??? or NO MODEL at Analyzer
CONFIGURED MACHINE SETUP menu MACHINE SETUP-
>MODEL NUMBER
Do not report any other faults
Disable all machine and engine functions
(i.e., command engine shutdown and do
not permit start).
9944 99 CURRENT FEEDBACK GAINS OUT OF RANGE A gain of 1 is used for the factory gain(s)
that was out of range; all functions shall
be placed in Creep mode.
9945 99 CURRENT FEEDBACK CALIBRATION
CHECKSUM INCORRECT
9979 99 FUNCTIONS LOCKED OUT - GROUND Disable all machine and engine functions
MODULE SOFTWARE VERSION IMPROPER (i.e., command engine shutdown and do
not permit start).
6.3.2 ClearSky CSV3 Smart Fleet DTC Fault Codes

Table 35. Diagnostic Trouble Codes (DTC) – Telematics and Communication
Help Message Flash Trigger

DTC Action Latch Condition
Code
• DriveState = CREEP (or ELEVATED) DTC 66111 is active OR a FUNCTIONAL

FUNCTIONS IN CREEP - 6_8
682 • LiftUpState = CREEP INTERLOCK is received and REMOVAL IN- Latched
CONNECTIVITY INTERLOCK
TERLOCK is set to CREEP
• LiftDownState = CREEP
While TransportState = FALSE
FUNCTIONS IN CREEP AND DTC 66111 is active OR a FUNCTIONAL
683 RESTRICTED TO TRANSPORT 6_8 • DriveState = PREVENTED INTERLOCK is received and REMOVAL IN- Latched
- CONNECTIVITY INTERLOCK TERLOCK is set to CREEP + TSPRT LK
• LiftUpState = PREVENTED
800S HC3, 860SJ HC3 31222415 257

Fault Codes
Table 35. Diagnostic Trouble Codes (DTC) – Telematics and Communication (continued)
Help Message Flash Trigger

DTC Action Latch Condition
Code
While TransportState = TRUE
• DriveState = CREEP (or ELEVATED)
• DriveState = PREVENTED DTC 66111 is active OR a FUNCTIONAL

FUNCTIONS LOCKED OUT - 6_8
684 • LiftUpState = PREVENTED INTERLOCK is received and REMOVAL IN- Latched
CONNECTIVITY INTERLOCK
TERLOCK is set to MACHINE LOCKOUT
• DriveState = PREVENTED
ALL FUNCTIONS LOCKED DTC 66111 is active OR a FUNCTIONAL
685 OUT - CONNECTIVITY 6_8 • LiftDownState = PREVENTED INTERLOCK is received and REMOVAL IN- Latched
INTERLOCK TERLOCK is set to MACHINE LOCKOUT
AND
Engine Shutdown Command Sent to ECU
(Only for Engine Driven Machines)
DTC 66111 is active OR a FUNCTIONAL

ENGINE START PREVENTED 6_8 Engine Start Prevented
686* INTERLOCK is received and REMOVAL IN- Not Latched
- CONNECTIVITY INTERLOCK
TERLOCK is set to MACHINE LOCKOUT
After Startup complete, CM messages
GM to Ignore Processes that require CAN Commu- are received then subsequently lost for
CANBUS FAILURE - 6_6 > 1000ms OR No CM messages 3000ms
66111 nication / Requests / Acknowledgements with Not Latched
CONNECTIVITY MODULE after startup has completed and Ma-
CM
chine Setup CLEARSKY is set to CS550
Note: Creep restricts drive motors to a low maximum speed.
Note: * This DTC is applicable only for Engine Driven Machines.
258 31222415 800S HC3, 860SJ HC3

SECTION 7
HYDRAULICS
7.1 GENERAL INFORMATION AND SAFETY
This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, as well as where and how to check
those pressures.
Electrical and hydraulic functions are often related. Verify that electrical components of the circuit are functioning properly whenever
troubleshooting the hydraulic circuit.
Always check the following before beginning to troubleshoot a circuit that is not functioning correctly.
1. Check hydraulic oil level in reservoir. Level should be in middle of sight glass with all cylinders retracted.
2. Check hoses, tubes, fittings and other hydraulic components for leaks, bends, kinks, interference, etc.
3. Check for air in the hydraulic system. Erratic machine performance and/or spongy cylinder operation are signs of air in the
hydraulic system. If air in the hydraulic system is suspected, you will hear air leakage when hydraulic fittings are loosened and see
air bubbles in the hydraulic fluid.
4. Loose fittings, faulty O-rings or seals, trapped oil, leaks, system opened for service, etc., can cause air in the system. Determine
what is causing air to enter the system and correct it. Bleed air from the system.
WARNING
DO NOT service the machine without following all safety precautions as outlined in
Section – Safety, page 11, of this manual.
Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various
hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition source is present.
Hydraulic fluid has a flash point that ranges from 300° - 600°F (150° - 318°C) and an auto-ignition temperature of 500° - 750°F (262° - 402°
C) (If applicable).
Accordingly, periodically inspect all hydraulic system components, hoses, tubes, lines, fittings, etc. Carefully examine any deterioration
and determine whether any further use of the component would constitute a hazard. If in doubt, replace the component.
WARNING
Never work under an elevated boom until boom has been safely restrained from
movement.
Ensure platform is empty before performing any maintenance work at or near to
cylinder assembly.
Whenever you disconnect a hydraulic line, coupler, fitting or other component, slowly and cautiously loosen the part involved. A hissing
sound or slow seepage of hydraulic fluid may occur in most cases. After the hissing sound has ceased, continue removing the part. Any
escaping oil should be directed into an appropriate container. Cap or otherwise block off the part to prevent further fluid seepage.
800S HC3, 860SJ HC3 31222415 259

Hydraulics
Hydraulic system maintenance will, at times, require that the engine be operated. Always follow safety precautions.
A major cause of hydraulic component failure is contamination. Keeping the hydraulic fluid as clean as possible will help avoid
downtime and repairs. Dirty or contaminated hydraulic oil can damage internal components and void the manufacturer’s warranty.
When servicing the system, cap or plug hydraulic fittings, hoses and tube assemblies. Plug all cylinder ports, valves and the hydraulic
reservoir, and openings until installation occurs. Protect threads from contamination and damage.
Manufacturer’s recommended hydraulic oil cleanliness levels are based on the three digit ISO code for 6 micron/14 micron particle sizes
found in one ml of fluid (reference ISO 4406: 199(E). The acceptable level is 17/14 or below; anything higher requires system cleaning
and filter replacement.
Note: The human eye can only distinguish particles down to 40 microns.
Refer to Section – Preventive Maintenance and Inspection Schedules, page 38, for the appropriate maintenance intervals based on hours of
operation, but if your equipment is exposed to extremely dirty or hostile conditions service may be required more frequently. Always use
OEM filters to assure the necessary filtration requirements are met.
Note: Replace the reservoir breathers to prevent dust contamination into the reservoir.
Some hydraulic functions are actuated by interfacing with electrical system components (switches, solenoids and sensors). When the
hydraulic system is not functioning properly, check the electrical aspect of the malfunctioning circuit also. Refer to Section – Electrical
Schematics, page 711, in this manual.
7.2 THEORIES OF OPERATION
7.2.1 Cylinders
Cylinders are of the single and double acting type.
The main lift cylinder is single acting. A single acting cylinder is actuated by directing pressurized oil to one side of the piston to extend
the cylinder. The distance extended is controlled by a valve used to actuate the cylinder. A single acting cylinder is retracted by opening
a valve to provide an unpressurized path for oil to leave the cylinder.
The platform level, jib lift, telescope, and steer cylinders are double acting. A double acting cylinder is actuated by directing pressurized
oil to one side of the piston to extend the cylinder. The distance extended is controlled by a valve used to actuate the actuate the
cylinder. A double acting cylinder is retracted by directing pressurized oil to the opposite side of the piston. The distance retracted is
controlled by a valve used to actuate the cylinder.
The chassis level cylinders can function as both single and double acting cylinders.
Holding valves are used in the cylinders on this machine to prevent retraction should a hydraulic line or hose rupture or develop a leak
between the cylinder and the associated control valve.
7.2.2 Valves
Solenoid Control Valves
Solenoid Control Valves are used to control oil flow, activating and deactivating functions.
When a circuit is activated and the control valve solenoid energizes, the valve spool is shifted and oil flow is re-routed to enable a
function. Once the circuit is deactivated the valve spool returns to neutral (center) and oil flow deactivating the function.
A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spool is machine fitted in the bore of
the valve body. Lands on the spool divide the bore into various chambers, which, when the spool is shifted, align with corresponding
ports in the valve body re-routing oil flow. At the same time other ports would be blocked to flow. The spool is spring-loaded to center
position, therefore when the control is released, the spool automatically returns to neutral.
Poppet Valves
Poppet Valves are used control oil flow, activating and deactivating functions. They can be either a normally open or normally closed
design. In the closed position, poppet valves operate like a check valve blocking oil flow. In the open position, poppet valves allow oil
flow to pass.
260 31222415 800S HC3, 860SJ HC3

Hydraulics
Relief Valves
Relief valves are installed at various points within the hydraulic system to protect associated systems and components against excessive
pressure. Excessive pressure can be developed when a component reaches it's limit of travel and pressurized fluid continues to be
supplied. The relief valve supplies an alternate path of flow thus preventing system components from being subjected to excessive
pressure, torque, and/or force. The relief valve is installed in the pressurized side of the circuit with the relief pressure set slightly higher
than the load requirement. The valve diverts excess pressurized oil back to the reservoir when the set relief pressure of the valve is
exceeded.
Crossover Relief Valves
Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system.
When the circuit is activated and the required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the
reservoir. Individual, integral relief’s are provided for each side of the circuit.
Proportional Valve
Oil flow is proportional to the amount of voltage supplied to the valve coil. Voltage can be regulated by the position of the machine
joystick, the position of the rheostat on the platform console box, and machine personality settings.
7.3 HYDRAULIC COMPONENTS
To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be
familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components
that are referred to throughout this section.
800S HC3, 860SJ HC3 31222415 261

Hydraulics
Figure 48. Hydraulic Component Location
1. Main Valve 4. Auxiliary Pump 7. Dual Select Valve
2. Platform Valve Filter 5. Platform Valve 8. Flow Divider (2WD)

3. Dual Flow Divider (4WD) 6. Hydraulic Filter 9. High Pressure Filter
Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the machine until the
hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the
use of a calibrated gauge. Pressure readings are acceptable if they are within ± 5% of specified pressures.
To ensure all pressures are set correctly, the following procedures must be followed in order.
1. Start-up after overhaul or replacement of components.
2. Set up of the function pump.
3. Adjustments made at the main valve block.
4. Adjustments made at the platform valve.
262 31222415 800S HC3, 860SJ HC3

Hydraulics
7.3.1 Start-up After Overhaul or Replacement of Components

PRE-FILL OF BOTH THE DRIVE AND FUNCTION PUMP
Machine without oil cooler: When filling the oil tank, fill it to the very top of the tank. This will give you enough head pressure from the
tank to gravity fill the case on both pumps. The excess oil will be used to fill the cylinders during start up. The top case port on the
outside of the drive pump has a 3/4 in. tee fitting. Remove the cap from the end of the tee. You should see oil in 1-2 minutes, tighten up
the cap. The drive pump case is done. Next, go the function pump, using a 3/8 in. Allen wrench remove the plug on the inside of the
pump next to the turn-table side sheet. When oil flows out of the pump, 2-3 minutes, re-install the plug. Both pumps are pre-filled. Not
doing this causes the pumps to start dry, and reduces the efficiency of the pump and can cause premature failure.
Machine with oil cooler: When filling the oil tank, fill it to the very top of the tank. This will help give you enough head pressure from
the tank to gravity fill the case on both pumps. The top case port on the outside of the pump has a 3/4 in. tee fitting. Remove the cap
from the center of the tee. You should see oil in 1-2 minutes. If not, depending on hose routing, the drive pump may not gravity feed. Oil
has to flow through the oil cooler to get to the pump. Hose up an external hand pump to this tee fitting, and give it about six pumps
after it has started pumping oil. This should be sufficient. Install the cap back onto the tee fitting. The drive pump is done. Next, go the
function pump, using a 3/8 in. Allen wrench remove the plug on the inside of the pump next to the turn-table side sheet. When oil flows
out of the pump, 2-3 minutes, re-install the plug. Both pumps are pre-filled. Not doing this causes the pumps to start dry, and reduces
the efficiency of the pump and can cause premature failure.
PURGING OF THE FUNCTION PUMP SUCTION HOSE.

Large pockets of air get trapped in this line and must be removed at low pressure. Head pressure from the tank is not enough. Here are
three methods of purging the air from the hose at low pressure.
1. At the main control valve, remove the 3/4 in. hose from port “P1” and remove the 1 inch hose from port “T” by using a 12-16
connector, connect them together. Start the machine and let it run for approx. 10 seconds. Shut off the machine, remove the 12-16
adapter and re-hose.
2. Remove the 3/4 in. hose from port “P1” and hold it into a 5 gallon bucket and start the machine. The air should purge very quickly,
(seconds). Shut off the machine and re-hose.
3. Remove the 3/4 in. hose from port “P1”, using a #12 male union add approx. 30 in. of 3/4 in. hose to it. Remove the return filter cap
at the top of the tank, lift out the element making sure the canister stays in the tank. Hold the hose end down in the canister and
start the machine and let it run approx. 10 seconds. Re-install the filter and re-hose the machine.
Note: **If using a shop vac to create suction on the oil tank while doing maintenance, both steps “1” and “2” will need done.
Note: **If installing a new drive pump, step “1” will need done.
Note: **If installing a new function pump, step “1” and “2” will need done.
Note: **If installing a new function pump and the suction hose is capped without draining a lot of oil out of the hose, which creates a
large air void, step “2” will not need to be done.
Note: **When operating a function such as Lift Up, if the function pump makes a loud noise and the lift up stops and starts, that is a
sign of cavitation, air going through the pump at high pressure. This will in a short time destroy the pump and contaminate the
entire system. Make sure all suction hoses are tight and free of leaks at the tank and pump. A suction hose does not leak when
the engine is running, it will allow air to be drawn into the pump causing cavitation. After the machine is shut down, then you
will see a very slow leak.
800S HC3, 860SJ HC3 31222415 263

Hydraulics
7.3.2 Set Up of the Function Pump

STAND BY PRESSURE OR LOAD SENSE PRESSURE
1. Install a low pressure gauge at port “M1” of the main valve block. A low pressure gauge capable of reading 500 psi.
2. Start the engine from the ground control. The gauge should read between 400-440 psi (27.5 to 30 Bar). To make an adjustment to
this pressure, go to the engine compartment and locate the function pump.
264 31222415 800S HC3, 860SJ HC3

Hydraulics
3. There are (2) adjustments at the top of the pump. They are located on the pump compensator which has (4) bolts mounting it to
the pump. The stand by adjustment is at the top. To adjust this, a 4 mm and 6 mm allen wrench will be needed. The adjustment
screw is facing the front of the pump, or toward the engine.
a. First, using the 4 mm wrench, loosen the setscrew on the side of the compensator (facing you) which is in line with the
adjustment screw. This is a jam nut screw which holds the main adjustment from turning. Loosen it 1 turn.
b. Next, using the 6 mm wrench adjust the main adjustment clockwise to increase or counterclockwise to decrease. The pressure
should read between 400-440 psi (27.5 to 30 Bar).
HIGH PRESSURE RELIEF

1. Install a high pressure gauge at the “M1” port of the main valve block.
2. Activate telescope in and hold. The gauge should read 2600 psi.
800S HC3, 860SJ HC3 31222415 265

Hydraulics
3. To make an adjustment to this pressure, go back to the engine compartment to the function pump. The high pressure relief
adjustment is the lower one of the (2) on the compensator. To adjust this, a 4 mm and 6 mm allen wrench will be needed. The
adjustment screw is facing the shaft end of the pump, or toward the engine.
a. First, using the 4 mm wrench, loosen the setscrew on the side of the compensator (facing you) which is in line with the
adjustment screw. This is a jam nut screw which holds the main adjustment from turning. Loosen it 1 turn.
b. Next, using the 6 mm wrench adjust the main adjustment clockwise to increase or counterclockwise to decrease. This
adjustment will be reset at the end of this procedure to 2500 psi (172 Bar). This is the maximum relief pressure for all
functions governed by this pump.
7.3.3 Adjustments Made at the Main Valve Block

SWING LEFT AND RIGHT
1. Lock the Turntable lock pin.
2. Install the high pressure gauge at port M2.
3. From the ground control, activate swing RIGHT. the gauge should read 1700 psi (117 Bar).
4. The adjustment cartridge is located on the left face of the valve block. There are two adjustable relief valves on this face and the
swing relief is toward the top of the block. Turn clockwise to increase, counterclockwise to decrease.
Note: Swing left is not used to set the relief valve. The swing left pressure will default to approximately 1575 psi (108.6 bar).
STEER
1. Install a high pressure gauge at port M3. Activate steer left or right. The gauge should read 2500 psi (172 Bar).
2. The adjustment cartridge is located on the left face of the valve block. There are two adjustable relief valves on this face and the
steer relief is the lower one. Turn clockwise to increase, counterclockwise to decrease.
266 31222415 800S HC3, 860SJ HC3

Hydraulics
5
1
3
Figure 49. Main Valve Identification
1. Main Dump Valve (Coil Resistance 7.1 Ohms @ 20°C) (50–55 ft. lb. (68–75 Nm)) 4. Lift Valve (Coil resistance 8.8 Ohms @ 20°C) (19–21 ft. lb. (26–29 Nm))
2. Steer Valve (Coil Resistance 7.1 Ohms @ 20°C) (24–26 ft. lb. (33–36 Nm)) 5. Swing Valve (Coil Resistance 7.1 Ohms @ 20°C) (24–26 ft. lb. (33–36 Nm))
3. Tele Solenoid Valve (Coil resistance 8.8 Ohms @ 20°C) (19–21 ft. lb. (26–29 Nm)) 6. Telescope Flow Valve (Coil resistance 4.5 Ohms @ 20°C) (50–55 ft. lb. (68–75 Nm))
7.3.4 Adjustments Made at the Platform Valve Assembly

PLATFORM JIB UP AND DOWN
1. Install a high pressure gauge at port M of the platform valve. Activate jib down, you should read 2250 psi (155 Bar).
2. The jib down relief valve is located on the front face of the platform valve. Turn clockwise to increase, counter-clockwise to
decrease.
800S HC3, 860SJ HC3 31222415 267

Hydraulics
5 4
1001244114-B
MAF26171B
Figure 50. Platform Valve Identification (800S HC3)
1. Level Up and Down 4. Rotate Orifice
2. Platform Rotate Valve 5. Platform Level Orifice

3. Platform Dump Valve 6. Check Valve
268 31222415 800S HC3, 860SJ HC3

Hydraulics
MAF26181
Figure 51. Platform Valve Identification (860SJ HC3)
1. Platform Level Solenoid Valve 3. Platform Rotator Solenoid Valve

2. Platform Jib Solenoid Valve 4. Platform Dump Valve
800S HC3, 860SJ HC3 31222415 269

Hydraulics
7.4 TORQUE VALUES
7.4.1 Valve Torque Specifications
Figure 52. Main Valve Cartridge Torque Values
Table 36. Cartridge Torque Values

ft. lbs. Nm
1 33-37 45-50
2 19-21 26-29
3 19-21 26-29
4 14-16 19-22
5 19-21 26-29
6 23-27 31-37
7 33-37 45-50
8 24-26 33-36
9 50-55 68-75
10 19-21 26-29
11 24-26 33-36
270 31222415 800S HC3, 860SJ HC3

Hydraulics
Table 36. Cartridge Torque Values (continued)

ft. lbs. Nm
12 24-26 33-36
13 50-55 68-75
14 19-21 26-29
15 70-80 95-108
16 33-37 45-50
17 50-55 68-75
18 95-100 129-136
19 23-27 31-37
20 23-27 31-37
Table 37. Coil Torque Values

ft. lbs. Nm
A 5-7 7-10
B 5-7 7-10
C 5-7 7-10
800S HC3, 860SJ HC3 31222415 271

Hydraulics
Figure 53. Platform Valve Cartridge Torque Values (800S HC3)

ft. lbs. Nm
1 NA NA
2 20 27.1
3 25 33.9
4 20 27.1
5 20 27.1
6 20 27.1

ft. lbs. Nm
A 5 6.7
B 6 8
272 31222415 800S HC3, 860SJ HC3

Hydraulics
2,A
3,A
4,A
1,B
5
8
7
6
MAF26191
Figure 54. Platform Valve Cartridge Torque Values (860SJ HC3)

ft. lbs. Nm
1 25 33.9
2 20 27.1
3 20 27.1
4 20 27.1
5 20 27.1
6 20 27.1
7 20 27.1
8 20 27.1

ft. lbs. Nm
A 5 6.7
B 6 8
800S HC3, 860SJ HC3 31222415 273

Hydraulics
7.5 HYDRAULIC DIAGRAM - CHASSIS
7.5.1 Oscillating Axle
274 31222415 800S HC3, 860SJ HC3

Hydraulics
7.5.2 4WD (without arctic package)
800S HC3, 860SJ HC3 31222415 275

Hydraulics
7.5.3 4WD, 2WS (with arctic package)
276 31222415 800S HC3, 860SJ HC3

Hydraulics
7.5.4 4WD, 2WS (with Tow bar) (with Arctic package) For Deutz Engine
800S HC3, 860SJ HC3 31222415 277

Hydraulics
278 31222415 800S HC3, 860SJ HC3

Hydraulics
7.5.5 4WD, 2WS For Deutz Engine
800S HC3, 860SJ HC3 31222415 279

Hydraulics
7.5.6 4WD, 2WS (with Tow bar) For Deutz Engine
280 31222415 800S HC3, 860SJ HC3

Hydraulics
800S HC3, 860SJ HC3 31222415 281

282
SECTION 8
ELECTRICALS
8.1 GENERAL INFORMATION
8.1.1 Applying Silicone Dielectric Compound to Electrical Connections
Note: This section is not applicable for battery terminals.
CAUTION
JLG PN 0100048 Dielectric Grease (Novagard G661) is the only material approved
for use as a dielectric grease.
Note: Do NOT apply dielectric grease to the following connections:
• Main Boom Rotary sensor connections (on Celesco Sensor),
• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electrical connections except for those mentioned above for the following reasons:
• To prevent oxidation at the mechanical joint between male and female pins.
• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. This procedure applies to all plug
connections not enclosed in a box. Silicone grease should not be applied to connectors with external seals.
1. To prevent oxidation, silicone grease must be packed completely around male and female pins on the inside of the connector
prior to assembly. This is most easily achieved by using a syringe.
Note: Over a period of time, oxidation increases electrical resistance at the connection, eventually causing circuit failure.
2. To prevent shorting, silicone grease must be packed around each wire where they enter the outside of the connector housing.
Also, silicone grease must be applied at the joint where the male and female connectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the connector should also be sealed.
CAUTION
This condition is especially common when machines are pressure washed since the
washing solution is much more conductive than water.
3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only.
Note: Curing-type sealants might also be used to prevent shorting and would be less messy, but would make future pin removal
more difficult.
When applied to electrical connections, dielectric grease helps to prevent corrosion of electrical contacts and improper conductivity
between contacts from moisture intrusion. Open and sealed connectors benefit from the application of dielectric grease.
Dielectric grease shall be applied to all electrical connectors at the time of connection (except those noted under Exclusions).
800S HC3, 860SJ HC3 31222415 283

Electricals
8.1.2 Dielectric Grease Application

Dielectric grease helps to prevent corrosion of electrical contacts and improper conductivity between contacts from moisture intrusion.
Non-waterproof connectors benefit from the application of dielectric grease.
Installation
The following is general guidance for the installation of dielectric grease in a connector system.
• Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors.
• Apply dielectric grease to plug/male connector housing which typically contains sockets contact/female terminals.
• Leave a layer of dielectric grease on the mating face of the connector, completely covering each connector terminal hole. Refer the
pictures shown below.
• Assemble the connector system immediately to prevent moisture ingress or dust contamination.
The following connector systems are specifically addressed because of their widespread use at JLG. However, this guidance may be
applied to similar devices.
AMP Mate-N-Lok
This connector system is widely used inside enclosures for general-purpose interconnect. Follow the general guidance for installation.
AMP Faston
This connector system is typically used on operator switches at JLG. Follow the general guidance for installation.
AMP Micro-Fit
This connector system is typically used on control modules at JLG. Follow the general guidance for installation.
AMP Mini Fit Jr

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Mini Fit Sr
DIN Connectors
This connector is typically used on hydraulic valves. Follow the installation instructions.
Exceptions
Some waterproof connector applications do benefit from dielectric grease, and some non waterproof connectors do not benefit from
dielectric grease.
In the exceptions below, we have found dielectric grease is not needed for some applications, and in some cases can interfere with the
intended connection. Dielectric grease shall be used as an exception in other applications.
Enclosures
Application of dielectric grease is not required in properly sealed enclosures. To meet criteria, the enclosure must be rated to at least
IP56 (dust protected; protected from powerful jets of water).
Carling Switch Connectors
Carling switches may experience high impedance, or discontinuity, due to silicone dielectric grease ingress when switching inductive
loads. Therefore, dielectric grease shall not be applied to Carling switch mating connectors unless specifically noted.
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8.2 ELECTRICAL CONNECTORS
BM110458A
Figure 55. Electrical Connectors - Sheet 1 of 2
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BM110459A
Figure 56. Electrical Connectors - Sheet 2 of 2
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8.2.1 Deutsch Connectors

DT/DTP Series Assembly
Figure 57. DT/DTP Contact Installation
1. Grasp crimped contact about 25mm behind the contact barrel.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.
4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedgelock will snap
into place. Rectangular wedges are not oriented. Thy may go in either way.
Note: The receptacle is shown - use the same procedure for plug.
DT/DTP Series Disassembly
Figure 58. DT/DTP Contact Removal
1. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from
the contact with a screwdriver.
3. Hold the rear seal in place, as removing the contact may displace the seal.
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HD30/HDP20 Series Assembly
Figure 59. HD/HDP Contact Installation
1. Grasp contact about 25mm behind the contact crimp barrel.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in
place.
Figure 60. HD/HDP Locking Contacts Into Position
Note: For unused wire cavities, insert sealing plugs for full environmental sealing.
HD30/HDP20 Series Disassembly
Figure 61. HD/HDP Contact Removal
1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
2. Slide tool along into the insert cavity until it engages contact and resistance is felt.
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3. Pull contact-wire assembly out of connector.
Figure 62. HD/HDP Unlocking Contacts
Note: Do Not twist or insert tool at an angle.
8.3 ELECTRICAL COMPONENT TERMINOLOGY
To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be
familiar with the name and location of the electrical components of the machine. The illustrations are provided to give visual aid. For
details of harnesses and components, refer to Section – Harness Layouts, page 290.
8.4 HARNESS LAYOUTS
Note: Service information are not available at the time of publication.
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8.5 BOARD LAYOUTS
8.5.1 Ground Control Module Pin Connections
J8
J14
J1 J7
J12
J2
J3
J4
BM109373A
Connector Pin Function Type
J1 1 ENGINE THROTTLE ACTUATOR DIGITAL OUTPUT

NATURAL 2 LP START ASSIST DIGITAL OUTPUT
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DRIVE / LEFT TRACK FORWARD

3 DIGITAL OUTPUT
COIL DIGITAL OUTPUT
4 GROUND GROUND INPUT
DRIVE / LEFT TRACK REVERSE
6 DIGITAL OUTPUT
COIL
7 LP LOCK / ELECTRIC FAN DRIVE DIGITAL OUTPUT
IGNITION ON RELAY /
10 DIGITAL OUTPUT
ALTERNATOR
11 START SOLENOID DIGITAL OUTPUT
12 ENGAGE GLOW PLUGS DIGITAL OUTPUT
13 APU ENABLE RELAY DIGITAL OUTPUT
14 ENGINE COOLANT TEMPERATURE ANALOG INPUT
15 ENGINE OIL PRESSURE ANALOG INPUT
16 ENGINE SPEED FREQUENCY INPUT
20 2-SPEED VALVE DIGITAL OUTPUT
21 CHARGE PUMP FILTER BY-PASS DIGITAL INPUT
22 GENERATOR ENABLE RELAY DIGITAL OUTPUT
23 BRAKE VALVE DIGITAL OUTPUT
24 NOT CONNECTED N/C N/C
25 RS-485 HIGH SERIAL I/O
26 RS-485 LOW SERIAL I/O
28 ANALYZER POWER VOLTAGE OUTPUT
29 ANALYZER RS-232 RX SERIAL INPUT
30 ANALYZER RS-232 TX SERIAL OUTPUT
31 ANALYZER GROUND GROUND INPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT
33 RS-485 GROUND GROUND INPUT
34 AIR FILTER BY-PASS DIGITAL INPUT
35 NOT CONNECTED DIGITAL INPUT
J2 1 STEER DUMP VALVE DIGITAL OUTPUT

GRAY 2 HORN OUTPUT DIGITAL OUTPUT
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3 TOWER TELESCOPE IN SOLENOID DIGITAL OUTPUT
4 MAIN TELESCOPE IN SOLENOID DIGITAL OUTPUT
5 PLATFORM LEVEL UP SOLENOID DIGITAL OUTPUT
PLATFORM LEVEL DOWN
7 DIGITAL OUTPUT
SOLENOID
8 RIGHT TRACK REVERSE COIL DIGITAL OUTPUT
9 NOT ALLOCATED DIGITAL OUTPUT
PLATFORM ROTATE LEFT
10 DIGITAL OUTPUT
SOLENOID
11 MAIN LIFT UP SOLENOID DIGITAL OUTPUT
12 JIB UP SOLENOID DIGITAL OUTPUT
13 MAIN DUMP VALVE DIGITAL OUTPUT
TOWER TELESCOPE OUT
15 DIGITAL OUTPUT
SOLENOID
16 MAIN TELESCOPE OUT SOLENOID DIGITAL OUTPUT
19 RIGHT TRACK FORWARD COIL DIGITAL OUTPUT
20 NOT ALLOCATED DIGITAL OUTPUT
PLATFORM ROTATE RIGHT
21 DIGITAL OUTPUT
SOLENOID
22 MAIN LIFT DOWN SOLENOID DIGITAL OUTPUT
23 JIB DOWN SOLENOID DIGITAL OUTPUT
24 RETURN FILTER BY-PASS DIGITAL INPUT
25 FUEL LEVEL SENSOR ANALOG INPUT
HEAD / TAIL LIGHT ENABLE
26 DIGITAL OUTPUT
RELAY
27 ALARM OUTPUT DIGITAL OUTPUT
31 FLOW CONTROL VALVE DIGITAL OUTPUT
32 TOWER LIFT DOWN SOLENOID DIGITAL OUTPUT
33 TOWER LIFT UP SOLENOID DIGITAL OUTPUT
34 SWING LEFT SOLENOID DIGITAL OUTPUT
35 SWING RIGHT SOLENOID DIGITAL OUTPUT
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DRIVE / LEFT TRACK CURRENT

1 GROUND INPUT
FEEDBACK
RIGHT TRACK CURRENT
2 GROUND INPUT
FEEDBACK
4 SWING CURRENT FEEDBACK GROUND INPUT
5 NOT CONNECTED GROUND INPUT
FLOW CONTROL CURRENT
6 GROUND INPUT
J3 FEEDBACK
BLACK 7 BATTERY VOLTAGE VBAT OUTPUT
8 UMS ANGLE SENSOR DIGITAL INPUT
9 CRIBBING ENGAGE SWITCH DIGITAL INPUT
10 NOT CONNECTED DIGITAL INPUT
11 CONFIGURATION #1 DIGITAL INPUT
12 NOT CONNECTED VOLTAGE OUTPUT
13 NOT CONNECTED ANALOG INPUT
14 LIFT CURRENT FEEDBACK GROUND INPUT

1 CRIBBING ENGAGED INDICATOR DIGITAL OUTPUT
2 500 LB CAPACITY LAMP DIGITAL OUTPUT
3 GLOW PLUG INDICATOR DIGITAL OUTPUT
4 ENGINE START DIGITAL INPUT
5 PLATFORM LEVEL DOWN DIGITAL INPUT
6 PLATFORM ROTATE LEFT DIGITAL INPUT
7 MAIN TELESCOPE IN DIGITAL INPUT
8 JIB DOWN DIGITAL INPUT
9 JIB LEFT DIGITAL INPUT
10 TOWER LIFT UP DIGITAL INPUT
J4 11 TOWER TELESCOPE IN DIGITAL INPUT
BLUE
12 HOUR METER DIGITAL OUTPUT
13 RETURN FILTER BY-PASS LAMP DIGITAL OUTPUT
PLATFORM OVERLOADED
14 DIGITAL OUTPUT
INDICATOR
15 BOOM MALFUNCTION INDICATOR DIGITAL OUTPUT
AUXILIARY POWER / FUNCTION
16 DIGITAL INPUT
ENABLE
17 PLATFORM LEVEL UP DIGITAL INPUT
18 PLATFORM ROTATE RIGHT DIGITAL INPUT
19 JIB UP DIGITAL INPUT
20 JIB RIGHT DIGITAL INPUT
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21 TOWER LIFT DOWN DIGITAL INPUT

22 TOWER TELESCOPE OUT DIGITAL INPUT
23 MAIN LIFT UP DIGITAL INPUT
24 BATTERY VOLTAGE VBAT OUTPUT
BATTERY VOLTAGE - (GROUND
25 VBAT OUTPUT
ENABLE PRESENT)
BATTERY LOW / NOT CHARGING
26 DIGITAL OUTPUT
INDICATOR
CHARGE PUMP FILTER BY-PASS
27 DIGITAL OUTPUT
LAMP
ENGINE HIGH COOLANT
28 DIGITAL OUTPUT
TEMPERATURE INDICATOR
ENGINE LOW OIL PRESSURE
29 DIGITAL OUTPUT
INDICATOR
30 MAIN TELESCOPE OUT DIGITAL INPUT
33 MAIN LIFT DOWN DIGITAL INPUT
34 SWING LEFT DIGITAL INPUT
35 SWING RIGHT DIGITAL INPUT
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1 PLATFORM EMS DIGITAL INPUT
2 PLATFORM MODE DIGITAL INPUT
3 GROUND MODE DIGITAL INPUT
4 CAPACITY ANGLE SWITCH ANALOG INPUT
5 +5 VOLTS VOLTAGE OUTPUT
6 CAN1 TERMINATOR TERM I/O
7 CAPACITY LENGTH SWITCH ANALOG INPUT
IN/OUT OF TRANSPORT
11 DIGITAL INPUT
SWITCHES
12 BROKEN CABLE SWITCH DIGITAL INPUT
13 CAN1 HIGH SERIAL I/O
GROUND MODE POWER TO
14 DIGITAL INPUT
PLATFORM
15 FOOTSWITCH DIGITAL INPUT
J7 18 CAN1 SHEILD GROUND INPUT
BLACK
TOWER TELESCOPE PROXIMITY
21 (800A ONLY)/DRIVE DIGITAL INPUT
ORIENTATION SWITCH
TOWER LIFT PROXIMITY (800A
22 DIGITAL INPUT
ONLY)
GROUND FUNCTION ENABLE
23 DIGITAL INPUT
AVAILABLE
24 CAN1 LOW SERIAL I/O
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BOOM ANGLE PROXIMITY

35 DIGITAL INPUT
SWITCH

1 MODULE GROUND FEEDBACK GROUND OUTPUT
J8 2 MODULE POWER VBAT INPUT

BLACK 3 GROUND TO PLATFORM MODULE GROUND INPUT
4 POWER TO PLATFORM MODULE VBAT OUTPUT
1 NOT CONNECTED FREQUENCY INPUT

2 NOT CONNECTED FREQUENCY INPUT
3 CAN2 HIGH (TELEMATICS) SERIAL I/O
J12 4 CAN2 LOW (TELEMATICS) SERIAL I/O

BLACK CAN2 SHIELD (TELEMATICS
5 GROUND INPUT
8 MSSO DIGITAL INPUT

1 CAN HIGH CH3 SERIAL I/O
2 CAN LOW CH3 SERIAL I/O
3 CAN CH3 TERM TERM I/O
4 CAN CH3 TERM TERM I/O
J14 7 LS DIGITAL INPUT 7 DIGITAL INPUT

GRAY 8 HS DIGITAL INPUT 29 DIGITAL INPUT
9 ME DIGITAL OUTPUT 19 DIGITAL OUTPUT
10 ME DIGITAL OUTPUT 20 DIGITAL OUTPUT
11 CURRENT LIMITED VBAT (200 mA) VBAT OUTPUT
13 CAN HIGH CH1 SERIAL I/O
14 CAN LOW CH1 SERIAL I/O
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8.5.2 Platform Control Module Pin Connections
Connector Pin Assignment Function

1 TOWER LIFT UP HS DIGITAL INPUT
2 TOWER LIFT DOWN HS DIGITAL INPUT
3 TOWER TELESCOPE IN HS DIGITAL INPUT
4 TOWER TELESCOPE OUT HS DIGITAL INPUT
J1 5 MAIN TELESCOPE IN HS DIGITAL INPUT

NATURAL 6 MAIN TELESCOPE OUT HS DIGITAL INPUT
7 PLATFORM ROTATE RIGHT HS DIGITAL INPUT
8 PLATFORM ROTATE LEFT HS DIGITAL INPUT
9 PLATFORM LEVEL UP HS DIGITAL INPUT
10 PLATFORM LEVEL DOWN HS DIGITAL INPUT
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11 JIB UP HS DIGITAL INPUT
12 JIB DOWN HS DIGITAL INPUT
13 SPEED PUMP POTENTIOMETER GROUND GROUND
14 ENGINE START HS DIGITAL INPUT
15 AUXILIARY POWER HS DIGITAL INPUT
16 CRAB STEER SELECT HS DIGITAL INPUT
17 COORDINATED STEER SELECT HS DIGITAL INPUT
18 SWITCH POWER BATTERY VOLTAGE
19 JIB 1000 LB ENABLE HS DIGITAL INPUT
20 EIM PLATFORM OVERLOAD HS DIGITAL INPUT
21 500/1000 LB CAPACITY SELECT HS DIGITAL INPUT
22 DRIVE ORIENTATION SYSTEM FEATURE ENABLE HS DIGITAL INPUT
23 SPARE PIN HS DIGITAL INPUT
25 LEVEL SENSOR 1 SIGNAL HS DIGITAL INPUT
26 LEVEL SENSOR 2 SIGNAL HS DIGITAL INPUT
27 TWO SPEED VALVE(HIGH ENGINE) HS DIGITAL INPUT
28 TORQUE MODE HS DIGITAL INPUT
29 SOFT TOUCH OVERRIDE HS DIGITAL INPUT
30 HEAD/TAIL LIGHT HS DIGITAL INPUT
31 HORN HS DIGITAL INPUT
32 CREEP MODE HS DIGITAL INPUT
33 DUAL-FUEL SELECT HS DIGITAL INPUT
34 SPEED PUMP POTENTIOMETER REFERENCE VOLTAGE +7 REFERENCE VOLTAGE
35 SPEED PUMP POTENTIOMETER ANALOG INPUT

3 BATTERY VOLTAGE BATTERY VOLTAGE
4 DRIVE ORIENTATION SYSTEM OVERRIDE SWITCH HS DIGITAL INPUT
5 PLATFORM STOWED HS DIGITAL INPUT
J2
6 CHASSIS TILTED INDICATOR LAMP OUTPUT
BLUE
7 FUNCTION ENABLE INDICATOR LAMP OUTPUT
8 VEHICLE SYSTEM DISTRESS INDICATOR LAMP OUTPUT
9 CREEP SPEED INDICATOR LAMP OUTPUT
10 BROKEN CABLE INDICATOR LAMP OUTPUT
11 PLATFORM OVERLOADED INDICATOR LAMP OUTPUT
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12 500 LB CAPACITY INDICATOR LAMP OUTPUT
13 1000 LB CAPACITY INDICATOR LAMP OUTPUT
14 DRIVE ORIENTATION SYSTEM INDICATOR LAMP OUTPUT
15 GENERATOR ON INDICATOR LAMP OUTPUT
16 SOFT TOUCH TRIGGERED INDICATOR LAMP OUTPUT
17 GLOW PLUG ENGAGED INDICATOR LAMP OUTPUT
18 LAMP RETURN GROUND
19 SPARE PIN LAMP OUTPUT
20 UPRIGHT TILTED INDICATOR LAMP OUTPUT
21 LOW FUEL INDICATOR LAMP OUTPUT
22 1/4 FUEL LEVEL INDICATOR LAMP OUTPUT
25 FUEL LEVEL INDICATOR RETURN GROUND
26 ANALYZER POWER ANALYZER POWER
27 ANALYZER GROUND ANALYZER GROUND
28 ANALYZER RX ANALYZER RX
29 ANALYZER TX ANALYZER TX
30 SPARE PIN LAMP OUTPUT
31 SPARE PIN DIGITAL OUTPUT
34 SWITCH POWER BATTERY VOLTAGE
35 FULL FUEL LEVEL INDICATOR LAMP OUTPUT

1 GROUND MODE GROUND MODE
2 PLATFORM EMS PLATFORM EMS
3 PLATFORM EMS TO GROUND MODULE PLATFORM MODE
4 FOOTSWITCH (FUNCTION ENABLE SWITCH) POWER BATTERY VOLTAGE
5 PLATFORM ROTATE LEFT ME DIGITAL OUTPUT
J7 6 PLATFORM ROTATE RIGHT ME DIGITAL OUTPUT

BLACK 7 SOFT TOUCH LIMIT SWITCH POWER BATTERY VOLTAGE
8 FOOTSWITCH SIGNAL DIGITAL INPUT
9 GENERATOR ON SIGNAL DIGITAL INPUT
10 +7 REFERENCE VOLTAGE +7 REFERENCE VOLTAGE
11 SPARE PIN +5V REFERENCE VOLTAGE
12 SPARE PIN +5V REFERENCE VOLTAGE
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13 SPARE PIN ANALOG INPUT
14 GROUND RETURN GROUND
15 PLATFORM LEVEL UP HS DIGITAL OUTPUT
16 PLATFORM LEVEL DOWN HS DIGITAL OUTPUT
17 JIB BLOCK LIMIT SWITCH HS DIGITAL INPUT
18 SOFT TOUCH LIMIT SWITCH HS DIGITAL INPUT
19 PLATFORM ALARM LAMP OUTPUT
20 ALARM RETURN GROUND
21 SPARE PIN GROUND
22 SPARE PIN GROUND
24 SPARE PIN DIGITAL OUTPUT
25 JIB UP ME DIGITAL OUTPUT
26 JIB DOWN ME DIGITAL OUTPUT
27 JIB RIGHT ME DIGITAL OUTPUT
28 JIB LEFT ME DIGITAL OUTPUT
29 GROUND RETURN GROUND
30 CAN LOW CAN LOW
31 CAN HIGH CAN HIGH
32 CAN SHIELD CAN SHIELD
33 SPARE PIN GROUND
34 SPARE PIN GROUND

1 LIFT/SWING JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE
2 LIFT CENTER TAP ANALOG INPUT
3 LIFT SIGNAL ANALOG INPUT
J5 4 SWING SIGNAL ANALOG INPUT

NATURAL 5 SWING CENTER TAP ANALOG INPUT
7 LIFT/SWING JOYSTICK RETURN GROUND
8 SPARE PIN BLANK

1 DRIVE/STEER JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE
J6 2 DRIVE CENTER TAP ANALOG INPUT

BLACK 3 DRIVE SIGNAL ANALOG INPUT
4 STEER SIGNAL ANALOG INPUT
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5 STEER LEFT ANALOG INPUT
6 STEER RIGHT ANALOG INPUT
7 DRIVE/STEER JOYSTICK RETURN GROUND
8 SPARE PIN BLANK
J8 1 MODULE GROUND GROUND

POWER 2 MODULE POWER BATTERY VOLTAGE
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8.6 AMP CONNECTOR
8.6.1 Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (Refer to Figure — Connector Assembly Figure 1, page 303).
Proceed as follows:
Figure 63. Connector Assembly Figure 1
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (Refer to Figure — Connector Assembly
Figure 1, page 303).
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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 (Refer to Figure —
Connector Assembly Figure 2, page 304).
Figure 64. AMP Connector
3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by
squeezing them inward (Refer to Figure — Connector Assembly Figure 3, page 304).
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4. Slide the wedge lock into the housing until it is flush with the housing (Refer to Figure — Connector Assembly Figure 4, page 305).
Figure 68. Connector Disassembly
8.6.2 Disassembly
1. Insert a 4.8 mm (3/16 in.) wide screwdriver blade between the mating seal and one of the red wedge lock tabs.
2. Pry open the wedge lock to the open position.
3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is
removed.
Note: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
8.6.3 Wedge Lock

The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat
probe such as a pocket knife. DO NOT use a sharp point such as an ice pick.
8.6.4 Service - Voltage Reading
CAUTION
Do not pierce wire insulation to take voltage readings.
It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice
should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in
the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies the effectiveness of the
connector seals and could result in system failure.
800S HC3, 860SJ HC3 31222415 305

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Figure 69. Connector Installation
306 31222415 800S HC3, 860SJ HC3

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8.7 TELEMATICS GATEWAY
Personnel using machines equipped with an optional telematics gateway will be able to view the following data through their telematics
device:
JLG LABEL DESCRIPTION UNIT

Engine Speed Actual engine speed. RPM
Indicates the level of DEF (diesel exhaust fluid) within the DEF tank if the machine is
equipped with DEF tank.
DEF Tank Level (If Equipped) Percentage (%)

• 0% = Empty
• 100% = Full
• 00 - No Machine Faults
JLG Machine Faults: Active / Not- • 01 - Active Machine Fault

Bit
Active
• 10 - Error
• 11 - Not available
Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions. Liters
Total Idle Hours Total time of engine operation during idle conditions. Seconds
Total Engine Hours Total time of engine operation. Seconds
Total Fuel Used Total amount of fuel used during vehicle operation. Liters
Fuel Rate Amount of fuel consumed by engine per unit of time. Liters/Hour
Ratio of fuel volume to the total volume of the fuel storage container. When a low fuel
limit switch is present, the fuel level will indicate “full” until the switch opens, which
will then indicate 10% fuel remaining.
Fuel Level Percentage (%)
When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents the total fuel in all fuel
storage containers. When Fuel Level 2 is used, Fuel Level 1 represents the fuel level in
the primary or left side fuel storage container.
DM1 Engine Faults Shows actual engine fault codes. N/A
800S HC3, 860SJ HC3 31222415 307

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8.7.1 Telematics-Ready (TCU) Plug

The telematics-ready (TCU) plug is a standard 12-pin Deutsch connector. Pin-out locations are shown below:
308 31222415 800S HC3, 860SJ HC3

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Figure 70. Telematics Gateway Harness
800S HC3, 860SJ HC3 31222415 309

Electricals
X1609 (TCU)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
1 RED 1-0 BAT 16 AWG GXL X1606 (B)
2 BLK 0-0 GND 16 AWG GXL S1615 (1)
4 ORN 2-0 IGN 16 AWG GXL S1614 (1)
9 GRN CANL2 16 AWG GXL MS1619-2 (B)
10 YEL CANL2 16 AWG GXL MS1619-2 (A)
MS1619-2 (CAN-T 2)
A YEL CANH2 18 AWG GXL X1609 (10)
B GRN CANH2 18 AWG GXL X1609 (9)
MS1619-3 (CAN-T 2)
A YEL CANH2 18 AWG GXL MS1620-2 (A)
B GRN CANH2 18 AWG GXL MS1620-2 (B)
CO1613-J1 (GATEWAY 1)
9 GRN CAN1 18 AWG GXL MS1618-2 (B)
10 YEL CANH1 18 AWG GXL MS1618-2 (A)
11 BLK 0-2 GND 16 AWG GXL S1615 (2)
12 ORN 2-2 IGN 16 AWG GXL S1614 (2)
CO1613-J2 (GATEWAY 2)
9 GRN CANL2 18 AWG GXL MS1620-3 (B)
10 YEL CANH2 18 AWG GXL MS1620-3 (A)
MS1620-2 (CAN-T 2)
A YEL CANH2 18 AWG GXL MS1619-3 (A)
B GRN CANL2 18 AWG GXL MS1619-3 (B)
MS1620-3 (CAN-T 2)
A YEL CANH2 18 AWG GXL CO1613-J2 (10)
B GRN CANL2 18 AWG GXL CO1613-J2 (9)
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S1614
1 ORN 2-0 IGN 16 AWG GXL X1609 (4)
2 ORN 2-1 IGN 16 AWG GXL X1606 (H)
3 ORN 2-2 IGN 16 AWG GXL CO1613-J1 (12)
S1615
1 BLK 0-0 IGN 16 AWG GXL X1609 (2)
2 BLK 0-1 IGN 16 AWG GXL X1606 (A)
3 BLK 0-2 IGN 16 AWG GXL CO1613-J1 (11)
MS1618-2 (CAN-T 1)
A YEL CANH1 18 AWG GXL CO1613-J1 (10)
B GRN CANL1 18 AWG GXL CO1613-J1 (9)
MS1618-3 (CAN-T 1)
A YEL CANH1 18 AWG GXL X1606 (C)
B GRN CANL1 18 AWG GXL X1606 (D)
X1606 (DIAG)
A BLK 0-1 GND 16 AWG GXL S1615 (2)
B RED 1-0 BAT 16 AWG GXL X1609 (1)
C YEL CANH1 16 AWG GXL MS1618-3 (A)
D GRN CANL1 18 AWG GXL MS1618-3 (B)
E GRN 2-1 IGN 16 AWG GXL S1614 (2)
FROM TO
WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE PIN REFERENCE PIN
CAN L2 GRN 18 AWG 1151 GXL MS1619-3 B MS1620-2 B
CAN L2 GRN 18 AWG 151 GXL X1609 9 MS1619-2 B
CAN L1 GRN 18 AWG 157 GXL MS1618-2 B CO1613-J1 9
CAN L2 GRN 18 AWG 225 GXL MS1620-3 B CO1613-J2 9
CAN L1 GRN 18 AWG 1076 GXL MS1618-3 B X1606 D
CAN H2 YEL 18 AWG 155 GXL X1609 10 MS1619-2 A
CAN H2 YEL 18 AWG 233 GXL MS1620-3 A CO1613-J2 10
CAN H1 YEL 18 AWG 157 GXL MS1618-2 A CO1613-J1 10
CAN H2 YEL 18 AWG 1150 GXL MS1619-3 A MS1620-2 A
800S HC3, 860SJ HC3 31222415 311

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FROM TO
WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE PIN REFERENCE PIN
CAN H1 YEL 18 AWG 1079 GXL MS1618-3 A X1606 C
0-0 GND BLK 16 AWG 1006 GXL X1609 2 S1615 1
0-1 GND BLK 16 AWG 1145 GXL X1606 A S1615 2
0-2 GND BLK 16 AWG 223 GXL CO1613-J1 11 S1615 2
1-0 BAT RED 16 AWG 2150 GXL X1609 1 X1606 B
2-0 IGN ORN 16 AWG 939 GXL X1609 4 S1614 1
2-1 IGN ORN 16 AWG 1212 GXL S1614 2 X1606 H
2-2 IGN ORN 16 AWG 287 GXL CO1613-J1 12 S1614 2
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SECTION 9
REMOVAL AND INSTALLATION
9.1 WHEEL AND TIRE
WARNING
DO NOT service the machine without following all safety precautions as outlined in
the Section – Safety, page 11 of this manual.
Removing Wheel and Tire Assembly from Machine

1. Park the machine on a firm and level surface and fully retract the boom. Lower the boom on the machine’s boom rest stop.
WARNING
Make sure to properly position counterweight prior to servicing Wheel/Axle and re-
lated components.
2. Rotate machine and position counterweight 180° from axle/wheel being serviced.
3. Turn key select switch to (center) OFF position, push in power/ emergency stop switch (down) to OFF and remove the key.
4. Put the Do Not Operate Tag on the ignition key switch.
WARNING
Never work under improperly supported machine, could result in serious injury or
death.
CAUTION
Service only one Wheel/Axle and related component at a time.
7. Loosen but Do Not remove the lug nuts on the wheel and tire assembly to be removed.
8. Place a suitable jack under axle pad closest to wheel being removed. Raise machine and position a suitable support beneath axle.
Allow sufficient room to lower machine onto support and to remove wheel and tire assembly.
9. Lower machine onto support.
10. Remove lug nuts in alternating pattern.
11. Remove wheel and tire assembly from machine.
800S HC3, 860SJ HC3 31222415 313

Removal and Installation
Figure 71. Wheel Lug Nut Tightening Sequence

Wheel Installation
It is extremely important to apply and maintain proper wheel mounting torque.
WARNING
Wheel nuts must be installed and maintained at the proper torque to prevent loose
wheels, broken studs, and possible dangerous separation of wheel from the axle. Be
sure to use only the nuts matched to the cone angle of the wheel.
Tighten lug nuts to proper torque to prevent wheels from coming loose. Use a torque wrench to tighten fasteners. If you do not have a
torque wrench, tighten fasteners with a lug wrench, then immediately have a service garage or dealer tighten lug nuts to proper torque.
Over-tightening will break studs or permanently deform mounting stud holes in wheels. The proper procedure for attaching wheels is as
follows:
1. Position wheel and tire assembly onto axle.
2. Install all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.
3. Tighten nuts in the following sequence as shown in Figure – Wheel Lug Nut Tightening Sequence, page 314.
4. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart
as shown below.
Table 42. Wheel Torque Chart
TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
70 ft. lbs. 170 ft. lbs. 300 ft. lbs.

(95 Nm) (230 Nm) (406 Nm)
5. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150
hours of operation.
6. Remove machine from supports.
7. Close and secure the hood cover.
8. Remove the Do Not Operate Tag from the ignition key switch.
314 31222415 800S HC3, 860SJ HC3

9.2 CHASSIS/FRAME ASSEMBLY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic
be familiar with the name and location of the major assemblies of the chassis/frame. Procedures and illustrations are provided to give
visual aid.
9.2.1 Axle and Drive Assemblies Troubleshooting
Problem Possible Causes Remedy
1. Oil level too low. 1. Fill oil to correct level. Refer to Section – Capacities, page
24.
2. Axle and/or wheel end housings filled with incorrect oil or 2. Drain axle and/or wheel end housings and fill to correct
oil level low. level. Refer to Section – Capacities, page 24.
3. Incorrect alignment of swing bearing. 3. Correct alignment by adding or removing shims as

needed.
4. Incorrect pinion (input) gear of swing drive. 4. Correct bearing preload by adding or removing shims as
1. Excessive axle noise while driving.
needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end housings and fill to correct
level. Refer to Section – Capacities, page 24.
8. Axle housing damaged. 8. Replace damaged parts.
1. Universal joint(s) worn or damaged. 1. Repair or replace universal joints as needed.
2. Vibration or Intermittent noise when 2. Gears damaged. 2. Determine cause and repair as needed.
traveling. 3. Swing drive joint incorrectly tightened. 3. Tighten capscrews to correct torque.
4. Drive universal joint(s) worn or damaged. 4. Repair or replace joints as needed.
1. Hose fittings loose. 1. Tighten fittings.
2. Steering cylinder O-rings and/or seals worn or damaged. 2. Replace O-rings and seals.
3. Oil leaking from steering cylinder.
3. Piston rod seal worn or damaged. 3. Replace piston rod seal.
4. Cylinder tube damaged. 4. Replace cylinder tube.
9.2.2 Drive Hub and Motor

Removal
1. Before removing the drive hub and motor, remove the wheel and tire assembly. Refer to Section – Wheel and Tire, page 313.
WARNING
lated components.
800S HC3, 860SJ HC3 31222415 315

WARNING
death.
CAUTION
Note: The drive motors can be removed through the axle flange as part of the wheel drive assembly, or they can be removed sepa-
rately through the bottom of the frame while leaving the drive hub bolted to the axle.
4. Use a jack to lift the frame enough so the tire and wheel assembly is off the ground. Place blocking strong enough to support the
weight of the machine under the frame and remove the jack.
Note: The foam-filled tire & wheel assembly weighs approximately 640 lb. (300 kg).
5. Remove lugnuts (1) securing wheel and remove tire and wheel assembly. Using suitable lifting device lift the tire and wheel
assembly and place in a suitable area.
6. Tag and disconnect the hydraulic lines running to the drive motor (3). Cap or plug all openings to ensure no dirt enters the
hydraulic system.
7. Use a supporting device capable of handling the weight of the drive hub (2) and drive motor (3).
Note: Drive hub weighs approximately 222 lb. (100.7 kg) and drive motor (3) weigh approximately 34 lb. (15.4 kg).
8. Remove mounting bolts (4), washers (5) and gasket (6)/O-ring (6) securing drive hub (2) and drive motor (3) as shown in Figure –
Drive Hub and Motor – Removal/Installation, page 317. Discard gasket (6)/O-ring (6).
9. Remove drive motor (3) from machine and place on a clean surface.
10. Remove bolts (7) and washers (8) securing drive hub (2) onto machine.
11. Remove drive hub (2) from machine and place on a clean surface.
Inspection
Refer to Section – Drive Assembly, page 439 for detailed disassembly and assembly of drive hub (2) and drive motor (3).
Installation
1. Use suitable lifting device to support the drive hub (2).
Note: Drive hub weighs approximately 222 lb. (100.7 kg) and drive motor (3) weigh approximately 34 lb. (15.4 kg).
2. Position drive hub (2) on mounting location as shown in Figure – Drive Hub and Motor – Removal/Installation, page 317.
3. Install drive hub (2) onto machine using bolts (7) and washers (8). Torque bolts to 190 ft. lbs. (260 Nm).
Note: Apply High Strength Threadlocking Compound to bolts before installation.
CAUTION
Incorrect shaft alignment may result in damage to drive shaft, bearings, or seal
which can cause external oil leakage.
316 31222415 800S HC3, 860SJ HC3

4. Position drive motor (3) and gasket (6)/O-ring (6) onto mounting location as shown in Figure – Drive Hub and Motor – Removal/
Installation, page 317.
5. Make sure that the motor shaft is properly aligned.
6. Using bolts (4) and washers (5) attach the drive motor onto machine. Torque bolts to 70 ft. lbs. (95 Nm).
Note: Apply medium strength threadlocking compound to bolts before installation.
7. Remove tag from all disconnected hydraulic hoses.
8. Install Previously removed hydraulic hoses to the drive motor (3).
9. Start the machine and check the motor for proper functioning.
10. Using adequate support, install wheel and tire assembly and secure using lugnuts (1). Refer to Section – Wheel and Tire, page 313,
for torque details.
2
6
4
5
1
8
7
BM110877A
Figure 72. Drive Hub and Motor - Removal/Installation
800S HC3, 860SJ HC3 31222415 317

Note: Refer to Figure – Drive Hub and Motor – Removal/Installation, page 317 for below callout table.
1. Lugnut 4. Bolt 7. Bolt

2. Drive Hub 5. Washer 8. Washer
3. Drive Motor 6. Gasket
9.2.3 Spindle Assembly

Removal
WARNING
An improperly supported machine can fall. Safely raise and adequately support the
machine so that it will remain stable and in place before attempting to remove
spindle assembly.
CAUTION
Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space
to raise the machine and to remove the spindle assembly.
WARNING
lated components.
2. Rotate machine and position counterweight 180° from axle/wheel components being serviced.
WARNING
death.
CAUTION
4. Place a Do Not Operate tag on the ignition key switch.
7. Use suitable lifting device, jack or hoist. Make sure that machine will remain in place during removal.
8. Properly disconnect any electrical connections.
9. Label, disconnect and cap/plug all hydraulic connections.
10. For removal/installation of wheel and tire assembly, refer to Section – Wheel and Tire, page 313.
318 31222415 800S HC3, 860SJ HC3

11. For removal/installation of drive hub and motor, refer to Section – Drive Hub and Motor, page 315.
12. For removal/installation of steer cylinder (11), refer to Section – Steer Cylinder, page 409 for pivot pin removal at rod end of steer
cylinders from spindle assembly (4).
13. Remove the left side of the spindle assembly (4).

a. Remove capscrews (1), plates (2) and kingpins (3) from top and bottom of the spindle assembly (4). Refer to Figure – Spindle
Assembly - Removal/Installation, page 320.
b. Remove thrust washers (5, 6, 7, 9) and bearings (8) from top and bottom of the axle assembly (10). Refer to Figure – Spindle
c. Remove the left side of the spindle assembly (4).
Installation
CAUTION
Make sure that the front axle assemblies are free from any dirt and debris.
Note: Properly clean tapered portion of axle assemblies and kingpins (3).
Note: Apply medium strength threadlocking compound to bolt before installation.
1. Install the left side of the spindle assembly (4).

a. Install bearings (8) and thrust washers (5, 6, 7, 9) in top and bottom of the axle assembly (10). Refer to Figure – Spindle
b. Position and align spindle assembly (4) onto mounting holes of axle assembly (10).
c. Install steer cylinder (11). Refer to Section – Steer Cylinder, page 411 for pivot pin installation at rod end of steer cylinders to
the spindle assembly (4).
d. Install kingpins (3), plates (2) and capscrews (1) in top and bottom of the spindle assembly (4). Refer to Figure – Spindle
e. Tighten the capscrews (1) to a torque of 85 ft. lbs. (115 Nm).
2. Do steps a thru e to install the right side of the spindle assembly (4).
3. Properly connect electrical and hydraulic connections.
4. Remove supports from the machine.
6. Remove the Do Not Operate tag from the ignition key switch.
7. Turn the vehicle ON.
8. Verify for proper operation of Steering system.
800S HC3, 860SJ HC3 31222415 319

10
7
1
8
2
11 4
1
BM110873A
Figure 73. Spindle Assembly - Removal/Installation
1. Capscrew 5. Thrust Washer 9. Thrust Washer
2. Plate 6. Thrust Washer 10. Axle Assembly
3. Kingpin 7. Thrust Washer 11. Steer Cylinder
4. Spindle Assembly 8. Bearing
9.2.4 Axle Assembly

Removal
WARNING
lated components.
320 31222415 800S HC3, 860SJ HC3

4. Put the Do Not Operate tag on the ignition key switch.
7. Properly support corner of frame nearest to component being serviced.
8. Cap or plug all openings of hydraulic lines and ports.
WARNING
Never work under improperly supported machine. Working under improperly sup-
ported machine might result in serious injury or death.
Note: The axle weighs approximately 499 lb. (227 kg).
CAUTION
9. For removal/installation of wheel and tire assembly, refer to Section – Wheel and Tire Assembly, page 313.
10. For removal/installation of drive hub and motor, refer to Section – Drive Hub and Motor, page 315.
11. For removal/installation of steering cylinder, refer to Section – Steer Cylinder, page 409.
12. For removal/installation of spindle assembly, refer to Section – Spindle Assembly, page 318.
13. Support the axle (1) and remove bolt (2) securing keeper pin (3) to chassis frame as shown in Figure – Axle without Tow Package -
Removal/Installation, page 322 and Figure – Axle with Tow Package - Removal/Installation., page 323.
14. Remove keeper pin (3) from axle pivot pin (4).
15. Remove axle pivot pin (4), washer (5) and bearings (6) from axle (1). Discard bearings (6).
Note: Use suitable brass drift and mallet to remove axle pivot pin (4).
16. Remove axle (1) from machine and put axle on a clean surface.
Installation
CAUTION
Make sure that the axle assemblies and pivot pins are free from any dirt and debris.
Properly clean the mounting and adjacent areas of chassis frame.
Note: Refer to Section – Pins and Composite Bearing Repair Guidelines, page 42, while inspecting pins and bearings.
1. Install bearings (6) onto pivot holes of axle (1) as shown in Figure – Axle without Tow Package - Removal/Installation, page 322 and
Figure – Axle with Tow Package - Removal/Installation., page 323.
800S HC3, 860SJ HC3 31222415 321

2. Position and align holes of axle (1) onto mounting holes of chassis frame and install axle pivot pin (4) and washer (5).
Note: Use suitable brass drift and mallet to install axle pivot pin (4).
3. Install keeper pin (3) on pivot pin (4).
4. Install keeper pin (3) to chassis frame using bolt (2).
5. Torque tighten the bolt (2) to 285 ft. lbs. (388 Nm).
6. Connect previously removed hydraulic and electrical connection.
7. Remove any supporting equipment/devices used during installation.
6
5
3 1
BM110872A
2
Figure 74. Axle without Tow Package - Removal/Installation
322 31222415 800S HC3, 860SJ HC3

Note: Refer to Figure – Axle without Tow Package - Removal/Installation, page 322 for below callout table.
1. Axle 3. Keeper Pin 5. Washer

2. Bolt 4. Pivot Pin 6. Bearing
4
6
5
3
1
2 BM110880A
Figure 75. Axle with Tow Package - Removal/Installation
1. Axle 3. Keeper Pin 5. Washer

2. Bolt 4. Pivot Pin 6. Bearing
9.3 BOOM
9.3.1 Boom Components Terminology

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/ mechanic
be familiar with the name and location of the major assemblies of the boom, jib and powertrack. The following illustration identifies the
components that are referred to throughout this section.
Refer to Section – Boom Inspection and Maintenance, page 44 for details of wire rope tensioning & inspection instructions.
800S HC3, 860SJ HC3 31222415 323

5
1
3
2
6
BM111618A
Figure 76. Boom Components Location (800S)
1. Base Boom Section 3. Fly Boom Section 5. Powertrack Assembly
2. Mid Boom Section 4. Platform Rotator Assembly 6. Boom Tower Link
4
5
3
6 2
7
BM111619A
Figure 77. Boom Components Location (860SJ - US Built)
324 31222415 800S HC3, 860SJ HC3

Note: Refer Figure – Boom Components Location (860SJ - US Built), page 324 for below callouts
1. Base Boom Section 4. Platform Rotator Assembly 7. Boom Tower Link
2. Mid Boom Section 5. Jib Assembly
3. Fly Boom Section 6. Powertrack Assembly
4
5
3
6 2
7
BM111619A
Figure 78. Boom Components Location (860SJ - China Built)
1. Base Boom Section 4. Platform Rotator Assembly 7. Boom Tower Link
2. Mid Boom Section 5. Jib Assembly
3. Fly Boom Section 6. Powertrack Assembly
9.3.2 Troubleshooting
This section provides an easy reference guide covering the most common problems that occur during operation of the boom.
Note: Troubleshooting guide is used if no DTC help messages appear. Otherwise refer to Section – Machine Fault Codes for
troubleshooting.
Problem Possible Causes Corrective Action

1. Broken hydraulic hose(s) or tube(s) and/or connections 1. Locate break, replace hose(s) or tube(s), tighten connections.
leaking.
2. Extend/retract hydraulic system not operating properly. 2. Refer to Section – Hydraulic Circuits, page 111.
1. Boom will not extend or retract.
3. Faulty cylinders. 3. Repair cylinders. Refer to Section – Hydraulic Cylinders, page
507 for detailed instructions.
4. Electrical System not operating properly. 4. Refer to Section – Electrical Schematics.
800S HC3, 860SJ HC3 31222415 325

Problem Possible Causes Corrective Action

2. Boom shifts to right or left when 1. Boom side wear pads improperly shimmed or worn. 1. Shim wear pads to correct gap. Replace wear pads as
extending. needed. Refer to Section – Boom Wear Pad Inspection.
1. Insufficient lubrication. 1. Lubricate at regular intervals. Refer to Section – Preventive

Maintenance and Inspection Schedules, page 38. Replace worn
3. Excessive pivot pin noise and/or pins as needed.
wear. 2. Worn bearing(s). 2. Replace bearing(s) and lubricate at regular intervals Refer to
Section – Preventive Maintenance and Inspection Schedules, page
38.
1. Broken hydraulic hoses or tubes and/ or connection leaks. 1. Locate break, replace hose(s) or tube(s), tighten connections.
2. Lift/lower hydraulic system not operating properly. 2. Refer to Section – Hydraulic Circuits, page 111.
3. Faulty cylinders. 3. Repair cylinders. Refer to Section – Hydraulic Cylinders, page

4. Boom will not raise or lower.
507 for detailed instructions.
4. Seized boom pivot pin bushing. 4. Replace bushing.
5. Electrical System not operating properly. 5. Refer to Section – Electrical Schematics.
1. Wire rope(s) tension not properly adjusted. 1. Adjust wire rope(s). Refer to Section – Wire Rope.
2. Wire rope(s) stretched or binding. 2. Replace wire ropes as needed. Refer to Section – Wire Rope.
3. Wear pads loose, contaminated, excessively worn or 3. Replace wear pad. Refer to Section – Boom Wear Pad
damaged. Inspection.
5. Drooping wire rope, or jerky boom
extend or retract functions. 4. Contaminated, corroded or rusted wear pad sliding surfaces. 4. Remove contamination and/or corrosion from wear pad
sliding surfaces and lubricate. If the surfaces cannot be
reconditioned, replace the boom section(s).
5. Extend/retract hydraulic system not operating properly. 5. Refer to Section – Hydraulic Circuits, page 111.
6. Damaged boom section. 6. Replace the damaged boom section.
1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section
– Boom Wear Pad Inspection.
2. Rapid cycle times with heavy loads. 2. Reduce cycle times.
6. Rapid boom pad wear. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 3. Remove contamination and/or corrosion from wear pad
sliding surfaces and lubricate. If the surfaces cannot be
reconditioned, replace the boom section(s).
4. Operating in extremely dusty/abrasive conditions. 4. Clean equipment frequently.
1. Improper wire rope adjustment. 1. Adjust to correct tension. Refer to Section – Boom Inspection
and Maintenance. Replace wire rope as needed.
2. Wire rope sheave(s) not properly lubricated. 2. Lubricate wire rope. Refer to Section – Wire Rope.
7. Excessive wire rope wear.
3. Wire rope sheave(s) not rotating freely. 3. Lubricate wire rope. Refer to Section – Wire Rope.
4. Improper wire rope lubrication. 4. Lubricate at regular intervals. Refer to Section – Wire Rope.
Replace wire rope as needed.
9.3.3 Main Boom Powertrack

Removal
1. Park the machine on a firm and level surface and fully retract the boom. Lower the boom on the machine's boom rest stop.
2. Open both the side hoods. Allow the system fluids to cool.
326 31222415 800S HC3, 860SJ HC3

3. Disconnect battery power from the machine, turn key select switch to (center) OFF position and push in power/emergency stop
switch (down) to OFF. Remove the key.
5. Disconnect wiring harness from ground control box.
6. Tag and disconnect hydraulic lines from connectors at boom assembly.
7. Use suitable container to retain any residual hydraulic fluid. Cap and plug all openings of hydraulic lines and ports.
8. Remove hydraulic lines and electrical cables from powertrack.
9. Using suitable lifting device, adequately support powertrack weight along entire length.
10. Remove bolts (1) and washers from shim (3) securing push tube (2) to fly boom (4) as shown in Detail A of Figure – Powertrack -
Removal/Installation, page 329.
11. Remove bolts (5), washers and nuts from shim (6) securing push tube (2) with block (20) as shown in Detail A of Figure –
Powertrack - Removal/Installation, page 329.
12. Remove bolts (16, 18, 19) from wear pad (15) securing push tube (2) with power track assembly (11) as shown of Figure –
13. Remove the push tube (2) from the base boom (10) and place it on clean dry surface.
14. Remove bolts (8) securing powertrack assembly (11) with the clamp block (9) to the power track support (13) as shown in Detail B
of Figure – Powertrack - Removal/Installation, page 329.
15. Remove the bolt (14) securing powertrack assembly (11) with the power track support (13) as shown Detail B of Figure –
16. Remove powertrack assembly (11) from base boom (10) and carefully place it on the flat and clean dry surface.
17. If necessary, remove bolt (17) to remove bracket (22) from the mid boom (7).
18. If necessary, remove bolt (12) and (21) from Power track support (13) and remove it from base boom (10) as shown in Figure –
Powertrack - Removal/Installation, page 329
Installation
CAUTION
Make sure that the powertrack assemblies are free from any dirt and debris. Prop-
erly clean the mounting and adjacent areas of boom assembly.
Note: Prior to install powertrack assembly, refer to Section – Powertrack Maintenance, page 625, for detailed Disassembly/Assembly
instructions.
Note: Apply Medium Strength Threadlocking compound to the bolts before installation.
1. If previously removed, position and install powertrack support (13) onto mounting locations of base boom (10) using bolt (12) and
(21) as shown in Figure – Powertrack - Removal/Installation, page 329. Torque bolts (21) to 35 ft. lbs. (48 Nm).
Note: Apply medium strength threadlocking compound to bolts before installation.
2. Align and place powertrack assembly (11) onto powertrack support (13).
3. Align and route powertrack links on powertrack support (13).
4. If previously removed, install bracket (22) using bolts (17) and washer onto mid boom (7). Torque bolts (17) to 38 ft. lbs. (48 Nm).
Figure – Powertrack - Removal/Installation, page 329.
800S HC3, 860SJ HC3 31222415 327

5. Align push tube (2) at the mounting location on boom assembly and Install bolts (1), shims (3) and washer to secure push tube (2)
with the fly boom (4) as shown in Figure – Powertrack - Removal/Installation, page 329. Torque bolts (1) to 38 ft. lbs. (48 Nm).
6. Install bolts (5), nuts and washer with shim (6) and block (20) to secure push tube (2) with bracket (22) onto the boom assembly,
as shown inFigure – Powertrack - Removal/Installation, page 329. Torque bolts (5) to 38 ft. lbs. (48 Nm).
7. Align and place powertrack assembly (11) onto the powertrack support (13).
8. Install bolts (8) securing clamp block (9) and powertrack assembly (11) to the power track support (13).
9. Install bolts (14) and washer to secure powertrack assembly (11) to the power track support (13).
10. Install bolts (16), (18) and (19) and secure wear pad (15) with the push tube (2) and powertrack assembly (11).
11. Remove tag and reconnect all hydraulic lines.
12. Remove tag and reconnect all electrical connections to the ground control box.
13. Remove lifting devices and/or supports from the powertrack and boom assembly.
14. Properly connect the battery.
16. Remove the Do Not Operate Tag from ignition key switch.
17. Start the engine and operate all boom functions several times to bleed any air out of the hydraulic system.
18. Check for fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.
19. Lower the boom assembly and shut engine OFF.
20. Clean up all debris, fluid, etc. near or around the machine.
328 31222415 800S HC3, 860SJ HC3

12
13
19
18
C
15
D
16
C
D
10
8
14
7 11
9
4
2
A
2
21
17
22 20
6
5
A
1
BM110884A
Figure 79. Powertrack - Removal/Installation
800S HC3, 860SJ HC3 31222415 329

Note: Refer to Figure – Powertrack - Removal/Installation, page 329 for below table.
1. Bolt 7. Mid Boom 13. Power Track Support 19. Bolt

2. Push Tube 8. Bolt 14. Bolt 20. Block
3. Shim 9. Clamp Block 15. Wear Pad 21. Bolt
4. Fly Boom 10. Base Boom 16. Bolt 22. Bracket
5. Bolt 11. Powertrack assembly 17. Bolt

6. Shim 12. Bolt 18. Bolt
9.3.4 Main Boom Assembly

Removal
1. Using suitable lifting equipment, adequately support boom assembly weight along entire length.
NOTICE
Hydraulic lines and ports should be capped immediately after disconnecting lines
to avoid entry of contaminants into system.
2. Tag and disconnect hydraulic lines from telescope cylinder. Use a suitable container to retain any residual hydraulic fluid. Cap
hydraulic lines and ports.
3. Use an adequate support for the main boom lift cylinder. Extend main boom cylinder with auxiliary power switch to gain access to
remove rod end pin.
Note: The main boom lift cylinder weighs approximately 600–692 lb (271–314 kg).
4. Using a suitable brass drift and hammer, remove hardware securing the main boom lift cylinder rod end pin to the base boom
section.
5. Remove the main boom lift cylinder pin from base boom. Retract the main boom lift cylinder by using the auxiliary power switch.
6. Using an adequate supporting device, support the timing link so it doesn’t fall when the pin is removed.
330 31222415 800S HC3, 860SJ HC3

7. Remove hardware securing timing link to boom assembly. Remove pin from boom assembly.
1
MAF25781
8. Using a suitable brass drift and hammer, remove hardware securing the main boom section to the upright.
MAF25801
9. Using all applicable safety precautions, carefully lift boom assembly clear of upright and lower to ground or suitably supported
work surface.
Installation
1. Using a suitable lifting device, position boom assembly on upright so that the pivot holes in both boom and upright are aligned.
2. Install boom pivot pin, ensuring that location of hole in pin is aligned with attach point on upright.
800S HC3, 860SJ HC3 31222415 331

3. If necessary, gently tap pin into position with soft headed mallet. Secure pin mounting hardware.
MAF25801
4. Align holes of boom assembly and timing link, install pivot pin, ensuring that location of hole in pin is aligned with attach point of
timing link.
1
MAF25781
5. Using suitable lifting device, align main lift cylinder rod end with mounting holes on boom assembly.
6. Extend the main lift cylinder by using the auxiliary power switch. Using a suitable brass drift and hammer, install hardware secured
to the main lift cylinder rod end pin into the base boom section.
332 31222415 800S HC3, 860SJ HC3

7. Connect all wiring to the ground control box.
8. Connect all hydraulic lines running along side of boom assembly.
9. Adjust retract and extend cables to the proper torque. Refer to Section – Wire Rope Tensioning Procedure, page 44.
10. Using all applicable safety precautions, operate machine systems and raise and extend boom fully, noting the performance of the
extension cycle.
11. Retract and lower boom, noting the performance of the retraction cycle.
9.3.5 Boom Sensors

Removal
1. Park the machine on a firm and level surface.
2. Lower and retract the boom/platform. Turn Machine OFF and place a Do Not Operate tag on the key switch.
4. Disconnect battery power from the machine and remove the key.
5. Identify the locations of boom angle sensor (9) and proximity sensors (13 and 17) as shown in Figure – Boom Sensors (Elevation,
Dual and Transport Switches) - Removal/Installation, page 335.
6. Disconnect wiring harness and electrical connectors from boom angle sensor (9) and proximity sensors (13 and 17).
7. Loosen and remove screws (4) that attach the boom angle sensor bracket (5) as shown in Detail A of Figure – Boom Sensors
(Elevation, Dual and Transport Switches) - Removal/Installation, page 335.
8. Slide and remove boom angle sensor (9) from slot of sensor bracket (8).
9. Remove bolt (1), washers (2 and 7) and nut (6) that attach the sensor shield (3) to the boom angle sensor (9).
10. Remove bolts (10), washers (11) and sensor cover bracket (12) from mounting location on base boom as shown in Detail B of
Figure – Boom Sensors (Elevation, Dual and Transport Switches) - Removal/Installation, page 335.
11. Loosen and remove jam nuts attaching proximity sensor (13) to the base boom brackets as shown in Detail B of Figure – Boom
Sensors (Elevation, Dual and Transport Switches) - Removal/Installation, page 335.
Retain jam nuts.
12. Remove bolts (14), washers (15) and sensor cover bracket (16 ) from mounting location on base boom as shown in Detail C of
Figure – Boom Sensors (Elevation, Dual and Transport Switches) - Removal/Installation, page 335.
13. Loosen and remove jam nuts attaching proximity sensors (13 and 17) to the base boom brackets as shown in Detail C of Figure –
Boom Sensors (Elevation, Dual and Transport Switches) - Removal/Installation, page 335.
Retain jam nuts.
14. Remove proximity sensors (13 and 17) from the base boom.
Sensors Inspection and Replacement

Inspect the sensor and the wiring harness connector terminals for continuity. Replace a defective or faulty sensor with a new sensor.
Installation
CAUTION
Make sure that the mounting locations of sensors on boom are clean and free from
debris.
Note: Apply medium strength threadlocking compound to bolts and screws before installation.
1. Position and align proximity sensors (13 and 17) onto mounting holes of base boom bracket as shown in Detail B of Figure – Boom
800S HC3, 860SJ HC3 31222415 333

2. Position and align proximity sensor (13) onto mounting holes of base boom bracket as shown in Detail C of Figure – Boom Sensors
(Elevation, Dual and Transport Switches) - Removal/Installation, page 335.
3. Measure the distance "A" from the outer surface of the sensor mounting boss (18) to the mid boom (19) through the sensor
mounting hole as shown in View D of Figure – Boom Sensors (Elevation, Dual and Transport Switches) - Removal/Installation, page
335.
a. If the measured dimension is greater than 28.5 mm (1.125 in.), thread sensors until they bottom out on the mid boom, then
back them out a total of 6 full turns.
b. If the measured dimension is less than 28.5 mm (1.125 in.), thread sensors until they bottom out on the mid boom, back them
out a total of 4 full turns.
4. Secure proximity sensors (13 and 17) on base boom bracket using jam nut from both sides.
5. Install sensor cover bracket (12) on base boom bracket using bolts (10) and washers (11) as shown in Detail B of Figure – Boom
6. Install sensor cover bracket (16) on base boom bracket using bolts (14) and washers (15) as shown in Detail C of Figure – Boom
7. Install sensor shield (3) on boom angle sensor (9) using previously removed hardware.
8. Position and align boom angle sensor (1) on the slot of sensor bracket (8).
9. Install boom angle sensor (9) on base boom using screws (4) as shown in Detail A of Figure – Boom Sensors (Elevation, Dual and
Transport Switches) - Removal/Installation, page 335. Torque screws to 15 ft. lbs. (20 Nm).
10. Connect wiring harness electrical connectors to connectors of boom angle sensors (9) and proximity sensors (13 and 17).
334 31222415 800S HC3, 860SJ HC3

6
3 7
2
1
A 9
8
DIM "A"
A
D 18
B 13
17
19
12 17
11
16
10
13 15
14
13
B
C BM110885A
Figure 80. Boom Sensors (Elevation, Dual and Transport Switches) - Removal/Installation
800S HC3, 860SJ HC3 31222415 335

Note: Refer to Figure – Boom Sensors (Elevation, Dual and Transport Switches) - Removal/Installation, page 335 for below table.
1. Bolt 8. Sensor Bracket 15. Washer
2. Washer 9. Boom Angle Sensor 16. Sensor Cover Bracket
3. Sensor Shield 10. Bolt 17. Proximity Sensor
4. Screw 11. Washer 18. Mounting Boss
5. Bracket 12. Sensor Cover Bracket 19. Mid Boom
6. Nut 13. Proximity Sensor
7. Washer 14. Bolt
9.3.6 JIB
Figure 81. Jib Assembly - Removal/Installation

Removal
1. For platform and support removal refer to Section – Platform, page 337.
Note: The jib assembly weighs approximately 302 lb (137.1 kg).
2. Using a suitable lifting device to support the jib assembly and position the assembly level with ground.
NOTICE
to avoid entry of contaminants into system.
3. Tag and disconnect hydraulic lines from platform level cylinder and jib lift cylinder. Use suitable container to retain any residual
hydraulic fluid. Cap or plug all openings of hydraulic lines and ports.
4. Remove mounting hardware from platform level cylinder pin #1. Using a suitable brass drift and hammer, remove the cylinder pin
from jib assembly.
336 31222415 800S HC3, 860SJ HC3

5. Remove mounting hardware from jib assembly boom pivot pin #2. Using a suitable brass drift and hammer, remove the pivot pin
from boom assembly. Remove the jib assembly from the machine.
Installation
Note: The jib assembly weighs approximately 302 lb (137.1 kg).
1. Using a suitable lifting device to support the jib assembly and position the assembly level with ground.
2. Align jib boom pivot weldment with attach holes in fly boom assembly. Using a soft head mallet, install pivot pin #2 into fly boom
assembly and secure with mounting hardware.
3. Align the platform level cylinder with attach holes in jib boom pivot weldment. Using a soft head mallet, install platform level
cylinder pin #1 into jib pivot weldment and secure with mounting hardware.
4. Remove cap or plugs from openings of hydraulic lines and ports and connect hydraulic lines to platform level cylinder and jib lift
cylinder as tagged during removal.
9.4 PLATFORM
9.4.1 Platform Support
Figure 82. Location of Components Platform Support

Removal
1. Disconnect electrical cables from control console.
2. Tag and disconnect the hydraulic lines from the rotator. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic
lines and ports.
3. Remove the bolts securing the platform to the platform support, then remove the platform.
Note: The platform support weighs approximately 125 lb. (56.8 kg).
800S HC3, 860SJ HC3 31222415 337

4. Using a suitable lifting device, support the platform support.
5. Remove the bolts and locknuts securing the support to the rotator.
6. Using a suitable brass drift and hammer, remove the rotator shaft, then remove the support from the rotator.
Installation
1. Using a suitable device, support the platform support and position it on the rotator.
Note: The platform support weighs approximately 125 lb. (56.8 kg).
2. Install the rotator center bolt.
338 31222415 800S HC3, 860SJ HC3

3. Apply Medium Strength Threadlocking Compound to the bolts and locknuts securing the support to the rotator and install the
bolts and locknuts
4. Torque the nut on the rotator center bolt to 586 ft. lbs. (795 Nm). Torque the retaining bolts to 40 ft. lbs. (55 Nm).
5. Position the platform on the platform support and install the bolts securing the platform to the platform support.
6. Connect the electrical cables to the platform control console.
800S HC3, 860SJ HC3 31222415 339

A, B, D
C, D 1001167596-M
MAF15860M
Figure 83. Platform Support Torque Values
A. Torque to 40 ft. lbs. (55 Nm) D. Check torque every 150 hours of operation
B. Medium Strength Threadlocking Compound E. Torque to 71.5 ft. lbs. (97 Nm)
C. Torque to 586 ft. lbs. (795 Nm)
340 31222415 800S HC3, 860SJ HC3

9.4.2 Bolt-On External Fall Arrest

The Bolt-On External Fall Arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside
the platform. Exit/Enter the platform through the gate area only. The system is designed for use by one person.
Personnel must use fall protection at all times. A full body harness is required with lanyard not to exceed 6 ft. (1.8 m) in length, that
limits the maximum arrest force to 900 lb. (408 kg).
Bolt-On External Fall Arrest System capacity is 310 lb. (140 kg) - one (1) person maximum.
Do not move the platform during use of the Bolt-On External Fall Arrest system.
WARNING
Do not operate any machine functions while outside of platform. Be careful when
entering/exiting the platform at elevation.
WARNING
If the Bolt-On External Fall Arrest System is used to arrest a fall or is otherwise dam-
aged, the entire system must be replaced and the platform fully inspected before
returning to service. Refer to the Service Manual for removal and installation
procedures.
The Bolt-On External Fall Arrest System requires an Annual Inspection and Certifica-
tion. The Annual Inspection and Certification must be performed by a qualified per-
son other than the user.
Inspection Before Use

The Bolt-On External Fall Arrest system must be inspected before each use of the mobile elevating work platform. Replace components if
there are any signs of wear or damage.
Before each use, perform a visual inspection of the following components:
• Cable: Inspect cable for proper tension, broken strands, kinks, or any signs of corrosion.
Figure 84. Bolt-On External Fall Arrest Cable Tension
• Fittings & Brackets: Ensure all fittings are tight and there are no signs of fractures. Inspect brackets for any damage.
• Attachment Ring: No cracks or signs of wear are acceptable. Any signs of corrosion requires replacement.
• Attaching Hardware: Inspect all attaching hardware to ensure there are no missing components and hardware is properly tightened.
• Platform Rails: No visible damage is acceptable.
800S HC3, 860SJ HC3 31222415 341

Installation
1. Install the retaining hardware (bolts, nuts, and washers) and secure the brackets to the platform rail. Tighten the nuts but do not
torque them yet.
2. Attach the fall arrest cable to the right hand bracket Using the attaching bolt and nut. Orient the bolt as shown below. Do not
tighten the nut so cable can still rotate.
3. Install the Attachment Ring onto the cable.
4. Without twisting the fall arrest cable, pull it through the left hand bracket and mark the top of the swaged cable end. Install the
fall arrest cable through the left hand bracket and secure it using the belleville washers, washer, retaining nut, and jam nuts. Orient
the hardware as shown below and with the belleville washers so the gap is present at the outside diameter of the washers. install
the nuts onto the cable finger tight so the mark on the cable does not move.
342 31222415 800S HC3, 860SJ HC3

5. Use the two jam nuts to prevent the cable from rotating while the nut is tightened. Tighten the nut until the belleville washers are
fully compressed and no gap is present at the outside diameter of the washers. Ensure the cable has not rotated during tightening.
6. Tighten the first jam nut against the retaining nut to keep the nut from loosening. Tighten the remaining jam nut against the first
jam nut.
7. Torque the nuts and bolts securing the brackets to 15 ft. lbs. (20 Nm).
Figure 85. Bolt-On External Fall Arrest System
1. Belleville Washer 4. Jam Nut 7. Cable

2. Washer 5. LH Bracket 8. RH Bracket
3. Hex Nut 6. Attachment Ring 9. Decal
800S HC3, 860SJ HC3 31222415 343

9.5 ENGINE
WARNING
Engine fuel lines are pressurized. DO NOT attempt repairs unless specific training
has been completed.
Disclaimer and Scope

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

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/ mechanic
be familiar with the names and locations of the engine components. The following illustration identifies the components that are
referred to throughout this section as shown in Figure – Deutz TD2.9L4 (T4F) Engine Components, page 345, Figure — Deutz D2011LO40
(T4I) Engine Components, page 347, Figure – Deutz TD2.9L4 (China III & IV) Engine Component Location, page 349, Figure — Deutz TD2.9L4
(Stage V) Engine Components, page 351, Figure — Ford MSG425-DF Engine Component Location - Sheet 1 of 2, page 353, and Figure – Ford
MSG425-DF Engine Component Location - Sheet 2 of 2, page 354.
344 31222415 800S HC3, 860SJ HC3

22
21 7
20 2
6
3
19
18
17
16
10
11
12
13
14
15
BM109696A
Figure 86. Deutz TD2.9L4 (T4F) Engine Components
800S HC3, 860SJ HC3 31222415 345

Note: Refer to Figure – Deutz TD2.9L4 (T4F) Engine Components, page 345 for below table.
1. Breather Hose 9. Fuel Filter 17. Water Pump

2. Compensator 10. High Pressure Pump 18. Thermostat
3. Clamp 11. Oil Cooler 19. Temperature Sender
4. Starter 12. Alternator 20. Fuel Pump
5. Inlet 13. Dipstick 21. Fuel Filter

6. Flywheel with Ring Gear 14. Plug 22. ECU (Engine Control Unit)
7. Clamp 15. Oil Filter

8. Outlet 16. Belt Drive
346 31222415 800S HC3, 860SJ HC3

14 15
10
11
13
12
16
2
20
17
19
18
3
1
2
9
8 5
7
BM110898A
Figure 87. Deutz D2011LO40 (T4I) Engine Components
800S HC3, 860SJ HC3 31222415 347

Note: Refer to Figure — Deutz D2011LO40 (T4I) Engine Components, page 347 for below table.
1. Dipstick 8. Alternator 15. Temperature Transmitter
2. Filler Cap 9. V-Belt 16. Fuel Supply Pump
3. Glow Plug 10. Speed Sensor 17. Glow Plug
4. Thermostat 11. Oil Filter 18. Oil Lube Pump

5. Flywheel with Ring Gear 12. Fuel Filter 19. Pressure Control Valve
6. Starter 13. Oil pressure Sensor 20. Control Module
7. Muffler 14. Throttle Actuator
348 31222415 800S HC3, 860SJ HC3

12 1
2
11 3
13
14
15
6
10
7
16 9 30
17 8
29
28
18
19
20
21
22
23
24
25
26
27 BM110901A
Figure 88. Deutz TD2.9L4 (China III & IV) Engine Component Location
800S HC3, 860SJ HC3 31222415 349

Note: Refer to Figure – Deutz TD2.9L4 (China III & IV) Engine Component Location, page 349 for below table.
1. Fill Cap 11. Pressure Sensor 21. Oil Cooler

2. Temperature Sender 12. Charger Air Manifold 22. Glow Plug
3. Breather Line 13. ECU Module 23. Fill Cap
4. EGR Module 14. Fuel Supply Pump 24. Dipstick

5. EGR Control Valve 15. Fuel Filter 25. Oil Filter
6. Turbocharger 16. Injector 26. Alternator
7. Oil Return Tube 17. Pressure Sensor 27. Belt Drive
8. Shuttle Valve 18. Fuel Filter 28. Coolant Pump
9. Flywheel 19. Volume Control Valve 29. Temperature Sender
10. Housing 20. High Pressure Pump 30. Starter
350 31222415 800S HC3, 860SJ HC3

3
8
7 6
9
10
12
11
23
22
21
20 13
14
15
17 16
19 18
BM111620A
Figure 89. Deutz TD2.9L4 (Stage V) Engine Components
800S HC3, 860SJ HC3 31222415 351

Note: Refer to Figure — Deutz TD2.9L4 (Stage V) Engine Components, page 351 for below table.
1. Oil Fill Cap 9. Fuel Filter 17. Oil Fill Cap
2. Breather Hose 10. Fuel Pump 18. Pressure Sensor

3. Turbocharger 11. Temperature Sender 19. Oil Filter
4. Compensator 12. Fuel Injector 20. Belt Drive
5. Starter 13. Overflow Valve 21. Water Pump
6. Pressure Sensor 14. Oil Cooler 22. Thermostat
7. Flywheel with Ring Gear 15. Alternator 23. Temperature Sender
8. ECU (Engine Control Unit) 16. Dipstick
352 31222415 800S HC3, 860SJ HC3

5
4 6
7
3
2 8
9
10
11
17
12
16
13
14
15
18
19
20
21
22
28
27
26
25
24
23
BM111453A
Figure 90. Ford MSG425-DF Engine Component Location - Sheet 1 of 2
800S HC3, 860SJ HC3 31222415 353

Note: Refer to Figure – Ford MSG425-DF Engine Component Location - Sheet 1 of 2, page 353 for below table.
1. Exhaust Pipe Outlet 11. Fan 21. Fuel Injector

2. Gas Line Hose 12. Coolant Outlet 22. ECU Module
3. LP Mixer 13. Exhaust Pipe Inlet 23. Engine Mount (Rear)
4. Surge Tank 14. Engine Mount (LH Front) 24. Hitch Pin
5. Radiator Support 15. Piston Pump Assembly 25. Engine Mount (RH Front)
6. Lockout Valve 16. Gear Pump Assembly 26. Engine Tray
7. Radiator Assembly 17. Muffler 27. Radiator Lower Hose
8. Air Intake Hose 18. Intake Manifold 28. Air Filter

9. Radiator Upper Hose 19. Relay
10. LP Vapor Regulator 20. Coil and Boot Assembly with Spark Plug
29
37
36
35
34
33
32
31
30
BM110522B
Figure 91. Ford MSG425-DF Engine Component Location - Sheet 2 of 2
354 31222415 800S HC3, 860SJ HC3

Note: Refer to Figure – Ford MSG425-DF Engine Component Location - Sheet 2 of 2, page 354 for below table.
29. Temperature Sensor 32. Starter 35. Thermostat (Includes Housing)
30. Oil Pressure Switch 33. Dipstick 36. Pulley
31. Oil Filter 34. Alternator 37. Belt Tensioner
9.5.2 Engine Serial Number

The engine serial number is stamped onto the crankcase and onto the name plate which is attached on air charger casing. Information
contained in the serial number is required in correspondence with the engine manufacturer.
9.5.3 Engine Replacement
CAUTION
Use a suitable hoist or overhead crane and sling with a minimum lifting capacity of
1654 lb. (750 kg).
Engine/Transmission Removal
Note: The radiator assembly must be removed from the machine before engine/transmission removal. Refer to Section – Radiator As-
sembly, page 376. Several additional components must be removed before engine/transmission removal. They will be addressed
in the following procedures.
6. If necessary, remove tray retaining bolt located at the bottom of the engine tray near to pumps assembly which allow tray to
swing out for access.
7. Attach hydraulic tank vacuum and use an approved container to capture any residual hydraulic oil when disconnecting hydraulic
lines. Refer to Section – Fluids and Lubrication, page 21, for detailed instructions.
10. Label, disconnect and cap/plug all hydraulic connections on the engine/transmission.
Note: Engine/transmission harness is routed and attached to engine/ transmission using hold-down clamps and plastic wire ties at
various places on engine. Before removing engine/transmission, ensure that harness has been completely separated (discon-
nected) from engine/ transmission. Move harness clear of engine/transmission, and with help of an observer, ensure that en-
gine/transmission clears the harness during removal.
11. Label and disconnect all electrical wire connections on engine/transmission.
800S HC3, 860SJ HC3 31222415 355

12. Label, disconnect and cap the fuel supply (1), return line (2) and low-pressure gas hose (3) as shown below.
BM110548A
Figure 92. FOR DEUTZ TD2.9L4 (T4F, Stage V, China III and IV)
BM110549A
Figure 93. FOR DEUTZ D2011LO40 (T4I)
356 31222415 800S HC3, 860SJ HC3

BM110550A
Figure 94. FOR FORD MSG425-DF
13. Loosen and remove fuel filter bracket bolts and fuel filter assembly. Refer to Section – Pre-Fuel Filter and Fuel Supply Pump
Assembly, page 394, for removal instructions.
14. Label and remove all clamps securing any fuel line on engine.
15. Remove exhaust pipe from exhaust manifold.
Note: Emission Sensitive Exhaust Assembly must be replaced exactly as removed.
16. Remove generator and pulley assembly from engine mount. Refer to Section – Generator Pulley, page 431, for more details.
17. Remove air cleaner assembly. Refer to Section – Air Filter Assembly, page 368.
18. Remove the radiator/oil cooler assembly. Refer to Section – Radiator Assembly, page 376, for detailed removal instructions.
19. Remove mounting hardware, engine mounts and brackets from engine tray (4) as shown in Figure – Engine Assembly Removal/
Installation of Deutz TD2.9L4 (T4F) and Stage V, page 358, Figure – Engine Assembly Removal/Installation Deutz D2011LO40 (T4I), page
359, Figure – Engine Assembly Removal/Installation Deutz TD2.9L4 (China III and IV), page 360 and Figure – Engine Assembly Removal/
Installation of Ford MSG425-DF, page 361.
20. Remove mounting hardware, engine mounts and brackets from engine tray (4).
21. Connect lifting device onto lifting points of the engine assembly (5).
22. Slightly lift and pull engine assembly (5) out of machine. Have an assistant ensure that engine/transmission clears all frame
components during removal.
23. Place engine assembly (5) on a flat and level surface.
800S HC3, 860SJ HC3 31222415 357

BM110938A
Figure 95. Engine Assembly Removal/Installation of Deutz TD2.9L4 (T4F) and Stage V
4. Engine Tray 6. Bolt (Torque to 111 ft. lb. (150 Nm))

5. Engine Assembly 7. Bolt (Torque to 70 ft. lb. (95 Nm))
358 31222415 800S HC3, 860SJ HC3

5 6
BM112636A
Figure 96. Engine Assembly Removal/Installation Deutz D2011LO40 (T4I)
4. Engine Tray 5. Engine Assembly 6. Bolt (Torque to 111 ft. lb. (150 Nm))
800S HC3, 860SJ HC3 31222415 359

BM110930A
Figure 97. Engine Assembly Removal/Installation Deutz TD2.9L4 (China III and IV)
4. Engine Tray 6. Bolt (Torque to 111 ft. lb. (150 Nm))

5. Engine Assembly 7. Bolt (Torque to 70 ft. lb. (95 Nm))
360 31222415 800S HC3, 860SJ HC3

9
10
9
10
8
9
BM111404A
Figure 98. Engine Assembly Removal/Installation of Ford MSG425-DF
800S HC3, 860SJ HC3 31222415 361

Note: Refer to Figure – Engine Assembly Removal/Installation of Ford MSG425-DF, page 361 for below table.
4. Engine Tray 9. Torque Bolts to 48 ft. lbs. (65 Nm)

5. Engine Assembly 10. Torque Bolts to 20.6 ft. lbs. (28 Nm)
8. Torque Bolts to 40.5 ft. lbs. (55 Nm)
Installation
CAUTION
Use a suitable hoist or overhead crane and sling with a minimum lifting capacity of
1654 lb. (750 kg). Make sure that the engine tray is free from any dirt and debris.
Properly clean the mounting and adjacent areas.
Note: Apply Medium and High Strength Threadlocking Compound to hardware before installation.
1. Attach a lifting chain onto lifting points of the engine assembly (5) and lift engine clear from the ground.
2. Lift engine assembly (5) and slowly push and lower into engine compartment. Have an assistant ensure that engine assembly (5)
clears frame, hose and harness components during engine installation.
3. Position engine mounts and brackets over engine tray (4) as shown in Figure – Engine Assembly Removal/Installation of Deutz
TD2.9L4 (T4F) and Stage V, page 358, Figure – Engine Assembly Removal/Installation Deutz D2011LO40 (T4I), page 359, Figure – Engine
Assembly Removal/Installation Deutz TD2.9L4 (China III and IV), page 360 and Figure – Engine Assembly Removal/Installation of Ford
MSG425-DF, page 361.
4. Align engine mounting holes onto engine tray (4) and install engine assembly (5) using previously removed mounting hardware as
shown in Figure – Engine Assembly Removal/Installation of Deutz TD2.9L4 (T4F) and Stage V, page 358, Figure – Engine Assembly
Removal/Installation Deutz D2011LO40 (T4I), page 359, Figure – Engine Assembly Removal/Installation Deutz TD2.9L4 (China III and IV),
page 360 and Figure – Engine Assembly Removal/Installation of Ford MSG425-DF, page 361.
5. Remove lifting chains.
6. Torque engine mounting bolts as per torque chart shown below. Also you can refer to Figure – Engine Assembly Removal/
Installation of Deutz TD2.9L4 (T4F) and Stage V, page 358, Figure – Engine Assembly Removal/Installation Deutz D2011LO40 (T4I), page
359, Figure – Engine Assembly Removal/Installation Deutz TD2.9L4 (China III and IV), page 360 and Figure – Engine Assembly Removal/
Installation of Ford MSG425-DF, page 361.
Callout Torque Value

6. 111 ft. lbs. (150 Nm)
7. 70 ft. lbs. (95 Nm)
8. 40.5 ft. lbs. (55 Nm)
9. 48 ft. lbs. (65 Nm)
10. 20.6 ft. lbs. (28 Nm)
7. Swing engine tray back into the position and ensure hydraulic oil cooler hoses are clear while closing the engine tray (4). Adjust
hoses accordingly if necessary.
8. Install air cleaner. Refer to Section – Air Filter Assembly, page 368.
9. Install radiator assembly. Refer to Section – Radiator Assembly, page 376.
10. Install generator and pump assembly. Refer to Section – Generator Pulley, page 431, for more details.
11. Install exhaust pipe.
362 31222415 800S HC3, 860SJ HC3

12. Install previously removed fuel filter assembly. Refer to Section – Pre-Fuel Filter and Fuel Supply Pump Assembly, page 394 for
installation.
13. Route and connect previously removed fuel supply (1), return line (2) and low-pressure gas hose (3) onto its connecting points in
engine assembly (5).
14. Connect and secure all the previously labeled hydraulic hoses, fuel lines and electrical wire connections on engine and
transmission.
15. If equipped, install heater and cooling hoses to engine and tighten clamps.
16. Check that all hydraulic system, electrical system, cooling system, fuel system and exhaust system connections are correct and
connected tightly.
18. Check for proper fluid levels prior to startup. Refer to Section – Capacities, page 24.
21. Start engine and run to normal operating temperature then shut off engine. While engine is cooling, check for leaks.
CAUTION
Do Not mix coolant types.
Do Not use unapproved additives.
22. Allow engine to cool. Check radiator coolant level. Add coolant as required.
23. Check for leaks from engine, main hydraulic pump and lines, transmission, hydraulic reservoir and fuel tank. Check levels of all
fluids and lubricants. Fill as required.
24. Start the engine and check engine rpm at full throttle.
Note: During full throttle check: DO NOT operate any hydraulic function. DO NOT steer or apply any pressure to the steering
wheel. Keep transmission in (N) NEUTRAL.
25. Operate all boom functions through their entire range of motion several times to bleed any air out of the hydraulic system..
26. Check hydraulic oil level. If oil is warm, oil level should be visible in gauge window.
27. Check for proper operation of all components.
28. Turn engine OFF.
29. Close and secure both the side hoods.
9.5.4 Surge Tank (Deutz TD2.9L4 (T4F, Stage V, China III and IV))
Removal
800S HC3, 860SJ HC3 31222415 363

lines.
8. Place a Do Not Operate tag on key select switch.
9. Disconnect electrical connector of engine harness from the electrical connector of coolant level sensor attached at bottom of
surge tank.
10. Loosen and remove the surge tank cap (1) as shown in Figure – Surge Tank Removal/Installation, page 366.
11. Drain out coolant from tank into an approved container.
12. Remove clamp and disconnect hose (2) from bottom of surge tank (6) as shown in Figure – Surge Tank Removal/Installation, page
366.
13. Remove clamps and disconnect low pressure hoses (3) from fittings of surge tank (6).
Note: Label and cap/plug the hose openings.
14. Remove port fitting from surge tank (6).
15. Loosen the nut and remove the coolant level sensor (4) from surge tank (6).
16. Remove hardware attaching tank bracket (5) to the radiator support (7).
Note: Surge tank bracket (5) changes as per machine with engine requirement. Prior to remove tank bracket (5) from engine verify
bracket and its fitting arrangement.
17. Remove surge tank (6) from the engine assembly.
18. Remove hardware attaching surge tank (6) to bracket (5).
19. Place surge tank (6) on a clean surface.
Inspection
1. Inspect sensor and wiring harness connector terminal for continuity. Replace a defective or faulty sensor with a new part.
2. Do a leakage check of the surge tank. If necessary, replace the tank with a new part.
Installation
CAUTION
Make sure that the mounting and adjacent area of engine and radiator assembly is
free from any dirt and debris.
1. Position and install surge tank (6) onto the tank bracket (5) using previously removed hardware.
2. Install coolant level sensor (4) onto surge tank (6). Tighten the nut.
3. Position and install surge tank (6) onto radiator support (7) using previously removed hardware.
4. Install fittings onto pressure ports of the surge tank (6).
Note: Make sure to orient fittings at an angles as shown in Figure – Surge Tank Removal/Installation, page 366.
5. Connect and secure all the previously labeled hydraulic hoses onto surge tank (6) and secure using clamps.
364 31222415 800S HC3, 860SJ HC3

6. Connect electrical connector of engine harness onto electrical connector of coolant level sensor (4).
CAUTION
7. Fill the surge tank (6) with coolant. Refer to Section – Capacities, page 24.
8. Install and tighten the surge tank cap (1).
12. Start engine and run to normal operating temperature. Visually check for leaks with engine running. Check coolant level in surge
tank and fill or drain as necessary.
800S HC3, 860SJ HC3 31222415 365

6
2
7 5
45°±5° 90°±5°
BM110926A
Figure 99. Surge Tank Removal/Installation
Refer to Figure – Surge Tank Removal/Installation, page 366 for below table.
1. Surge Tank Cap 4. Coolant Level Sensor 7. Radiator Support

2. Hose 5. Tank Bracket
3. Low Pressure Hose 6. Surge Tank
366 31222415 800S HC3, 860SJ HC3

9.5.5 Pump Coupling Kit

Note: Prior to remove pump coupling kit make sure to remove pumps assemblies, refer to Section – Hydraulic Pumps, page 419.
Removal
lines.
8. Place a Do Not Operate tag on key select switch.
9. Disconnect any electrical connection from pump coupling kit.
10. Remove bolts that attach the adapter plate (1) to the flywheel (3) of the engine assembly as shown in Figure – Pump Coupling Kit
Removal/Installation, page 368.
11. Remove adapter plate (1) from the flywheel (3).
12. Remove bolts that attach the coupling assembly (2) to the flywheel (3) of the engine assembly.
13. Remove coupling assembly (2) from the flywheel (3).
14. Place adapter plate (1) and coupling assembly (2) onto clean surface.
Installation
CAUTION
Make sure that the mounting and adjacent area of engine assembly is free from any
dirt and debris.
Note: Apply Medium Strength Threadlocking Compound to bolts before installation.
1. Position and align mounting holes of coupling assembly (2) onto flywheel (3) as shown in Figure – Pump Coupling Kit Removal/
Installation, page 368.
2. Install coupling assembly (2) onto flywheel (3) using previously removed bolts.
3. Position and align mounting holes of adapter plate (1) onto flywheel (3).
4. Install adapter plate (1) onto flywheel (3) using previously removed bolts.
5. Connect previously removed hydraulic and electrical connections.
800S HC3, 860SJ HC3 31222415 367

BM110909A
Figure 100. Pump Coupling Kit Removal/Installation
1. Adapter Plate 2. Coupling Assembly 3. Fly Wheel
9.5.6 Air Filter Assembly

Removal
6. Disconnect and label all electrical connections from air filter assembly.
7. Remove mounting clamps and attaching parts from air intake hose (1).
8. Carefully pull air intake hose (1) out from engine assembly and air filter assembly (3) mounting locations.
368 31222415 800S HC3, 860SJ HC3

9. For Deutz TD2.9L4 (T4F/Stage V/China III/China IV) Engines:
• Remove hardware attaching bracket (5) to radiator support bracket (6).
• Disconnect restriction tube (4) from restriction indicator (2) as shown in Figure — Air Filter Assembly Removal/Installation — For
Deutz TD2.9L4 (T4F, Stage V, China III and IV), page 370.
• Remove hardware attaching Clamp (7) of the air filter assembly (3) to the Tray (8).
10. For Ford MSG425-DF Engines:
• Remove hardware attaching bracket (5) to radiator support bracket (6).
• Disconnect restriction tube (4) form restriction indicator (2) as shown in Figure — Air Filter Assembly Removal/Installation — For
Ford MSG425-DF, page 375.
• Remove hardware attaching Seal (9) to air filter assembly (3) and radiator support bracket (6).
11. For Deutz D2011LO40 (T4I) Engines:
• Remove hardware attaching plate (10) to radiator support bracket (6).
• Remove restriction indicator (2) from air filter assembly (3) as shown in Figure — Air Filter Assembly Removal/Installation — For
Deutz D2011LO40 (T4I), page 374.
12. Remove air filter assembly (3) form engine assembly and place on clean surface.
13. Remove clamp from air filter assembly (3).
Installation
1. Position and align air filter assembly (3) onto mounting locations on engine brackets.
2. Position air intake hose (1) onto mounting locations of engine assembly and air filter assembly (3).
3. Connect air intake hose (1) onto engine assembly and air filter assembly (3) using mounting clamps and attaching parts.
4. For Deutz TD2.9L4 (T4F/Stage V/China III/China IV) Engines:
• Install Clamp (7) of air filter assembly (3) to the Tray (9) using previously removed hardware.
• Install the hardware attaching bracket (5) in the radiator support bracket (6).
• Connect restriction tube (4) to the restriction indicator (2) as shown in Figure — Air Filter Assembly Removal/Installation — For
Deutz TD2.9L4 (T4F, Stage V, China III and IV), page 370.
5. For Ford MSG425-DF Engines:
• Install Seal (9) to the air filter assembly (3) and radiator support bracket (6) using previously removed hardware as shown in
Figure — Air Filter Assembly Removal/Installation — For Ford MSG425-DF, page 375.
• Install bracket (5) to the radiator support bracket (6) using previously removed hardware.
• Connect restriction tube (4) to the restriction indicator (2) as shown in Figure — Air Filter Assembly Removal/Installation — For
Ford MSG425-DF, page 375.
6. For Deutz D2011LO40 (T4I) Engines:
• Install restriction indicator (2) onto air filter assembly (3) as show in Figure — Air Filter Assembly Removal/Installation — For
Deutz D2011LO40 (T4I), page 374.
• Install plate (10) to the radiator support bracket (6) using previously removed hardware as show in Figure — Air Filter Assembly
Removal/Installation — For Deutz D2011LO40 (T4I), page 374.
7. Connect previously labeled electrical connection to air filter assembly.
800S HC3, 860SJ HC3 31222415 369

7
6
8
2
BM112641A
Figure 101. Air Filter Assembly Removal/Installation — For Deutz TD2.9L4 (China III)
370 31222415 800S HC3, 860SJ HC3

Note: Refer to Figure — Air Filter Assembly Removal/Installation — For Deutz TD2.9L4 (China III), page 370 for below table.
1. Air Intake Hose 4. Restriction Tube 7. Clamp

2. Restriction Indicator 5. Bracket 8. Support Tray
3. Air Filter Assembly 6. Radiator Support Bracket
800S HC3, 860SJ HC3 31222415 371

7
6
8
2
BM110921A
Figure 102. Air Filter Assembly Removal/Installation — For Deutz TD2.9L4 (China IV)
372 31222415 800S HC3, 860SJ HC3

Note: Refer to Figure — Air Filter Assembly Removal/Installation — For Deutz TD2.9L4 (China IV), page 372 for below table.
1. Air Intake Hose 4. Restriction Tube 7. Clamp

2. Restriction Indicator 5. Bracket 8. Support Tray
800S HC3, 860SJ HC3 31222415 373

10
6 3
BM112637A
Figure 103. Air Filter Assembly Removal/Installation - For Deutz D2011LO40 (T4I)
1. Air Intake Hose 3. Air Filter Assembly 10. Plate
2. Restriction Indicator 6. Radiator Support Bracket
374 31222415 800S HC3, 860SJ HC3

1
9
BM110922A
Figure 104. Air Filter Assembly Removal/Installation - For Ford MSG425-DF
1. Air Intake Hose 4. Restriction Tube 9. Seal

2. Restriction Indicator 5. Bracket
800S HC3, 860SJ HC3 31222415 375

9.5.7 Radiator Assembly

Radiator Assembly Replacement
Before considering radiator assembly replacement for other than obvious damage, conduct a cooling system pressure test check coolant
specific gravity, coolant level, fan belt tension and temperature indicator.
• If engine runs hot, check temperature of radiator hoses.
• If hoses are not hot, thermostat may be stuck in closed position.
• If engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked
cylinder head or block, and/or other internal engine damage.
Note: The Deutz D2011LO40 (T4I) engine is cooled by engine oil.
Note: Prior to do removal/installation of Radiator Assembly, make sure to remove air filter assembly and surge tank assembly. Refer to
Section – Air Filter Assembly, page 368 and Section – Surge Tank, page 363.
Removal
2. Turn key Select switch to (center) OFF position, push in power/emergency stop switch (down) to OFF and remove the key.
6. Disconnect and label any electrical connections to radiator assembly.
7. Place a suitable container beneath radiator drain.
8. Place a funnel at base of radiator to channel drained coolant into a container.
9. Open drain plugs and slowly remove to allow coolant to drain.
10. Transfer coolant into a properly labeled container. Dispose of properly if coolant needs replaced.
11. Close radiator drain plug.
12. Remove clamps or fittings attaching radiator hoses (1 and 2) to radiator assembly (3) and engine assembly (4) as shown in Detail A
of Figure — Radiator Assembly Removal/Installation — Deutz TD2.9L4 (T4F, Stage V, China III and IV), page 378, Figure – Radiator
Assembly Removal/Installation - Deutz D2011LO40 (T4I), page 380 and Figure — Radiator Assembly Removal/Installation — For Ford
13. Disconnect and label radiator hoses (1 and 2) as shown in Detail A.
14. Remove mounting hardware and brackets attaching radiator assembly (3) to support bracket (5).
15. Carefully lift the radiator assembly (3) out of the engine compartment.
16. Remove hardware attaching fan (6) and fan adapter (7) to engine assembly (4) as shown in Detail A.
17. Remove fan (6) and fan adapter (7) from engine assembly (4) and place on clean surface.
Installation
1. Position fan (6) and fan adapter (7) onto engine assembly (4).
2. Install fan (6) and fan adapter (7) onto engine assembly (4) using hardware as shown in Detail A.
Note: Apply Medium Strength Threadlocking Compound to hardware before installation.
3. Position radiator assembly (3) onto engine compartment at the original mounting orientation.
376 31222415 800S HC3, 860SJ HC3

4. Install radiator assembly (3) onto support bracket (5) using previously removed brackets and hardware as shown in Detail A of
Figure — Radiator Assembly Removal/Installation — Deutz TD2.9L4 (T4F, Stage V, China III and IV), page 378, Figure – Radiator
Assembly Removal/Installation - Deutz D2011LO40 (T4I), page 380 and Figure — Radiator Assembly Removal/Installation — For Ford
5. Make sure to maintain a clearance between fan tip and radiator assembly shroud as shown in View B of Figure — Radiator
Assembly Removal/Installation — For Ford MSG425-DF, page 381.
6. Uncap and connect previously labeled radiator hoses (1 and 2) onto radiator assembly (3) and engine assembly (4) using clamps or
fittings as shown in Detail A.
7. Install air filter assembly and surge tank assembly. Refer to Section – Air Filter Assembly, page 368 and Section – Surge Tank, page
363.
CAUTION
8. Open surge tank cap and fill the radiator completely with coolant. Replace and tighten surge tank cap. Refer to Section –
Capacities, page 24, for proper capacities.
10. Start engine and run engine to operating temperature. Visually check for leaks with engine running. Check all fluid levels for
correct levels.
11. Shut the engine OFF.
800S HC3, 860SJ HC3 31222415 377

3 4
6
7
BM110941A
Figure 105. Radiator Assembly Removal/Installation — Deutz TD2.9L4 (T4F, Stage V, China III and IV)
378 31222415 800S HC3, 860SJ HC3

Note: Refer to Figure — Radiator Assembly Removal/Installation — Deutz TD2.9L4 (T4F, Stage V, China III and IV), page 378 for below
table.
1. Radiator Hose 4. Engine Assembly 7. Fan Adapter
2. Radiator Hose 5. Radiator Support Bracket

3. Radiator Assembly 6. Fan
800S HC3, 860SJ HC3 31222415 379

1
2
3 4
7
6
BM110939A
Figure 106. Radiator Assembly Removal/Installation - Deutz D2011LO40 (T4I)

380 31222415 800S HC3, 860SJ HC3

A
B
6 4
7
2
BM110944A
Figure 107. Radiator Assembly Removal/Installation - For Ford MSG425-DF
800S HC3, 860SJ HC3 31222415 381

Note: Refer to Figure – Radiator Assembly Removal/Installation - For Ford MSG425-DF, page 381 for below table.
*Make sure to maintain gap of 13 mm (± 2 mm) from Fan Tip to Radiator Shroud.

9.5.8 Thermostat
Thermostat Replacement
Before considering thermostat replacement, check the coolant level, fan belt tension and instrument cluster temperature indicator.
• If engine seems to take a long time to warm up, thermostat may be stuck in the open position and requires replacement.
• If engine runs hot, check temperature of upper radiator hose.
• If hose is not hot, thermostat may be stuck in closed position.
• If engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked
cylinder head or block, and/or other internal engine damage.
Thermostat Removal
7. Slowly turn surge tank cap to first stop and allow any pressure to escape. Remove surge tank cap.
8. Place a funnel at base of radiator to channel drained coolant into container. Loosen the drain plug and slowly remove to allow
coolant to drain.
9. Transfer coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced.
10. Disconnect, label and cap hoses attached to the thermostat.
11. Disconnect and label electrical connection attached to thermostat.
12. For Deutz TD2.9L4 (T4F, Stage V, China III and IV) Engines:
• Remove bolts securing thermostat housing (1A) to engine assembly.
• Remove thermostat housing (1A), old gasket and thermostat. Clean gasket surfaces. Do Not let any debris into thermostat
opening. Refer to Figure – Thermostat Location on Engines, page 384 for location of thermostat on engine.
13. For Deutz D2011LO40 and Ford MSG425-DF Engines:
• Remove thermostat housing (1B or 1C) using suitable tool from engine assembly. Clean dirt and debris from thermostat
opening. Refer to Figure – Thermostat Location on Engines, page 384 for location of thermostat on engine.
Thermostat Installation
Note: ALWAYS use correct thermostat and install a new gasket.
NEVER operate engine without a thermostat, or engine damage will occur.
382 31222415 800S HC3, 860SJ HC3

1. For Deutz TD2.9L4 (T4F, Stage V, China III and IV) Engines:
Install thermostat, thermostat gasket and thermostat housing (1A) onto engine assembly using previously removed bolts. Refer to
Figure – Thermostat Location on Engines, page 384 for location of thermostat on engine.
2. For Deutz D2011LO40 and Ford MSG425-DF Engines:

Install thermostat (1B or 1C) using suitable tool onto engine assembly. Refer to Figure – Thermostat Location on Engines, page 384
for location of thermostat on engine.
3. Connect previously labeled electrical and hose connections to thermostat.
4. Open the surge tank cap, fill system complete to the “Full Cold” level with coolant. Install and tighten the surge tank cap.
8. Start engine and run to normal operating temperature. Visually check for leaks with engine running.
CAUTION
9. Check coolant level in surge tank and fill or drain as necessary.
800S HC3, 860SJ HC3 31222415 383

1A
1C
1B
BM110929A
Figure 108. Thermostat Location on Engines
1A. Thermostat Housing (For Deutz T4F, Stage V, China III and IV Engines) 1C. Thermostat Housing (For Ford MSG425-DF Engine)
1B. Thermostat Housing (For Deutz D2011LO40 Engine)
384 31222415 800S HC3, 860SJ HC3

9.5.9 Coolant Temperature Sensor
BM110931A
1. Coolant Temperature Sensor
Engine coolant temperature sensor (1) is located near to thermostat housing as shown above.
Note: Coolant temperature sensor (1) location varies as per machine with engine requirement. Prior to service temperature sensor veri-
fy location and its fitting arrangement on engine assembly.
Removal
7. Disconnect temperature sensor connector from wiring harness connector.
8. Loosen and remove coolant temperature sensor (1) from engine block.
Inspection and Replacement

Inspect sensor and wiring harness connector terminals for continuity. Replace a defective or faulty sensor with a new part.
Installation and Testing
1. Apply a lubricate to O-ring of temperature sensor.
2. Install coolant temperature sensor (1) onto engine block as shown.
800S HC3, 860SJ HC3 31222415 385

3. Connect sensor connector to wiring harness connector.
7. Check for proper coolant level.
8. Start engine, allow it to reach operating temperature and observe operator instrument cluster for warning indication. If sensor is
not defective, the problem could be as follows:
a. Possibly in a shorted wire
b. Improper-running engine
c. Improper or low coolant
d. Obstructed or faulty radiator and coolant pump
e. Loose fan belt, defective instrument display etc.
9. Turn engine OFF.
9.5.10 Relay Assembly

Removal
6. Disconnect and label all electrical connections from relay assembly.
Note: Record wiring connections to relay assembly to ensure correct installation later.
7. Remove hardware attaching relay (1) to bracket (2) as shown in Figure – Relay Assembly Removal/Installation, page 387.
8. Remove mounting bracket (2) from engine tray using hardware as shown in Figure – Relay Assembly Removal/Installation, page 387.
Installation
Note: Prior to do installation verify circuit of relay assembly and if necessary, replace unit with new assembly.
1. Position bracket (2) onto mounting location of engine tray.
2. Install bracket (2) onto engine tray using hardware as shown in Figure – Relay Assembly Removal/Installation, page 387.
3. Position and install relay (1) onto mounting bracket (2) using previously removed hardware.
4. Connect previously labeled electrical connections onto relay assembly.
386 31222415 800S HC3, 860SJ HC3

BM110990A
Figure 109. Relay Assembly Removal/Installation
A. For Deutz TD2.9L4 (T4F, Stage V, China III and IV) 1. Relay
B. For Deutz D2011LO40 (T4I) 2. Bracket

3. Contactor
800S HC3, 860SJ HC3 31222415 387

9.5.11 Starter
Testing Starter on Engine
For Starter (1) testing procedures refer to Section – Starter, page 87.
Removal
Remove starter (1) only if it fails. Follow below instructions to remove starter from engine Relay Assembly.
6. Disconnect and label electrical connections from starter.
7. Remove wires from solenoid stud. Remove positive (+) battery cable from starter (1).
8. Disconnect and label wire from starter solenoid housing stud. Record how wires are installed to ensure correct installation later.
9. Loosen but Do Not remove hardware securing starter as shown in Figure – Starter Removal/Installation, page 389. Support starter
securely as it is relatively heavy and will fall if not supported.
10. Support starter and remove fasteners securing starter. Remove negative (-) ground cable from starter mounting bolt.
11. Remove starter (1) from engine assembly.
Installation
1. Position starter (1) onto mounting opening on flywheel housing.
2. Position negative (-) ground cable over correct starter mounting bolt. Secure starter (1) with previously removed hardware as
shown in Figure – Starter Removal/Installation, page 389.
3. Connect positive (+) battery cable to solenoid stud. Install wires to solenoid stud, and secure with lock washer and nut.
4. Connect previously labeled electrical connections to starter.
388 31222415 800S HC3, 860SJ HC3

D
1
1 A
1
B
1
C
BM110942A
Figure 110. Starter Removal/Installation
A. For Deutz TD2.9L4 (T4F and Stage V) C. Ford MSG425-DF 1. Starter
B. For Deutz D2011LO40 (T4I) D. For Deutz TD2.9L4 (China III and IV)
800S HC3, 860SJ HC3 31222415 389

9.5.12 Alternator
Removal
Remove alternator (1) only if it fails. Follow below instructions to remove Alternator from engine assembly.
6. Disconnect and label electrical connections from alternator.
7. Remove hardware attaching pulley to alternator (1).
Note: Record belt routing for future installation.
8. Remove mounting capscrew securing alternator (1) to engine assembly as shown on Figure – Alternator Removal/Installation, page
391.
9. Remove alternator (1) form engine assembly and place on clean surface.
Installation
1. Position and align mounting holes of alternator (1) onto engine bracket.
2. Install alternator (1) onto engine bracket using previously removed hardware as shown on Figure – Alternator Removal/Installation,
page 391.
3. Install pulley onto alternator (1) using previously removed hardware.
4. Route belt properly onto pulley.
5. Check for proper belt alignment. (Refer to appropriate Operation and Safety Manual).
6. Connect previously labeled electrical connection to alternator.
390 31222415 800S HC3, 860SJ HC3

C
BM110943A
Figure 111. Alternator Removal/Installation
A. For Deutz TD2.9L4 (T4F, Stage V, China III and IV) C. Ford MSG425-DF
B. For Deutz D2011LO40 (T4I) 1. Alternator
800S HC3, 860SJ HC3 31222415 391

9.5.13 Fuel Tank

Note: Fuel tank is a one-piece unit. It is located on tank tray plate opposite to engine. If it is determined that fuel tank must be re-
moved, fuel must be drained before tank removal. Discard used fuel as per approved guideline.
Removal
6. Disconnect, label and cap all hydraulic hoses and electrical wirings attached to fuel tank. Cap/Plug all fittings and openings to keep
dirt and debris from entering to fluid system.
7. Remove and retain drain plug (1) from fuel tank (2) as shown in Figure – Fuel Tank Removal/Installation, page 393. Drain fuel into an
approved and suitable container. Discard the used fuel as per approved guideline.
8. Remove nuts, washers and mounting strap (4) attaching fuel tank (2) onto tank tray plate (3).
9. Remove fuel tank (2) from machine and place on clean surface.
Inspection
1. Inspect fuel tank thoroughly for any cracks, slices, leaks or other damage.
2. With fuel tank removed from machine, plug all openings except one elbow fitting. Install elbow fitting, and apply approximately 1
- 1.5 psi (7 - 10 kPa) of air pressure through elbow.
3. Check reservoir for leaks by applying a soap solution to exterior and look for bubbles to appear at cracked or damaged area.
4. If necessary, replace faulty oil sensor from fuel tank by removing attached hardware.
Installation
CAUTION
Make sure that the mounting and adjacent area at tank-side tray plate is free from
any dirt and debris.
1. Position and align mounting holes of fuel tank (2) onto tank tray plate (3).
Note: Make sure to install tank into its original orientation.
2. Attach fuel tank (2) onto tank tray plate (3) using mounting strap (4), washers and nuts. Torque nuts to 35 ft. lbs. (48 Nm).
Note: Apply Medium Strength Threadlocking Compound to nuts before installation.
3. Install drain cap (1) onto fuel tank (2).
4. Uncap and connect the previously labeled hydraulic hoses and electrical connection to their appropriate locations.
Note: Make sure that all lines are free of kinks and sharp bends.
5. Fill fuel tank according to specifications. Refer to Section – Capacities, page 24.
6. Check fuel tank and supply and return hoses for leaks.
392 31222415 800S HC3, 860SJ HC3

1
3
BM110965A
Figure 112. Fuel Tank Removal/Installation
1. Drain Cap 3. Tank Mount

2. Fuel Tank 4. Mounting Strap
800S HC3, 860SJ HC3 31222415 393

9.5.14 Pre-Fuel Filter and Fuel Pump

Note: This section is applicable for Deutz TD2.9L4 (T4F, Stage V, China III and IV) and Ford MSG425-DF Engines.
Removal
lines.
9. For Deutz (T4F, Stage V, China III and IV):

a. Disconnect electrical connectors from fuel filter (2) as shown in Figure — Pre-Fuel Filter and Fuel Pump - Removal/Installation
(For Deutz (T4F, Stage V, China III and IV)), page 396.
b. Remove clamps from supply hoses connected to the fuel filter (2).
c. Disconnect fuel supply hoses from the fuel filter (2).
d. Remove hardware attaching fuel filter (2) to the tank side mounting plate.
e. Remove fuel filter (2) from machine.
10. For Ford MSG425-DF:

a. Disconnect electrical connectors from fuel Supply Pump (1) as shown in Figure — Pre-Fuel Filter and Fuel Pump - Removal/
Installation (For Ford MSG425-DF), page 397.
b. Remove clamps from supply hoses connected to the fuel filter (2) and supply pump (1).
c. Disconnect fuel supply hoses from the fuel filter (2) and supply pump (1).
d. Remove hardware attaching fuel filter (2) to the tank side mounting plate.
e. Remove fuel filter (2) from machine.
f. Remove hardware attaching fuel supply pump (1) to the tank side mounting plate.
g. Remove fuel supply pump (1) from machine.
Installation
CAUTION
Make sure that the mounting and adjacent area at tank-side tray plate is free from
any dirt and debris.
Note: If necessary, to replace pre-fuel filter, refer to Section – Replacing the Fuel Pre-Filter, page 63 for Deutz TD2.9L4 (T4F, Stage V, China
III and IV) for detailed instructions.
394 31222415 800S HC3, 860SJ HC3

1. Position and align fuel supply pump (1) onto the tank side mounting plate as shown in Figure — Pre-Fuel Filter and Fuel Pump -
Removal/Installation (For Deutz (T4F, Stage V, China III and IV)), page 396 and Figure — Pre-Fuel Filter and Fuel Pump - Removal/
Installation (For Ford MSG425-DF), page 397.
2. Install fuel supply pump (1) onto mounting plate using previously removed hardware.
3. Position and align fuel filter (2) onto the tank side mounting plate.
4. Install fuel filter (2) onto mounting plate using previously removed hardware.
5. Connect and secure all the previously labeled hydraulic hoses onto supply pump (1) and fuel filter (2) and secure using clamps.
Note: Make sure that to orient fittings of supply hoses onto fuel filter (2) at an angle down to -45° from horizontal.
6. Connect previously removed electrical connector onto supply pump (1).
7. Check all hydraulic and electrical system connections are correct and connected tightly.
8. Check for proper fluid levels prior to startup. Refer to Section – Capacities, page 24.
800S HC3, 860SJ HC3 31222415 395

2
1
BM110999A
Figure 113. Pre-Fuel Filter and Fuel Pump - Removal/Installation (For Deutz (T4F, Stage V, China III and IV))
1. Fuel Pump 2. Fuel Filter
396 31222415 800S HC3, 860SJ HC3

BM110564A
Figure 114. Pre-Fuel Filter and Fuel Pump - Removal/Installation (For Ford MSG425-DF)
1. Fuel Pump 2. Fuel Filter
800S HC3, 860SJ HC3 31222415 397

9.5.15 Ford 2.5L Engine Fuel System Repair

Propane Fuel Filter Replacement
Figure 115. Filter Lock Assembly
1. Electric Lock off Solenoid 5. Electrical Connector 9. Fuel Inlet

2. Housing Seal 6. Fuel Outlet 10. Ring
3. Filter Magnet 7. O-ring
4. Filter Housing 8. Filter
REMOVAL
1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
3. Slowly loosen the Filter housing and remove it.
4. Pull the filter housing from the Electric lock off assembly.
5. Remove the filter from the housing.
6. Locate Filter magnet and remove it.
7. Remove and discard the housing seal.
8. If equipped, remove and discard the retaining bolt seal.
9. Remove and discard mounting plate to lock off O-ring seal.
INSTALLATION
NOTICE
Be sure to reinstall the filter magnet into the housing before installing new seal
1. Install the mounting plate to lock off O-ring seal.
2. If equipped, install the retaining bolt seal.
3. Install the housing seal.
4. Drop the magnet into the bottom of the filter housing.
5. Install the filter into the housing.
6. If equipped, install the retaining bolt into the filter housing.
398 31222415 800S HC3, 860SJ HC3

7. Install the filter up to the bottom of the electric lock off.
8. Tighten the filter bowl retainer to 106 in. lbs. (12 Nm).
9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane
Fuel System Leak Test.
Propane Fuel System Pressure Relief
CAUTION
The propane fuel system operates at pressures up to 312 psi (21.5 bar). To minimize
the risk of fire and personal injury, relieve the propane fuel system pressure (where
applicable) before servicing the propane fuel system components.
To relieve propane fuel system pressure:
1. Close the manual shut-off valve on the propane fuel tank.
2. Start and run the vehicle until the engine stalls.
3. Turn the ignition switch OFF.
CAUTION
Residual vapor pressure will be present in the fuel system. Ensure the work area is
well ventilated before disconnecting any fuel line.
Propane Fuel System Leak Test
CAUTION
Never use an open flame of any type to check for propane fuel system leaks.
Always inspect the propane fuel system for leaks after performing service. Check for leaks at the fittings of the serviced or replaced
component. Use a commercially available liquid leak detector or an electronic leak detector. When using both methods, use the
electronic leak detector first to avoid contamination by the liquid leak detector
800S HC3, 860SJ HC3 31222415 399

9.6 TRANSMISSION
Refer to Section — Hydraulic Pumps, page 419 for detailed instructions on pump assemblies.
9.7 HYDRAULIC CYLINDERS
9.7.1 Main Lift Cylinder

Removal
1. Elevate the boom enough to gain access to the lift cylinder lower pivot pin.
2. Use an adequate lifting device to support the weight of the boom and associated components as shown below.
Note: The lifting device must be able to support approximately 5350 lb. (2430 kg).
3. Tag and disconnect the hydraulic hoses from the lift cylinder.
4. Use an adequate lifting device to support the lift cylinder.
Note: The 800S lift cylinder weighs approximately 691.8 lb. (313.8 kg). The 860SJ lift cylinder weighs approximately 620 lb. (281
kg).
5. Remove the bolt and keeper pin securing the main lift cylinder pivot pin and remove the pivot pin.
400 31222415 800S HC3, 860SJ HC3

6. Remove the bolt and keeper pin securing the lower lift cylinder pivot pin and remove the pivot pin.
MAF25871
7. Using the lifting device, slide the lift cylinder back enough to allow the cylinder end to clear the attachment point on the boom.
8. Slide the lift cylinder sideways enough to remove it from the machine.
Installation
1. Using an adequate lifting device, position the lift cylinder in the machine in the same manner that it was removed.
kg).
2. Using a suitable brass drift and hammer, install the barrel end pivot pin. Secure pivot pin with mounting hard-ware.
MAF25871
3. Extend the cylinder rod until it aligns with the attachment point on the boom. Take care not to extend the cylinder rod too far.
800S HC3, 860SJ HC3 31222415 401

4. Using a suitable brass drift and hammer, install the rod end pivot pin. Secure pivot pin with mounting hardware.
9.7.2 Telescope Cylinder/Boom Cable

Removal
1. Make sure the machine is on a firm, level surface.
2. Raise the boom to a horizontal position.
3. Extend the boom approximately 2 ft. (0.6 m). This will enable access to the bolts that secure the cable mount block to the boom fly
section.
4. Tag and disconnect all hydraulic hoses running to the telescope cylinder. Cap or plug all openings to prevent any foreign matter
from entering the hydraulic system.
5. Using a 3/8 drive extension approximately 4 ft. (1.2 m) long, remove the bolts and washers securing the cable mount block to the
boom fly section.
6. Remove the four bolts, shims, and attachment blocks that secure the telescope cylinder barrel to the boom mid section.
402 31222415 800S HC3, 860SJ HC3

7. Remove the four bolts, shims, and mounting blocks that secure the telescope cylinder rod to the boom base section.
NOTICE
When removing the telescope cylinder from the boom, it may be necessary at some
point to turn the cylinder slightly in order to clear assemblies mounted within the
boom. Care must be taken to move the cylinder slowly from the boom. Damage to
components may result from forcible impact with these assemblies.
kg).
8. Using overhead cranes or other suitable lifting/supporting devices, carefully pull the telescope cylinder out from the back of the
boom. At the same time, also pull the cable mount block out so the extension cables come out with the telescope cylinder and do
not bind. The lifting/supporting devices will have to be repositioned to support the weight of the cylinder as it is drawn out of the
boom.
9. Push the boom fly sections back in to gain access to the boom retraction cable.
10. Remove the screws securing the sheave guards to the boom mid section and remove the sheave guards.
800S HC3, 860SJ HC3 31222415 403

11. Remove the adjusting nuts and lock nuts from the opposite end of the retraction cables at the front of the boom base section. To
aid in installing new retraction cables, fasten a length of tie wire as long as the retraction cables to the ends of the cables.
12. Twist the ends of the retraction cables to remove the ends of the cables from the slots in the side of the boom fly section.
13. From the rear of the boom, pull out the boom retraction cables.
Installation
1. Attach the threaded end of the new retraction cables to the tie wires used in the removal procedure.
2. From the front of the boom, pull the retraction cables through the boom and through the attachment holes in the bottom of the
boom base section. Loosely install the adjustment nuts and jam nuts.
3. Install new retract sheaves, then route the opposite end of the retraction cables around the sheaves. Push the ends of the cables
through the slots in the side of the boom fly section.
404 31222415 800S HC3, 860SJ HC3

4. Install the sheave guards and secure them in place with the retaining screws.
5. Pull the boom sections out to approximately where they were extended to for telescope cylinder removal.
6. Install a new extend sheave on the end of the telescope cylinder.
7. Route new extend cables around the telescope cylinder. Loosely fasten the threaded end of the cables to the rod end of the
telescope cylinder with the adjusting nuts and lock nuts. Install the opposite end of the cables in the cable mount block.
8. Use tape or tie straps to fasten the cables to the telescope cylinder assembly. It is important that the tape or straps be strong
enough to hold the cable in place yet weak enough to break and fall away when the cables are adjusted.
NOTICE
When pushing the telescope cylinder into the boom, it may be necessary at some
boom. Care must be taken to move the cylinder slowly into the boom. Damage to
kg).
9. Using adequate lifting equipment, carefully push the telescope cylinder assembly and cables back into the boom.
800S HC3, 860SJ HC3 31222415 405

10. Apply medium strength threadlocking compound to the bolts and fasten the telescope cylinder rod to the boom base section with
the bolts, shims, mounting blocks.
11. Apply medium strength threadlocking compound to the bolts and fasten the telescope cylinder barrel to the boom mid section
with the bolts, shims, mounting blocks.
12. Using a 3/8 drive extension approximately 4 ft. (1.2 m) long, install the bolts and washers securing the cable mount block to the
boom fly section. Tape the bolts to the socket at the end of the extension to prevent it from coming out of the socket before it
engages the mounting threads.
13. Connect all the hydraulic lines to the cylinder as tagged during the removal procedure.
14. Adjust the boom cables as outlined under Section — Wire Rope Tensioning Procedure.
15. Run the boom through all lift and telescope functions and check for proper operation or any leakage.
406 31222415 800S HC3, 860SJ HC3

9.7.3 Rotator and Level Cylinder

Removal
Note: Refer to Figure — Removal/Installation of Components - Rotator and Level Cylinder, page 408.
800S
1. Remove the Platform and Platform Support. Refer to Section — Platform, page 337.
2. Extend the fly boom section out to gain access to the platform level cylinder pin.
3. Tag and disconnect hydraulic lines to rotator. Use suitable container to retain any residual hydraulic fluid. Cap or plug all openings
of hydraulic lines and ports.
Note: The rotator weighs approximately 54 lb. (25 kg).
4. Supporting the rotator, remove hardware from pin #1. Using a suitable brass drift and hammer remove pin #1.
Note: The platform level cylinder weighs approximately 63.3 lb. (28.7 kg).
5. Supporting the platform level cylinder, remove the hardware from pin #2. Using a suitable brass drift and hammer, remove pin #2
from the rotator and remove the rotator.
6. Tag and disconnect hydraulic lines to platform level cylinder. Use suitable container to retain any residual hydraulic fluid. Cap or
plug all openings of hydraulic lines and ports.
7. Remove the hardware from pin #3. Using a suitable brass drift and hammer remove pin #3 from the fly boom and remove platform
level cylinder.
860SJ
1. Remove the Platform and Platform Support. Refer to Section — Platform, page 337.
2. Extend the fly boom section out to gain access to the platform level cylinder pin.
3. Tag and disconnect hydraulic lines to rotator. Use suitable container to retain any residual hydraulic fluid. Cap or plug all openings
of hydraulic lines and ports.
Note: The jib assembly weighs approximately 302 lb. (137.1 kg).
4. Supporting the rotator and jib assembly, remove hardware from pin #1. Using a suitable brass drift and hammer remove pin #1
from the jib assembly.
5. Remove the hardware from pin #2. Using a suitable brass drift and hammer, remove pin #2 from the jib assembly and remove the
rotator.
6. Supporting the platform level cylinder, remove the hardware from pin #3. Using a suitable brass drift and hammer remove pin #3
from the jib assembly.
7. Remove the hardware from pin #4. Using a suitable brass drift and hammer remove pin #4 from the fly boom. Remove the
platform level cylinder.
800S HC3, 860SJ HC3 31222415 407

Figure 116. Removal/Installation of Components - Rotator and Level Cylinder

Installation
Note: Refer to Figure — Removal/Installation of Components - Rotator and Level Cylinder, page 408
800S
1. Support the platform level cylinder. Using a suitable brass drift and hammer, install pin #3 to the fly boom. Install hardware
securing pin #3.
2. Support the rotator, using a suitable brass drift and hammer, install pin #2 to the rotator. Install hardware securing pin #2.
3. Using a suitable brass drift and hammer, install pin #1 to the rotator. Install hardware securing pin #1 and torque to 35 ft. lbs. (48
Nm).
408 31222415 800S HC3, 860SJ HC3

4. Remove cap or plugs from openings of hydraulic lines and ports and connect hydraulic lines to rotator and platform level cylinder
as tagged during removal.
860SJ
1. Support the platform level cylinder. Using a soft head mallet, install pin #4 to the fly boom. Install hardware securing pin #4.
Note: The jib assembly weighs approximately 302 lb. (137.1).
2. Support the jib assembly. Using a soft head mallet install pin #3 to jib assembly. Install hardware securing pin #3.
3. Support the rotator, using a soft head mallet, install pin #2 to the jib assembly. Install hardware securing pin #2 and torque to 41 ft.
lbs. (55 Nm).
4. Using head mallet install pin #1 to jib assembly and install the rotator. Install hardware securing pin #1 and torque to 35 ft. lbs. (48
Nm).
5. Remove cap or plugs from openings of hydraulic lines and ports and connect hydraulic lines to rotator and platform level cylinder
as tagged during removal.
9.7.4 Steer Cylinder

Removal
WARNING
lated components.
2. Rotate machine and position counterweight 180 degree from axle/wheel components being serviced.
WARNING
death.
CAUTION
3. Turn key Select switch to (center) OFF position, push in power/emergency stop switch (down) to OFF and remove the key.
7. Tag and disconnect hydraulic lines to steer cylinder (5). Use suitable container to retain any residual hydraulic fluid.
8. Cap or plug all openings of hydraulic lines and ports.
9. If necessary, use suitable lifting device, jack, or hoist. Make sure that machine will remain in place during removal.
800S HC3, 860SJ HC3 31222415 409

10. Support spindle assembly (3) and cylinder (5) and remove bolt and keeper pin from rod end of cylinder (5) as shown in Figure —
Steer Cylinder - Removal/Installation (Without Tow Package), page 411 and Figure — Steer Cylinder - Removal/Installation (With Tow
Package), page 412.
Note: The steer cylinder (5) weighs approximately 32.4 lb. (14.7 kg).
11. Using a suitable brass drift and soft head mallet, remove pivot pin (1) from spindle assembly (3).
12. Remove the bolt and keeper pin from the pin (2) of the barrel end of cylinder (5).
13. Using a suitable brass drift and soft head mallet, remove pin (2) and washer from mounting bracket of axle assembly (6) as shown
in Figure — Steer Cylinder - Removal/Installation (Without Tow Package), page 411 and Figure — Steer Cylinder - Removal/Installation
(With Tow Package), page 412.
14. Remove steer cylinder (5) from machine and place on clean and dirt-free surface.
15. If necessary, remove tie-rod (4) from mounting locations as shown in Figure — Steer Cylinder - Removal/Installation (Without Tow
Package), page 411 and Figure — Steer Cylinder - Removal/Installation (With Tow Package), page 412.
Installation
CAUTION
Make sure that the cylinder assemblies and pivot pins are free from any dirt and de-
bris. Properly clean the mounting and adjacent areas of axle and steering
assemblies.
Note: When inspecting pins and bearings Refer to Section – Pins and Composite Bearing Repair Guidelines, page 42.
Note: Prior to install cylinder onto machine mounting location, refer to Section — Hydraulic Cylinders, page 507, for detailed instruction
for Disassembly/Assembly of cylinder.
1. Position and align piston end of steer cylinder (5) with the mounting holes on axle assembly (6) as shown in Figure — Steer
Cylinder - Removal/Installation (Without Tow Package), page 411 and Figure — Steer Cylinder - Removal/Installation (With Tow
Package), page 412.
2. Using a soft head mallet, install pin (2) and washer to secure piston end of steer cylinder (5) on axle assembly (6).
3. Install keeper pin and bolt to secure pin (2). Torque bolt to 35 ft. lbs. (50 Nm).
4. If previously removed, position and align mounting holes of tie-rod (4) on spindle assembly (3).
5. Position and align head end of steer cylinder (5) with the mounting holes on spindle assembly (3).
6. Using a soft head mallet, install pivot pin (1) on spindle assembly (3) as shown in Figure — Steer Cylinder - Removal/Installation
(Without Tow Package), page 411 and Figure — Steer Cylinder - Removal/Installation (With Tow Package), page 412.
7. Install keeper pin and bolt to secure pivot pin (1). Torque bolts to 35 ft. lbs. (50 Nm).
Note: Apply medium strength threadlocking compound to bolt before installation
8. Remove cap or plugs from openings of hydraulic lines and ports.
9. Connect hydraulic lines to steer cylinder (5) as tagged during removal.
11. Remove the Do Not Operate Tag from the ignition key switch.
12. Remove any lifting devices and/or supports used during removal and installation of steer cylinder.
410 31222415 800S HC3, 860SJ HC3

6
2
*
5
BM110952A
Figure 117. Steer Cylinder - Removal/Installation (Without Tow Package)
*While installing steer cylinder (5), make sure that these ports are pointing in the upward direction as shown in Figure — Steer Cylinder - Removal/Installation (Without Tow
Package), page 411.
1. Pivot pin 3. Spindle Assembly 5. Steer Cylinder
2. Pin 4. Tie Rod 6. Axle Assembly
800S HC3, 860SJ HC3 31222415 411

4 *
BM110954A
Figure 118. Steer Cylinder - Removal/Installation (With Tow Package)
*While installing steer cylinder (5), make sure that these ports are pointing in the upward direction as shown in Figure — Steer Cylinder - Removal/Installation (With Tow
Package), page 412.
1. Pivot pin 3. Spindle Assembly 5. Steer Cylinder
2. Pin 4. Tie Rod 6. Axle Assembly
412 31222415 800S HC3, 860SJ HC3

9.8 HYDRAULIC VALVES
9.8.1 Platform Control Valve

Removal
1. Tag and disconnect the hydraulic lines from the platform control valve. Use suitable container to retain any residual hydraulic fluid.
Cap hydraulic lines and ports.
2. Remove hardware securing high pressure filter to filter mounting bracket. Remove high pressure filter.
3. Remove hardware securing filter mounting bracket to valve mount. Remove filter mounting bracket.
4. Remove hardware securing cover to the platform support. Remove cover.
800S HC3, 860SJ HC3 31222415 413

5. Remove hardware securing the mounting bracket to the platform support. Take out the mounting bracket along with platform
control valve.
6. Remove hardware securing the platform control valve to the mounting bracket. Remove platform control valve.
414 31222415 800S HC3, 860SJ HC3

Installation
1. Install platform control valve onto the mounting bracket and secure using hardware.
2. Install the mounting bracket onto the platform support and secure using hardware.
3. Install cover onto the platform support and secure with mounting hardware.
4. Install filter mounting bracket on side of valve mount and secure with mounting hardware.
800S HC3, 860SJ HC3 31222415 415

5. Install high pressure filter onto filter mounting bracket and secure with mounting hardware.
6. Remove tag and reconnect the hydraulic lines to the platform control valve.
9.8.2 Main Control Valve

Removal
2. Disconnect battery power from the machine, turn key select switch to (center) OFF position and push in power/emergency stop
switch (down) to OFF. Remove the key.
4. Open both the side hoods. Allow the system fluids to cool.
5. Tag and disconnect hydraulic lines and electrical connection from control valve.
6. Using suitable container to retain any residual hydraulic fluid. Cap and plug all openings of hydraulic lines and ports.
7. Remove bolts (3) and washers (4) securing main control valve (1) onto frame mounting plate (2) as shown in Figure —Main Control
Valve - Removal/Installation, page 418.
8. Remove main control valve (1) from frame mounting plate (2).
Note: The main control valve approximately weighs 38 lb. (17.2 kg).
9. Carefully place the main control valve (1) onto clean surface.
Installation
CAUTION
Change in temperatures have a significant impact on pressure readings. Prior to in-
stall make sure that the control valve hydraulic pressures are correctly set. Refer to
Section — Start-up After Overhaul or Replacement of Components, page 263.
CAUTION
Make sure that the main control valve is free from any dirt and debris. Properly
clean the mounting and adjacent areas of frame.
1. Position main control valve (1) onto the frame mounting plate (2).
2. Align mounting holes of control valve (1) with holes on mounting plate (2).
416 31222415 800S HC3, 860SJ HC3

3. Attach main control valve (1) onto mounting plate (2) using bolts (3) and washers (4) as shown in Figure — Main Control Valve -
Removal/Installation, page 418. Torque bolts (3) to 35 ft. lbs. (48 Nm).
Note: Apply medium strength threadlocking compound to bolts (3) before installation.
4. Remove tag and reconnect all hydraulic lines.
5. Remove tag and reconnect all electrical connections to the main control valve as tagged during removal.
6. Properly connect the battery.
8. Remove the Do Not Operate Tag from ignition key switch.
800S HC3, 860SJ HC3 31222415 417

3
4
1
BM111000A
Figure 119. Main Control Valve - Removal/Installation
1. Main Control Valve 3. Bolt

2. Mounting Plate 4. Washer
418 31222415 800S HC3, 860SJ HC3

9.9 HYDRAULIC PUMPS
9.9.1 Variable Pump Assembly

Removal
WARNING
Ensure that pressure is properly relieved from the hydraulic system before proceed-
ing to remove the pump.
1. Disconnect the hydraulic hoses from the inlet and the outlet ports of the variable pump assembly.
NOTICE
Cap all the hydraulic hoses to prevent entrapment of dust and dirt.
2. Remove bolts (1) and washers (2) securing the variable pump assembly (3) to the hydrostatic pump assembly (4) as shown in
Figure — Variable Pump Removal/Installation — Deutz Engine, page 420 and Figure — Variable Pump Removal/Installation — Ford
Engine, page 420.
3. Carefully remove the variable pump assembly (3) from the hydrostatic pump assembly (4).
4. Carefully place the variable pump assembly (3) on a clean working surface.
5. Remove and discard the O-ring (5) from the hydrostatic pump assembly (4).
Installation
NOTICE
Disassembly of the pump should be performed on a clean work surface in a dirt-free
work area.
1. Check the gear teeth on the shaft for scoring, pitting, tapering, and damage. If damaged, replace with a new assembly.
2. Apply a thin film of spline grease on the gear shaft.
3. Insert a new O-ring (5) in the groove of the hydrostatic pump assembly (4).
4. Carefully install the variable pump assembly (3) on the hydrostatic pump assembly (4) and secure using two bolts (1) and washers
(2). Torque the bolts to 20-24 ft. lbs. (27-33 Nm).
Note: Apply Medium Strength Threadlocking Compound to the bolts before installation.
5. Remove caps from the hydraulic hoses and reconnect to their original locations.
800S HC3, 860SJ HC3 31222415 419

5
3
2
1 BM112689A
Figure 120. Variable Pump Removal/Installation — Deutz Engine
1. Bolt 3. Variable Pump Assembly 5. O-ring
2. Washer 4. Hydrostatic Pump Assembly
5
3
2
1 BM112688A
Figure 121. Variable Pump Removal/Installation — Ford Engine
1. Bolt 3. Variable Pump Assembly 5. O-ring
2. Washer 4. Hydrostatic Pump Assembly
9.9.2 Hydrostatic Pump Assembly

Removal
WARNING
Ensure that pressure is properly relieved from the hydraulic system before proceed-
ing to remove the pump.
420 31222415 800S HC3, 860SJ HC3

1. Disconnect the hydraulic hoses from the inlet and the outlet ports of the hydrostatic pump.
NOTICE
Cap all the hydraulic hoses to prevent entrapment of dust and dirt.
2. Remove bolts (1) and washers (2) securing the hydrostatic pump assembly (3) to the engine assembly (4) as shown in Figure —
Hydrostatic Pump - Removal/Installation — Deutz Engine, page 422 and Figure — Hydrostatic Pump - Removal/Installation — Ford
Engine, page 422.
3. Remove the hydrostatic pump assembly (3) from the engine assembly (4).
4. Carefully place the hydrostatic pump assembly (3) on a clean working surface.
Installation
NOTICE
Disassembly of the pump should be performed on a clean working surface in a dirt-
free work area.
1. Check the gear teeth on shaft for scoring, pitting, tapering, and damage. If damaged, replace with a new assembly.
2. Apply a thin film of spline grease on the gear shaft.
3. Carefully insert the shaft into the engine assembly (4) and secure the hydrostatic pump assembly (3) using bolts (1) and washers
(2).
Note: For Ford MSG425-DF engine, torque the bolts to 50.2 – 55.3 ft. lbs. (68 - 75 Nm).
Note: For Deutz Engine, torque the bolts to 46 - 56 ft. lbs. (62 - 76 Nm).
Note: Apply Medium Strength Threadlocking Compound to the bolts before installation.
4. Remove caps from the hydraulic hoses and reconnect to their original locations.
5. Fill the hydraulic pump to the required level.
800S HC3, 860SJ HC3 31222415 421

2
1
BM112691A
Figure 122. Hydrostatic Pump — Removal/Installation — Deutz Engine
Note: Refer to Figure – Hydrostatic Pump — Removal/Installation — Deutz Engine, page 422 for below callout table.
1. Bolt 3. Hydrostatic Pump Assembly
2. Washer 4. Engine Assembly
4 3
2
1
BM112690A
Figure 123. Hydrostatic Pump — Removal/Installation — Ford Engine
1. Bolt 3. Hydrostatic Pump Assembly
2. Washer 4. Engine Assembly
9.10 ELECTRICAL COMPONENTS
9.10.1 Battery
Note: Eye protection is recommended before inspecting and/or replacing the battery.
Removal
422 31222415 800S HC3, 860SJ HC3

3. Place a Do Not Operate tag to the ignition key switch.
6. Disconnect negative and positive battery cable.
7. Remove caps (1), nuts (2), washers (3), J-bolts (4) and bracket (5) securing battery (6).
8. Remove battery (6) from engine-side sheet bracket.
9. place battery into clean and dry surface.
Inspection
1. Visually inspect the battery.
2. Check terminals for corrosion.
3. Replace the battery if it has a cracked, melted, leakage or damaged case.
Installation
1. Place battery (6) onto its mounting location.
2. Install battery (6) using bracket (5), J-bolts (4), washers (3), nuts (2) and caps (1).
3. Connect negative and positive battery cable.
6. Remove Do Not Operate tag from ignition key switch.
7. Pull out power/ emergency stop switch (UP) to ON position, turn key select switch to ON position.
800S HC3, 860SJ HC3 31222415 423

5
1 6
2
3
A
BM110968A
Figure 124. Battery Removal/Installation
424 31222415 800S HC3, 860SJ HC3

Note: Refer to Figure — Battery Removal/Installation, page 424 for below table.
1. Cap 3. Washer 5. Bracket

2. Nut 4. J-Bolt 6. Battery
9.11 TURNTABLE
9.11.1 Swing Bearing

Removal
1. From Ground Control station, operate the boom adequately to provide access to frame opening to rotary coupling.
WARNING
Never work beneath the boom without first engaging boom safety prop or provid-
ing adequate overhead sling support and/or blocking.
2. Attach an adequate support sling to the boom and draw all slack from sling. Prop or block the boom if feasible.
3. From inside turntable, remove mounting hardware which attach rotary coupling retaining yoke brackets to turntable.
NOTICE
to avoid the entry of contaminants into the system.
4. Tag and disconnect the hydraulic lines from the fittings on the top of the rotary coupling. Use a suitable container to retain any
residual hydraulic fluid. Immediately cap lines and ports.
5. Attach suitable overhead lifting equipment to the base of the turntable weldment.
6. Use a suitable tool to scribe a line on the inner race of the swing bearing and on the underside of the turntable. This will aid in
aligning the bearing upon installation. Remove the bolts and washers which attach the turntable to the bearing inner race. Discard
the bolts.
7. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing. Ensure that no damage occurs to the
turntable, bearing or frame-mounted components.
8. Carefully place the turntable on a suitably supported trestle.
9. Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame. This line will aid in aligning the bearing
upon installation. Remove the bolts and washers which attach the outer race of the bearing to the frame. Discard the bolts. Use
suitable lifting equipment to remove the bearing from the frame, then move the bearing to a clean, suitably supported work area.
800S HC3, 860SJ HC3 31222415 425

Figure 125. Swing Bearing Removal (800S)
426 31222415 800S HC3, 860SJ HC3

Figure 126. Swing Bearing Removal (860SJ)
800S HC3, 860SJ HC3 31222415 427

Installation
1. Using suitable lifting equipment, carefully lower the swing bearing into position on the frame. Ensure the scribed line of the outer
race of the bearing aligns with the scribed line on the frame. If a new swing bearing is used, ensure that the filler plug fitting is at
90 degrees from the fore and aft center line of the frame.
CAUTION
JLG Industries recommends that all removed bearing bolts be discarded and re-
placed with new bolts. Since the swing bearing is the only structural link between
the frame and turntable, it is imperative that such replacement hardware meets JLG
specifications. Use of genuine JLG hardware is highly recommended.
2. Apply a light coating of High Strength Threadlocking Compound to the new bearing bolts and loosely install the bolts and
washers through the frame and outer race of bearing.
NOTICE
If compressed air or electrically operated impact wrench is used for tightening the
bearing attachment bolts, the torque setting accuracy of the tool should be
checked prior to use.
3. Refer to the Torque Sequence diagram as shown in Figure — Swing Bearing Torque Sequence, page 614, Clean any residue off the
new bearing bolts, then apply a light coating of High Strength Threadlocking Compound and install the bolts and washers
through the frame and outer race of the bearing. Tighten the bolts to an initial torque of 190 ft. lbs. (260 Nm) w/High Strength
Threadlocking Compound.
4. Using suitable lifting equipment, carefully position the turntable assembly above the machine frame.
5. Carefully lower the turntable onto the swing bearing, ensuring that the scribed line of the inner race of the bearing aligns with
scribed line on the turntable. If a new swing bearing is used, ensure that the filler plug fitting is at 90 degrees from the fore and aft
center line of the turntable.
6. Clean any residue off the new bearing bolts, then apply a light coating of High Strength Threadlocking Compound and install the
bolts and washers through the turntable and inner race of the bearing.
7. Following the Torque Sequence diagram shown in Figure — Swing Bearing Torque Sequence, page 614, tighten the bolts to a
torque of 190 ft. lbs. (260 Nm).
8. Remove the lifting equipment.
9. Install the rotary coupling retaining yoke brackets, apply a light coating of High Strength Threadlocking Compound to the
attaching bolts and secure the yoke to the turntable with the mounting hardware.
10. Connect the hydraulic lines to the rotary coupling as tagged prior to removal.
11. At ground control station, use boom lift control to lower boom to stowed position.
12. Using all applicable safety precautions, activate the hydraulic system and check the swing system for proper and safe operation.
Torque Values
1. Outer Race - 190 ft. lbs. (258 Nm) w/High Strength Threadlocking Compound.
2. Inner Race - 190 ft. lbs. (258 Nm) w/High Strength Threadlocking Compound.
3. See Swing Bearing Torquing Sequence.
WARNING
Check the inner and outer swing bearing bolts for missing or looseness after first 50
hours of operation and every 600 hours thereafter.
428 31222415 800S HC3, 860SJ HC3

9.11.2 Counterweight
If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure — Counterweight
Bolt Torque, page 429.
Figure 127. Counterweight Bolt Torque
1. Counterweight Plate 3. Torque bolts to 480 ft. lbs. (651 Nm)

2. Apply High Strength Threadlocking Compound to Bolt Threads and to Threads in 4. Torque bolts to 285 ft. lbs. (388 Nm)
Counterweight
5. Counterweight Casting
800S HC3, 860SJ HC3 31222415 429

3
1
BM109837A
Figure 128. Counterweight Bolt Torque (China Built Only)
1. Torque bolts 4. Washer

2. Cap Plug 5. Weight
3. Plate Washer
430 31222415 800S HC3, 860SJ HC3

9.12 GENERATOR PULLEY
9.12.1 7500W and 4000W - Deutz TD2.9L4 (T4F and Stage V Engines)
REMOVAL
1. Remove the hardware securing the pulley belt tensioner assembly (1) to the generator (4) and remove pulley belt tensioner.
2. Remove hardware attaching tapered bushing (2) to the generator pulley (3) and remove tapered bushing and pulley from the
generator shaft.
Note: The generator approximately weighs 103 lb (47 kg).
3. Using suitable lifting equipment, adequately support engine assembly weight along entire length.
4. Remove the hardware securing generator (4) to the engine and remove generator from engine assembly.
INSTALLATION
1. Install generator (4) to the engine and secure with hardware. Torque hardware to 71.5 ft. lbs. (97 Nm).
2. Install generator pulley (3) and tapered bushing (2) on the generator shaft and secure with hardware. Torque hardwares for
tapered bushing with 9 ft. lbs. (12 Nm).
Note: Ensure that generator pulley is aligned with engine pulley.
3. Install pulley belt tensioner assembly (1) to generator and secure with hardware.
2 MAF33770
Figure 129. Generator and Pulley (7500W and 4000W) - Deutz TD2.9L4 and Deutz TD2.9L4 (Stage V) Engines
800S HC3, 860SJ HC3 31222415 431

9.12.2 2500W - Ford

REMOVAL
1. Remove the hardware securing the pulley belt adjusting arm (1) to the generator (2) and remove pulley belt adjusting arm.
2. Remove hardware securing engine pulleys (3) to the engine shaft and remove the pulleys.
Note: The generator approximately weighs 36.5 lb (16 kg).
INSTALLATION
1. Install generator (2) to the engine and secure with hardware. Torque hardwares to 51.6 ft. lbs. (70 Nm).
2. Install engine pulleys (3) on the engine shaft and secure with hardware.
3. Install pulley belt adjusting arm (1) to generator and secure with hardwares. Torque hardware for adjuster to engine to 35 ft. lbs.
(47.4 Nm) and adjuster to generator to 14 ft. lbs. (19 Nm).
Note: Adjust the belt tension to 90 lb (400N).
Figure 130. Generator and Pulley (2500W) - Ford
9.12.3 2500W - Deutz D2011LO40

REMOVAL
1. Remove the hardware securing the pulley belt adjusting arm (1) to the generator (2) and remove adjusting arm.
2. Remove hardware attaching engine pulley (3) to engine shaft and remove engine pulley.
432 31222415 800S HC3, 860SJ HC3

INSTALLATION
1. Install generator (2) to the engine and secure with hardware.
2. Install engine pulley (3) to the engine shaft and secure with hardware. Torque hardwares to 38 lb. ft (52 Nm).
3. Install pulley belt adjusting arm (1) to generator (2) and secure with hardware.
3 1
2
MAF33040
Figure 131. Generator and Pulley (2500W) - Deutz D2011LO40
9.12.4 7500W Skypower - Deutz D2011LO40

REMOVAL
generator shaft.
INSTALLATION
1. Install generator (4) to the engine and secure with hardwares. Torque hardwares to 71.5 ft. lbs. (97 Nm).
800S HC3, 860SJ HC3 31222415 433

tapered bushing with 9 lb. ft (12 Nm).
3. Install pulley belt tensioner (1) to generator and secure with hardware.
Figure 132. Generator and Pulley (7500W Skypower) - Deutz D2011LO40
9.12.5 7500W Skypower - Ford DF

REMOVAL
generator shaft.
Note: The generator approximately weighs 94.3 lb (42.8 kg).
INSTALLATION
2. Install generator pulley (3) and tapered bushing (2) on the generator shaft and secure with hardware.
434 31222415 800S HC3, 860SJ HC3

Figure 133. Generator and Pulley (7500W Skypower) - Ford DF
9.12.6 4000W - Deutz D2011LO40

REMOVAL
generator shaft.
Note: The generator approximately weighs 95 lb (43 kg).
INSTALLATION
tapered bushing with 9 lb. ft (12 Nm).
800S HC3, 860SJ HC3 31222415 435

Figure 134. Generator and Pulley (4000W) - Deutz D2011LO40
9.12.7 2500W - Deutz TD2.9L4

REMOVAL
1. Remove the hardware securing the pulley belt adjusting arm (1) to the generator (2) and remove pulley belt adjusting arm.
2. Remove hardware attaching engine pulley (3) to engine shaft and remove engine pulley.
INSTALLATION
2. Install engine pulley (3) to the engine shaft and secure with hardware.
436 31222415 800S HC3, 860SJ HC3

3. Install pulley belt adjusting arm (1) to generator and secure with hardware.
MAF33780
Figure 135. Generator and Pulley (2500W) - Deutz TD2.9L4
800S HC3, 860SJ HC3 31222415 437

438
SECTION 10
DISASSEMBLY AND ASSEMBLY
10.1 DRIVE ASSEMBLY
10.1.1 Drive Hub

MAIN COVER PLATE DISASSEMBLY
Note: Refer to Figure — Main Cover Plate Disassembly, page 439; Figure — Carrier Subassembly Removal - Sheet 1 of 2, page 440 & Figure
— Carrier Subassembly Removal - Sheet 2 of 2, page 441.
1. Perform roll check and leak check prior to disassembling the unit.
2. Remove the magnetic pipe plug (6H) from cover plate (6A) and drain the oil out of the gearbox.
Note: Record the condition and volume of the oil.
3. Remove eight bolts (17) followed by four special bolts (18) from cover subassembly.
4. Lift the cover subassembly off of the unit.
5. Lift ring gear (4) off the unit.
Figure 136. Main Cover Plate Disassembly
4. Ring Gear 17. Hex Bolt

6A. Cover Plate 18. Special Bolt
6H. Pipe Plug
6. If applicable remove spacer (14) from the input shaft (11).
7. Remove the sun gear (13).
8. Lift out the Carrier subassembly from the unit.
9. Remove the input spacer (12) from the unit.
800S HC3, 860SJ HC3 31222415 439

Disassembly and Assembly
10. Remove two thrust spacers (15) and thrust bearing (16) from the internal gear (2).
11. Remove internal gear (2) from the unit.
12. Remove input shaft subassembly from the hub spindle subassembly.
13. Take out input coupling subassembly of the hub spindle subassembly.
Figure 137. Carrier Subassembly Removal - Sheet 1 of 2
2. Internal Gear 13. Sun Gear

11. Input Shaft 15. Thrust Washer
12. Input Spacer 16. Thrust Bearing
Note: Figure — Main Cover Plate Disassembly, page 439, refers to 30, 35, 50, 64 & 73: 1 Ratios.
440 31222415 800S HC3, 860SJ HC3

BM102079A
Figure 138. Carrier Subassembly Removal - Sheet 2 of 2
2. Internal Gear 13. Sun Gear 16. Thrust Bearing
11. Input Shaft 14. Spacer 19. Coupling
12. Input Spacer 15. Thrust Washer
Note: Figure — Carrier Subassembly Removal - Sheet 1 of 2, page 440 refers to 18, 24, 31 & 43: 1 Ratios.
CARRIER DISASSEMBLY
Note: Refer to Figure — Carrier Disassembly, page 442.
1. Drive planet shaft (3E) out of the carrier pin holes, forcing the roll pin (3G) to sheer off.
2. Hold on to the planet gear (3F) and push the planet shaft (3E) out of the carrier (3A) the thrust washers (3B) & (3h) will slide off the
shaft as it is removed.
3. Using a hammer and punch, drive the roll pin (3G) out of the planet shaft (3E) and carrier (3A).
4. Remove first set of needle bearings (3C) from the inside of the planet gear (3F).
5. Remove thrust washer (3D) from planet gear (3F).
6. Remove second set of needle bearings (3C) from the inside of the planet gear (3F).
7. Repeat steps from 1 to 6 for the remaining two planet gears (3F).
800S HC3, 860SJ HC3 31222415 441

Figure 139. Carrier Disassembly
3A. Carrier 3D. Thrust Washer 3G. Roll Pin

3B. Washer 3E. Planet Shaft 3H. Ball Indent Washer
3C. Needle Bearing 3F. Cluster Gear
COUPLING DISASSEMBLY
Note: Refer to Figure — Coupling Disassembly, page 442.
CAUTION
Safety glasses must be worn during this next steps.
1. If necessary, remove Internal retaining ring (20) from the groove of coupling (19).
2. If necessary, remove external retaining ring (21) from the groove of coupling (19).
21
19
20
BM110099A
Figure 140. Coupling Disassembly
19. Coupling 20. Internal Retaining Ring 21. External Retaining Ring
442 31222415 800S HC3, 860SJ HC3

INPUT SHAFT DISASSEMBLY

Note: Refer to Figure — Input Shaft Disassembly, page 443.
CAUTION
Safety glasses must be worn during this next steps.
1. If necessary, remove external retaining ring (10) from the groove of the input shaft (11).
BM102082A
Figure 141. Input Shaft Disassembly
10. External Retaining Ring 11. Input Shaft
COVER DISASSEMBLY
Note: Refer to Figure — Cover Disassembly, page 444.
1. Remove the O-ring (5) from groove in cover (6A) and discard O-ring (5).
2. Remove two thrust washers (15) and thrust bearing (16) from cover (6A).
3. Remove two hex bolts (6C) from disengage cap (6D), if required.
4. Remove the disengage cap (6D) from the cover cap (6B).
5. Pull the disengage rod (6E) out of the cover cap (6B).
6. Remove O-ring (6F) from the cover cap (6B) and discard it.
7. Remove two hex bolts (6C) from cover cap (6B), if required.
8. Remove cover cap (6B) from cover plate (6A).
9. Remove O-ring (6G) and discard it.
10. Remove pipe plug (6H) from the cover (6A).
800S HC3, 860SJ HC3 31222415 443

BM102083A
Figure 142. Cover Disassembly
5. O-ring 6D. Disengage Cap 6H. Pipe Plug
6A. Cover Plate 6E. Disengage Rod 15. Thrust Washer

6B. Cover Cap 6F. O-ring 16. Thrust Bearing
6C. Hex Bolt 6G. O-ring
HOUSING-SPINDLE DISASSEMBLY
Note: Refer to Figure — Housing Spindle Disassembly, page 445.
CAUTION
Safety glasses must be worn during these next steps.
1. Remove Internal retaining ring (9) from the groove of the spindle (1A).
2. Remove thrust washer (7) from the spindle (1A).
3. Remove spring (8) from the spindle (1A).
4. Remove thrust washer (7) from the spindle (1A).
444 31222415 800S HC3, 860SJ HC3

5. Set the unit on a bench so that the spindle (1A) flange is down.
BM102084A
Figure 143. Housing Spindle Disassembly
1A. Spindle 1E. Bearing Cup 1I. External Retaining Ring 5. O-ring
1B. Lip Seal 1F. Bearing Cone 1J. Pipe Plug 8. Spring
1C. Bearing Cup 1G. Housing 1N. Stud 7. Thrust Washer
1D. Bearing Cone 1H. Thrust Washer 1Q. Boot Seal 9. Internal Retaining Ring
Figure 144. Housing Cross Section
6. Remove the O-ring (5) from the housing (1G) and discard it.
CAUTION
7. Remove retaining ring (1I) from the groove of spindle (1A).
8. Remove thrust washer (1H) from the spindle (1A).
9. Remove two pipe plugs (1J) from the housing (1G).
800S HC3, 860SJ HC3 31222415 445

10. Turn the unit over and carefully place the unit on a support base until the spindle (1A) post rests on it. Ensure there is enough gap
to lower the housing (1G) down.
Figure 145. Housing Cross Section
11. Use a dead blow hammer on the housing (1G) flange to drive the inboard bearing cone (1F) off of the spindle (1A).
12. Lift the spindle (1A) out of the housing (1G).
13. If required, remove boot seal (1Q) from the housing (1G).
14. Remove lip seal (1B) from the housing (1G).
15. Remove the bearing cone (1D) from the bearing cup (1C).
16. Using a hammer and punch drive the inboard bearing cup (1E) out of the housing (1G). Be careful not to damage the counterbore
in the housing.
17. Turn the housing (1G) over and drive the outboard bearing cup (1C) out of the housing (1G). Be careful not to damage the
counterbore in the housing.
COVER SUBASSEMBLY
Note: Refer to Figure — Cover Disassembly, page 444.
1. Screw pipe plug (6H) into cover plate (6A) using thread sealant and hand hexagonal wrench.
2. Apply grease and position O-ring (6G) over cover cap (6B) until it rests against the flange.
3. Blow out internal groove of cover cap (6B) with air hose. Place greased O-ring (6F) into internal groove of cover cap (6B).
Note: The disconnect rod (6E) may be used to push the greased O-ring (6F) into position in the O-ring groove of the cover cap
(6B).
4. Place cover cap (6B) into cover plate (6A) with larger flange hole on cover cap (6B) located over pipe plug (6H) fasten cover cap
(6B) with two bolts (6C) located 180 degrees apart. Torque bolts to 70-80 in. lbs. (95- 108 Nm).
5. Place disengage cap (6D) on cover cap (6B) with nipple facing out. Secure with two bolts (6C) located 180 degrees apart. Torque
bolts (6C) to 70-80 in. lbs. (95-108 Nm).
6. Turn cover plate (6A) over and push disconnect rod (6E) into cover cap (6B), until disconnect rod (6E) bottoms out on the
disengage cap (6D).
7. Grease and install O-ring (5) into groove on the cover plate (6A).
8. Grease and install thrust washers (15) and thrust bearing (16) into cover plate (6A).
Note: Thrust washers (15) has to be assembled onto either sides of thrust bearing (16) and then, this has to be greased and in-
stalled as a single unit into cover plate (6A).
446 31222415 800S HC3, 860SJ HC3

CARRIER SUBASSEMBLY
Note: Refer to Figure — Carrier Disassembly, page 442.
1. Apply a liberal coat of grease to the bore of cluster gear (3F). This will enable the needle rollers (3C) to be held in place during
assembly.
2. Install first row of 14 needle rollers (3C) into the bore of cluster gear (3F).
Note: The last roller installed must be installed end wise. That is the end of the last roller must be placed in between the ends of
the two rollers that form the space and then slid parallel to the other rollers into place.
3. Place one spacer (3D) on top of the needle rollers (3C) inside the planet gear (3F).
4. Install second row of 14 needle rollers (3C) into the bore of cluster gear (3F) against spacer (3D). Grease and install ball indent
washers (3H) onto the counterbores of either sides of cluster gear (3F) with indents away from the cluster gears.
5. Place carrier (3A) into tool fixture so that one of the roll pin holes is straight up.
6. Start planet shaft (3E), with end opposite roll pin hole first, through the planet shaft hole in carrier (3A), making sure that the roll
pin hole with the large chamfer in the planet shaft is straight up.
7. Using ample grease to hold it in position, slide one thrust washer (3B) over planet shaft (3E) with tang resting in the cast slot of
carrier (3A).
8. With large end of cluster gear (3F) facing the roll pin hole in the carrier (3A), place cluster gear (3F) into position in carrier (3A) and
push planet shaft (3E) through the cluster gear (3F) without going all the way through.
9. Slide the second thrust washer (3B) between the cluster gear (3F) and the carrier (3A) with the tang of washer located in the cast
slot of carrier (3A). Finish sliding planet shaft (3E) through the thrust washers (3H) & (3B) and into carrier (3A).
10. Position the chamfered side on the planet shaft (3E) roll pin hole so that it is in line with the hole in the carrier (3A) using a 1/8 in.
(3.17 mm) diameter punch.
11. After using a 3/16 in. (4.76 mm) punch to align the two roll pin holes. Drive the roll pin (3G) through carrier (3A) and into planet
shaft (3E) until the roll pin (3G) is flush with the bottom of the cast tang slot in the carrier (3A). Use a 1/4 in. (6.35 mm) pin punch to
make sure the roll pin (3G) is flush in the slot.
12. Repeat the steps from 1 through 11 for the remaining two cluster gears (3F).
HOUSING SPINDLE SUBASSEMBLY

Note: Refer to Figure — Housing Spindle Disassembly, page 445.
1. If required, using stud pressing fixture press studs (1N) into the flange holes of the hub (1G), be sure stud heads are tight to the
hub flange face.
2. Place hub (1G) on table such that long hub end is up.
3. Press bearing cup (1E) using T148905 with the large diameter side up into cover end of hub (1G).
4. Turn hub (1G) over and press bearing cup (1C) into hub (1G) using T148905 with small diameter side up.
Note: Apply generous amount of lubricating oil on all bearings at the time of installation.
5. Place bearing cone (1D) on bearing cup (1C).
6. Press bearing seal (1B) with the open face down into the hub (1G), be sure seal is flush with the hub face.
Note: Generally Seals should not be reused.
7. If the unit requires seal boot (1Q) place on hub (1G) with flange end facing up. Coat the inside surface of the seal - boot - flange
with liberal amount of grease.
800S HC3, 860SJ HC3 31222415 447

8. Place spindle (1A) with large diameter end down on the bench and coat the seal shoulder with oil.
9. Place hub (1G) onto spindle (1A) making sure the seal (1B) is in position on the seal shoulder of spindle (1A).
Note: The bearing cone (1F) is a press fit onto spindle (1A) and is installed using snap ring assembly tool T205660.
10. Place snap ring assembly tool T205660 onto spindle (1A).
11. Place bearing cone (1F) onto the tapered portion of snap ring assembly tool T205660.
12. Place spacer (1H) and retaining ring (1I) onto the top of the bearing cone (1F).
13. Slowly press bearing cone (1F) spacer (1H) and retaining ring (1I) all at once using a bearing pressing tool, T137970, until the
retaining ring (1I) falls into the retaining ring groove on the spindle (1A).
14. Install pipe plug (1J) into hub (1G).
15. Grease and install O-ring (5) into hub (1G).
16. Grease and install thrust washer (7) into spindle (1A).
17. Install spring (8) into spindle (1A) until it bottoms on thrust washer (7).
18. Grease and place second thrust washer (7) on spring (8).
19. Using retaining ring pliers, push retaining ring (9) against thrust washer (7) until retaining ring snaps into place in the spindle (1A)
groove.
COUPLING SUBASSEMBLY
Note: Refer to Figure — Coupling Disassembly, page 442.
CAUTION
1. If necessary, install external retaining ring (21) into groove on OD of coupling (19).
2. If necessary, install Internal retaining ring (20) into retaining ring groove of the coupling (19).
INPUT SHAFT SUBASSEMBLY

Note: Refer to Figure — Input Shaft Disassembly, page 443.
CAUTION
1. If necessary, install retaining ring (10) onto the groove of input shaft (11).
CARRIER SUBASSEMBLY
Note: Refer to Figure — Main Cover Plate Disassembly, page 439; Figure — Carrier Subassembly Removal - Sheet 1 of 2, page 440 & Figure
— Carrier Subassembly Removal - Sheet 2 of 2, page 441.
1. Place hub-spindle subassembly on the table with spindle flange side down.
2. Set the internal gear (2) with the spline down, so that the spline of the spindle (1A) is in mesh with the internal spline of the
internal gear (2).
3. Install input shaft subassembly with the retaining ring end down into the spindle counterbore.
448 31222415 800S HC3, 860SJ HC3

4. Slide thrust spacer (12) over the input shaft (11) make sure the large end is against the spindle (1A).
Note: Refer to Figure — Carrier Subassembly Removal - Sheet 2 of 2, page 441 with 18, 24, 31 & 43: 1 Ratios.
5. Place carrier subassembly with the large end of cluster gears facing up. Position all three punch marks on the face of large gears at
12 o’clock and secure the gear teeth using timing fixture.
6. With longer shoulder side of ring gear (4) facing down, place the ring gear into mesh with the cluster gear (3F) and remove this
assembly from timing fixture.
Note: Be sure that the punch marks remain in their correct location during ring gear (4) installation.
7. Place Thrust washer (15), thrust bearing (16) and thrust washer (15), in order on the pilot diameter on internal gear (2).
Note: For 30, 35, 50, 54 & 73:1 ratios Skip step 8.
8. Install input gear (13) with counterbore down in mesh with the input shaft (11) splines counterbore down.
9. With small end of cluster gear (3F) down and while holding ring gear (4) in mesh with carrier sub assembly, place assembly into
internal gear (2).
Figure 146. Timing Mark on Carrier Subassembly
10. Once in place rotate the ring gear (4) until hole marked “X” is aligned with one of shoulder bolt holes in hub (1G).
Note: If the gears do not mesh easily or carrier sub assembly does not rotate freely, then remove the carrier and Ring gear and
check timing (Step 5).
Note: Check each cluster gear (3f) to make sure that the timing punch-marks is in line with a tooth on the large end & a tooth on
the small end of the cluster gear. These two teeth must be in line with the punch-marks on every cluster gear (3f).
Note: For 30, 35, 50, 54 & 73:1 ratios Skip step 11.
11. Install spacer (14) onto the input shaft (11) against the input gear (13).
Note: Refer to Figure — Carrier Subassembly Removal - Sheet 2 of 2, page 441 with 18, 24, 31 & 43: 1 Ratios.
Note: For 18,24, 37 & 43:1 ratios Skip step 12.
12. Install input gear (13) with counterbore down to mesh with the teeth of cluster gear (3F).
13. Install cover subassembly onto the ring gear (4) being sure that the pipe plugs in the hub (1G) and cover (6A) are in time with each
other. Be sure the thrust washers (15) & (16) remain on the cover (6).
800S HC3, 860SJ HC3 31222415 449

14. Install four shoulder bolts (18) into the four marked counterbore holes in the hub (1G) start shoulder bolts (18) by hand for the
length of at least two threads or two full turns before running down and torque to 45-47 ft. lbs. (61- 64 Nm).
15. Place the remaining eight bolts (17) into the remaining holes and torque to 45-47 ft. lbs. (61- 64 Nm).
16. Turn the assembly over and insert Input Coupling Subassembly into the spindle (1A) counterbore.
17. The unit should now be leak and roll checked as per “The Roll Test” and “The Leak Test”. The motor can be reinstalled into the
gearbox for the leak check to seal it off and the unit pressurized through a pipe plug hole on the cover.
10.1.2 Drive Brake

Disassembly
1. Supporting brake:, remove the six socket head capscrews and washers (13 & 14) in equal increments to ensure the spring pressure
within the brake is reduced gradually and evenly.
If a press is available, the cylinder housing (8) can be restrained while removing the six capscrews and washers (13 & 14). The brake
assembly can now be fully dismantled and the parts examined.
2. Remove cylinder housing (8) and piston (9) subassembly and dismantle if required, removing O-ring seals (15 & 17) and backing
rings (16 & 18) as necessary.
3. Remove gasket (7) from housing (2).
4. Remove friction plates (3 & 6) and pressure plate (4).
5. Remove two dowel pins (19).
6. Remove springs (22 & 23).
7. Should it be necessary to replace ball bearing (10) or shaft seal (12), reverse remainder of brake subassembly, supporting on face C
of housing (2).
8. Remove internal retaining ring (11).
9. Using arbor press or similar to break Threadlocking Compound seal, remove brake shaft (1) from housing (2) and lay aside.
10. Reverse housing (2) and press out ball bearing (10). Shaft seal (12) can also be removed if necessary.
Inspection
1. Inspect friction plates (3 & 6) and friction surface on pressure plate (4) for wear or damage.
2. Examine friction plates (3) and brake shaft (1) for wear or damage to the splines.
3. Examine input and output splines of brake shaft (1) for wear or damage.
4. Examine compression springs (22 & 23) for damage or fatigue.
5. Check ball bearing (10) for axial float or wear.
6. Examine O-ring seals (15 & 17) and backing rings (16 & 18) for damage.
Assembly
1. Lightly lubricate rotary shaft seal (12) and assemble to housing (2) taking care not to damage seal lip.
2. Apply ring of Medium Strength Threadlocking Compound or equivalent adhesive to full circumference of housing (2) bearing
recess adjacent to shoulder.
Apply complete coverage of Medium Strength Thread locking Compound to outside diameter of bearing (10) and assemble fully
In housing (2), retaining with internal retaining ring (11). Remove excess adhesive with a clean cloth. Press shaft (1) through
bearing (10), ensuring bearing inner ring Is adequately supported.
3. Assemble correct quantity of springs (22 & 23) in orientation required.
4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or equivalent) silicon grease and assemble together with backing rings (16 &
18) to piston (9). To ensure correct brake operation. It is important that the backing rings are assembled opposite to the
pressurized side of piston.
450 31222415 800S HC3, 860SJ HC3

5. Correctly orientate piston (9) aligning spaces with the two dowel pin holes and, assemble into cylinder housing (8) taking care not
to damage seals and carefully lay aside.
6. Locate 2-off pins (19) in housing (2) followed by pressure plate (4) and friction plates i.e. an inner (3) followed by an outer (6) in
correct sequence.
7. Position gasket (7) in correct orientation.
8. Align two holes in cylinder with dowel pins (19) and assemble piston & cylinder sub-assembly to remainder of brake securing with
6 capscrews and washers (13 & 14). Torque to 55 ft.Ibs. (75 Nm).
Note: The use of a suitable press (hydraulic or arbor) pressing down on cylinder end face B will ease assembly of the capscrews (13).
Figure 147. Drive Brake
1. Shaft 6. Outer Plate 11. Retaining Ring 16. Backup Ring 21. Plug
2. Housing 7. Gasket 12. Shaft Seal 17. O-ring 22. Spring (Natural)
3. Friction Plate 8. Cylinder 13. Capscrew 18. Backup Ring 23. Spring (Blue)
4. Pressure Plate 9. Piston 14. Lockwasher 19. Dowel Pin

5. Gasket 10. Ball Bearing 15. O-ring 20. Plug
800S HC3, 860SJ HC3 31222415 451

10.1.3 Drive Motor

Description
The drive motors are low to medium power, two-position axial piston motors incorporating an integral servo piston. They are designed
for operation in both open and closed circuit applications. The standard control is a direct acting single line hydraulic control. The
integral servo piston controls motor displacement.
The motors are spring biased to maximum displacement and hydraulically shifted to minimum displacement. Minimum and maximum
displacement can be set with fixed internal stops. The large diameter servo piston allows smooth acceleration and deceleration with
relatively large circuit orificing.
Bias spring
Servo piston
Minimum Swashplate
Angle
Stop
Output
Cylinder Shaft
Block
Shaft
Seal
Endcap Piston Slipper Bearing

Valve plate BM100100A
Figure 148. Drive Motor Cross Section

Shaft Seal Replacement
Removal
1. Remove the snap ring (1) retaining the shaft seal and support washer.
1. Snap Ring 2. Support Washer 3. Shaft Seal
2. Remove the support washer (2).
3. Carefully pry out the shaft seal (3).
Note: To avoid damaging the shaft during removal, install a large sheet metal screw into the chuck of a slide hammer. Drive the
screw into the seal surface and use the slide hammer to pull the seal.
4. Discard the seal.
Inspect the Components

Inspect the new seal, the motor housing seal bore and the sealing area on the shaft for rust, wear and contamination. Polish the shaft
and clean the housing if necessary.
452 31222415 800S HC3, 860SJ HC3

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

Removal
1. Disconnect the speed sensor electrical connector.
2. Using an 11/16 in. wrench, loosen the locknut.
3. Using a 1/2 in. wrench, remove the speed sensor and o-ring from the motor.
Installation
1. Turn speed sensor with o-ring (2) in (CW) by hand until bottom end gently touches the speed ring (3).
2. Back out speed sensor (CCW) 1/4 turn. Continue backing out until the flats are 22° either side of the motor shaft center line (20° to
30° is acceptable). Do not back out more than 3/4 turn from touching bottom.
3. Using a 1/2 in wrench to hold the speed sensor (4), torque the lock nut (1) to 10 ft. lbs. (13 Nm) with an 11/16 in. wrench.
4. Plug in electrical connection and start machine to test for proper operation.
800S HC3, 860SJ HC3 31222415 453

ADJUSTMENT AND TROUBLESHOOTING

1. Wire configuration
Red = Power
White = Speed signal
Black = Ground (common)
Green = Direction
2. Speed signal
Check for speed output using a Volt Ohm Meter (VOM). Place VOM across the ground and speed pins or terminals, (Black =
Ground, White = Speed Signal) and set VOM to the DC Volt scale and low range. To check for an output, turn pump or motor very
slowly by hand or check output just as the prime mover is coming to a stop.
Note a voltage pulse at meter. It will likely be difficult to read exact, simply note a pulse (approximately 60 pulses per rev). If there
is no indication of a pulse, repeat installation steps and recheck.
3. Directional signal
Check for a direction signal change using a VOM. Use the same VOM setup as in the above speed signal check. Turn the motor
slowly and note a polarity change (±) on the VOM display as you change the motor direction.
Loop Flushing Valve

Removal
454 31222415 800S HC3, 860SJ HC3

1. Using a 11/16 in. internal hex wrench remove plug (1) and (2).
BM100102A
Figure 149. Loop Flushing Spool
1. Plug 6. O-ring 11. Washer
2. Plug 7. Spring 12. Shift Spool

3. Plug 8. Spring 13. Orifice Poppet
4. O-ring 9. Spring
5. O-ring 10. Washer
2. Using a 1/4 in. hex wrench remove plug (3).
3. Remove O-rings (4, 5 and 6).
4. Using pliers, remove centering springs (7, 8 and 9).
5. Remove spring retaining washers (10 and 11).
6. Remove shift spool (12).
7. Remove orifice poppet (13).

Inspect new O-rings and the sealing area for rust, wear, or contamination. Also check springs and poppet for wear.
Installation
1. Install orifice poppet (13).
2. Install shift spool (12).
3. Install spring retaining washers onto springs (10 and 11).
4. Carefully install centering springs (7, 8 and 9).
5. Install new O-rings (6, 4 and 5).
6. Using a 1/4 in. hex wrench torque plug (3) to 20 ft. lbs. (27 Nm).
7. Using a 11/16 in. internal hex, torque plugs (2 and 1) to 27 ft. lbs. (37 Nm).
Anti-Cavitation Valve
Removal
The anti-cavitation valve is installed into the high pressure port. The high pressure port depends on motor rotation. If rotation is
counterclockwise, the high pressure port is A. If rotation is clockwise, the high pressure port is B.
800S HC3, 860SJ HC3 31222415 455

1. Using a 5/16 in. internal hex wrench remove valve plug (6). Remove and discard O-ring (5).
2. Remove spring (4) and relief valve (3) from end cap.
3. Using a 5/16 in. internal hex wrench remove plug (1). Remove and discard O-ring (2).

Inspect sealing area for rust, wear, or contamination. Check spring (4) and relief valve (3) for wear and damage. Relief valve (3) is non-
serviceable, replace as complete unit if damaged.
Installation
1. Lubricate and insert relief valve (3) and spring (4) in original location.
2. Lubricate and install new O-ring (5) on valve plug (6).
3. If needed lubricate and install new O-ring (2) on plug (1).
4. Using a 5/16 in. internal hex wrench to install valve plug (6) into port with relief valve (3). Torque to 59 ft. lbs. (80 Nm).
5. If needed using a 5/16 in. internal hex wrench to install plug (1) into port without relief valve (3). Torque to 59 ft. lbs. (80 Nm).
Troubleshooting
Table 43. Excessive Noise and/or Vibration
Item Description Action
Check oil level in reservoir and oil supply to the motor. Insufficient hydraulic fluid could lead to cavitation that Fill the reservoir to the proper level and ensure that oil
would cause system noise. supply to the motor is adequate and the lines are
unobstructed.
Check for air in the system. Air trapped within the system lines, or the motor itself, Ensure that all of the system lines and components are
could result in cavitation that would cause system noise. purged of air.
Inspect the output shaft couplings. A loose or incorrect shaft coupling will produce Ensure that the correct coupling is used and that it fits
vibrations that could result in system noise. properly onto the shaft.
Inspect the output shaft alignment. Misaligned shafts create excessive frictional vibration Ensure that the shafts are properly aligned.
that could result in system noise.
Hydraulic oil viscosity above limits. Viscosity above acceptable limits will result in cavitation Replace hydraulic oil with appropriate fluid for operating
that would lead to system noise. conditions.
456 31222415 800S HC3, 860SJ HC3

Table 44. System Operating Hot

Check oil level in reservoir and oil supply to the pump. Insufficient amount of hydraulic fluid will not meet the Fill the reservoir to the proper level.
cooling demands of the system.
Inspect the heat exchanger, (if so equipped). If the heat exchanger fails, or becomes obstructed, it Ensure that heat exchanger is receiving adequate air
may not meet the cooling demands of the system. flow and that the heat exchanger is in good operating
condition. Repair or replace as necessary.
Check the system relief valves. If a system relief valve becomes unseated for an Repair or replace any malfunctioning relief valves as
extended period of time or fails for any other reason, applicable and verify that the loads on the machine are
the system could become overheated. not excessive.
Table 45. Won’t Shift or Slow to Start

Check the signal line to the servo control port. Obstructed or restricted flow through the servo control Ensure that the signal lines are not obstructed or
signal lines could result in slow shift or no shift restricted and that signal pressure is adequate to shift
conditions within the motor. the motor.
Check that the correct supply and drain orifices are Supply and drain orifices determine the shift rate of the Ensure that the proper control orifices are installed in
properly installed and are not obstructed. motor. The smaller the orifice, the longer the time it the motor and verify that they are not obstructed. Clean
takes to shift the motor. Obstruction will also increase or replace as necessary.
shift times.
Disassembly
Note: Removal of the end cap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that
these 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.
6
9
5 11
2
7
13
12
10
8
4
BM100103A
1. Plug 6. O-ring 11. Washer

2. Plug 7. Spring 12. Shift Spool
3. Plug 8. Spring 13. Orifice Poppet
4. O-ring 9. Spring
5. O-ring 10. Washer
1. Using a 11/16 in. wrench remove plug (1) and (2).
800S HC3, 860SJ HC3 31222415 457

2. Using a 5/8 in. hex wrench remove plug (3).
3. Remove O-rings (4, 5 and 6).
4. Using pliers, remove centering springs (7, 8 and 9).
5. Remove spring retaining washers (10 and 11).
6. Remove shift spool (12).
7. Remove orifice poppet (13).
17
19
15
14
21
18
16
16
20 BM100104A
Figure 151. Plugs, Fittings and Speed Sensor
14. Lock Nut 17. Control Line Plug 20. Drain Plug
15. O-ring Plug 18. Cavity Plug 21. Work Port Plug
16. Control Line Plug 19. Drain Plug
8. Remove all fittings from the unit. Discard any O-rings on the fittings.
9. Using an 11/16 in. hex wrench, loosen the speed sensor lock nut (14) if equipped. Then remove the speed sensor using a Vi in. hex
wrench. Units without speed sensor have an O-ring plug (15) installed in that location; remove it with a Va in. internal hex wrench.
10. Using a 1/4 in. internal hex wrench, remove control line plugs (16, 17). Discard O-rings. Using a 3 mm hex wrench, remove cavity
plug (18, if equipped with two-line control) from X2 cavity.
11. Using a 5/16 in. internal hex wrench, remove drain plugs (19, 20). Discard O-rings.
458 31222415 800S HC3, 860SJ HC3

12. Using a 9/16 in. internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O-rings.
Figure 152. End Cap
22. Screw 23. End Cap 24. O-ring
13. Using an 8 mm internal hex wrench, remove the end capscrews (22).
14. Remove the end cap (23). Remove O-ring (24) from the housing or end cap.
Note: When the end capscrews are removed, pressure from the servo spring will cause the end cap to bind on the shaft. Press
down on the portion of the end cap covering the servo piston and hold the end cap level while removing.
25
27
30
29
29
26
28
BM100106A
Figure 153. Valve Plate & Rear Shaft Bearing
25. Valve Plate 27. O-ring 29. Angle Stop

26. End Cap 28. O-ring 30. Servo Spring
CAUTION
Take care not to scratch the surface of the valve plate.
800S HC3, 860SJ HC3 31222415 459

15. Remove the valve plate (25) and timing pin (26) from the end cap.
Note: Each displacement has a unique valve plate. For identification, the last two digits of the valve plate part number are stamped
on its surface.
16. Remove and discard the O-rings (27 and 28).
17. Remove the rear shaft bearing (29) from the end cap with a bearing puller.
Note: The bearing may be difficult to remove with a puller. Try this as an alternative: Pack the bearing cavity with heavy grease.
After the shaft is removed, insert it into the bearing cavity and tap lightly with a soft mallet on the splined end. The grease
will force the bearing out. Use caution not to drive the bearing past the rear shaft journal as the bearing may become
trapped on the shaft and damaged.
18. Remove minimum angle stop (29) and servo spring (30) from the housing.
Figure 154. Cylinder Kit
31. Cylinder Kit Assembly
19. Turn the housing on its side and remove the cylinder kit assembly (31). Set the assembly aside, being careful not to scratch the
running surface.
Note: Grooves on the surface of the cylinder kit identify its displacement:
Table 46. Displacement Identifiers

# of Grooves Frame L Frame K
1 25 38
2 30 45
3 35 --
Figure 155. Shaft Seal
32. Snap Ring 33. Support Washer 34. Shaft Seal
460 31222415 800S HC3, 860SJ HC3

20. Turn the housing over and remove the snap ring (32) retaining the shaft seal and support washer. Remove the support washer (33)
and carefully pry out the shaft seal (34). Discard the seal.
Note: To avoid damaging the shaft during seal removal. Install a large sheet metal screw into the chuck of a slide hammer. Drive
the screw into the seal surface and use the slide hammer to pull the seal.
36
35
37
38
BM100109A
Figure 156. Shaft & Front Bearing
35. Inner Snap Ring 37. Bearing

36. Snap Ring 38. Shaft
21. Remove the inner snap ring (35) and the shaft / bearing assembly.
22. Remove the snap-ring (36) retaining the shaft front bearing. Pull the bearing (37) off of the shaft (38).
Lift here
39
40
43
42
41
BM100110A
Figure 157. Swashplate & Servo Piston
39. Swashplate 42. O-ring

40. Servo Piston 43. Journal Bearings
41. Piston Seal
23. Turn housing over and remove the swashplate (39) by lifting on the end opposite the servo lever.
24. Remove the servo piston (40). Remove the piston seal (41) and O-ring (42) from the servo piston. Discard the seal and O-ring.
800S HC3, 860SJ HC3 31222415 461

25. Remove the journal bearings (43) from the housing. If the bearings are to be reused, note the location and orientation of each
bearing for reassembly.
44
45
47
48
49
46
53
52
50
51
BM100111A
Figure 158. Cylinder Kit Disassembly
44. Piston 48. Holddown Pins 52. Block Spring
45. Slipper Retainer 49. Retaining Ring 53. Inner Block Spring Washer
46. Cylinder Block 50. Block Spring Washer
47. Ball Guide 51. Spiral Retaining Ring
26. Remove pistons (44) and slipper retainer (45) from the cylinder block (46).
Note: The pistons are not selectively fitted, however units with high hourly usage may develop wear patterns. Number the pistons
and bores for reassembly if they are to be reused.
27. Remove the ball guide (47), hold-down pins (48) and retaining ring (49) from the cylinder block.
Note: Most repairs do not require block spring removal. Perform this procedure only if you suspect problems with the block
spring.
WARNING
Risk of personal injury: Compressing the block spring requires force of about 80 to
90 lbf (350 to 400 N). Use a press sufficient to maintain this force with reasonable ef-
fort. Ensure the spring is secure before attempting to remove the spiral retaining
ring. Release the pressure slowly after the retaining ring is removed.
28. Turn the block over. Using a press, apply pressure on the block spring washer (50) to compress the block spring. Compress the
spring enough to safely remove the spiral retaining ring (51). While maintaining pressure, unwind the spiral retaining ring (51).
Carefully release the pressure and remove the outer block spring washer (50), block spring (52) and inner block spring washer (53)
from the cylinder block.
Inspection
After disassembly, wash all parts (including the end-cap and housing) thoroughly with clean solvent and allow to air dry. Blow out oil
passages in the housing and end cap with compressed air. Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or resurfacing.
462 31222415 800S HC3, 860SJ HC3

Piston
Inspect the pistons for damage and discoloration. Discolored pistons may indicate excessive heat; do not reuse.
BM100112A
Slippers
Inspect the running surface of the slippers. Replace any piston assemblies with scored or excessively rounded slipper edges. Measure the
slipper foot thickness. Replace any piston assemblies with excessively worn slippers. Check the slipper axial end-play. Replace any piston
assemblies with excessive end-play.
Minimum slipper foot thickness and maximum axial end-play are given in the table below.
Table 47. Slipper Foot Thickness & End Play
Measurement L Frame mm (in.) K Frame mm (in.)

Slipper Foot Thickness 2.71 4.07
(0.11) (0.16)
Piston/Slipper End Play 0.15
(0.006)
Cylinder Block
Measure the cylinder block height. Replace blocks worn beyond the minimum height specification. Inspect the running surface of the
cylinder block. Replace or resurface worn or scratched blocks. Blocks may be resurfaced to the specifications shown in the drawing,
provided resurfacing will not reduce the block height below the minimum specification. Refer to Table — Cylinder Block Measurements,
page 463.
Table 48. Cylinder Block Measurements
Measurement L25 mm (in.) L30 mm (in.) L35 mm (in.) K38 mm (in.) K45 mm (in.)
Minimum Cylinder Block
50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
Height (A)
Cylinder Block Surface 0.002 0.002 0.002 0.002 0.002

Flatness (7.9) (0.0000079) (0.0000079) (0.0000079) (0.0000079)
Ball Guide and Slipper Retainer

Inspect the ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper retainer
indicates excessive heat. Do not reuse.
Slipper retainer
Ball gu ide
BM100113A
800S HC3, 860SJ HC3 31222415 463

Valve Plate
The condition of the valve plate is critical to the efficiency of the motor. Inspect the valve plate surfaces carefully for excessive wear,
grooves, or scratches. Replace or resurface grooved or scratched valve plates. Measure the valve plate thickness and replace if worn
beyond the minimum specification. Valve plates may be resurfaced to the specifications shown in the drawing, provided resurfacing will
not reduce the thickness below the minimum specification.
3.83 mm [0.151 in ] min .
0.025 mm
[0.001 in]
0.0076 mm
[0.00030 in ]
convex max
BM100115A
Swashplate and Journal Bearings

Inspect the running face, servo ball-joint and swashplate journal surfaces for damage or excessive wear. Some material transfer may
appear on these surfaces and is acceptable providing the surface condition meets specifications shown. Measure the swashplate
thickness from the journals to the running face. Replace swashplate if damaged or worn beyond minimum specification. Replace
swashplate if the difference in thickness from one side to the other exceeds specification.
Inspect the journal bearings for damage or excessive wear. Replace journal bearings if scratched, warped, or excessively worn. The
polymer wear layer must be smooth and intact.
Shaft Bearing
Inspect bearings for excessive wear or contamination. Rotate the bearings while feeling for uneven movement. Bearings should spin
smoothly and freely. Replace bearings that appear worn or do not rotate smoothly.
Shaft
Inspect the motor shaft. Look for damage or excessive wear on the output and block splines. Inspect the bearing surfaces and sealing
surface. Replace shafts with damaged or excessively worn splines, bearing surfaces, or sealing surfaces.
Servo Piston and Minimum Angle Stop
Inspect the minimum angle stop, servo piston head and servo piston ball-socket for damage or excessive wear. Replace if necessary.
464 31222415 800S HC3, 860SJ HC3

BM100118A
Loop Flushing Spool

Inspect the loop flushing spool. Check for cracks or damage. Replace if necessary.
BM100119A
Assembly
1. Install new O-ring (1) and piston seal (2) to the servo piston (3). Install the piston seal over the O-ring.
Note: Installing the piston seal stretches it, making it difficult to install the servo piston in its bore. Allow 30 minutes for the seal to
relax after installation. To speed up seal relaxation, compress the seal by installing the piston head into the servo cavity in
the end-cap and let it stand for at least five minutes.
2
3
BM100120A
Figure 159. Servo Piston
1. O-ring 2. Piston Seal 3. Servo Piston
2. After piston seal has relaxed, lubricate and install servo piston into the housing bore. Align the piston with the ball socket facing
the inside of the housing.
WARNING
Risk of personal injury: Compressing the block spring requires about 80 to 90 lbf
(350 to 400 N) of force. Use a press sufficient to maintain this force with reasonable
effort. Ensure the spring is secure before attempting to install the spiral retaining
ring. Release the pressure slowly after the retaining ring is installed.
800S HC3, 860SJ HC3 31222415 465

3. Install the inner block spring washer (4), block spring (5) and outer washer (6) into the cylinder block. Using a press, compress the
block spring enough to expose the retaining ring groove. Wind the spiral retaining ring (7) into the groove in the cylinder block.
11
12
10
BM100121A
Figure 160. Cylinder Kit Assembly
4. Block Spring Washer 7. Spiral Retaining Ring 10. Ball Guide
5. Block Spring 8. Retaining Ring 11. Piston
6. Outer Washer 9. Holddown Pins 12. Slipper Retainer
4. Turn the block over and install the retaining ring (8), hold-down pins (9) and ball guide (10) to the cylinder block.
5. Install the pistons (11) to the slipper retainer (12). Install the piston/retainer assembly into the cylinder block. Ensure the concave
surface of the retainer seats on the ball guide. If you're reusing the pistons, install them to the original block bores. Lubricate the
pistons, slippers, retainer and ball guide before assembly. Set the cylinder kit aside on a clean surface until needed.
6. Install the journal bearings (13) into the housing seats. Use assembly grease to keep the bearings seated during assembly. Ensure
the locating nubs drop into the cavities in the seats. If you're reusing the bearings, install them in the original location and
orientation. Lubricate the journal bearings.
14
13
13
BM100122A
Figure 161. Swashplate and Journal Bearing
13. Journal Bearings 14. Swashplate
7. Install the swashplate (14) into the housing. Tilt the swashplate and guide the servo lever ball into its socket in the servo piston
rod. Ensure the swashplate seats into the journal bearings and moves freely. Lubricate the running surface of the swashplate.
466 31222415 800S HC3, 860SJ HC3

8. Press front shaft bearing (15) onto shaft (16). Press bearing onto shaft with lettering facing out. Lubricate bearing rollers. Install
snap-ring (17) onto shaft.
BM100123A
Figure 162. Shaft and Front Bearing
15. Front Shaft Bearing 17. Snap Ring
16. Shaft 18. Snap Ring
9. While holding the swashplate in place, turn the housing on its side. Install the install shaft/bearing assembly into housing from the
flange end. Install the snap-ring (18).
10. Verify swashplate and bearings are properly seated. Install the cylinder kit (19) onto the shaft. Install with the slippers facing the
swashplate. Rock the shaft to align the block splines and slide the cylinder kit into place. Orient the motor with the shaft pointing
downward and verify the cylinder kit, swashplate, journal bearings and servo piston are all secure and properly installed.
Figure 163. Cylinder Kit Installation
19. Cylinder Kit
800S HC3, 860SJ HC3 31222415 467

11. Lubricate and install the servo spring (20) and minimum angle stop (21) into the housing bore.
21
20
BM100125A
Figure 164. Servo Spring and Minimum Angle Stop
20. Servo Spring 21. Minimum Angle Stop
12. Press the rear shaft bearing (22) into the end cap. Install the bearing with letters facing out. Press until bearing surface is 0.08 ±0.01
in. (2 ±0.25 mm) above end cap surface.
22 3 mm
23 [0.12 in ]
2 mm
[0.08 in]
23
22
24
23
BM100126A
22. Rear Shaft Bearing 23. Timing Pin 24. Valve Plate
13. Install timing pin (23) into its bore in the end cap. Install the pin with its groove facing toward or away from the shaft. Press the pin
until the end protrudes 0.12 ±0.01 in. (3 ±0.25 mm) above end cap surface.
14. Install the valve plate (24) onto the end cap. Install the valve plate with the yellow surface toward the cylinder block. Align the slot
in the valve plate with the timing pin. Apply a liberal coat of assembly grease to the end cap side of the valve plate to keep it in
place during installation.
468 31222415 800S HC3, 860SJ HC3

15. Install the end cap (25) onto the housing with the end capscrews (26). Check to ensure the end cap will properly seat onto the
housing without interference. Improper assembly of the internal components may prevent the end cap from seating properly.
Ensure the O-rings seat properly when installing the end cap.
26
8 mm
35-45 ft.lbs .
(47-61 Nm)
25
BM100127A
Figure 165. End Cap
25. End Cap 26. Screw
16. Using an 8 mm internal hex wrench, tighten the end capscrews. Tighten the screws in opposite corners slowly and evenly to
compress the servo spring and properly seat the end cap. Torque end capscrews 35-45 ft. lbs. (47-61 Nm).
17. Before installing the shaft seal, ensure the shaft turns smoothly with less than 120 in. lbs. (13.5 Nm) of force. If the shaft does not
turn smoothly within the specified maximum force, disassemble and check the unit.
18. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with the cup side facing the motor. Press seal into
housing until it bottoms out. Press evenly to avoid binding and damaging the seal. Install seal support washer (28) and snap ring
(29).
Figure 166. Shaft Seal
27. Shaft Seal 28. Seal Support Washer 29. Snap Ring
800S HC3, 860SJ HC3 31222415 469

19. Install remaining plugs and fittings to the housing. Refer to the drawing below for wrench sizes and installation torques.
BM100129A
Figure 167. Plugs and Fittings Installation
20. Install orifice poppet (30).

37
36
39 33
41
34
30 11/ 16 in
40 27 ft .lbs.
(37 Nm)
5/ 8 in
20 ft .lbs.
(27 Nm)
31
32
35
38
42
11/ 16 in
27 ft .lbs.
(37 Nm)
BM100130A
30. Orifice Poppet 35. Spring 40. Plug
31. Shift Spool 36. Spring 41. Plug
32. Spring 37. O-ring 42. Plug

33. Spring 38. O-ring
34. Spring 39. O-ring
21. Install shift spool (31).
22. Install spring retaining washers onto springs (32 and 33).
23. Carefully install centering springs (34, 35 and 36).
24. Install new O-rings (37, 38 and 39).
25. Using a 5/8 in. wrench torque plug (40) to 20 ft. lbs. (27 Nm).
470 31222415 800S HC3, 860SJ HC3

26. Using a 11/16 in. wrench, torque plugs (41 and 42) to 27 ft. lbs. (37 Nm).
Initial Start-up Procedures

Follow this procedure when starting-up a new motor or when installing a motor that has been removed.
WARNING
Unintended movement of the machine or mechanism may cause injury to the tech-
nician or bystanders. To protect against unintended movement, secure the machine
or disable / disconnect the mechanism while servicing.
Prior to installing the motor, inspect for damage incurred during shipping. Make certain all system components (reservoir, hoses, valves,
fittings, heat exchanger, etc.) are clean prior to filling with fluid.
1. Fill the reservoir with recommended hydraulic fluid. Always filter fluid through a 10 micron filter when pouring into the reservoir.
Never reuse hydraulic fluid.
2. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for properly tightened fittings and be certain it is free
of restrictions and air leaks.
3. Fill the pump and motor housing with clean hydraulic fluid. Pour filtered oil directly into the upper most case drain port.
4. To ensure the pump and motor stay filled with oil, install case drain lines into the upper most case drain ports.
5. Install a 0 to 500 psi (0 to 35 bar) gauge in the charge pressure gauge port of the pump to monitor system pressure during start
up.
Note: Follow recommendations in the vehicle / machine operator’s manual for prime mover start up procedures.
6. While watching the pressure gauge, run the engine at the lowest possible speed until system pressure builds to normal levels
(minimum 160 psi [11 bar]). Once system pressure is established, increase to full operating speed. If system pressure is not
maintained, shut down the prime mover, determine cause and take corrective action.
7. Operate the hydraulic system for at least fifteen minutes under light load conditions.
8. Check and adjust control settings as necessary after installation.
9. Shut down the prime mover and remove the pressure gauge. Replace plug at the charge pressure gauge port.
10. Check the fluid level in the reservoir; add clean filtered fluid if necessary. The motor is now ready for operation.
10.2 BOOM AND JIB ASSEMBLY
10.2.1 Main Boom

Disassembly
Note: The following procedure assumes the boom is removed from the machine.
1. Extend the boom approximately 2 ft. (0.6 m). This will enable access to the bolts that secure the cable mount block to the boom fly
section.
2. Remove hardware securing the telescope cylinder.
800S HC3, 860SJ HC3 31222415 471

3. Remove hardware securing the cover plate on the bottom front of the base boom section.
Note: Do not allow wire rope to rotate. This may damage the wire rope.
4. Clamp both threaded ends of wire rope to prevent rotation. Remove jam nuts and nuts which secure the wire rope adjustments to
the bottom front of the base boom section.
Note: Do not clamp on threads.
5. Remove jam nuts and nuts which secure the wire rope adjustments to the bottom front of the base boom section.
6. Using a 3/8 drive extension approximately 4 ft. (1.2 m) long, remove the bolts and washers securing the cable mount block to the
boom fly section.
7. Remove the four bolts, shims, and attachment blocks that secure the telescope cylinder barrel to the boom mid section.
472 31222415 800S HC3, 860SJ HC3

8. Remove the four bolts, shims, and mounting blocks that secure the telescope cylinder rod to the boom base section.
NOTICE
When removing the telescope cylinder from the boom, it may be necessary at some
boom. Care must be taken to move the cylinder slowly from the boom. Damage to
Note: The 800S telescope cylinder weighs approximately 606.4 lb (275.4 kg). The 860SJ telescope cylinder weighs approximately
589.2 lb (267.2 kg).
800S HC3, 860SJ HC3 31222415 473

9. Using overhead cranes or other suitable lifting/supporting devices, carefully pull the telescope cylinder out from the back of the
boom. At the same time, also pull the cable mount block out so the extension cables come out with the telescope cylinder and do
not bind. The lifting/supporting devices will have to be repositioned to support the weight of the cylinder as it is drawn out of the
boom.
Figure 169. Boom Assembly Cutaway - Sheet 1 of 2
474 31222415 800S HC3, 860SJ HC3

Figure 170. Boom Assembly Cutaway - Sheet 2 of 2
1. Base Boom 6. Retract Sheave 11. Retract Cable Adjustment
2. Mid Boom 7. Sheave Block 12. Proximity Switch
3. Fly Boom 8. Extend Cable 13. Wear Pad
4. Telescope Cylinder 9. Retract Cable 14. Shims
5. Extend Sheave 10. Extend Cable Adjustment 15. Wear Pad
800S HC3, 860SJ HC3 31222415 475

1
6
7
2
3
4 8
9
MAF25831
Figure 171. Boom Components - Sheet 1 of 2
1. Pivot Pin 4. Level Link 7. Lift Cylinder Pivot Pin
2. Power Link 5. Boom Pivot Pin 8. Tower Pin

3. Tower 6. Upright 9. Level Link Pin
476 31222415 800S HC3, 860SJ HC3

Figure 172. Boom Components - Sheet 2 of 2
1. Pivot Pin 5. Level Cylinder Attach Pin 9. Lift Cylinder
2. Level Link Pivot Pin 6. Level Cylinder 10. Level Switch
3. Lift Cylinder Pivot Pin 7. Level Cylinder Pivot Pin
4. Boom Rest 8. Rotator
800S HC3, 860SJ HC3 31222415 477

10. Carefully remove the telescope cylinder and sheave assembly. Place telescope cylinder on a suitable trestle.
a. Remove hardware from the wear pads; remove wear pads from cylinder.
b. Remove hardware from the wire rope guard; remove guard from cylinder.
c. Remove hardware from the sheave pin; remove pin and sheave from cylinder.
BM102434A
Figure 173. Disassembly of Sheave Assembly
11. Remove hardware which secures the wear pads to the front of base boom section; remove wear pads from the top, sides and
bottom of the base boom section.
12. Using an overhead crane or suitable lifting device, remove mid and fly boom sections from base section. Note: When removing
mid and fly boom sections from base boom section, retract wire rope must be dragged along with boom sections.
13. Remove hardware which secures the wear pads to the rear end of mid boom section; remove the wear pads from the top, sides
and bottom of the mid boom section.
14. Remove hardware which secures the sheave guards and sheave assemblies to mid boom section, remove sheave assemblies from
mid boom section.
15. Remove hardware which secures the wear pads to the front of mid boom section; remove wear pads from the top, sides and
bottom of the mid boom section.
16. Using an overhead crane or suitable lifting device, remove fly boom section from mid section. Note: When removing fly boom
section from mid boom section, retract wire rope must be dragged along with fly boom section.
17. Remove hardware which secures the wear pads to the rear end of fly boom section; remove wear pads from the top, sides and
bottom of the fly boom section.
478 31222415 800S HC3, 860SJ HC3

18. When removing wire rope from fly boom section, push the cable into fly boom. Route wire rope back through holes in the side of
the fly boom section.
Figure 174. Disassembly Wire Rope Routing Procedure
Inspection
Note: When inspecting pins and bearings Refer to the guidelines established in Section — Pins and Composite Bearing Repair Guidelines,
page 42.
1. Inspect all sheaves (extend and retract wire ropes and telescope cylinder) for excessive groove wear, burrs or other damage.
Replace sheaves as necessary.
Note: To check the size, contour and amount of wear, a groove gauge is used. Replace the sheave if worn as shown in the follow-
ing drawing.
Figure 175. Dimension of Sheaves When New
2. Inspect extend and retract wire rope sheave bearings for wear, scoring, or other damage, and for ovality.
3. Inspect extend wire rope and retract wire rope sheave pins for scoring, tapering and ovality. Replace pins as necessary.
4. Inspect telescope cylinder sheave pin for scoring, tapering and ovality. Replace pins as necessary.
5. Inspect boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace pins as necessary.
800S HC3, 860SJ HC3 31222415 479

6. Inspect telescope cylinder attach point for scoring, tapering and ovality. Replace pins as necessary.
7. Inspect main lift cylinder attach pin for wear, scoring, tapering and ovality, or other damage. Ensure pin surfaces are protected
prior to installation. Replace pins as necessary.
8. Inspect inner diameter of boom pivot bushing for scoring, distortion, wear, or other damage. Replace bearing as necessary.
9. Inspect all wear pads for excessive wear or other damage. Replace pads when worn to within 1/8 in. (3.2 mm) of threaded insert.
10. Inspect extend and retract wire rope attach point components for cracks, stretching, distortion, or other damage. Replace
components as necessary.
11. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary.
12. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as
necessary.
Assembly
Note: When installing fly section wear pads, install same number and thickness of shims as were removed during disassembly.
1. Measure inside dimensions of the base and mid sections to determine the number of shims required for proper lift.
2. Measure inside dimensions of the mid section to determine the number of shims required for proper lift.
480 31222415 800S HC3, 860SJ HC3

3. Install side, top and bottom wear pads to the rear end of fly section; shim evenly to the measurements of the inside of mid section.
Figure 176. Proximity Switch Adjustment
800S HC3, 860SJ HC3 31222415 481

4. Install retract wire ropes into rear end of fly section, route wire ropes through holes in side of fly boom section and pull into slot.
Figure 177. Routing Installation of Retract Wire Ropes
5. Install side, top and bottom wear pads to the rear end of mid section; shim evenly to the measurements of the inside of mid
section.
NOTICE
When assembling boom sections, ensure that the boom sliding trajectories have
been cleared of chains, tools, and other obstructions.
6. Shim the insides of the boom sections for a total of 1/16 in. (0.062) clearance (if the action is centered, there will be 1/32 clearance
on each side).
7. Slide fly boom section into the mid boom section. Shim boom, if necessary, for a total of 1/16 in. (0.062) clearance.
8. Install wear pads into the forward position of the mid boom section. Shim boom, if necessary, for a total of 2/10 in. (0.20)
clearance.
9. Properly position the retraction wire rope sheaves assemblies at the rear end of the mid boom section; ensure all sheave-to-
mounting block attachment holes align. Install the sheave pins and secure them with mounting hardware. Position retract wire
ropes onto the sheaves.
10. Install sheave guards to rear end of mid boom section and secure with mounting hardware.
11. Slide mid boom section into the base boom section. Allow the retraction wire ropes to trail between the bottom surfaces of boom
sections. Shim boom, if necessary, for a total of 1/16 in. (0.062) clearance.
12. Install wear pads into the forward position of the base boom section. Shim boom, if necessary, for a total of 2/10 in. (0.20)
clearance.
13. Install sheave block to bottom of base boom section and adjust block so that retract wire ropes do not come into contact with
boom surfaces.
14. Install wire rope threaded ends through attachment holes in the bottom of base boom section. Loosely install nuts and jam nuts
onto the threaded ends of wire ropes.
15. Pull the boom sections out to approximately where they were extended to for telescope cylinder removal.
16. Install a new extend sheave on the end of the telescope cylinder.
17. Route new extend cables around the telescope cylinder. Loosely fasten the threaded end of the cables to the rod end of the
telescope cylinder with the adjusting nuts and lock nuts. Install the opposite end of the cables in the cable mount block.
482 31222415 800S HC3, 860SJ HC3

18. Use tape or tie straps to fasten the cables to the telescope cylinder assembly. It is important that the tape or straps be strong
enough to hold the cable in place yet weak enough to break and fall away when the cables are adjusted.
NOTICE
When pushing the telescope cylinder into the boom, it may be necessary at some
boom. Care must be taken to move the cylinder slowly into the boom. Damage to
Note: The 800S telescope cylinder weighs approximately 606.4 lb (275.4 kg). The 860SJ telescope cylinder weighs approximately
589.2 lb (267.2 kg).
19. Using adequate lifting equipment, carefully push the telescope cylinder assembly and cables back into the boom.
20. Apply Medium Strength Threadlocking Compound to the bolts and fasten the telescope cylinder rod to the boom base section
21. Apply Medium Strength Threadlocking Compound to the bolts and fasten the telescope cylinder barrel to the boom mid section
800S HC3, 860SJ HC3 31222415 483

22. Using a 3/8 drive extension approximately 4 ft. (1.2 m) long, install the bolts and washers securing the cable mount block to the
boom fly section. Tape the bolts to the socket at the end of the extension to prevent it from coming out of the socket before it
engages the mounting threads.
23. Connect all the hydraulic lines to the cylinder as tagged during the removal procedure.
24. Adjust the boom cables as outlined under Section — Wire Rope Tensioning Procedure.
10.2.2 JIB (860SJ HC3 Only)

Disassembly
1. Remove mounting hardware from jib pivot pins #3 and #4. Using a suitable brass drift and hammer, remove the pins from jib pivot
weldment.
2. Remove mounting hardware from rotator support pins #5 and #6. Using a suitable brass drift and hammer, remove the pins from
rotator support.
3. Remove mounting hardware from lift cylinder pin #7. Using a suitable brass drift and hammer, remove the cylinder pin from jib
boom.
Figure 178. Jib Assembly - Removal/Installation

Inspection
Note: When inspecting pins and bearings Refer to Section — Pins and Composite Bearing Repair Guidelines, page 42.
1. Inspect fly boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace pins as necessary.
484 31222415 800S HC3, 860SJ HC3

2. Inspect fly boom pivot attach points for scoring, tapering and ovality, or other damage. Replace pins as necessary.
3. Inspect inner diameter of fly boom pivot bearings for scoring, distortion, wear, or other damage. Replace bearings as necessary.
4. Inspect lift cylinder attach pin for wear, scoring, tapering and ovality, or other damage. Ensure pin surfaces are protected prior to
installation. Replace pins as necessary.
5. Inspect inner diameter of rotator attach point bearings for scoring, distortion, wear, or other damage.
6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary.
7. Inspect structural units of jib boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections
as necessary.
Assembly
1. Align rod end of jib lift cylinder with attach holes in jib assembly. Using a soft head mallet, install cylinder pin #7 into jib and
secure with mounting hardware.
2. Align rotator support with attach hole in jib assembly. Using a soft head mallet, install rotator support pin #6 into jib and secure
with mounting hardware.
3. Align bottom tubes with attach holes in rotator support. Using a soft head mallet, install rotator support pin #5 into jib assembly
and secure with mounting hardware.
4. Align jib assembly with attach hole in jib boom pivot weldment. Using a soft head mallet, install jib assembly pin #4 into jib boom
pivot and secure with mounting hardware.
5. Align bottom tubes with attach holes in jib boom pivot weldment. Using a soft head mallet, install jib assembly pin #3 into jib
boom pivot weldment and secure with mounting hardware.
10.2.3 Helac Rotary Actuator

Theory of Operation
The rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert axial piston motion into powerful
shaft rotation. Each actuator is composed of a housing with integrated gear ring (1) and only two moving parts: the central shaft with
integrated bearing tube and mounting flange (2), and the annular piston sleeve (3). Helical spline teeth machined on the shaft engage
matching splines on the inside diameter of the piston. The outside diameter of the piston carries a second set of splines, of opposite
hand, which engage with matching splines in the housing. As hydraulic pressure is applied, the piston is displaced axially within the
housing similar to the operation of a hydraulic cylinder while the splines cause the shaft to rotate. When the control valve is closed, oil is
trapped inside the housing, preventing piston movement and locking the shaft in position.
The shaft is supported radially by the large upper radial bearing and the lower radial bearing. Axially, the shaft is separated from the
housing by the upper and lower thrust washers. The end cap is adjusted for axial clearance and locked in position by set screws or pins.
The actuators are equipped with factory installed counterbalance valves, which performs four major functions.
• Protects the actuator in the event of overload
• Enables the actuator to hold position without drifting when external loads are applied
• Reduces hydraulic backlash by pressuring the hydraulic fluid
• Provides a constant controlled rate of rotation in over-center load conditions
800S HC3, 860SJ HC3 31222415 485

Figure 179. Rotary Actuator (Exploded View) (For 800S HC3)
1. Housing 200. T-Seal 304. Thrust Washer

2. Shaft 202. T-Seal 304.1. Wiper Seal
3. Piston Sleeve 204. O-ring 400. Counterbalance Valve
486 31222415 800S HC3, 860SJ HC3

4. End Cap 205. Cup Seal 401. Counterbalance Valve

109. Lock Pin 207. Backup Ring
113. Capscrew 302. Wear Guide
Figure 180. Rotary Actuator (Exploded View) (For 860SJ HC3)
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

01. Housing 106. Port Plug 200. T-Seal 302. Wear Guide 401. Counterbalance Valve
02. Shaft 109. Lock Pin 202. T-Seal 304. Thrust Washer 420. Bushing
03. Piston Sleeve 113. Capscrew 204. O-ring 421 Bushing
04. End Cap 205. Cup Seal
206. Exclusion Seal
207. Backup Ring
800S HC3, 860SJ HC3 31222415 487

Figure 181. Rotator - Assembly Drawing
PARTS HARDWARE SEALS BEARINGS ACCESSORIES

01. Housing 103. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
02. Shaft 106. Port Plug 202. T-Seal 304. Thrust Washer 401. Counterbalance Valve
03. Piston Sleeve 109. Lock Pin 204. O-ring 421 Bushing
04. End Cap 113. Capscrew 205. Cup Seal 420.1 Bushing
206. Exclusion Seal 420.2 Bushing
207. Backup Ring 421 Bushing
Tools Required for Assembly/Disassembly

Upon assembly and disassembly of the actuator there are basic tools required. The tools and their intended functions are as follows:
1. Pipe Vise
2. Hex Wrench - Removal and replacement of port plugs and set screws.
3. Assorted Screws
4. Safety Glasses
5. End Cap Removal Tools
488 31222415 800S HC3, 860SJ HC3

6. Drill
7. Flashlight- Helps in locating and examining timing marks, component failure and overall condition.
8. Rubber mallet- removal and installation of shaft and piston sleeve assembly.
9. Plastic Mandrel
10. Pry bar- removal of end cap and manual rotation of shaft.
11. Felt Marker- Highlights timing marks and outlines troubled areas. Permanent ink is recommended.
12. T - Handle Screw Extractor
13. Hex Wrench Set - Removal and replacement of port plugs and set screws (106,110).
14. Seal tools - Removal and installation of seals and wear guides.
15. Punch
16. Dowel Pins - Removal and installation of end cap.
CAUTION
To avoid injury: be careful when handling the screwdriver when hot.
Before Disassembly
Inspect the actuator for corrosion prior to disassembly. Severe corrosion can make it difficult to remove the lock pins (109) and unthread
the end cap (04). If corrosion is evident, soak the lock pins and end cap with penetrating oil for several hours before disassembly.
Disassembly is considerably easier if the actuator is firmly secured to the work bench. A pipe vise or mounting fixture work well.
800S HC3, 860SJ HC3 31222415 489

Disassembly
CAUTION
Secure product to slotted table or vise.
CAUTION
Contents under pressure. Wear approved eye protection. Use caution when remov-
ing port plugs and fittings.
NOTICE
Make sure work area is clean.
1. Remove port plugs (106) and drain oil. Inspect oil for signs of contamination, i.e. water, metal shavings.
2. Using a 1/8 in. (3.18 mm) drill bit, drill a hole in the center of each lock pin to a depth of approximately 3/16 in. (4.76 mm).
490 31222415 800S HC3, 860SJ HC3

3. Remove the lock pins using an "Easy Out” (a size #2 is shown). If the pin will not come out with the” Easy Out”, use 5/16 in. (8 mm)
drill bit to a depth of 1/2 in. (12.7 mm) to drill out the entire pin.
4. Install the end cap removal tools provided with the Helac seal kit
5. Using a metal bar, or similar tool, unscrew the end cap (04) by turning it counterclockwise.
800S HC3, 860SJ HC3 31222415 491

6. Remove the end cap (04) and set aside for later inspection.
7. Remove the stop tube if equipped. The stop tube is an available option to limit the rotation of the actuator.
8. Some actuators have two sets of small punched timing marks that indicate timing between the gear sets. The location and
appearance of the marks can vary slightly between models. One set indicates the timing between the piston sleeve (03) and the
housing (01), the second set between the piston and the shaft (lower photo). To ensure correct rotation and accurate end
positions, it is essential that the actuator be correctly timed when it is reassembled. If present, the punched timing marks can be
used, but it is recommended to make timing marks with a marker before disassembly as outlined in steps 9 and 10 below.
492 31222415 800S HC3, 860SJ HC3

9. Prior to removing the shaft, (02), use a felt marker to clearly indicate the timing marks between shaft and piston sleeve (03). This
will greatly simplify timing during assembly.
10. Remove the shaft (02). It may be necessary to strike the threaded end of the shaft with a rubber mallet.
11. Before removing the piston (03), mark the housing (01) ring gear in relation to the piston O.D. gear. There should now be timing
marks on the housing (01) ring gear, the piston (03) and the shaft (02).
800S HC3, 860SJ HC3 31222415 493

12. To remove the piston (03) use a rubber mallet and a plastic mandrel so the piston is not damaged.
13. At the point when the piston gear teeth come out of engagement with the housing gear teeth, mark the piston and housing with
a marker as shown.
14. Remove the o-ring (204) and backup ring (207) from end cap (04) and set aside for inspection.
NOTICE
Carefully remove seals using removal tools with rounded edges.
494 31222415 800S HC3, 860SJ HC3

15. Remove the wear guides (302) from the end cap (04) and shaft (02).
16. Remove the main pressure seal (205).
BM103706A
17. Remove the thrust washers (304), from the end cap (04) and shaft (02).
18. Remove the wiper seal (304.1) from its groove in the end cap (04) and shaft (02).
800S HC3, 860SJ HC3 31222415 495

19. Remove the piston O.D. seal (202) from the piston.
20. Remove the piston I.D. seal (200). You may now proceed to the inspection process.
Inspection
NOTICE
Small or minor surface scratches can be carefully polished.
1. Clean all parts in a solvent tank and dry with compressed air prior to inspecting. Carefully inspect all critical areas for any surface
finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth.
496 31222415 800S HC3, 860SJ HC3

2. Inspect the thrust washers (304) for rough or worn edges and surfaces. Measure it’s thickness to make sure it is within
specifications (Not less than 0.092 in. or 34 mm).
3. Inspect the wear guide condition and measure thickness (not less than 0.123 in. or 3.12 mm).
Assembly
1. Gather all the components and tools into one location prior to re-assembly. Use the cut away drawing to reference the seal
orientations.
800S HC3, 860SJ HC3 31222415 497

2. Install the thrust washer (304) onto shaft (02) and end cap (04).
3. Install the exclusion seal (206) into the groove on the shaft (02) and end cap (04) around the outside edge of the thrust washer
(304).
4. Using a seal tool install the main pressure seal (205) onto shaft (02) and end cap (04). Use the seal tool in a circular motion.
498 31222415 800S HC3, 860SJ HC3

5. Install the wear guide (302) on the end cap (04) and shaft (02).
6. Install the O-ring (204) and backup ring (207) into the inner seal groove on the end cap (04).
7. Install the inner T-seal (200) into the piston (03) using a circular motion.
Install the outer T-seal (202) by stretching it around the groove in a circular motion.
Each T-seal has 2 backup rings (see drawing for orientation).
8. Beginning with the inner seal (200) insert one end of backup ring in the lower groove and feed the rest in using a circular motion.
Make sure the wedged ends overlap correctly.
Repeat this step for the outer seal (202).
800S HC3, 860SJ HC3 31222415 499

9. Insert the piston (03) into the housing (01) as shown, until the outer piston seal (202) is touching inside the housing bore.
BM100379A
10. Looking from the angle shown, rotate the piston (03) until the marks you put on the piston and the housing (01) during
disassembly line up as shown. Using a rubber mallet, tap the piston into the housing up to the point where the gear teeth meet.
BM100380A
11. Looking from the opposite end of the housing (01) you can see if your timing marks are lining up. When they do, tap the piston
(03) in until the gear teeth mesh together. Tap the piston into the housing the rest of the way until it bottoms out.
BM100381A
500 31222415 800S HC3, 860SJ HC3

12. Install the shaft (02) into the piston (03). Be careful not to damage the seals. Do not engage the piston gear teeth yet.
BM100382A
13. Looking from the view shown, use the existing timing marks to line up the gear teeth on the shaft (02) with the gear teeth on the
inside of the piston (03). Now tap the flange end of the shaft with a rubber mallet until the gear teeth engage.
BM100383A
14. Install two bolts in the threaded holes in the flange. Using a bar, rotate the shaft in a clockwise direction until the wear guides are
seated inside the housing bore.
NOTICE
As the shaft is rotated, be careful not to disengage the piston and house gearing.
800S HC3, 860SJ HC3 31222415 501

15. Install the stop tube onto the shaft end, if equipped. Stop tube is an available option to limit the rotation of an actuator.
16. Coat the threads on the end of the shaft with anti-seize grease to prevent galling.
17. Thread the end cap (04) onto the shaft (02) end. Make sure the wear guide remains in place on the end cap as it is threaded into
the housing (01).
BM100387A
18. Tighten the end cap (04). In most cases the original holes for the lock pins will line up.
502 31222415 800S HC3, 860SJ HC3

19. Place the lock pins (109) provided in the Helac seal kit in the holes with the dimple side up. Then, using a punch, tap the lock pins
to the bottom of the hole.
BM100389A
20. Insert the set screws (113) over the lock pins. Tighten them to 25 in. lbs. (2.825 Nm).
BM100390A
Installing Counterbalance Valve

Refer to Figure — Rotator Counterbalance Valve, page 504.
1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old Threadlocking
compound.
2. Make sure the new valve has the O-rings in the counterbores of the valve to seal it to the actuator housing.
3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve. Medium Strength
Threadlocking Compound should be applied to the shank of the three bolts at the time of installation.
4. Torque the 1/4 in. bolts 110 to 120 in. lbs. (12.4 to 13.5 Nm). Do not torque over 125 in. lbs. (14.1 Nm). Torque the 5/16 in. bolts 140
in. lbs. (15.8 Nm). Do not torque over 145 in. lbs (16.3 Nm).
5. Make sure the valve is seated against the housing valve flat. If it is raised up on any side or corner, remove the valve to determine
what the obstruction is. If possible, test this using a hydraulic hand pump or electric test.
800S HC3, 860SJ HC3 31222415 503

BM100391A
Figure 182. Rotator Counterbalance Valve

Greasing Thrust Washers
1. After the actuator is assembled but before it is put into service, the thrust washer area must be packed with Lithium grease.
2. There are two grease ports located on both the shaft flange and the end cap. They are plugged with capscrews (6) or set screws.
Remove the grease port screws from the shaft flange and end cap. (See exploded view)
BM100392A
NOTICE
If a hydraulic test bench is not available, the actuator can be rotated by hand, open
the pressure ports and use a pry bar with capscrews inserted into the shaft flange
to turn the shaft in the desired direction.
504 31222415 800S HC3, 860SJ HC3

3. Insert the tip of a grease gun into one port and apply grease to the shaft flange. Continue applying until grease flows from the
opposite port. Cycle the actuator five times and apply grease again. Repeat this process on the end cap. Insert the capscrews into
the grease ports and tighten to 25 in. lbs. (2.8 Nm).
BM100393A
Testing the Actuator

If the equipment is available, the actuator should be tested on a hydraulic test bench. The breakaway pressure – the pressure at which
the shaft begins to rotate — should be approximately 400 psi (28 bar). Cycle the actuator at least 25 times at 3000 psi (210 bar) pressure.
After the 25 rotations, increase the pressure to 4500 psi (315 bar) to check for leaks and cracks. Perform the test again at the end of the
rotation in the opposite direction.
Testing the Actuator for Internal Leakage
If the actuator is equipped with a counterbalance valve, plug the valve ports. Connect the hydraulic lines to the housing ports. Bleed all
air from the actuator (refer to Section – Installation and Bleeding) Rotate the shaft to the end of rotation at 3000 psi (210 bar) and
maintain pressure. Remove the hydraulic line from the non-pressurized side.
Continuous oil flow from the open housing port indicates internal leakage across the piston. Replace the line and rotate the shaft to the
end of rotation in the opposite direction. Repeat the test procedure outlined above for the other port. If there is an internal leak,
disassemble, inspect and repair.
Installation and Bleeding
After installation of the actuator on the equipment, it is important that all safety devices such as tie rods or safety cables are properly
reattached.
To purge air from the hydraulic lines, connect them together to create a closed loop and pump hydraulic fluid through them. Review the
hydraulic schematic to determine which hydraulic lines to connect. The linear feet and inside diameter of the hydraulic supply lines
together with pump capacity will determine the amount of pumping time required to fully purge the hydraulic system.
Bleeding may be necessary if excessive backlash is exhibited after the actuator is connected to the hydraulic system. The following steps
are recommended when a minimum of two gallons (8 liters) is purged.
800S HC3, 860SJ HC3 31222415 505

1. Connect a 3/16 in. inside diameter x 5/16 in. outside diameter x 5 ft. clear, vinyl drain tube to each of the two bleed nipples. Secure
them with hose clamps. Place the vinyl tubes in a clean 5 gallon container to collect the purged oil. The oil can be returned to the
reservoir after this procedure is completed.
2. With an operator in the platform, open both bleed nipples 1/4 turn. Hydraulically rotate the platform to the end of rotation (either
clockwise or counterclockwise), and maintain hydraulic pressure. Oil with small air bubbles will be seen flowing through the tubes.
Allow a 1/2 gallon of fluid to be purged from the actuator.
3. Keep the fittings open and rotate the platform in the opposite direction to the end position. Maintain hydraulic pressure until an
additional 1/2 gallon of fluid is pumped into the container.
4. Repeat steps 2 and 3. After the last 1/2 gallon is purged, close both bleed nipples before rotating away from the end position.
Troubleshooting
Problem Cause Solution
1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed
OEM’s pressure specifications. Load may be above
maximum capacity of the actuator.
b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic lines for
restrictions and leaks.
c. Control or counterbalance valve has internal leak c. Disconnect hydraulic lines and bypass valve. Leave
valve ports open and operate the actuator through
housing ports (do not exceed OEM’s operating
pressure). The valve must be replaced if a steady flow
of fluid is seen coming from the valve ports.
d. Piston and/or shaft seal leak d. Remove the plug and the housing’s valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in Section
— Testing the Actuator of this manual.
e. Corrosion build-up on the thrust surfaces e. Re-build the actuator. Remove all rust then polish.
Replacement parts may be needed.
f. Swollen seals and composite bearings caused by f. Re-build the actuator. Use fluid that is compatible
incompatible hydraulic fluid with seals and bearings.
2. Operation is erratic or not responsive a. Air in actuator a. Purge air from actuator. Refer to Section –
Installation and Bleeding of this manual.
506 31222415 800S HC3, 860SJ HC3

Table 49. Troubleshooting (continued)

Problem Cause Solution
3. Shaft will not fully rotate a. Twisted or chipped gear teeth overload conditions a. Check for gear binding. Actuator may not be able to
be rebuilt and may need to be replaced.
b. Port fittings are obstructing the piston during stroke b. Check thread length of port fittings. Fittings should
not reach inside the housing bore.
4. Selected position cannot be maintained a. Control or counterbalance valve has internal leak a. Disconnect hydraulic lines and bypass valve. Leave
valve ports open and operate the actuator through
housing ports (do not exceed OEM’s operating
pressure). The valve must be replaced if a steady flow
of fluid is seen coming from the valve ports.
b. Piston and/or shaft seal leak b. Remove the plug and the housing’s valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in Section
— Testing the Actuator of this manual.
c. Air in actuator c. Purge air from actuator. Refer to Section –
Installation and Bleeding of this manual.
10.3 HYDRAULIC CYLINDERS
10.3.1 Axle Lockout Cylinder

Disassembly
NOTICE
Disassembly of the cylinder should be performed on a clean work surface in a dirt
free work area.
WARNING
Rod can fall out of barrel and cause injury or damage to the equipment. Be careful
when removing axle cylinder. Opening bleed valve can cause rod to fall out of
barrel.
1. Open bleeder valve. Rotate rod and remove from barrel.
2. Remove wiper. Do not scratch barrel bore.
3. Remove two wear rings and rod seal from grooves of rod bore. Do not scratch barrel bore.
4. Remove counterbalance valve.
Cleaning and Inspection

1. Inspect bore and rod for scoring, pitting, or excessive wear.
2. Remove minor surface blemishes with wet sandpaper. Pitting requires replacement of barrel and rod.
3. Clean all parts with approved solvent and dry with compressed air.
800S HC3, 860SJ HC3 31222415 507

Assembly
Note: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See respective JLG Parts Manual.
Note: Apply a light film of hydraulic oil to all components prior to assembly.
NOTICE
When installing new seals, ensure seals are installed properly. Improper seal installa-
tion could result in cylinder leakage and improper cylinder operation.
1. Install two new wear rings and rod seal in rod bore grooves. Make sure they are not twisted.
2. Install new wiper in barrel.
3. Lubricate rod bore with clean hydraulic fluid.
NOTICE
Extreme care should be taken when installing the rod. Avoid pulling the rod off-cen-
ter, which could cause damage to the rod and cylinder barrel surfaces.
4. Install rod in bore and push to top of the bore.
5. Install counterbalance valve. Torque to 22 ft. lbs. (30 Nm).
6. Bleed system.
508 31222415 800S HC3, 860SJ HC3

Figure 183. Axle Lockout Cylinder
1. Barrel 4. Rod Seal 7. Plug

2. Rod 5. Wear Ring 8. Plug
3. Wiper Seal 6. Counterbalance Valve 9. Bleeder Valve
800S HC3, 860SJ HC3 31222415 509

10.3.2 Jib Lift Cylinder (860SJ HC3)

Disassembly
NOTICE
free work area.
1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
WARNING
Do not fully extend cylinder to the end of stroke. Retract cylinder slightly to avoid
trapping pressure.
2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support
the cylinder rod, if applicable.
3. Remove the counterbalance holding valves and plugs from the cylinder port block. Discard O-rings.
4. Place the cylinder barrel into a suitable holding fixture.
Figure 184. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cylinder head retainer
capscrew and remove capscrew from cylinder barrel
510 31222415 800S HC3, 860SJ HC3

6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable.
NOTICE
Extreme care should be taken when removing the cylinder rod, head and piston.
Avoid pulling the rod off-center, which could cause damage to the piston and cylin-
der barrel surfaces.
800S HC3, 860SJ HC3 31222415 511

7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from
the cylinder barrel.
ROD SUPPORT
SUPPORT TABLE
BM100471A
Figure 185. Cylinder Rod Support
512 31222415 800S HC3, 860SJ HC3

18
18
17
12
13
12
13
11
10
9
16
10
11
3
8 14
15
7
4
5
6
19
21
18
20 19
21
18
BM109400A
Figure 186. Jib Lift Cylinder
800S HC3, 860SJ HC3 31222415 513

Note: Refer to Figure — Jib Lift Cylinder, page 513 for below table.
1. Barrel 7. O-ring 13. Backup Ring 19. Plug
2. Rod 8. Backup Ring 14. Tapered Bushing 20. Plug
3. Head 9. Piston 15. Capscrew 21. Counterbalance Valve

(Torque to 5.5 - 4.5 ft. lbs. (7.6 - 6.2 Nm)) (Torque to 50 - 55 ft. lbs. (68 - 75 Nm))
4. Wiper Seal 10. Seal 16. Capscrew
(Torque to 23.7 - 19.7 ft. lbs. (32.4 - 26.4 Nm))
5. Seal 11. Lock Ring 17. Spacer
6. Wear Ring 12. O-ring 18. Bearing
8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.
9. Remove capscrew from drilled holes.
10. Insert the capscrew in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the capscrew until the
bushing is loosen on the piston.
11. Remove the bushing from the piston.
Figure 187. Tapered Bushing Removal
12. Screw the piston counterclockwise by hand and remove the piston from cylinder rod.
13. Remove and discard the piston O-rings, seal rings, backup rings, guide lock ring, hydraulic lock seal.
14. Remove piston spacer from the rod.
15. Remove the rod from the holding fixture. Remove the cylinder head gland. Discard the O-rings, backup rings, rod seals, wear rings
and wiper seals.
Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality or other damage. If necessary, dress rod with Scotch Brite or equivalent.
Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if
necessary.
5. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.
6. Inspect threaded portion of piston for damage. Dress threads as necessary.
514 31222415 800S HC3, 860SJ HC3

7. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.
8. Inspect cylinder head inside diameter for scoring, tapering, ovality or other damage. Replace if necessary.
9. Inspect seal and O-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.
10. Inspect cylinder head outside diameter for scoring, tapering, ovality or other damage. Replace if necessary.
11. Inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace if necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced.
c. Lubricate inner side of steel bushing prior to bearing installation.
d. Using an arbor of the correct size, carefully press the bearing into steel bushing.
Note: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings.
BM100473A
Figure 188. Composite Bearing Installation
12. If applicable, inspect port block fittings and holding valve. Replace if necessary.
13. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair if necessary.
14. If applicable, inspect piston rings for cracks or other damage. Replace if necessary.
Assembly
Note: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual.
800S HC3, 860SJ HC3 31222415 515

1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.
Figure 189. Rod Seal Installation
NOTICE
Figure 190. Cylinder Head Seal Installation
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable
cylinder head gland groove.
Figure 191. Wiper Seal Installation
516 31222415 800S HC3, 860SJ HC3

3. Place a new O-ring and backup seal in the applicable outside diameter groove of the cylinder head.
Figure 192. Installation of Head Seal Kit
4. Carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.
5. Carefully slide the piston spacer on the rod.
6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.
7. Place a new O-ring and backup rings in the inner piston diameter groove.
8. Carefully thread the piston on the cylinder rod hand tight, ensuring that the O-ring and backup rings are not damaged or
dislodged.
9. Thread piston onto rod end and install the tapered bushing.
Note: When installing the tapered bushing, piston and mating end of rod must be free of oil.
10. Assemble the tapered bushing loosely into the piston and insert capscrew through the drilled holes in the bushing and into the
tapped holes in the piston.
Figure 193. Tapered Bushing Installation
11. Tighten the capscrew evenly and progressively in rotation to 5.5 - 4.5 ft. lbs. (7.6-6.2 Nm).
800S HC3, 860SJ HC3 31222415 517

12. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4 in.
diameter) as follows:
a. Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrew.
b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrew.
Figure 194. Seating the Tapered Bearing
13. Rotate the capscrew evenly and progressively in rotation to 5 ft. lbs. (7 Nm).
14. Remove the cylinder rod from the holding fixture.
NOTICE
When installing hydrolock piston seals, ensure seals are installed properly. Refer to
Figure – Hydrolock Piston Seal Installation, page 518 for correct seal orientation. Im-
proper seal installation could result in cylinder leakage and improper cylinder
operation.
Figure 195. Hydrolock Piston Seal Installation
15. Place new hydrolock seal and guidelock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D. of
the piston is recommended to install the solid seal).
Figure 196. Piston Seal Kit Installation
518 31222415 800S HC3, 860SJ HC3

16. Position the cylinder barrel in a suitable holding fixture.
NOTICE
Extreme care should be taken when installing the cylinder rod, head, and piston.
17. With barrel clamped secured and adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the
piston loading O-ring and seal ring are not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.
Figure 197. Rod Assembly Installation
19. Secure the cylinder head gland using the capscrew. Torque capscrew to 18 ft. lbs. (25 Nm).
20. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the re-installation of any
holding valve or valves.
21. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new O-rings as applicable. Torque
valves to 50 - 55 ft. lbs. (68 - 75 Nm).
10.3.3 Main Boom Lift Cylinder (800S HC3)

Disassembly
NOTICE
free work area.
WARNING
trapping pressure.
3. Remove the proportional valve, lift holding valve, relief valve, check valve and plugs. Discard O-rings.
800S HC3, 860SJ HC3 31222415 519

capscrew and remove capscrew from cylinder barrel.
Figure 199. Capscrew Removal
NOTICE
520 31222415 800S HC3, 860SJ HC3

ROD SUPPORT
SUPPORT TABLE
BM100471A
800S HC3, 860SJ HC3 31222415 521

Figure 201. Main Boom Lift Cylinder (800S HC3)
1. Barrel 9. Piston 17. Capscrew

2. Rod 10. Guidelock Ring 18. Bushing
3. Head 11. Guidelock Ring 19. Plug
4. Wiper Seal 12. O-ring 20. Plug
5. Rod Seal 13. Backup Ring 21. Plug

6. Wear Ring 14. Spacer 22. Cartridge, Relief Valve
7. O-ring 15. Tapered Bushing 23. Cartridge, Lift Holding Solenoid
8. Backup Ring 16. Capscrew 24. Cartridge, Lift Relief Proportional Solenoid
522 31222415 800S HC3, 860SJ HC3

PISTON
TAPERED
BUSHING
ROD
CAPSCREWS
13. Remove and discard the piston O-rings, seal rings, wear rings and backup rings.
and wiper seals.
Cleaning And Inspection

necessary.
800S HC3, 860SJ HC3 31222415 523

11. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace if necessary.
12. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent.
Assembly
524 31222415 800S HC3, 860SJ HC3

NOTICE
800S HC3, 860SJ HC3 31222415 525

3. Place a new O-ring and backup ring in the applicable outside diameter groove of the cylinder head.
4. Install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the
rod to the rod end, as applicable.
5. Carefully slide the piston spacer onto the rod.
dislodged.
9. Thread piston onto rod hand tight and install the tapered bushing.
11. Tighten the capscrew evenly and progressively in rotation to 30 ft. lbs. (41 Nm).
526 31222415 800S HC3, 860SJ HC3

13. Rotate the capscrew evenly and progressively in rotation to 30 ft. lbs. (41 Nm).
15. Place new seal and wear rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D. of the piston is
recommended to install the solid seal).
NOTICE
Extreme care should be taken when installing the cylinder rod, head and piston.
800S HC3, 860SJ HC3 31222415 527

19. Secure the cylinder head gland using the capscrew. Torque capscrew to 302 ft. lbs. (410 Nm).
21. Install the relief valve before installing the plug. Torque the relief valve as shown Figure —Main Boom Lift Cylinder (800S HC3), page
522. Install the remaining plugs, using new O-rings as applicable.
22. Install the proportional valve, lift holding valve, relief valve, check valve and plugs, using new O-rings as applicable.
10.3.4 Main Boom Lift Cylinder (860SJ HC3)

Disassembly
NOTICE
free work area.
WARNING
trapping pressure.
3. Remove the proportional valve, lift holding valve, relief valve, check valve and plugs. Discard O-rings.
528 31222415 800S HC3, 860SJ HC3

5. Mark cylinder head and barrel with center punch marks for later realignment. Using a hook spanner wrench, unscrew the cylinder
head cap from the barrel.
Figure 213. Cylinder Head Removal
NOTICE
800S HC3, 860SJ HC3 31222415 529

ROD SUPPORT
SUPPORT TABLE
BM100471A
530 31222415 800S HC3, 860SJ HC3

Figure 215. Main Boom Lift Cylinder (860SJ HC3)
1. Barrel 10. Bearing Ring 19. Spacer
2. Rod 11. O-ring 20. Plug
3. Head 12. Backup Ring 21. Plug
4. Tube Spacer 13. Piston 21. Plug

5. Wiper 14. Piston Seal 23. Relief Valve
6. Retaining Ring 15. O-ring 24. Proportional Valve
7. Rod Seal 16. Steel Ball 25. Poppet valve

8. Backup ring 17. Set Screw 26. Locking Insert
9. Buffer ring 18. Bushing
800S HC3, 860SJ HC3 31222415 531

9. Loosen and remove the setscrew and steel ball which attaches the piston to the rod.
Figure 216. Piston Removal
10. Screw the piston counterclockwise and remove the piston from cylinder rod.
NOTICE
Remove seals using a brass or plastic pick only. Do not use a knife, sharp object, or
screw driver. Make note of seal orientation before removing for proper installation.
11. Remove and discard the piston seal from outside grooves of piston.
12. Remove and discard the O-rings from inside groove of the piston.
Figure 217. Piston Seal Disassembly
14. Remove the rod from the holding fixture. Remove the cylinder head gland.
15. Remove and discard Retaining ring, rod seal, wiper, backup ring, buffer ring and Bearing ring from inside groove of the head.
16. Remove and discard O-ring and backup ring from outside groove of the head.
Figure 218. Cylinder Head Disassembly
532 31222415 800S HC3, 860SJ HC3

CLEANING AND INSPECTION

necessary.
BM100473A
Assembly
800S HC3, 860SJ HC3 31222415 533

NOTICE
3. Install backup ring and O-ring in outside groove of the cylinder head.
4. Install Retaining ring, Rod seal, Wiper, Backup ring, Buffer ring and Bearing ring in inside groove of the head.
Figure 221. Cylinder Head Assembly
5. Carefully install the cylinder head on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head
8. Install new O-ring in inside groove of the piston.
9. Install setscrew and steel ball on the piston and attach the piston on the rod.
Figure 222. Piston Seal Installation
534 31222415 800S HC3, 860SJ HC3

11. Place new piston seal in the outer diameter of piston groove. (A tube, with I. D. slightly larger than the O. D. of the piston is
NOTICE
Figure 223. Cylinder Head Tightening
15. Screw the cylinder head into the barrel using a hookspanner wrench and torque cylinder head to 554.4 - 453.6 ft. lbs. (1146 -
1000.9 Nm).
16. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any
17. Install the new O-rings and plugs into the cylinder portblock and torque plug as shown in Figure —Main Boom Lift Cylinder (860SJ
HC3), page 531.
18. Install the Proportional valve, Poppet valve, Relief valve and plugs, using new O-rings as applicable.
10.3.5 Platform Level Cylinder (800S HC3)

Disassembly
NOTICE
free work area.
WARNING
trapping pressure.
800S HC3, 860SJ HC3 31222415 535

3. Remove the counterbalance valves and fittings from the cylinder port block. Discard O-rings.
NOTICE
536 31222415 800S HC3, 860SJ HC3

ROD SUPPORT
SUPPORT TABLE
BM100471A
800S HC3, 860SJ HC3 31222415 537

Figure 227. Platform Level Cylinder (800S HC3)
1. Barrel 9. Piston 17. Counterbalance Valve (Barrel End)

2. Rod 10. T-Seal 18. Counterbalance Valve (Rod End)
3. Head 11. Wear Ring 19. Bushing
4. Wiper Seal 12. O-ring 20. Capscrew

5. Rod Seal 13. Backup Ring 21. Capscrew
6. Wear Ring 14. Tube Spacer 22. Plug
7. O-ring 15. Tapered Bushing
8. Backup Ring 16. Washer Ring
538 31222415 800S HC3, 860SJ HC3

PISTON
TAPERED
BUSHING
ROD
CAPSCREWS
13. Remove and discard the piston hydrolock seals, guidelock rings.
and wiper seals.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent.
necessary.
800S HC3, 860SJ HC3 31222415 539

a. Thoroughly clean hole (steel bushing) of burrs, dirt etc. to facilitate bearing installation.
BM100473A
Assembly
540 31222415 800S HC3, 860SJ HC3

NOTICE
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear rings into the
applicable cylinder head gland groove.
800S HC3, 860SJ HC3 31222415 541

4. Install washer ring onto rod, carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or
dislodged. Push the head along the rod to the rod end, as applicable.
dislodged.
9. Thread piston onto rod and install the tapered bushing.
11. Tighten the capscrew evenly and progressively in rotation to 10 ft. lbs (13 Nm).
542 31222415 800S HC3, 860SJ HC3

13. Tighten the capscrew evenly and progressively in rotation to 10 ft. lbs (13 Nm).
NOTICE
When installing hydrolock piston seals, ensure seals are installed properly. Refer to
Figure – Hydrolock Piston Seal Installation, page 543 for correct seal orientation. Im-
proper seal installation could result in cylinder leakage and improper cylinder
operation.
Figure 236. Hydrolock Piston Seal Installation
800S HC3, 860SJ HC3 31222415 543

15. Place new hydrolock seal and guidelock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D. of
the piston is recommended to install the solid seal).
NOTICE
Extreme care should be taken when installing the cylinder rod, head, and piston.
piston loading hydrolock seals, guidelock rings are not damaged or dislodged.
19. Secure the cylinder head gland using the washer ring and capscrew. Torque capscrew to 55 ft. lbs. (75 Nm).
21. Install the cartridge-type holding valves and fittings in the rod port block, using new O-rings as applicable. Torque valves to 50-55
ft. lbs. (68-75 Nm).
544 31222415 800S HC3, 860SJ HC3

10.3.6 Platform Level Cylinder (860SJ HC3)

Disassembly
NOTICE
free work area.
WARNING
trapping pressure.
3. Remove the counterbalance valves and fittings from the cylinder port block. Discard O-rings.
4. Place the cylinder barrel into a suitable holding fixture. Tap around outside of cylinder head retainer with a suitable hammer to
break thread-locking compound.
800S HC3, 860SJ HC3 31222415 545

5. Unscrew cylinder head with hook spanner wrench.
Figure 240. Cylinder Head Removal
NOTICE
Pulling rod off-center can damage piston and cylinder barrel surfaces. Use extreme
care when removing cylinder rod, head, and piston.
6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel.
546 31222415 800S HC3, 860SJ HC3

7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible.
ROD SUPPORT
SUPPORT TABLE
BM100471A
800S HC3, 860SJ HC3 31222415 547

Figure 242. Platform Level Cylinder (860SJ HC3)
1. Barrel 8. Bearing 15. O-Ring

2. Rod 9. Dry Bearing 16. Setscrew
3. Head 10. O-Ring 17. Ball

4. Wiper 11. Backup Ring 18. Spacer
5. Retaining Ring 12. O-Ring 19. Bushing
6. Rod Seal 13. Piston 20. Plug

7. Backup Ring 14. Piston Seal 21. Counterbalance Valve
8. Loosen and remove the setscrew and steel ball which attaches the piston to the rod.
548 31222415 800S HC3, 860SJ HC3

9. Screw the piston counterclockwise and remove the piston from cylinder rod.
Figure 243. Piston Removal
NOTICE
Remove seals using a brass or plastic pick only. Do not use a knife, sharp object, or
screw driver. Make note of seal orientation before removing for proper installation.
10. Remove and discard the piston seal from outside grooves of piston.
11. Remove and discard the O-rings from inside groove of the piston.
Figure 244. Piston Seal Disassembly
13. Remove the rod from the holding fixture. Remove the cylinder head gland.
14. Remove and discard Retaining ring, rod seal, wiper, backup ring, buffer ring and Bearing ring from inside groove of the head.
15. Remove and discard O-ring and backup ring from outside groove of the head.
Figure 245. Cylinder Head Disassembly
800S HC3, 860SJ HC3 31222415 549


necessary.
10. Inspect cylinder head outside diameter for scoring, tapering or ovality other damage. Replace if necessary.
BM100473A
Assembly
550 31222415 800S HC3, 860SJ HC3

NOTICE
3. Install backup ring and O-ring in outside groove of the cylinder head.
4. Install Retaining ring, Rod seal, Wiper, Backup ring, Buffer ring and Bearing ring in inside groove of the head.
Figure 248. Cylinder Head Assembly
5. Carefully install the cylinder head on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head
8. Install new O-ring in inside groove of the piston.
800S HC3, 860SJ HC3 31222415 551

9. Install setscrew and steel ball on the piston and attach the piston on the rod.
Figure 249. Piston Seal Installation
11. Place new piston seal in the outer diameter of piston groove. (A tube, with I. D. slightly larger than the O. D. of the piston is
NOTICE
Figure 250. Cylinder Head Tightening
15. Screw the cylinder head into the barrel using a hookspanner wrench and torque cylinder head to 451 - 369 ft. lbs. (612 - 500 Nm).
16. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any
17. Install the new O-rings and plugs into the cylinder portblock.
552 31222415 800S HC3, 860SJ HC3

10.3.7 Steer Cylinder

Disassembly
NOTICE
free work area.
WARNING
trapping pressure.
4. Using a hook Spanner, loosen the spanner nut retainer and remove spanner nut from cylinder barrel.
Figure 252. Spanner Nut Removal
NOTICE
800S HC3, 860SJ HC3 31222415 553

ROD SUPPORT
SUPPORT TABLE
BM100471A
554 31222415 800S HC3, 860SJ HC3

Figure 254. Steer Cylinder
1. Piston 6. Barrel 11. Spanner Nut

2. Wear Ring 7. Head 12. Wiper Seal
3. Seal 8. O-ring 13. Rod Seal

4. Setscrew 9. Backup Ring 14. Bushing
5. Rod 10. C- Ring
8. Loosen and remove setscrew which attaches the piston to the rod.
10. Remove and discard the piston O-rings, seal rings.
11. Remove the rod from the holding fixture. Remove the cylinder head gland. Discard the O-rings, backup rings, rod seals, C-ring and
wiper seal.
800S HC3, 860SJ HC3 31222415 555


necessary.
10. Inspect cylinder head outside diameter for scoring, tapering or ovality other damage. Replace if necessary.
BM100473A
12. Inspect piston rings for cracks or other damage. Replace if necessary.
Assembly
556 31222415 800S HC3, 860SJ HC3

NOTICE
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove.
800S HC3, 860SJ HC3 31222415 557

3. Place a new O-ring backup ring and C-ring in the applicable outside diameter groove of the cylinder head.
4. Install spanner nut onto rod. Carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or
dislodged. Push the head along the rod to the rod end, as applicable.
dislodged. Torque piston to 325-390 ft. lbs. (441-529 Nm).
7. Install the setscrews on the piston. Torque the setscrews to 3-4 ft. lbs (4-5 Nm) and attached the piston onto the rod.
Note: Apply Medium Strength Threadlocking Compound to setscrew thread of piston.
9. Place new seal and wear ring in the outer piston diameter grooves. (A tube, with I.D. slightly larger than the O.D. of the piston is
Figure 260. Installation of Piston Seal Kit
NOTICE
558 31222415 800S HC3, 860SJ HC3

13. Screw the cylinder head gland into the barrel using a spanner nut and torque gland to 76-84 ft. lbs. (103-114 Nm).
Note: Apply Medium Strength Threadlocking Compound to spanner nut thread.
14. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted).
10.3.8 Telescope Cylinder

Disassembly
NOTICE
free work area.
WARNING
trapping pressure.
3. If applicable, remove the cartridge type holding valve and fittings from the cylinder port block. Discard O-rings.
4. Place the cylinder barrel into a suitable holding fixture
800S HC3, 860SJ HC3 31222415 559

NOTICE
560 31222415 800S HC3, 860SJ HC3

ROD SUPPORT
SUPPORT TABLE
BM100471A
800S HC3, 860SJ HC3 31222415 561

Figure 264. Telescopic Cylinder
1. Barrel 9. Piston 17. Valve assembly
2. Rod 10. T-Seal 18. Capscrew

3. Head 11. Wear Ring 19. Capscrew
4. Wiper 12. O- ring 20. Capscrew
5. Rod Seal 13. Backup Ring 21. Plug

6. Wear Ring 14. Tapered Bushing 22. Plug
7. O- ring 15. Tube Spacer
8. Backup Ring 16. Capscrew
9. Remove capscrew from drilled holes
562 31222415 800S HC3, 860SJ HC3

13. Remove and discard the piston O-rings, seal rings, wear rings and backup rings.
14. Remove setscrew from the piston spacer. Remove spacer from the rod.
and wiper seals.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent.
necessary.
800S HC3, 860SJ HC3 31222415 563

11. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.
BM100473A
Assembly
564 31222415 800S HC3, 860SJ HC3

NOTICE
2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear rings into the
applicable cylinder head gland groove.
800S HC3, 860SJ HC3 31222415 565

4. Carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head
5. Carefully slide the piston spacer on the rod. Install setscrew on the spacer.
dislodged.
9. Thread piston onto rod until it abuts the spacer end and install the tapered bushing.
566 31222415 800S HC3, 860SJ HC3

b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces betweenthe capscrew.
15. Place new T-seal and wear rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D. of the piston is
NOTICE
17. With barrel clamped secured, and adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the
800S HC3, 860SJ HC3 31222415 567

19. Secure the cylinder head gland using the capscrew. For Torque capscrew Refer to Figure — Telescopic Cylinder, page 562.
21. Install the valve assembly. For Torque capscrew Refer to Figure — Telescopic Cylinder, page 562.
568 31222415 800S HC3, 860SJ HC3

10.4 TURNTABLE
10.4.1 Swing Drive

Motor Control Valve Disassembly
Figure 275. Motor Control Valve
1P. O-ring Plug 23. Plug 35. Hydraulic Tubing
6. Hydraulic Brake 30. Elbow Fitting 99. O-ring
21. Hex Bolt 31. Hydraulic Motor
22. Lockwasher 32. Motor Control Valve
1. Place unit on bench with the motor end up.
2. Remove O-ring Plug (1P) and drain the oil from the gearbox.
3. Remove Hydraulic Tubing Assembly (35) by loosening fittings on both ends of tube with a wrench.
4. Using a wrench, loosen jam nuts on Elbow Fittings (30) and remove fittings from Brake (6) and Motor Control Valve (32).
5. Remove O-ring Plugs (23) from Motor Control Valve (32).
6. Remove Motor Control Valve (32) from Motor (31) by removing the four Bolts (21) and washers (22).
7. Remove O-ring (99) between Motor Control Valve (32) and Motor (31). Discard O-ring.
800S HC3, 860SJ HC3 31222415 569

Motor and Brake Disassembly
Figure 276. Motor and Brake
6. Brake Housing 8F. O-ring 8L. Spring
8A. Brake Piston 8H. O-ring/Backup Ring 8M. Pressure Plate

8D. O-ring 8J. Brake Rotor 8N. Internal Retaining Ring
8E. O-ring/Backup Ring 8K. Brake Stator
1. With unit resting on bench with Motor (31) end up, loosen Hex Bolts (29) and remove Lift Lugs (28) from the Motor (31).
2. Pull Motor (31) straight up and remove Motor (31) from Brake Housing (6).
3. Remove O-ring (26) from between Motor (31) and Brake Housing (6).
4. Insert and tighten the 0.250 – 20 UNC flat Socket Head Capscrews through the Pressure Plate (8M) and into the Brake Piston (8A)
to compress the springs and relieve pressure on the Retaining Ring (8N).
5. Using retaining ring pliers, remove Retaining Ring (8N) which holds the Brake Piston assembly in place.
6. Lift Brake Piston Assembly (8A) out of the Brake Housing (6). If the Brake Piston assembly (8A) will not lift out, apply less than 50 psi
air to the “brake port” to remove Brake Piston (8A). Remove the Inner (Rotor) (8J), Outer (Stator) Plates (8K), from inside Brake
Housing (6).
7. Remove O-rings (8D, 8F) and Backup Rings (8E, 8H) from the Brake Housing (6). Discard O-rings and Backup Rings.
8. Remove 0.250 – 20 UNC flat Socket Head Capscrews and lift the Pressure Plate (8M) from the Brake Piston (8A).
9. Apply less than 50 psi (3.45 bar) air to the “brake port” to remove Brake Piston (8A).
CAUTION
The Piston may move quickly. Eye protection should be worn during this
procedure.
10. Remove Rotors (8J) and Stators (8K) from Brake Housing (6).
570 31222415 800S HC3, 860SJ HC3

Main Drive Disassembly
Figure 277. Main Drive Assembly
1A. Output Shaft (Pinion) 5. O-ring 12. Bolt
1G. Housing 5A. O-ring 13. Dowel Pin
2. Internal Gear 6. Brake Housing 20. Pipe Plug
3F. Carrier subassembly 8. Sun Gear 44. Ring
4. Ring Gear 11. Thrust Washer
1. Remove Sun Gear (8) with Retaining Ring (44) inside.
2. With the unit resting on the Output Shaft (Pinion) (1A), remove the Bolts (12) from the Brake Housing (6).
3. Remove the Brake Housing (6) from the main assembly.
4. Remove O-ring (5A) from between Brake Housing (6) and Ring Gear (4).
5. Remove Thrust Washer (11) from between Brake Housing (6) and Carrier Subassembly.
6. Remove Ring Gear (4) from Housing (1G).
7. Remove O-ring (5) from between Ring Gear (4) and Housing (1G).
8. Remove Carrier Sub-Assembly.
9. Remove Thrust Washer (11) from between Carrier Sub-Assembly and Internal Gear (2).
10. Remove Internal Gear (2).
800S HC3, 860SJ HC3 31222415 571

Hub-Shaft Disassembly
Figure 278. Hub-Shaft
1A. Output Shaft 1D. Bearing Cone 1G. Housing
1B. Lip Seal 1E. Bearing Cone 1H. Thrust Washer

1C. Bearing Cup 1F. Bearing Cup 1I. Retaining Ring
1. Using retaining ring pliers remove Retaining Ring (1I) from groove in Output Shaft (1A) and discard.
CAUTION
Eye protection should be worn during this procedure.
2. Remove Thrust Washer (1H).
3. While supporting the Housing (1G) on the Output Shaft (1A) end, press the Output Shaft (1A) out of the Housing (1G).
Note: The Lip Seal (1B) will be pressed out of the Housing (1G) by the Bearing Cone (1D) during this step.
4. Remove the Bearing Cone (1E) from the Housing (1G).
5. Use a bearing puller to remove the Bearing Cone (1D) from the Shaft (1A).
6. Bearing Cups (1C & 1F) will remain in Housing (1G).
Note: If bearing replacement is necessary, the Bearing Cups (1C & 1F) can be removed with a slide hammer puller or driven out
with a punch.
572 31222415 800S HC3, 860SJ HC3

Carrier Disassembly
3B 3F 3G
3C
3D
3C 3B
3E
3A
BM102128A
Figure 279. Carrier
3A. Carrier 3D. Spacer 3G. Roll Pin

3B. Thrust Washers 3E. Planet Shaft
3C. Needle Bearing 3F. Cluster Gear
1. Using a 3/16 in. punch drive the Roll Pin (3G) which holds the Planet Shaft (3E) in the Carrier (3A) down into the Planet Shaft (3E)
until it bottoms.
Note: Make sure that the Roll Pin has bottomed. Otherwise, damage to the carrier could occur when the Planet Shaft is removed.
2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a small punch to remove the Roll Pin (3D) from the Planet Shaft (3E).
3. Slide the Planet Gear (3F), the two Thrust Washers (3B) out of the Carrier (3A).
4. Remove both rows of Needle Bearings (3C) and the Spacer (3D) from the bore of the Planet Gear (3F).
5. Repeat Steps 1 thru 4 for the remaining two Cluster Gears (3F).
800S HC3, 860SJ HC3 31222415 573

Hub-Shaft Assembly
Note: Refer to Figure — Hub-Shaft, page 572.
1. Press Bearing Cup (1C) into Housing (1G) taking care to ensure cup starts square with the bore of Hub (1G).
2. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing (1G).
3. Press or tap Seal (1B) Into the counterbore of Housing (1G) to the point where it becomes flush with the Housing (1G) face. Care
should be taken to ensure Seal (1B) is being correctly installed (smooth face up). Apply grease to the rubber portion of the seal
bore.
4. Invert Hub (1G) and press Bearing Cup (1E) into counterbore of Housing (1G).
5. Carefully lower Housing (1G) onto the Output Shaft (1A) until Bearing Cone (1D) contacts the Output Shaft (1A).
6. Press on the small end of the Bearing Cone (1D), being careful not to contact the bearing cage, until the Bearing Cone (1D) seats
on the shoulder of the Output Shaft (1A).
7. Start the Bearing Cone (1F) onto the Output Shaft (1A).
8. Press or tap the Bearing Cone (1F) onto the Output Shaft (1A) until it is just seated in the Bearing Cup (1E). while rotating the
Housing (G).
9. Install Bearing Spacer (1H) onto Output Shaft (1A) and against Bearing Cone (1F).
10. Install Retaining Ring (1I) into the groove in the Output Shaft (1A). This Retaining Ring (1I) should never be reused in a repair or
rebuild.
WARNING
11. Tap the Retaining Ring (1I) with a soft metal punch to ensure that the Retaining Ring (1I) is completely seated in the groove of the
Output Shaft (IA).
WARNING
12. Install O-ring Plug (1P) and torque to 23 to 24 ft. lbs. (31 to 32 Nm).
574 31222415 800S HC3, 860SJ HC3

Carrier Assembly
Note: Refer to Figure — Carrier, page 573.
1. Apply a liberal Coat of grease to the bore of Cluster Gear (3F). This will enable the Needle Rollers (3C) to be held in place during
assembly.
2. Install the first row of Needle Rollers (3C) into the bore of Cluster Gear (3F).
3. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of the Needle Rollers (3C).
4. Place second row of Needle Rollers (3C) into bore of Cluster Gear (3F) against Spacer (3D).
5. Place Carrier (3A) so that one of the roll pin holes is straight up.
6. Start Planet Shaft (3E) through the hole in Carrier (3A). Using ample grease to hold it in position, slide one Thrust Washer (3B) over
the Planet Shaft (3E) with the tang resting in the cast slot of the Carrier (3A).
7. With large end of Cluster Gear (3F) facing the roll pin hole in the Carrier, place the Cluster Gear into position in carrier (3A) and
push Planet Shaft (3E) through the Cluster Gear (3F) without going all the way through.
8. Slide the second Thrust Washer (3B) between the Cluster Gear (3F) and the Carrier (3A) with the tang of the washer located in the
cast slot of the Carrier (3A). Finish sliding the Planet Shaft (3E) through the Thrust Washer (3B) and into the Carrier (3A).
9. Position the non-chamfered side on the Planet Shaft (3E) roll pin hole so that it is in line with the hole in the Carrier (3A) using a 1/
8 in. (3 mm) diameter punch.
10. After using a 3/16 in. (5 mm) punch to align the two roll pin holes. Drive the Roll Pin (3G) through Carrier (3A) and into the Planet
Shaft (3E) until the Roll Pin (3G) is flush with the bottom of the cast slot in the Carrier (3A) outside diameter at the thrust washer
(3B) tang. Use a 1/4 in. (6 mm) pin punch to make sure the Roll Pin (3G) is flush in the slot.
11. Repeat Steps 1 through 10 for the remaining two Cluster Gears (3F).
800S HC3, 860SJ HC3 31222415 575

Main Drive Assembly
Note: Refer to Figure — Main Drive Assembly, page 571.
1. With the Hub Shaft Sub-Assembly resting on the Shaft (1A) install Internal Gear (2). The spline of the Internal Gear (2) bore will
mesh with the spline of the Output Shaft (1A). This will be a tight fit.
2. Inspect the location of the Internal Gear (2) on the Output Shaft (1A). The portion of the Output Shaft (1A) should protrude
through the Internal Gear (2) bore.
3. Install 4 Dowel Pins (13) into counterbore holes in Hub (IG).
4. Install Thrust Washer (11) in counterbore of Carrier Sub-Assembly (Small Cluster-Gear end) Use grease to hold in place.
5. Place O-ring (5) into Hub counterbore. Use grease to hold O-ring in place.
WARNING
Beware of sharp edges of the counterbore while seating this O-ring.
6. Place Carrier Sub-Assembly on bench with the large end of Cluster Gears (3F) facing up with one at the 12 o'clock position. Find
the punch marked tooth on each gear at the large end and locate at 12 o'clock (straight up) from each planet pin. Marked tooth
will be located just under the Carrier on upper two gears. Check the timing through the slots in the carrier (See Carrier
Subassembly).
7. With large shoulder side of Ring Gear (4) facing down, place Ring Gear (4) over (into mesh with) cluster gears (3F). Be sure that
cluster gear timing marks (punch marks) remain in correct location during Ring Gear (4) installation. The side of the Ring Gear (4)
with an "X" or punch mark stamped on it should be up.
8. While holding Ring Gear (4) and Cluster Gears (3F) in mesh, place small end of Cluster Gears (3F) into mesh with the Internal Gear
(2). On the Ring Gear (4) locate the hole marked "X", or punch marked, over one of the marked counterbored holes (Step 5) in Hub
(1G). Check timing through the slots in the carrier. Rotate carrier in assembly to check for freedom of rotation.
Note: If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the
Cluster Gear timing.
9. Install Thrust Washer (11) into the counterbore on the face of the carrier. Use grease to hold in place.
10. Place O-ring (5A) into counterbore or Brake Housing (6). Use grease to hold O-ring in place.
CAUTION
Beware of sharp edges of the counterbore while seating this O-ring.
11. Install the Brake Housing (6), taking care to correctly align Pipe Plug (20) with those in the Hub (1G).
12. Install Bolts (12) through the Brake Housing (6) into the Hub (1G) and torque to 23-27 ft. lbs. (31-37 Nm).
13. With gearbox standing on the pinion end fill gearbox with 43 oz. of ISO 80W90 gear oil.
14. Install Retaining Ring (44) into the groove in the Sun Gear (8).
15. Install the Sun Gear (8) into mesh with the Planet Gears (3F).
16. Install Pipe Plug (20) into Brake Housing (6) torque to 23-24 ft. lbs. (31-32 Nm).
576 31222415 800S HC3, 860SJ HC3

Motor and Brake Assembly
Note: Refer to Figure — Motor Control Valve, page 570.
1. Starting with a Stator (8K), alternately stack and install Stators (8K) into Lobes of Brake Housing (6) and Rotors (8J) (internal splines)
onto splines of Sun Gear (8).
Note: There should always be a Stator on the top and bottom of the stack.
2. Insert Brake Piston (8A) completely into Brake Housing (6) without O-rings (8D, 8F) and Backup Rings (8E, 8H) to check fit of brake.
The Brake Piston (8A) should slide into Brake Housing (6) without being forced. If Brake Piston (8A) does not fit, check for burrs or
size problems before proceeding.
3. Grease O-rings (8D, 8F) and install smaller diameter O-ring (8F) into smaller diameter O-ring groove in Brake Housing (6) and install
larger diameter O-ring (8D) into larger diameter O-ring groove in Brake Housing (6).
4. Insert smaller diameter Solid Backup Ring (8H) into smaller groove in Brake Housing (6) between O-ring (8F) and side of groove
towards Output Shaft (1A).
5. Insert larger diameter Solid Backup Ring (8E) into groove in Brake Housing (6) between O-ring (8D) and side of groove towards
Motor (31).
6. Lightly grease cylinder walls of Brake Housing (6) and install Brake Piston (8A) into Brake Housing (6). If necessary, place T-134711
on top of brake and lightly tap until Brake Piston (8A) contacts brake disk stack.
7. Insert 8 Springs (8L) into Brake Piston (8A) spring holes.
8. Install Pressure Plate (8M) into Brake Housing (6) bore and onto top of Springs (8L).
9. Insert and tighten the 0.250 – 20 UNC Flat Head Capscrews through the Pressure Plate (8M) and into the Brake Piston (8A) to
compress the springs. Tighten Socket Head Capscrews incrementally to evenly compress the Springs (8L).
CAUTION
10. Using retaining ring pliers, install large Retaining Ring (8N) into groove in Brake Housing (6) making sure that it is seated properly.
Note: Use caution when installing retaining ring (8N) into Brake Housing (6). It may cause injury if it slips out of retaining ring
pliers.
11. Remove the Flat Head Capscrews from the Brake Piston (8A) incrementally to release the tension of the springs slowly. Discard Flat
Head Capscrews.
12. The Unit should undergo brake test refer to Section — Roll, Leak and Brake Testing, page 115.
13. Grease and install the O-ring (26) into the Motor (31) pilot.
14. Install Motor (31) into the Brake Housing (6). Insure the motor valve mounting face is aligned with the radial brake release port in
the Housing (1G).
15. Install Bolts (29) into Brake Housing (6) through Lifting Lugs (28) and Motor (31) flange. Torque bolts to 80-100 ft. lbs. (108-136
Nm).
800S HC3, 860SJ HC3 31222415 577

Motor Control Valve Assembly
Note: Refer to Figure — Motor Control Valve, page 569.
1. Install O-rings (99) into counterbore on Motor Valve face. Assemble the Motor control Valve (32) onto the Motor (31) with Bolt (21)
and Lock Washers (22). Torque Bolts (21) to 18-20 ft. lbs. (23-26 Nm).
Note: Be sure to align the holes in the control valve with the motor ports.
2. Install Elbow Fittings (30) into Brake (6). Do not tighten jam nuts.
3. Install Elbow Fittings (30) into Motor Control Valve (32). Do not tighten jam nuts.
4. Assemble Tube (35) into Elbow Fittings (30) and torque to 13-15 ft. lbs. (18-20 Nm). Tighten the jam nuts on the Elbow Fittings (30)
and torque to 13-15 ft. lbs. (18-20 Nm).
5. Install one O-ring Plug (23) into Motor Control Valve (32) and torque to 18-20 ft. lbs. (23-26 Nm).
6. Pressure test brake, tube and control valve connections by applying 3000 psi (207 bar) pressure to the open port in the Motor
Control Valve (32) and holding lor 1 minute. Check lor leaks al the control-valve-motor interface and the tube connections. Release
pressure and install the remaining O-ring Plug (23) into Motor Control Valve (32) and torque to 18-20 ft. lbs. (23-26 Nm).
Figure 280. Swing Drive Assembly
578 31222415 800S HC3, 860SJ HC3

Note: Refer to Figure — Swing Drive Assembly, page 578 for below table.
1A. Output Shaft 1H. Tanged Washer 4. Ring Gear 11. Thrust washer
1B. Lip Seal 1I. Retaining Ring 5. O-ring 12. Bolt
1C. Bearing 1P. Pipe Plug 5A. O-ring 13. Dowel Pin
1D. Bearing 2. Internal Gear 6. Brake Housing 1P. Pipe Plug
1G. Housing 3. Carrier Assembly 8. Sun Gear 44. Internal Retaining Ring
Figure 281. Swing Motor and Brake Assembly
800S HC3, 860SJ HC3 31222415 579

Note: Refer to Figure — Swing Motor and Brake Assembly, page 579 for below table.
8A. Piston 13. Thrust Washer 26. O-ring 34. Rotor Set 43. Backup Washer
8B. O-ring 14. Lock washer 27. Bolt 35. Wear Plate 43. Housing
8C. Backup Ring 15. Pipe Plug 28. End Cover 36. Drive Link 44. Backup Washer
8D. O-ring 18. O-ring 29. Commutator Seal 37. Coupling Shaft 45. Seal
8E. Backup Ring 19. Lifting lug 30. Ring Seal 38. Inner Bearing 46. Washer
8F. Rotor Disc 20. Bolt 31. Commutator and Ring 39. Thrust Washer
Assembly
8G. Stator Disc 21. Elbow 32. Ring 40. Thrust Bearing
8H. Spring 24. Tube 33. Manifold 41. Inner Seal
Figure 282. Bearing Cone Press Tool (T144566)
Figure 283. Bearing Cone Pressing Tool (T145741)
580 31222415 800S HC3, 860SJ HC3

Figure 284. Bearing Cup Pressing Tool (T149013)
Figure 285. Locknut Wrench Tool (T151047)
800S HC3, 860SJ HC3 31222415 581

Figure 286. Bearing Cup Pressing Tool (T155291)
Figure 287. Seal Press Tool (T175741)
582 31222415 800S HC3, 860SJ HC3

Figure 288. Swing Drive Test Plate (T187845) MAF24050
Figure 289. Leak Test Adapter Plate (T201476)
800S HC3, 860SJ HC3 31222415 583

10.4.2 Swing Motor

Disassembly and inspection
1. Place the Torqmotor™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of
the housing (18) mounting flange or port bosses. Remove manifold port O-rings (18A) if applicable.
WARNING
If the torqmotor™ is not firmly held in the vise, it could be dislodged during the
service procedures, causing injury.
2. Scribe an alignment mark down and across the Torqmotor™ components from end cover (2) to housing (18) to facilitate
reassembly orientation where required. Loosen two shuttle or relief valve plugs (21) for disassembly later if included in end cover.
3/16 or 3/8 inch Allen wrench or 1 inch hex socket required.
584 31222415 800S HC3, 860SJ HC3

3. Remove the five, six, or seven special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for
damaged threads, or sealing rings, under the bolt head. Replace damaged bolts.
800S HC3, 860SJ HC3 31222415 585

4. Remove end cover assembly (2) and seal ring (4). Discard seal ring.
Note: Refer to the appropriate “alternate cover construction” on the exploded view to determine the end cover construction being
serviced.
Figure 290. Swing Drive Motor
1. Special Bolts 6. Commutator Ring 8D. Stator Half 13. Bearing/Bushing, Inner 18. Housing
2. End Cover 7. Manifold 9. Wear Plate 14. Thrust Washer 18A. O-ring
3. Seal Ring-Commutator 8. Rotor Set 10. Drive Link 15. Thrust Bearing 19. Bearing/Bushing, Outer
4. Seal Ring 8A. Rotor 11. Not Used 16. Seal 20. Dirt & Water Seal
5. Commutator Ring 8B. Stator or Stator Vane 12. Coupling Shaft 17. Backup Washer 21. Plug
586 31222415 800S HC3, 860SJ HC3

5. If the end cover (2) is equipped with shuttle valve components, remove the two previously loosened plugs (21).
NOTICE
Be ready to catch the shuttle valve or relief valve components that will fall out of
the end cover valve cavity when the plugs are removed.
Note: O-ring is not included in seal kit but serviced separately, if required.
Note: The insert and if included the orifice plug in the end cover (2) must not be removed as they are serviced as an integral part
of the end cover.
6. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice
plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces.
Replace end cover as necessary.
Note: A polished pattern (not scratches) on the cover from rotation of the commutator (5) is normal. Discoloration would indicate
excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of
end cover, commutator, manifold and rotor set.
800S HC3, 860SJ HC3 31222415 587

7. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs.
8. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until
seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinelling. If any of
these conditions exist, replace commutator and commutator ring as a matched set.
588 31222415 800S HC3, 860SJ HC3

9. Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist.
A polished pattern on the ground surface from commutator or rotor rotation is normal. Remove and discard the seal rings (4) that
are on both sides of the manifold.
Note: The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for
service. Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor
set.
800S HC3, 860SJ HC3 31222415 589

10. Remove rotor set (8) and warplane (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C)
to stator (8B) contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set and wear plate.
You may have to shift the rotor set on the warplane to work the drive link out of the rotor (8A) and warplane. Inspect the rotor set
in its assembled form for nicks, scoring, or spalling on any surface and for broken or worn splines. If the rotor set component
requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the warplane for cracks, brinelling, or
scoring. Discard seal ring (4) that is between the rotor set and wear plate.
Note: The rotor set (8) components may become disassembled during service procedures. Marking the surface of the rotor and sta-
tor that is facing UP, with etching ink or grease pencil before removal from Torqmotor™ will ensure correct reassembly of ro-
tor into stator and rotor set intoTorqmotor™. Marking all rotor components and mating spline components for exact
repositioning at assembly will ensure maximum wear life and performance of rotor set and Torqmotor™.
Note: Series TG and TH may have a rotor set with two stator halves (8B & 8D) with a seal ring (4) between them and two sets of
seven vanes (8C & 8E). Discard seal ring only if stator halves become disassembled during the service procedures.
Note: A polished pattern on the wear plate from rotor rotation is normal.
590 31222415 800S HC3, 860SJ HC3

11. Place rotor set (8) and wear plate (9) on a flat surface and center rotor (8A) in stator (8B) such that two rotor lobes (180 degrees
apart) and a roller vane (8C) centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler
gage at this common centerline. If there is more than 0.005 inches (0.13 mm) of clearance, replace rotor set.
Note: If rotor set (8) has two stator halves (8B & 8D) and two sets of seven vanes (8C & 8E) as shown in the alternate construction
TG rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor.
12. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and
worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. Remove and discard seal ring
(4) from housing (18).
13. Remove thrust bearing (11) from top of coupling shaft (12). Inspect for wear, brinelling, corrosion and a full complement of
retained rollers.
800S HC3, 860SJ HC3 31222415 591

14. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its
withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used. Remove any key (12A), nut (12B), washer
(12C), bolt (12D), lock washer (12E), or retaining ring (12F).
15. Remove coupling shaft (12), by pushing on the output end of shaft. Inspect coupling shaft bearing and seal surfaces for spalling,
nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or keyway.
Replace coupling shaft if any of these conditions exist.
Note: Minor shaft wear in seal area is permissible. If wear exceeds 0.020 inches (0.51 mm) diametrically, replace coupling shaft.
Note: A slight “polish” is permissible in the shaft bearing areas. Anything more would require coupling shaft replacement.
16. Remove and discard seal ring (4) from housing (18).
592 31222415 800S HC3, 860SJ HC3

17. Remove thrust bearing (15) and thrust washer (14) Inspect for wear, brinelling, corrosion and a full complement of retained rollers.
18. Remove seal (16) and backup washer (17) from Small Frame, housing (18). Discard both.
BM102160A
19. Remove housing (18) from vise, invert it and remove and discard seal
20. A blind hole bearing or seal puller is required.
800S HC3, 860SJ HC3 31222415 593

21. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be
removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in
these areas, discard the housing assembly.
594 31222415 800S HC3, 860SJ HC3

22. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they
are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained
in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. The
bushing (19) or (13) to coupling shaft diameter clearance must not exceed 0.010 inch (0.025 mm). A bearing, bushing, or thrust
washer that does not pass inspection must be replaced. If the housing has passed this inspection the disassembly of the
Torqmotor™ is completed.
Note: The depth or location of bearing/bushing (13) in relation to the housing wear plate surface and the depth or location of
bearing/bushing (19) in relation to the beginning of bearing/bushing counterbore should be measured and noted before re-
moving the bearings/ bushings. This will facilitate the correct reassembly of new bearings/bushings.
800S HC3, 860SJ HC3 31222415 595

23. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and
(13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously
retained in the housing by bearing (13).
Assembly
Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ unit. Lubricate all seals and seal rings with SAE
10W40 oil or clean grease before assembly.
Note: Individual seals and seal rings as well as a complete seal kit are available. The parts should be available through most OEM parts
distributors or Parker approved Torqmotor™ distributors. (Contact your local dealer for availability).
Note: Unless otherwise indicated, do not oil or grease parts before assembly.
Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from
mating surfaces of the end cover, commutator set, manifold rotor set, wear plate and housing and from port and sealing areas.
DANGER
Since they are flammable, be extremely careful when using any solvent. Even a
small explosion or fire could cause injury or death.
WARNING
Wear eye protection and be sure to comply with OSHA or other maximum air pres-
sure requirements.
596 31222415 800S HC3, 860SJ HC3

1. If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing
(19) with clean corrosion resistant grease recommended in the material section. Press the new bearing/bushing into the
counterbore at the mounting flange end of the housing, using the appropriate sized bearing mandrel, which will control the
bearing/ bushing depth.
Torqmotor™ housings require the use of bearing mandrel to press bearing/ bushing (19) into the housing to a required depth of
0.151/0.161 inches (3.84/4.09 mm) from the end of the bearing counterbore.
Note: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with
the press base and the bearing/bushing is not cocked when pressing a bearing/bushing into the housing.
NOTICE
If the bearing mandrel specified in the “tools and materials required for servicing”
section is not available and alternate methods are used to press in bearing/bushing
(13) and (19) the bearing/bushing depths specified must be achieved to ensure ad-
equate bearing support and correct relationship to adjacent components when
assembled.
NOTICE
Because the bearing/bushings (13) and (19) have a press fit into the housing they
must be discarded when removed. They must not be reused.
800S HC3, 860SJ HC3 31222415 597

2. The Torqmotor™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch
(.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the
outer bearing/ bushing (19).
BM102172A
598 31222415 800S HC3, 860SJ HC3

BM102173A
BM102174A
800S HC3, 860SJ HC3 31222415 599

3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore.
The Torqmotor™ dirt and water seal (20) must be pressed in until its flange is flush against the housing.
4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange.
600 31222415 800S HC3, 860SJ HC3

5. On the Torqmotor™ assemble a new backup washer (17) and new seal (16) with the seal lip facing toward the inside of
Torqmotor™, into their respective counterbores in housing (18) if they were not assembled in procedure 2.
NOTICE
Original design large frame, TF & TG torqmotors™ that do not have backup washer
(25) when disassembled must be assembled with a new backup washer (17), new
backup washer (25) and new seal (16).
6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqmotor™.
Note: Torqmotors™ require one thrust washer (14) with thrust bearing (15). The coupling shaft will be seated directly against the
thrust.
800S HC3, 860SJ HC3 31222415 601

7. Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal.
602 31222415 800S HC3, 860SJ HC3

8. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing
(19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in the housings.
NOTICE
The outer bearing (19) is not lubricated by the system’s hydraulic fluid. Be sure it is
thoroughly packed with the recommended grease, Parker gear grease specification
#045236, e/m lubricant #k-70m.
Note: Mobil Mobilith SHC ® 460.
Note: A 102 Tube (PN 406010) is included in each seal kit.
Note: The coupling shaft (12) will be flush or just below the housing wear plate surface on Torqmotors™ when properly seated.
The coupling shaft must rotate smoothly on the thrust bearing package.
800S HC3, 860SJ HC3 31222415 603

9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove.
Note: One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 degrees apart, will facilitate
the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off
the heads of either 3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as required that are over 0.5 inch (12.7 mm) longer than the bolts
(1) used in the Torqmotor™.
10. Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the
coupling shaft splines.
Note: Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in
their original position in the mating coupling shaft splines.
11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18).
604 31222415 800S HC3, 860SJ HC3

12. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the
rotor set stator (8B).
13. Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into
mesh with the drive link splines.
Note: It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7)
over the drive link.
Note: If necessary, go to the appropriate, “Rotor Set Component Assembly Procedure.”
Note: The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original
rotor-drive link spline contact. A rotor set without a counterbore and that was not etched before disassembly can be rein-
stalled using the drive link spline pattern on the rotor splines if apparent, to determine which side was down. The rotor set
seal ring groove faces toward the wear plate (9).
14. “Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7).”
Note: The manifold (7) is made up of several plates bonded together permanently to form an integral component. The manifold
surface that must contact the rotor set has it’s series of irregular shaped cavities on the largest circumference or circle
around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which sur-
face must contact the rotor set.
800S HC3, 860SJ HC3 31222415 605

15. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface
is against the rotor set.
16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold.
17. Assemble the commutator ring (6) over alignment studs onto the manifold.
606 31222415 800S HC3, 860SJ HC3

18. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto
manifold (7) with seal ring side up.
800S HC3, 860SJ HC3 31222415 607

19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If
the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18). The correct 5
bolt end cover bolt hole relationship to housing port bosses.
608 31222415 800S HC3, 860SJ HC3

20. Assemble the 5 or 7 special bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the
other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place
with a final torque of 50-55 ft. lbs. (68-75 Nm) for the seven 3/8-24 threaded bolts.
Note: The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the bolts re-
quired with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part
number if replacement is required.
21. Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. lbs. (12-16 Nm) if cover is so equipped.
Torque the two relief valve plug assemblies (21) in end cover assembly to 45-55 ft. lbs. (61-75 Nm) if cover is so equipped.
800S HC3, 860SJ HC3 31222415 609

One Piece Stator Construction

A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled by the following
procedures.
1. Place stator (8B) onto wear plate (9) with seal ring (4) side down, after following Torqmotor™ assembly procedures 1 through 13.
Be sure the seal ring is in place.
2. If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two
bolts (1) finger tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary.
610 31222415 800S HC3, 860SJ HC3

3. Assemble the rotor (8A), counterbore down if applicable, into stator (8B) and onto wear plate (9) with rotor splines into mesh with
drive link (10) splines.
Note: If the manifold side of the rotor was etched during Torqmotor disassembly, this side should be up. If the rotor is not etched
and does not have a counterbore, use the drive link spline contact pattern apparent on the rotor splines to determine the ro-
tor side that must be against the wear plate.
4. Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets.
NOTICE
Excessive force used to push the rotor vanes into place could shear off the coating
applied to the stator vane pockets.
800S HC3, 860SJ HC3 31222415 611

5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive
link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B), creating the necessary clearance to assemble the
seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.
6. Remove the two assembled bolts (1) if used to retain stator and wear plate.
10.4.3 Procedure for Setting Swing Gear Backlash

Ensure mounting plate and turntable base plate are clean and painted with a uniform coating of minimum thickness (no runs, drips,
etc.).
Set backlash to 0.008 to 0.012 in. (0.203 - 0.304 mm) using the following procedure:
1. Place the machine on firm, level ground.
2. Place shim (JLG PN 1001125492) between pinion and bearing at bearing high spot (shown below). The bearing high spot should
be stamped with “X” on the surface below teeth and marked with yellow paint in the tooth space.
612 31222415 800S HC3, 860SJ HC3

3. Apply High Strength Threadlocking Compound and torque pivot bolt to 205 ft. lbs. (280 Nm) (shown below).
Note: Torque shoulder bolt against turntable base plate. Shoulder bolt will not tighten against the swing drive mounting plates.
4. Remove turntable lock pin.
5. Apply High Strength Threadlocking Compound and pre-torque swing drive mounting bolts to 30 ft. lbs. (42 Nm).
6. Tighten the set-screw until the pinion is completely snug against the shim and bearing and then back off the setscrew.
7. Apply High Strength Threadlocking Compound and torque jack bolt 50 ft. lbs. (68 Nm).
8. Apply High Strength Threadlocking Compound to the jam nut and tighten.
800S HC3, 860SJ HC3 31222415 613

9. Torque the capscrews shown in step 5 to 340 ft. lbs. (461 Nm).
10. Remove shim and discard.
Figure 291. Swing Bearing Torque Sequence
Note: Swing Bearing Torque Sequence is typical for both inner and outer races.
614 31222415 800S HC3, 860SJ HC3

Figure 292. Swing Drive and Turntable Bearing
1. Swing Drive 4. Swing Bearing 7. Grease Line

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

For detailed assembly/disassembly procedures, contact JLG or local JLG dealer for information.
800S HC3, 860SJ HC3 31222415 615

10.4.5 Rotary Coupling Seal Kit

Use the following procedure to install the seal kit.
1. If not already removed, remove the axle oscillation valve from the cylinder barrel. The spool of the valve protrudes into the barrel
and will damage the spool and seals if left in place.
2. Remove snap ring (7) from end.
3. Remove thrust ring (3) from the same end.
4. Remove center body (1) from housing (3).
5. Cut off old seals (2, 4, 5).
6. Remove proximity switch.
7. Assemble lip seals (2) in direction shown in Figure — Rotary Coupling Seal Installation, page 617.
8. Reassemble O-ring (4).
9. Heat cap seals (5) in hydraulic oil for 5 minutes at 300° F (149° C).
10. Assemble cap seals over O-rings.
11. Reinsert center body into housing (lube with hydraulic oil).
12. Replace thrust ring and snap ring.
616 31222415 800S HC3, 860SJ HC3

Figure 293. Rotary Coupling Seal Installation
800S HC3, 860SJ HC3 31222415 617

Figure 294. Rotary Coupling Cutaway
1. Center Body 5. Seal 9. O-ring
2. Seal 6. Thrust Ring 10. Proximity Switch

3. Housing 7. Snap Ring
4. O-ring 8. Valve Block (Axle Oscillation)
618 31222415 800S HC3, 860SJ HC3

Figure 295. Rotary Coupling Port Location (7 Port)
800S HC3, 860SJ HC3 31222415 619

Figure 296. Rotary Coupling Installation
1. Housing 8. Locknut 15. Retaining Ring 22. Plug 29. Locknut
2. Body 9. Washer 16. Plug 23. Check Valve 30. Capscrew
3. Rotary Coupling 10. Washer 17. Torque Lug 24. Plunger Valve 31. Proximity Switch
4. Block Valve Assembly 11. Seal 18. Capscrew 25. Spring
5. Bolt 12. O-ring 19. O-ring 26. Seal

6. Bolt 13. Cap Seal 20. O-ring 27. Bracket
7. Bracket 14. Thrust Ring 21. Bearing 28. Washer
620 31222415 800S HC3, 860SJ HC3

Table 50. Coupling Port Information Table (7 port)

Operating Pressure PSI
Port No. Outlets Port Size Description Proof Pressure PSI (Bar)
(Bar)
1 1 -8 Brake 450 (31) 675 (46.5)
2 2 -6 2 Speed 4500 (310) 6750 (465)

3 1 -6 Steer 2500 (172) 3750 (258.5)
4 1 -6 Steer 2500 (172) 3750 (258.5)
5 2 1-6, 1-16 Drive Reverse 4500 (310) 6750 (465)
6 1 -16 Drive Forward 4500 (310) 6750 (465)
7 3 2-8, 1-6 Drain 250 (17) 375 (26)
800S HC3, 860SJ HC3 31222415 621

10.5 GENERATOR DISASSEMBLY AND ASSEMBLY

Refer to Section – 7500W Generator Schematic, page 741 , to determine if trouble is in stator, rotor, control box, or combination of these
components.
1. Rotor
2. Stator Assembly
CAUTION
DO NOT damage rotor or stator windings during disassembly and assembly
procedure.
Disassembly
1. Mark and disconnect all electrical leads, secure using cable ties.
2. Remove brush holder assembly.
3. Disassemble generator parts shown in Figure – 7500W Generator Disassembly and Assembly, page 623 .
4. Clean all parts with approved solvent and dry with compressed air, If applicable.
5. Inspect all part for damage. Replace if necessary.
Assembly
1. Assemble generator parts using torque values in table.
2. Reconnect all leads. Use cable ties to secure leads away from moving or hot parts.
622 31222415 800S HC3, 860SJ HC3

REMOVE BRUSH HOLDER

BEFORE DISASSEMBLING
ROTOR AND STATOR.
APPLY MEDIUM STRENGTH

THREADLOCKING COMPOUND
OR EQUIVALENT TO SCREW APPLY SAE 30W OIL TO BOTH ENDS OF STUDS
BEFORE INST ALLING. BEFORE INST ALLING
TOOL NEEDED
TORQUES
95 in. lbs. (10.7 Nm)

38 ft. lbs. (52 Nm)
(BELT TENSIONER)
BM110470A
Figure 297. 7500W Generator Disassembly and Assembly
800S HC3, 860SJ HC3 31222415 623


Refer to Section – 4000W Generator Schematic, page 747 , to determine if trouble is in stator, rotor, control box, or combination of these
components.
1. Rotor
2. Stator Assembly
CAUTION
DO NOT damage rotor or stator windings during disassembly and assembly
procedure.
Disassembly
1. Mark and disconnect all electrical leads, secure using cable ties.
2. Disassemble generator parts shown in Figure – 4000W Generator Disassembly and Assembly, page 625 .
3. Clean all parts with approved solvent and dry with compressed air, If applicable.
4. Inspect all part for damage. Replace if necessary.
Assembly
1. Assemble generator parts using torque values shown in Figure – 4000W Generator Disassembly and Assembly, page 625 .
2. Reconnect all leads. Use cable ties to secure leads away from moving or hot parts.
624 31222415 800S HC3, 860SJ HC3

A
95 in. lbs. (10.7 Nm)
APPLY SAE 30W OIL TO BOTH ENDS OF STUDS

BEFORE INSTALLING
Tool Needed:
MAF44350
Figure 298. 4000W Generator Disassembly and Assembly
10.6 POWERTRACK MAINTENANCE
10.6.1 One Piece Bracket Maintenance

1. Place the powertrack on a workbench.
800S HC3, 860SJ HC3 31222415 625

2. Remove the screws from the bars on one side of the powertrack on the first link.
3. Remove the screws from the flat bar on the other side of the powertrack.
4. Pull up on the loose side of the round bar to allow the poly roller to slide off.
626 31222415 800S HC3, 860SJ HC3

5. Slide the poly roller off of the round bar.
6. Hold the round bar to remove the other screw.
7. Slide the flat bar out.
800S HC3, 860SJ HC3 31222415 627

8. Remove the snap ring from one side of the bracket.
9. Remove the snap ring from the other side of the bracket.
10. Push down with slight pressure on the link and slide the bracket side up and over the extrusion on the link.
11. Repeat the previous step on the other side.
628 31222415 800S HC3, 860SJ HC3

12. Slide the bracket off of the powertrack.
10.6.2 Two Piece Bracket Maintenance

1. Loosen the screw.
2. Slide the roller off the bar.
800S HC3, 860SJ HC3 31222415 629

3. Hold the bar tightly and remove the other screw.
4. Hold the flat bar and remove the screws.
5. Remove the snap rings and pins.
6. Remove the screws from the bar. Remove the snap ring and pin.
630 31222415 800S HC3, 860SJ HC3

7. Slide the link out.
10.6.3 Snap Rings and Screws
NOTICE
When performing maintenance on the powertrack, make sure to discard and re-
place all old screws.
Make sure screws are tight and installed properly.
Make sure that all snap rings are closed and seated.
An open snap ring is shown below.
800S HC3, 860SJ HC3 31222415 631

A snap ring that is not seated is shown below.
BM102427A
A seated and closed snap ring is shown below.
10-24 x 0.812 button torx socket head with blue locking patch:
• Tighten to 45-50 in. lbs. (5-5.6 Nm).
• Use T-25 torx bit.
• Do not reuse this screw. After removing replace with a new one
632 31222415 800S HC3, 860SJ HC3

SECTION 11
TORQUE/CONNECTION INFORMATION
11.1 HYDRAULIC FITTINGS
11.1.1 Tapered Thread Types

NPTF = national tapered fuel (Dry Seal) per SAE J476/J512
BSPT = British standard pipe tapered per ISO7-1
11.1.2 Straight Thread Types, Tube and Hose Connections

JIC = 37° flare per SAE J514
SAE = 45° flare per SAE J512
ORFS = o-ring face seal per SAE J1453
800S HC3, 860SJ HC3 31222415 633

Torque/Connection Information
MBTL = metric flareless bite type fitting, pressure rating L(medium) per ISO 8434, DIN 2353
MBTS = metric flareless bite type fitting, pressure rating S (high) per ISO 8434, DIN 2353
BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
11.1.3 Straight Thread Types, Port Connections

ORB = o-ring boss per SAE J1926, ISO 11926
MPP = metric pipe parallel o-ring boss per SAE J2244, ISO 6149, DIN 3852
MFF = metric flat face port per ISO 9974-1

BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852-2
634 31222415 800S HC3, 860SJ HC3

11.1.4 Flange Connection Types

FL61 = code 61 flange per SAE J518, ISO 6162
FL62 = code 62 flange per SAE J518, ISO 6162
11.1.5 Tightening Methods

1. Torque = Application of a twisting force to the applicable connection by use of a precise measurement instrument (i. e. torque
wrench).
2. Finger Tight = The point where the connector will no longer thread onto the mating part when tightened by hand or fingers.
Finger Tight is relative to user strength and will have some variance. The average torque applied by this method is 3 ft-lbs [4 N-m].
Also referred to as 'Hand Tight.’
3. TFFT = Turns From Finger Tight; Application of a preload to a connection by first tightening the connection by hand (fingers) and
applying an additional rotation counted by a defined number of turns by use of a tool.
4. FFWR = Flats from Wrench Resistance; Application of a pre-load to a connection by tightening to the point of initial wrench
resistance and turning the nut a described number of ‘flats’. A ‘flat’ is one side of the hexagonal tube nut and equates to 1/6 of a
turn. Also referred to as the ’Flats Method’.
11.1.6 Assembly and Torque Specifications

Prior to selecting the appropriate torque from the tables within this section, it is necessary to properly identify the connector being
installed. Refer to the Figures and Tables in this section.
11.1.7 General Tube Type Fitting Assembly Instructions

1. Take precautions to ensure that fittings and mating components are not damaged during storage, handling or assembly. Nicks and
scratches in sealing surfaces can create a path for leaks which could lead to component contamination and/or failure.
2. When making a connection to tubing, compression or flare, inspect the tube in the area of the fitting attachment to ensure that
the tube has not been damaged.
3. The assembly process is one of the leading causes for contamination in air and hydraulic systems. Contamination can prevent
proper tightening of fittings and adapters from occurring.
a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned and inspected for damage. Replace fittings as necessary before re-
installing.
c. Sealing compounds should be applied where specified; however, care should be taken not to introduce sealant into the
system.
d. Avoid applying sealant to the area of the threads where the sealant will be forced into the system. This is generally the first
two threads of a fitting.
e. Sealant should only be applied to the male threads.
f. Straight thread fittings do not require sealants. O-rings or washers are provided for sealing.
g. When replacing or installing an O-ring, care is to be taken while transferring the O-ring over the threads as it may become
nicked or torn. When replacing an O-ring on a fitting, the use of a thread protector is recommended.
h. When installing fittings with O-rings, lubrication shall be used to prevent scuffing or tearing of the O-ring. Refer to Section —
O-ring Installation (Replacement), page 689 in this section.
800S HC3, 860SJ HC3 31222415 635

4. Take care to identify the material of parts to apply the correct torque values.
a. Verify the material designation in the table headings.
b. If specifications are given only for steel fittings and components, the values for alternate materials shall be as follows:
Aluminum and Brass- reduce steel values by 35%;
Stainless Steel - Use the upper limit for steel.
5. To achieve the specified torque, the torque wrench is to be held perpendicular to the axis of rotation.
6. Refer to the appropriate section in this manual for more specific instructions and procedures for each type of fitting connection.
11.1.8 Assembly Instructions for American Standard Pipe Thread Tapered Connections.
1. Inspect components to ensure male and female port threads are free of rust, splits, dirt, foreign matter, or burrs.
2. Apply a high temperature thread sealant with PTFE, to the male pipe threads if not already applied. Ensure the first 1 to 2 threads
are uncovered to prevent system contamination.
3. Assemble connection hand tight.
4. Mark fittings, male and female.
NOTICE
Over tightening may cause deformation of the pipe fitting and damage to the join-
ing fitting, flange or component may occur.
NOTICE
Never back off (loosen) pipe threaded connectors to achieve alignment. Meet the
minimum required turns and use the last turn for alignment.
5. Rotate male fitting the number of turns per Table. refer to Section — FFWR and TFFT Methods, page 687 for procedure
requirements.
Note: TFFT values provided in below mentioned table are applicable for the following material configurations:
a. Steel fittings with steel mating components.

b. Steel fittings with aluminum or brass mating components.
c. Aluminum or brass fittings with steel mating components.
d. Aluminum or brass fittings with aluminum or brass mating components.
NPTF Pipe Thread
636 31222415 800S HC3, 860SJ HC3

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

** Refer to Section — FFWR and TFFT Methods, page 687 for FFWR procedure requirements.
11.1.9 Assembly Instructions for British Standard Pipe Thread Tapered Connections
1. Inspect components to ensure male and female port threads are free of rust, splits, dirt, foreign matter, or burrs.
2. Apply a high temperature thread sealant with PTFE, to the male pipe threads if not already applied. Ensure the first 1 to 2 threads
are uncovered to prevent system contamination.
3. Assemble connection hand tight.
4. Mark fittings, male and female.
NOTICE
Over tightening may cause deformation of the pipe fitting and damage to the join-
ing fitting, flange or component may occur.
NOTICE
Never back off (loosen) pipe threaded connectors to achieve alignment. Meet the
minimum required turns and use the last turn for alignment.
800S HC3, 860SJ HC3 31222415 637

5. Rotate male fitting the number of turns as per below mention table.
Note: TFFT values provided in below table are applicable for the following material configurations:
a. Steel fittings with steel mating components.

b. Steel fittings with aluminum or brass mating components.
c. Aluminum or brass fittings with steel mating components.
d. Aluminum or brass fittings with aluminum or brass mating components.
638 31222415 800S HC3, 860SJ HC3

BSPT Pipe Thread
Turns From Finger
Thread Size ØA* Tight (TFFT)**
MATERIAL Dash Size
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
4 1/4 - 19 0.52 13.16 2 to 3
6 3/8 - 19 0.66 16.66 2 to 3
BRASS FITTINGS WITH
BRASS MATING
COMPONENTS 16 1 - 11 1.31 33.25 1.5 to 2.5
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5

11.1.10 Assembly Instructions for 37° (JIC) Flare Fittings

1. Inspect the flare for obvious visual squareness and concentricity issues with the tube OD. Ensure surface is smooth, free of rust,
weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or adapter.
NOTICE
DO NOT force a misaligned or short hose/tube into alignment. It puts undesirable
strain onto the joint eventually leading to leakage.
2. Align tube to fitting and start threads by hand.
NOTICE
The torque method should NOT be used on lubricated or oily fittings. No lubrication
or sealant is required. The lubrication would cause increased clamping force and
cause fitting damage.
800S HC3, 860SJ HC3 31222415 639

3. Torque assembly to value listed in below mentioned table while using the Double Wrench Method.
Note: Torque values provided in below table are segregated based on the material configuration of the connection.
Aluminum/brass fittings or aluminum/brass mating components’ indicate either the following material configurations:
a. Steel fittings with aluminum or brass mating components.
b. Aluminum or brass fittings with steel mating components.
c. Aluminum or brass fittings with aluminum or brass mating components.
37° Flare (JIC) Thread - Steel
TYPE/FITTING IDENTIFICATION Torque Flats from

Wrench Re-
Dash Thread Size ØA* ØB* [Ft-Lb] [Nm]
Material sistance (F.F.
Size (UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max W.R)**
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 –

3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 –
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2
STEEL FITTINGS
WITH STEEL MAT- 8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
ING COMPO-
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
NENTS; UN-
LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
THREADS
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1

640 31222415 800S HC3, 860SJ HC3

37° Flare (JIC) Thread - Aluminum Brass
TYPE/FITTING IDENTIFICATION Torque Flats From

Wrench Resist-
Dash Thread Size ØA* ØB* [Ft-Lb] [Nm]
Material ance (F.F.W.R)
Size (UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max **
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 –

3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 –
4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
ALUMINUM/BRASS FIT- 8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
TINGS OR ALUMINUM/
BRASS MATING COM- 10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
PONENTS; UN-LUBRI-
CATED THREADS 12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1

11.1.11 Assembly Instructions for 45° SAE Flare Fittings

1. Inspect the flare for obvious visual squareness and concentricity issues with the tube OD. Ensure surface is smooth, free of rust,
weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or adapter.
NOTICE
DO NOT force a misaligned or short hose/tube into alignment. It puts undesirable
strain onto the joint eventually leading to leakage.
2. Align tube to fitting.
800S HC3, 860SJ HC3 31222415 641

3. Tighten fitting by hand until hand tight.
NOTICE
The torque method should NOT be used on lubricated or oily fittings. No lubrication
or sealant is required. The lubrication would cause increased clamping force and
cause fitting damage.
Torque fitting to value listed in below table while using the Double Wrench Method outlined in this section.
1. Steel fittings with aluminum or brass mating components.
2. Aluminum or brass fittings with steel mating components.
3. Aluminum or brass fittings with aluminum or brass mating components.
45° Flare (SAE)
Steel
TYPE/FITTING IDENTIFICATION TORQUE

Turns From
Thread Finger
Dash ØA* ØB* [Ft-Lb] [Nm]
Material Size Tight
Size (TFFT)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
STEEL FIT- 4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19 1/4 to 1/2

TINGS WITH 6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33 1/4 to 1/2
STEEL MAT-
ING COMPO- 8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62 1/4 to 1/2
NENTS; UN-
LUBRICATED 10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89 1/4 to 1/2
THREADS 12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125 1/4 to 1/2

642 31222415 800S HC3, 860SJ HC3

Aluminum /Brass

Turns From Fin-
Thread [Ft-Lb] [Nm]
Dash ØA* ØB* ger Tight (TFFT)
Material Size
Size **
4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12 1/4 to 1/2
ALUMINUM/BRASS
FITTINGS OR ALU- 6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20 1/4 to 1/2
MINUM/BRASS
8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41 1/4 to 1/2
MATING COMPO-
NENTS; UN-LUBRI- 10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58 1/4 to 1/2
CATED THREADS
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83 1/4 to 1/2

11.1.12 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings

1. Ensure proper O-ring is installed. If O-ring is missing install per O-ring Installation (Replacement). Refer to Section — O-ring
Installation (Replacement), page 689 for procedure.
2. Ensure surface is smooth, free of rust, weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or
adapter.
NOTICE
Care to be taken when lubricating O-ring. Avoid adding oil to the threaded connec-
tion of the fitting. The lubrication would cause increased clamping force and cause
fitting damage.
3. Pre-lubricate the O-ring with Hydraulic Oil.
4. Place the tube assembly against the fitting body so that the flat face comes in contact with the O-ring. Hand thread the nut onto
the fitting body.
5. Torque nut to value listed in below mentioned table while using the Double Wrench Method. Refer to Section — FFWR and TFFT
Methods, page 687 for procedure if using the FFWR method.
a. Steel fittings with aluminum or brass mating components.
b. Aluminum or brass fittings with steel mating components.
c. Aluminum or brass fittings with aluminum or brass mating components.
800S HC3, 860SJ HC3 31222415 643

O-ring Face Seal (ORFS)
Steel
Das- Thread [Ft-Lb] [Nm]

ØA* ØB* Swivel &
Material h Size Tube Nuts
Hose Ends
Size (UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
STEEL FITTINGS
WITH STEEL 10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4
MATING COMPO-
12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
NENTS; UN-LU-
BRICATED 16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
THREADS
20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4

Aluminum /Brass
FLATS FROM WRENCH RE-

SISTANCE(F.F.W.R)**
Thread [Ft-Lb] [Nm]
Dash ØA* ØB* Swivel &
Material Size Tube Nuts
Size Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
ALUMINUM/ 8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4
BRASS FITTINGS 10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4
OR ALUMINUM/
BRASS MATING 12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
COMPONENTS;
UN-LUBRICATED 16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 244 257 269 331 348 365 1/4 to 1/2 1/2 to 3/4

644 31222415 800S HC3, 860SJ HC3

11.1.13 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
NOTICE
A non-square tube end can cause improperly seated fittings and leakage.
1. Inspect the components to ensure free of contamination, external damage, rust, splits, dirt, foreign matter, or burrs. Ensure tube
end is visibly square. If necessary replace fitting or tube.
2. Lubricate thread and cone of fitting body or hardened pre-assembly tool, as well as the progressive ring and nut threads.
3. Slip nut and progressive ring over tube, assuring that they are in the proper orientation.
4. Push the tube end into the coupling body.
5. Slide collect into position and tighten until finger tight. Mark nut and tube in the finger-tight position. Tighten nut to the number
of flats listed while using the Double Wrench Method. The tube must not turn with the nut.
800S HC3, 860SJ HC3 31222415 645

DIN 24° CONE (MBTL and MBTS)
TYPE/FITTING IDENTIFICATION DIN 24° CONE FLARELESS BITE FITTING (WITH OR WITHOUT O-RING)
Torque
Tube Thread M
ØA* ØB* C* ØD* Flats From
O.D. Size [Ft-Lb] [Nm]
Material Type Wrench Resist-
M- ance (F.F.W.R)**
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom
ax
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
8 M14 x 1.5 12.50 14.00 7.00 8.20 FFWR is the recommended method of fitting 1.5 to 1.75
10 M16 x 1.5 14.50 16.00 7.00 10.20 assembly. 1.5 to 1.75
STEEL DIN24°
12 M18 x 1.5 16.50 18.00 7.00 12.20 Torque values are application specific due to 1.5 to 1.75
FITTINGS CONE
WITH FLARE- variability in the fitting supplier, coating, lubri-
15 M22 x 1.5 20.50 22.00 7.00 15.20 1.5 to 1.75
STEEL LESS cation, and other physical characteristic of the
MATING BITE 18 M26 x 1.5 24.50 26.00 7.50 18.20 connection. 1.5 to 1.75
COMPO- (MBTL) 22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75
Consult Engineering on the generation of torque
NENTS FITTING
values for the particular application.
28 M36 x 2 33.90 36.00 7.50 28.20 1.5 to 1.75
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
TYPE/FITTING IDENTIFICATION DIN 24° CONE FLARELESS BITE FITTING (WITH OR WITHOUT O-RING)
Torque
Tube Thread M
ØA* ØB* C* ØD* Flats From
O.D. Size [Ft-Lb] [Nm]
Material Type Wrench Resist-
M- ance (F.F.W.R)**
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom
ax
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75
8 M16 x 1.5 14.50 16.00 7.00 8.20 FFWR is the recommended method of fitting 1.5 to 1.75
10 M18 x 1.5 16.50 18.00 7.50 10.20 assembly. 1.5 to 1.75
STEEL DIN24°
12 M20 x 1.5 18.50 20.00 7.50 12.20 Torque values are application specific due to 1.5 to 1.75
FITTINGS CONE
WITH FLARE- variability in the fitting supplier, coating, lubri-
14 M22 x 1.5 20.50 22.00 8.00 14.20 1.5 to 1.75
STEEL LESS cation, and other physical characteristics of the
MATING BITE 16 M24 x 1.5 22.50 24.00 8.50 16.20 connection. 1.5 to 1.75
COMPO- (MBTS) 20 M30 x 2 27.90 30.00 10.50 20.20 1.5 to 1.75
Consult Engineering on the generation of torque
NENTS FITTING
values for the particular application.
25 M36 x 2 33.90 36.00 12.00 25.20 1.5 to 1.75
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
Note: * ØA, ØB, C, & ØD thread dimensions for reference only.

646 31222415 800S HC3, 860SJ HC3

11.1.14 Assembly Instructions for Bulkhead (BH) Fittings

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

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

Torque
Thread Size
3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
37° FLARE (JIC) BULK-
STEEL FITTINGS 6 9/16-18 25 27 28 34 37 38
HEAD FITTING
8 3/4-16 50 53 55 68 72 75
10 7/8-14 85 90 94 115 122 127
12 1 1/16-12 135 142 149 183 193 202
800S HC3, 860SJ HC3 31222415 647


Torque
Thread Size
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
Bulkhead Fittings (BH) - METRIC

Torque
Connecting
Thread M Size
Material Type Tube O.D. [Ft-Lb] [Nm]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
DIN 24° CONE FLARE- 15 M22 x 1.5 44 47 50 60 64 68
STEEL FITTINGS LESS BITE (MBTL)
BULKHEAD FITTING 18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325

Torque
Connecting
Thread M Size
6 M14 x 1.5 17 15 16 23 20 22
DIN 24° CONE FLARE- 8 M16 x 1.5 22 18 19 30 24 26
STEEL FITTINGS LESS BITE (MBTS)
BULKHEAD FITTING 10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
648 31222415 800S HC3, 860SJ HC3


Torque
Connecting
Thread M Size
14 M22 x 1.5 44 47 50 60 64 68
16 M24 x 1.5 70 75 80 95 102 108
20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
11.1.15 Assembly Instructions for O-Ring Boss (ORB) Fittings

1. Inspect components to ensure that male and female port threads are free of rust, splits, dirt, foreign matter, or burrs.
2. Ensure proper O-ring is installed. If O-ring is missing install per O-ring Installation (Replacement). Refer to Section — O-ring
Installation (Replacement), page 689 for procedure.
NOTICE
fitting damage.
4. For Non-Adjustable and Plugs, thread the fitting by hand until contact.
5. For Adjustable fittings, refer to Section — Adjustable Stud End Assembly, page 688 for proper assembly.
6. Torque the fitting or nut to value while using the Double Wrench Method
a. The table headings identify the straight thread o-ring port and the type on the other side of the fitting. The torque will be
applied to the straight thread o-ring port.
b. Torque values are segregated based on the material configuration of the connection. ‘Aluminum/brass fittings or aluminum/
brass mating components’ indicate either the following material configurations:
• Steel fittings with aluminum or brass mating components.
• Aluminum or brass fittings with steel mating components.
• Aluminum or brass fittings with aluminum or brass mating components.
7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port.
800S HC3, 860SJ HC3 31222415 649

O-ring Boss (ORB) - Table 1 of 6
HEX TYPE PLUGS & STUD ENDS WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPO-
SITE END
Torque
Dash Thread Size ØA*
Material [Ft-Lb] [Nm]
Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
6 9/16-18 0.56 14.28 29 31 32 40 42 43
STEEL FITTINGS WITH 8 3/4-16 0.75 19.10 52 55 57 70 75 77
STEEL MATING COM-
PONENTS; UN-LUBRI- 10 7/8-14 0.87 22.22 85 90 94 115 122 127
CATED THREADS 12 11/16-12 1.06 27.00 135 142 149 185 193 202
14 13/16-12 1.19 30.10 175 184 193 235 249 262
16 15/16-12 1.31 33.30 200 210 220 270 285 298
20 15/8-12 1.63 41.30 250 263 275 340 357 373
24 17/8-12 1.87 47.60 305 321 336 415 435 456
32 21/2-12 2.50 63.50 375 394 413 510 534 560
HEX TYPE PLUGS & STUD ENDS WITH 37° (JIC) OR L SERIES DIN (MBTL) OP-
POSITE END
Torque
Thread Size ØA*
Material Dash Size [Ft-Lb] [Nm]
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
ALUMINUM/BRASS
FITTINGS OR ALUMI- 5 1/2-20 0.50 12.70 15 16 17 20 22 23
NUM/BRASS MATING
COMPONENTS; UN- 6 9/16-18 0.56 14.28 19 20 21 26 27 28
LUBRICATED 8 3/4-16 0.75 19.10 34 36 37 46 49 50
THREADS
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 11/16-12 1.06 27.00 88 93 97 119 126 132
14 13/16-12 1.19 30.10 114 120 126 155 163 171
650 31222415 800S HC3, 860SJ HC3

HEX TYPE PLUGS & STUD ENDS WITH 37° (JIC) OR L SERIES DIN (MBTL) OP-
POSITE END
Torque
Thread Size ØA*
16 15/16-12 1.31 33.30 130 137 143 176 186 194
20 15/8-12 1.63 41.30 163 171 179 221 232 243
24 17/8-12 1.87 47.60 198 208 218 268 282 296
32 21/2-12 2.50 63.50 244 256 268 331 347 363
Note: * ØA Thread OD dimension for reference only.

**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install
torque.
TYPE/FITTING IDENTIFICATION STUD ENDS WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE END
Torque
Thread Size 0A*
2 5/16-24 0.31 7.93 – – – – – –
3 3/8-24 0.37 9.52 – – – – – –
4 7/16-20 0.44 11.11 26 27 28 35 37 38
5 1/2-20 0.50 12.70 30 32 33 40 43 45
6 9/16-18 0.56 14.28 35 37 39 46 50 53

STEEL MATING COM-
10 7/8-14 0.87 22.22 100 105 110 135 142 149
PONENTS; UN-LUBRI-
CATED THREADS 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
800S HC3, 860SJ HC3 31222415 651

TYPE/FITTING IDENTIFICATION STUD ENDS WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE END
Torque
Thread Size 0A*
2 5/16-24 0.31 7.93 – – – – – –
3 3/8-24 0.37 9.52 – – – – – –
4 7/16-20 0.44 11.11 17 18 18 23 24 24
5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
FITTINGS OR ALUMI-
NUM/BRASS MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; UN-LU-
BRICATED THREADS 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

torque.
652 31222415 800S HC3, 860SJ HC3

ADJUSTABLE STUD END WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE
END
Torque
Thread Size ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
6 9/16-18 0.56 14.28 29 31 32 40 42 43
STEEL MATING COM-
PONENTS; UN-LUBRI- 10 7/8-14 0.87 22.22 85 90 94 115 122 127
CATED THREADS 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
END
Torque
Thread Size ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
ALUMINUM/BRASS 5 1/2-20 0.50 12.70 15 16 17 20 22 23
FITTINGS OR ALUMI-
NUM/BRASS MATING 6 9/16-18 0.56 14.28 19 20 21 26 27 28
COMPONENTS; UN-LU-
BRICATED THREADS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
800S HC3, 860SJ HC3 31222415 653

END
Torque
Thread Size ØA*
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

torque.
TYPE/FITTING IDENTIFICATION ADJUSTABLE STUD END WITH (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END
Torque
Thread Size ØA*
2 5/16-24 0.31 7.93 – – - – – –
3 3/8-24 0.37 9.52 – – - – – –
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 30 32 33 40 43 45
6 9/16-18 0.56 14.28 35 37 39 46 50 53

STEEL MATING COM-
10 7/8-14 0.87 22.22 100 105 110 135 142 149
PONENTS; UN-LUBRI-
CATED THREADS 12 11/16-12 1.06 27.00 135 142 149 185 193 202
14 13/16-12 1.19 30.10 175 184 193 235 249 262
16 15/16-12 1.31 33.30 200 210 220 270 285 298
20 15/8-12 1.63 41.30 250 263 275 340 357 373
24 17/8-12 1.87 47.60 305 321 336 415 435 456
32 21/2-12 2.50 63.50 375 394 413 510 534 560
654 31222415 800S HC3, 860SJ HC3

TYPE/FITTING IDENTIFICATION ADJUSTABLE STUD END WITH (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END
Torque
Thread Size ØA*
2 5/16-24 0.31 7.93 – – – – – –
3 3/8-24 0.37 9.52 – – - – – –
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
FITTINGS OR ALUMI-
NUM/BRASS MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; UN-LU-
14 13/16-12 1.19 30.10 114 120 126 155 163 171
16 15/16-12 1.31 33.30 130 137 143 176 186 194
20 15/8-12 1.63 41.30 163 171 179 221 232 243
24 17/8-12 1.87 47.60 198 208 218 268 282 296
32 21/2-12 2.50 63.50 244 256 268 331 347 363

torque.
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

Torque
Thread
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
4 7/16-20 0.44 11.11 10 11 11 14 15 15
STEEL MATING COM-
PONENTS; UN-LUBRI- 6 9/16-18 0.56 14.28 34 36 38 46 49 52
CATED THREADS 8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 11/16-12 1.06 27.00 135 142 149 185 193 202
14 13/16-12 1.19 30.10 175 184 193 235 249 262
800S HC3, 860SJ HC3 31222415 655


Torque
Thread
ØA*
16 15/16-12 1.31 33.30 200 210 220 270 285 298
20 15/8-12 1.63 41.30 250 263 275 340 357 373
24 17/8-12 1.87 47.60 305 321 336 415 435 456
32 21/2-12 2.50 63.50 375 394 413 510 534 560

Torque
Thread
ØA*
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5
4 7/16-20 0.44 11.11 6 7 7 8 9 9
5 1/2-20 0.50 12.70 9 10 10 12 14 14
6 9/16-18 0.56 14.28 22 24 25 30 33 34
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
FITTINGS OR ALUMI-
NUM/BRASS MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; UN-LU-
14 13/16-12 1.19 30.10 114 120 126 155 163 171
16 15/16-12 1.31 33.30 130 137 143 176 186 194
20 15/8-12 1.63 41.30 163 171 179 221 232 243
24 17/8-12 1.87 47.60 198 208 218 268 282 296
32 21/2-12 2.50 63.50 244 256 268 331 347 363

torque.
656 31222415 800S HC3, 860SJ HC3

TYPE/FITTING IDENTIFICATION ZERO LEAK GOLD® HOLLOW HEX PLUGS

Torque
Thread
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18

STEEL MATING COM- so
10 7/8-14 0.87 22.22 46 48 62 65 68
PONENTS; UN-LUBRI-
CATED THREADS 12 11/16-12 1.06 27.00 51 54 57 69 73 77
14 13/16-12 1.19 30.10
16 15/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on Caterpillar applications.
20 15/8-12 1.63 41.30 Consult specific service procedure if encountered.
24 17/8-12 1.87 47.60
32 21/2-12 2.50 63.50
TYPE/FITTING IDENTIFICATION ZERO LEAK GOLD 8 HOLLOW HEX PLUGS

Torque
Thread
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 28 30 32 38 41 43
FITTINGS OR ALUMI-
NUM/BRASS MATING 10 7/8-14 0.87 22.22 46 48 so 62 65 68
COMPONENTS; UN-LU-
14 13/16-12 1.19 30.10
16 15/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on Caterpillar applications.
20 15/8-12 1.63 41.30 Consult specific service procedure if encountered.
24 17/8-12 1.87 47.60
32 21/2-12 2.50 63.50

torque.
800S HC3, 860SJ HC3 31222415 657

11.1.16 Assembly Instructions for Adjustable Port End Metric Fittings

1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter, or burrs.
2. If O-ring is not pre-installed, install proper size, taking care not to damage it. Refer to Section — O-ring Installation (Replacement),
page 689 for instructions.
CAUTION
fitting damage.
4. For Non-Adjustable Fittings and Plugs, thread the fitting by hand until contact.
6. Torque the fitting or nut to value while using the Double Wrench Method.
a. The table headings identify the Metric port and the type on the other side of the fitting. The torque will be applied to the
Metric port.
658 31222415 800S HC3, 860SJ HC3

Metric Flat Face Port (MFF) L Series - Table 1 of 3
FORM A (SEALING WASHER) STUD ENDS WITH 37° FORM B (CUTTING FACE) STUD ENDS WITH 37° (JIC)
(JIC) or L SERIES DIN (MBTL) OPPOSITE END OR L SERIES DIN (MBTL) OPPOSITE END
Torque Torque
Thread M Connecting
Material Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
ALUMINUM/BRASS M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
FITTINGS OR ALU-
MINUM/BRASS M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
MATING COMPO- M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
NENTS; UN-LUBRI-
CATED THREADS M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
Torque Torque
Thread M Connecting
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
ALUMINUM/BRASS
FITTINGS OR ALU- M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
MINUM/BRASS
M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
MATING COMPO-
NENTS; UN-LUBRI- M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
CATED THREADS
M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
800S HC3, 860SJ HC3 31222415 659

Torque Torque
Thread M Connecting
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
FORM G/H (O-RING W/ RETAINING RING)STUD ENDS

FORM E (EOLASTIC SEALING RING) STUD ENDS WITH
TYPE/FITTING IDENTIFICATION & ADJUSTABLE STUD ENDS WITH 37° (JIC) OR L SER-
37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
IES DIN (MBTL)OPPOSITE END
Torque Torque
Thread M Connecting
M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
STEEL FITTINGS M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
WITH STEEL MAT-
ING COMPO- M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
NENTS; UN- M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
LUBRICATED
THREADS M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
660 31222415 800S HC3, 860SJ HC3

FORM G/H (O-RING W/ RETAINING RING)STUD ENDS

FORM E (EOLASTIC SEALING RING) STUD ENDS WITH
TYPE/FITTING IDENTIFICATION & ADJUSTABLE STUD ENDS WITH 37° (JIC) OR L SER-
37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
IES DIN (MBTL)OPPOSITE END
Torque Torque
Thread M Connecting
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
ALUMINUM/
BRASS FITTINGS M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
OR ALUMINUM/ M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
BRASS MATING
COMPONENTS; M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
UN-LUBRICATED M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
800S HC3, 860SJ HC3 31222415 661

662
BANJO FITTINGS WITH L SERIES DIN (MBTL) OPPO- HIGH PRESSURE BANJO FITTINGS WITH L SERIES DIN FORM E (EOLASTIC SEALING RING) HOLLOW HEX
SITE END (MBTL) OPPOSITE END PLUGS
Connect- Torque Torque Torque

Thread M Size ing Tube

O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Material
(metric) (mm) No-

Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Max Min Nom Max
m
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
STEEL FITTINGS WITH
M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
31222415
STEEL MATING COMPO-
NENTS; UN-LUBRICATED M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
THREADS
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
M33x2 28 – – – – – – 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 – – – – – – 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 – – – – – – 516 542 568 700 735 770 266 280 293 360 380 397
800S HC3, 860SJ HC3

BANJO FITTINGS WITH L SERIES DIN (MBTL) OPPO- HIGH PRESSURE BANJO FITTINGS WITH L SERIES DIN FORM E (EOLASTIC SEALING RING) HOLLOW HEX
SITE END (MBTL) OPPOSITE END PLUGS

Thread M Size ing Tube
Material O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
800S HC3, 860SJ HC3

(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
ALUMINUM/ BRASS FIT-
TINGS OR ALUMINUM/ M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
BRASS MATING COMPO-
NENTS; UN-LUBRICATED M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
THREADS
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
M33x2 28 – – – – – – 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 – – – – – – 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 – – – – – – 335 352 369 454 477 500 173 182 190 235 247 258
31222415
663
Metric Flat Face Port (MFF) S Series - Table 1 of 3
FORM A (SEALING WASHER) STUD ENDS WITH (ORFS) FORM B (CUTTING FACE) STUD ENDS WITH (ORFS)
OR S SERIES DIN (MBTS) OPPOSITE END OR S SERIES DIN (MBTS) OPPOSITE END
Torque Torque
ThreadM Connecting
Material Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
STEEL FITTINGS M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
WITH STEEL
MATING COMPO- M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
NENTS; UN-LU- M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
BRICATED
THREADS M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770
Torque Torque
ThreadM Connecting
M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
BRASS FITTINGS M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
OR ALUMINUM/
BRASS MATING M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
COMPONENTS;
UN-LUBRICATED M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
THREADS M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
664 31222415 800S HC3, 860SJ HC3

Torque Torque
ThreadM Connecting
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
FORM E (EOLASTIC SEALING RING) STUD ENDS AND HEX FORM G/H (O-RING W/ RETAINING RING)STUD ENDS &
TYPE/FITTING IDENTIFICATION TYPE PLUGS WITH (ORFS) OR S SERIES DIN (MBTS) OPPO- ADJUSTABLE STUD ENDS WITH (ORFS) OR S SERIES
SITE END DIN (MBTS)OPPOSITE END
Connect- Torque Torque
ThreadM Size ing Tube
Material O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
STEEL FIT-
TINGS WITH M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
STEEL MATING M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
COMPONENTS;
UN-LUBRI- M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
CATED M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
800S HC3, 860SJ HC3 31222415 665

FORM E (EOLASTIC SEALING RING) STUD ENDS AND HEX FORM G/H (O-RING W/ RETAINING RING)STUD ENDS &
TYPE/FITTING IDENTIFICATION TYPE PLUGS WITH (ORFS) OR S SERIES DIN (MBTS) OPPO- ADJUSTABLE STUD ENDS WITH (ORFS) OR S SERIES DIN
SITE END (MBTS)OPPOSITE END
Con- Torque Torque
Thread M necting
Material Size Tube O. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
D.
M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
ALUMINUM/ M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
BRASS FIT-
TINGS OR ALU- M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
MINUM/ M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
BRASS MATING
COMPONENTS; M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
UN-LUBRI- M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
CATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
666 31222415 800S HC3, 860SJ HC3

800S HC3, 860SJ HC3

BANJO FITTINGS WITH S SERIES DIN (MBTS) OPPOSITE END HIGH PRESSURE BANJO FITTINGS WITH S SERIES DIN (MBTS) FORM E (EOLASTIC SEALING RING) HOLLOW HEX
OPPOSITE END PLUGS
Thread M
ing Tube
Size [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Material O.D
(metric) (mm) No- No-

Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Max Min Max
m m
M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 – – – – – –
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 – – – – – –
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 – – – – – –
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 – – – – – –
STEEL FITTINGS
WITH STEEL MAT- M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
31222415
ING COMPONENTS;
UN-LUBRICATED M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 – – – – – –
THREADS
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 – – – – – –
M33x2 28 – – – – – – 266 280 293 360 380 397 – – – – – –
M42x2 35 – – – – – – 398 418 438 540 567 594 – – – – – –
M48x2 42 – – – – – – 516 542 568 700 735 770 – – – – – –
667
BANJO FITTINGS WITH S SERIES DIN (MBTS) OPPOSITE HIGH PRESSURE BANJO FITTINGS WITH S SERIES DIN (MBTS) FORM E (EOLASTIC SEALING RING) HOLLOW HEX
668
END OPPOSITE END PLUGS
Torque Torque Torque
Thread M Connecting
Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Material
(metric) (mm) No- Ma-

Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Min Nom Max
m x
M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 – – – – – –
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 – – – – – –
M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 – – – – – –
ALUMINUM/ BRASS M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 – – – – – –

FITTINGS OR ALU-
M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
MINUM/ BRASS
MATING COMPO- M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 – – – – – –
NENTS; UN-LUBRI-
CATED THREADS M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 – – – – – –
M33x2 28 – – – – – – 173 182 190 235 247 258 – – – – – –
M42x2 35 – – – – – – 259 272 285 351 369 386 – – – – – –
M48x2 42 – – – – – – 335 352 369 454 477 500 – – – – – –
31222415
800S HC3, 860SJ HC3
11.1.17 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
NOTICE
fitting damage.
a. The table headings identify the Metric port and the type on the other side of the fitting. The torque will be applied to the
Metric port.
Metric Pipe Parallel O-Ring Boss (MPP)
STUD ENDS WITH 37° (JIC) OR L SERIES DIN (MBTL) STUD ENDS WITH (ORFS) OR S SERIES DIN (MBTS) OP-
OPPOSITE END POSITE END
Torque Torque
Thread M Connecting
M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
STEEL FITTINGS
WITH STEEL M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
MATING COMPO-
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
NENTS; UN-LU-
BRICATED M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
THREADS
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
800S HC3, 860SJ HC3 31222415 669

Torque Torque
Thread M Connecting
M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
M20 x 1.5 – – – – – – – 59 62 65 80 84 88
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
M30 x 2 – 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 – 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
Torque Torque
Thread M Connecting
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
ALUMINUM/ M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50

BRASS FITTINGS M20 x 1.5 – – – – – – – 30 40 42 41 54 57
OR ALUMINUM/
BRASS MATING M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
COMPONENTS;
UN-LUBRICATED M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
THREADS M30 x 2 – 62 65 68 84 88 92 114 120 125 155 163 169
M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 – 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
670 31222415 800S HC3, 860SJ HC3

11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings

NOTICE
fitting damage.
a. The table headings identify the BSPP port and the type on the other side of the fitting. The torque will be applied to the BSPP
port.
800S HC3, 860SJ HC3 31222415 671

British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
FORM A**(SEALING WASHER) STUD ENDS WITH 37° FORM B** (CUTTING FACE) STUD ENDS WITH 37° (JIC)
(JIC) or L SERIES DIN (MBTL) OPPOSITE END OR L SERIES DIN (MBTL)OPPOSITE END
Torque Torque
BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
GSize
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
G1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
WITH STEEL MAT-
ING COMPO- G1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
NENTS; UN- G1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
LUBRICATED
THREADS G3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
G1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
Torque Torque
BSPP Connecting
GSize
G1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
G1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
ALUMINUM/ G1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
OR ALUMINUM/
BRASS MATING G1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
COMPONENTS;
UN-LUBRICATED G1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
THREADS G3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
G1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
672 31222415 800S HC3, 860SJ HC3

Torque Torque
BSPP Connecting
GSize
G1-1/2A 42 139 146 153 188 198 207 302 318 333 409 431 451
Note: ** Non typical for JLG Straight Male Stud Fittings, reference only.
British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
FORM G/H*** (0-RING W/ RETAINING RING) STUD

FORM E*(EOLASTIC SEALING RING) STUD ENDS WITH
TYPE/FITTING IDENTIFICATION ENDS & ADJUSTABLE STUD ENDS WITH 37° (JIC) ORL
37° (JIC) ORL SERIES DIN (MBTL) OPPOSITE END
SERIES DIN (MBTL) OPPOSITE END
Torque Torque
BSPP Connecting
GSize
G1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
G1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
WITH STEEL
MATING COMPO- G1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
NENTS; UN-LU- G1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
BRICATED
THREADS G3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
G1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594
800S HC3, 860SJ HC3 31222415 673

FORM G/H*** (0-RING W/ RETAINING RING) STUD

FORM E*(EOLASTIC SEALING RING) STUD ENDS WITH
TYPE/FITTING IDENTIFICATION ENDS & ADJUSTABLE STUD ENDS WITH 37° (JIC) ORL
37° (JIC) ORL SERIES DIN (MBTL) OPPOSITE END
SERIES DIN (MBTL) OPPOSITE END
Torque Torque
BSPP Connecting
Material Thread TubeO.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
GSize
G1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
G1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
G1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
ALUMINUM/
G3/8A 12 34 36 37 46 49 so 34 36 37 46 49 so
BRASS FITTINGS
OR ALUMINUM/ G1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
BRASS MATING
COMPONENTS; G1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
UN-LUBRICATED
G3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS
G1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
G1-1/2A 42 259 272 285 351 369 386 259 272 285 351 369 386
Note: * Typical for JLG Straight Male Stud Fittings.

*** Typical for JLG Adjustable Fittings.
674 31222415 800S HC3, 860SJ HC3

British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
800S HC3, 860SJ HC3

BANJO FITTINGS WITH L SERIES DIN (MBTL) OPPOSITE HIGH PRESSURE BANJO FITTINGS WITH L SERIES DIN FORM E (EOLASTIC SEALING RING) HOLLOW HEX
END (MBTL) OPPOSITE END PLUGS
Connecting
BSPP Thread G Tube O.D
Material [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
STEEL FITTINGS
WITH STEEL MATING G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
COMPONENTS; UN-
31222415
LUBRICATED G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
THREADS
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
G 1A 28 – – – – – – 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 – – – – – – 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 – – – – – – 516 542 568 700 735 770 332 349 365 450 473 495
675
BANJO FITTINGS WITH L SERIES DIN (MBTL) OPPOSITE HIGH PRESSURE BANJO FITTINGS WITH L SERIES DIN FORM E (EOLASTIC SEALING RING) HOLLOW HEX
676
END (MBTL) OPPOSITE END PLUGS
BSPP Connecting
Material Thread G Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
ALUMINUM/ BRASS
FITTINGS OR ALUMI- G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
NUM/ BRASS MATING

COMPONENTS; UN-LU- G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
BRICATED THREADS
G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
G 1A 28 – – – – – – 153 161 169 207 218 229 96 101 106 130 137 144
G 1-1/4A 35 – – – – – – 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 – – – – – – 335 352 369 454 477 500 216 227 237 293 308 321
31222415
800S HC3, 860SJ HC3
British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3
FORM A** (SEALING WASHER) STUD ENDS WITH (ORFS) FORM B** (CUTTING FACE) STUD ENDS WITH (ORFS) ORS
ORS SERIES DIN (MBTS) OPPOSITE END SERIES DIN (MBTS) OPPOSITE END
Torque Torque
BSPP Connecting
GSize
G1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
G1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
STEEL FIT-
G3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
TINGS WITH
STEEL MATING G1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
COMPONENTS;
UN-LUBRI- G1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
CATED
G3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
THREADS
G1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
FORM A** (SEALING WASHER) STUD ENDS WITH FORM B** (CUTTING FACE) STUD ENDS WITH (ORFS) ORS
(ORFS) ORS SERIES DIN (MBTS) OPPOSITE END SERIES DIN (MBTS) OPPOSITE END
BSPP ing Tube
Material Thread O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
GSize
G1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
G1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/
BRASS FIT- G3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
TINGS OR ALU- G3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
MINUM/
BRASS MATING G1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
COMPONENTS;
UN-LUBRI- G1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
CATED G3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
THREADS
G1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
800S HC3, 860SJ HC3 31222415 677

FORM A** (SEALING WASHER) STUD ENDS WITH FORM B** (CUTTING FACE) STUD ENDS WITH (ORFS) ORS
(ORFS) ORS SERIES DIN (MBTS) OPPOSITE END SERIES DIN (MBTS) OPPOSITE END
BSPP ing Tube
Material Thread O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
GSize
G1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500
Note: ** Non typical for JLG Straight Male Stud Fittings, reference only.
FORM E* (EOLASTIC SEALING RING) STUD ENDS AND FORM G/H*** (Q-RING W/ RETAINING RING) STUD
TYPE/FITTING IDENTIFICATION HEX TYPE PLUGS WITH (ORFS) or S SERIES DIN (MBTS) ENDS & ADJUSTABLE STUD ENDS WITH (ORFS) ORS
OPPOSITE END SERIES DIN (MBTS) OPPOSITE END
Torque Torque
BSPP Connecting
Material Thread G Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
STEEL FITTINGS G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
WITH STEEL
MATING COMPO- G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
NENTS; UN-LU- G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
BRICATED
THREADS G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594
678 31222415 800S HC3, 860SJ HC3

FORM E* (EOLASTIC SEALING RING) STUD ENDS AND FORM G/H*** (Q-RING W/ RETAINING RING) STUD
TYPE/FITTING IDENTIFICATION HEX TYPE PLUGS WITH (ORFS) or S SERIES DIN (MBTS) ENDS & ADJUSTABLE STUD ENDS WITH (ORFS) ORS
OPPOSITE END SERIES DIN (MBTS) OPPOSITE END
Torque Torque
BSPP Connecting
Material Thread G Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
G1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
G3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
ALUMINUM/
G3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
BRASS FITTINGS
OR ALUMINUM/ G1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
BRASS MATING
COMPONENTS; G1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
UN-LUBRICATED
G3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
THREADS
G1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386
Note: * Typical for JLG Straight Male Stud Fittings.

*** Typical for JLG Adjustable Fittings.
800S HC3, 860SJ HC3 31222415 679

680
BANJO FITTINGS WITH S SERIES DIN (MBTS) OPPOSITE END HIGH PRESSURE BANJO FITTINGS WITH S SERIES DIN (MBTS) OPPOSITE
TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY
END
Con- Torque Torque Torque

necting
BSPP Tube O. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Material Thread G D.
Size N-
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min o- Max Min Nom Max
m
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77
31222415
STEEL FITTINGS G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
WITH STEEL
MATING COM- G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133
Fitting type not typically specified on Caterpillar
PONENTS; UN- G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 applications.
LUBRICATED
THREADS G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 Refer to the specific procedure in this Service
Manual.
G 1A 25 – – – – – – 236 248 260 320 336 353
G 1-1/4A 30 – – – – – – 398 418 438 540 567 594
G 1-1/2A 38 – – – – – – 516 542 568 700 735 770
800S HC3, 860SJ HC3

BANJO FITTINGS WITH S SERIES DIN (MBTS) OPPOSITE END HIGH PRESSURE BANJO FITTINGS WITH S SERIES DIN (MBTS) OPPOSITE
TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY
END
Con- Torque Torque Torque
necting
BSPP Tube O. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Material Thread G D.
800S HC3, 860SJ HC3

Size N-
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min o- Max Min Nom Max
m
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
ALUMINUM/ G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
BRASS FITTINGS Fitting type not typically specified on Caterpillar
OR ALUMINUM/ G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87 applications.
BRASS MATING
COMPONENTS; G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Refer to the specific procedure in this Service
UN-LUBRICATED Manual.
THREADS G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165
G 1A 25 – – – – – – 153 161 169 207 218 229
G 1-1/4A 30 – – – – – – 259 272 285 351 369 386
G 1-1/2A 38 – – – – – – 335 352 368 454 477 499
31222415
681
11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62)

1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs.
3. Position flange and clamp halves.
4. Place lock washers on bolt and bolt through clamp halves.
5. Tighten all bolts by hand.
6. Torque bolts in diagonal sequence in two or more increments to the torque listed.
682 31222415 800S HC3, 860SJ HC3

Flange Code (FL61 and FL62) - Inch Fasteners
800S HC3, 860SJ HC3

TYPE/FITTING IDENTIFICATION STEEL 4-BOLT FLANGE SAE J518(INCH FASTENERS)
Inch Fastener Torque for Flanges Equipped with GRADE 5 Screws Fastener Torque for Flanges Equipped with GRADE 8 Screws
Flange Size Bolt Thread
Flange A*
Type Size [Ft-Lb] [Nm] [Ft-Lb] [Nm]
SAE
Dash
Size (in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35

12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
CODE 61SPLIT
FLANGE 32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
31222415
(FL61)
40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
683
TYPE/FITTING IDENTIFICATION STEEL 4-BOLT FLANGE SAE J518(INCH FASTENERS)
684
Fastener Torque for Flanges Equipped with GRADE 5 Screws Fastener Torque for Flanges Equipped with GRADE 8 Screws
Inch Flange Flange Size Bolt Thread
A*
Type SAE Dash Size [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 5/16-18 – – – – – – 24 25 26 32 34 35
12 0.75 19 2.00 50.80 3/8-16 – – – – – – 44 46 49 60 63 66
16 1.00 25 2.25 57.15 7/16-14 – – – – – – 68 71 75 92 97 101
CODE 62SPLIT
FLANGE 20 1.25 32 2.62 66.55 1/2-13 – – – – – – 111 116 122 150 158 165
(FL62)
20 1.25 32 2.62 66.55 – – – – – – – – – – – – –
24 1.50 38 3.12 79.25 5/8-11 – – – – – – 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 – – – – – – 332 348 365 450 473 495
Note: * A dimension for reference only.
31222415
800S HC3, 860SJ HC3
Flange Code (FL61 and FL62) - Metric Fasteners
800S HC3, 860SJ HC3

TYPE/FITTING IDENTIFICATION STEEL 4-BOLT FLANGE SAE J518 (INCH FASTENERS)
Fastener Torque for Flanges Equipped with CLASS 8.8 Fastener Torque for Flanges Equipped with CLASS 10.9
Inch Flange Flange Size A* Bolt Thread Size Screws Screws
Type SAE Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
12 0.75 19 1.88 47.75 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
24 1.50 38 2.75 69.85 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
CODE 61 SPLIT
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
31222415
FLANGE (FL61)
40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
685
TYPE/FITTING IDENTIFICATION STEEL 4-BOLT FLANGE SAE J518 (INCH FASTENERS)
686
Fastener Torque for Flanges Equipped with CLASS 8.8 Fastener Torque for Flanges Equipped with CLASS 10.9
Inch Flange Flange Size A* Bolt Thread Size Screws Screws
Type SAE Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 – – – – – – 24 25 26 32 34 35
12 0.75 19 2.00 50.80 M10 x 1.5 – – – – – – 52 54 57 70 74 77
16 1.00 25 2.25 57.15 M12 x 1.75 – – – – – – 96 101 105 130 137 143
CODE 62 SPLIT
20 1.25 32 2.62 66.55 M12 x 1.75 – – – – – – 96 101 105 130 137 143
FLANGE (FL62)
20 1.25 32 2.62 66.55 M14 x 2 – – – – – – 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 – – – – – – 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 – – – – – – 406 426 446 550 578 605
Note: * A dimension for reference only.
31222415
800S HC3, 860SJ HC3
11.1.20 Double Wrench Method

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

1. FFWR (Flats from Wrench Resistance Method)
a. Tighten the swivel nut to the mating fitting until no lateral movement of the swivel nut can be detected; finger tight
condition.
b. Mark a dot on one of the swivel hex nut flats and another dot in line on the connecting tube adapter.
c. Use the double wrench method per Appendix A, turn the swivel nut to tighten. The nut is to be rotated clockwise the number
of hex flats.
d. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots, to
indicate the connection has been properly tightened.
FFWR Method
800S HC3, 860SJ HC3 31222415 687

2. TFFT (Turns from Finger Tight Method)

a. Tighten the swivel nut to the mating fitting until no lateral movement of the swivel nut can be detected; finger tight
condition.
b. Mark a dot on one of the swivel hex nut flats and another dot in line on the connecting tube adapter.
c. Use the double wrench method, turn the swivel nut to tighten. The nut is to be rotated clockwise the number of turns.
d. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots, to
indicate the connection has been properly tightened.
11.1.22 Adjustable Stud End Assembly

For Adjustable Stud End Connections; the following assembly steps are to be performed:
1. Lubricate the o-ring with a light coat of hydraulic oil.
2. Position #1 – The o-ring should be located in the groove adjacent to the face of the back-up washer. The washer and o-ring should
be positioned at the extreme top end of the groove as shown.
3. Position #2 – Position the locknut to just touch the backup washer as shown. The locknut in this position will eliminate potential
back up washer.
4. Position #3 – Install the connector into the straight thread box port until the metal backup washer contacts the face of the port as
shown.
5. Position #4 – Adjust the connector to the proper position by turning out (counterclockwise) up to a maximum of one turn as
shown to provide proper alignment with the mating connector, tube assembly, or hose assembly.
6. Position #5 – Using two wrenches, use the backup wrench to hold the connector in the desired position and then use the torque
wrench to tighten the locknut to the appropriate torque.
7. Visually inspect, where possible, the joint to ensure the oring is not pinched or bulging out from under the washer and that the
backup washer is properly seated flat against the face of the port.
Figure 299. Adjustable Stud End Assembly
688 31222415 800S HC3, 860SJ HC3

11.1.23 O-ring Installation (Replacement)

Care must be taken when installing O-rings over threads during replacement or installation. O-rings could become nicked or torn. A
damaged O-ring could lead to leakage problems.
1. Inspect O-ring for tears or nicks. If any are found replace O-ring.
2. Ensure proper O-ring to be installed. Many O-rings look the same but are of different material, different hardness, or are slightly
different diameters or widths.
3. Use a thread protector when replacing O-rings on fittings.
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.
5. Inspect O-ring for any visible nicks or tears. Replace if found.
800S HC3, 860SJ HC3 31222415 689

11.2 TORQUE CHARTS
11.2.1 SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Tensile Clamp Torque Torque Lubricated (Loctite® 242™ or (Loctite® 262™ or Vi-
Size TPI Bolt Dia
Stress Area Load 271™ or Vibra-TITE™ bra-TITE™131)
(Dry) 111 or 140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
5000059K

Torque Torque
Tensile Clamp Torque (Dry) Torque Lubricated (Loctite® 242™ or (Loctite® 262™ or Vi-
Size TPI Bolt Dia
111 or 140)
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
690 31222415 800S HC3, 860SJ HC3


Torque Torque
Tensile Clamp Torque (Dry) Torque Lubricated (Loctite® 242™ or (Loctite® 262™ or Vi-
Size TPI Bolt Dia
111 or 140)
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
11/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
11/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
13/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
11/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
5000059K
Note: 1. These torque values do not apply to cadmium plated fasteners.
2. All torque values are static torque measured per standard audit methods tolerance = ±10%.
3. * Assembly uses hardened washer.
800S HC3, 860SJ HC3 31222415 691

SAE Fastener Torque Chart (Continued)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Tensile Clamp (Dry or Loctite® 263) K=0.20 (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra-
Size TPI Bolt Dia
Stress Area Load Vibra-TITE™ 111 or 140) K= TITE™ 131) K=0.15
0.18
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
5000059K

Size TPI Bolt Dia
0.18
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
692 31222415 800S HC3, 860SJ HC3


Size TPI Bolt Dia
0.18
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
11/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
11/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
13/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
11/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
5000059K
800S HC3, 860SJ HC3 31222415 693

Values for Magni Coating Fasteners (Ref 4150701)

Tensile Clamp (Dry) K=0.17 (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra-
Size TPI Bolt Dia
0.16
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
5000059K

Size TPI Bolt Dia
0.16
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
694 31222415 800S HC3, 860SJ HC3


Size TPI Bolt Dia
0.16
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
11/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
11/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
13/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
11/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
5000059K
800S HC3, 860SJ HC3 31222415 695


Tensile Clamp (Dry or Loctite® 263) K=0.17 (Loctite® 242™ or 271™ or Vi- (Loctite® 262™ or Vibra-
Size TPI Bolt Dia
Stress Area Load bra-TITE™ 111 or 140) K= TITE™ 131) K=0.15
0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5000059K

Tensile Clamp (Loctite® 242™ or 271™ or Vi-
Size TPI Bolt Dia (Loctite® 262™ or Vibra-
Stress Area Load (Dry or Loctite® 263) K=0.17 bra-TITE™ 111 or 140) K= TITE™ 131) K=0.15
0.16
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
696 31222415 800S HC3, 860SJ HC3


Tensile Clamp (Loctite® 242™ or 271™ or Vi-
Size TPI Bolt Dia (Loctite® 262™ or Vibra-
Stress Area Load (Dry or Loctite® 263) K=0.17 bra-TITE™ 111 or 140) K= TITE™ 131) K=0.15
0.16
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
11/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
11/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
13/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
11/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
5000059K
800S HC3, 860SJ HC3 31222415 697


SOCKET HEAD CAP SCREWS
Clamp
Tensile (Dry) K=0.17 (Loctite® 242™ or 271™ or Vi- (Loctite® 262™ or Vibra-TITE™
Size TPI Bolt Dia Load See
Stress Area bra-TITE™ 111 or 140) or Pre- 131) K=0.15
Note 4
coat® 85 K=0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5000059K

Clamp
Note 4
coat® 85 K=0.16
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
698 31222415 800S HC3, 860SJ HC3


Clamp
Note 4
coat® 85 K=0.16
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
11/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
11/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
13/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
11/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
5000059K
4. Clamp load listed for SHCS is same as grade 8 or class 10.9 and does not represent full strength capability of SHCS. If higher
load is required, additional testing is required.
800S HC3, 860SJ HC3 31222415 699

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

Clamp
Tensile (Dry) K=0.17 (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra-
Stress Area Vibra-TITE™ 111 or 140) or TITE™ 131) K=0.15
Note 4
Precoat® 85 K=0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5000059K

Clamp
Note 4
Precoat® 85 K=0.16
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
700 31222415 800S HC3, 860SJ HC3


Clamp
Note 4
Precoat® 85 K=0.16
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
11/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
11/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
13/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
11/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
5000059K
800S HC3, 860SJ HC3 31222415 701

11.2.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Clamp Load
Tensile (Dry or Loctite® 263™) Torque (Lube) (Loctite® 262™ or (Loctite® 242™ or
Size Pitch See
Stress Area 271™ or Vibra-TITE™ 271™ or Vibra-TITE™
Note 4
131) 111or 141)
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
5000059K
702 31222415 800S HC3, 860SJ HC3

Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Clamp Load
Tensile Stress (Dry or Loctite® 263™) K= (Lube or Loctite®242™ or (Loctite® 262™ or Vibra-
Size Pitch See
Area 0.20 271™ or Vibra-TITE™ 111 TITE™ 131) K=0.15
Note 4
or 140) K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
5000059K
800S HC3, 860SJ HC3 31222415 703

Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

Clamp Load
Tensile Stress (Dry or Loctite® 263™) K= (Lube or Loctite® 242™ or (Loctite® 262™or Vibra-
Size Pitch See
Area 0.17 271™ or Vibra-TITE™ 111 TITE™ 131) K=0.15
Note 4
or 140) K=0.16
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070
5000059K
Note: 1. These torque values do not apply to cadmium plated fasteners
2. All torque values are static torque measured per standard audit methods tolerance = ±10%
3. * assembly uses hardened washer
704 31222415 800S HC3, 860SJ HC3

Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,

CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
Tensile Stress Clamp Load See (Dry or Loctite® 263™) K= (Lube or Loctite®242™ or (Loctite® 262™ or Vibra-
Size Pitch
Area Note 4 0.17 271™ or Vibra-TITE™ 111 TITE™ 131) K=0.15
or 140) K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
5000059K
800S HC3, 860SJ HC3 31222415 705

706
SECTION 12
SCHEMATICS
12.1 HYDRAULIC SCHEMATICS
Figure 300. Hydraulic Schematic - Sheet 1 of 4
800S HC3, 860SJ HC3 31222415 707

Schematics
708 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 709

Schematics
710 31222415 800S HC3, 860SJ HC3

Schematics
12.2 ELECTRICAL SCHEMATICS
Figure 304. Electrical Schematic - Sheet 1 of 13
800S HC3, 860SJ HC3 31222415 711

Schematics
712 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 713

Schematics
714 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 715

Schematics
716 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 717

Schematics
718 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 719

Schematics
720 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 721

Schematics
722 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 723

Schematics
12.3 DEUTZ EMR2 SCHEMATICS
12.3.1 Vehicle Side Connection Diagram
BM110471A
724 31222415 800S HC3, 860SJ HC3

Schematics
12.3.2 Engine Side Connection Diagram - Sheet 1 of 2
BM110471A
800S HC3, 860SJ HC3 31222415 725

Schematics
12.3.3 Engine Side Connection Diagram - Sheet 2 of 2
BM110471A
726 31222415 800S HC3, 860SJ HC3

Schematics
12.3.4 Engine Plug Pin
800S HC3, 860SJ HC3 31222415 727

Schematics
12.3.5 Vehicle Plug Pin Identification
728 31222415 800S HC3, 860SJ HC3

Schematics
12.4 DEUTZ EMR5 SCHEMATICS
12.4.1 Power Harness
800S HC3, 860SJ HC3 31222415 729

Schematics
12.4.2 Exhaust After Treatment Harness
730 31222415 800S HC3, 860SJ HC3

Schematics
12.4.3 Equipment Harness - Sheet 1 of 5
800S HC3, 860SJ HC3 31222415 731

Schematics
732 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 733

Schematics
734 31222415 800S HC3, 860SJ HC3

Schematics
800S HC3, 860SJ HC3 31222415 735

Schematics
12.4.8 Engine Plug Pin Identification
Pin No. Description

A01 INJS3
A02 INJS4
A03 INJS5
A04 Fuel metering unit (BAT+)
A05 Fuel metering unit (low side)
A06
A07 Rail fuel pressure supply
A08 Fan speed visco supply
A09 Boost pressure and temperature supply
A10 Customer Temperature
A11 Exhaust pressure P3
A12 EGR position sensor signal
A13 Air inlet temperature
A14 Fan speed visco
A15 Oil warning lamp
A16 INJS0
A17 INJS1
A18 INJS2
A19 EGR control pos
A20 EGR control neg
A21 DPF differential pressure sensor supply
A22 EGR feedback supply
A23 Oil level sensor (Hella)
A24 Oil pressure supply
A25 Rail fuel pressure ground
A26 Rail pressure sensor signal
A27 Boost temperature
A28 Coolant temperature
A29 Exhaust pressure P3 ground
736 31222415 800S HC3, 860SJ HC3

Schematics
Pin No. Description

A30 Differential pressure sensor
A30 Differential pressure sensor (see analog input)
A31 INJS3
A32 INJS4
A33 INJS0
A34 Regeneration indication lamp
A35 Fan actuator
A36 Air inlet temperature ground
A37 Cam shaft speed sensor positive
A38 Crankshaft sensor shield
A39 Crank shaft speed sensor positive
A40 EGR feedback ground
A41 Starter low side
A42 Boost pressure and temperature ground
A43 Boost pressure sensor signal
A44 Oil pressure sensor input signal
A45 Switched Battery UB2
A46 INJS5
A47 INJS1
A48 INJS2
A49 After run active
A51 Customer Temperature ground
A52 Cam shaft speed sensor negative
A53 Camshaft speed sensor shield
A54 Crank shaft speed sensor negative
A55 Reserve Ground
A56 Reserve Ground
A57 Oil pressure ground
A58 Water in fuel switch
A59 Exhaust gas temperature 1
800S HC3, 860SJ HC3 31222415 737

Schematics
12.4.9 Vehicle Plug Pin Identification
Pin No. Description

K01 BATTERY PLUS
K02 BATTERY MINUS
K03 BATTERY PLUS
K04 BATTERY MINUS
K05 BATTERY PLUS
K06 BATTERY MINUS
K07 EGR temperature behind venturi ground
K08 ITV-H-bridge pos
K08 Intake air throttle pos
K09 Intake air throttle neg
K09 ITV-H-bridge neg
K10 Electrical connected with K9
K11 Vehicle speed sensor ground
K12 Speed switch on/off
K13 Coolant level
K14 Redundant brake switch
K15 Clutch switch
K16 Regeneration activation switch
K17 Air filter differential
K18 Speed switch (+)
K19 Gearbox neutral switch
K20 Preheat sense
K21 Low fuel pressure ground
K22 Controller parameter choise
K23 Delta P venturi supply
K24 Reserve pressure input supply
K25 Fuel pump relay
K26 Intake air throttle (PWM) low side switch
K27 Reserve
K28 Disk seperator
K29 Switched Battery UB2
738 31222415 800S HC3, 860SJ HC3

Schematics
Pin No. Description

K30 Reserve
K31 Engine stop switch
K32 Speed switch (hold/resume)
K33 EGR Temperature behind venturi
K34 Vehicle speed sensor
K35 Terminal 50
K36 Reserve analog temperaturee input
K37 Speed switch (-)
K38 Parking brake switch
K39 Ambient temperature
K40 Engine brake switch
K41 Brake main switch
K42 Override switch
K43 Low fuel pressure supply
K44 App2 supply
K45 App1 supply
K46 Air intake throttle feedback supply

K47 Exhaust flap
K48 Preheat lamp
K49 Engine speed output
K50 Reserve 2
K52 Multiple state switch 2 ground
K53 CAN2 low
K54 CAN1 high
K55 Exhaust gas temperature 2 ground
K56 Exhaust gas temperature 2
K57 Multiple state switch 2
K58 Low fuel pressure
K59 LIN bus
K61 Throttle 1a
K62 APP1 ground
K63 Throttle 2a
K65 Diagnostic lamp ground
K66 Diagnostic switch
800S HC3, 860SJ HC3 31222415 739

Schematics
Pin No. Description

K67 Intake air throttle (PWM) status
K69 OBD lamp
K70 Diagnostic lamp
K71 Engine running lamp
K72 Prehead relay
K74 Torque / droop Line ground
K75 CAN2 high
K76 CAN1 low
K77 Reserve pressure input ground
K78 Reserve analog pressure input
K79 Torque / droop Line
K80 Feedback intake air throttle
K81 Delta p venturi
K83 Throttle 1b
K84 APP2 ground
K85 Throttle 2b
K86 Controller mode
K87 Digital ground
K88 Terminal 15
K91 Sent1
K92 Warning temperature lamp
K93 Reserve 3
K94 Reserve 1
740 31222415 800S HC3, 860SJ HC3

12.5.1
800S HC3, 860SJ HC3

Voltage Readings
a) Tolerance − ± 10% unless
Voltage readings taken with PLG31 Voltage readings taken with PLG4/RC4 connected.
connected to RC31 on PC1. Resistance readings taken with PLG4/RC4 disconnected.
b) Condition − 70 ° F (21 ° C); cold
1 ohm machine (no warm-up); no load
PLG31 Ridge denotes Pin 1 V9
Pin1 c) Power rpm (3600 at 60 Hz, 3000 at
V11 d) Reference − single arrow :

reference to circuit common
(lead 42); double arrow :
V10
Pin 7 Circuit Common referenceto points indicated
RC31
e) Wiring Diagram
V7
26 ohms
I1 = 1 amps DC (60 Hz) V1 Thru V6 Taken At Basket Receptacle
No greater than 3.5 amps V8 V1 X to Y − 240 volts A C ±10%
DC under load
V2 X to Z − 240 volts AC ±10%
See Section 8-4
V3 Y to Z − 240 volts AC ±10%
for PC1 data
I1
Troubleshooting Circuit Diagram
12.5 7500W GENERATOR SCHEMATIC
V4 X to G − 120 volts A C ±10%

V5 Y to G − 120 volts A C ±10%
V6 Z to G − 208 volts A C ±10%
V7 Rotor:
20 volts DC at no load ±20%
70 volts DC at full load ±10%
V8 Exciter:
138 volts AC at no load ±10%
155 volts AC at full load ±10%
I2 = 1 amps DC (60 Hz)
No greater than 3.5 amps V9 Voltage Feedback:
DC under load 240 volts A C ±10%
V10 Shutdown Signal:
I2 0 volts DC during normal oper a
V11 PWM Signal: 0 to +15 volts DC
1.5 volts DC normal no load
4.3 volts DC at full load
31222415
V12 Generator Enable:
Battery voltage when gener ator is
enabled (on)
0 volts DC when gener ator is not en-
SeeSection 8-6 abled (off )
for PC2 data V13 Batter y Voltage
RC1 * If 12 volts DC is present, check rotor

and if r ot or checks ok, replace con-
trol boar d PC1.
V12 SeeSection 8-3 for

waveforms A,B Measure Output Voltages V1
Waveform A Thru V6 At Basket Receptacle
V13 Check Resistance atTE1

C to D,
C to E,
Test Equipmen t Needed: C to F,
Ridge denotes Pin 1 Pin 5 - Circuit Common
PLG1 E to F,
D to F
Voltage readings taken with All readings should be 1
PLG1 connected to RC1 on PC2. ohm. Check with lead 42 lift-
ed. Replace generator if
windings are shorted to case
or open.
MAF46940
741
Schematics
Schematics
12.5.2 Generator and Controller Circuit Diagram
MAF46950
742 31222415 800S HC3, 860SJ HC3

Schematics
12.5.3 Power Board PC1 Circuit Diagram
MAF46960
800S HC3, 860SJ HC3 31222415 743

Schematics
12.5.4 Power Board PC2 Electrical Circuit Diagram
MAF46970
744 31222415 800S HC3, 860SJ HC3

Schematics
12.5.5 Lead Connection List

Note: Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Note: Apply small amount of dielectric grade, non-conductive electric grease to connectors where factory-applied grease had been
present.
Table 51. Lead Connection List for Generator

Leads Connections
1A STATOR TO CB1
2A STATOR TO CB1
3A STATOR TO CB1
4A STATOR TO TE1 (C)
5A STATOR TO RC4 (3)
5B PLG2 (C) TO PLG4 (3)
5C RC2 (C) PLG31 (8)
6B PLG2 (D) TO PLG4 (4)
6C RC2 (D) PLG31 (9)
9A RC5 (B) TO PLG3 (B) (Customer Supplied)
9B RC3 (B) PLG1 (8)
12A PLG2 (E) TO PLG4 (5)
12B RC2 (E) PLG1 (9)
12C RC4 (5) TO BRUSH
13A PLG2 (F) TO PLG4 (6)
13B RC2 (F) PLG31 (4)
13C RC4 (6) TO BRUSH
15A PLG1 (6) TO PLG31 (6)
16A PLG1 (3) TO PLG31 (1)
17A PLG1 (4) TO PLG31 (2)
21A CB1 TO TE1 (F)
21B PLG2 (A) TO PLG4 (1)
21C PLG1 (1) TO RC2 (A)
21D RC4 (1) TO CB1
22A CB1 TO TE1 (E)
22B PLG2 (B) TO PLG4 (2)
22C PLG1 (2) TO RC2 (B)
22D RC4 (2) TO CB1
23A CB1 TO TE1 (D)
42A RC5 (C) TO PLG3 (C) (Customer Supplied)
800S HC3, 860SJ HC3 31222415 745

Schematics
Table 51. Lead Connection List for Generator (continued)

Leads Connections
42B RC3 (C) TO CONNECTION POINT 1
42C PLG31 (7) TO CONNECTION POINT 1
42D PLG1 (5) TO CONNECTION POINT 1
42F END BELL SHROUD TO ENGINE MOUNT
42G CHASSIS TO TE1 (B)
43A RC5 (A) TO PLG3 (A) (Customer Supplied)
43B RC3 (A) TO CONNECTION POINT 2
43C PLG31 (3) TO CONNECTION POINT 2
43D PLG1 (7) TO CONNECTION POINT 2
746 31222415 800S HC3, 860SJ HC3

Schematics
12.6 4000W GENERATOR SCHEMATIC
12.6.1 Generator and Controller Circuit Diagram
CR1
C1
7
5 6
RC2 RC2
C D
PLG2 PLG2
5 6
PLG4 PLG4
3 4 NORM ALVOLTAGE: (81-84)
RC4 RC4 50 HZ 230V
60 HZ 240V
5 6
60HZ - CONNECT 90 TO 3T
50 HZ - SLEEVE END & SECURE
DO NOT CONNECT - FIELD OPTION
1 90
4
CR
1
8 9
B +12VTO ENAB
CB1
RC4
C -ENABLE
81 84
3T
1T 2T
MAF44360
800S HC3, 860SJ HC3 31222415 747

Schematics
12.6.2 Lead Connection List

Note: Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Note: Apply small amount of dielectric grade, non-conductive electric grease to connectors where factory-applied grease had been
present.
Leads Connections
GND ENGINE TO 3T
1A STATOR TO CB1
4A STATOR TO CB1
5C CR1 (4) TO RC2 (C)
6C RC2 (D) TO C1
7A CR1 (7) TO C1
8A CR1 (A) TO RC5 (C)
9A CR1 (B) TO RC5 (B)
81B CB1 TO 1T
84B CB1 TO 2T
90A STATOR TO 3T
JUMPA ROTOR LEAD TO DIODE
748 31222415 800S HC3, 860SJ HC3

Blank page
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417
Visit our website for JLG Worldwide Locations.

www.jlg.com

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Service & Maintenance Manual

DATE REVISION DESCRIPTION

800S HC3, 860SJ HC3 31222415 3

800S HC3, 860SJ HC3 31222415 5

READ THIS FIRST........................................................................................................................................... 5

800S HC3, 860SJ HC3 31222415 7

4.3 Calibration Procedures......................................................................................................... 94

8 31222415 800S HC3, 860SJ HC3

9.7 Hydraulic Cylinders ........................................................................................................... 400

800S HC3, 860SJ HC3 31222415 9

1.1.2 Operation & Safety Manual

1.1.3 Do Not Operate Tags

1.2 SAFETY INFORMATION

800S HC3, 860SJ HC3 31222415 11

1.2.1 Safety Alert System and Signal Words

1.3 SAFETY HAZARDS

1.3.1 Personal Hazards

• Do not smoke while servicing the machine.

• Never refuel during electrical storms.

1.3.2 Equipment Hazards

1.3.3 General Hazards

• Only use approved, nonflammable cleaning solvents.

12 31222415 800S HC3, 860SJ HC3

1.3.4 Operational Hazards

• Never check for leaks using any part of your body.

• Lithium ion batteries should never be opened or tampered with.

1.4 SAFETY DECALS

1.5 MACHINE VERIFICATION

800S HC3, 860SJ HC3 31222415 13

2.1.1 Machine Specifications

Unrestricted 500 lb (227 kg)

Restricted 750 lb (340 kg)

Restricted 1000 lb (454 kg)

Maximum Operating Slope 4°

Maximum Travel Grade (Gradeability)*

Maximum Vertical Platform Height

Outside 21.7 ft. (6.6 m)

Maximum Wind Speed 28 mph (12.5 m/s)

Gross Machine Weight (Platform Empty)

800S 33,030 lb (14,982 kg)

* With boom in stowed position

800S HC3, 860SJ HC3 31222415 15

2.1.2 Machine Dimensional Data

Tail Swing 4 ft. 8.14 in. (1.43 m)

Platforms 36 in. x 96 in. (0.91 m x 2.44 m)

Ground Bearing Pressure - 860SJ 81 psi (5.7 kgm/cm2)

Occupied Floor Area 107.17 ft.² (9.96 m2)

2.1.3 Engine Data

Fuel Diesel (10,000 ppm Max Sulfur Content)

Oil Capacity 11 Quarts (10.5 L)

Low RPM 1000 ± 50 rpm

Average Fuel Consumption

Table 2. Deutz TD 2.9 L4 T4F Specs

Fuel Ultra Low Sulfur Diesel (15 ppm)

Cooling System Capacity 3.3 Gallon (12.5 L)

Low RPM 1200 ± 50 rpm

16 31222415 800S HC3, 860SJ HC3

Table 2. Deutz TD 2.9 L4 T4F Specs (continued)