860 SJ
860 SJ
860 SJ
Model
800S
810SJ
860SJ
S/N 0300182743 &
B300001328 to Present
3121631
AS/NZS
INTRODUCTION
A GENERAL C MAINTENANCE
This section contains the general safety precautions which
must be observed during maintenance of the aerial platform.
It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
possible injury to themselves or others, or damage to the SAFETY VIOLATION.
equipment. A maintenance program must be followed to
ensure that the machine is safe to operate. • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER. TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during maintenance • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-
are inserted at the appropriate point in the manual. These pre- FORMING ANY MAINTENANCE.
cautions are, for the most part, those that apply when servic-
ing hydraulic and larger machine component parts. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
Your safety, and that of others, is the first consideration when CAUGHT ON OR ENTANGLED IN EQUIPMENT.
engaging in the maintenance of equipment. Always be con-
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
scious of weight. Never attempt to move heavy parts without
MACHINE AND IN SERVICE MANUAL.
the aid of a mechanical device. Do not allow heavy objects to
rest in an unstable position. When raising a portion of the • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
equipment, ensure that adequate support is provided. SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL-
ANT SYSTEM.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE • NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL- BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
ITY OF THE OWNER/OPERATOR. BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
HAS BEEN ENGAGED.
3121631 A-1
INTRODUCTION
REVISON LOG
A-2 3121631
TABLE OF CONTENTS
3121631 i
TABLE OF CONTENTS
ii 3121631
TABLE OF CONTENTS
3121631 iii
TABLE OF CONTENTS
iv 3121631
TABLE OF CONTENTS
3121631 v
TABLE OF CONTENTS
vi 3121631
LIST OF FIGURES
3121631 vii
LIST OF FIGURES
viii 3121631
LIST OF FIGURES
3121631 ix
LIST OF FIGURES
x 3121631
LIST OF FIGURES
3121631 xi
LIST OF FIGURES
xii 3121631
LIST OF FIGURES
3121631 xiii
LIST OF FIGURES
xiv 3121631
LIST OF TABLES
3121631 xv
LIST OF TABLES
xvi 3121631
SECTION 1 - SPECIFICATIONS
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.2 SPECIFICATIONS AND PERFORMANCE DATA
Table 1-2. Specifications and Performance Data
Table 1-1. Operating Specifications
Swing 360°
Maximum Work Load (Capacity)
ANSI Tail Swing 4 ft. 8 in. (1.42 m)
Unrestricted: 500 lbs. (227 kg) Platforms 36 in. x 72 in. (0.91m x 1.83m)
Restricted 36 in. x 96 in. (0.91m x 2.44m)
800S 1000lbs. (450kg) Overall Width 8 ft. 2 in. (2.48 m)
810S/860SJJ 750lbs. (340kg)
Stowed Height
Maximum Work Load (Capacity) 800S 9 ft.11 in.(3.02 m)
CE & Australia 810SJ 9 ft. 8 in.(2.97 m)
Unrestricted: 500 lbs. (230 kg) 860SJ 10 ft.(3.05 m)
Maximum Capacity - Dual Rating Stowed Length
ANSI, CSA 800S 37 ft. 3 in.(11.35 m)
800S 1000 lbs. (454 kg) 810SJ/860SJ 40 ft.(12.2 m)
810SJ/860SJ 750 lbs. (340 kg)
Wheel base
Maximum Travel Grade (Gradeability)* 800S/860SJ 10 ft.(3.06 m)
2WD 25% 810SJ 10 ft. 1 in. (3.07m)
4WD 45%
Ground Clearance
Maximum Travel Grade (Side Slope)* 5° 800S/860SJ 11 in.(0.28 m)
Maximum Vertical Platform Height: 810SJ 13 in.(0.32m)
800S 80 ft. (24.3 m) Drive Speed
810SJ 80 ft. 6 in. (24.6 m) Stowed 2WD 3.5 mph (5.6 kph)
860SJ 86 ft. (26.2 m) Stowed 4WD 3.5 mph (5.6 kph)
Maximum Horizontal Platform Reach Elevated 0.75 mph (1.2 kph)
800S 71 ft. (21.6 m) Ground Bearing Pressure - 800S 72 psi (5.06 kgm/cm2)
810SJ 72 ft. (21.9 m)
860SJ 75 ft. (22.9 m) Ground Bearing Pressure - 810SJ/860SJ 81 psi (5.7 kgm/cm2)
Turning Radius (outside) Max. Tire Load - 800S 17,350 lbs. (7870 kg)
800S/ 860SJ 19.8 ft. (6.02 m) Max. Tire Load - 810SJ 18,700 lbs. (8482 kg)
810SJ 19.7 ft. (6.01 m)
Max. Tire Load - 860SJ 20,200 lbs. (9163 kg)
Turning Radius (inside)
800S/ 860SJ 12.6 ft. (3.8 m)
810SJ 12.4 ft. (3.9 m)
Maximum Drive Speed 3.5 mph (5.6 kmph)
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 lbs. (14,982 kg)
810SJ 36,350 lbs. (16,488 kg)
860SJ 36,230 lbs. (16,433 kg)
* With boom in stowed position
3121631 1-1
SECTION 1 - SPECIFICATIONS
1-2 3121631
SECTION 1 - SPECIFICATIONS
3121631 1-3
SECTION 1 - SPECIFICATIONS
1.7 LUBRICATION
Table 1-14. UCon Hydrolube HP-5046
Hydraulic Oil Type Synthetic Biodegradable
Specific Gravity 1.082
Table 1-12. Hydraulic Oil
Pour Point, Max -58°F (-50°C)
Hydraulic System pH 9.1
S.A.E. Viscosity
Operating
Grade Viscosity
Temperature Range
at 0° C (32° F) 340 cSt (1600SUS)
+0° to + 180° F 10W
(-18° to +83° C) at 40° C (104° F) 46 cSt (215SUS)
+0° to + 210° F 10W-20, 10W30 at 65° C (150° F) 22 cSt (106SUS)
(-18° to +99° C) Viscosity Index 170
+50° to + 210° F 20W-20
(+10° to +99° C) Table 1-15. Mobil DTE 10 Excel 32 Specs
NOTE: Hydraulic oils must have anti-wear qualities at least to API ISO Viscosity Grade #32
Service Classification GL-3, and sufficient chemical stability Specific Gravity 0.877
for mobile hydraulic system service. JLG Industries recom- Pour Point, Max -40°F (-40°C)
mends Mobilfluid 424 hydraulic oil, which has an SAE vis-
cosity index of 152. Flash Point, Min. 330°F (166°C)
Viscosity
NOTE: When temperatures remain consistently below 20 degrees at 40° C 33cSt
F. (-7 degrees C.), JLG Industries recommends the use of
at 100° C 6.6 cSt
Mobil DTE13. Aside from JLG recommendations, it is not
advisable to mix oils of different brands or types, as they at 100° F 169 SUS
may not contain the same required additives or be of com- at 210° F 48 SUS
parable viscosities. cp at -20° F 6,200
Viscosity Index 140
.
Table 1-13. Mobilfluid 424 Specs
1-4 3121631
SECTION 1 - SPECIFICATIONS
ISO Viscosity Grade 32/46 Telescope Out 2500 psi (172 Bar)
Specific Gravity .922 Swing, Left & Right 1700 psi (117 Bar)
Pour Point, Max -25°F (-32°C) Steer 2500 psi (172 Bar)
Flash Point, Min. 428°F (220°C) Platform Level Up 2600 psi (179 Bar)
Operating Temp. 0 to 180°F (-17 to 162°C) Platform Level Down 1800 psi (124 Bar)
Weight 7.64 lb. per gal. Jib, Up & Down 1700 psi (117 Bar)
(0.9 kg per liter)
Viscosity 1.9 MAJOR COMPONENT WEIGHTS
at 40° C 37 cSt
at 100° C 8.4 cSt Table 1-19. Component Weights
Viscosity Index 213 Component Pounds Kilograms
NOTE: Must be stored above 32°F (14°C) Turntable (bare) 3700 1678
Counterweight (800S) 7000 3175
Table 1-17. Exxon Univis HVI 26 Specs Counterweight (860SJ) 8750 3969
Upright 1050 476
Specific Gravity 32.1
Tower 685 311
Pour Point -76°F (-60°C)
Fly Boom (SJ) 472 214
Flash Point 217°F (103°C)
Fly Boom (S) 490 222
Viscosity
Mid Boom (SJ) 750 340
at 40° C 25.8 cSt
Mid Boom (S) 740 336
at 100° C 9.3 cSt
Base Boom (SJ) 1400 635
Viscosity Index 376
Base Boom (S) 1410 640
NOTE: Mobil/Exxon recommends that this oil be checked on a
Boom Assembly 3337 1514
yearly basis for viscosity.
Telescope Cylinder (800S) 590 268
Telescope Cylinder (810SJ) 570 259
Telescope Cylinder (860SJ) 579 263
Slave Cylinder 73 33
Torque Hub (2WD) 218 99
Tire & Wheel (pneu) 269 122
Tire & Wheel (FF) 544 247
3121631 1-5
SECTION 1 - SPECIFICATIONS
1-6 3121631
SECTION 1 - SPECIFICATIONS
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type (Timken OK 40 pounds minimum).
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MILSpec MIL-L-2105.
HO Hydraulic Oil. Refer Section 1.7, Hydraulic Oil.
EO Engine (crankcase). Gas (5W30)- API SN, -Arctic ACEA AI/BI, A5/B5 - API SM, Lube Point(s) - Repack
SL, SJ, EC, CF, CD - ILSAC GF-4. Diesel (15W40, 5W30 Arctic) - API CJ-4. Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation.
3. Wheel Drive Hub
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-
MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
FREQUENCIES MUST BE INCREASED ACCORDINGLY.
3121631 1-7
SECTION 1 - SPECIFICATIONS
Interval - Change after first 50 hours and every 6 months Lube Point(s) - Fill Cap
or 300 hours thereafter or as indicated by Condition Capacity - Tank (to Full mark on sight gauge) S/N
Indicator. 0300182743 to 0300196954 & S/N B300001092 to
B300001096 - Approx. 40 gallons (151 liters)
5. Hydraulic Charge Filter
S/N 0300196955 to Present & S/N B300001097 to Pres-
ent - Approx. 21 gallons (79.5 liters)
System Capacity - 59 gallons (223 liters)
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.
7. Platform Filter
1-8 3121631
SECTION 1 - SPECIFICATIONS
3121631 1-9
SECTION 1 - SPECIFICATIONS
1-10 3121631
SECTION 1 - SPECIFICATIONS
11. Fuel/Water Separator - Deutz TD 2.9 L4 China III B. Air Filter (Deutz TD 2.9)
3121631 1-11
SECTION 1 - SPECIFICATIONS
4&3*"-/6.#&3
4&3*"-/6.#&345".1&%
1-"5&
0/'3".&
1-12 3121631
SECTION 1 - SPECIFICATIONS
Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
3121631 1-13
SECTION 1 - SPECIFICATIONS
To rqu e
Torqu e
Torq ue
Tor que
Torq ue
1-14 3121631
SECTION 1 - SPECIFICATIONS
Torq ue
Tor que
Torqu e
Torq ue
Cl amp L oa d
To rqu e
To rque
3121631 1-15
SECTION 1 - SPECIFICATIONS
To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
1-16 3121631
SECTION 1 - SPECIFICATIONS
To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue
3121631 1-17
SECTION 1 - SPECIFICATIONS
NOTES:
1-18 3121631
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form
and the Inspection and Preventive Maintenance Schedule for
MAINTENANCE items requiring inspection during the performance of these
inspections. Reference the appropriate areas of this manual for
General servicing and maintenance procedures.
This section provides the necessary information needed by Annual Machine Inspection
those personnel that are responsible to place the machine in
operation readiness and maintain its safe operating condition. The Annual Machine Inspection must be performed on an
For maximum service life and safe operation, ensure that all annual basis, no later than thirteen (13) months from the date
the necessary inspections and maintenance have been com- of the prior Annual Machine Inspection. JLG Industries recom-
pleted before placing the machine into service. With proper mends this task be performed by a Factory-Trained Service
care, maintenance, and inspections performed per JLG's rec- Technician. JLG Industries, Inc. recognizes a Factory-Trained
ommendations, and with any and all discrepancies corrected, Service Technician as a person who has successfully com-
this product will be fit for continued use. pleted the JLG Service Training School for the subject JLG
product model. Reference the machine Service and Mainte-
nance Manual and appropriate JLG inspection form for perfor-
Preparation, Inspection, and Maintenance mance of this inspection.
It is important to establish and conform to a comprehensive Reference the JLG Annual Machine Inspection Form and the
inspection and preventive maintenance program. The follow- Inspection and Preventive Maintenance Schedule for items
ing table outlines the periodic machine inspections and main- requiring inspection during the performance of this inspec-
tenance recommended by JLG Industries, Inc. Consult your tion. Reference the appropriate areas of this manual for servic-
national, regional, or local regulations for further requirements ing and maintenance procedures.
for aerial work platforms. The frequency of inspections and
maintenance must be increased as environment, severity and For the purpose of receiving safety-related bulletins, it is
frequency of usage requires. important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each Annual
Pre-Start Inspection Machine Inspection, notify JLG Industries, Inc. of the current
machine ownership.
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 Preventive Maintenance
each change of operator. Reference the Operator’s and Safety
In conjunction with the specified inspections, maintenance
Manual for completion procedures for the Pre-Start Inspec-
shall be performed by a qualified JLG equipment mechanic.
tion. The Operator and Safety Manual must be read in its JLG Industries, Inc. recognizes a qualified JLG equipment
entirety and understood prior to performing the Pre-Start
mechanic as a person who, by possession of a recognized
Inspection. degree, certificate, extensive knowledge, training, or experi-
ence, has successfully demonstrated the ability and profi-
Pre-Delivery Inspection and Frequent Inspection ciency to service, repair, and maintain the subject JLG product
model.
The Pre-Delivery Inspection and Frequent Inspection shall be
performed by a qualified JLG equipment mechanic. JLG Indus- Reference the Preventive Maintenance Schedule and the
tries, Inc. recognizes a qualified JLG equipment mechanic as a appropriate areas of this manual for servicing and mainte-
person who, by possession of a recognized degree, certificate, nance procedures. The frequency of service and maintenance
extensive knowledge, training, or experience, has successfully must be increased as environment, severity and frequency of
demonstrated the ability and proficiency to service, repair, and usage requires.
maintain the subject JLG product model.
3121631 2-1
SECTION 2 - GENERAL
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operation and Safety Manual
At each Operator change.
Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
rental delivery. and applicable JLG inspection form.
Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
purchased used.
Annual Machine Annually, no later than 13 months from the date of Owner, Dealer, or User Factory Trained Service Service and Maintenance Manual
Inspection the prior inspection. Technician and applicable JLG inspection form.
(Recommended)
Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance Maintenance Manual.
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are disconnected,
clear adjacent areas as well as the openings and fittings
themselves. As soon as a line or component is discon-
General nected, cap or cover all openings to prevent entry of for-
The following information is provided to assist you in the use eign matter.
and application of servicing and maintenance procedures
3. Clean and inspect all parts during servicing or mainte-
contained in this book.
nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
Safety and Workmanship sure all parts are clean before they are installed. New
parts should remain in their containers until they are
Your safety, and that of others, is the first consideration when
ready to be used.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without
the aid of a mechanical device. Do not allow heavy objects to
Components Removal and Installation
rest in an unstable position. When raising a portion of the 1. Use adjustable lifting devices, whenever possible, if
equipment, ensure that adequate support is provided. mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as near
Cleanliness perpendicular as possible to top of part being lifted.
1. The most important single item in preserving the long 2. Should it be necessary to remove a component on an
service life of a machine is to keep dirt and foreign mate- angle, keep in mind that the capacity of an eyebolt or
rials out of the vital components. Precautions have been similar bracket lessens, as the angle between the sup-
taken to safeguard against this. Shields, covers, seals, porting structure and the component becomes less
and filters are provided to keep air, fuel, and oil supplies than 90 degrees.
clean; however, these items must be maintained on a 3. If a part resists removal, check to see whether all nuts,
scheduled basis in order to function properly. bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.
2-2 3121631
SECTION 2 - GENERAL
2. Discard bearings if the races and balls (or rollers) are pit- Hydraulic Lines and Electrical Wiring
ted, scored, or burned.
Clearly mark or tag hydraulic lines and electrical wiring, as well
3. If bearing is found to be serviceable, apply a light coat of as their receptacles, when disconnecting or removing them
oil and wrap it in clean (waxed) paper. Do not unwrap from the unit. This will assure that they are correctly rein-
reusable or new bearings until they are ready to install. stalled.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer or Hydraulic System
bore, apply pressure to the outer race. If the bearing is to 1. Keep the system clean. If evidence of metal or rubber
be installed on a shaft, apply pressure to the inner race. particles are found in the hydraulic system, drain and
flush the entire system.
Gaskets
2. Disassemble and reassemble parts on clean work sur-
Check that holes in gaskets align with openings in the mating face. Clean all metal parts with non-flammable cleaning
parts. If it becomes necessary to hand-fabricate a gasket, use solvent. Lubricate components, as required, to aid
gasket material or stock of equivalent material and thickness. assembly.
Be sure to cut holes in the right location, as blank gaskets can
cause serious system damage.
3121631 2-3
SECTION 2 - GENERAL
Lubrication and Servicing 2. Use every precaution to keep the hydraulic oil clean. If
the oil must be poured from the original container into
Components and assemblies requiring lubrication and servic- another, be sure to clean all possible contaminants from
ing are shown in the Lubrication Chart in Section 1. the service container. Always clean the mesh element of
the filter and replace the cartridge any time the system
2.3 LUBRICATION AND INFORMATION oil is changed.
3. While the unit is shut down, a good preventive mainte-
Hydraulic System nance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a
1. The primary enemy of a hydraulic system is contamina- functional check of each system, before placing the
tion. Contaminants enter the system by various means, machine back in service.
e.g., using inadequate hydraulic oil, allowing moisture,
grease, filings, sealing components, sand, etc., to enter Lubrication Specifications
when performing maintenance, or by permitting the
Specified lubricants, as recommended by the component
pump to cavitate due to insufficient system warm-up or
manufacturers, are always the best choice, however, multi-pur-
leaks in the pump supply (suction) lines.
pose greases usually have the qualities which meet a variety of
2. The design and manufacturing tolerances of the compo- single purpose grease requirements. Should any question
nent working parts are very close, therefore, even the arise, regarding the use of greases in maintenance stock, con-
smallest amount of dirt or foreign matter entering a sys- sult your local supplier for evaluation. Refer to Section 1 for an
tem can cause wear or damage to the components and explanation of the lubricant key designations appearing in the
generally results in faulty operation. Every precaution Lubrication Chart.
must be taken 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 Lubrication Chart in
Section 1. Always examine filters for evidence of metal
particles.
2-4 3121631
SECTION 2 - GENERAL
3121631 2-5
SECTION 2 - GENERAL
2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT
GUIDELINES NOTE: This instruction applies to repairs, or modifications to the
Filament wound bearings. machine and to welding performed from the machine on
an external structure, or component.
1. Pinned joints should be disassembled and inspected if
the following occurs:
Do the Following When Welding on JLG Equipment
a. Excessive sloppiness in joints.
• Disconnect the battery.
b. Noise originating from the joint during operation.
• Disconnect the moment pin connection (where fitted).
2. Filament wound bearings should be replaced if any of
the following is observed: • Ground only to structure being welded.
a. Frayed or separated fibers on the liner surface. Do NOT Do the Following When Welding on JLG
b. Cracked or damaged liner backing. Equipment
c. Bearings that have moved or spun in their housing.
• Ground on frame and weld on any other area than the
d. Debris embedded in liner surface. chassis.
3. Pins should be replaced if any of the following is • Ground on turntable and weld on any other area than the
observed (pin should be properly cleaned prior to turntable.
inspection):
• Ground on the platform/support and weld on any other
a. Detectable wear in the bearing area. area than the platform/support.
b. Flaking, pealing, scoring, or scratches on the pin sur- • Ground on a specific boom section and weld on any other
face. area than that specific boom section.
c. Rusting of the pin in the bearing area.
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
4. Re-assembly of pinned joints using filament wound valves, electrical wiring, or hoses to be between the
bearings. grounding position and the welded area.
a. Housing should be blown out to remove all dirt and
debris. Bearings and bearing housings must be free
of all contamination. FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
b. Bearing / pins should be cleaned with a solvent to PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
remove all grease and oil. Filament wound bearing RING, BOOM WIRE ROPES ETC.).
are a dry joint and should not be lubricated unless
otherwise instructed (i.e. sheave pins).
c. Pins should be inspected to ensure it is free of burrs,
nicks and scratches which would damage the bear-
ing during installation and operation.
2-6 3121631
SECTION 2 - GENERAL
NOTE: Refer the Operation and Safety Manual for completion procedures for the Pre-Start Inspection.
Inspections
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
Oscillating Axle/Lockout Cylinder Systems 1, 2, 4, 5
Extendable Axle Systems 3 3
Steer Components 1, 2
Spindle Thrust Bearing/Washers 1, 2
Drive Hubs 1, 4 1, 4
3121631 2-7
SECTION 2 - GENERAL
Inspections
2-8 3121631
SECTION 2 - GENERAL
Inspections
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
3121631 2-9
SECTION 2 - GENERAL
-40
4150548 E
2-10 3121631
SECTION 2 - GENERAL
4150548 E
3121631 2-11
SECTION 2 - GENERAL
4150548 E
2-12 3121631
SECTION 3 - CHASSIS & TURNTABLE
• any tears or rips (ragged edges) in the cord plies Tighten the lug nuts to the proper torque to prevent wheels
which exceeds 1 in. (2.5 cm) in any direction. from coming loose. Use a torque wrench to tighten the fasten-
• any punctures which exceed 1 in. in diameter. ers. If you do not have a torque wrench, tighten the fasteners
with a lug wrench, then immediately have a service garage or
• any damage to the bead area cords of the tire. dealer tighten the lug nuts to the proper torque. Over-tighten-
ing will result in breaking the studs or permanently deforming
If a tire is damaged but is within the above noted criteria, the
the mounting stud holes in the wheels. The proper procedure
tire must be inspected on a daily basis to ensure the damage
for attaching wheels is as follows:
has not propagated beyond the allowable criteria.
1. Start all nuts by hand to prevent cross threading. DO
Tire Replacement NOT use a lubricant on threads or nuts.
3121631 3-1
SECTION 3 - CHASSIS & TURNTABLE
TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
70 ft. lbs. 170 ft. lbs. 300 ft. lbs.
(95 Nm) (225 Nm) (405 Nm)
3-2 3121631
SECTION 3 - CHASSIS & TURNTABLE
28
28
19
26
27 20 18
23
22
17
30 24
19
25 2
OSCILLATING AXLE 8
21
6 13
12 5
16 7
11
10
1 14 4
5
15
40 9 FIXED AXLE
3
36
38
41 29 34
39 43
31 37 42
35
33 31
35
34 39
40
44 45
41
42
43
32 1001151037-C
1001154584-D
1001151034-F
1001231147-A
1001230783-A
MAE33370
Figure 3-1. Axle and Steering Installation without Tow Package- Sheet 1 of 2
3121631 3-3
SECTION 3 - CHASSIS & TURNTABLE
Figure 3-2. Axle and Steering Installation without Tow Package- Sheet 2 of 2
3-4 3121631
SECTION 3 - CHASSIS & TURNTABLE
14
4 14
13
12
96 3
8
2
10
16
4
11
7
1
26 27
22
24
30 41 18
25 29
17 23 28
17 21
34 26
19
21 31 17
17 35 37 25
21 36 21 20
36 27 33
5
28
39 30
32 29
38
18
1001155194-D
1001155192-E
1001232540-A
1001232539-A
MAE33400
Figure 3-3. Axle and Steering Installation with Tow Package- Sheet 1 of 2
3121631 3-5
SECTION 3 - CHASSIS & TURNTABLE
Figure 3-4. Axle and Steering Installation with Tow Package- Sheet 2 of 2
3-6 3121631
SECTION 3 - CHASSIS & TURNTABLE
3.3 OSCILLATING AXLE LOCKOUT TEST 15. If lockout cylinders do not function properly, have quali-
fied personnel correct the malfunction prior to any fur-
ther operation.
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- 3.4 FREE WHEELING OPTION
TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
SUSPECTED. To Disengage Drive Motors and Brakes (Free Wheel)
NOTE: Ensure boom is fully retracted, lowered and centered
for Emergency Towing
between drive wheels prior to beginning lockout cylinder 1. Chock wheels securely if not on flat level surface.
test.
2. Disconnect both drive hubs by reversing the disconnect
1. Place a 6 in. (15.2 cm) high block with ascension ramp in caps in the center of the hubs.
front of left front wheel. 3. If equipped, move steer/tow selector valve to float (tow)
2. From platform control console, start engine. position by pulling control knob out.
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 con-
trol lever to REVERSE and drive machine off of block and
ramp.
7. Have an assistant check to see that left front wheel or To Engage Drive Motors and Brakes (Normal
right rear wheel remains elevated in position off of
ground. Operation)
8. Carefully activate SWING control lever and return boom 1. If equipped, move steer/tow valve to steer position by
to stowed position (centered between drive wheels). pushing valve knob in.
When boom reaches center, stowed position, lockout
cylinders should release and allow wheel to rest on 2. Connect both drive hubs by inverting disconnect cap in
ground, it may be necessary activate DRIVE to release center of hub.
cylinders. 3. Remove chocks from wheels as required.
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 con-
trol 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.
3121631 3-7
SECTION 3 - CHASSIS & TURNTABLE
3.5 WHEEL DRIVE ASSEMBLY (2WD) plug all openings to ensure no dirt enters the hydraulic
system.
Removal NOTE: The torque hub and drive motor assembly weighs approxi-
mately 275 lbs. (125 kg).
NOTE: The drive motor can be removed through the axle flange as
4. Use a supporting device capable of handling the weight
part of the wheel drive assembly or they can be removed
of the torque hub drive brake and drive motor and
separately through the bottom of the frame while leaving
unbolt the torque hub from the frame. Remove the
the torque hub bolted to the axle.
entire assembly from the machine.
1. Use a jack to lift the frame enough so the tire and wheel 5. Remove the nuts and washers that secure the drive
assembly is off of the ground. Place blocking strong motor to the torque hub and drive brake and remove
enough to support the weight of the machine under the the drive motor. Remove and discard the o-ring
frame and remove the jack. between the drive motor and drive brake.
NOTE: The pneumatic tire & wheel assembly weighs approxi- 6. Remove the drive brake from the torque hub. Remove
mately 269 lbs. (122 kg). The foam-filled tire & wheel and discard the o-ring between the drive brake and
assembly weighs approximately 544 lbs. (247.25 kg). torque hub.
7. If necessary, remove the studs from the torque hub.
2. Remove the tire and wheel assembly.
3-8 3121631
SECTION 3 - CHASSIS & TURNTABLE
1. Use a jack to lift the frame enough so the tire and wheel
assembly is off of the ground. Place blocking strong
enough to support the weight of the machine under the
frame and remove the jack.
NOTE: The torque hub and drive motor assembly weighs approxi-
mately 270 lbs. (122 kg).
3121631 3-9
SECTION 3 - CHASSIS & TURNTABLE
3-10 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-11
SECTION 3 - CHASSIS & TURNTABLE
Disassembly 2. Remove the magnetic pipe plug (6H) from cover plate
(6A) and drain the oil out of the gearbox.
MAIN COVER PLATE DISASSEMBLY NOTE: Record the condition and volume of the oil.
NOTE: Refer to Figure 3-7.,Figure 3-8. & Figure 3-9. 3. Remove eight bolts (17) followed by four special bolts
(18) from cover subassembly.
1. Perform roll check and leak check prior to disassembling 4. Lift the cover subassembly off of the unit.
the unit.
5. Lift ring gear (4) off the unit.
6A
18
17
6H
4. Ring Gear
6A. Cover Plate
6H. Pipe Plug
17. Hex Bolt
18. Special Bolt
3-12 3121631
SECTION 3 - CHASSIS & TURNTABLE
6. If applicable remove spacer (14) from the input shaft 11. Remove internal gear (2) from the unit.
(11).
12. Remove input shaft subassembly from the hub spindle
7. Remove the sun gear (13). subassembly.
8. Lift out the Carrier subassembly from the unit. 13. Take out input coupling subassembly of the hub spindle
subassembly.
9. Remove the input spacer (12) from the unit.
10. Remove two thrust spacers (15) and thrust bearing (16)
from the internal gear (2).
INPUT COUPLING
SUBASSEMBLY
HUB-SPINDLE
SUBASSEMBLY
11
2
15
16
15
12
CARRIER
SUBASSEMBLY
13
2. Internal Gear
11. Input Shaft
12. Input Spacer
13. Sun Gear
15. Thrust Washer
16. Thrust Bearing
Figure 3-8. Carrier Subassembly Removal
NOTE: Figure 3-7. refers to 30, 35, 50, 64 & 73: 1 Ratios.
3121631 3-13
SECTION 3 - CHASSIS & TURNTABLE
19 HUB-SPINDLE
SUBASSEMBLY
11
2
16
15
15 CARRIER
12 SUBASSEMBLY
13
14
2. Internal Gear
11. Input Shaft
12. Input Spacer
13. Sun Gear
14. Spacer
15. Thrust Washer
16. Thrust Bearing
19. Coupling
3-14 3121631
SECTION 3 - CHASSIS & TURNTABLE
CARRIER DISASSEMBLY 4. Remove first set of needle bearings (3C) from the inside
of the planet gear (3F).
NOTE: Refer to Figure 3-10.
1. Drive planet shaft (3E) out of the carrier pin holes, forc- 5. Remove thrust washer (3D) from planet gear (3F).
ing the roll pin (3G) to sheer off.
6. Remove second set of needle bearings (3C) from the
2. Hold on to the planet gear (3F) and push the planet inside of the planet gear (3F).
shaft (3E) out of the carrier (3A) the thrust washers (3B) &
(3h) will slide off the shaft as it is removed. 7. Repeat steps from 1 to 6 for the remaining two planet
gears (3F).
3. Using a hammer and punch, drive the roll pin (3G) out of
the planet shaft (3E) and carrier (3A).
3B 3H
3C 3D 3C
3F
3H 3B
3G
3A
3E
3A. Carrier
3B. Washer
3C. Needle Bearing
3D. Thrust Washer
3E. Planet Shaft
3F. Cluster Gear
3G. Roll Pin
3H. Ball Indent Washer
Figure 3-10. Carrier Disassembly
3121631 3-15
SECTION 3 - CHASSIS & TURNTABLE
COUPLING DISASSEMBLY 1. If necessary, remove Internal retaining ring (20) from the
groove of coupling (19).
NOTE: Refer to Figure 3-11.
2. If necessary, remove external retaining ring (21) from
the groove of coupling (19).
21
19
20
19. Coupling
20. Internal Retaining Ring
21. External Retaining Ring
3-16 3121631
SECTION 3 - CHASSIS & TURNTABLE
11
10
3121631 3-17
SECTION 3 - CHASSIS & TURNTABLE
COVER DISASSEMBLY 5. Pull the disengage rod (6E) out of the cover cap (6B).
NOTE: Refer to Figure 3-13. 6. Remove O-ring (6F) from the cover cap (6B) and discard
it.
1. Remove the O-ring (5) from groove in cover (6A) and dis-
card O-ring (5). 7. Remove two hex bolts (6C) from cover cap (6B), if
required.
2. Remove two thrust washers (15) and thrust bearing (16)
from cover (6A). 8. Remove cover cap (6B) from cover plate (6A).
3. Remove two hex bolts (6C) from disengage cap (6D), if 9. Remove O-ring (6G) and discard it.
required.
10. Remove pipe plug (6H) from the cover (6A).
4. Remove the disengage cap (6D) from the cover cap (6B).
5
15
16
15
6A
6H
6G
6B
6C
6F
6E
6D
6C
3-18 3121631
SECTION 3 - CHASSIS & TURNTABLE
HOUSING-SPINDLE DISASSEMBLY 2. Remove thrust washer (7) from the spindle (1A).
NOTE: Refer to Figure 3-14. 3. Remove spring (8) from the spindle (1A).
4. Remove thrust washer (7) from the spindle (1A).
5. Set the unit on a bench so that the spindle (1A) flange is
SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. down.
1A
1Q
1B
1D
1C
1N
1J
1G
1E
1F
1H
1I
5
7
8
7
9
3121631 3-19
SECTION 3 - CHASSIS & TURNTABLE
6. Remove the O-ring (5) from the housing (1G) and 8. Remove thrust washer (1H) from the spindle (1A).
discard it.
9. Remove two pipe plugs (1J) from the housing (1G).
10. Turn the unit over and carefully place the unit on a
SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. support base until the spindle (1A) post rests on it.
Ensure there is enough gap to lower the housing (1G)
7. Remove retaining ring (1I) from the groove of spindle down.
(1A).
11. Use a dead blow hammer on the housing (1G) flange to 16. Using a hammer and punch drive the inboard bearing
drive the inboard bearing cone (1F) off of the spindle cup (1E) out of the housing (1G). Be careful not to
(1A). damage the counterbore in the housing.
12. Lift the spindle (1A) out of the housing (1G). 17. Turn the housing (1G) over and drive the outboard
bearing cup (1C) out of the housing (1G). Be careful not
13. If required, remove boot seal (1Q) from the housing (1G).
to damage the counterbore in the housing.
14. Remove lip seal (1B) from the housing (1G).
15. Remove the bearing cone (1D) from the bearing cup
(1C).
3-20 3121631
SECTION 3 - CHASSIS & TURNTABLE
Assembly 4. Place cover cap (6B) into cover plate (6A) with larger
flange hole on cover cap (6B) located over pipe plug
COVER SUBASSEMBLY (6H) fasten cover cap (6B) with two bolts (6C) located
180 degrees apart. Torque bolts to 70-80 in. lbs. (95- 108
NOTE: Refer to Figure 3-13. Nm).
1. Screw pipe plug (6H) into cover plate (6A) using thread 5. Place disengage cap (6D) on cover cap (6B) with nipple
sealant and hand hexagonal wrench. facing out. Secure with two bolts (6C) located 180
degrees apart. Torque bolts (6C) to 70-80 in. lbs. (95-108
2. Apply grease and position o-ring (6G) over cover cap Nm).
(6B) until it rests against the flange.
6. Turn cover plate (6A) over and push disconnect rod (6E)
3. Blow out internal groove of cover cap (6B) with air hose. into cover cap (6B), until disconnect rod (6E) bottoms
Place greased o-ring (6F) into internal groove of cover out on the disengage cap (6D).
cap (6B).
7. Grease and install o-ring (5) into groove on the cover
NOTE: The disconnect rod (6E) may be used to push the greased o- plate (6A).
ring (6F) into position in the o-ring groove of the cover cap
(6B). 8. Grease and install thrust washers (15) and thrust bearing
(16) into cover plate (6A).
3121631 3-21
SECTION 3 - CHASSIS & TURNTABLE
CARRIER SUBASSEMBLY 6. Start planet shaft (3E), with end opposite roll pin hole
first, through the planet shaft hole in carrier (3A),
NOTE: Refer to Figure 3-10. making sure that the roll pin hole with the large chamfer
1. Apply a liberal coat of grease to the bore of cluster gear in the planet shaft is straight up.
(3F). This will enable the needle rollers (3C) to be held in 7. Using ample grease to hold it in position, slide one
place during assembly. thrust washer (3B) over planet shaft (3E) with tang
2. Install first row of 14 needle rollers (3C) into the bore of resting in the cast slot of carrier (3A).
cluster gear (3F). 8. With large end of cluster gear (3F) facing the roll pin
hole in the carrier (3A), place cluster gear (3F) into
NOTE: The last roller installed must be installed end wise. That is
position in carrier (3A) and push planet shaft (3E)
the end of the last roller must be placed in between the
through the cluster gear (3F) without going all the way
ends of the two rollers that form the space and then slid
through.
parallel to the other rollers into place.
9. Slide the second thrust washer (3B) between the cluster
3. Place one spacer (3D) on top of the needle rollers (3C)
gear (3F) and the carrier (3A) with the tang of washer
inside the planet gear (3F).
located in the cast slot of carrier (3A). Finish sliding
4. Install second row of 14 needle rollers (3C) into the bore planet shaft (3E) through the thrust washers (3H) & (3B)
of cluster gear (3F) against spacer (3D). Grease and and into carrier (3A).
install ball indent washers (3H) onto the counterbores of
10. Position the chamfered side on the planet shaft (3E) roll
either sides of cluster gear (3F) with indents away from
pin hole so that it is in line with the hole in the carrier
the cluster gears.
(3A) using a 1/8 in. (3.17 mm) diameter punch.
5. Place carrier (3A) into tool fixture so that one of the roll
11. After using a 3/16 in. (4.76 mm) punch to align the two
pin holes is straight up.
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 ¼ 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).
3-22 3121631
SECTION 3 - CHASSIS & TURNTABLE
HOUSING SPINDLE SUBASSEMBLY 10. Place snap ring assembly tool T205660 onto spindle
(1A).
NOTE: Refer to Figure 3-14.
11. Place bearing cone (1F) onto the tapered portion of
1. If required, using stud pressing fixture press studs (1N) snap ring assembly tool T205660.
into the flange holes of the hub (1G), be sure stud heads
are tight to the hub flange face. 12. Place spacer (1H) and retaining ring (1I) onto the top of
the bearing cone (1F).
2. Place hub (1G) on table such that long hub end is up.
13. Slowly press bearing cone (1F) spacer (1H) and retaining
3. Press bearing cup (1E) using T148905 with the large ring (1I) all at once using a bearing pressing tool,
diameter side up into cover end of hub (1G). T137970, until the retaining ring (1I) falls into the
4. Turn hub (1G) over and press bearing cup (1C) into hub retaining ring groove on the spindle (1A).
(1G) using T148905 with small diameter side up. 14. Install pipe plug (1J) into hub (1G).
NOTE: Apply generous amount of lubricating oil on all bearings at 15. Grease and install o-ring (5) into hub (1G).
the time of installation.
16. Grease and install thrust washer (7) into spindle (1A).
5. Place bearing cone (1D) on bearing cup (1C).
17. Install spring (8) into spindle (1A) until it bottoms on
6. Press bearing seal (1B) with the open face down into the thrust washer (7).
hub (1G), be sure seal is flush with the hub face.
18. Grease and place second thrust washer (7) on spring (8).
NOTE: Generally Seals should not be reused.
19. Using retaining ring pliers, push retaining ring (9)
7. If the unit requires seal boot (1Q) place on hub (1G) with against thrust washer (7) until retaining ring snaps into
flange end facing up. Coat the inside surface of the seal - place in the spindle (1A) groove.
boot - flange with liberal amount of grease.
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.
3121631 3-23
SECTION 3 - CHASSIS & TURNTABLE
COUPLING SUBASSEMBLY 3. Install input shaft subassembly with the retaining ring
end down into the spindle counterbore.
NOTE: Refer to Figure 3-11.
4. Slide thrust spacer (12) over the input shaft (11) make
sure the large end is against the spindle (1A).
SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. NOTE: Refer to Figure 3-9. with 18, 24, 31 & 43: 1 Ratios.
NOTE: Be sure that the punch marks remain in their correct loca-
SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. tion during ring gear (4) installation.
1. If necessary, install retaining ring (10) onto the groove of 7. Place Thrust washer (15), thrust bearing (16) and thrust
input shaft (11). washer (15), in order on the pilot diameter on internal
gear (2).
CARRIER SUBASSEMBLY
NOTE: For 30, 35, 50, 54 & 73:1 ratios Skip step 8.
NOTE: Refer to Figure 3-7., Figure 3-8. & Figure 3-9.
1. Place hub-spindle subassembly on the table with 8. Install input gear (13) with counterbore down in mesh
spindle flange side down. with the input shaft (11) splines counterbore down.
2. Set the internal gear (2) with the spline down, so that 9. With small end of cluster gear (3F) down and while
the spline of the spindle (1A) is in mesh with the internal holding ring gear (4) in mesh with carrier sub assembly,
spline of the internal gear (2). place assembly into internal gear (2).
CARRIER
SUBASSEMBLY
TIMING MARK TIMING MARK
TIMING MARK
3-24 3121631
SECTION 3 - CHASSIS & TURNTABLE
10. Once in place rotate the ring gear (4) until hole marked 13. Install cover subassembly onto the ring gear (4) being
“X” is aligned with one of shoulder bolt holes in hub sure that the pipe plugs in the hub (1G) and cover (6A)
(1G). are in time with each other. Be sure the thrust washers
(15) & (16) remain on the cover (6).
NOTE: If the gears do not mesh easily or carrier sub assembly does
not rotate freely, then remove the carrier and Ring gear 14. Install four shoulder bolts (18) into the four marked
and check timing (Step 5). counterbore holes in the hub (1G) start shoulder bolts
(18) by hand for the length of at least two threads or two
NOTE: Check each cluster gear (3F) to make sure that the timing full turns before running down and torque to 45-47 ft.
punch-marks is in line with a tooth on the large end & a lbs. (61- 64 Nm).
tooth on the small end of the cluster gear. THESE TWO
TEETH MUST BE IN LINE WITH THE PUNCH-MARKS ON 15. Place the remaining eight bolts (17) into the remaining
EVERY CLUSTER GEAR (3F). holes and torque to 45-47 ft. lbs. (61- 64 Nm).
NOTE: For 30, 35, 50, 54 & 73:1 ratios Skip step 11. 16. Turn the assembly over and insert Input Coupling Sub-
assembly into the spindle (1A) counterbore.
11. Install spacer (14) onto the input shaft (11) against the
input gear (13). 17. The unit should now be leak and roll checked as per
“The Roll Test” and “The Leak Test”. The motor can be
NOTE: Refer to Figure 3-9. with 18, 24, 31 & 43: 1 Ratios reinstalled into the gearbox for the leak check to seal it
off and the unit pressurized through a pipe plug hole on
NOTE: For 18,24, 37 & 43:1 ratios Skip step 12. the cover.
12. Install input gear (13) with counterbore down to mesh
with the teeth of cluster gear (3F).
3121631 3-25
SECTION 3 - CHASSIS & TURNTABLE
If a press is available, the cylinder housing (8) can be Apply complete coverage of Loctite 641 to outside
restrained while removing the six capscrews and diameter of bearing (10) and assemble fully In housing
washers (13 & 14). (2), retaining with internal retaining ring (11). Remove
excess adhesive with a clean cloth.
The brake assembly can now be fully dismantled and
the parts examined. Press shaft (1) through bearing (10), ensuring bearing
inner ring Is adequately supported.
2. Remove cylinder housing (8) and piston (9) subassembly
and dismantle if required, removing O-ring seals (15 & 3. Assemble correct quantity of springs (22 & 23) in orien-
17) and backing rings (16 & 18) as necessary. tation required.
3. Remove gasket (7) from housing (2). 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or
4. Remove friction plates (3 & 6) and pressure plate (4). equivalent) silicon grease and assemble together with
backing rings (16 & 18) to piston (9). To ensure correct
5. Remove two dowel pins (19).
brake operation. It is important that the backing rings
6. Remove springs (22 & 23). are assembled opposite to the pressurized side of pis-
7. Should it be necessary to replace ball bearing (10) or ton.
shaft seal (12), reverse remainder of brake subassembly, 5. Correctly orientate piston (9) aligning spaces with the
supporting on face C of housing (2). two dowel pin holes and, assemble into cylinder hous-
8. Remove internal retaining ring (11). ing (8) taking care not to damage seals and carefully lay
9. Using arbor press or similar to break Loctite seal, remove aside.
brake shaft (1) from housing (2) and lay aside. 6. Locate 2-off pins (19) in housing (2) followed by pressure
10. Reverse housing (2) and press out ball bearing (10). plate (4) and friction plates i.e. an inner (3) followed by
Shaft seal (12) can also be removed if necessary. an outer (6) in correct sequence.
7. Position gasket (7) in correct orientation.
Inspection
8. Align two holes in cylinder with dowel pins (19) and
1. Inspect friction plates (3 & 6) and friction surface on
assemble piston & cylinder sub-assembly to remainder
pressure plate (4) for wear or damage.
of brake securing with 6 capscrews and washers (13 &
2. Examine friction plates (3) and brake shaft (1) for wear or 14). Torque to 55 ft.Ibs. (75 Nm).
damage to the splines.
NOTE: The use of a suitable press (hydraulic or arbor) pressing
3. Examine input and output splines of brake shaft (1) for down on cylinder end face B will ease assembly of the cap-
wear or damage. screws (13).
4. Examine compression springs (22 & 23) for damage or
fatigue.
5. Check ball bearing (10) for axial float or wear.
6. Examine O-ring seals (15 & 17) and backing rings (16 &
18) for damage.
3-26 3121631
SECTION 3 - CHASSIS & TURNTABLE
13
14
20
7
17
18
9
15
16
3 21
4
19
22
23
2
12
10
11
1. Shaft 6. Outer Plate 11. Retaining Ring 16. Backup Ring 21. Plug
2. Housing 7. Gasket 12. Shaft Seal 17. O-ring 22. Spring (Natural)
3. Friction Plate 8. Cylinder 13. Capscrew 18. Backup Ring 23. Spring (Blue)
4. Pressure Plate 9. Piston 14. Lockwasher 19. Dowel Pin
5. Gasket 10. Ball Bearing 15. O-ring 20. Plug
3121631 3-27
SECTION 3 - CHASSIS & TURNTABLE
Bias spring
Servo piston
Minimum
Angle Swashplate
Stop
1. Snap Ring
Output 2. Support Washer
Cylinder Shaft 3. Shaft Seal
Block Figure 3-20. Removing the Shaft Seal
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.
3-28 3121631
SECTION 3 - CHASSIS & TURNTABLE
1. Using a 11/16 in. internal hex wrench remove plug (1) INSTALLATION
and (2).
1. Install orifice poppet (13).
6 2. Install shift spool (12).
9
3. Install spring retaining washers onto springs (10 and 11).
11
2
4. Carefully install centering springs (7, 8 and 9).
11/16 in
27 ft.lbs. 5. Install new O-rings (6, 4 and 5).
(37 Nm)
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).
10 12
8
4
1 13
11/16 in
27 ft.lbs.
(37 Nm) 7
5/8 in
5 3 20 ft.lbs.
(27 Nm)
3121631 3-29
SECTION 3 - CHASSIS & TURNTABLE
Troubleshooting
Check for air in the system. Air trapped within the system lines, or the motor itself, could result in cavi- Ensure that all of the system lines and components are purged of air.
tation that would cause system noise.
Inspect the output shaft cou- A loose or incorrect shaft coupling will produce vibrations that could result Ensure that the correct coupling is used and that it fits properly onto the
plings. in system noise. shaft.
Inspect the output shaft align- Misaligned shafts create excessive frictional vibration that could result in Ensure that the shafts are properly aligned.
ment. system noise.
Hydraulic oil viscosity above limits. Viscosity above acceptable limits will result in cavitation Replace hydraulic oil with appropriate fluid for operating conditions.
that would lead to system noise.
Check the system relief valves. If a system relief valve becomes unseated for an extended period of time or Repair or replace any malfunctioning relief valves as applicable and verify
fails for any other reason, the system could become overheated. that the loads on the machine are not excessive.
Check that the correct supply and Supply and drain orifices determine the shift rate of the motor. The smaller Ensure that the proper control orifices are installed in the motor and verify
drain orifices are properly installed the orifice, the longer the time it takes to shift the motor. Obstruction will that they are not obstructed. Clean or replace as necessary.
and are not obstructed. also increase shift times.
3-30 3121631
SECTION 3 - CHASSIS & TURNTABLE
Disassembly
NOTE: Removal of the end cap voids warranty. 17
19
During assembly, coat all moving parts with a film of clean
hydraulic oil. This assures that these parts will be lubricated
during start-up.
15
Replace all O-Rings and gaskets.
6 21
9
5 11
2
7
13 18
3
10 12
16
8
4 16
1
20
3121631 3-31
SECTION 3 - CHASSIS & TURNTABLE
25
22
27
30
23 29
29
26
24
28
22. Screw
23. End Cap 25. Valve Plate
24. O-ring 26. End Cap
27. O-ring
Figure 3-24. End Cap 28. O-ring
29. Angle Stop
13. Using an 8 mm internal hex wrench, remove the end 30. Servo Spring
capscrews (22).
Figure 3-25. Valve Plate & Rear Shaft Bearing
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. TAKE CARE NOT TO SCRATCH THE SURFACE OF THE VALVE PLATE.
Press down on the portion of the end cap covering the
servo piston and hold the end cap level while removing.
15. Remove the valve plate (25) and timing pin (26) from the
end cap.
17. Remove the rear shaft bearing (29) from the end cap
with a bearing puller.
3-32 3121631
SECTION 3 - CHASSIS & TURNTABLE
18. Remove minimum angle stop (29) and servo spring (30) 20. Turn the housing over and remove the snap ring (32)
from the housing. retaining the shaft seal and support washer. Remove the
support washer (33) and carefully pry out the shaft seal
(34). Discard the seal.
36
35
31. Cylinder Kit Assembly 37
19. Turn the housing on its side and remove the cylinder kit
assembly (31). Set the assembly aside, being careful not
to scratch the running surface.
NOTE: Grooves on the surface of the cylinder kit identify its dis-
placement:
35. Inner Snap Ring
Table 3-5. Displacement Identifiers 36. Snap Ring
37. Bearing
# of Grooves Frame L Frame K 38. Shaft
1 25 38 Figure 3-28. Shaft & Front Bearing
2 30 45
3 35 -- 21. Remove the inner snap ring (35) and the shaft / bearing
assembly.
22. Remove the snap-ring (36) retaining the shaft front
bearing. Pull the bearing (37) off of the shaft (38).
32
33
34
3121631 3-33
SECTION 3 - CHASSIS & TURNTABLE
Lift here
44
39
45
47
40
48
43
42
49
41
46
53
52
39. Swashplate 50
40. Servo Piston
41. Piston Seal 51
42. O-ring
43. Journal Bearings
27. Remove the ball guide (47), hold-down pins (48) and
retaining ring (49) from the cylinder block.
3-34 3121631
SECTION 3 - CHASSIS & TURNTABLE
SLIPPERS
Inspect the running surface of the slippers. Replace any piston
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES assemblies with scored or excessively rounded slipper edges.
FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO Measure the slipper foot thickness. Replace any piston assem-
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS blies with excessively worn slippers. Check the slipper axial
SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. end-play. Replace any piston assemblies with excessive end-
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED. play.
28. Turn the block over. Using a press, apply pressure on the Minimum slipper foot thickness and maximum axial end-play
are given in the table below.
block spring washer (50) to compress the block spring.
Compress the spring enough to safely remove the spiral
Table 3-6. Slipper Foot Thickness & End Play
retaining ring (51). While maintaining pressure, unwind
the spiral retaining ring (51). Carefully release the pres- L Frame K Frame
sure and remove the outer block spring washer (50), Measurement
mm (in.) mm (in.)
block spring (52) and inner block spring washer (53)
Slipper Foot Thickness 2.71 4.07
from the cylinder block.
(0.11) (0.16)
Inspection Piston/Slipper End Play 0.15
(0.006)
After disassembly, wash all parts (including the end-cap and
housing) thoroughly with clean solvent and allow to air dry.
Blow out oil passages in the housing and end cap with com- CYLINDER BLOCK
pressed air. Conduct inspection in a clean area and keep all Measure the cylinder block height. Replace blocks worn
parts free from contamination. Clean and dry parts again after beyond the minimum height specification. Inspect the run-
any rework or resurfacing. ning surface of the cylinder block. Replace or resurface worn
or scratched blocks. Blocks may be resurfaced to the specifica-
PISTON tions shown in the drawing, provided resurfacing will not
Inspect the pistons for damage and discoloration. Discolored reduce the block height below the minimum specification.
pistons may indicate excessive heat; do not reuse. Table 3-7, Cylinder Block Measurements.
Minimum Slipper
slipper fo ot
thickness
3121631 3-35
SECTION 3 - CHASSIS & TURNTABLE
Measurement L25 mm (in.) L30 mm (in.) L35 mm (in.) K38 mm (in.) K45 mm (in.)
Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
Cylinder Block Surface Flatness 0.002 0.002 0.002 0.002 0.002
(7.9) (0.0000079) (0.0000079) (0.0000079) (0.0000079)
0.0025 mm
[0.0001 in]
VALVE PLATE
The condition of the valve plate is critical to the efficiency of 25.8 mm
LV [1.015 in]
the motor. Inspect the valve plate surfaces carefully for exces-
sive wear, grooves, or scratches. Replace or resurface grooved KV 24.6 mm
[0.969 in]
or scratched valve plates. Measure the valve plate thickness Thickness equality
side to side:
and replace if worn beyond the minimum specification. Valve 0.05 mm [0.002 in]
plates may be resurfaced to the specifications shown in the
drawing, provided resurfacing will not reduce the thickness
below the minimum specification.
3.83 mm [0.151 in] min.
0.025 mm
[0.001 in]
3-36 3121631
SECTION 3 - CHASSIS & TURNTABLE
2
3
SHAFT
Inspect the motor shaft. Look for damage or excessive wear on
the output and block splines. Inspect the bearing surfaces and
sealing surface. Replace shafts with damaged or excessively
worn splines, bearing surfaces, or sealing surfaces.
1
SERVO PISTON AND MINIMUM ANGLE STOP
Inspect the minimum angle stop, servo piston head and servo
piston ball-socket for damage or excessive wear. Replace if
necessary.
3
1. O-ring
LOOP FLUSHING SPOOL
2. Piston Seal
Inspect the loop flushing spool. Check for cracks or damage.
3. Servo Piston
Replace if necessary.
Figure 3-31. Servo Piston
3121631 3-37
SECTION 3 - CHASSIS & TURNTABLE
4. Turn the block over and install the retaining ring (8),
hold-down pins (9) and ball guide (10) to the cylinder
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES block.
ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO 5. Install the pistons (11) to the slipper retainer (12). Install
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS the piston/retainer assembly into the cylinder block.
SECURE BEFORE ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING. Ensure the concave surface of the retainer seats on the
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED. ball guide. If you're reusing the pistons, install them to
the original block bores. Lubricate the pistons, slippers,
3. Install the inner block spring washer (4), block spring (5) retainer and ball guide before assembly. Set the cylinder
and outer washer (6) into the cylinder block. Using a kit aside on a clean surface until needed.
press, compress the block spring enough to expose the
retaining ring groove. Wind the spiral retaining ring (7) 6. Install the journal bearings (13) into the housing seats.
into the groove in the cylinder block. Use assembly grease to keep the bearings seated during
assembly. Ensure the locating nubs drop into the cavi-
ties in the seats. If you're reusing the bearings, install
11 them in the original location and orientation. Lubricate
the journal bearings.
12
14
10 13
9
8
13
3-38 3121631
SECTION 3 - CHASSIS & TURNTABLE
8. Press front shaft bearing (15) onto shaft (16). Press bear- 10. Verify swashplate and bearings are properly seated.
ing onto shaft with lettering facing out. Lubricate bear- Install the cylinder kit (19) onto the shaft. Install with the
ing rollers. Install snap-ring (17) onto shaft. slippers facing the swashplate. Rock the shaft to align
the block splines and slide the cylinder kit into place.
Orient the motor with the shaft pointing downward and
verify the cylinder kit, swashplate, journal bearings and
servo piston are all secure and properly installed.
19
15
16
19. Cylinder Kit
3121631 3-39
SECTION 3 - CHASSIS & TURNTABLE
12. Press the rear shaft bearing (22) into the end cap. Install 15. Install the end cap (25) onto the housing with the end
the bearing with letters facing out. Press until bearing capscrews (26). Check to ensure the end cap will prop-
surface is 0.08 ±0.01 in. (2 ±0.25 mm) above end cap sur- erly seat onto the housing without interference.
face. Improper assembly of the internal components may
prevent the end cap from seating properly. Ensure the
22 3 mm
23 [0.12 in]
O-rings seat properly when installing the end cap.
2 mm
[0.08 in]
26
8 mm
35-45 ft.lbs.
23 (47-61 Nm)
22
24
25
23
Figure 3-37. Valve Plate and Rear Bearing 16. Using an 8 mm internal hex wrench, tighten the end
capscrews. Tighten the screws in opposite corners
13. Install timing pin (23) into its bore in the end cap. Install slowly and evenly to compress the servo spring and
the pin with its groove facing toward or away from the properly seat the end cap. Torque end capscrews 35-45
shaft. Press the pin until the end protrudes 0.12 ±0.01 in. ft. lbs. (47-61 Nm).
(3 ±0.25 mm) above end cap surface. 17. Before installing the shaft seal, ensure the shaft turns
14. Install the valve plate (24) onto the end cap. Install the smoothly with less than 120 in. lbs. (13.5 Nm) of force. If
valve plate with the yellow surface toward the cylinder the shaft does not turn smoothly within the specified
block. Align the slot in the valve plate with the timing maximum force, disassemble and check the unit.
pin. Apply a liberal coat of assembly grease to the end
cap side of the valve plate to keep it in place during
installation.
3-40 3121631
SECTION 3 - CHASSIS & TURNTABLE
18. Cover shaft splines with an installation sleeve. Install a 19. Install remaining plugs and fittings to the housing. Refer
new shaft seal (27) with the cup side facing the motor. to the drawing below for wrench sizes and installation
Press seal into housing until it bottoms out. Press evenly torques.
to avoid binding and damaging the seal. Install seal sup-
port washer (28) and snap ring (29). 5/16 in 1/4 in
63 ft.lbs. 33 ft.lbs.
(85 Nm) (45 Nm)
29
28
27
9/16 in
125 ft.lbs.
(170 Nm)
5/16in
63 ft.lbs.
(85 Nm)
3121631 3-41
SECTION 3 - CHASSIS & TURNTABLE
40 27 ft.lbs.
(37 Nm) UNINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE
5/8 in INJURY TO THE TECHNICIAN OR BYSTANDERS. TO PROTECT AGAINST UNIN-
20 ft.lbs.
(27 Nm)
TENDED MOVEMENT, SECURE THE MACHINE OR DISABLE / DISCONNECT THE
MECHANISM WHILE SERVICING.
31
32 Prior to installing the motor, inspect for damage incurred dur-
35 ing shipping. Make certain all system components (reservoir,
38
hoses, valves, fittings, heat exchanger, etc.) are clean prior to
filling with fluid.
42
11/16 in
27 ft.lbs. 1. Fill the reservoir with recommended hydraulic fluid.
(37 Nm) Always filter fluid through a 10 micron filter when pour-
ing 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
30. Orifice Poppet 34. Spring 37. O-ring 40. Plug be certain it is free of restrictions and air leaks.
31. Shift Spool 35. Spring 38. O-ring 41. Plug
3. Fill the pump and motor housing with clean hydraulic
32. Spring 36. Spring 39. O-ring 42. Plug
fluid. Pour filtered oil directly into the upper most case
33. Spring
drain port.
Figure 3-41. Loop Flushing Spool
4. To ensure the pump and motor stay filled with oil, install
case drain lines into the upper most case drain ports.
21. Install shift spool (31).
22. Install spring retaining washers onto springs (32 and 33). 5. Install a 0 to 500 psi (0 to 35 bar) gauge in the charge
23. Carefully install centering springs (34, 35 and 36). pressure gauge port of the pump to monitor system
pressure during start up.
24. Install new O-rings (37, 38 and 39).
25. Using a 5/8 in. wrench torque plug (40) to 20 ft. lbs. (27 NOTE: Follow recommendations in the vehicle / machine opera-
Nm). tor’s manual for prime mover start up procedures.
26. Using a 11/16 in. wrench, torque plugs (41 and 42) to 27
ft. lbs. (37 Nm). 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 sys-
tem pressure is established, increase to full operating
speed. If system pressure is not maintained, shut down
the prime mover, determine cause and take corrective
action.
10. Check the fluid level in the reservoir; add clean filtered
fluid if necessary. The motor is now ready for operation.
3-42 3121631
SECTION 3 - CHASSIS & TURNTABLE
NOTE: The brake must be released before performing the roll test.
This can be accomplished by either pressure testing using
the Brake Leak Test procedure below or by tightening the
12 bolts into the piston through the end plate (See Brake
Disassembly Procedure).
ROLL TEST
BOLT B
The purpose of the roll test is to determine if the unit's gears
are rotating freely and properly. You should be able to rotate
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con- 1. Tighten (but do not torque) bolt “A" until snug.
cerned if the gears in your unit seem to roll hard as long as 2. Go to the opposite side of the bolt circle and tighten
they roll with consistency. Release the pressure at the Brake bolt “B” until equally snug.
Housing (6) and remove the test fixtures.
3. Crisscross around the bolt circle and tighten remaining
bolts.
LEAK TEST (MAIN UNIT)
The purpose of a leak test is to make sure the unit is air tight. 4. Now use a torque wrench to apply the specified torque
You can tell if your unit has a leak if the pressure gauge read- to bolt “A”.
ing on your air checker starts to fall after the unit has been 5. Using the same sequence, crisscross around the bolt cir-
pressurized and allowed to equalize. Leaks will most likely cle and apply an equal torque to the remaining bolts.
occur at the pipe plugs, the main seal or wherever o-rings or
gaskets are located. The exact location of a leak can usually be
detected by brushing a soap and water solution around the
main seal and where the o-rings or gaskets meet on the exte-
rior of the unit, then checking for air bubbles. If a leak is
detected in a seal, o-ring or gasket, the part must be replaced
and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20 min-
utes.
Brake Test
3121631 3-43
SECTION 3 - CHASSIS & TURNTABLE
Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (30)
and remove fittings from Brake (6) and Motor Control
NOTE: Refer to Figure 3-42. Valve (32).
5. Remove O-ring Plugs (23) from Motor Control Valve (32).
1. Place unit on bench with the motor end up.
6. Remove Motor Control Valve (32) from Motor (31) by
2. Remove O-ring Plug (1P) and drain the oil from the removing the four Bolts (21) and washers (22).
gearbox.
32
31
23
22
21
6
1P
35
3-44 3121631
SECTION 3 - CHASSIS & TURNTABLE
Motor and Brake Disassembly 4. Remove the Springs (8L) from the piston.
5. Apply less than 50 psi (3.45 bar) air to the “brake port” to
NOTE: Refer to Figure 3-43.
remove Brake Piston (8A).
1. With unit resting on bench with Motor (31) end up,
loosen Hex Bolts (29) and remove Lift Lugs (28) from the
Motor (31). THE PISTON MAY MOVE QUICKLY. EYE PROTECTION SHOULD BE WORN DUR-
ING THIS PROCEDURE.
2. Pull Motor (31) straight up and remove Motor (31) from
Brake Housing (6).
6. Remove Rotors (8J) and Stators (8K) from Brake Housing
3. Remove O-ring (26) from between Motor (31) and Brake (6).
Housing (6).
6
8K
8J 8K
8J 8K
8J
8K 8J
8K
8A 28
8L 29
26
31
3121631 3-45
SECTION 3 - CHASSIS & TURNTABLE
Main Drive Disassembly 5. Remove Thrust Washer (11) from between Brake Hous-
ing (6) and Carrier Subassembly.
NOTE: Refer to Figure 3-44. 6. Remove Ring Gear (4) from Housing (1G).
1. Remove Sun Gear (8) with Retaining Ring (44) inside. 7. Remove O-ring (5) from between Ring Gear (4) and
Housing (1G).
2. With the unit resting on the Output Shaft (Pinion) (1A),
remove the Bolts (12) from the Brake Housing (6). 8. Remove Carrier Sub-Assembly.
3. Remove the Brake Housing (6) from the main assembly. 9. Remove Thrust Washer (11) from between Carrier Sub-
Assembly and Internal Gear (2).
4. Remove O-ring (5A) from between Brake Housing (6)
and Ring Gear (4). 10. Remove Internal Gear (2).
1A
13
Carrier
Subassembly
11
5
5A
6
1G Hub-Shaft 20
2
Subassembly
3F
44
4 11
8
12
3-46 3121631
SECTION 3 - CHASSIS & TURNTABLE
Hub-Shaft Disassembly NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by
the Bearing Cone (1D) during this step.
NOTE: Refer to Figure 3-45.
4. Remove the Bearing Cone (1E) from the Housing (1G).
1. Using retaining ring pliers remove Retaining Ring (1I)
5. Use a bearing puller to remove the Bearing Cone (1D)
from groove in Output Shaft (1A) and discard.
from the Shaft (1A).
6. Bearing Cups (1C & 1F) will remain in Housing (1G).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
2. Remove Thrust Washer (1H). NOTE: If bearing replacement is necessary, the Bearing Cups (1C &
1F) can be removed with a slide hammer puller or driven
3. While supporting the Housing (1G) on the Output Shaft out with a punch.
(1A) end, press the Output Shaft (1A) out of the Housing
(1G).
1B
1C
1F
1A 1H
1D
1G
1E
1I
3121631 3-47
SECTION 3 - CHASSIS & TURNTABLE
Carrier Disassembly 2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a
small punch to remove the Roll Pin (3D) from the Planet
Shaft (3E).
NOTE: Refer to Figure 3-46.
3. Slide the Planet Gear (3F), the two Thrust Washers (3B)
1. Using a 3/16 in. punch drive the Roll Pin (3G) which out of the Carrier (3A).
holds the Planet Shaft (3E) in the Carrier (3A) down into 4. Remove both rows of Needle Bearings (3C) and the
the Planet Shaft (3E) until it bottoms. Spacer (3D) from the bore of the Planet Gear (3F).
NOTE: Make sure that the Roll Pin has bottomed. Otherwise, dam- 5. Repeat Steps 1 thru 4 for the remaining two Cluster
age to the carrier could occur when the Planet Shaft is Gears (3F).
removed.
3B 3F 3G
3C
3D
3C 3B
3E
3A
3-48 3121631
SECTION 3 - CHASSIS & TURNTABLE
1. Press Bearing Cup (1C) into Housing (1G) taking care to 13. Apply a liberal Coat of grease to the bore of Cluster Gear
ensure cup starts square with the bore of Hub (1G). (3F). This will enable the Needle Rollers (3C) to be held in
place during assembly.
2. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing
(1G). 14. Install the first row of Needle Rollers (3C) into the bore of
Cluster Gear (3F).
3. Press or tap Seal (1B) Into the counterbore of Housing
(1G) to the point where it becomes flush with the Hous- 15. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of
ing (1G) face. Care should be taken to ensure Seal (1B) is the Needle Rollers (3C).
being correctly installed (smooth face up). Apply grease
16. Place second row of Needle Rollers (3C) into bore of
to the rubber portion of the seal bore.
Cluster Gear (3F) against Spacer (3D).
4. Invert Hub (1G) and press Bearing Cup (1E) into counter-
17. Place Carrier (3A) so that one of the roll pin holes is
bore of Housing (1G).
straight up.
5. Carefully lower Housing (1G) onto the Output Shaft (1A)
18. Start Planet Shaft (3E) through the hole in Carrier (3A).
until Bearing Cone (1D) contacts the Output Shaft (1A).
Using ample grease to hold it in position, slide one
6. Press on the small end of the Bearing Cone (1D), being Thrust Washer (3B) over the Planet Shaft (3E) with the
careful not to contact the bearing cage, until the Bearing tang resting in the cast slot of the Carrier (3A).
Cone (1D) seats on the shoulder of the Output Shaft
19. With large end of Cluster Gear (3F) facing the roll pin
(1A).
hole in the Carrier, place the Cluster Gear into position in
7. Start the Bearing Cone (1F) onto the Output Shaft (1A). carrier (3A) and push Planet Shaft (3E) through the Clus-
ter Gear (3F) without going all the way through.
8. Press or tap the Bearing Cone (1F) onto the Output Shaft
(1A) until it is just seated in the Bearing Cup (1E). while 20. Slide the second Thrust Washer (3B) between the Cluster
rotating the Housing (G). Gear (3F) and the Carrier (3A) with the tang of the
washer located in the cast slot of the Carrier (3A). Finish
9. Install Bearing Spacer (1H) onto Output Shaft (1A) and
sliding the Planet Shaft (3E) through the Thrust Washer
against Bearing Cone (1F).
(3B) and into the Carrier (3A).
10. Install Retaining Ring (1I) into the groove in the Output
21. Position the non-chamfered side on the Planet Shaft (3E)
Shaft (1A). This Retaining Ring (1I) should never be
roll pin hole so that it is in line with the hole in the Car-
reused in a repair or rebuild.
rier (3A) using a 1/8 in. (3 mm) diameter punch.
22. After using a 3/16 in. (5 mm) punch to align the two roll
pin holes. Drive the Roll Pin (3G) through Carrier (3A)
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
and into the Planet Shaft (3E) until the Roll Pin (3G) is
11. Tap the Retaining Ring (1I) with a soft metal punch to flush with the bottom of the cast slot in the Carrier (3A)
ensure that the Retaining Ring (1I) is completely seated outside diameter at the thrust washer (3B) tang. Use a 1/
in the groove of the Output Shaft (IA). 4” (6 mm) pin punch to make sure the Roll Pin (3G) is
flush in the slot.
23. Repeat Steps 1 through 10 for the remaining two Cluster
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. Gears (3F).
12. Install O-ring Plug (1P) and torque to 23 to 24 ft. lbs. (31
to 32 Nm).
3121631 3-49
SECTION 3 - CHASSIS & TURNTABLE
Main Drive Assembly NOTE: If gears do not mesh easily or Carrier Assembly does not
rotate freely, then remove the Carrier and Ring Gear and
NOTE: Refer to Figure 3-44. check the Cluster Gear timing.
24. With the Hub Shaft Sub-Assembly resting on the Shaft 32. Install Thrust Washer (11) into the counter-bore on the
(1A) install Internal Gear (2). The spline of the Internal face of the carrier. Use grease to hold in place.
Gear (2) bore will mesh with the spline of the Output
33. Place O-ring (5A) into counter-bore or Brake Housing (6).
Shaft (1A). This will be a tight fit.
Use grease to hold O-Ring in place.
25. Inspect the location of the Internal Gear (2) on the Out-
put Shaft (1A). The portion of the Output Shaft (1A)
should protrude through the Internal Gear (2) bore.
BEWARE OF SHARP EDGES OF THE COUNTER-BORE WHILE SEATING THIS O-
26. Install 4 Dowel Pins (13) into counterbore holes in Hub RING.
(IG).
34. Install the Brake Housing (6), taking care to correctly
27. Install Thrust Washer (11) in counterbore of Carrier Sub- align Pipe Plug (20) with those in the Hub (I G).
Assembly (Small Cluster-Gear end) Use grease to hold in
place. 35. Install Bolts (12) through the Brake Housing (6) into the
Hub (1G) and torque to 23-27 ft. lbs. (31-37 Nm).
28. Place O-ring (5) into Hub counter-bore. Use grease to
hold O-ring in place. 36. With gearbox standing on the pinion end fill gearbox
with 43 oz. of ISO VG150/VG220 gear oil.
37. Install Retaining Ring (44) into the groove in the Sun
BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEATING THIS Gear (8).
ORING.
38. Install the Sun Gear (8) into mesh with the Planet Gears
29. Place Carrier Sub-Assembly on bench with the large end (3F).
of Cluster Gears (3F) facing up with one at the 12 o'clock
39. Install Pipe Plug (20) into Cover (6) torque to 23-24 ft. lbs.
position. Find the punch marked tooth on each gear at
(31-32 Nm).
the large end and locate at 12 o'clock (straight up) from
each planet pin. Marked tooth will be located just under
the Carrier on upper two gears. Check the timing
through the slots in the carrier (See Carrier Sub-Assem-
bly).
30. 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.
31. While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
with the Internal Gear (2). On the Ring Gear (4) locate
the hole marked "X", or punch marked, over one of the
marked counter-bored holes (Step 5) in Hub (1G). Check
timing through the slots in the carrier. Rotate carrier in
assembly to check for freedom of rotation.
3-50 3121631
SECTION 3 - CHASSIS & TURNTABLE
1. Alternate Stators (8K) (O.D. lobes) with Rotors (8J) (I.D. 1. Lay assembly down with motor ports facing up. Remove
splines) into bore of Brake Housing (6). starting with a the two plastic plugs in the motor ports, being careful
Stator (8K) and ending with a Stator (8K). not to lose the O-ring in each port. Assemble the Motor
control Valve (32) onto the Motor (31) with Bolt (21) and
2. Grease the O-rings (8F) & (8D) and backup rings (8H) &
Lock Washers (22). Torque Bolts (21) to 23-27 ft. lbs. (31-
(8E). and place them in their respective grooves in the
37 Nm).
Brake Housing (6) and Piston (8A). Make sure the backup
rings are correctly positioned. NOTE: Be sure to align the holes in the control valve with the
motor ports.
3. Apply grease sparingly to the Piston O.D. (8A) and the
bore of the Brake Housing (6). Insert Piston (8A) into
2. Install Elbow Fittings (30) into Brake (6). Do not tighten
Brake Housing (6) be sure not to damage the O-rings.
jam nuts.
4. Install Springs (8L) into the spring pockets of the Piston
3. Install Elbow Fittings (30) into Motor Control Valve (32).
(8A).
Do not tighten jam nuts.
5. Test the brake and perform the roll test. Remove the
4. Assemble Tube (35) into Elbow Fittings (30) and torque
Brake Test Plate.
to 13-15 ft. lbs (18-20 Nm). Tighten the jam nuts on the
6. Install the O-ring (26) onto the pilot of the Motor (31), Elbow Fittings (30) and torque to 13-15 ft. lbs. (18-20
use grease to keep the O-ring in place. Nm).
7. Place Motor (31) into Brake pilot and line up holes. 5. Install one O-ring Plug (23) into Motor Control Valve (32)
and torque to 30-31 ft. lbs. (41-42 Nm).
8. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble
Hex Bolts (29) with Lift Lugs (28) through the Motor (31) 6. Pressure test brake, tube and control valve connections
and Brake (6) against Motor flange. Torque to 80-100 ft. by applying 3000 psi (207 bar) pressure to the open port
lbs. (108-136 Nm). in the Motor Control Valve (32) and holding for 1 minute.
Check for leaks at the control-valve-motor interface and
the tube connections. Release pressure and install the
remaining O-ring Plug (23) into Motor Control Valve (32)
and torque to 30-31 ft. lbs. (41-42 Nm).
3121631 3-51
SECTION 3 - CHASSIS & TURNTABLE
1. Housing 1G. Retaining Ring 3C. Needle Bearing 5. O-ring 11. Dowel Pin
1A. Output Shaft 1H. Pipe Plug 3D. Thrust Washer 6 O-Ring 12. Pipe Plug
1B. Lip Seal 2. Internal Gear 3E. Planet Shaft 7. Brake Housing 16. ID Plate
1C. Bearing 3. Carrier Assembly 3F. Cluster Gear 8. Sun Gear 17. Screw Drive
1D. Bearing 3A. Carrier 3G. Rollpin 9. Thrust washer 25. Internal Retaining Ring
1E. Housing 3B. Tanged Washer 4. Ring Gear 10. Bolt
1F. Thrust Washer
3-52 3121631
SECTION 3 - CHASSIS & TURNTABLE
18
1001101060 A
8A. Piston 8H. Spring 21. Elbow 32. Ring 40. Thrust Bearing
8B. 0-Ring 13. Thrust Washer 24. Tube 33. Manifold 41. Inner Seal
8C. Backup Ring 14. Lock washer 26. O-ring 34. Rotor Set 43. Backup Washer
8D. O-Ring 15. Pipe Plug 27. Bolt 35. Wear Plate 43. Housing
8E. Backup Ring 18. 0-Ring 28. End Cover 36. Drive Link 44. Backup Washer
8F. Rotor Disc 19. Lifting lug 29. Commutator Seal 37. Coupling Shaft 45. Seal
8G. Stator Disc 20. Bolt 30. Ring Seal 38. Inner Bearing 46. Washer
31. Commutator and Ring Assy 39. Thrust Washer
3121631 3-53
SECTION 3 - CHASSIS & TURNTABLE
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.
4. Remove end cover assembly (2) and seal ring (4). Discard
seal ring.
3-54 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-55
SECTION 3 - CHASSIS & TURNTABLE
5. If the end cover (2) is equipped with shuttle valve com- inspection of end cover, commutator, manifold and rotor
ponents, remove the two previously loosened plugs set.
(21).
7. Remove commutator ring (6). Inspect commutator ring
for cracks, or burrs.
3-56 3121631
SECTION 3 - CHASSIS & TURNTABLE
9. Remove manifold (7) and inspect for cracks surface scor- NOTE: The rotor set (8) components may become disassembled
ing, brinelling or spalling. Replace manifold if any of during service procedures. Marking the surface of the rotor
these conditions exist. A polished pattern on the ground and stator that is facing UP, with etching ink or grease pen-
surface from commutator or rotor rotation is normal. cil before removal from Torqmotor™ will ensure correct
Remove and discard the seal rings (4) that are on both reassembly of rotor into stator and rotor set intoTorqmo-
sides of the manifold. tor™. Marking all rotor components and mating spline
components for exact repositioning at assembly will
ensure maximum wear life and performance of rotor set
and Torqmotor™.
3121631 3-57
SECTION 3 - CHASSIS & TURNTABLE
NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets 14. Check exposed portion of coupling shaft (12) to be sure
of seven vanes (8C & 8E) as shown in the alternate con- you have removed all signs of rust and corrosion which
struction TG rotor set assembly view, check the rotor lobe might prevent its withdrawal through the seal and bear-
to roller vane clearance at both ends of rotor. ing. Crocus cloth or fine emery paper may be used.
Remove any key (12A), nut (12B), washer (12C), bolt
12. Remove drive link (10) from coupling shaft (12) if it was (12D), lock washer (12E), or retaining ring (12F).
not removed with rotor set and wear plate. Inspect drive
link for cracks and worn or damaged splines. No percep-
tible lash (play) should be noted between mating spline
parts. Remove and discard seal ring (4) from housing
(18).
Inspection Areas
3-58 3121631
SECTION 3 - CHASSIS & TURNTABLE
NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 19. Remove housing (18) from vise, invert it and remove and
0.020 inches (0.51 mm) diametrically, replace coupling discard seal
shaft.
20. A blind hole bearing or seal puller is required.
NOTE: A slight “polish” is permissible in the shaft bearing areas.
Anything more would require coupling shaft replacement.
16. Remove and discard seal ring (4) from housing (18).
17. Remove thrust bearing (15) and thrust washer (14)
Inspect for wear, brinelling, corrosion and a full comple-
ment of retained rollers.
18. Remove seal (16) and backup washer (17) from Small
Frame, housing (18). Discard both.
3121631 3-59
SECTION 3 - CHASSIS & TURNTABLE
22. If the housing (18) assembly has passed inspection to NOTE: The depth or location of bearing/bushing (13) in relation to
this point, inspect the housing bearings/bushings (19) the housing wear plate surface and the depth or location
and (13) and if they are captured in the housing cavity of bearing/bushing (19) in relation to the beginning of
the two thrust washers (14) and thrust bearing (15). The bearing/bushing counterbore should be measured and
bearing rollers must be firmly retained in the bearing noted before removing the bearings/ bushings. This will
cages, but must rotate and orbit freely. All rollers and facilitate the correct reassembly of new bearings/bushings.
thrust washers must be free of brinelling and corrosion.
The bushing (19) or (13) to coupling shaft diameter
clearance must not exceed 0.010 inch (0.025 mm). A
bearing, bushing, or thrust washer that does not pass
inspection must be replaced. If the housing has passed
this inspection the disassembly of the Torqmotor™ is
completed.
3-60 3121631
SECTION 3 - CHASSIS & TURNTABLE
Assembly
Replace all seals and seal rings with new ones each time you
reassemble the Torqmotor™ unit. Lubricate all seals and seal
rings with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a complete seal kit
are available. The parts should be available through most
OEM parts distributors or Parker approved Torqmotor™
distributors. (Contact your local dealer for availability).
3121631 3-61
SECTION 3 - CHASSIS & TURNTABLE
3. Press a new dirt and water seal (20) into the housing (18)
outer bearing counterbore.
The Torqmotor™ dirt and water seal (20) must be
pressed in until its flange is flush against the housing.
3-62 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-63
SECTION 3 - CHASSIS & TURNTABLE
NOTE: The coupling shaft (12) will be flush or just below the hous-
ing wear plate surface on Torqmotors™ when properly
seated. The coupling shaft must rotate smoothly on the NOTE: One or two alignment studs screwed finger tight into hous-
thrust bearing package. ing (18) bolt holes, approximately 180 degrees apart, will
facilitate the assembly and alignment of components as
required in the following procedures. The studs can be
made by cutting off the heads of either 3/8-24 UNF 2A or 5/
16-24 UNF 2A bolts as required that are over 0.5 inch (12.7
mm) longer than the bolts (1) used in the Torqmotor™.
3-64 3121631
SECTION 3 - CHASSIS & TURNTABLE
10. Install drive link (10) the long splined end down into the 12. Apply a small amount of clean grease to a new seal ring
coupling shaft (12) and engage the drive link splines (4) and assemble it into the seal ring groove on the wear
into mesh with the coupling shaft splines. plate side of the rotor set stator (8B).
13. Install the assembled rotor set (8) onto wear plate (9)
NOTE: Use any alignment marks put on the coupling shaft and
with rotor (8A) counterbore and seal ring side down and
drive link before disassembly to assemble the drive link
the splines into mesh with the drive link splines.
splines in their original position in the mating coupling
shaft splines.
11. Assemble wear plate (9) over the drive link (10) and
alignment studs onto the housing (18).
NOTE: The rotor set rotor counterbore side must be down against
wear plate for drive link clearance and to maintain the
original rotor-drive link spline contact. A rotor set without
a counterbore and that was not etched before disassembly
can be reinstalled using the drive link spline pattern on the
rotor splines if apparent, to determine which side was
down. The rotor set seal ring groove faces toward the wear
plate (9).
3121631 3-65
SECTION 3 - CHASSIS & TURNTABLE
14. Apply clean grease to a new seal ring (4) and assemble it 16. Apply grease to a new seal ring (4) and insert it in the
in the seal ring groove in the rotor set contact side of seal ring groove exposed on the manifold.
manifold (7).
15. Assemble the manifold (7) over the alignment studs and
drive link (10) and onto the rotor set. Be sure the correct
manifold surface is against the rotor set.
18. Assemble a new seal ring (3) flat side up, into commuta-
tor (5) and assemble commutator over the end of drive
link (10) onto manifold (7) with seal ring side up.
3-66 3121631
SECTION 3 - CHASSIS & TURNTABLE
19. Assemble a new seal ring (4) into end cover (2) and
assemble end cover over the alignment studs and onto
the commutator set. If the end cover has only 5 bolt
holes be sure the cover holes are aligned with the 5
threaded holes in housing (18). The correct 5 bolt end
cover bolt hole relationship to housing port bosses.
3121631 3-67
SECTION 3 - CHASSIS & TURNTABLE
20. Assemble the 5 or 7 special bolts (1) and screw in finger NOTE: The special bolts required for use with the relief or shuttle
tight. Remove and replace the two alignment studs with valve (24) end cover assembly (2) are longer than the bolts
bolts after the other bolts are in place. Alternately and required with standard and cover assembly. Refer to the
progressively tighten the bolts to pull the end cover and individual service parts lists or parts list charts for correct
other components into place with a final torque of 50-55 service part number if replacement is required.
ft. lbs. (68-75 Nm) for the seven 3/8-24 threaded bolts.
21. Torque the two shuttle valve plug assemblies (21) in end
cover assembly to 9-12 ft. lbs. (12-16 Nm) if cover is so
equipped.
Torque the two relief valve plug assemblies (21) in end
cover assembly to 45-55 ft. lbs. (61-75 Nm) if cover is so
equipped.
Thrust
Washers Housing
Steel
Washer
Seal
Thrust Backup
Bearing Washer
Not To Scale
Shaft
3-68 3121631
SECTION 3 - CHASSIS & TURNTABLE
One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read-
ily assemble into the stator vane pockets.
A disassembled rotor (8A) stator (8B) and vanes (8C) that can-
not be readily assembled by hand can be assembled by the
following procedures.
1. Place stator (8B) onto wear plate (9) with seal ring (4)
side down, after following Torqmotor™ assembly proce-
dures 1 through 13. Be sure the seal ring is in place.
EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD
SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.
3121631 3-69
SECTION 3 - CHASSIS & TURNTABLE
3.12 Procedure For Setting Swing Gear Backlash 4. Remove turntable lock pin.
5. Apply JLG Threadlocker P/N 0100019 and pre-torque
Ensure mounting plate and turntable base plate are clean and
swing drive mounting bolts to 30 ft. lbs. (42 Nm).
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:
3-70 3121631
SECTION 3 - CHASSIS & TURNTABLE
NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races.
3121631 3-71
SECTION 3 - CHASSIS & TURNTABLE
14
15 13
12
10
16
4
7 11
2
3
6
5 11
1001094899 D
3-72 3121631
SECTION 3 - CHASSIS & TURNTABLE
3.13 SWING BEARING 2. Check the turntable to bearing Attach bolts as follows:
a. Elevate the fully retracted main boom to full eleva-
Turntable Bearing Mounting Bolt Condition Check tion.
b. At the position indicated on Figure 3-52. try to insert
the 0.0015” feeler gauge between the bolt head and
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL hardened washer at the arrow indicated position.
LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE c. Lower the boom to horizontal and fully extend the
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE boom.
SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. d. At the position indicated on Figure 3-54., try and
insert the 0.0015” feeler gauge between the bolt
NOTE: This check is designed to replace the existing bearing bolt head and hardened washer at the arrow indicated
torque checks on JLG Lifts in service. This check must be position.
performed after the first 50 hours of machine operation
and every 600 hours of machine operation thereafter. If
during this check any bolts are found to be missing or
loose, replace missing or loose bolts with new bolts and
torque to the value specified in the torque chart, after lubri-
cating the bolt threads with JLG Threadlocker P/N
0100019. After replacing and retorquing bolt or bolts
recheck all existing bolts for looseness.
3121631 3-73
SECTION 3 - CHASSIS & TURNTABLE
3-74 3121631
3121631
Figure 3-53. Swing Bearing Tolerance Boom Placement (Sheet 2 of 2)
3-75
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3 - CHASSIS & TURNTABLE
3-76 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-77
SECTION 3 - CHASSIS & TURNTABLE
3-78 3121631
SECTION 3 - CHASSIS & TURNTABLE
7. Clean any residue off the new bearing bolts, then apply
a light coating of JLG Threadlocker P/N 0100019 and
8. Carefully place the turntable on a suitably supported
install the bolts and washers through the turntable and
trestle.
inner race of the bearing.
9. Use a suitable tool to scribe a line on the outer race of
8. Following the Torque Sequence diagram shown in Fig-
the swing bearing and the frame. This line will aid in
ure 3-50., Swing Bearing Torque Sequence, tighten the
aligning the bearing upon installation. Remove the bolts
bolts to a torque of 190 ft. lbs. (260 Nm).
and washers which attach the outer race of the bearing
to the frame. Discard the bolts. Use suitable lifting 9. Remove the lifting equipment.
equipment to remove the bearing from the frame, then
10. Install the rotary coupling retaining yoke brackets, apply
move the bearing to a clean, suitably supported work
a light coating of JLG Threadlocker P/N 0100011 to the
area.
attaching bolts and secure the yoke to the turntable
with the mounting hardware.
SWING BEARING INSTALLATION 11. Connect the hydraulic lines to the rotary coupling as
1. Using suitable lifting equipment, carefully lower the tagged prior to removal.
swing bearing into position on the frame. Ensure the 12. At ground control station, use boom lift control to lower
scribed line of the outer race of the bearing aligns with boom to stowed position.
the scribed line on the frame. If a new swing bearing is
used, ensure that the filler plug fitting is at 90 degrees 13. Using all applicable safety precautions, activate the
from the fore and aft center line of the frame. hydraulic system and check the swing system for proper
and safe operation.
3121631 3-79
SECTION 3 - CHASSIS & TURNTABLE
3-80 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-81
SECTION 3 - CHASSIS & TURNTABLE
4 3
1
2
3
5
4
6
7 7
7 5
2 1
6
1
2
5
5
3-82 3121631
SECTION 3 - CHASSIS & TURNTABLE
8
1001107531 A
1. Housing 7. Bracket 13. Cap Seal 18. Capscrew 23. Check Valve 28. Washer
2. Body 8. Locknut 14. Thrust Ring 19. O-ring 24. Plunger Valve 29. Locknut
3. Rotary Coupling 9. Washer 15. Retaining Ring 20. O-ring 25. Spring 30. Capscrew
4. Block Valve Assembly 10. Washer 16. Plug 21. Bearing 26. Seal 31. Proximity Switch
5. Bolt 11. Seal 17. Torque Lug 22. Plug 27. Bracket
6. Bolt 12. O-ring
3121631 3-83
SECTION 3 - CHASSIS & TURNTABLE
Operating Proof
Port
Outlets Port Size Description Pressure Pressure
No.
PSI (Bar) PSI (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)
3-84 3121631
SECTION 3 - CHASSIS & TURNTABLE
1/2 in.
(13 mm)
CIRCUIT
BREAKER
INSPECTING BRUSHES
Remove the end panel. Inspect the wires. Remove the brush
holder assembly. Pull the brushes from the holders.
3121631 3-85
SECTION 3 - CHASSIS & TURNTABLE
2
3
Acceptable Unacceptable
Brushes must ride
completely on slip
rings
1/4 in (6 mm)
Or Less - Replace
7/16 in - 1/2 in
2 (11 - 12 mm) New
Figure 3-62. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3-86 3121631
SECTION 3 - CHASSIS & TURNTABLE
Troubleshooting
Table 3-9. Troubleshooting
Trouble Remedy
No generator output at platform AC receptacles. Be sure generator control switch is turned on at platform.
Check and secure electrical connections at platform, generator, and control box.
Check plug PLG3 connection and/or connections at receptacles RC3 and RC5.
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.
Low generator output at platform AC recepta- Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
cles. Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes if necessary.
Disconnect leads 12 and 13 from brushes, and check continuity across slip rings nominal reading is 26 ohms).
Replace generator if rotor is open.
Disconnect stator weld leads 1, 2, and 3 from circuit breaker CB1, and check continuity between leads. Replace
generator if necessary.
Disconnect plug PLG4 and check continuity between exciter leads 5 and 6. Replace generator if necessary.
High generator output at platform AC recepta- Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
cles. Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes if necessary.
Check power board PC1 and connections, and replace if necessary.
Erratic generator output at platform AC recepta- Check and secure electrical connections at platform, generator, and control box.
cles. Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes n necessary.
Disconnect leads 12 and 13 from brushes, and check continuity across slip rings nominal reading is 26 ohms).
Replace generator if rotor is open.
3121631 3-87
SECTION 3 - CHASSIS & TURNTABLE
DO NOT DAMAGE ROTOR OR STATOR WINDINGS DURING DISASSEMBLY AND 2. Reconnect all leads. Use cable ties to secure leads away
ASSEMBLY PROCEDURE. from moving or hot parts.
DISASSEMBLY
1. Mark and disconnect all electrical leads, secure using
cable ties.
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3-88 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-89
SECTION 3 - CHASSIS & TURNTABLE
3-90 3121631
3121631
Figure 3-66. Generator Electrical Circuit Diagram
3-91
SECTION 3 - CHASSIS & TURNTABLE
3-92
SECTION 3 - CHASSIS & TURNTABLE
3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-93
SECTION 3 - CHASSIS & TURNTABLE
3-94 3121631
SECTION 3 - CHASSIS & TURNTABLE
Lead Connection List for Generator NOTE: Apply small amount of dielectric grade, nonconductive
electric grease to connectors where factory-applied grease
NOTE: Table shows physical lead connections and should be used had been present.
with circuit diagram (table replaces wiring diagram).
Leads Connections
1A STATOR TO CB1
2A STATOR TO CB1
3A STATOR TO CB1
4A STATOR TO TE1 (C)
5A STATOR TO RC4 (3)
5B PLG2 (C) TO PLG4 (3)
5C RC2 (C) PLG31 (8)
6A STATOR TO RC4 (4)
6B PLG2 (D) TO PLG4 (4)
6C RC2 (D) PLG31 (9)
9A RC5 (B) TO PLG3 (B) (Customer Supplied)
9B RC3 (B) PLG1 (8)
12A PLG2 (E) TO PLG4 (5)
12B RC2 (E) PLG1 (9)
12C RC4 (5) TO BRUSH
13A PLG2 (F) TO PLG4 (6)
13B RC2 (F) PLG31 (4)
13C RC4 (6) TO BRUSH
15A PLG1 (6) TO PLG31 (6)
16A PLG1 (3) TO PLG31 (1)
17A PLG1 (4) TO PLG31 (2)
21A CB1 TO TE1 (F)
21B PLG2 (A) TO PLG4 (1)
21C PLG1 (1) TO RC2 (A)
21D RC4 (1) TO CB1
22A CB1 TO TE1 (E)
22B PLG2 (B) TO PLG4 (2)
22C PLG1 (2) TO RC2 (B)
22D RC4 (2) TO CB1
23A CB1 TO TE1 (D)
42A RC5 (C) TO PLG3 (C) (Customer Supplied)
42B RC3 (C) TO CONNECTION POINT 1
42C PLG31 (7) TO CONNECTION POINT 1
42D PLG1 (5) TO CONNECTION POINT 1
42F END BELL SHROUD TO ENGINE MOUNT
42G CHASSIS TO TE1 (B)
43A RC5 (A) TO PLG3 (A) (Customer Supplied)
43B RC3 (A) TO CONNECTION POINT 2
43C PLG31 (3) TO CONNECTION POINT 2
43D PLG1 (7) TO CONNECTION POINT 2
3121631 3-95
SECTION 3 - CHASSIS & TURNTABLE
FUEL FILTER
HOSE CLAMP FUEL PUMP FUEL REGULATOR
TORQUE
TO BE 9-13 IN. LBS.
(1-1.4 Nm.)
ROUTE TO LP
REGULATOR
VALVE ON
ENGINE
1001217193 D
3-96 3121631
SECTION 3 - CHASSIS & TURNTABLE
TAIL PIPE
SEE DETAIL A
DETAIL A
3121631 3-97
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL B
SEE DETAIL C
SECURE ENGINE
HARNESS TO STANDOFF
1001217193 D
1. High Pressure Fuel Hose 4. LP Gas Hose 7. High Pressure Fuel Hose 10. Battery Bracket
2. Hose Clamp 5. Engine Tray Pin 8. High Pressure Fuel Hose 11. Battery
3. Fuel Regulator Mount Bracket 6. Ford Engine with Pumps 9. Battery Cable Kit 12. Battery Hold Down Bracket
3-98 3121631
SECTION 3 - CHASSIS & TURNTABLE
TO ATTACH LANYARD
TO TURNTABLE
DETAIL B
DETAIL C
1001217193 D
3121631 3-99
SECTION 3 - CHASSIS & TURNTABLE
3-100 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-101
SECTION 3 - CHASSIS & TURNTABLE
3-102 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-103
SECTION 3 - CHASSIS & TURNTABLE
3-104 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-105
SECTION 3 - CHASSIS & TURNTABLE
3-106 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-107
SECTION 3 - CHASSIS & TURNTABLE
3-108 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-109
SECTION 3 - CHASSIS & TURNTABLE
3-110 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-111
SECTION 3 - CHASSIS & TURNTABLE
3-112 3121631
SECTION 3 - CHASSIS & TURNTABLE
1. Fan 9. Turbocharger 17. Rear Engine Mount 25. Flywheel 33. Oil Filter
2. Adapter 10. Exhaust Pipe 18. Coupling 26. Fuel Filter 34. Belt Tensioner
3. Drive Belt 11. Spark Arrester 19. Pump Adapter Plate 27. Pressure Sensor 35. Plug
4. Water Pump 12. Pressure Sensor 20. Pump Assembly 28. Rear Engine Mount 36. Alternator
5. Fuel Injector 13. Front Engine Mount 21. Gear Pump Assembly 29. Oil Pan Drain Plug 37. Adapter
6. Thermostat 14. Motor Mount 22. Oil Drain Hose 30. Front Engine/Generator Mount 38. Pulley
7. Oil Fill Cap 15. Shuttle Valve 23. Oil Drain Valve 31. Oil Fill Cap
8. Temperature Sender 16. Catalytic Converter/Muffler 24. Pump Coupler 32. Oil Cooler
3121631 3-113
118
119
3-114
95 115 114 112
120 116 113
3 4 96
92 117
2 121
5 59
100
98 111
97
110
1 SUPPLY
7 109 69
8 6
102
91 94 68
93 103 108 RETURN 66
90 64
101 104 107 67 65
9 99 106
70
105
SECTION 3 - CHASSIS & TURNTABLE
88
86 87
85
10 84
71
11 83 56
82 63
15 72 55 61
16 81 62
73
17 89 80 58 57
VENT
79 74
78 76 54
14 77 75
12
13 52 50
1 53 49 48 47
30
29
26 51
46
25
18
31 38
19
20
32 37
27 33 39
40
NOTE: 34 41 45
HITCH PIN (110) 42 LOCATED ON
23 35
SHOWN HERE 21 28 36 43 TANK SIDE
24 44
FOR CLARITY. 22
3121631
SECTION 3 - CHASSIS & TURNTABLE
1. Bolt 26. Flatwasher 51. Flanged Bushing 76. Flatwasher 101. Screw
2. Bolt 27. Trim Flex 52. Screw 77. Locknut 102. Fuel Pump
3. Flatwasher 28. Flanged Bushing 53. Flatwasher 78. Flatwasher 103. Clamp
4. Spacer 29. Clamp 54. Pivot Pin 79. Locknut 104. Clamp
5. Engine Control Unit 30. Flatwasher 55. Keeper Pin 80. Nut 105. Hose
6. Clip 31. Seal 56. Screw 81. Flatwasher 106. Bolt
7. Flatwasher 32. Bolt 57. Hose 82. Screw 107. Flatwasher
8. Inlet Hose 33. Flatwasher 58. Clamp 83. Bracket 108. Nut
9. Clamp 34. Bracket Assembly 59. Clamp 84. Locknut 109. Fuel Filter
10. Air Cleaner Assembly 35. Lanyard 60. Elbow Barbed Fitting 85. Starwasher 110. Clamp
11. Clamp 36. Bolt 61. Pipe Sealant 86. Bolt 111. Elbow Barbed Fitting
12. Bolt 37. Flatwasher 62. Elbow Fitting 87. Power Module Replay 112. Bolt
13. Flatwasher 38. Nut 63. Clamp 88. Capscrew 113. Flatwasher
14. Shim 39. Flatwasher 64. Screw 89. Bumper 114. Elbow Barbed Fitting
15. Locknut 40. Screw 65. Clip 90. Intake Pipe 115. Bolt
16. Flatwasher 41. Bolt 66. Pipe Sealant 91. Clamp 116. Screw
17. Bolt 42. Locknut 67. Elbow Barbed Fitting 92. Pipe 117. Clamp
18. Flatwasher 43. Relay 68. Clamp 93. Flatwasher 118. Locknut
19. Locknut 44. Flatwasher 69. Hose 94. Bolt 119. Hose Loop
20. Hitch Pin 45. Battery Bracket 70. Hose 95. Screw 120. Bracket
21. Locknut 46. Battery Hold-down Bolt 71. Relay 96. Clip 121. Hose
22. Flatwasher 47. Battery 72. Bolt 97. Locknut
23. Bolt 48. Battery Hold-Down 73. Bolt 98. Flatwasher
24. Tray 49. Flatwasher 74. Flatwasher 99. Flatwasher
25. Bolt 50. Locknut 75. Relay Mounting Plate 100. Fuel Pump Mount Plate
Figure 3-76. Deutz T4F TD2.9L Engine Components - Sheet 3 of 3
3121631 3-115
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL A
DETAIL A 1001185674-E
1001185676-G
MAE33310
3-116 3121631
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL C
1
DETAIL C 1001185674-E
1001185676-G
MAE33320
3121631 3-117
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL D
2
3
1
1001185674-E
DETAIL D 1001185676-G
MAE33330
3-118 3121631
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL B
1
2
DETAIL B
1001185674 E
3121631 3-119
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL B
DETAIL B 1001185676-G
MAE33290G
3-120 3121631
SECTION 3 - CHASSIS & TURNTABLE
4
5
3
6
1001185676-G
MAE33300G
3121631 3-121
SECTION 3 - CHASSIS & TURNTABLE
1001185674 E
3-122 3121631
SECTION 3 - CHASSIS & TURNTABLE
MAE19630C
3121631 3-123
SECTION 3 - CHASSIS & TURNTABLE
DETAIL F
MAE19640C
3-124 3121631
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL C
SEE DETAIL A
DETAIL C
MAE19650C
3121631 3-125
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL D
SUPPLY LINE TO 9
FINE FUEL FILTER 8
6
10
11
DETAIL D DETAIL B
MAE19660C
3-126 3121631
SECTION 3 - CHASSIS & TURNTABLE
SEE DETAIL E
3121631 3-127
SECTION 3 - CHASSIS & TURNTABLE
GLOW PLUG
SOLENOID
BATTERY
GRD.
ENGINE TRAY
KEEPER PIN BOLT
ENGINE BLOCK
1. Battery Cable Kit 4. Battery Bracket 7. Diesel Fuel Decal 10. J-Bolt
2. Deutz China III Engine with Pumps 5. Solenoid Assembly Relay 8. Battery 11. Fuel Pump Bracket
3. Deutz Engine Fuel Harness 6. Fuel Hose 9. Battery Hold Down Bracket
3-128 3121631
SECTION 3 - CHASSIS & TURNTABLE
NOTE: Refer to engine manufacturer’s manual for detailed oper- Change Engine Oil
ating and maintenance instructions.
1. Allow engine to warm up. Engine oil should reach
Check Oil Level approximately 176° F (80° C).
2. Make sure machine and engine are level.
1. Make sure machine and engine are level and switch
engine OFF before checking oil level. 3. Switch off engine.
2. Remove oil dipstick and wipe with clean cloth. 4. Place oil tray under engine.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level as shown in figure below
HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
with an approved grade and type of oil outlined in
DRAINING.
engine manufacturer’s operator’s manual.
3121631 3-129
SECTION 3 - CHASSIS & TURNTABLE
3-130 3121631
SECTION 3 - CHASSIS & TURNTABLE
3.19 DEUTZ EMR 2 The EMR2 is equipped with safety devices and measures in the
hardware and software in order to ensure emergency running
The EMR2 consists of the sensors, the control unit and the (Limp home) functions.
actuator. Engine-side controls as well as the JLG Control Sys- In order to switch the engine off, the EMR2 is switched in a de-
tem are connected by means of separate cable harnesses to energized fashion over the ignition switch. A strong spring in
the EMR control unit. the actuator presses the control rod in the de-energized con-
dition into the zero position. As a redundancy measure, an
The sensors attached to the engine provide the electronics in additional solenoid serves for switching off and this, indepen-
the control unit with all the relevant physical parameters In dently of the actuator, also moves the control rod in the de-
accordance with the information of the current condition of energized condition into the zero position.
the engine and the preconditions (throttle position etc.), the
After the programming, that is carried out over the ISO9141
EMR2 controls an actuator that operates the control rod of the
interface, the EMR2 possesses a motor-specific data set and
injection pump and thus doses the fuel quantity in accordance
this is then fixedly assigned to the engine. Included in this are
with the performance requirements.
the various application cases as well as the customer’s wishes
regarding a particular scope of function.
The exact position of the regulating rod is reported back and,
if necessary, is corrected, by means of the control rod travel Each EMR2 module is matched by serial number to the engine.
sensor, situated together with the rotation magnets in a hous- Modules cannot be swapped between engines.
ing of the actuator.
3121631 3-131
3-132
SECTION 3 - CHASSIS & TURNTABLE
3121631
3121631
Figure 3-94. Deutz EMR 2 Vehicle Side Connection Diagram
3-133
SECTION 3 - CHASSIS & TURNTABLE
3-134
SECTION 3 - CHASSIS & TURNTABLE
3121631
3121631
Figure 3-96. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3-135
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3 - CHASSIS & TURNTABLE
3-136 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-137
3-138
SECTION 3 - CHASSIS & TURNTABLE
3121631
3121631
Figure 3-100. EMR2 Fault Codes - Sheet 2 of 5
3-139
SECTION 3 - CHASSIS & TURNTABLE
3-140
SECTION 3 - CHASSIS & TURNTABLE
3121631
3121631
Figure 3-102. EMR2 Fault Codes - Sheet 4 of 5
3-141
SECTION 3 - CHASSIS & TURNTABLE
3-142
SECTION 3 - CHASSIS & TURNTABLE
3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
29 2 978 1-2-6 Diagnostic fault check of synchronism of Plausibility error between sensor and idle Threshold for error detection is an internal ECU
hand throttle and Low idle switch(LIS). switch threshold.
The accelerator pedal must have detected full
load and idle plausibility at least once.
29 3 932 1-2-6 Diagnostic fault check of short circuit to sup- The signal exceeds the applicatable threshold; If the signal is below the applicatable threshold
ply voltage signal range violation APP_uRawSRCHiHTLIS_C, the signal
(signal range check high) of acceleration range violation is reset
pedal signal. after the healing debouncing.
In case when the CCP is active (CCP_stActive =
1)and the reading from the EEPROM
memory is successful, the
signal is below the threshold
APP_uHTLISCCPHi[1], a signal range violation
is reset
after debouncing.
29 4 937 1-2-6 Diagnostic fault check of short circuit to The signal is below the applicatable threshold; If the signal exceeds the applicatable threshold
ground (signal range check low) of accelera- signal range violation APP_uRawSRCLoHTLIS_C, the signal
tion pedal 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 double Sensor defect. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- Short cut to battery or open loop. and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it.
compared with the position of the second If the signal is below the applicatable threshold
pedal APP_uRaw1SRCHigh_C, the signal
range violation is reset after
the healing debouncing.
91 4 940 2-2-6 Analog accelerator pedal sensor 1 or double Short circuit to ground. Check cabling, check accelerator pedal sensor
accelerator pedal sensor: the voltage mea- and if necessary replace it, check
sured by ECU is out of the target range or the connection cable and if necessary repair or
calculated pedal position is implausible replace it
compared with the position of the second If the signal exceeds the applicatable threshold
pedal APP_uRaw1SRCLow_C, the signal
range violation is reset after the
healing
3121631 3-143
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
91 11 976 2-2-6 Diagnostic fault check of synchronism of sin- Measured voltage of accelerator pedal 1 is out of Threshold for error detection is an internal ECU
gle potentiometer and Low idle switch(LIS). plausible range. threshold.
Check cabling, check accelerator pedal and
pedal sensor and if necessary replace it,
check connection cable and if necessary repair
or replace it.
When the PWM period APP_tiPWMPer is in
between APP_tiSRCLoPWMPer_C and
APP_tiSRCHiPWMPer_C .
94 1 474 216 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Check low fuel pressure system (fuel feed
culated by ECU is underneath the target pump, relay , fuse, wiring, sensor) and if
range; the ECU activates a system reaction necessary repair or replace it.
94 3 472 216 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range Short cut to battery or open loop connection cable and if necessary repair or
replace it
94 4 473 216 Low fuel pressure sensor: the voltage of sen- cable break or short circuit, sensor defective, Check cabling, if sensor not working, check sen-
sor measured by ECU is out of the target connection cable damaged sor and if necessary replace it, check
range short cut to ground connection cable and if necessary repair or
replace it
97 3 464 228 Fuel filter water level sensor: the voltage of Sensor not connected or sensor defect. Check of wiring and water in fuel sensor.
sensor measured by ECU is out of the target Check cabling, if charge Water in Fuel sensor is
range not working, check sensor and if
necessary replace it,
check connection cable and if necessary repair
or replace it.
97 4 465 228 Fuel filter water level sensor: the voltage of cable break or short circuit, sensor defective, Check sensor and if necessary replace it, check
sensor measured by ECU is out of the target connection cable damaged. connection cable
range. Short cut to ground. and if necessary repair or replace it.
97 12 1157 228 Fuel filter water level sensor: the maximum Water level in fuel pre-filter reservoir over limit Measure Voltage at Water in Fuel Sensor and
level is exceeded (bad fuel quality) renew harness if needed.
100 1 736 231 Oil pressure is below the target range (warn- Oilpressure too low (pressure below warning Threshold for error detection is an internal ECU
ing threshold) threshold) threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value
100 1 737 231 Oil pressure is below the target range (shut Oilpressure too low (pressure below shut off Threshold for error detection is an internal ECU
off threshold) threshold). threshold.
Check oil level, check engine for oil leckage,
measure oil pressure external to evaluate
sensor value.
100 3 732 224 Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiring
measured by ECU is out of the target range Check cabling. If sensor not working, check sen-
sor and if necessary replace it,
check connection cable and if necessary repair
or replace it.
3-144 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
100 4 733 224 Oil pressure sensor: the voltage of sensor Short circuit to ground The sensed raw voltage value Oil_uRawPSwmp
measured by ECU is out of the target range is above Oil_SRCPSwmp.uMin_C
Check cabling, if sensor not working, check sen-
sor and if necessary replace it, check
connection cable and if necessary repair or
replace it
No detail informationen!
102 1 774 223 charge air pressure below lower limit measured charge air pressure below the thresh- Check complete air system of engine for mas-
old. sive leakage, especially from compressor
to intake air manifold.
Check air filter.
Exchange charge air presure sensor.
102 2 88 223 Charge air pressure messured by sensor is Charged air cooler pressure below threshold. Check waste gate system if necessary replace
above the shut off threshold. TC,
check CAC if all channels are clean,check charge
air piping if nececery.
102 2 89 223 Charge air pressure messured by sensor is Charge air pressure above shut off threshold Check waste gate system if necessary replace
above the warning threshold TC, check CAC if all channels are clean,
check charge air piping if necessery.
102 2 772 223 Deviation between sensed intake manifold deviation between ambient pressure sensor 1) Exchange boost pressure sensor
pressure is not plausible compared to envi- and charge air pressure sensor at not 2) Exchange ECU
ronment pressure. Which sensor is not okay running engine to high
can not be said.
102 3 776 223 Charge air pressure sensor: the measured The Sensor Voltage is above the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and if necessary replace it, check connection
cable and if necessary repair or replace it.
102 4 777 223 Charge air pressure sensor: the measured The Sensor Voltage is below the Threshold. Check cabling, if charge air pressure/tempera-
voltage of sensor by ECU is out of the target ture sensor is not working, check sensor
range and
if necessary replace it, check connection cable
and if necessary repair or replace it
105 0 996 233 Charge air temperature downstream calcu- Charge air temperature (downstream) over Check CAC system and clean it. Check fan func-
lated by ECU is above the target range. warning threshold. tionality.
The ECU activates a system reaction. Check cooling perfomance with temperature
measurement.
105 0 997 233 Charge air temperature downstream calcu- Charge air temperature (downstream) over the Check CAC system and clean it. Check fan func-
lated by ECU is under the shut down thresh- low threshold. tionality. Check cooling perfomance
old. with temperature measurement.
The ECU activates a system reaction.
105 1 992 128 Charged Air cooler down stream tempera- Sensed temperature within intake air manifold actual temperature below -40°C?
ture. < threshold. exchange sensor
Temperature below lower physical thresh-
old.
105 3 994 128 Charge air temperature sensor: the voltage Short circuit to battery. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage > limit age) > Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it.
3121631 3-145
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
105 4 995 128 Charge air temperature sensor: the voltage Short circuit to ground or open load. The sensor raw signal Air_uRawTCACDs (volt-
of sensor measured by ECU is out of the tar- sensor voltage < limit. age) is below Air_SRCTCACDs.uMin_C.
get range. Check CAC-sensor and if necessary replace it,
check connection cable and if
necessary repair or replace it
107 0 752 136 Air filter differential pressure: the pressure Pressure loss above target range with system Check airfilter and if necessary clean or renew it,
difference of the intake air between the filter reaction, air filter clogged or defective, check cabling, check sensor and if
inlet and outlet calculated by ECU is above sensor not working, connection cable damaged necessary replace it, check connection cable
the target range and the ECU activates a Pressure value above warning threshold and if necessary repair or replace it
system reaction
110 0 98 232 Coolant temperature: the coolant tempera- Cooling temperature too high. Coolant temper- Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target ature above warning threshold level, check cooling system in general,
range; the ECU activates a system reaction check thermostat function, check water pump
110 0 99 232 Coolant temperature: the coolant tempera- Coolant temperature above shut off threshold. Clean radiator, check fan drive, check coolant
ture calculated by ECU is above the target level, check cooling system in general,
range. check thermostat function, check water pump
The ECU activates a system reaction
110 1 93 225 Coolant temperature sensor: the voltage of Suspected components:wiring harness, cool- Check wiring harness and connected Coolant
the sensor measured by ECU is out of the tar- ant temperature sensor. Temp Sens.
get range.
110 3 96 225 Coolant temperature sensor: the voltage of Short cut to battery or open load. Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- connection cable and if necessary
get range repair or replace it.
110 4 97 225 Coolant temperature sensor: the voltage of Voltage Surveillance has found shortcut to Check sensor and if necessary replace it, check
the sensor measured by ECU is out of the tar- Ground at Coolant Temperatur Sensor. connection cable and if necessary
get range repair or replace it
Measure Voltage at Coolant Temperature Sen-
sor and renew harness if needed.
111 1 101 235 Coolant level: the coolant level calculated by Coolant level too low, leakage in cooling sys- Check coolant level, inspect cooling system for
ECU is underneath the allowed minimum. tem, sensor defective, wiring damaged. leakage and if necessary repair it,
check sensor and wiring
157 3 877 147 Rail pressure sensor: the voltage of sensor Short cut to battery. Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. Damaged rail pressure sensor. necessary replace it,
check connection cable and if necessary repair
or replace it.
157 4 878 147 Rail pressure sensor: the voltage of sensor Check cabling, check rail pressure sensor and if Check cabling, check rail pressure sensor and if
measured by ECU is out of the target range. necessary replace it, necessary replace it,
check connection cable and if necessary repair check connection cable and if necessary repair
or replace it. or replace it.
164 2 1381 839 Rail pressure safety function is not executed Rail pressure is still above threshold. Threshold for error detection is an internal ECU
correctly threshold.
Reset the fault and at reappearance check ECU
and injection system
168 0 1180 318 Battery voltage: the voltage measured by Battery voltage over limit Check alternator, regulator of alternator and if
ECU is out of the target range necessary replace it, check wiring and
voltage of alternator
168 1 1181 318 Battery voltage: the voltage measured by Battery voltage below limit Check alternator, cabling, contact resistance,
ECU is out of the target range safety fuses, too high load in energy
system, check battery and if necessary replace it
3-146 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
168 2 47 318 Battery voltage: the voltage measured by If Batteryvoltage (Ubatt_U) > 17V or 31V for Check wiring harness and connected alternator.
ECU is out of the target range, system reac- mor than =0.5sec a warning is generated
tion is initiated Battery voltage above warning threshold
168 3 45 318 Battery voltage: the voltage measured by Battery voltage above warning threshold Check wiring harness and connected alternator.
ECU is out of the target range, system reac- (~38,9Volt), Short cut to battery possible.
tion is initiated
168 4 46 318 Battery voltage: the voltage measured by Battery voltage below warning threshold, Check wiring harness and connected alternator.
ECU is out of the target range, system reac- Short cut to ground
tion is initiated
171 3 417 312 Sensor error SCR-System environment tem- open loop to sensor Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check high and if necessary replace it, check connection
cable and if necessary repair or replace it.
171 4 418 312 Sensor error SCR-System environment tem- short circuit to Ground Check cabling, if environment temperature sen-
perature; DPF-System air inlet temperature; sor is not working, check sensor
signal range check low and if necessary replace it, check connection
cable and if necessary repair or replace it
172 0 1425 226 sensed intake air temperature at air filter > sensed intake air temperature at air filter > Check outside conditions:
physical high limit physical high limit Temperature > Threshold within the intake air
system of the engine?
E.G: engine sucks in air from hot asphalt out of
paver bucket
Sensor positioned within black air filter housing
above engine lid at hot environmental
conditions and idling or similar?
=> if yes check with application team to adapt
limits
if not check sensor and wiring harness
exchange sensor
172 1 1183 226 sensed air temperature within air intake sensed air temperature within air intake path of Cold start and ambient temperature < thresh-
path of engine below physical low limit engine below physical low limit old
Check wiring harness to AFST-sensor
Exchange AFST-sensor
190 0 389 214 Engine speed: the engine speed calculated Overspeed monitoring during 1 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over Limit.
190 2 421 213 ECU measures a deviation between cam- Offset error between crankshaft and camshaft. Threshold for error detection is an internal ECU
shaft and crankshaft angle to target. threshold, occurs by offset between
crankshaft and camshaft.
Check increment wheel position, clean and
adjust if necessary, check sensor postition.
Check Camshaft and Crankshaft senor or wiring.
190 8 419 212 Camshaft speed sensor: the ECU receives no When disturbed camshaft signal detected. Threshold for error detection is an internal ECU
signal and uses the signal from crankshaft Error in sensor or wiring. threshold, occurs by disturbed
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
3121631 3-147
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
190 8 422 212 Sensor crankshaft speed; disturbed signal Error in sensor or wiring. Threshold for error detection is an internal ECU
Crankshaft sensor defect. threshold, occurs by disturbed
crankshaft signal.
Check increment wheel position, clean and
adjust if necessary, check sensor postition.
Check Crankshaft Sensor or wiring.
190 11 390 214 Engine speed: the engine speed calculated Overspeed monitoring during 2 level of FOC check powertrain settings regarding overspeed
by ECU is above the target range; the ECU (Failure overrun condition) if engine speed
activates a system reaction was over limit.
190 12 420 212 Camshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the camshaft signal.
engine speed Check increment wheel position, clean and
Threshold: adjust if necessary, check sensor postition.
Check Camshaft Sensor or wiring.
190 12 423 212 Crankshaft speed sensor: the ECU receives no Error in sensor or wiring. Threshold for error detection is an internal ECU
signal and uses the signal from camshaft threshold, occurs by disturbed or no
speed sensor as alternative to calculate the Crankshaft signal.
engine speed. Check increment wheel position, clean and
adjust if necessary, check Crankshaft
sensor postition or wiring.
190 14 391 214 Engine speed: the engine speed calculated Overspeed monitoring during ORC (Override check powertrain settings regarding overspeed
by ECU is above the target range; the ECU conditions) if engine speed was over
activates a system reaction 2900rpm
190 14 1222 2-1-2 Camshaft- and Crankshaft speed sensor sig- Sensors for engine speed are defect. Threshold for error detection is an internal ECU
nal not available on CAN or defect. threshold.
Check wiring, check cabels and repair or replace
if necessary.
411 0 791 693 delta pressure across venturi in EGR line sensed value of venturi difference pressure > Threshold for error detection is an internal ECU
above physical high limit high limit threshold.
EGR-Valve blocked open
EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect
411 1 792 693 delta pressure across venturi in EGR line sensed value of venturi difference pressure < Threshold for error detection is an internal ECU
below physical low limit low limit threshold.
Check correct mounting of difference pressure
sensor at venturi tube
Exchange difference pressure sensor broken
411 3 795 693 The sensed raw voltage EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the maxi- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
411 4 381 693 Range check cannot be done or interrupted. EGR or wiring defect Check wiring harness and connected EGR.
3-148 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
411 4 796 693 The sensed raw voltage value EGR Delta pressure Sensor defect Check cabling. If charge EGR Delta pressure sen-
Air_uRawPEGRDeltaP is above the mini- sor is not working, check sensor and
mum threshold. if necessary replace it, check connection cable
and if necessary repair or replace it.
411 11 793 693 DFC is stored in EEPROM and status kept until deviation between desired O2 concentration in Threshold for error detection is an internal ECU
check is allowed intake air manifold threshold.
to be carried out again and the real O2-concentration within intake air EGR-Valve mechanically blocked open or closed
DFC can be reset by service routine 216 manifold > limit EGR-pipe blocked with metall plate instead
sealing downstream EGR-Valve
EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position =>
Check intake throttle
Exhaust pressure too high => Check Exhaust
pressure
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect
412 3 1007 682 EGR downstream temperature sensor: the Short circuit to battery. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage > limit Exchange TEGR-sensor.
the target range.
412 4 1008 682 EGR downstream temperature sensor: the Short circuit to ground or open load. Check wiring harness to TEGR-sensor.
voltage of sensor measured by ECU is out of sensor voltage < limit Exchange TEGR-sensor.
the target range.
630 12 376 281 Internal hardware monitoring: the ECU finds Section could not be erased Threshold for error detection is an internal ECU
an error during the access to its EEPROM threshold.
memory or works with an alternative value There is no healing possible for the error. In the
every new initialization phase, the
debounce level is set to zero.
If not programmed, EEPROM is defect --> ECU is
defect, reprogramm ECU and if
necessary replace it.
630 12 377 281 Internal hardware monitoring: the ECU finds Minimum 3 blocks could not be readed, There is no healing possible for the error. In the
an error during the access to its EEPROM EEPROM has Checksum Error every new initialization phase, the
memory or works with an alternative value debounce level is set to zero.
If not programmed, EEPROM is defect -->ECU is
defect, reprogramm ECU and if
necessary replace it
630 12 378 281 Internal hardware monitoring: the ECU finds Block could not be written for minimum 3 times Threshold for error detection is an internal ECU
an error during the access to it's EEPROM threshold.
memory or works with an alternative value If not programmed, EEPROM is defect --> ECU is
defect, reprogramm ECU and if
necessary replace it.
639 14 84 271 CAN bus 0: the ECU is not allowed to send CAN BusOff error; CAN 0 (Customer CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold.
detected. BusOff bit for CAN A node is set.
Check wiring of CAN bus and if necessary repair
it, check connection cable and if
necessary repair or replace it, check resistance in
CAN lines (120 Ohm)
3121631 3-149
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
651 3 580 154 Injector cyl. 1: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 1 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
damaged test for diagnosis.
651 5 568 154 Injector cyl. 1: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 1 threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
652 3 581 155 Injector cyl. 2: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 2 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
damaged test for diagnosis.
652 5 569 155 Injector cyl. 2: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 2 threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
653 3 582 156 Injector cyl. 3: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 3 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
damaged test for diagnosis.
653 5 570 156 Injector cyl. 3: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 3 threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
654 3 583 161 Injector cyl. 4: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 4 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
test for diagnosis.
654 5 571 161 Injector cyl. 4: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 4 threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
655 3 584 162 Injector cyl. 5: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 5 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
test for diagnosis.
655 5 572 162 Injector cyl. 5: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 5 threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
656 3 585 163 Injector cyl. 6: the current drop measured by Suspected Components: Threshold for error detection is an internal ECU
ECU is above the target range injector cylinder 6 threshold.
wiring harness, cable break or short circuit, sen- Check wiring harness, injectors and if necessary
sor defective, connection cable repair/replace it. Use SerDia Injector
test for diagnosis.
3-150 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
656 5 573 163 Injector cyl. 6: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU
nection cyl. 6 threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
676 11 543 263 Cold start aid relay error. Relay defect or wire harness problem Threshold for error detection is an internal ECU
threshold.
check wire harness, replace relay
676 11 544 263 Cold start aid relay open load Relay or wire harness Threshold for error detection is an internal
threshold.
check wire harness, replace relay
677 3 956 512 Start relay (high side power stage): the cur- Short cut HighSide-output to battery. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the tar- threshold.
get range. Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
677 3 960 512 Start relay (low side power stage): the cur- Shortcut LowSide-Output to battery. Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- threshold.
get range. Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
677 4 957 512 Start relay (high side power stage): Shortcut HighSide-output to ground. Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold.
the target range. Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
677 4 961 512 Start relay (low side power stage): the cur- Shortcut LowSide-Output to ground. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the tar- threshold.
get range. Check cabling and start relay and if necessary
replace it,
check connection cable of terminal 50 and if
necessary repair or replace it.
677 5 958 512 Start relay (low side power stage): the cur- Open circuit/disconnection LowSide-Output. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the tar- threshold.
get range Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
677 12 959 512 Start relay (low side power stage): the cur- Temperature over limit. Threshold for error detection is an internal ECU
rent drop measured by ECU is above the tar- threshold.
get range. Check cabling and start relay and if necessary
replace it,
check connection cable and if necessary repair
or replace it.
691 8 928 928 Supply module heater: PWM time periode PWM signal for temperature readout from sup- The Time period of the received PWM signal
out of valid range. ply module to the control unit is out of SCR_tiSMPerPwm is within the specified
range. range of150ms to 250ms
Supply modul defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
3121631 3-151
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
729 3 549 263 wiring to the intake air heater device is Intake Air Heater Device: overload, short-circuit Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, Check wiring to the intake air
heater device.
729 4 551 263 wiring to the air intake heater is faulty Relay (for cold start aid) cable break or short to Threshold for error detection is an internal ECU
ground: threshold.
Electrical error, check wiring to the air intake
heater.
729 5 545 263 The cold start aid relay is according to wiring Relay defect or wire harness problem Threshold for error detection is an internal ECU
faulty. threshold.
Electrical error, check wires
729 12 547 263 The cold start aid relay is overheated, which High temperature around the cold start relay. Check the functionality of relay and replace it if
causes this error needed.
Check the temperature around the cold start
relay during worst case operation.
898 9 305 118 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
- active short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
1079 13 946 282 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of the Pin A19: DEF press / Exh.PressBeforeTurb (P3) / working voltage and if necessary correct
power supply voltage of sensor output 1. Air Pump Press it,
/BrnFuelPressAfterDV2 Pin K19: Fan Speed Sen- check connection cable and if necessary repair
sor or replace it,
Pin A21: LDF6T / OilPress / LowFuelPress Pin if error is not removable, change ECU.
A17: Rail Pressure Sensor
Suspected components EDC17cv54
Pin A21: CAM speed Pin K44: Delta Press Venturi
/ Poti EGR or Inlet Throttle
Pin A24: LDF6T / OilPress / LowFuelPressPin
K43: Reserve 5V Sensor Supply
Pin A09: second footpedal
Suspected components EDC17cv56
Pin A21: Cam speed Pin K44: DEF press / Air Fil-
terDiffPress
Pin A24: LDF6T / OilPress / LowFuelPress Pin
K43: second footpedal
Pin A09: Delta Press Venturi
1080 13 947 282 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of the Pin K16: second footpedal working voltage and if necessary correct
power supply voltage of sensor output 2. Pin A20: Exh.PressAfterTurb/DPFDiffPress/ it, check connection cable and if necessary
BrnDV1Press/HCIPressDV1DV2 repair or replace it, if error is not removable,
Suspected components EDC17cv54 change ECU.
Pin K45: DPF Diff Press / Exh. Press After Turb /
Fan Speed Sensor
Pin A46: first footpedal
Suspected components EDC17cv56
Pin A22: Fan Speed Sensor
Pin K45: Position EGR or Intake throttle flap
Pin K46: First footpedal
3-152 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
1109 2 121 341 Request of engine shut off: the operator Engine Shut Off demand has been ignored by Depending on error requested a shut off.
ignores the engine shut off request within an the user
allowed period.
1136 0 1398 681 ECU internal temperature; temperature Short-Circuit in ECU, ECU heated by hot air Close warm air circuits, replace ECU
measured by ECU is out of the target range
1231 14 85 271 CAN bus 1: the ECU is not allowed to send CAN BusOff error; CAN 1 (Diagnostic CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold.
detected BusOff bit for CAN B node is set.
Warning, no diagnostic with SERDIA2010 Check wiring of CAN bus and if necessary repair
possible it, check connection cable and if
necessary repair or replace it, check resistance in
CAN lines (120 Ohm)
1235 14 86 271 CAN bus 2: the ECU is not allowed to send CAN BusOff error; CAN 2 (Engine CAN) Threshold for error detection is an internal ECU
messages, because the status "BusOff" is threshold.
detected. BusOff bit for CAN C node is set.
Warning, depends on engine, EAT. Check wiring of CAN bus and if necessary repair
it, check connection cable and if
necessary repair or replace it, check resistance in
CAN lines (120 Ohm)
1237 2 747 145 Override switch switch: the ECU receives a Switch is blocked, taster locked, connection If the Block Button is pressed shorter than the
permanent signal. cable damaged Maximum Plausible pressing Time.
plausbility error "override switch > 250ms Check cabling, if sensor is not working, check
pressed". switch and if necessary replace it, check
connection cable and if necessary repair or
replace it.
1761 0 1593 129 The urea tank level sensor detects a value Suspected components: Check level sensor and float gauge
higher than the maximum allowed thresh- Urea Quality Sensor defect
old mechanical defect at the float gauge
1761 1 1594 129 The DEF tank level sensor detects a value Suspected components: Check level sensor and float gauge
lower than the minimum allowed threshold Urea Quality Sensor defect
mechanical defect at the float gauge
1761 14 1655 138 The urea tank volume ratio is below the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <5% below applicable threshold 5% Check DEF level sensor.
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 the actual urea tank level SCRUTnk_rVol_mp [%] is Check urea level => if empty, then fill in urea
threshold of <2.5% below 2.5% Check DEF level sensor.
If there is urea in the tank, then move the floater
of the level sensor. The floater must
be free. If you lift the sensor body, then
SCRUTnk_rVol_mp must change.
Exchange DEF level sensor, if no change of value
or it's implausible.
3121631 3-153
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
1761 14 1880 138 The DEF tank level is below the threshold. actual DEF tank level SCRUTnk_rVol_mp [%] is Check DEF level => if empty, refill
below the threshold Check DEF level sensor.
If there is urea in the tank loose the sensor and
move it. The floater must be free and
move if you lift the sensor body.
SCRUTnk_rVol_mp must change.
Compare SCRUTnk_rVol_mp to:
1 = SCR_rawUTnkLvl
2 = SCR_rAdapUtnkLvl
3 = SCRUTnk_rActTnkVol
*SCRUTnk_facVolPer_mp
In case of malfunction, exchange DEF level sen-
sor.
2791 0 1763 415 Internal actuator temperature is above Overheating of EGR actuator during operation. Let EGR actuator cool down and check heat
threshold. accumulation during worst case operation.
2791 2 1753 415 corrupted CAN communication with actua- CAN bus error or faulty EGR actuator. Threshold for error detection is an internal ECU
tor. threshold.
Check other CAN bus components. If no mes-
sage is sent, fix the wiring.
If o.k. exchange EGR actuaror.
2791 3 1758 415 Overvoltage at EGR actuator. High voltage from the battery Check battery voltage.
2791 4 1759 415 Undervoltage at EGR actuator. Low voltage from the battery. Check battery voltage.
2791 6 1757 415 Overcurrent to EGR actuator. High voltage from battery. Check battery voltage. Check if EGR is blocked or
EGR actuator is blocked or moving very hard. not running smoothly.
If everything is o.k. change EGR actuator.
2791 7 1752 415 EGR actuator is mechanically blocked. EGR actuator faulty or blocked. Threshold for error detection is an internal ECU
threshold.
Check the EGR actuator and EGR valve to
mechanical blockage / clean.
Check for free movement of the valve. If it'S
blocked, then exchange the EGR valve.
2791 7 1761 415 EGR actuator spring broken. mechanical damage of spring due to overstress. Threshold for error detection is an internal ECU
threshold.
Exchange EGR actuator.
2791 12 1755 415 Internal electrical fault of EGR actuator. Internal damage of EGR actuator due to high Threshold for error detection is an internal ECU
temperature or electrical wiring issue. threshold.
Exchange EGR actuator.
2791 13 1754 415 EGR actuator can not learn stop positions. Error detection during the learning process. Threshold for error detection is an internal ECU
Possibly only second failure if other EGRTV threshold.
failures occure. Start Serdia Usecase to reset EGR actuator.
Check EGR valve and mounting situation. If o.k.
change EGR actuator.
2791 13 1756 415 EGR actuator can not learn stop positions Interruption of learning process due to mechan- Threshold for error detection is an internal ECU
because procedure was interrupted. ical damage. threshold.
Start Serdia Usecase to reset EGR actuator.
2791 13 1760 415 Stop positions of EGR valve not o.k. Mechanical damage of EGR actuator. Threshold for error detection is an internal ECU
EGR valve is blocked or moving very hard. threshold.
Start Serdia Usecase to reset EGR actuator.
2791 16 1762 415 Internal actuator temperature above thresh- overheating of EGR actuator Let EGR actuator cool down, check heat accu-
old. mulation during worst case operation.
3-154 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
2797 4 1337 565 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 0 threshold.
Check wiring, component, ECU
Note: affected injector has to be evaluated
according to firing order
2797 4 1339 565 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 0 Note: affected injector has to be evaluated
according to firing order
2798 4 1338 566 Injector diagnosis: Timeout of Injetor detec- Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
tion cylinder bank 1 threshold.
Check wiring, component, ECU
Note: affected injector has to be evaluated
according to firing order
2798 4 1340 566 Injector test: Short cut to ground on cylinder Short-Circuit to ground on component wiring Check wiring, component, ECU
bank 1 Note: affected injector has to be evaluated
according to firing order
3031 0 1135 669 The urea tank temperature sensor detects a Sensed urea tank temperature > physical range Case "CANBUS sensor":
value above the maximum allowed thresh- high limit Check urea tank temperature: really hot?
old Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Tank heater permantly on?
Check wiring of DEF-quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really hot?
Check urea tank temperature SCR_tSensUTnkT
Compare urea tank temperature to EnvT_t or to
SCR_tSMT (the urea temperature
inside the supply module) identical?
Tank heater permantly on?
Check wiring of analog DEF T & Level sensor
3031 1 1136 669 The urea tank temperature sensor detects a sensed urea tank temperature < physical range Case "CANBUS sensor":
value lower than the minimum allowed low limit Check ambient temperature EnvT_t => About
threshold. -40 °C? If yes Error could be plausible
Check CANBus-message of DEF sensor urea tank
temperature Com_dRxSCR2Byt2
Compare it to Com_dRxSCR1Byt1 (urea tem-
perature at quality sensor) identical?
Check wiring of DEF-quality sensor
Check quality sensor
Case "analog DEF T & Level sensor":
Check urea tank temperature: really that cold?
Check ambient temperature EnvT_t =>
About -40 °C? If yes Error could be plausible
Check urea tank temperature SCR_tSensUTnkT
Check wiring of analog DEF T & Level sensor
Check analog DEF T & Level sensor
3224 2 129 596 DLC Error of CAN-Receive-Frame AT1IG1Vol Not Used Threshold for error detection is an internal ECU
NOX Sensor (SCR-system upstream cat; DPF- threshold.
system downstream cat); length of frame Check Nox-Sensor and the wiring from CAN-
incorrect BUS.
3121631 3-155
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
3224 9 130 597 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX sensor and sensor connection check
AT1IG1Vol; NOX sensor (SCR-system
upstream cat; DPF-system downstream cat)
3234 2 138 114 DLC Error of CAN-Receive-Frame AT1O1Vol Failure of the CAN Bus message NOX downstream sensor and sensor connection
NOX Sensor (SCR-system downstream cat; check
DPF-system downstream cat); length of
frame incorrect
3234 9 139 117 Timeout Error of CAN-Receive-Frame Failure of the CAN Bus message NOX downstream sensor and sensor connection
AT1OG1Vol; NOX sensor (SCR-system down- check
stream cat; DPF-system downstream cat)
3361 3 1077 677 Urea dosing valve (low side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range See substitute function
Check the wiring
3361 3 1078 677 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range Check the wiring
3361 4 1079 677 Urea dosing valve (low side power stage): Fault in the wiring Check the wiring
the current drain measured by ECU is above
the target range
3361 4 1080 677 Urea dosing valve (high side power stage): Fault in the wiring Threshold for error detection is an internal ECU
the current drain measured by ECU is above threshold
the target range Check the wiring
3361 6 1075 677 Urea dosing valve: the current measured Fault in the wiriing Check wiring
value by ECU at the end of the injection is too Defect urea dosing injection valve Check the urea dosing injection valve
high
3519 3 1898 277 The integrated diagnostic of the tempera- Wrong diagnostic of the short circuits logic Check the wiring to the suction unit in the DEF
ture sensor of the Urea Quality Sensor recog- inside the temperature sensor of the UQS tank.
nized a short circuit to battery. CAN Communication corrupted Check the CAN bus communication of the suc-
The UQS Sensor is an combined sensor of tion unit. In case the communication is
tank temperature, filling grade and DEF corrupt, exchange the suction unit.
quality and it is also an CAN sensor --> no
PIN
3519 4 1899 277 The integrated diagnostic of the tempera- DEF quality sensor in the suction unit of the DEF Check the wiring to the suction unit of the DEF
ture sensor of the Urea Quality Sensor recog- tank is defect tank.
nized a short circuit to ground CAN Communication corrupted Check the CAN bus communication from the
suction unit. In case the signal is corrupt,
exchange the suction unit in the DEF tank.
3-156 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
3519 12 1895 277 The integrated temperature sensor of the Temperature sensor inside the UQS defect. Check the temperature sensor signal for plausi-
Urea Quality Sensor measures higher tem- CAN Communication corrupted. bility. In case of improper signal,
perature than threshold Overheating of the DEF tank due to malfunction exchange the suction unit in the tank.
of the heating valve. Check CAN bus communication for proper sig-
Flow direction is of coolant is wrong due to nal. In case of improper signal, exchange
mixed up the hoses routed to the heating the suction unit in the tank.
valve. Check the function of heating valve and routing
Overheating of the DEF tank due to heat transfer of the hoses. The coolant flow through
from neighbor parts. 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 installa-
tion of the DEF tank.
3519 13 1908 277 Temperature at UQS out of range the speci- Suspected Components Check temperature system and/or DEF quality
fied thresholds; invalid quality of the tem- Tank heater sensor
perature DEF sensor
3520 2 1904 2-7-8 Measured DEF Quality from UQS is too low. Suspected components: Check that there is liquid urea of known quality
Quality value received from UQS is < 22 % for Urea quality sensor defect in the tank first
a certain time and a certain number or for Wrong installation (measuring air) Check urea tank level. Add urea until level is at
measuring conditions not observed for a cer- Urea level sensor defect least 10 cm above sensor.
tain time. Non urea filled in tank Ensure that urea is not frozen / sufficient urea is
CANBUS problems liquid
Evaluation conditions for new quality check not Check Sensor: Are urea tank temperature and
fulfilled after one previous mal detection level displayed? Changes the level if you
refill urea?
Check electrical connection
Check CANBus
New quality detection is carried out if urea re-
fill is detected or if an quality evaluation
was triggered and was not finished success-
fully: To provoke a quality measurement: refill
urea, at least 10 % of tank volume
Wait until quality evaluation was carried out,
can take up to 30 minutes => check value.
It should be about 33 %
Exchange quality sensor
3520 3 1896 278 The integrated diagnostic of the Urea Quality wiring harness of UQS corrupted Threshold for error detection is an internal ECU
Sensor recognized a short circuit to battery CAN Communication corrupted threshold.
Check the wiring harness from the ECU to the
suction unit of the DEF tank
Check the CAN bus communication. If the signal
is corrupt, then exchange the suction
unit.
3520 4 1897 278 The integrated diagnostic of the Urea Quality wiring harness to the suction unit in the DEF Threshold for error detection is an internal ECU
Sensor recognized a short circuit to ground. tank is corrupted threshold.
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.
3121631 3-157
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
3520 13 1907 278 Urea quality at UQS out of range the speci- Suspected components Check DEF quality and/or DEF quality sensor
fied thresholds; invalid quality of the urea DEF quality sensor
qualiy DEF
3532 3 1911 127 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or sensor.
greater than the maximum physical range UQS defect
threshold
Comment: tank temperature is measured by
the UQS sensor
3532 4 1912 127 The urea quality value from the sensor is Suspected Components: Check DEF quality and/or Sensor.
lower than the minimum physical range UQS defect
threshold.
3711 12 1455 711 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC
DPF temperature < Threshold 1 temperature, is below or above Exh_tSensOxiCatUs within Stand-still: > 450
Temperature Phy_tPfWgh, the weighted the target temperature towards the end of the °C? If
DPF temperature > Threshold 2 stand-still main phase. not:
towards the end of the stand-still main => Check air path of engine: EGR-Valve,
phase. Intake-Throttle, Turbocharger and Piping
each for leakage and correct function
Check temperature difference across DOC by
Exh_tSensOxiCatDs -
Exh_tSensOxiCatUs within Stand-still: <
100°C? If not:
Check exhaust pipe downstream turbo charger
for oil?
check injectors: is an injector got stuck?
Too many hydrocarbons in exhaust? White
smoke (at hot EAT system, not at cold
start)?
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check exhaust gas temperature sensors within
EAT-system: T upstream DOCC, T
downstream DOC & T upstream SCR catalyst
all three of them can influence Phy_tPfWgh
3936 14 1917 2-8-6 Standstill escalation by time. In case the Stand-still request ignored by the operator. Perform Stand-still. If soot load level of DPF has
standstill request will not be released within Display / stand-still request lamp broken. increased too high already call service
50 h by the driver this fault code will be set. to perform stand-still.
In case the DPF soot load level remove DPF =>
Exchange DPF.
4334 0 1122 665 The absolute pressure value of the urea Suspected Components: Check the urea pump
pump is greater than an applicable maximal Urea pump defect Check the supply module pressur sensor
filtered pressure threshold Supply module pressure sensor defect Clean the urea pump (filter)
Pump contains dirty parts
4334 1 1123 665 Urea supply module pressure sensor: The Check the urea pump Check the urea pump
absolute pressure value of the urea pump is Check the supply module pressur sensor Check the supply module pressur sensor
less than an applicable minimal filtered Clean the urea pump (filter) Clean the urea pump (filter)
pressure threshold
3-158 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
4334 2 1866 665 absolute difference of sensed urea pump absolute difference of sensed urea pump pres- Check environment pressure sensor (EnvP_p)
pressure (SCR_pAbsSensUPmpP) and ambi- sure (SCR_pAbsSensUPmpP) and => plausible value?
ent pressure (EnvP_p) > limit ambient pressure (EnvP_p) > limit Engine shut-off and immediately re-started?
abs(UPmpP_pDiffPmpEnv_mp) > abs(UPmpP_pDiffPmpEnv_mp) > => Shut-off again. Wait until afterun of
UPmpP_pDiffPmpEnv_C (250 hPa) UPmpP_pDiffPmpEnv_C ECU has finished, re-Start engine
Back-flow line free? Does the urea pump pres-
sure show values < 1000 hPa in SCR
state emptying (64)?
Check revision valve => Does the urea pump
pressure show values < 1000 hPa in SCR
state emptying (64)? => exchange supply
module
Supply module pressure sensor defect =>
exchange supply module
4341 3 1104 675 Urea heater supply line: the current drain Electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
4341 4 1105 675 Urea heater supply line: the current drain Electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
4341 5 1102 675 Urea heater supply line: the current drain Electrical error Threshold for error detection is an internal ECU
measured by ECU is above the target range threshold
Check wire harness
Check supply line
4343 3 1096 673 Urea pressure line heater: the current drain shortcut to battery Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
broken heating element in pressure line Check heating element
4343 4 1097 673 Urea pressure line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Short cut to ground or broken wiring, broken Check heating element
heating element in pressure line
4343 5 1094 673 Urea pressure line heater: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Broken wiring, broken heating element in pres- Check heating element
sure line
4345 3 1092 674 Urea backflow line heater: the current drain Shortcut to battery Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Short cut to battery or broken wiring, broken Check heating element
heating element in backflow line
4345 4 1093 674 Urea backflow line heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Short cut to ground or broken wiring, broken Check heating element
heating element in backflow line
3121631 3-159
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
4345 5 1090 674 Urea backflow line heater: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Broken wiring, broken heating element in back- Check heating element
flow line
4360 0 1069 668 The filtered urea cat upstream temperature Sensed temperature upstream SCR > physical Check temperature difference across DOC
is greater than an applicable maximum tem- high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at higher
perature threshold engine load => high difference > 100 K?
If yes, the engine emitts too many Hydrocar-
bons => check injectors: is an injector got
stuck?
=> Check EGR Valve
If difference normal the exhaust out of the engie
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 cat is Sensed temperature upstream SCR catalyst < Cold start and ambient temperature < Thresh-
less than an applicable minimum tempera- than physical low limit old? Missdetection?
ture threshold Check wiring harness to UCatUsT-sensor
Exchange UCatUsT-sensor
4360 2 1865 668 Error at static plausibility check: Error at static plausibility check: Check whether temperature sensor upstream of
absolut temperature difference of sensed absolut temperature difference of sensed tem- SCR catalyst is physically mounted
temperature upstream SCR catalyst and perature upstream SCR catalyst and within exhaust pipe
ambient temperature > as static plausibility ambient temperature > as static plausibility If cold start condition can be made sure (engine
limit limit was off for at least 8 h) compare
at engine cold start (engine was off for at at engine cold start (engine was off for at least 8 values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
least 8 h), temperature upstream of SCR cat- h), temperature upstream of SCR Exh_tOxiCatDs and
alyst is expected to be identical to ambient catalyst is expected to be identical to ambient SCR_tSensUCatUsT at ignition on, without
temperature => see enable conditions for temperature => see enable conditions for starting the engine. All identical?
details. details. Compare values of Exh_TOxiCatUs,
Error at dynamic plausibility check: Error at dynamic plausibility check: Exh_tOxiCatDs and SCR_tSensUCatUsT after 15
temperature difference of sensed tempera- temperature difference of sensed temperature min in constant operation point: show all simi-
ture upstream SCR catalyst and ambient upstream SCR catalyst and ambient lar values (30 K tolerance width). Are
temperature < as dynamic plausibility limit temperature < as dynamic plausibility limit ambient temperature and (EnvT_t), cooling
dynamic check is blocked if static plausibility dynamic check is blocked if static plausibility water temperature (EngDa_tEng) plausible?
check is already faulty check is already faulty Sensor coated with urea crystalls? Dismount
=> Temperature upstream SCR catalyst => Temperature upstream SCR catalyst must urea injector and inspect temperature
must be by 40°C higher than ambient tem- be by 40°C higher than ambient sensor upstream SCR catalyst visually
perature if engine runs and a certain delay temperature if engine runs and a certain delay Check wiring of sensor
time has expired. time has expired. Replace sensor
4361 3 1072 668 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst > maximum limit Check wiring
of the target range Short circuit to battery Replace UCatUsT-sensor
4361 4 1073 668 Urea catalyst upstream temperature sensor: Voltage of temperature sensor upstream SCR Check sensor
the voltage of sensor measured by ECU is out catalyst < minimum limit Check wiring
of the target range Short circuit to ground Replace UCatUsT-sensor
3-160 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
4365 2 1137 6-6-9 Signal error in case of Urea tank temperature CAN message is not send properly. Check sensor connector
trnasmitted via CAN-signal Com_tUTnkT. Check CANbus
4365 3 1138 6-6-9 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The Sensed raw voltage value SCR_uRawUTnkT
is below SCR_SRCUTnkT.uMax_C.
Check wiring.
4365 3 1914 669 Internal error of DEF quality sensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF quality sensor
Wiring harness
4365 4 1139 6-6-9 Urea tank temperature sensor: he current Shortcut or open load. Threshold for error detection is an internal ECU
drain measured by ECU is above the target threshold.
range. The sensed raw voltage value SCR_uRawUTnkT
is above SCR_SRCUTnkT.uMin_C.
Check wiring.
4365 4 1915 6-6-9 Internal error of DEF quality sensor. Suspected componentes: Check wiring harness and DEF qualitysensor
DEF quality sensor
Wiring harness
4366 3 1112 671 Urea tank heating valve: the current drain Shortcut to battery Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
4366 4 1113 671 Urea tank heating valve: the current drain Shortcut to ground Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
4366 5 1110 671 Urea tank heating valve: the current drain Open load Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 Check wiring
Broken wiring Check urea tank heating valve
Urea tank heating valve defect
4375 3 1120 666 Urea supply module pump: the current drain Shortcut to battery Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 The hardware detects absence of any short cir-
Broken wiring cuit to battery on the PWM output power
Pump in urea supply module defect stage for the urea pump module actuator
Check wiring
Check pump in the urea supply module
4375 4 1121 666 Urea supply module pump: the current drain Shortcut to ground Threshold for error detection is an internal ECU
measured by ECU is above the target range If this error detected during the heating phase is threshold
a result error: KWP 1089 The hardware detects a short circuit to ground
Broken wiring error on the PWM output power stage
Pump in urea supply module defect for the UreaPump Module Motor Actuator. The
error is updated by setting bit 1 of
measuring point UPmp-
Mot_stPrevTstRslt_mp
Check wiring
Check pump in the urea supply module
3121631 3-161
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
4375 5 1118 666 Urea supply module pump: the ECU can not Open load Threshold for error detection is an internal ECU
measure any reaction during pump control Broken wiring threshold
Pump in urea supply module defect The hardware detects the presence of load on
the PWM output power stage for the
urea pump module actuator.
Check wiring
Check pump in the urea supply module
4376 3 1131 667 Urea supply module reversal valve: the cur- Shortcut to battery Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- Fault in the wiring threshold
get range Reversal valve in the urea supply module defect Check wiring
Check urea supply modul
4376 4 1132 667 Urea supply module reversal valve: the cur- Shortcut to ground Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- Fault in the wiring threshold
get range Reversal valve in the urea supply module defect Check wiring
Check urea supply modul
4376 5 1129 667 Urea supply module reversal valve: the cur- Open load Threshold for error detection is an internal ECU
rent drain measured by ECU is above the tar- Fault in the wiring threshold
get range Reversal valve in the urea supply module defect Check wiring
Check urea supply modul
4765 0 1039 683 The exhaust temperature value from the sensed temperature upstream DOC > shut-off Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle,
is above an applicable upper shutoff thresh- Check Turbocharger and Piping each for leakage
old and correct function
TOxiCatUs_tShOffThresHiAds_C = Thresh- Check injectors: is an injector got stuck?
old 1 in Normal and Exchange temperature sensor upstream DOC
Heatmodes
(TOxiCatUs_tShOffThresHiRgn_C = Thresh-
old 2
in stand-still)
4765 0 1040 683 The exhaust temperature value from the Sensed temperature upstream DOC > warning Check air path of engine: EGR-Valve, Intake-
sensor befor DOC limit Throttle, Turbocharger and Piping each
is above an applicable upper warning for leakage and correct function
threshold Check injectors: is an injector got stuck?
TOxiCatUs_tWarnThresHi_C = Threshold Exchange temperature sensor upstream DOC
3-162 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
4768 2 1036 683 Static plausibility check: Static plausibility check: Check ambient temperature => value plausi-
The exhaust temperature value from the The exhaust temperature value from the sensor ble?
sensor before DOC, the exhaust temperature before DOC, the exhaust temperature upstream DOC sensor mounted within exhaust
value from the sensor after DOC, the temper- value from the sensor after DOC, the tempera- line?
ature value from the sensor before ture value from the sensor before T upstream DOC sensor physically mounted in
SCR-Cat, the environment temperature and SCR-Cat, the environment temperature and the correct position upstream DOC? (not
the coolant engine temperature their ratios coolant engine temperature their ratios upstream SCR or downstream DOC?)
to each other exceed their related thresh- to each other exceed their related thresholds. Check T upstream DOC sensor
olds. (difference between temperature after DOC and Check other T-sensors within EAT-system
Dynamic plausibility check with environ- temperature before DOC > Threshold 1 (Exh_tOxiCatDs & UCatUsT_tFlt_mp show
ment temperature sensor value: difference between temperature befor DOC and plausible values? No errors on them?
The exhaust temperature value from the before SCR > Threshold 2
sensor before DOC is lower than an applica- difference between temperature after DOC and
ble environment temperature threshold before SCR < Threshold 3
difference between temperature after DOC and
ambinet temperature < Threshold 4
differnece between temperatur ambient tem-
perature 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 (< envi-
ronmental temperature + Threshold 6)
4768 2 1881 683 At engine cold start conditions the sensed Difference temperature of exhaust gas temper- Check whether all exhaust gas temperature
exhaust gas temperature downstream DOC ature downstream DOC and fixed sensors within the EAT system are
(Exh_tSensTOxiCatDs) ambient temperature at ignition on exceeds a mounted properly: Within the exhaust line and
has exceeded the sum of ambient tempera- certain limit earlier than the difference at correct positions.
ture (EnvT_t) + offset (40°C) earlier than the temperature of exhaust gas temperature Check the position of the sensor upstream SCR
sensed exhaust gas upstream DOC and fixed ambient temperature which might be physically mounted in
temperature upstream of DOC at ignition on. the wrong position.
(Exh_tSensTOxiCatUs). If cold start condition can be made sure (engine
The check is only performed once each igni- was off for at least 8 h) compare
tion cycle and only if the start is judged a cold values of EnvT_t, EngDa_tEng, Exh_TOxiCatUs,
start. Exh_tOxiCatDs and
Error status is frozen for that ignition cycle. SCR_tSensUCatUsT at ignition on, without
No healing possible. starting the engine. All identical? Then the
sensors itself are okay.
Check exhaust piping for leakage.
Check wiring of sensors
Replace sensors
Check DOC => physicallly intact?
4768 3 1044 683 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is above upstream DOC
ECU is out of the target range Exh_SRCTOxiCatUs.uMax_C Exchange temperature sensor upstream DOC
Shortcut to battery
4768 4 1045 683 Oxidation catalyst upstream temperature The sensed raw voltage value Check wiring harness to temperature sensor
sensor: the voltage of sensor measured by Exh_uRawTOxiCatUs is upstream DOC
ECU is out of the target range below Exh_SRCTOxiCatUs.uMin_C Exchange temperature sensor upstream DOC
Shortcut to ground
3121631 3-163
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
5763 3 1024 594 Actuator of the external EGR valve: the ECU Short cut to battery or open loop. Check cabling, actuator defect, check actuator
detects a short circuit to battery or open and if necessary replace it, check
load. connection cable and if necessary repair or
replace it.
5763 3 1226 594 Actuator EGR-valve: short cut to battery is Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 3 1227 594 Actuator EGR-valve: short cut to battery on Short-Circuit to battery on component wiring Threshold for error detection is an internal ECU
ECU pin is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 4 1025 594 Actuator of the external EGR valve: the ECU Short cut to ground Check cabling, actuator defect, check actuator
detects a short circuit to ground. and if necessary replace it, check
connection cable and if necessary repair or
replace it.
5763 4 1228 594 Actuator EGR-valve: short cut to ground on Short-Circuit to ground on component wiring Threshold for error detection is an internal ECU
ECU pin is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 4 1229 594 Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal ECU
ECU pin is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 4 1232 5-9-4 Actuator error EGR-Valve (2.9;3.6) or Throt- Monitoring for CY146 Under Voltage. Threshold for error detection is an internal ECU
tle-Valve (4.1;6.1;7.8); Voltage below threshold.
threshold Check wiring, component
3.6) Drosselklappe (4.1;6.1;7.8); Voltage
below threshold;
5763 5 1023 5-9-4 Actuator error EGR-Valve; signal range check Short circuit to ground. Check wiring, check cabels and repair or replace
low, measured current is below target if necessary, check actuator with
SERDIA 2010 test for EGR and if necessary
replace it.
5763 6 1014 594 Actuator error EGR-Valve. Short cut to batterie. Check wiring and repair or replace if necessary,
Signal range check high. check actuator with SERDIA test for
EGR and if necessary replace it.
5763 6 1022 5-9-4 Actuator error EGR-Valve; signal range check Short circuit to battery or open circuit. Check cabling, actuator defect, check actuator
high, measured current by ECU is over target and if necessary replace it, check
connection cable and if necessary repair or
replace it.
5763 6 1223 594 Actuator EGR-Valve: Open load on ECU out- Open circuit on component wiring Threshold for error detection is an internal ECU
put is detected threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
5763 6 1224 594 Actuator EGR-valve: too high curent is going Overload on component wiring Threshold for error detection is an internal ECU
into the actuator. Output is switched off threshold.
Check wiring, component, ECU
Check repair with SerDia 2010 use case
3-164 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
5763 6 1230 5-9-4 Actuator error EGR-valve; Overload by short- Short Circuit over Load Threshold for error detection is an internal ECU
circuit threshold.
Check wiring, component
5763 7 1016 594 Actuator position for EGR valve is not plausi- Position error of throttle flap (deviation > 7%). Threshold for error detection is an internal ECU
ble, internal error, angular misalignement of threshold.
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 overtemperature due to high Temperature dependent Over Current Threshold for error detection is an internal ECU
current. threshold.
Check wiring, component
520521 5 1015 594 Actuator error EGR-Valve. Short cut to ground. Check wiring and repair or replace if necessary,
Signal range check low. check actuator with SERDIA test for
EGR and if necessary replace it.
523009 9 825 253 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the number of allowed activations. old of the pressure limiting valve. fault with Serdia.
523009 10 833 2-5-3 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset
the allowed opening time. old of the pressure limiting valve. fault with Serdia.
523212 9 171 3-3-3 Timeout Error of CAN-Receive-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer devices
ComEngPrt; Engine Protection
523240 9 179 527 Timeout CAN-message FunModCtl; Func- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
tion Mode Control short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
523350 4 565 151 Injector cylinder bank 1: the current drop Short circuit injection bank 1 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
523352 4 566 152 Injector cylinder bank 2: the current drop Short circuit injection bank 2 (all injectors of this Threshold for error detection is an internal ECU
measured by ECU is above the target range bank can be affected) threshold.
Check wiring harness, injectors and if necessary
repair/replace it.
523354 12 567 153 Internal hardware monitoring: the ECU Defective powerstage in ECU Threshold for error detection is an internal ECU
detects an error of its injector high current threshold.
output. Chip of CY33x defect power stage If error is not removable, change ECU.
components
523450 4 839 1-4-3 Diagnostic fault check for min error of COM The sensed raw value is less than the threshold. Check cabling, check sensor and if necessary
message. replace it,
check connection cable and if necessary repair
or replace it.
523470 2 826 146 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
523470 2 827 146 The pressure relief valve (PRV) has been Rail pressure has exceeded the trigger thresh- Threshold for error detection is an internal ECU
opened due to excessive pressure. old of the pressure limiting valve. threshold.
Reset the fault and at reappearance check injec-
tion system.
3121631 3-165
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523470 7 876 146 Rail pressure is out of the expected average Rail pressure is out of the expected average (A) Check railpressure relief valve and replace if
range. range. necessary.
PRV can not be opened. (B) Check high pressure pumps, pressure relief
valve and metering unit.
(C) Change components if necessary
523470 11 831 146 Rail pressure relief valve can not be opened Railpressure out of tolerance range (PRV can not Threshold for error detection is an internal ECU
due to the railpressure. be opened by a pressure peak in this threshold.
operating point) Check railpressure, check rail pressure sensor for
plausibility, check FCU.
523470 11 832 146 Rail pressure is out of the expected average Averaged rail pressure is outside the expected Threshold for error detection is an internal ECU
range. tolerance range. threshold.
The PRV can not be opened at this operating Check PRV and replace if necessary.
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 internal ECU
Shutoff conditions. threshold.
Check PRV opening counter and if necessary
replace PRV,
check rail-pressure sensor for plausibility and if
necessary replace it,
check FCU and if necessary replace it.
523470 12 829 146 Rail pressure relief valve is open. Warning PRV open Threshold for error detection is an internal ECU
Warning conditions. threshold.
Check PRV opening counter and if necessary
replace PRV,
check rail-pressure sensor for plausibility and if
necessary replace it,
check FCU and if necessary replace it.
523470 14 830 146 Rail pressure relief valve is open. (PRV) Open PRV Threshold for error detection is an internal ECU
threshold.
Only after ECU reset.
Check PRV opening counter and if necessary
replace it,
check rail-pressure sensor for plausibility and if
necessary replace it,
check FCU and if necessary replace it.
523550 12 980 515 Terminal 50 was operated for more than 2 Startinformation to Starter (T50-switch) Threshold for error detection is an internal ECU
minutes. This may happen due to short to erratic/defect. threshold.
battery or wrong usage of Terminal 50. Check cabling, if sensor not working, check start
Starter control is disabled until this error is switch and if necessary replace it,
healed. check connection cable and if necessary repair
or replace it.
523601 13 948 282 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check
detects a deviation of the target range of the Pin A18: DeltaPressVenturi / Position intake working voltage and if necessary correct
power supply voltage of sensor output 3. throttle flap it,
Pin K20: First footpedal check connection cable and if necessary repair
Pin K21: Air FilterDiffPress or replace it,
Suspected components EDC17cv54 and cv56 if error is not removable, change ECU.
Pin A07: Rail pressure
523612 3 644 555 supply voltage too high not used Threshold for error detection is an internal ECU
threshold.
3-166 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523612 4 646 555 supply voltage too low not used Threshold for error detection is an internal ECU
threshold.
523612 12 387 555 Internal hardware monitoring: the CPU of Injector shut off demand for the ICO coordinator Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- System responses: threshold.
nally; no item will be created in error mem- not Caution ! Sequence error, check error memory
ory for other errors.
523612 12 612 555 Internal hardware monitoring: the CPU of Plausibility check failed (MoCADC_uNTP_mp is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- higher than MoCADC_uNTPMax_C). threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory.
523612 12 613 555 Internal hardware monitoring: the CPU of Analysis of test voltage (Value is out of the tar- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- get -> ECU internal error) threshold.
nally; no item will be created in error mem- Check wiring, check connected sensors actua-
ory tors.
If error is still present, exchange ECU.
523612 12 614 555 Internal hardware monitoring: the CPU of Analysis of the ratiometric correction (Value is Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- out of the target -> ECU internal error) threshold.
nally; Check wiring, check connected sensors actua-
no item will be created in error memory tors.
If error is still present, exchange ECU.
523612 12 615 555 Internal hardware monitoring: the CPU of Error report due to an error in the plausbility of Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Function Coordination(FC) and threshold.
nally; Monitoring Modul(MM)(ECU internal error) If error is still present, exchange ECU.
no item will be created in error memory
523612 12 616 555 Internal hardware monitoring: the CPU of Error report due to an interrupted SPI communi- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- cation (ECU internal error) threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory
523612 12 617 555 Internal hardware monitoring: the CPU of multiple error in complete ROM-test during Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- postdrive detected (ECU internal error) threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory
523612 12 618 555 Internal hardware monitoring: the CPU of Too less bytes received by monitoring memory Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- from CPU as response (ECU internal threshold.
nally; no item will be created in error mem- error). Loss of synchronization sending bytes to If error is still present, exchange ECU.
ory the monitoring memory from CPU
523612 12 619 555 Internal hardware monitoring: the CPU of Suspected components: Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Injector threshold.
nally; no item will be created in error mem- ECU If error is still present, exchange ECU.
ory wiring harness/connector
523612 12 620 555 Internal hardware monitoring: the CPU of Error trying to set MM Response time (ECU Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- internal error) threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory
523612 12 621 555 Internal hardware monitoring: the CPU of Error detected in the internal ECU communica- Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- tion, Too many SPI errors during threshold.
nally; no item will be created in error mem- MoCSOP execution If error is still present, exchange ECU.
ory
3121631 3-167
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523612 12 623 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- under voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in undervoltage monitoring
523612 12 624 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- monitoring module (ECU internal error). threshold.
nally; no item will be created in error mem- If error is still present, exchange ECU.
ory
523612 12 625 555 Internal hardware monitoring: the CPU of Time out error trying to set or cancelling the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- alarm task (ECU internal error). Failure threshold.
nally; no item will be created in error mem- setting the alarm task period If error is still present, exchange ECU.
ory
523612 12 627 555 Internal hardware monitoring: the CPU of Error in time monitoring of the shut-off path Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- test (ECU internal error). Diagnostic fault threshold.
nally; no item will be created in error mem- check to report the timeout in the shut If error is still present, exchange ECU.
ory off path test
523612 12 628 555 Internal hardware monitoring: the CPU of Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- over voltage detection (ECU internal threshold.
nally; no item will be created in error mem- error). Diagnostic fault check to report the error If error is still present, exchange ECU.
ory in overvoltage monitoring
523612 12 629 555 The two voltage values (ADC_VAL1, Defect pedal or wiring Threshold for error detection is an internal ECU
ADC_VAL2), detected by threshold.
the accelerator pedal, are not plausible to Check Pedal, repair or exchange the Pedal.
each other. Check wiring.
If error is still present, exchange ECU.
523612 12 630 555 Impermissible offset between the engine Calculated engine speed in level 1/2 implausi- Threshold for error detection is an internal ECU
speed of level 2 and level 1 ble (-> ECU internal error). threshold.
If error is still present, exchange ECU.
523612 12 631 555 Diagnostic fault check to report the plausi- Implausible injection energizing time for either Threshold for error detection is an internal ECU
bility error between level 1 energizing time PiIx or MI1 or PoIx. threshold.
and level 2 information If error is still present, exchange ECU.
523612 12 632 555 Error in the plausibility of the start of ener- Implausible start of energising of either PiIx or Threshold for error detection is an internal ECU
gising angles MI1 or PoIx. threshold.
If error is still present, exchange ECU.
523612 12 633 555 Error in the plausibility of the energising The energising times of the zero fuel quantity Threshold for error detection is an internal ECU
times of the zero fuel quantity calibration calibration ZFC is out of the target. (-> threshold.
ECU internal error) If error is still present, exchange ECU.
523612 12 634 555 Error in the plausibility of PoI2 efficiency. Error in the plausibility of PoI2 efficiency. Threshold for error detection is an internal ECU
threshold.
If error is still present, exchange ECU.
523612 12 635 555 Error in the PoI2 shut-off. Error in the PoI2 shut-off. Threshold for error detection is an internal ECU
threshold.
If error is still present, exchange ECU.
523612 12 636 555 Error in the plausibility of PoI3 efficiency. Error in the plausibility of PoI3 efficiency. Threshold for error detection is an internal ECU
threshold.
If error is still present, exchange ECU.
3-168 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523612 12 637 555 Engine speed: the engine speed calculated Error in the plausibility of current energising Threshold for error detection is an internal ECU
by ECU is above the target range; the ECU time with maximum permitted energising threshold.
activates a system reaction time. Diagnostic fault check to report the error If error is still present, exchange ECU.
due to Over
Run
523612 12 638 555 Error in the plausibility of the wave correc- Error in the plausibility of the wave correction Threshold for error detection is an internal ECU
tion parts parts threshold.
If error is still present, exchange ECU.
523612 12 639 555 Plausibility error of the Rail pressure sensor In case the gradient of rail pressure is larger than Threshold for error detection is an internal ECU
the max threshold or lesser than the threshold.
min threshold. Check metering unit or cable.
Rail metering unit defect. Check Rail pressure. Check the Rail System of
Leakge in the Rail System. leakage.
523612 12 640 555 Error in the torque comparison between per- Error in the torque comparison between the Threshold for error detection is an internal ECU
missible engine torque and current actual permissible inner engine torque and the threshold.
torque current plausible actual torque. If error is still present, exchange ECU.
523612 12 641 555 Diagnosis of curr path limitation forced by The torque comparison is not plausible with the Threshold for error detection is an internal ECU
ECU monitoring level 2 torque monitoring. threshold.
If error is still present, exchange ECU.
523612 12 642 555 Diagnosis of lead path limitation forced by The setpoint path of the air system is limited by Threshold for error detection is an internal ECU
ECU monitoring level 2 the limitation torque of the functional threshold.
control unit monitoring. If error is still present, exchange ECU.
523612 12 643 555 Diagnosis of set path limitation forced by If the quantity setpoint is exceeds the limit of Threshold for error detection is an internal ECU
ECU monitoring level 2. the torque function. threshold.
If error is still present, exchange ECU.
523612 12 714 555 Error report "WDA wire is active" due to a Error detection by monitoring module Threshold for error detection is an internal ECU
defect query/response communication threshold.
Software reset.
523612 12 715 555 Error report "ABE wire is active" due to The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
undervoltage detection electrical system voltage (defective threshold.
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 to over- If the ABE/WDA powerstage shut-off is active Threshold for error detection is an internal ECU
voltage detection due to an overvoltage detection. threshold.
software reset.
523612 12 717 555 Error report "ABE/WDA active" due to an The reason is that a slow dropping of the vehicle Threshold for error detection is an internal ECU
unknown reason electrical system voltage (defective threshold.
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 CPU of Error during positive test (ECU internal error). Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- Diagnostic fault check to report that the threshold.
nally; no item will be created in error mem- positive test failed Reflash ECU. If error is still activ replace ECU.
ory
3121631 3-169
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523612 12 1857 555 Fault in the monitoring during the engine wiring is not according DEUTZ requirements Threshold for error detection is an internal ECU
start. Start requested in level 1, but not engine start conditions are not observed threshold.
released in level 2 which leads to no fuel low battery voltage during start check other active errors and fix them.
injection. malfunction of starter check all needed engine start conditions, e.g.
neutral switch.
check the engine speed during starting of the
engine. If it's too low, then check the
battery voltage and then check the starter for
malfunction.
523612 14 973 555 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- threshold.
nally;
no item will be created in error memory.
523612 14 974 555 Internal hardware monitoring: the CPU of Visibility of Softwareresets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- threshold.
nally;
no item will be created in error memory.
523612 14 975 555 Internal hardware monitoring: the CPU of Visibility of SoftwareResets in DSM Threshold for error detection is an internal ECU
the ECU is reset and the cause is logged inter- threshold.
nally; If possible the software update has to be done.
no item will be created in error memory Replace the ECU.
523613 0 856 134 Rail pressure: the fuel pressure in rail calcu- Pressure governor deviation exceeds the limit- Threshold for error detection is an internal ECU
lated by ECU is below the target range which ing value based on the engine speed. threshold.
is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
523613 0 857 134 Rail pressure: the fuel pressure in rail calcu- maximum positive deviation of rail pressure Threshold for error detection is an internal ECU
lated by ECU is below the target range which exceeded concerning set flow of fuel. threshold.
is dependant on the engine speed. (A) Check for leakage
(B) Check fuel-primary pressure
(C) Change components, check sensor and if
necessary replace it, check fuel system
and if necessary repair it
523613 0 858 134 Rail pressure: the fuel pressure in rail calcu- leakage is detected based on fuel quantity bal- Threshold for error detection is an internal ECU
lated by ECU is above the target range which ance. threshold.
is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
523613 0 859 134 Rail pressure: the fuel pressure in rail calcu- Maximum negative rail pressure deviation with Threshold for error detection is an internal ECU
lated by ECU is above the target range which metering unit on lower limit is exceeded. threshold.
is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
523613 0 862 134 Rail pressure: the fuel pressure in rail calcu- Rail pressure exceeds the limiting value. (A) Check backflow pressure
lated by ECU is above the target range. (B) Check pressure relief valve and metering
unit.
(C) Change components if necessary
3-170 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523613 1 861 134 Rail pressure: the fuel pressure in rail calcu- Rail pressure falls below the limiting value Threshold for error detection is an internal ECU
lated by ECU is below the target range based on the engine speed. threshold.
which is dependant on the engine speed. (A) Check backflow pressure
(B) Check Injector function with SerDia
(C) Change components (metering unit, injec-
tor) if necessary
523613 2 864 134 Rail pressure metering unit, Setpoint of Pressure pump delivery quantity in overrun Threshold for detection is an internal ECU
metering unit in overrun mode not plausi- exceeds the threshold based on the threshold.
ble. pressure. (A) Check backflow pressure
(B) Check pressure relief valve and metering
unit.
(C) Change components if necessary
523615 3 594 135 Fuel metering unit: the current drain mea- short circuit to battery high side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 3 596 135 Fuel metering unit: the current drain mea- short circuit to battery low side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 4 595 135 Fuel metering unit: the current drain mea- short circuit to ground high side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 4 597 135 Fuel metering unit: the current drain mea- short circuit to ground low side Threshold for error detection is an internal ECU
sured by ECU is above the target range threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 5 592 135 Detecting an open load fault in the metering wiring harness defective, cable break Threshold for error detection is an internal ECU
unit threshold.
Check wiring harness and metering unit if nec-
essary repair/replace it.
523615 12 593 135 powerstage of metering unit is overheated over temperature Threshold for error detection is an internal ECU
threshold.
Check functionality of metering unit and
replace it if needed.
Check temperature of metering unit and
improve the installation in case of overheating.
523632 3 1127 665 Urea supply module pressure sensor: the Shortcut to battery Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
523632 4 1128 665 Urea supply module pressure sensor: the Shortcut to ground Check wiring
current drain measured by ECU is above the Broken wiring Check pressure sensor in urea supply module
target range Pressure sensor in urea supply module defect
The sensed raw voltage value
SCR_uRawUPmpP is above
SCR_SRCUPmpP.uMin_C
523632 11 1117 666 Urea supply module pump: the current drain When the pump motor does not switch to pump Threshold for error is an internal ECU threshold
measured by ECU is above the target range actuation mode after temperature
measurement has
been carried out.
3121631 3-171
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523698 11 122 591 Shut off request from supervisory monitor- Engine Shut Off due to supervisory function Threshold for error detection is an internal ECU
ing function threshold.
Check error memory for additional errorcode to
find root cause.
Depending on additional error follow the docu-
mented "Take action for repair".
523718 3 1100 676 Urea heater relay: the current drain mea- Shortcut to battery Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase it threshold
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
523718 4 1101 676 Urea heater relay: the current drain mea- Shortcut to ground Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase it threshold
is a result error: KWP 1089 Check wiring
Broken wiring, broken relay Check SCR main relay
523718 5 1098 676 Urea heater relay: the current drain mea- Open load Threshold for error detection is an internal ECU
sured by ECU is above the target range If this error detected during the heating phase it threshold
is a result error: KWP 1089 Test SCR main relay
Broken wiring Check cabling, if necessary replace relay.
broken relay
523719 4 1109 672 Urea supply module heater: the current Shortcut to ground Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply mod-
Heating element in supply module defect ule
523719 5 1106 672 Urea supply module heater: the current Open load Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase is threshold
range a result error: KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply mod-
Heating element in supply module defect ule
523720 8 925 148 Supply module heater: Duration of switch on uty cycle for temperature readout from supply When the received supply module heater tem-
is too long. module heater to the control unit is out perature duty cycle SCR_rSMT is out of
of range; Supply modul defect, fault in the wir- the failurerange (SCR_rSMFailMax_C <
ing. SCR_rSMHtrT < SCR_rSMFailMin_C)
Supply module check and replace if necessary.
Check the wiring.
523720 8 926 148 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply When the received supply module heater duty
over error threshold. module heater to the control unit is not cycle SCR_rSMHtrT is in the valid range
valid. (SCR_r-
Supply modul defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
523721 8 930 689 Supply module heater: Dutycycle timing Duty cycle for temperature readout from supply Supply module check and replace if necessary.
over error threshold. module to the control unit is out of Check the wiring.
range.
Supply modul defect, fault in the wiring.
3-172 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523721 8 931 689 Supply module heater: Dutycycle timing out Duty cycle for temperature readout from supply When the received supply module duty cycle
of valid range. module to the control unit is not valid. SCR_rSMT is in the valid range
Supply modul defect, fault in the wiring. (SCR_rSMTVld-Min_C <= SCR_rSMT <=
SCR_rSMTVldMax_C), OR in the failure
range (SCR_rSMFailMin_C <=SCR_rSMT <=
SCR_rSMFailMax_C)
Supply module check and replace if necessary.
Check wiring.
523721 11 927 689 Supply module heater: temperature mea- Duty cycle for temperature readout from supply Threshold for detection is an internal ECU
surement not available. module heater to the control unit is not threshold.
available. No erasing in the current driving cycle.
Supply modul defect, fault in the wiring. Supply module check and replace if necessary.
Check the wiring.
523722 8 929 691 Supply module heater: Faulty PWM signal PWM Signal for temperature readout from sup- Threshold for error detection is an internal ECU
from supply module. ply module to the control unit is not valid. threshold.
Supply modul defect, fault in the wiring. When valid Sync followed by temperature
information signal is received AND valid sync
and temperaturesignal for both information is
received one after the other.
Supply module check and replace if necessary.
Check the wiring.
523776 9 291 119 Timeout Error of CAN-Receive-Frame TSC1TE Timeout Error (Missing CAN Bus message) Threshold for error detection is an internal ECU
- active threshold.
Check CAN Bus cabling (Bus sheduling, polarity,
short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
523777 9 292 119 Message TSC1-TE has been missing (passive) Passive timeout Error (Missing CAN Bus mes- Check CAN Bus cabling (Bus scheduling, polar-
sage) ity, short circuit, power interrupt), test
protocol of receiver, check CAN functional
range, check actuator
523895 13 559 1-5-8 Missing or wrong injector adjustment value Missing or wrong injector adjustment value for Threshold for error detection is an internal ECU
programming (IMA) injector 1 (in firing cyl. 1. threshold.
order). Check correct injector adjustment value (IMA).
Use SERDIA UseCase to check it.
523896 13 560 1-5-8 Missing or wrong injector adjustment value Missing or wrong injector adjustment value for Threshold for error detection is an internal ECU
programming (IMA) injector 2 (in firing cyl. 2 threshold.
order). check dataset and flash correct injector adjuste-
ment value (IMA). Use SERDIA
UseCase to check it.
523897 13 561 1-5-8 Missing or wrong injector adjustment value Missing or wrong parametrisation of injector Threshold for error detection is an internal ECU
programming (IMA) injector 3 (in firing adjustment cyl. 3. threshold.
order). Check correct injector adjustment value (IMA).
523898 13 562 1-5-8 Missing or wrong injector adjustment value Missing or wrong injector adjustment value for Threshold for error detection is an internal ECU
programming (IMA) injector 4 (in firing cyl. 4. threshold.
order). Check correct injector adjustment value (IMA).
523899 13 563 1-5-8 Missing or wrong injector adjustment value Missing or wrong injector adjustment value for Threshold for error detection is an internal ECU
programming (IMA) injector 5 (in firing cyl. 5. threshold.
order). Check correct injector adjustment value (IMA).
3121631 3-173
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523900 13 564 1-5-8 Missing or wrong injector adjustment value Missing or wrong injector adjustment value for Threshold for error detection is an internal ECU
programming (IMA) injector 6 (in firing cyl. 6. threshold.
order). Check correct injector adjustment value (IMA).
523912 4 73 7-2-2 @ engines < 4l: The sensed raw voltage value is below the mini- The sensed raw voltage value
Throttle valve error, Open Load or Short cut mum threshold. DPM_uRawBrnDVDsP is above the minimum
to Battery, blocked valve or wrong control threshold
signal for valve. DPM_SRCBrnDVDsP.uMin_C
@ engines with Burner T4i: @ CRT < 4l: check throttle valve
Pressure Sensor error after valve (DV2), @ engines with Burner T4i: check back-pressure
lower limit reached valve
523924 4 42 167 Overload at Pins O_V_RH2x: A01, K74, K91. Suspected components: Threshold for error detection is an internal ECU
Components on A01, K74, K91 cannot be 1- Pin K91: threshold.
activated. Clutch switch, Brake switch, Engine brake Check wiring harness and connected loads on
Internal ECU power stage switched off. demand, Regeneration activation, Parking pins A01, K74, K91 and/or reflash ECU.
brake, Gearbox N, Fan control 1 If error is still present, exchange ECU.
2- Pin K74:
Boost air cooler bypass or electrical fuel pump
relay, Fan control 2/fuel valve for flame
star
523925 3 38 731 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A88, K57 cannot be 1- Lamps K57: Warn Ash Charge, Diagnostic, pins A88, K57.
activated. Warn Coolant Temp/Level, Warn Oil,
Internal ECU power stage switched 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 relais 3 Suspected components: Threshold for error detection is an internal ECU
Overload at Pins O_V_RH3x: A88, K57 1- Pin A88: threshold.
Preheat relay, Exhaust flap Check wiring harness and connected loads on
2- Pin K 57: pinsA88, K57.
- control lamps: If error is still present, exchange ECU.
- OBD, preheat lamp, warning temp., warning
oil, maintenance lamp, regeneration
indicator, alternator management, engine run-
ning, diagnostic
523926 4 44 732 Short circuit to ground aktuator relais 4. Suspected components: Fan, Wiring harness Threshold for error detection is an internal ECU
Overload at Pins O_V_PCV: A90 threshold.
Check wiring harness and connected loads on
pin A90.
If error is still present, exchange ECU.
523927 3 40 733 Short circuit to battery error of actuator relay Suspected Components: Check wiring harness and connected loads on
2. Components on Pin A04, A05 cannot be 1- Urea Pump A04 pins A04, A05.
activated. 2- SCR Heater A05
Internal ECU power stage switched off.
523935 12 168 763 Timeout Error of CAN-Transmit-Frame Fault is detected if a TimeOut of the EEC3VOL1 Check wiring harness and customer nodes
EEC3VOL1; Engine send messages frame has occured.
523936 12 169 764 Timeout Error of CAN-Transmit-Frame Timeout Error (Missing CAN Bus message) Check wiring harness and customer nodes
EEC3VOL2; Engine send messages
3-174 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523938 9 133 766 Timeout Error (BAM to packet) for CAN- Failure of the CAN Bus message NOX sensor and sensor connection check
Receive-Frame AT1IGCVol1 information;
factors & Sensorcalibration for NOX Sensor
(SCR-system upstream cat; DPF-system
downstream cat)
523939 9 134 766 Broadcast Announce Message of the calibra- Defective Nox sensor, faulty parameterization NOX sensor and sensor connection check
tion message
of the upstream catalytic NOx sensor has
failed.
Timeout Error (BAM to BAM) for CAN-
Receive-Frame AT1IGCVol1 information.
factors & Sensorcalibration for NOX Sensor
(SCR-system upstream cat, DPF-system
downstream cat).
523940 9 135 766 Timeout Error (PCK2PCK) for CAN-Receive- Failure of the CAN Bus message NOX sensor and sensor connection check
Frame AT1IGCVol1 information; factors &
Sensorcalibration for NOX Sensor (SCR-sys-
tem upstream cat; DPF-system
downstream cat)
523941 9 140 767 Timeout Error (BAM to packet) for CAN- Timeout Error (Missing CAN Bus message) NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information; check
factors & Sensorcalibration for NOX Sensor
(SCR-system downstream cat; DPF-system
downstream cat)
523942 9 141 767 Timeout Error (BAM to BAM) for CAN- Defective Nox sensor, faulty parameterization. NOX downstream sensor and sensor connection
Receive-Frame AT1OGCVol2 information, check.
Calibration message 1 of the after catalyst
NOx sensor has failed.
Factors & Sensorcalibration for NOX Sensor
(SCR-system downstream cat, DPF-system
downstream cat)
523943 9 142 767 Timeout Error (PCK2PCK) for CAN-Receive- The fault is detected when a timeout error in NOX downstream sensor and sensor connection
Frame AT1OGCVol2 information; factors & packet 2 of NOxSenVol2Rx frame occurs. check
Sensorcalibration for NOX Sensor (SCR-sys-
tem downstream cat; DPF-system
downstream cat)
523960 0 1011 771 Physical range check high for EGR cooler Sensed temperature downstream EGR-cooler EGR-Valve blocked open
downstream temperature. > limit. EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect
523960 1 1012 771 Physical range check low for EGR cooler sensor voltage > lower limit EGR-Valve blocked open
downstream temperature. EGR-Valve actuator defect
EGR-cooler defect (check for coolant water)
Reed Valve defect
Intake throttle blocked in closed position
Exhaust pressure too high
Check Nox-sensor upstream SCR catalyst
dp venturi sensor defect
3121631 3-175
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
523982 0 360 737 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not high. to too high battery voltage. repair or replace if necessary.
523982 1 361 737 Powerstage diagnosis disabled; Indicating Powerstage diagnostic can be deactivated due Check wiring, check alternator, check cables and
that battery voltage is not low. to too low battery voltage. repair or replace if necessary.
523984 3 1239 788 Actuator relay 5: the voltage measured by Short-Circuit to battery to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
Check wiring, component, ECU
523986 4 1241 176 Actuator relay 4: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
Check wiring, component, ECU
523987 4 1242 791 Actuator relay 5: the voltage measured by Short-Circuit to ground to component Threshold for error detection is an internal ECU
ECU is out of the target range threshold.
Check wiring, component, ECU
524050 11 1434 8-3-6 CAN; not used not used not used
524051 11 1435 8-3-7 CAN; not used not used not used
524057 2 1505 8-4-3 Low fuel pressure: the low fuel pressure cal- Fuel pressure below warning threshold Threshold for error detection is an internal ECU
culated by ECU is underneath the target threshold.
range; the ECU activates a system reaction Check low fuel pressure system (fuel feed
pump, relay , fuse, wiring, sensor) and if
necessary repair or replace it.
524063 3 1558 869 SCR heater mainrelay; short circuit to battery Short-Circuit to battery on wiring to component Check wiring, component
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 4 1559 869 Connection between heating valve (Y31) on Faulty wiring, faulty heater relay (K27-K31), Disconnect plug from heating valve (Y31) and
the control unit Pin A:92 and defective heating valve (Y31), reset fault.
Load side SCR heater main relay (K31) is a broken element in heating. If fault is still present you have to look in the wir-
short cut to ground. ing of Y31 to the control unit Pin A:92.
Threshold 1 < If error is no longer present, you have to check
SCRHtr_rUHtrMeasRatio_mp < Threshold the wiring of Y31 via relay K31
2 and possibly the heating cables and relay (K27-
K30).
524063 5 1555 869 Urea backflow line heater: broken wiring Open Load on wiring to component Check wiring, component
detected
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 5 1556 869 Urea main relay: broken wiring detected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
524063 5 1557 869 Urea pressure line heater: broken wiring Open load on wiring to component Check wiring, component
detected
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 5 1560 869 SCR relay for suction line not connected relay defect Check wiring, component
Threshold 1 < relay not connected
SCRHtr_rUHtrMeasRatio_mp < Threshold wiring harness broken
2 problems with supply voltage
3-176 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524063 5 1561 869 Open load on wiring to component Open load on wiring to component Check wiring, component
Threshold 1 <
SCRHtr_rUHtrMeasRatio_mp < Threshold
2
524063 5 1562 869 SCR heater tank; open load Open load on wiring to component Check wiring, component
524063 12 1646 869 SCR supply module temperature is not Suspected components: Check
reaching a threshold before a calibratable Enviroment temperature sensor defect Environment temperature sensor
time is exceeded. SCR supply module temperature sensor defect SCR supply module temperature sensor
Corresponding to the environmental Tem- SCR supply module electrical heater defect SCR supply module electrical heater
perature a specific defrosting time is given.
After starting the defrosting a clock counter
is starting. Does the counter reach the given
defrosting time limit, an error will be
detected. Is the temperature reached in time
the clock counter will be reset
Example: by using the calibrated tempera-
ture/time curve --> environmental temper-
ature 0°C --> defrosting time limit 6000s --
> if the clock counter reaches 6000s the error
will
be detected
524065 0 1565 892 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check for crystallisation in exhaust line
from the urea cat upstream cal high range limit f(exhaust volume upstream SCR and dwnstream of urea injector
sensor is greater than an applicable maxi- flow) Check correct connection from exhaust line to
mum pressure threshold UCatUsP_pRelFlt_mp > UCatUsP_pMax_mp pressure sensor upstream SCR catalyst:
syphons?, water in tube?, water in sensor?
Check that exhaust pipe outlet is free (down-
stream SCR catalyst)
Check wiring of pressure sensor upstream SCR
catalyst
Check pressure sensor upstream SCR catalyst:
sensor has no connection to vehicle body? =>
Ensure that sensor is free
Does sensor oscillate heavely at engine low idle
/ high idle? => try to supress the
oscillating
Exchange pressure sensor upstream SCR cata-
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
3121631 3-177
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524065 1 1566 892 The relativ pressure value of the exhaust gas sensed presure upstream SCR catalyst > physi- Check correct connection from exhaust line to
from the urea cat upstream sensor is less cal high range limit f(exhaust volume pressure sensor upstream SCR catalyst:
than an applicable minimum pressure flow) leakage?
threshold UCatUsP_pRelFlt_mp < UCatUsP_pMin_mp Check electric connector: 4h pin open / new
connector type used? pressure exchange
from inside electrical connector with the envi-
ronemt possible
Check exhaust line: any leakages upstream of
SCR catalyst?
Check wiring of pressure sensor upstream SCR
catalyst
Exchange pressure sensor upstream SCR cata-
lyst
Check calculated exhaust volume flow of
engine within EDC: SCR_dvolSCRUs
pausible? If not:
Check T sensor upstream SCR catalyst, check
complete engine air path: EGR-Valve,
Intake throttle, turbocharger, piping for leak-
age and function
Check SCR catalyst: Broken? Exchange SCR-Cat-
alyst
524065 2 1598 892 Comparison of urea cat upstream exhaust absolut value of difference between sensed Check electric connector: 4h pin open / new
gas- and environment pressure, the differ- pressure upstream SCR catalyst and connector type used?
ence should not exceed a certain limit environmental pressure > limit pressure exchange from inside electrical con-
abs(UCatUsP_pDiffEnvCat_mp) > Thresh- abs(UCatUsP_pDiffEnvCat_mp) > Threshold nector with the environemt possible?
old water in sensor?
sensor frozen?
Check wiring of pressure sensor upstream SCR
catalyst
Exchange pressure sensor upstream SCR cata-
lyst
Check intake manifold pressure sensor
(Air_pCACDs)
Check ambient pressure sensor (EnvP_p)
524065 3 1569 892 voltage of pressure sensor upstream SCR > voltage of pressure sensor upstream SCR > volt- Check wiring of pressure sensor upstream SCR
voltage high limit age high limit catalyst
Check pressure sensor upstream SCR catalyst
Exchange pressure sensor upstream SCR cata-
lyst
524065 4 1570 892 voltage of pressure sensor upstream SCR < voltage of pressure sensor upstream SCR < volt- Check wiring of pressure sensor upstream SCR
voltage low limit age low limit catalyst. Check pressure sensor
upstream SCR catalyst. Exchange pressure sen-
sor upstream SCR catalyst
3-178 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524067 0 1581 894 Filtered urea supply module heater temper- sensed temperature of supply module heater > Compare SCR_tSMT with SCR_tSMHtrT. Both
ature value is above an applicable maximum physical high range limit show the same value?
heater temperature threshold of the supply Check urea tank temperature
module (SCR_tAdapUTnkT). Very hot (> 70°C), urea
The temperature is read out via the PWM sig- tank heater
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module heater temperature sensor
defect
Supply module heater defect
Supply module defect
524067 0 1585 894 Filtered urea supply module temperature sensed temperature of urea within supply mod- Compare SCR_tSMT with SCR_tSMHtrT. Both
value (SCR_tSMT) is above an applicable ule > physical high range limit show the same value?
maximum temperature threshold of the Check urea tank temperature
supply module (SCR_tAdapUTnkT). Very hot (> 70°C), ure tank
The temperature is read out via the PWM sig- heater
nal of the urea pump. That is only possible in permanet on?
status init of the SCR-system short after igni- Does the pump never stop working? Check wir-
tion was switched on. When that state is ing to supply module
left the sensed temperature value is frozen. Compare SCR_tSMT with SCR_tSMHtrT. Both
show different values or urea tank
temperature (SCR_tAdapUTnkT) is cold:
exchange urea pump unit
Supply module temperature sensor defect
Supply module heater defect
Supply module defect
524067 1 1582 894 Filtered urea supply module heater temper- sensed temperature of supply module heater < Check ambient temperature EnvT_t < Thresh-
ature value is below an applicable minimum threshold old?
heater temperature threshold of the supply Compare SCR_tSMT with SCR_tSMHtrT
module Check wiring with regard to supply modul
The temperature is read out via the PWM sig- heater
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module heater temperature sensor
tion was switched on. When that state is defect
left the sensed temperature value is frozen. Supply module defect
524067 1 1586 894 Filtered urea supply module temperature sensed temperature of urea within supply mod- Check ambient temperature EnvT_t < thresh-
(SCR_tSMT) value is below an applicable ule < physical low range limit old?
minimum temperature threshold of the sup- Compare SCR_tSMT with SCR_tSMHtrT
ply module Check wiring with regard to supply modul
The temperature is read out via the PWM sig- heater
nal of the urea pump. That is only possible in exchange urea pump unit
status init of the SCR-system short after igni- Supply module temperature sensor defect
tion was switched on. When that state is Supply module defect
left the sensed temperature value is frozen.
3121631 3-179
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524067 2 1867 894 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module heater temperature and supply module heater temperature and and CEngTds_t and
ambient temperature ambient temperature SCR_tAdapUTnkT => All identical? If not:
UPmpT_tDiffPmpHtrAmb_mp > threshold UPmpT_tDiffPmpHtrAmb_mp > threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Supply module temperature sensor defect
Problem at Supply module unit (broken?) =>
exchange supply module
524067 2 1868 894 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t
supply module temperature and ambient supply module temperature and ambient and CEngTds_t and
temperature > threshold temperature UPmpT_tDiffPmpAmb_mp > SCR_tAdapUTnkT => All identical? If not:
threshold Has the machine been brought from cold envi-
ronment into a warm one or vice versa
without engine running, e.g. at workshop?
Environment temperature sensor defect
Coolant temperature sensor defect
Supply module temperature sensor defect
Problem at Supply module unit (broken?) =>
exchange supply module
524074 9 1533 246 Open load sensor internally at NOx-sensor Open load sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
dismounting. => If water inside, replace sen-
sor.
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 NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
Check NOx-Sensor downstream SCR catalyst:
water inside? Shake out sensor after
dismounting. => If water inside, replace sen-
sor.
Check mounting position of sensor and judge it
regarding condense water formation /
agglomeration? Rearrange if critical and possi-
ble
Check wiring harness
Exchange sensor
3-180 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524076 9 1535 248 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
dismounting. => If water inside, replace sen-
sor.
Check mounting position of sensor and judge it
regarding condense water formation /
agglomeration.
Check wiring harness
Exchange sensor
524077 11 1536 249 Short circuit sensor internally at NOx-sensor Short circuit sensor internally at NOx-sensor Threshold for error detection is an internal ECU
downstream SCR downstream SCR threshold.
NOx Sensors are CAN Sensors --> no HW Pin Check NOx-Sensor upstream SCR catalyst:
on the ECU water inside? Shake out sensor after
dismounting. => If water inside, replace sen-
sor.
Check mounting position of sensor and judge it
regarding condense water formation /
agglomeration.
Check wiring harness
Exchange sensor
524078 9 1537 255 Lambda value of NOx-Sensor downstream sensed lambda value of Nox-sensor down- Check whether NOx-sensor downstream SCR
SCR is out of range. stream SCR catalyst is > physical high limit catalyst is physically mounted within the
When the filtered Lambda concentration ComRxSCR_rCanLamDs_mp > threshold exhaust line
value at the sensor Check Lambda values of NOx-sensor down-
(ComRxSCR_rFltLamDs_mp) is greater than stream SCR catalystat at idle conditions,
the physical range check max. lambda ComRxSCR_rCanLamDs_mp > threshold?
threshold Compare to ComRxSCR_rCanLamUs_mp. Val-
ues must be almost identical
Check CANBus of NOx-sensor downstream SCR
catalyst
Check NOx-sensor downstream SCR catalyst
wiring
Check NOx-sensor downstream SCR catalyst
itself
Replace NOx-sensor downstream SCR catalyst
3121631 3-181
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524079 9 1538 256 sensed lambda value of NOx-sensor down- sensed lambda value of NOx-sensor down- Compare to ComRxSCR_rCanLamUs_mp.
stream SCR catalyst is < physical low limit stream SCR catalyst is < physical low limit ComRxSCR_rCanLamDs_mp must be
ComRxSCR_rCanLamDs_mp < threshold ComRxSCR_rCanLamDs_mp < threshold almost identical!
If almost identical,
Check air path of engine: EGR-Valve, Intake-
Throttle, Turbocharger and Piping each
for leakage and correct function
Check injection system of engine. Injector
stuck?
if sensed lambda upstream SCR higher
(ComRxSCR_rCanLamUs_mp) : Diesel in
Urea-tank?
Check CANBus of NOx-sensor downstream SCR
catalyst
Check NOx-sensor downstream SCR catalyst
wiring
Check NOx-sensor downstream SCR catalyst
itself
Replace NOx-sensor downstream SCR catalyst
524080 9 1539 257 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check whether NOx-sensor upstream SCR cata-
upstream SCR catalyst is > physical high SCR catalyst is > physical high limit lyst is physically mounted within the
limit ComRxSCR_rCanLamUs_mp > Threshold exhaust line
ComRxSCR_rCanLamUs_mp > Threshold Check Lambda values of NOx-sensor upstream
SCR catalystat at idle conditions,
ComRxSCR_rCanLamUs_mp < Threshold?
Compare to ComRxSCR_rCanLamDs_mp. Must
be almost identical
Check CANBus of NOx-sensor upstream SCR cat-
alyst
Check NOx-sensor upstream SCR catalyst wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
524081 9 1540 258 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check air path of engine: EGR-Valve, Intake-
upstream SCR catalyst is < physical low limit SCR catalyst is < physical low limit Throttle, Turbocharger and Piping each
ComRxSCR_rCanLamUs_mp < Threshold ComRxSCR_rCanLamUs_mp < Threshold for leakage and correct function
Check injection system of engine. Injector
stuck?
Check CANBus of NOx-sensor upstream SCR cat-
alyst
Check NOx-sensor upstream SCR catalyst wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
524083 9 1542 261 sensed NOx-value of NOx-sensor down- sensed Nox-value of Nox-sensor downstream Check CANBus of NOx-sensor downstream SCR
stream SCR catalyst < Threshold SCR catalyst < physical low limit catalyst
Check NOx-sensor downstream SCR catalyst
wiring
Check NOx-sensor downstream SCR catalyst
itself
Replace NOx-sensor downstream SCR catalyst
3-182 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524085 9 1544 912 sensed Nox-value of Nox-sensor upstream sensed Nox-value of Nox-sensor upstream SCR Check CANBus of NOx-sensor upstream SCR cat-
SCR catalyst < Threshold catalyst < physical low limit alyst
Check NOx-sensor upstream SCR catalyst wiring
Check NOx-sensor upstream SCR catalyst itself
Replace NOx-sensor upstream SCR catalyst
524100 9 1666 924 Timeout error of CAN-Transmit-Frame Com- Open load on CANBUS wiring. Check wiring, component.
DPFHisDat.
524104 9 1676 928 Timeout error of CAN-Receive-Frame Com- Time out of Check CANBUS EAT Control Receive Threshold for error detection is an internal ECU
RxDPFCtl. CM1 Module Customer Recieve Message, PGN65348. threshold.
Message. The message is not received. Check CANBUS EAT Control Receive Message,
PGN65348.
CM1 Module Customer Recieve Message.
524118 9 1672 9-4-2 Timeout error of CAN-Receive-Frame If the frame CM1 message is not transmitted Check CAN Bus cabling (Bus sheduling, polarity,
ComRxCM1 successfully short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
524121 9 1683 9-4-5 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
RxTrbChActr short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
524125 9 1687 9-4-9 Timeout error of CAN-Receive-Frame Com- Timeout Error (Missing CAN Bus message) Check CAN Bus cabling (Bus sheduling, polarity,
TxTrbChActr short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
524141 7 1827 192 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
524141 7 1858 192 DEF dosing valve is blocked with crystalized While SCR system is starting up and fter urea Check electrical connection of urea injector:
urea or other deposits. pressure reaches 10000 hPa, the DEF - wiring harness
dosing module is tested. Expectation is that - connector
urea pressure drops below 1500 hPa if Conduct SERDIA use-case "injection test". If it is
injector works properly. The test is repeated up faulty:
to 3 times before an error is set. - remove urea injector from exhaust line:
SCRSysPresMon_stPresDropDet_mp = 0 while - check for crystallisation direct on injector noz-
SCRCo_stStatus_mp = 16. zle / plate
Suspected component: - rinse it thoroughly in water
wiring harness - remount urea injector and conduct SERDIA
DEF dosing valve use-case "injection test"
The error is stored into the EEPROM of the ECU If the error is still active, then exchange urea
and status at ECU shut down is injector.
regained at ignition on.
3121631 3-183
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524147 13 1639 966 No proper urea pressure level could be build This error shows up, if no proper urea pressure Make sure that frozen lines, pump or tank can be
up within the SCR system state "Fill Lines" level could be build up within the SCR excluded!
=> SCRCo_stStatus_mp = 1 within some system state "Fill Lines" => Check whether there is urea in the urea tank
miuntes SCRCo_stStatus_mp = 1 within some minutes Check urea lines:
Once the urea pump pressure has exceeded the All lines connected? The right lines connected to
threshold the error is declared as the correct places?
okay. Suction line blocked?
Suspected components: No leakage? Not also urea to the outside but also
Suction line blocked air into the lines, especially in the
PWM Powerstage has a defect and a default suction line!
value which leads not to a rising pressure Perform service routine "pressure test":
Pump Pressure sensor defect Does the urea pump work? => check wiring
pump filter contains dirty parts harness & PWM signal for pump
reverting valve continously 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 continously open
Urea suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
Pump Pressure sensor broken
524152 2 1874 971 CAN message is not received fora definite CAN message is not received for a definite time Check eletrical connection oif urea quality sen-
time => error is set. As soon as the message => error is set. As soon as the sor
is received the error heals. message is received the error heals. Check engine CAN bus
Check urea quality sensor itself
Exchange urea quality sensor
524153 2 1875 997 CAN message is not reseived for a definite CAN message is not reseived for a definite time Check eletrical connection of suction unit sen-
time => error is set. As soon as the message => error is set. As soon as the sor (combined sensor with tank level and
is received the error heals. message is received the error heals. tank 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 message) Check CAN Bus cabling (Bus sheduling, polarity,
ComRxEBC2 from wheel speed sensor. Defect on wheel speed sensor. short circuit, power interrupt), test
protocol of receiver, check CAN functional
range.
Replace the wheel speed sensor.
3-184 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524177 7 1863 995 The error shows up, if no proper urea presure This error shows up, if no proper urea presure Make sure that DEF lines, pump and tank are not
could be build up within the SCR system could be build up within the SCR system frozen.
state "Fill Lines" => SCRCo_stStatus_mp = state "Fill Lines" => SCRCo_stStatus_mp = 1. Check for DEF level in the tank.
1. 3 cases can lead to the error: Check DEF lines:
Case A: increasing pressure is detected within Are all DEF lines connected?
15s the check has passed => no error Is the suction line blocked?
Case B: The pressure threshold was not reached Is ther any leakage? Not only urea to the outside
within the 60s but case A was not but also air into the lines, especially in
positiv. the suction line!
Case C: The minimum pressure of 3000 hPa was Perform SERDIA usecase "pressure test":
not reached within the 60s. Does the DEF pump work? => check wiring har-
ness & PWM signal for pump.
Does the urea pressure increase?
All errors are already healed?
If still unsuccessful so far:
Check urea pressure sensor: At ignition on and
SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
Check DEF pump filter: Is any dirt inside?
Suspected components:
Suction line
PWM Powerstage has a defect and a default
value which leads not to a rising pressure
DEF pump pressure sensor defect
DEF pump filter contains dirty parts
3121631 3-185
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524178 7 1864 996 The urea pump is not able to control the urea The urea pump controller is not able to control Make sure that DEF lines, pump and tank are not
pressure between 9bar and 11 bar. the urea pressure between 9bar and 11 frozen.
bar due to malfunction in the SCR system. Check for DEF level in the tank
Suspected components: Check DEF lines:
- DEF pump broken All lines connected? The right lines connected to
- Reverting valve continously open the correct places?
- Urea suction line, backflow line broken or con- Suction line blocked?
nection swapped Is there any leakage? Not also urea to the out-
- PWM Powerstage has a defect side but also air into the lines, especially
- Pump Pressure sensor broken in the suction line!
Perform SERDIA usecase "pressure test":
Does the DEF pump work properly? => check
wiring harness & PWM signal for pump
Does the DEF pressure rise?
Is the error healed?
If still unsuccessful so far:
- Check DEF pressure sensor: At ignition on and
SCR system state = 0 ("Init check"),
SCR_pAbsAdapUPmpP shall be identical to
EnvP_p. Fulfilled: Sensor okay!
- Check reverting valve
- Check DEF pump filter: dirt inside?
Suspected components:
DEF pump broken
Reverting valve continously open
DEF suction line, backflow line broken or con-
nection swapped
PWM Powerstage has a defect
DEF pump pressure sensor broken
524190 14 1891 272 Not enough urea in tank or low urea quality Low DEF tank level Check DEF level in tank. If there is no DEF, refill
or hardware tampering failure is detected or Low DEF quality up to volume above the warning
hardware failure is detected Hardware Tampering is active threshold.
Hardware Failure is active Check the DEF quality in the tank. If wrong fluid
is filled, refill with proper DEF.
Check other errors based on hardware malfunc-
tions.
524191 14 1892 273 A low DEF tank level or a low DEF quality is Low DEF tank level Threshold for error detection is an internal ECU
detected or hardware tampering(system Low DEF quality threshold.
components are pinched off) or hardware Hardware Tampering is active Check the DEF level in tank. If there is no DEF,
failures as shortcut to battery, shortcut to Hardware Failure is active refill up above the warning level.
ground Check DEF quality filled in the tank.
etc. are detected. Check other errors based on hardware tamper-
ing or failure.
3-186 3121631
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524193 8 1893 275 The total time in standstill-regeneration Stand-still mode is very often aborted by the Read out stand-still statistics => see service
mode exceeds the long-limit threshold operator. manual:
within last 500h total engine run time. Stand-still mode does not reach required tem- Stand-still operation finished or often inter-
The error is activated if the engine runs to perature level and regeneration level is rupted by driver / engine shut-off? => Run
many times in Standstill regeneartion. therefore reached after a short time again stand-still and instruct operator
Stand-still operation required often by soot
load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPf allow it:
Perform Stand-still and check reached temper-
ature 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?
Temerature 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
3121631 3-187
SECTION 3 - CHASSIS & TURNTABLE
Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524194 8 1894 276 The total time in standstill-regeneration Stand-still mode is aborted / interrupted too Read out stand-still statistics => see service
mode exceeds the long-limit threshold: 2,5h often by the operator manual:
stand-still operation within 50h total motor Stand-still is required too often due to miscalcu- Stand-still operation finished or often inter-
run time. lation in the soot model rupted by driver / engine shut-off? => Run
The error is activated if the engine runs to Stand-still mode does not reache temperature stand-still and instruct operator
much time in short Standstill regeneartion. level and regeneration level is therefore Stand-still operation required often by soot
reached after a short time again. load => Check dp DPF pressure sensor
Stand-still mode does not reach required tem-
perature level:
Check engine air path: Intake Trottle, EGR-Valve
and turbocharger okay?
Any leakage in engine air intake sytem or
exhaust gas system?
Check temperature sensors within exhaust sys-
tem: upstream DOC, downstream DOC
If soot load level of DPF allows it:
Perform Stand-still and check reached temper-
ature 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?
Temerature 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
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Deutz Blink
SPN FMI Description Possible Cause Action
Code Code
524195 14 1900 279 The standstill request of detected crystalli- Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line and
zation is ignored for more than reached a level which indicates inspect visually the injector and the
5h(>300min) crystallisation inside of exhaust line. exhaust line for urea crystallisation upstream of
This will be activated if there is a standstill The error detection depends on the sensed pres- SCR catalyst:
request activated by Crystalisation Monitor- sure upstream of the SCR catalyst and If crystallisation can be clearly seen, then stand-
ing. the calculated exhaust volume flow through still must be processed.
the mixer pipe. Has the engine been operated in low load for
In case of error is set, but no crystallisation can longer time? If yes, then it could be the
be found in the mixing pipe, a possible reaoson for crystallisation.
reason can be the defect sensors: Does the NOx-Sensors work properly? Compare
- exhaust pressure & temperature upstream of ComRxSCR_rNOxUs to
the SCR catalyst, ComRxSCR_rNOxDs, when
- the ambient pressure ComRxSCR_stNOxRdyUs = 1 &
- the exhaust mass flow => Check air path sys- ComRxSCR_stNOxRdyDs = 1 (Warm engine
tem at the engine. and EAT-system,
SCRT_tCatAvrgExhGs_mp > 250°C,
SCR_stStatus = "Dosing" = 8): sensed NOx
upstream of SCR catalyst must be higher than
downstream of SCR catalyst.
Go to idle and wait until SCR system enters sta-
tus "stand-by" (no dosing),
SCRT_tCatAvrgExhGs_mp < 225°C:
ComRxSCR_rNOxUs = ComRxSCR_rNOxDs
Clean urea injector: rinse it thourougly under
water
Check EGR-Path: difference pressure sensor at
venturi tube, EGR cooler, EGR-Valve,
Reed-Valve, Intake throttle regarding function
and leakage. Does the EGR-cooler leak
water in the exhaust?
Check air path for leakage
Check turbocharger
No crystallisation can be seen in the mixing
pipe:
Check exhaust pressure sensor upstream of SCR
catalyst (SCR_pSensUCatUsP):
tube, water in sensor?
Check environmental pressure sensor
(EnvP_p): plausible?
Check exhaust temperature sensor upstream of
SCR-catalyst (SCR_tSensUCatUsT):
plausible compared to Exh_tOxiCatUs &
Exh_tOxiCatDs e.g. when engine has idled for
20 minutes?
=> Run stand-still to remove crystallisation
and to reset the DFC
5232719 3 1108 672 Urea supply module heater: the current Short circuit to battery Threshold for error detection is an internal ECU
drain measured by ECU is above the target If this error detected during the heating phase it threshold
range is a result error:KWP 1089 Check wiring
Broken wiring Check cabling, if necessary replace supply mod-
Heating element in supply module defect ule
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3.20 GM ENGINE GENERAL MAINTENANCE • Check ignition coil and spark plug cables for hardening,
cracking, chafing, separation, split boot covers and proper
fit.
Maintenance of the Drive Belt
• Replace spark plugs at the proper intervals as prescribed in
The serpentine drive belt utilizes a spring loaded tensioner the engine manufacturer’s manual.
which keeps the belt properly adjusted. The drive belt is an • Check to make sure all electrical components are fitted
integral part of the cooling and charging systems and should securely.
be inspected frequently.
• Check the ground and platform control stations to ensure
When inspecting the belts check for: all warning indicator lights are functioning.
• Cracks or breaks.
Checking/Filling Engine Oil Level
• Chunking of the belt.
• Splits.
• Material hanging from the belt. AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED FULL MARK)
CAN CAUSE AN OIL LEAK, A FLUCTUATION OR DROP IN THE OIL PRESSURE AND
• Glazing and hardening. ROCKER ARM "CLATTER" IN THE ENGINE.
• Damaged or improperly aligned pulleys.
• Improperly performing tensioner.
CARE MUST BE TAKEN WHEN CHECKING THE ENGINE OIL LEVEL. OIL LEVEL
Check the belt tensioner by pressing down on the midway MUST BE MAINTAINED BETWEEN THE “ADD” MARK AND “FULL” MARK ON THE
point of the longest stretch between pulleys. The belt should DIPSTICK.
not depress beyond 1/2 in. (13mm). If the depression is more
than allowable adjust the tension. To ensure that you are not getting a false reading, make sure
NOTE: Do not over tighten the belt as doing so could cause pre- the following steps are taken to before check the oil level.
mature failures in other belt driven components. 1. Stop the engine if in use.
2. Allow sufficient time (approximately 5 minutes) for the
oil to drain back into the oil pan.
THE ENGINE MANUFACTURER DOES NOT RECOMMEND THE USE OF "BELT 3. Remove the dipstick. Wipe with a clean cloth or paper
DRESSING" OR "ANTI SLIPPING AGENTS" ON THE DRIVE BELT. towel and reinstall. Push the dipstick all the way into the
dipstick tube.
Engine Electrical System Maintenance 4. Remove the dipstick and note the oil level.
The engine electrical system incorporates computers and 5. Oil level must be between the "FULL" and "ADD" marks.
microprocessors to control the engine ignition, fuel control
and emissions. Due to the sensitivity of the computers to good
electrical connections periodic inspection of the electrical wir-
ing is necessary. When inspecting the electrical system use the
following:
• Check the entire engine wire harness for rubbing chafing, 7. Remove the oil filter cap from the valve rocker arm
cuts or damaged connections, repair if necessary. cover.
8. Add the required amount of oil to bring the level up to
• Check all wire harness connectors to ensure they are fully
but not over "FULL" mark on the dipstick.
seated and locked.
9. Reinstall the oil fill cap to the valve rocker cover and
wipe away any excess oil.
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Changing The Engine Oil Coolant Fill Procedure - Dual Fuel Engine
WHEN CHANGING THE OIL, ALWAYS CHANGE THE OIL FILTER. CHANGE OIL DAMAGE TO THE ENGINE COULD OCCUR IF NOT PROPERLY FILLED WITH COOL-
WHEN THE ENGINE IS WARM FROM OPERATION AS THE OILS WILL FLOW ANT. LPG FUELED ENGINES ARE MOST PRONE TO CREATING AN AIR LOCK DUR-
FREELY AND CARRY AWAY MORE IMPURITIES. ING A COOLANT FILL OPERATION DUE TO THE ELECTRONIC PRESSURE
REGULATOR (EPR) BEING THE HIGHEST POINT IN THE COOLING SYSTEM. AN
To change the oil use the following steps: EPR THAT APPEARS TO HAVE FROST FORMING ON IT IS A SIGN THAT THE
ENGINE COOLING SYSTEM CONTAINS AIR. THE APPEARANCE AND TEMPERA-
1. Start the engine and run until it reaches normal operat-
TURE OF THE EPR SHOULD BE MONITORED DURING THE COOLANT FILL OPER-
ing temperature.
ATION. A WARM EPR IS AN INDICATION THAT THE COOLING SYSTEM IS
2. Stop the engine. PROPERLY FILLED AND FUNCTIONING.
3. Remove the drain plug and allow the oil to drain.
4. Remove and discard the oil filter and its sealing ring.
5. Coat the sealing ring on the filter with clean engine oil MAKE SURE ENGINE IS COOL BEFORE PERFORMING ANY MAINTENANCE
and wipe the sealing surface on the filter mounting sur- WORK.
face to remove any dust, dirt and debris. Tighten the fil-
ter securely (follow the filter manufacturers 1. Loosen the worm gear clamp on the coolant line run-
instructions). Do not over tighten. ning into the EPR as shown below and remove the hose
from the EPR. Place a rag under the hose to prevent
6. Check the sealing ring on drain plug for any damage,
coolant from running onto the engine/machine.
replace if necessary, wipe the plug with a clean rag and
wipe the sealing surface on the pan and reinstall the pan
plug. Do not over tighten.
7. Fill the crankcase with oil.
8. Start the engine and check for oil leaks.
9. Stop the engine and check the oil level to ensure the oil
level is at "FULL".
10. Dispose of the oil and filter in a safe manner.
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2. Remove the radiator cap. Fill the radiator with coolant 5. Next, verify that the 2 coolant hoses on the EPR are
until coolant starts to appear from the previously warm. If they are not warm repeat step 3 and 4, other-
removed hose at the EPR. Reinstall the hose back onto wise continue to step 6.
the EPR and continue to fill radiator with coolant.
3. With the radiator cap still removed, start the engine and
run until the thermostat opens. The thermostat opens at
170° F (77° C), which can be checked using the JLG
handheld analyzer.
WITH THE ENGINE RUNNING OR WHEN SHUTTING OFF THE ENGINE, SOME
HEATED COOLANT MAY SPILL OUT DUE TO AIR "BURPING" OUT OF THE SYS-
TEM WITH THE RADIATOR CAP OFF.
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SECTION 3 - CHASSIS & TURNTABLE
EPR Assembly When the engine is cranking, sufficient vacuum will be intro-
duced into the secondary chamber from the mixer drawing
The EPR assembly is a combination Low Pressure Regulator the secondary diaphragm down onto the spring loaded lever
and a Voice Coil Assembly. The Voice coil is an electronic actu- and opening the secondary valve allowing vaporized fuel to
ator which is controlled by an internal microprocessor. The pass to the mixer. This mechanical action in conjunction with
microprocessor provides output data to the ECM and receives the EPR reactions causes the downward action on the second-
input data over a CAN BUS connection. The internal micropro- ary lever causing it to open wider allowing more fuel to flow to
cessor receives electrical signals from the Fuel Pressure Sensor the mixer.
FPS and the Fuel Temperature Pressure FTP and communi-
cates the data to the ECM. The ECM uses the FPS and FTP data
to calculate the location of the secondary lever in the LPR and THE VOICE COIL SECTION OF THE EPR ASSEMBLY IS AN EMISSIONS CONTROL
sends that data back to the EPR via the CAN BUS. The internal DEVICE AND CANNOT BE REBUILT. IF THE COIL ASSEMBLY FAILS TO OPERATE
microprocessor in the EPR will then output a signal, which PROPERLY, REPLACE IT WITH AN OEM REPLACEMENT PART ONLY.
causes the voice coil to move and position the secondary lever
to the correct location.
Propane fuel enters the primary port of the LPR and passes
through the primary jet and into the primary/ exchanger
chamber. As the propane passes through the heat exchanger
the fuel expands and creates pressure inside the chamber. The
pressure rises as the fuel expands when the pressure rises
above 1.5 psi (10.34 kpa), sufficient pressure is exerted on the
primary diaphragm to cause the diaphragm plate to pivot and
press against the primary valve pin thus closing off the flow of
fuel. This action causes the flow of fuel into the regulator to be
regulated.
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3121631 3-195
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3.22 GM ENGINE FUEL SYSTEM REPAIR Propane Fuel System Leak Test
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3121631 3-199
SECTION 3 - CHASSIS & TURNTABLE
Electronic Pressure Regulator (EPR) Assembly 11. Remove the (3) three nuts from the EPR isolators and the
EPR mounting bracket.
Replacement
12. Remove the EPR from the bracket.
13. Remove the (3) three mounting isolators.
INSTALLATION
DO NOT USE TEFLON TAPE ON ANY FUEL FITTING. USE A LIQUID PIPE THREAD
SEALANT WHEN INSTALLING FITTINGS.
CHECK ALL THE O-RINGS ON THE VAPOR AND WATER FITTINGS FOR ANY DAM-
AGE REPLACE IF NECESSARY.
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10. Start the vehicle and leak check the propane fuel system REMOVAL
at each serviced fitting Refer to Propane Fuel System
1. Disconnect the TMAP electrical connector.
Leak Test.
2. Remove the two retaining bolts.
3. Remove the TMAP.
INSTALLATION
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SECTION 3 - CHASSIS & TURNTABLE
INSTALLATION 3. Attach mixer and throttle body together. The two parts
do not bolt together; they will be secured when you
mount it on the intake. Notice the orientation of the air
inlet and throttle body cover.
LIGHTLY LUBRICATE BOTH THROTTLE CONTROL DEVICE TO ADAPTER O-RINGS.
Mixer Replacement
See Figure 3-118.
REMOVAL
1. Remove the Throttle control device Refer to Electronic
Throttle Body Replacement.
2. Remove the four (4) bolts to the throttle control device
to mixer adapter bolts.
3. Remove and discard the mixer to adapter gasket.
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SECTION 3 - CHASSIS & TURNTABLE
1. Install the hose clamps to each hose and set the clamp
back on each hose to make installation easier. Heated Exhaust Gas Oxygen Sensor Replacement
2. Fit the hose to the fittings. REMOVAL
3. Secure by positioning each of the clamps. 1. Disconnect Negative battery cable.
3121631 3-203
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3121631 3-205
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Checks Action
Important Preliminary Checks
Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that:
1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL.
Several of the following symptom procedures call for a careful visual and physical check. The visual and physical checks are very important. The
checks can lead to correcting a problem without further checks that may save valuable time.
LPG Fuel System Check 1. Verify the customer complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between lean and rich.
IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operating correctly at that time.
Visual and Physical Checks ² Check all ECM system fuses and circuit breakers.
² Check the ECM ground for being clean, tight and in its proper location.
² Check the vacuum hoses for splits, kinks and proper connections.
² Check thoroughly for any type of leak or restriction.
² Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
² Check for proper installation of the mixer module assembly.
² Check for air leaks at the mixer assembly.
² Check the ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
² Check the wiring for the following items:
- Proper connections, pinches or cuts.
² The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the scan
tool readings do not indicate the problems, then proceed in a logical order, easiest to check or most likely to cause first.
Intermittent
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC).
Preliminary Checks ² Refer to Important Preliminary Checks.
² Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the replacement of good parts.
Faulty Electrical Connections or Wiring ² Faulty electrical connections or wiring can cause most intermittent problems.
² Check the suspected circuit for the following conditions:
- Faulty fuse or circuit breaker
- Connectors poorly mated
- Terminals not fully seated in the connector (backed out)
- Terminals not properly formed or damaged
- Terminal to wires poorly connected
- Terminal tension insufficient
² Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If necessary, replace all the
connector terminals in the problem circuit in order to ensure the proper contact tension.
² Checking for poor terminal to wire connections requires removing the terminal from the connector body.
Operational Test If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the problem occurs, an abnormal
voltage or scan reading indicates the problem may be in that circuit.
3121631 3-207
SECTION 3 - CHASSIS & TURNTABLE
Checks Action
Intermittent Malfunction Indicator Lamp The following components can cause intermittent MIL and no DTC(s):
(MIL) ² A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur
when the faulty component is operating.
² The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
² The ignition secondary voltage shorted to a ground.
² The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to ground.
² The Control Module grounds.
Loss of DTC Memory To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine until the Malfunction Indicator Lamp illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory when the ignition is turned OFF. If the TMAP DTC does not store
and remain, the ECM is faulty
Additional Checks
No Start
DEFINITION: The engine cranks OK, but does not start.
Preliminary Checks Refer to Important Preliminary Checks.
Control Module Checks If a scan tool is available:
² Check for proper communication with both the ECM.
² Check the fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
² Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage and/or continuity for
each circuit.
Sensor Checks ² Check the TMAP sensor.
² Check the Magnetic pickup sensor (RPM).
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create a no start condition.
² Check for air intake system leakage between the mixer and the throttle body.
² Verify proper operation of the low pressure lock-off solenoids.
² Check the fuel system pressures. Refer to the LPG Fuel System Diagnosis.
² Check for proper mixer air valve operation.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions.
² Check for the proper ignition voltage output with J 26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS).
² Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
² Check for bare or shorted ignition wires.
² Check for loose ignition coil connections at the coil.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than
the gasoline fuel supply system.
² Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.
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Checks Action
Exhaust System Checks ² Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes.
- Inspect the muffler for signs of heat distress or for possible internal failure.
² Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
Hard Start
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
Preliminary Checks ² Refer to Important Preliminary Checks.
² Make sure the vehicle's operator is using the correct starting procedure.
Sensor Checks ²Check the Engine Coolant Temperature sensor with the scan tool. Compare the engine coolant temperature with the ambient air temperature
on a cold engine. IF the coolant temperature reading is more than 5 degrees greater or less than the ambient air temperature on a cold engine,
check for high resistance in the coolant sensor circuit. Refer to DTC 111.
² Check the Crankshaft Position (CKP) sensor.
²Check the Throttle position (TPS) sensor.
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition.
² Verify the excess flow valve in the LPG manual shut-off valve is not tripped.
² Check mixer module assembly for proper installation and leakage.
² Verify proper operation of the low pressure lock-off solenoids.
² Verify proper operation of the EPR.
² Check for air intake system leakage between the mixer and the throttle body.
² Check the fuel system pressures. Refer to the Fuel System Diagnosis.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions.
² Check for the proper ignition voltage output with J 26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS).
² Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
² Check for bare or shorted ignition wires.
² Check for moisture in the distributor cap if applicable.
² Check for loose ignition coil connections.
Important:
1. If the engine starts but then immediately stalls, Check the Crankshaft Position (CKP).
2. Check for improper gap, debris or faulty connections.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than the
gasoline fuel supply system.
² Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.
² Check the intake and exhaust manifolds for casting flash.
Exhaust System Checks ² Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes.
- Inspect the muffler for signs of heat distress or for possible internal failure.
² Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in the GM Base Engine Service
Manual.
3121631 3-209
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Checks Action
Additional Checks ²
Cuts Out, Misses
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases which is not normally felt above 1500 RPM. The exhaust has a steady spit-
ting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Checks ² Refer to Important Preliminary Checks.
Ignition System Checks ² Start the engine.
² Wet down the secondary ignition system with water from a spray bottle and look/listen for arcing or misfiring as you apply water.
² Check for proper ignition output voltage with spark tester J 26792.
² Check for a cylinder misfire.
² Verify that the spark plugs are correct for use with LPG (R42LTS).
² Remove the spark plugs in these cylinders and check for the following conditions:
² Insulation cracks
² Wear
² Improper gap
² Burned electrodes
² Heavy deposits
² Visually/Physically inspect the secondary ignition for the following:
² Ignition wires for arcing, cross-firing and proper routing.
² Ignition coils for cracks or carbon tracking.
Engine Mechanical Checks ² Perform a cylinder compression check.
² Check the engine for the following:
- Improper valve timing
- Bent pushrods
- Worn rocker arms
- Worn camshaft lobes
- Broken or weak valve springs
² Check the intake and exhaust manifold passages for casting flash.
Fuel System Checks ² Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
² Check the condition of the wiring to the low pressure lock-off solenoid.
Additional Check Check for Electromagnetic Interference (EMI).
² EMI on the reference circuit can cause a missing condition.
² Monitoring the engine RPM with a scan tool can detect an EMI.
² A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present.
² If the problem exists, check the routing of the secondary wires and the ground circuit.
Hesitation, Sag, Stumble
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it's
severe enough.
Preliminary Checks Refer to Important Preliminary Checks.
Fuel System Checks ² Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
² Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below specification, there is possibly a
faulty low pressure regulator or a restriction in the fuel system.
² Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
² Check LPL electrical connection.
² Check the mixer air valve for sticking or binding.
² Check the mixer module assembly for proper installation and leakage.
² Check the EPR electrical connections.
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Checks Action
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a prob-
lem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly.
² Check for the proper ignition voltage output with J 26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS).
² Check for faulty spark plug wires.
² Check for fouled spark plugs.
Additional Check ² Check for manifold vacuum or air induction system leaks
² Check the generator output voltage.
Backfire
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Preliminary Check ² Refer to Important Preliminary Checks.
Ignition System Checks Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operat-
ing conditions. The ignition system must be maintained in peak condition to prevent backfire.
² Check for the proper ignition coil output voltage using the spark tester J26792 or the equivalent.
² Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the
wires.
² Check the connection at each ignition coil.
² Check for deteriorated spark plug wire insulation.
² Check the spark plugs. The correct spark plugs for LPG are (R42LTS).
² Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Engine Mechanical Check Important! The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than a
gasoline fuel supply system.
² Check the engine for the following:
- Improper valve timing
- Engine compression
- Manifold vacuum leaks
- Intake manifold gaskets
- Sticking or leaking valves
- Exhaust system leakage
² Check the intake and exhaust system for casting flash or other restrictions.
Fuel System Checks ² Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
Lack of Power, Sluggishness, or Sponginess
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal.
Preliminary Checks ² Refer to Important Preliminary Checks.
² Refer to the LPG Fuel system OBD System Check.
² Compare the customer's vehicle with a similar unit. Make sure the customer has an actual problem. Do not compare the power output of the
vehicle operating on LPG to a vehicle operating on gasoline as the fuels do have different drive feel characteristics.
² Remove the air filter and check for dirt or restriction.
² Check the vehicle transmission Refer to the OEM transmission diagnostics.
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Checks Action
Fuel System Checks ² Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis.
² Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent.
² Check for proper installation of the mixer module assembly.
² Check all air inlet ducts for condition and proper installation.
² Check for fuel leaks between the LPR and the mixer.
² Verify that the LPG tank manual shut-off valve is fully open.
² Verify that liquid fuel (not vapor) is being delivered to the LPR.
Sensor Checks ² Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance. Check for proper operation of the MAP sensor.
² Check for proper operation of the TPS sensor.
Exhaust System Checks ² Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes.
- Inspect the muffler for signs of heat distress or for possible internal failure.
- Check for possible plugged catalytic converter.
Engine Mechanical Check Check the engine for the following:
² Engine compression
² Valve timing
² Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.
Additional Check ² Check the ECM grounds for being clean, tight and in their proper locations.
² Check the generator output voltage.
² If all procedures have been completed and no malfunction has been found, review and inspect the following items:
² Visually and physically, inspect all electrical connections within the suspected circuit and/or systems.
² Check the scan tool data.
Poor Fuel Economy
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this vehicle at one time, as previously
shown by an by refueling records.
Preliminary Checks ² Refer to Important Preliminary Checks.
² Check the air cleaner element (filter) for dirt or being plugged.
² Visually (Physically) check the vacuum hoses for splits, kinks and proper connections.
² Check the operators driving habits for the following items:
- Is there excessive idling or stop and go driving?
- Are the tires at the correct air pressure?
- Are excessively heavy loads being carried?
- Is their often rapid acceleration?
² Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
² Suggest that a different operator use the equipment and record the results.
Fuel System Checks ² Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis.
² Check the fuel system for leakage.
Sensor Checks ² Check the Temperature Manifold Absolute Pressure (TMAP) sensor.
Ignition System Checks ² Verify that the spark plugs are correct for use with LPG (R42LTS).
² Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
² Check the ignition wires for the following items:
- Cracking
- Hardness
- Proper connections
Cooling System Checks ² Check the engine thermostat for always being open or for the wrong heat range.
3-212 3121631
SECTION 3 - CHASSIS & TURNTABLE
Checks Action
Additional Check ² Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual.
² Check for dragging brakes.
Rough, Unstable, or Incorrect Idle, Stalling
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the
engine.
Preliminary Check Refer to Important Preliminary Checks.
Sensor Checks ²Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white powdery coating. The sensor will result in a
high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel delivered to the engine causing a severe drive-
ability problem.
²Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
²Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks ²Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will
help identify the problem.
²Check for a sticking mixer air valve.
²Verify proper operation of the EPR.
²Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
²Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
²Check mixer module assembly for proper installation and connection.
Ignition System Checks ²Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS).
²Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
²Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the
wires.
Additional Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than
the gasoline fuel supply system.
²Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command.
²Check the ECM grounds for being clean, tight and in their proper locations.
²Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed
resulting in poor idle quality.
Engine Mechanical Check ² Check the engine for the following:
- Broken motor mounts
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes
Surges/Chuggles
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal.
Preliminary Checks Refer to Important Preliminary Checks.
Sensor Checks ² Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
3121631 3-213
SECTION 3 - CHASSIS & TURNTABLE
Checks Action
Fuel System Checks ² Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will
help identify the problem.
² Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis.
² Verify proper fuel control solenoid operation.
² Verify that the LPG manual shut-off valve is fully open.
² Check the in-line fuel filter for restrictions.
Ignition System Checks ² Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
² Verify that the spark plugs are correct for use with LPG (R42LTS).
² Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
- Check the Crankshaft Position (CKP) sensor
Additional Check ² Check the ECM grounds for being clean, tight and in their proper locations.
² Check the generator output voltage.
² Check the vacuum hoses for kinks or leaks.
² Check Transmission.
3-214 3121631
SECTION 3 - CHASSIS & TURNTABLE
3121631 3-215
SECTION 3 - CHASSIS & TURNTABLE
3-216 3121631
SECTION 3 - CHASSIS & TURNTABLE
3.24 COUNTERWEIGHT Machines originally equipped with foam filled tires cannot be
converted to pneumatic tires and 4 wheel drives cannot be
Both the 800S, 810SJ and the 860SJ share the same tail and converted to 2 wheel drives without adding counterweight.
frame counterweights regardless of market. However, there is No counterweight difference is required between the narrow
a difference in frame counterweights depending on the and wide pneumatic tire options. Similarly, no counterweight
equipped tires and wheel drive options. Pneumatic tire difference is required between the narrow and wide foam
machines require more frame counterweight than is required filled tires.
with foam filled tires and 2 wheel drive machines require more
counterweight than 4 wheel drives.
3121631 3-217
SECTION 3 - CHASSIS & TURNTABLE
NOTES:
3-218 3121631
SECTION 4 - BOOM & PLATFORM
3121631 4-1
SECTION 4 - BOOM & PLATFORM
Support Removal 4. Remove the bolts securing the support to the rotator.
BOLTS
ROTATOR
PLATFORM SUPPORT
4-2 3121631
SECTION 4 - BOOM & PLATFORM
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).
3121631 4-3
SECTION 4 - BOOM & PLATFORM
A,B,D
NOTE: If any rotator bolts are replaced, replace all
bolts on the rotator and torque them.
C,D
4.2 ROTATOR AND SLAVE CYLINDER 6. Tag and disconnect hydraulic lines to the platform
(slave) leveling cylinder. Use a suitable container to
retain any residual hydraulic fluid. Cap hydraulic lines
Removal and ports. Remove the platform (slave) cylinder.
4-4 3121631
SECTION 4 - BOOM & PLATFORM
4.3 MAIN BOOM POWERTRACK 6. Remove bolt #1 securing the push tube on the fly boom
section.
Removal
1. Disconnect wiring harness connectors located in tower
upright.
3121631 4-5
4-6
HOSE AND CABLE CARRIER
SECTION 4 - BOOM & PLATFORM
1001156965 B
3121631
SECTION 4 - BOOM & PLATFORM
4.4 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of
the powertrack.
One Piece Bracket Maintenance
1. Place the powertrack on a workbench.
3121631 4-7
SECTION 4 - BOOM & PLATFORM
5. Slide the poly roller off of the round bar. 7. Slide the flat bar out.
6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket.
9. Remove the snap ring from the other side of the bracket.
4-8 3121631
SECTION 4 - BOOM & PLATFORM
10. Push down with slight pressure on the link and slide the Two Piece Bracket Maintenance
bracket side up and over the extrusion on the link.
1. Loosen the screw.
3121631 4-9
SECTION 4 - BOOM & PLATFORM
4. Hold the flat bar and remove the screws. 6. Remove the screws from the bar. Remove the snap ring
and pin.
4-10 3121631
SECTION 4 - BOOM & PLATFORM
Snap Rings and Screws A snap ring that is not seated is shown below.
Make sure that all snap rings are closed and seated.
10-24 x 0.812 button torx socket head with blue locking patch:
• Tighten to 45-50 in. lbs. (5-5.6 Nm).
CLOSED • Use T-25 torx bit.
• Do not reuse this screw. After removing replace with a new
OPEN one.
3121631 4-11
SECTION 4 - BOOM & PLATFORM
4.5 MAIN BOOM ASSEMBLY 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.
Removal
1. Using suitable lifting equipment, adequately support
boom assembly weight along entire length.
Boom Disassembly
NOTE: The following procedure assumes the boom is removed
from the machine.
NOTE: Do not allow wire rope to rotate. This may damage the
wire rope.
4-12 3121631
SECTION 4 - BOOM & PLATFORM
7. Remove the four bolts, shims, and mounting blocks that 8. Using overhead cranes or other suitable lifting/support-
secure the telescope cylinder rod to the boom base sec- ing devices, carefully pull the telescope cylinder out
tion. 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 lift-
ing/supporting devices will have to be repositioned to
support the weight of the cylinder as it is drawn out of
the boom.
3121631 4-13
SECTION 4 - BOOM & PLATFORM
4-14 3121631
SECTION 4 - BOOM & PLATFORM
3121631 4-15
SECTION 4 - BOOM & PLATFORM
4-16 3121631
SECTION 4 - BOOM & PLATFORM
%&5"*-$4+
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3121631 4-17
SECTION 4 - BOOM & PLATFORM
9. Carefully remove the telescope cylinder and sheave 13. Remove hardware which secures the wear pads to the
assembly. Place telescope cylinder on a suitable trestle. front of mid boom section; remove wear pads from the
top, sides and bottom of the mid boom section.
a. Remove hardware from the wear pads; remove wear
pads from cylinder. 14. Using an overhead crane or suitable lifting device,
b. Remove hardware from the wire rope guard; remove fly boom section from mid section. Note: When
remove guard from cylinder. removing fly boom section from mid boom section,
retract wire rope must be dragged along with fly boom
c. Remove hardware from the sheave pin; remove pin
section.
and sheave from cylinder.
15. 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.
16. 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.
4-18 3121631
SECTION 4 - BOOM & PLATFORM
Assembly
NOTE: When installing fly section wear pads, install same number
and thickness of shims as were removed during disassem-
bly.
3121631 4-19
SECTION 4 - BOOM & PLATFORM
NOTE: To avoid damaging the proximity switch, install and adjust the switch AFTER assem-
bling the switch block and compression spring, and after torquing the wire ropes.
To adjust the proximity switch, thread the switch all the way in and back out
1/8 to 1/2 a turn.
4-20 3121631
SECTION 4 - BOOM & PLATFORM
4. Install retract wire ropes into rear end of fly section, 9. Properly position the retraction wire rope sheaves
route wire ropes through holes in side of fly boom sec- assemblies at the rear end of the mid boom section;
tion and pull into slot. 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.
11. Slide mid boom section into the base boom section.
Allow the retraction wire ropes to trail between the bot-
tom surfaces of boom sections. Shim boom, if necessary,
for a total of 1/16 inch (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 inch (0.20) clearance.
5. Install side, top and bottom wear pads to the rear end of 16. Install a new extend sheave on the end of the telescope
mid section; shim evenly to the measurements of the cylinder.
inside of mid section.
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
WHEN ASSEMBLING BOOM SECTIONS, ENSURE THAT THE BOOM SLIDING TRA-
JECTORIES HAVE BEEN CLEARED OF CHAINS, TOOLS, AND OTHER OBSTRUC- and lock nuts. Install the opposite end of the cables in
TIONS. the cable mount block.
6. Shim the insides of the boom sections for a total of 1/16 18. Use tape or tie straps to fasten the cables to the tele-
inch (0.062) clearance (if the action is centered, there will scope cylinder assembly. It is important that the tape or
be 1/32 clearance on each side). straps be strong enough to hold the cable in place yet
weak enough to break and fall away when the cables are
7. Slide fly boom section into the mid boom section. Shim
adjusted.
boom, if necessary, for a total of 1/16 inch (0.062) clear-
ance.
8. Install wear pads into the forward position of the mid
boom section. Shim boom, if necessary, for a total of 2/ WHEN PUSHING THE TELESCOPE CYLINDER INTO THE BOOM, IT MAY BE NEC-
10 inch (0.20) clearance. ESSARY 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 INTO THE BOOM. DAMAGE TO COMPONENTS
MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES.
3121631 4-21
SECTION 4 - BOOM & PLATFORM
19. Using adequate lifting equipment, carefully push the 21. Apply JLG Threadlocker P/N 0100011 to the bolts and
telescope cylinder assembly and cables back into the fasten the telescope cylinder barrel to the boom mid
boom. section with the bolts, shims, mounting blocks.
4-22 3121631
SECTION 4 - BOOM & PLATFORM
3121631 4-23
SECTION 4 - BOOM & PLATFORM
7. Remove the four bolts, shims, and mounting blocks that 9. Push the boom fly sections back in to gain access to the
secure the telescope cylinder rod to the boom base sec- boom retraction cable.
tion. 10. Remove the screws securing the sheave guards to the
boom mid section and remove the sheave guards.
11. Remove the adjusting nuts and lock nuts from the oppo-
site end of the retraction cables at the front of the boom
base section. To aid in installing new retraction cables,
WHEN REMOVING THE TELESCOPE CYLINDER FROM THE BOOM, IT MAY BE
fasten a length of tie wire as long as the retraction
NECESSARY AT SOME POINT TO TURN THE CYLINDER SLIGHTLY IN ORDER TO cables to the ends of the cables.
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.
4-24 3121631
SECTION 4 - BOOM & PLATFORM
12. Twist the ends of the retraction cables to remove the 4. Install the sheave guards and secure them in place with
ends of the cables from the slots in the side of the boom the retaining screws.
fly section.
3121631 4-25
SECTION 4 - BOOM & PLATFORM
4-26 3121631
SECTION 4 - BOOM & PLATFORM
Lift Cylinder Removal 6. Remove the bolt and keeper pin securing the lower lift
cylinder pivot pin and remove the pivot pin.
1. Elevate the boom enough to gain access to the lift cylin-
der lower pivot pin.
2. Use an adequate supporting device to support the
weight of the boom and associated components as
shown below.
3121631 4-27
SECTION 4 - BOOM & PLATFORM
NOTE: Flexing a wire rope can often expose broken wires hidden
in valleys between strands.
4-28 3121631
SECTION 4 - BOOM & PLATFORM
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.
3121631 4-29
SECTION 4 - BOOM & PLATFORM
(ANSI Only)
(ANSI Only)
1 Boom Capacity Length Switch to trip boom when it’s 216" ± 1" (5486mm ± 25mm) from fully extended
2 150.75" ± 1" (3829mm ± 25mm) position of boom sections to Trip Capacity Length Switch (ANSI Only)
18.25" ± 1" (463.5mm ± 25mm) position of boom sections to trip Transport Length Switch
3 Boom Transport Length Switch to trip when boom is 18" ± 1" from fully retracted
4 Boom Capacity Angle Switch to trip when upper boom is 50° to 55° above horizontal. 52° is the preferred trip angle
Boom Capacity Angle Switch to reset when upper boom is 59° to 64° above horizontal. 61° is the preferred reset angle
5 Boom Elevation Switch to trip when upper boom is 7° to 12° above horizontal. 9° is the preferred trip angle
Boom Elevation Switch to reset when upper boom is 3° below horizontal to 2° above horizontal. 0° is the preferred reset angle
6 End of Stroke Switch should trip when boom is 5° to 7° from end of extended cylinder stroke
Figure 4-19. Elevation, Dual Capacity and Transport Switch Information - 800S
4-30 3121631
SECTION 4 - BOOM & PLATFORM
(ANSI Only)
BOOM CAPACITY
LE NG TH SWITCH (ANSI Only)
BOOM TRANSPORT
LE NG TH SWITCH
0271360 K
Figure 4-20. Elevation, Dual Capacity and Transport Switch Installation - 800S
3121631 4-31
SECTION 4 - BOOM & PLATFORM
(ANSI Only)
(ANSI Only)
1 Boom Capacity Length Switch to trip boom when it’s 180" ± 1" (4572mm ± 25mm) from fully extended
2 160.25" ± 1" (4070mm ± 25mm) position of boom sections to Trip Capacity Length Switch (ANSI Only)
18.25" ± 1" (463.5mm ± 25mm) position of boom sections to trip Transport Length Switch
3 Boom Transport Length Switch to trip when boom is 18" ± 1" from fully retracted
4 Boom Capacity Angle Switch to trip when upper boom is 44° to 49° above horizontal. 46° is the preferred trip angle
Boom Capacity Angle Switch to reset when upper boom is 52° to 57° above horizontal. 55° is the preferred reset angle
5 Boom Elevation Switch to trip when upper boom is 9° to 14° above horizontal. 12° is the preferred trip angle
Boom Elevation Switch to reset when upper boom is 1° below horizontal to 4° above horizontal. 2° is the preferred reset angle
6 End of Stroke Switch should trip when boom is 5° to 7° from end of extended cylinder stroke
Figure 4-21. Elevation, Dual Capacity, and Transport Switch Information - 810SJ & 860SJ
4-32 3121631
SECTION 4 - BOOM & PLATFORM
BOOM CAPACITY
ANGLE SWITCH (ANSI Only)
BOOM ELEVATION
SWITCH
BOOM CAPACITY
LENGTH SWITCH (ANSI Only)
BOOM TRANSPORT
LENGTH SWITCH
0271362 K
Figure 4-22. Elevation, Dual Capacity, and Transport Switch Installation - 810SJ & 860SJ
3121631 4-33
SECTION 4 - BOOM & PLATFORM
4.10 ELECTRONIC PLATFORM LEVELING PRIMARY AND SECONDARY TILT SENSOR INTERACTION
Two tilt sensors, mounted on each side of the platform support,
Description are used to measure the incline of the platform with respect to
gravity and control the automatic platform angle control func-
Electronic platform leveling replaces the conventional hydraulic
tion. The right one (as viewed from standing in the platform) is
method of platform leveling. The term “platform leveling” does
used as the primary sensor and the left one as a secondary
not refer to the system maintaining the platform at level (or 0°)
backup sensor.
with respect to gravity, but instead refers to the controls auto-
matically maintaining the platform within several degrees of a If a fault occurs with the primary sensor, control will revert to the
preset angle. secondary sensor. (This is discussed in more detail in the error
response section.)
To control electronic platform leveling the platform is equipped
with a pair of tilt sensors, one primary and one secondary, Because of the mounting orientation of the tilt sensors, the pri-
mounted to the non-rotating portion of the platform rotator, mary tilt sensor will output ascending voltage values with
level up and level down valves that are used to provide propor- increases in positive platform tilt angle. The backup or secondary
tional hydraulic flow for each directional function, and a control tilt sensor will output descending voltage values with increases
module that interprets the sensor readings and actuates the lev- in positive platform angle.
eling valves.
4-34 3121631
SECTION 4 - BOOM & PLATFORM
0273695 D
3121631 4-35
SECTION 4 - BOOM & PLATFORM
0273695 D
4-36 3121631
SECTION 4 - BOOM & PLATFORM
PLATFORM VALVES In order to provide a better system response, the controls also
compute the rate of angular change of the platform position
The platform specific valves are located in a manifold at the plat- and set the leveling valve positions to achieve a matching
form. velocity. The measured velocity is the average platform speed
There are six valves that control various platform functions. Two over the last 0.5 seconds. The desired valve command is com-
control Platform Level up and down for the leveling function, puted by comparing the measured velocity to the desired
two are used to rotate the platform, and two to control jib up and velocity and setting the valve opening to correspond to the
down. required amount of make-up angle. The amount the valve
opens when making an automatic correction is proportional
All platform valves are Pulse Width Modulated (PWM’d). PWM is a to and directly affected by:
method of setting the voltage across a valve, and therefore the
flow through it, by varying the On/Off duty cycle of the control
• Crackpoint setting
module output. PWM permits proportional flow control.
There is also a Platform Dump Valve, located in the platform • Velocity error (proportional factor)
valve manifold, which is used to hydraulically isolate the control
• Sum of velocity errors over time (integral factor)
valves and to improve hydraulic response.
These three factors are summed together with appropriate
The Ground Module controls this valve to enable automatic plat-
gain factors to compute the resulting current to the valves.
form leveling and to provide manual platform leveling in the
The operator does not have control over the latter two factors,
event that the Platform Module is inoperable.
but can affect the resulting current by adjusting the crack-
In ground mode, the platform dump valve is turned on whenever point. Increasing the crackpoint makes the valve current
any platform or jib valve output is turned on. Whenever all plat- higher, resulting in quicker more aggressive control and larger
form and jib valves are turned off, the platform dump valve is amounts of overshoot. Decreasing the crackpoint will result in
turned off. smoother operation but may not permit enough platform
velocity to keep up with the boom (i.e., may get platform time-
In platform mode, the platform dump valve is turned on when- out alarms) in some multi-function operations. The platform
ever the footswitch is depressed. controls are set up to provide smooth leveling operations for
the majority of conditions and will perform best for steady
Normal Operation operator command, as opposed to command values for func-
tion, that change frequently.
AUTOMATIC PLATFORM ANGLE CONTROL
The level system will assume a new fixed set point (fixed incline In order to obtain acceptable performance while performing all
of the platform with respect to gravity) each time the control sys- hydraulic functions, five sets of parameters are used. These
tem is powered up (cycling of the EMS) and each time the foot- “zones” allow compensation for differences in how the basket
switch is engaged. level changes when doing different functions. These zones are as
follows:
Automatic platform angle control only functions while operating
drive, telescope, lift or swing. It does not adjust the platform
1. Lift up
angle while operating any other function (e.g. rotate, jib, or
steer). Furthermore, machines equipped with control system 2. Lift down
software P5.0 and later, automatic platform angle control for
drive and swing may be disabled by using the analyzer. For this 3. Other boom functions
case, the platform angle setpoint is taken when the joystick
moves from a non-leveling function (drive/swing) to a leveling 4. Drive
function (lift/tele).
5. Auxiliary
The machine controls attempt to maintain the angle of the
platform to setpoint by providing a command proportional to The other boom functions zone includes Swing, Telescope, Jib
the angular error from setpoint. Since the sensors used to swing (It is not necessary to level with jib lift, since the mechani-
measure the platform angle are fluid-filled, gravity-based sen- cal linkage keeps the basket level).
sors, reading the sensors in real time would cause constant
correction of the platform position due to machine vibration These zones are prioritized when multiple functions are active.
and inertial changes of the boom. Therefore, the sensor read- The priorities are as follows.
ings are averaged over time, or filtered, in order to achieve a
more uniform reading. This filtering has the advantage of pro- 1. Auxiliary power and any other function, zone = auxiliary
viding smoother operation, but has the disadvantage of caus- power
ing a lag (or sluggishness) in the system response. This lag may
cause the platform to be several degrees from setpoint. 2. Drive and any other function, zone = Drive
3121631 4-37
SECTION 4 - BOOM & PLATFORM
3. Lift up and any other function, zone = Lift up Platform Leveling Fault
4. Lift down and any other function, zone = Lift down The JLG Control System takes a snapshot of the two sensor val-
5. Other boom functions, zone = Other boom functions ues and records the difference once on each power up. The Con-
trol system allows a ±5 degrees difference from those values. For
During the power-up procedure, function enable, in both Plat- example, if Sensor 1 is at 5 degrees and Sensor 2 is at 11 degrees,
form and Ground Mode, is delayed during the 1.5 second startup the difference is 6 degrees and the DTC is triggered when the
lamp test. During this 1.5 second startup period, the basket level sensors are 1 degree (or less) apart or 11 degrees (or more) apart.
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 If a fault occurs in the platform leveling system the following will
for 0.5 second. This will help to keep the valves from sticking. occur:
PLATFORM LEVEL MANUAL OVERRIDE 1. Automatic platform angle control will stop and the plat-
form dump valve will be disabled (level, rotate, and jib
In addition to automatic platform angle control, the operator is functions disabled). The exception is when there is a
able to manually adjust the platform level position by means of fault in only one sensor automatic platform angle con-
the level override switches located at the platform and ground trol will remain active as the control system will use the
control positions (similar to a Master/Slave hydraulic system). other sensor to control leveling.
If a command from the Platform Level Up and Down toggle 2. The level system fault lamp will flash (to indicate that
switch on either the platform or the ground is received, auto- the leveling function has been lost).
matic platform angle control will cease and the appropriate out-
put will be commanded to turn on. 3. The platform alarm will sound.
The duty cycle of the output shall be scaled from the pump 4. A system fault will be logged.
potentiometer. When the toggle switch is released, after one sec- 5. All function speeds (lift, swing, telescope and drive) will
ond, the current filtered value of tilt angle will be taken as the be placed in creep mode (except when the platform is in
new set point. the transport position see below).
In other words the operator can chose a platform level incline To reset the fault the emergency stop switch should be recycled.
other than level with gravity and the system will maintain the
chosen platform angle within several degrees of setpoint.
4-38 3121631
SECTION 4 - BOOM & PLATFORM
b. The Electronic Leveling System Fault Lamp shall 1. The Electronic Leveling System Fault Lamp will flash (to
flash (to indicate that the leveling function has been indicate that there is a leveling fault).
lost). 2. The platform alarm will sound.
c. The platform alarm will sound. 3. A system fault will be logged.
d. A system fault will be logged. 4. All function speeds (lift, swing, telescope, jib and drive)
will be placed in creep mode (except when the platform
e. All function speeds (lift, swing, telescope and drive) is in the transport position).
will be placed in creep mode (except when the plat-
form is in the transport position). 5. Automatic platform angle control remains active.
Lift, swing, drive and telescope will continue to operate.
2. In the case of a short to battery on one of the platform
leveling valves, the valve cannot be turned off and the In each of the cases above it will be necessary to re-cycle the EMS
following will occur: to clear the fault. Operable functions shall be in the creep mode
except while below elevation.
a. The platform dump valve will be turned off to pre-
vent unintended tilting of the platform.
3121631 4-39
SECTION 4 - BOOM & PLATFORM
When both sensors appear to be working but have measure- Additional Platform and Jib Valves
ments that disagree by ±5.5º The following will occur:
The high side drivers for the platform left and right and the jib up
1. All interactions with platform leveling shall cease.
and down valves are be located in the Platform Module and are
2. The Electronic Leveling System Fault Lamp shall flash (to PWM’d. The control for these functions are the same as currently
indicate that the leveling function has been lost). implemented for the EPBC except that the flow through the
valves is individually controllable instead of controlled by single
3. The platform alarm will sound. the flow control valve. The individually controlled duty cycle will
4. A system fault will be logged. be the same as would otherwise have been commanded to the
flow control valve.
5. All function speeds (lift, swing, telescope and drive) will
be placed in creep mode (except when the platform is in Only one platform or jib function is allowed at one time to limit
the transport position) the amount of current draw, minimizing the voltage drop on the
supply to the PM.
At this point, the operator must use the level up and down tog-
gle switch to manually level during descent. It shall be necessary The function is enabled first shall remain active until it is
to re-cycle the EMS to clear the fault. released. Any other function commanded while another func-
tion is active is ignored.
CAN Errors If only one other function is commanded when the active func-
The Ground Module has two direct outputs dedicated to overrid- tion is released, the other function will be activated.
ing the Platform Module’s control of the leveling valves. The
If more than one function is commanded when the active func-
EPBC Ground Module “Platform Level Up/Down” outputs are
tion is released, only one function shall be activated.
used to control the platform level up and down valves.
When in ground mode, if the Ground Module reads a platform Platform Leveling Calibration Procedure
leveling switch command, the switch command is communi-
cated over CAN to the Platform Module where it is handled nor- STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
mally.
1. Put machine into “Ground Mode”.
If Ground Module determines that CAN communication is inop-
erable, it turns on the platform control valve and the appropriate 2. Start machine and plug in Analyzer.
platform leveling override outputs while the switch is engaged. 3. Go to the “Access Level 2” screen.
If the Platform Module is still running when CAN is down nothing 4. Enter “33271” to get into Access Level 1 mode.
will operate when in platform mode. When the operator
switches to ground mode, the platform will not control any of its 5. Go to the “Personalities” menu and adjust the following
valve outputs and a CAN error message is signaled. personalities. Refer to the Personality Ranges/Defaults
table in Section 6 - JLG Control System for proper setting
Replacing the Level Sensors values.
Earlier generations of this machine had three different genera- Basket Level Up Min
tions of level sensors that were used on this machine. JLG P/N Basket Level Up Max
4360503, P/N 4360528, and P/N 4360544. P/N 4360528 and Basket Level Down Max
4360544 supersede P/N 4360503. If one of the 4360503 sensors Jib Up Min
fail, BOTH sensors must be replaced with two P/N 4360544 sen- Jib Down Min
sors. 4360503 Sensors can be identified by the code SSY0185-13
which is printed on the sensor. Otherwise, single 4360528 or 6. Recycle EMS.
4360544 9999 sensors may be replaced.
STEP 2: CALIBRATING THE PLATFORM LEVEL
SENSORS (FOR PLATFORM SOFTWARE PRIOR TO VERSION
P3.4)
1. Put machine into “Ground Mode”.
2. Start machine and plug in Analyzer.
3. Manually level the platform with the switch on the MTB.
4. Go to the “Access Level 2” screen.
5. Enter “33271” to get into Access Level 1 mode.
6. Go to the “Calibrations” menu and hit ENTER.
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SECTION 4 - BOOM & PLATFORM
7. Use RIGHT ARROW go to “Plat. Leveling” screen. 19. Hit ESC to exit.
8. Hit ENTER. “Calibrate?” prompt should appear. 20. Cycle power to the machine.
9. Hit ENTER again to calibrate level sensors. 21. The preceding steps will provide acceptable crackpoint
settings for the majority of machines. However, there
10. When calibration has been successful “Cal Complete” exists the possibility certain machines could still have
should appear. too high or too low a crackpoint setting.
11. Cycle power to the machine. If the operator can feel small jolts in the platform from
STEP 3: BLEEDING THE PLATFORM VALVES the valve opening during a leveling operation, the
crackpoint is likely too high. A high crackpoint may also
Start up the machine and exercise the following platform func- lead to over-leveling, causing the platform to drift
tions (from the ground) eight (8) to ten (10) times for 5 seconds beyond the set point. An example of this would be the
in each direction. platform tilting too far backwards during a Lift Up oper-
ation. Use the following guidelines to evaluate whether
Basket Rotate further crackpoint adjustment is required.
Basket Level
a. Telescope the boom halfway.
Jib U/D (if configured)
b. Perform a continued Lift Up command (do not cycle
STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN the joystick on/off repeatedly). If the basket leans
VALVE CRACKPOINTS backward (over compensates), the Level Down
crackpoint is too high. If the basket leans forward or
NOTE: Since the valve position which allows minimum oil flow
a BASKET LEVELING SYSTEM TIMEOUT fault occurs,
(crackpoint) is dependent on the oil pressure, verify the
the Level Down crackpoint is too low.
proper stand-by pressure as outlined in Section 5.4 prior to
setting the crackpoints. c. Perform a continued Lift Down command (do not
cycle the joystick on/off repeatedly). If the basket
1. Put machine into “Ground Mode”. leans forward (over compensates), the Level Up
crackpoint is too high. If the basket leans backwards
2. Start machine and plug in Analyzer. or the Tilt Cutout Alarm comes on, the Level Up
crackpoint is too low.
3. Go to the “Access Level 2” screen.
If Platform Level is slow to respond during Lift com-
4. Enter “33271” to get into Access Level 1 mode.
mands, causing PLATFORM LEVEL TIMED OUT faults, it
5. Go to the “Calibrations” menu and hit ENTER. may be necessary to increase the crackpoint settings.
Use the following guidelines to evaluate whether fur-
6. Go to the “Basket U Crkpt” Screen. Hit ENTER. ther crackpoint adjustment is required.
7. “Calibrate?” prompt should appear. Hit ENTER again. a. Perform a continued Lift Up command (do not cycle
8. You will hear engine go to 1800 rpm. the joystick on/off repeatedly). If the PLATFORM
LEVEL TIMED OUT fault sets or if Platform Level
9. Using UP ARROW, increase the value until you see the Down seems slow to respond, an increase in the
basket up movement. (Typically from 275 – 425). Platform Level Down crackpoint may be necessary.
10. Hit ENTER again. “Cal Complete” message should appear b. Perform a continued Lift Down command (do not
cycle the joystick on/off repeatedly). If the PLAT-
11. Engine should again return to idle. FORM LEVEL TIMED OUT fault sets or if Platform
Level Up seems slow to respond an increase in the
12. Hit ESC should return to “Basket U Crkpt” screen.
Platform Level Up crackpoint may be necessary.
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.
3121631 4-41
SECTION 4 - BOOM & PLATFORM
4.11 HELAC ROTARY ACTUATOR 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
Theory of Operation is adjusted for axial clearance and locked in position by set
screws or pins.
The rotary actuator is a simple mechanism that uses the sliding
spline operating concept to convert axial piston motion into The actuators are equipped with factory installed counterbal-
powerful shaft rotation. Each actuator is composed of a housing ance valves, which performs four major functions.
with integrated gear ring (1) and only two moving parts: the cen- • Protects the actuator in the event of overload
tral shaft with integrated bearing tube and mounting flange (2),
• Enables the actuator to hold position without drifting
and the annular piston sleeve (3). Helical spline teeth machined
when external loads are applied
on the shaft engage matching splines on the inside diameter of
the piston. The outside diameter of the piston carries a second • Reduces hydraulic backlash by pressuring the hydraulic
set of splines, of opposite hand, which engage with matching fluid
splines in the housing. As hydraulic pressure is applied, the pis- • Provides a constant controlled rate of rotation in over-cen-
ton is displaced axially within the housing similar to the opera- ter load conditions
tion 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.
Bars indicate starting positions of piston and Applying fluid pressure will displace the piston axially
shaft. Arrows indicate direction they will rotate. while the helical gearing causes the piston and shaft
The housing with integral ring gear remains sta- to rotate simultaneously.
tionary.
The double helix design compounds rotation: shaft
rotation is about twice that of the piston. Applying
pressure to the opposite port will return the piston
and shaft.
4-42 3121631
SECTION 4 - BOOM & PLATFORM
3121631 4-43
SECTION 4 - BOOM & PLATFORM
4-44 3121631
SECTION 4 - BOOM & PLATFORM
3121631 4-45
SECTION 4 - BOOM & PLATFORM
Disassembly
1. Remove port plugs (106.1) (106.2) and drain oil. Inspect
oil for signs of contamination, i.e. water, metal shavings.
7. Remove the end cap (4) and set aside for later inspec-
tion.
4-46 3121631
SECTION 4 - BOOM & PLATFORM
8. Remove the stop tube (400) if included. The stop tube is 10. Prior to removing the shaft, (2), use a felt marker to
an available option to limit the rotation of the actuator. clearly indicate the timing marks between shaft and pis-
ton. This will greatly simplify timing during assembly.
12. Before removing the piston (3), mark the housing (1)
ring gear in relation to the piston O.D. gear. There should
now be timing marks on the housing (1) ring gear, the
piston (3) and the shaft (2).
3121631 4-47
SECTION 4 - BOOM & PLATFORM
13. To remove the piston (3) use a rubber mallet and a plas- 16. Remove the wear guides (302) from the end cap (4) and
tic mandrel so the piston is no damaged. shaft (2).
14. At the point when the piston gear teeth come out of 17. Remove the main pressure seal (205).
engagement with the housing gear teeth, mark the pis-
ton and housing with a marker as shown.
18. Remove the thrust washers (304), from the end cap (4)
and shaft (2).
15. Remove the o-ring (204) and backup ring (207) from end
cap (4) and set aside for inspection.
4-48 3121631
SECTION 4 - BOOM & PLATFORM
Inspection
19. Remove the O-ring (304.1) from its groove in the end
cap (4) and shaft (2).
3121631 4-49
SECTION 4 - BOOM & PLATFORM
2. Coat the thrust washers (304) with a generous amount 5. Install the wear guide (302) on the end cap (4) and shaft
of Lithium grease. Install the thrust washer (304) onto (2).
shaft (2) and end cap (4).
6. Install the O-ring (204) and backup ring (207) into the
3. Install the exclusion (304.1) into it’s groove on the shaft inner seal groove on the end cap (4).
(2) and end cap (4) around the outside edge of the
thrust washer (304).
4. Using a seal tool install the main pressure seal (205) onto
shaft (2) and end cap (4). Use the seal tool in a circular
motion.
4-50 3121631
SECTION 4 - BOOM & PLATFORM
7. Install the inner T-seal (200) into the piston (3) using a
circular motion. Install the outer T-seal (202) by stretch-
ing it around the groove in a circular motion. Each T-seal
has 2 backup rings (see drawing for orientation).
10. Looking into the bore from the opposite end of the
housing (1) be sure the timing marks align correctly.
Rotate the piston as necessary until aligned, then gently
8. Insert the piston (3) into the housing (1) as shown, until
tap the piston (3) into the housing until the gear teeth
the outer piston seal (202) is touching inside the hous-
mesh together. Tap the piston into the housing until it
ing bore.
completely bottoms out against the ring gear.
11. Install the shaft (2) into the piston (3). Be careful not to
damage the seals. Do not engage the piston gear teeth
yet.
3121631 4-51
SECTION 4 - BOOM & PLATFORM
12. Looking at the actuator from the end opposite the shaft 14. Install the stop tube (400) onto the shaft end if neces-
flange, use the exisitng timing marks to align the gear sary. Stop tubes are an available option to limit the rota-
teeth on the shaft (2) with the gear teeth on the inside of tion of an actuator.
the piston (3). When the marks align, gently tap the
flange end of the shaft with a rubber mallet until the
gear teeth engage.
15. Coat the threads on the end of the shaft with antiseize
grease to prevent galling.
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SECTION 4 - BOOM & PLATFORM
16. Thread the end cap (4) onto the shaft (2) end. Make sure 18. Place the lock pins (109) provided in the Helac seal kit in
the wear guide stays in place on the end cap as it is the holes with the dimple side up. Then, using a punch,
threaded into the housing (1). tap the lock pins to the bottom of the hole.
17. Tighten the end cap (4) using a metal bar. In most cases 19. Insert the set screws (113) over the lock pins. Tighten
the original holes for the lock pins will align. them to 25 in. lbs. (2.8 Nm).
3121631 4-53
SECTION 4 - BOOM & PLATFORM
Installing Counterbalance Valve 3. The bolts that come with the valve are grade 8 bolts.
New bolts should be installed with a new valve. JLG
Refer to Figure 4-27., Rotator Counterbalance Valve. Threadlocker P/N 0100011 should be applied to the
shank of the three bolts at the time of installation.
1. Make sure the surface of the actuator is clean, free of any
contamination and foreign debris including old JLG 4. Torque the 1/4 inch bolts 110 to 120 inch. lbs. (12.4 to
Threadlocker. 13.5 Nm). Do not torque over 125 inch. lbs. (14.1 Nm).
Torque the 5/16-inch bolts 140 inch. lbs. (15.8 Nm). Do
2. Make sure the new valve has the O-rings in the counter- not torque over 145 inch. lbs(16.3 Nm).
bores of the valve to seal it to the actuator housing.
4-54 3121631
SECTION 4 - BOOM & PLATFORM
7. 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).
3121631 4-55
SECTION 4 - BOOM & PLATFORM
Installation and Bleeding 2. With an operator in the platform, open both bleed nip-
ples 1/4 turn. Hydraulically rotate the platform to the
After installation of the actuator on the equipment, it is impor- end of rotation (either clockwise or counterclockwise),
tant that all safety devices such as tie rods or safety cables are and maintain hydraulic pressure. Oil with small air bub-
properly reattached. bles will be seen flowing through the tubes. Allow a 1/2
To purge air from the hydraulic lines, connect them together gallon of fluid to be purged from the actuator.
to create a closed loop and pump hydraulic fluid through 3. Keep the fittings open and rotate the platform in the
them. Review the hydraulic schematic to determine which opposite direction to the end position. Maintain hydrau-
hydraulic lines to connect. The linear feet and inside diameter lic pressure until an additional 1/4 gallon of fluid is
of the hydraulic supply lines together with pump capacity will pumped into the container.
determine the amount of pumping time required to fully
purge the hydraulic system. 4. Repeat steps 2 & 3. After the last 1/2 gallon is purged,
close both bleed nipples before rotating away from the
Bleeding may be necessary if excessive backlash is exhibited end position.
after the actuator is connected to the hydraulic system. The
following steps are recommended when a minimum of two
gallons (8 liters) is purged.
1. Connect a 3/16” inside diameter x 5/16” outside diame-
ter x 5 foot clear, vinyl drain tube to each of the two
bleed nipples. Secure them with hose clamps. Place the
vinyl tubes in a clean 5-gallon container to collect the
purged oil. The oil can be returned to the reservoir after
this procedure is completed.
TYPICAL CONFIGURATION
OF ACTUATOR
4-56 3121631
SECTION 4 - BOOM & PLATFORM
Troubleshooting
Table 4-1. Troubleshooting
b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic lines for
restrictions and leaks.
c. Control or counterbalance valve has internal leak c. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate the actuator through housing ports
(do not exceed OEM’s operating pressure). The valve must
be replaced if a steady flow of fluid is seen coming from the
valve ports.
d. Piston and/or shaft seal leak d. Remove the plug and the housing’s valve ports. Operate
the actuator through the housing ports. Conduct the inter-
nal leakage test as described in the Testing section on page
24 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 incom- f. Re-build the actuator. Use fluid that is compatible with
patible hydraulic fluid seals and bearings.
2. Operation is erratic or not responsive a. Air in actuator a. Purge air from actuator. See bleeding procedures.
3. Shaft will not fully rotate a. Twisted or chipped gear teeth overload conditions a. Check for gear binding. Actuator may or may not be able
to be re-built and may need to be replaced.
b. Piston and/or shaft seal leak b. Remove the plug and the housing’s valve ports. Operate
the actuator through the housing ports. Conduct the inter-
nal leakage test as described in the Testing section of this
manual.
3121631 4-57
SECTION 4 - BOOM & PLATFORM
4.12 LOAD SENSING DEVICE 8. Select Machine Set-Up>Load Cell>1 Warn Only.
9. Select Machine Diagnostics>System Load Cell on the
Calibrating the Load Sensor Analyzer.
NOTE: Refer to Section 6 - JLG Control System. 10. Adjust P2 until the Load = 0%.
11. Place 525 lbs. (238 kg) in the center of the basket.
1. Place the boom in the following position.
12. Adjust P1 until the Load = 100%.
a. Boom - Stowed
13. Verify that the overload indicator lights continuously
b. Telescope - In and the alarm sounds continuously during an overload
c. Jib - 0 Degrees condition.
d. Swing - 0 Degrees 14. Remove the weight from the platform.
e. Basket Level - 0 Degrees 15. Adjust P2 until the Load = 0%.
f. Basket Rotate - 0 Degrees
16. Place 525 lbs. (238 kg) in the center of the basket.
g. Weight in Basket - 0
17. Adjust P1 until the Load = 100%.
h. Machine parked on firm, level surface
18. Remove the weight from the basket.
2. Activate both emergency stop switches and turn the key
switch to the platform position. 19. Seal the potentiometers with fingernail polish.
4-58 3121631
SECTION 4 - BOOM & PLATFORM
3121631 4-59
SECTION 4 - BOOM & PLATFORM
0"%
NOTE: Machine will treat Soft Touch/SkyGuard override switch as
if it is a Soft Touch and SkyGuard switch.
SkyGuard SkyLine™
1. Operate the telescope out function, then activate Sky-
Guard sensor.
In Ground Mode:
THE MACHINE OPERATOR IS REQUIRED TO PERFORM A DAILY FUNCTION TEST
TO ENSURE PROPER OPERATION OF THE SKYGUARD SYSTEM. 1. Operation is allowed regardless of SkyGuard activation.
4-60 3121631
SECTION 4 - BOOM & PLATFORM
SOFT TOUCH ONLY Engage the SkyGuard sensor and observe the Analyzer to
If Soft Touch only is selected in machine setup (refer to Table determine if the switch/relay closes.
6-2), machine will treat the Soft Touch/SkyGuard override
If the status of the switch/relay remains OPEN while the Sky-
switch as if it is a Soft Touch switch.
Guard sensor is actively engaged, it is possible the sensor has
SKYGUARD NOT SELECTED IN MACHINE SETUP failed and should be replaced immediately.
If the SkyGuard system is installed on the machine, but no If the status of the switch/relay remains CLOSED while the Sky-
option is selected in the machine setup (refer to Table 6-2), Guard sensor is actively engaged, a power or ground wire may
SkyGuard sensor status will be ignored. No function cutout or not be making good contact or may be loose or broken. Addi-
reversal will be implemented. tionally, there is a low probability that both relays may have
failed.
Diagnostics & Troubleshooting
If the switch/relay status is in disagreement, then one may
If SkyGuard does not function when the sensor is engaged, have failed or is not installed correctly. In this case, the
first verify the configuration under the machine will be inoperable.
MACHINE SETUP: SKYGUARD OPTION menu using the hand-
held Analyzer. Ensure the selected configuration matches the FAULT CODES
actual system installed on the machine. If not, select the cor- Refer to Table 6-9 for more fault code information
rect configuration, then verify operation.
• 0039 - SkyGuard switch activation fault
Additionally, use the handheld analyzer to navigate to the
DIAGNOSTICS: FEATURES SKYGUARD INPUTS menu to • 2563 - switch disagreement fault
determine additional SkyGuard fault information.
Boom
Drive Drive Boom Boom Boom Basket Basket
Steer Swing Lift Jib Lift
Forward Reverse Lift Up Tele Out Tele In Level Rotate
Down
R*/C** R C R R R R C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* DOS (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.
3121631 4-61
SECTION 4 - BOOM & PLATFORM
4.14 BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands,
kinks, or any signs of corrosion.
The Bolt-On External Fall Arrest system is designed to provide
a lanyard attach point while allowing the operator to access GAP
GAPSHOWING:
SHOWING:
areas outside the platform. Exit/Enter the platform through INCORRECT
INCORRECT
the gate area only. The system is designed for use by one per-
son.
Personnel must use fall protection at all times. A full body har-
ness is required with lanyard not to exceed 6 ft. (1.8 M) in
length, that limits the maximum arrest force to 900 lbs. (408
kg). NO GAP:
NO GAP: CORRECT
CORRECT
Bolt-On External Fall Arrest System capacity is 310 lb (140 kg) -
one (1) person maximum.
• Fittings & Brackets: Ensure all fittings are tight and there are
no signs of fractures. Inspect brackets for any damage.
IF THE BOLT-ON EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL
OR IS OTHERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND • Attachment Ring: No cracks or signs of wear are accept-
THE PLATFORM FULLY INSPECTED BEFORE RETURNING TO SERVICE. REFER TO able. Any signs of corrosion requires replacement.
THE SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES.
• Attaching Hardware: Inspect all attaching hardware to
THE BOLT-ON EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL ensure there are no missing components and hardware is
INSPECTION AND CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICA-
properly tightened.
TION MUST BE PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER.
• Platform Rails: No visible damage is acceptable.
Inspection Before Use
The Bolt-On External Fall Arrest system must be inspected Installation
before each use of the aerial work platform. Replace compo-
nents if there are any signs of wear or damage. 1. Install the retaining hardware (bolts, nuts, and washers)
and secure the brackets to the platform rail. Tighten the
Before each use, perform a visual inspection of the following nuts but do not torque them yet.
components:
BOLT
WASHER
WASHER
NUT
4-62 3121631
SECTION 4 - BOOM & PLATFORM
2. Attach the fall arrest cable to the right hand bracket 5. Use the two jam nuts to prevent the cable from rotating
Using the attaching bolt and nut. Orient the bolt as while the nut is tightened. Tighten the nut until the bel-
shown below. Do not tighten the nut so cable can still leville washers are fully compressed and no gap is pres-
rotate. ent at the outside diameter of the washers. Ensure the
cable has not rotated during tightening.
BOLT
NUT
4. Without twisting the fall arrest cable, pull it through the 7. Torque the nuts and bolts securing the brackets to
left hand bracket and mark the top of the swaged cable 15 ft.lbs. (20 Nm).
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.
WASHER
BELLEVILLE
NUT WASHER
JAM NUT
3121631 4-63
SECTION 4 - BOOM & PLATFORM
7
1,2,3,4
5
1. Belleville Washer
2. Washer
6 3. Hex Nut
4. Jam Nut
5. LH Bracket
6. Attachment Ring
7. Cable
8. RH Bracket
9. Decal
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SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in the
SYSTEM fitting, making sure the entire o-ring is completely satu-
rated.
When assembling connectors in the hydraulic that use o-ring
fittings, it is necessary to lubricate all fittings with hydraulic oil
prior to assembly. To lubricate the fittings, use one of the fol-
lowing procedures.
1. Hold the fitting in one hand while using the brush with
the other hand to dip into the container. Remove excess
hydraulic oil from the brush so an even film of oil is
applied on the o-ring.
3121631 5-1
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Brush-on Method
This method requires a sealed bottle brush.
5-2 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512
TORQUE SPECIFICATION
Tapered Thread Types
NPTF = national tapered fuel (Dry Seal) per SAE J476/J512
3121631 5-3
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Tightening Methods
Torque = Application of a twisting force to the applicable con-
nection by use of a precise measurement instrument (i.e.
MFF = metric flat face port per ISO 9974-1 torque wrench).
BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852- Finger Tight = The point where the connector will no longer
2 thread onto the mating part when tightened by hand or fin-
gers. Finger Tight is relative to user strength and will have
some variance. The average torque applied by this method is 3
ft. lbs. (4 Nm). Also referred to as ‘Hand Tight.’
TFFT = Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by hand (fin-
gers) and applying an additional rotation counted by a
defined number of turns by use of a tool.
FFWR = Flats From Wrench Resistance; Application of a pre-
load to a connection by tightening to the point of initial
wrench resistance and turning the nut a described number of
‘flats’. A ‘flat’ is one side of the hexagonal tube nut and equates
to 1/6 of a turn. Also referred to as the ‘Flats Method.’
5-4 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the
correct torque values.
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the con- a. Verify the material designation in the table head-
nector being installed. Refer to the Figures and Tables in this ings.
section. b. If specifications are given only for steel fittings and
components, the values for alternate materials shall
GENERAL TUBE TYPE FITTING ASSEMBLY be as follows: Aluminum and Brass- reduce steel val-
INSTRUCTIONS ues by 35%; Stainless Steel- Use the upper limit for
steel.
1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling 5. To achieve the specified torque, the torque wrench is to
or assembly. Nicks and scratches in sealing surfaces can be held perpendicular to the axis of rotation.
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting attach-
ment to ensure that the tube has not been damaged.
3. The assembly process is one of the leading causes for
contamination in air and hydraulic systems. Contamina-
tion can prevent proper tightening of fittings and adapt-
ers from occurring.
a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as nec-
essary before re-installing.
c. Sealing compounds should be applied where speci-
Figure 5-10. Torque Wrench Angle
fied; however, care should be taken not to introduce
sealant into the system. 6. Refer to the appropriate section in this manual for more
d. Avoid applying sealant to the area of the threads specific instructions and procedures for each type of fit-
where the sealant will be forced into the system. ting connection.
This is generally the first two threads of a fitting.
e. Sealant should only be applied to the male threads.
f. Straight thread fittings do not require sealants. O-
rings or washers are provided for sealing.
g. When replacing or installing an O-ring, care is to be
taken while transferring the O-ring over the threads
as it may become nicked or torn. When replacing an
O-ring on a fitting, the use of a thread protector is
recommended.
h. When installing fittings with O-rings, lubrication
shall be used to prevent scuffing or tearing of the O-
ring. See O-ring Installation (Replacement) in this
section.
3121631 5-5
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN-
MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR
Thread Tapered (NPTF) Connections. ALIGNMENT.
1. Inspect components to ensure male and female port
5. Rotate male fitting the number of turns per Table 5-1,
threads are free of rust, splits, dirt, foreign matter, or
NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT
burrs.
procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to
NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
the male pipe threads if not already applied. Ensure the
applicable for the following material configurations:
first 1 to 2 threads are uncovered to prevent system con-
tamination.
• STEEL fittings with STEEL mating components
3. Assemble connection hand tight. • STEEL fittings with ALUMINUM or BRASS mating compo-
4. Mark fittings, male and female. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR. mating components.
TYPE/FITTING IDENTIFICATION
Turns From Finger
Thread Size ØA*
Material Dash Size Tight (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
STEEL, ALUMINUM, OR BRASS MATING C
5-6 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for British Standard Pipe MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR
ALIGNMENT.
Thread Tapered (BSPT) Connections
5. Rotate male fitting the number of turns per Table 5-2,
1. Inspect components to ensure male and female port
BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT
threads are free of rust, splits, dirt, foreign matter, or
procedure requirements.
burrs.
NOTE: TFFT values provided in Table 5-2, BSPT Pipe Thread are
2. Apply a suitable thread sealant, such as Loctite 567, to
applicable for the following material configurations:
the male pipe threads if not already applied. Ensure the
first 1 to 2 threads are uncovered to prevent system con-
• STEEL fittings with STEEL mating components
tamination.
• STEEL fittings with ALUMINUM or BRASS mating compo-
3. Assemble connection hand tight. nents
4. Mark fittings, male and female. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND mating components.
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR.
TYPE/FITTING IDENTIFICATION
Turns From Finger
Thread Size ØA*
MATERIAL Dash Size Tight (TFFT)**
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
3121631 5-7
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table 5-3, 37° Flare
(JIC)Thread - Steel or Table 5-4, 37° Flare (JIC)Thread -
1. Inspect the flare for obvious visual squareness and con- Aluminum/Brass while using the Double Wrench
centricity issues with the tube OD. Ensure surface is Method per Double Wrench Method. Refer to FFWR and
smooth, free of rust, weld and brazing splatter, splits, TFFT Methods for procedure requirements if using the
dirt, foreign matter, or burrs. If necessary replace fitting FFWR method.
or adapter.
NOTE: Torque values provided in Table Table 5-3, 37° Flare
(JIC)Thread - Steel and Table 5-4, 37° Flare (JIC)Thread -
Aluminum/Brass are segregated based on the material
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT configuration of the connection.
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO LEAK-
AGE. ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
COMPONENTS’ indicate either the following material configu-
2. Align tube to fitting and start threads by hand. rations:
• STEEL fittings with ALUMINUM or BRASS mating compo-
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
• ALUMINUM or BRASS fittings with STEEL mating compo-
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
nents
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
5-8 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
3121631 5-9
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5-10 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using
1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section. Refer to
centricity issues with the tube OD. Ensure surface is FFWR and TFFT Methods for procedure requirements if using
smooth, free of rust, weld and brazing splatter, splits, the TFFT method.
dirt, foreign matter, or burrs. If necessary replace fitting
or adapter. NOTE: Torque values provided in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass are segre-
gated based on the material configuration of the connec-
tion.
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO LEAK- ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
AGE. COMPONENTS’ indicate either the following material configu-
rations:
2. Align tube to fitting.
• STEEL fittings with ALUMINUM or BRASS mating compo-
3. Tighten fitting by hand until hand tight. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. mating components.
3121631 5-11
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5-12 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal
(ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu-
Fittings minum/Brass while using the Double Wrench Method.
Refer to FFWR and TFFT Methods for procedure require-
1. Ensure proper O-ring is installed. If O-ring is missing ments if using the FFWR method.
install per O-ring Installation (Replacement).
NOTE: Torque values provided in Table 5-7, O-ring Face Seal
2. Ensure surface is smooth, free of rust, weld and brazing (ORFS) - Steel and Table 5-8, O-ring Face Seal (ORFS) - Alu-
splatter, splits, dirt, foreign matter, or burrs. If necessary minum/Brass are segregated based on the material config-
uration of the connection.
replace fitting or adapter.
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
COMPONENTS’ indicate either the following material configu-
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE rations:
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE • STEEL fittings with ALUMINUM or BRASS mating compo-
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
4. Place the tube assembly against the fitting body so that • ALUMINUM or BRASS fittings with ALUMINUM or
the flat face comes in contact with the O-ring. Hand BRASS mating components
thread the nut onto the fitting body.
Table 5-7. O-ring Face Seal (ORFS) - Steel
3121631 5-13
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
UN-LUBRICATED THREADS
5-14 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
3121631 5-15
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
[Ft-Lb] [N-m]
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
DIN 24° CONE FLARELESS BITE (MBTL) FITTING
[Ft-Lb] [N-m]
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75
DIN 24° CONE FLARELESS BITE (MBTS) FITTING
5-16 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
3121631 5-17
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Thread Size
TYPE
8 13/16-16 55 58 61 75 79 83
BULKHEAD FITTING
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
10 7/8-14 85 90 94 115 122 127
12 1 1/16-12 135 142 149 183 193 202
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
5-18 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
10 M16 x 1.5 22 23 24 30 31 33
(MBTL) BULKHEAD FITTING
12 M18 x 1.5 35 37 39 47 50 53
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
STEEL FITTINGS
3121631 5-19
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12
through Table 5-17 while using the Double Wrench
Fittings Method.
1. Inspect components to ensure that male and female a. The table headings identify the straight thread O-
port threads are free of rust, splits, dirt, foreign matter, or ring port and the type on the other side of the fit-
burrs. ting. The torque will be applied to the straight
thread O-ring port.
2. Ensure proper O-ring is installed. If O-ring is missing
install per O-ring Installation (Replacement). b. Torque values provided in Table 5-12 through Table
5-17 are segregated based on the material configu-
ration of the connection. ‘ALUMINUM/BRASS FIT-
T I N G S O R A LU M I N U M / B R A S S M AT I N G
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE COMPONENTS’ indicate either the following mate-
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE rial configurations:
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
• STEEL fittings with ALUMINUM or BRASS mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil.
• ALUMINUM or BRASS fittings with STEEL mating compo-
4. For Non-Adjustable and Plugs, thread the fitting by
nents
hand until contact.
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
5. For Adjustable fittings, refer to Adjustable Stud End mating components.
Assembly for proper assembly.
7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counterbore of the port.
5-20 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
3121631 5-21
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
STUD ENDS
TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 26 27 28 35 37 38
COMPONENTS; UN-LUBRICATED THREADS
5-22 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
3121631 5-23
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5-24 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
3121631 5-25
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5-26 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18,
Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5-
Metric (MFF) Fittings 23 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the Metric port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter or burrs. be applied to the Metric port.
2. If O-ring is not pre-installed, install proper size, taking b. Torque values provided in Table 5-18, Table 5-19,
care not to damage it. See O-ring Installation (Replace- Table 5-20, Table 5-21, Table 5-22, and Table 5-23 are
ment) for instructions. segregated based on the material configuration of
the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE
• STEEL fittings with ALUMINUM or BRASS mating compo-
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE
nents
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
• ALUMINUM or BRASS fittings with STEEL mating compo-
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
by hand until contact. mating components.
5. For Adjustable fittings, refer to Adjustable Stud End 7. Inspect to ensure the O-ring is not pinched and the
Assembly for proper assembly. washer is seated flat on the counterbore of the port.
3121631 5-27
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
Thread M Connecting Torque Torque
MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
5-28 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
Thread M Connecting Torque Torque
MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
3121631 5-29
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
TYPE/FITTING IDENTIFICATION
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
Thread M Connecting Torque Torque Torque
MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
5-30 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770
Thread M Connecting Torque Torque
MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
3121631 5-31
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
Thread M Connecting Torque Torque
MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
5-32 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
TYPE/FITTING IDENTIFICATION
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --
Thread M Connecting Torque Torque Torque
MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
3121631 5-33
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24
while using the Double Wrench Method.
Port Assembly Stud Ends
a. The table headings identify the Metric port and the
1. Inspect components to ensure that male and female type on the other side of the fitting. The torque will
threads and surfaces are free of rust, splits, dirt, foreign be applied to the Metric port.
matter or burrs. b. Torque values provided in Table 5-24 are segregated
2. If O-ring is not pre-installed, install proper size, taking based on the material configuration of the connec-
care not to damage it. See O-ring Installation (Replace- tion. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/
ment) for instructions. BRASS MATING COMPONENTS’ indicate either the
following material configurations:
• STEEL fittings with ALUMINUM or BRASS mating compo-
nents
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE • ALUMINUM or BRASS fittings with STEEL mating compo-
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
3. Pre-lubricate the O-ring with Hydraulic Oil.
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
7. Inspect to ensure the O-ring is not pinched and the
by hand until contact.
washer is seated flat on the counterbore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
Assembly for proper assembly.
5-34 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
UN-LUBRICATED THREADS
M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
3121631 5-35
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
COMPONENTS; UN-LUBRICATED THREADS
M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
5-36 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25,
Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5-
(BSPP) Fittings 30 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the BSPP port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter or burrs. be applied to the BSPP port.
2. If O-ring is not pre-installed, install proper size, taking b. Torque values provided in Table 5-25, Table 5-26,
care not to damage it. See O-ring Installation (Replace- Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are
ment) for instructions. segregated based on the material configuration of
the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE
• STEEL fittings with ALUMINUM or BRASS mating compo-
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE
nents
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
• ALUMINUM or BRASS fittings with STEEL mating compo-
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
by hand until contact. mating components.
5. For Adjustable fittings, refer to Adjustable Stud End 7. Inspect to ensure the O-ring is not pinched and the
Assembly for proper assembly. washer is seated flat on the counterbore of the port.
3121631 5-37
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Table 5-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
BSPP Thread Connecting Torque Torque
MATERIAL G Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 42 139 146 153 188 198 207 302 318 333 409 431 451
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
5-38 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Table 5-26. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE STUD
TYPE/FITTING IDENTIFICATION STUD ENDS ENDS
with 37° (JIC) or L series DIN (MBTL) opposite end with 37° (JIC) or L series DIN (MBTL) opposite end
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Thread Connecting Torque Torque
MATERIAL G Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 42 259 272 285 351 369 386 259 272 285 351 369 386
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
3121631 5-39
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Table 5-27. British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
TYPE/FITTING IDENTIFICATION
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
5-40 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP Thread Connecting Torque Torque
MATERIAL G Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
3121631 5-41
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Table 5-29. British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE STUD
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS ENDS
with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Thread Connecting Torque Torque
MATERIAL G Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
5-42 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Table 5-30. British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 Service Manual.
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 Service Manual.
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
3121631 5-43
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5-44 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Bolt Fastener Torque for Flanges Equipped with GRADE 5 Fastener Torque for Flanges Equipped with GRADE 8
Inch
Flange Size A* Thread Screws Screws
Flange
TYPE Size
SAE Dash [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
CODE 61 SPLIT FLANGE (FL61)
3121631 5-45
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Bolt Fastener Torque for Flanges Equipped with CLASS Fastener Torque for Flanges Equipped with CLASS
Inch Flange Flange Size A* Thread 8.8 Screws 10.9 Screws
TYPE SAE Dash Size [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
CODE 61 SPLIT FLANGE (FL61)
5-46 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper
hose installation. A twisted lay-line usually indicates the hose
To prevent undesired hose or connector rotation, two is twisted. See Figure 5-11. for double wrench method require-
wrenches must be used; one torque wrench and one back- up ments.
wrench. If two wrenches are not used, inadvertent component
rotation may occur which absorbs torque and causes
improper joint load and leads to leaks. For hose connections,
3121631 5-47
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1. Tighten the swivel nut to the mating fitting until no lat- 1. Lubricate the o-ring with a light coat of hydraulic oil.
eral movement of the swivel nut can be detected; finger 2. Position #1 – The o-ring should be located in the groove
tight condition. adjacent to the face of the backup washer. The washer
and o-ring should be positioned at the extreme top end
2. Mark a dot on one of the swivel hex nut flats and of the groove as shown.
another dot in line on the connecting tube adapter. See
Figure B.1. 3. Position #2 – Position the locknut to just touch the
backup washer as shown. The locknut in this position
3. Use the double wrench method per Appendix A, turn will eliminate potential backup washer damage during
the swivel nut to tighten as shown in Figure 5-11. The the next step.
nut is to be rotated clockwise the number of hex flats as
4. Position #3 – Install the connector into the straight
defined by the applicable Table in Section 5.0.
thread box port until the metal backup washer contacts
the face of the port as shown.
4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering 5. Position #4 – Adjust the connector to the proper posi-
the dots, to indicate the connection has been properly tion by turning out (counterclockwise) up to a maxi-
tightened. See Figure 5-12. mum of one turn as shown to provide proper alignment
with the mating connector, tube assembly, or hose
assembly.
6. Position #5 – Using two wrenches, use the backup
wrench to hold the connector in the desired position
and then use the torque wrench to tighten the locknut
to the appropriate torque.
7. Visually inspect, where possible, the joint to ensure the
o-ring is not pinched or bulging out from under the
washer and that the backup washer is properly seated
flat against the face of the port.
5-48 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
3121631 5-49
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.
SURFACE IN A DIRT FREE WORK AREA. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
1. Install two new wear rings and rod seal in rod bore
ROD CAN FALL OUT OF BARREL AND CAUSE INJURY OR DAMAGE TO THE grooves. Make sure they are not twisted.
EQUIPMENT. BE CAREFUL WHEN REMOVING AXLE CYLINDER. OPENING BLEED
VALVE CAN CAUSE ROD TO FALL OUT OF BARREL. 2. Install new wiper in barrel.
3. Lubricate rod bore with clean hydraulic fluid.
1. Open bleeder valve. Rotate rod and remove from barrel.
2. Remove wiper. Do not scratch barrel bore.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE ROD. AVOID PULL-
3. Remove two wear rings and rod seal from grooves of rod
bore. Do not scratch barrel bore. ING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE ROD AND
CYLINDER BARREL SURFACES.
4. Remove counterbalance valve.
4. Install rod in bore and push to top of the bore.
CLEANING AND INSPECTION
5. Install counterbalance valve. Torque to 22 ft. lbs. (30
1. Inspect bore and rod for scoring, pitting, or excessive Nm).
wear.
6. Bleed system.
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 com-
pressed air.
5-50 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1001204560 A
3121631 5-51
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Remove wiper. Do not scratch barrel bore. 2. Install new wiper in barrel.
3. Remove two wear rings and rod seal from grooves of rod 3. Lubricate rod bore with clean hydraulic fluid.
bore. Do not scratch barrel bore.
4. Remove counterbalance valve.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE ROD. AVOID PULL-
CLEANING AND INSPECTION ING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE ROD AND
CYLINDER BARREL SURFACES.
1. Inspect bore and rod for scoring, pitting, or excessive
wear. 4. Install rod in bore and push to top of the bore.
2. Remove minor surface blemishes with wet sandpaper. 5. Install counterbalance valve. Torque to 22-24 ft. lbs.
Pitting requires replacement of barrel and rod. (27-33 Nm).
3. Clean all parts with approved solvent and dry with com- 6. Bleed system.
pressed air.
5-52 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8
9 7*
6 6
4
6
5
4
1001230374-A
MAE33590A
3121631 5-53
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Jib Lift Cylinder (860SJ Only) (SN 0300182743 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
through 0300244707, SN B300001092 through inder head retainer capscrews and remove capscrews
B300002483) from cylinder barrel.
DISASSEMBLY BARREL
CAPSCREW
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA. WASHER
RING
1. Connect a suitable auxiliary hydraulic power source to
the cylinder port block fitting.
PUNCH MARK
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER CYLINDER HEAD
SLIGHTLY TO AVOID TRAPPING PRESSURE.
Figure 5-17. Capscrew Removal
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable. 6. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as 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. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
ROD SUPPORT CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
PROTECTED ROD CLAMP
7. With the barrel clamped securely, apply pressure to the
BARREL CLAMP
rod pulling device and carefully withdraw the complete
rod assembly from the cylinder barrel.
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
5-54 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
6**
7 22
7
6**
9*
11
14
8
13
10
14
13
15
16
12
16
17
18
2
21 5
19
20
3
4***
*Torque to 5 ft. lbs. (7 Nm)
**Torque to 50-55 ft. lbs. (68-75 Nm)
***Torque to 20 ft. lbs. (27 Nm)
23 1683609-L
MAE33470L
3121631 5-55
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove capscrews from drilled holes.
10. Insert the capscrews in the threaded holes in the outer 2. Inspect the cylinder rod for scoring, tapering, ovality or
piece of the tapered bushing. Progressively tighten the other damage. If necessary, dress rod with Scotch Brite
capscrews until the bushing is loosen on the piston. or equivalent. Replace rod if necessary.
11. Remove the bushing from the piston. 3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
5-56 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
O-RING BACKUP
WEAR RING RING
ROD SEAL
3121631 5-57
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston
cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the
ring into the applicable cylinder head gland groove. bushing and into the tapped holes in the piston.
PISTON
TAPERED
BUSHING
ROD
CAPSCREW
3. Place a new o-ring and backup seal in the applicable Figure 5-26. Tapered Bushing Installation
outside diameter groove of the cylinder head.
11. Tighten the capscrews evenly and progressively in rota-
tion to 5 ft. lbs. (7 Nm).
12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4 in. diameter) as follows:
a. Place the shaft against the cylinder rod and in con-
tact with the bushing in the spaces between the
capscrews.
b. Tap each space once; this means the tapered bush-
ing is tapped 3 times as there are 3 spaces between
the capscrews.
5-58 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
13. Rotate the capscrews evenly and progressively in rota- 17. With barrel clamped secured and adequately support-
tion to 5 ft. lbs. (7 Nm). ing the rod, insert the piston end into the barrel cylinder.
Ensure that the piston loading o-ring and seal ring are
14. Remove the cylinder rod from the holding fixture. not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. PISTON
ROD
SPACER
HEAD
BARREL WASHER RING
ROD
3121631 5-59
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Jib Lift Cylinder (860SJ Only) 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
(SN 0300244708 to Present) inder head retainer capscrews and remove capscrews
from cylinder barrel.
DISASSEMBLY
BARREL
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA. CAPSCREW
BARREL CLAMP EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
Figure 5-31. Cylinder Barrel Support
5-60 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
21
20**
21
18
18
17
18 18
20**
10
10
15*
14
11
9
13
12
13
11
19
20
6
16*** 7
8
5
4
21
1001248012-A
2 MAE33410A
3121631 5-61
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove capscrews from drilled holes.
10. Insert the capscrews in the threaded holes in the outer 2. Inspect the cylinder rod for scoring, tapering, ovality or
piece of the tapered bushing. Progressively tighten the other damage. If necessary, dress rod with Scotch Brite
capscrews until the bushing is loosen on the piston. or equivalent. Replace rod if necessary.
11. Remove the bushing from the piston. 3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
TAPERED 5. Inspect piston surface for damage and scoring and for
BUSHING distortion. Dress piston surface or replace piston as nec-
ROD essary.
CAPSCREW
6. Inspect threaded portion of piston for damage. Dress
threads as necessary.
Figure 5-35. Tapered Bushing Removal 9. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
12. Screw the piston counterclockwise by hand and remove 10. Inspect cylinder head outside diameter for scoring,
the piston from cylinder rod. tapering, ovality or other damage. Replace if necessary.
13. Remove and discard the piston o-rings, seal rings and
11. Inspect rod and barrel bearings for signs of correct
backup rings.
excessive wear or damage. Replace if necessary.
14. Remove piston spacer from the rod.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
15. Remove the rod from the holding fixture. Remove the
etc. to facilitate bearing installation.
cylinder head gland. Discard the o-rings, backup rings,
rod seals, wear rings and wiper seals. b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
5-62 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
BACK-UP RING
MAE33450
3121631 5-63
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston
cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the
ring into the applicable cylinder head gland groove. bushing and into the tapped holes in the piston.
PISTON
TAPERED
BUSHING
ROD
CAPSCREW
5-64 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE 17. With barrel clamped secured and adequately support-
INSTALLED PROPERLY. REFER TO HYDROLOCKK PISTON SEAL INSTALLATION ing the rod, insert the piston end into the barrel cylinder.
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD Ensure that the piston loading o-ring and seal ring are
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
ROD
SPACER
HEAD
Figure 5-43. Hydrolock Piston Seal Installation BARREL
PISTON
15. Place new hydrolock seal and guidelock rings in the
ROD
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).
CAPSCREW
MAE33440
MAE33460
3121631 5-65
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Main Boom Lift Cylinder 800S (SN 0300182743 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
through 0300239593, SN B300001092 through inder head retainer capscrews and remove capscrews
B300002483), 860SJ (0300182743 through from cylinder barrel.
0300239858, SN B300001092 through B300002483) BARREL
DISASSEMBLY
CAPSCREW
WASHER
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK RING
SURFACE IN A DIRT FREE WORK AREA.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER Figure 5-47. Capscrew Removal
SLIGHTLY TO AVOID TRAPPING PRESSURE.
6. Attach a suitable pulling device to the cylinder rod port
2. Operate the hydraulic power source and extend the cyl-
block end or cylinder rod end, as applicable.
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. Remove the proportional valve, lift holding valve, relief
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
valve, check valve and plugs. Discard o-rings.
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
4. Place the cylinder barrel into a suitable holding fixture. CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
ROD SUPPORT 7. With the barrel clamped securely, apply pressure to the
rod pulling device and carefully withdraw the complete
PROTECTED ROD CLAMP
rod assembly from the cylinder barrel.
BARREL CLAMP
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
5-66 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
30
30 5
28
33
1
31
1 9
32
31
2 2
10
7
29
10
26**
27
3*
4
23
11 22
21
12
19
18
19
22
25 20
13
15 14
6 24***
16
17
* Torque to 30 ft. lbs. (41 Nm)
5
8
** Torque to 5 ft. lbs. (7 Nm)
***Torque to 340 ft. lbs. (461 Nm)
1684199-G
1684202-I
MAE33600
1. Flatwasher 8. Rod Weldment 15. Wear Ring 22. Guidelock Ring 29. Relief Valve
2. Clamp 9. O-ring Plug 16. Rod Seal 23. Setscrew 30. Bolt
3. Capscrew 10. O-ring Plug 17. Wiper Seal 24. Capscrew 31. Locknut
4. Tapered Bushing 11. O-ring Plug 18. O-ring 25. Spacer 32. Plate
5. Bushing 12. Piston 19. Backup ring 26. Check Valve 33. Check Valve
6. Head 13. O-ring 20. Guidelock Ring 27. Lift Holding Solenoid
7. Barrel 14. Backup Ring 21. Seal 28. Lift Dump Proportional Solenoid
3121631 5-67
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove capscrews from drilled holes.
2. Inspect the cylinder rod for scoring, tapering, ovality or
10. Insert the capscrews in the threaded holes in the outer other damage. If necessary, dress rod with Scotch Brite
piece of the tapered bushing. Progressively tighten the or equivalent. Replace rod if necessary.
capscrews until the bushing is loosen on the piston.
3. Inspect threaded portion of rod for excessive damage.
11. Remove the bushing from the piston. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
essary.
6. Inspect threaded portion of piston for damage. Dress
threads as necessary.
7. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
8. Inspect cylinder head inside diameter for scoring, taper-
ing, ovality or other damage. Replace if necessary.
Figure 5-50. Tapered Bushing Removal 9. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
12. Screw the piston counterclockwise by hand and remove
the piston from cylinder rod. 10. Inspect cylinder head outside diameter for scoring,
tapering, ovality or other damage. Replace if necessary.
13. Remove and discard the piston o-rings, seal rings, wear
rings and backup rings. 11. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace if necessary.
14. Remove setscrew and piston spacer from the rod.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
15. Remove the rod from the holding fixture. Remove the etc. to facilitate bearing installation.
cylinder head gland. Discard the o-rings, backup rings,
b. Inspect steel bushing for wear or other damage. If
rod seals, wear rings and wiper seals.
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to bear-
ing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
5-68 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
BACKUP
RING
O-R ING SEAL
WEAR RING WIPER
SEAL
3121631 5-69
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston
cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the
ring into the applicable cylinder head gland groove. bushing and into the tapped holes in the piston.
PISTON
TAPERED
BUSHING
ROD
CAPSCREW
3. Place a new o-ring and backup seal in the applicable Figure 5-56. Tapered Bushing Installation
outside diameter groove of the cylinder head.
11. Tighten the capscrews evenly and progressively in rota-
tion to 30 ft. lbs. (41 Nm).
12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4 in. diameter) as follows:
a. Place the shaft against the cylinder rod and in con-
tact with the bushing in the spaces between the
capscrews.
b. Tap each space once; this means the tapered bush-
ing is tapped 3 times as there are 3 spaces between
the capscrews.
5-70 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
PISTON
ROD
SPACER
HEAD
BARREL
ROD
CA1SCREW
Figure 5-58. Piston Seal Kit Installation
16. Position the cylinder barrel in a suitable holding fixture. Figure 5-59. Rod Assembly Installation
3121631 5-71
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Main Boom Lift Cylinder 800S (SN 0300239594 to 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
Present, SN B300002484 to Present), inder head retainer capscrews and remove capscrews
860SJ (SN 0300239859 to Present) from cylinder barrel.
DISASSEMBLY BARREL
CAPSCREW
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA. WASHER
RING
1. Connect a suitable auxiliary hydraulic power source to
the cylinder port block fitting.
PUNCH MARK
CYLINDER HEAD
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
Figure 5-61. Capscrew Removal
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source. 6. Attach a suitable pulling device to the cylinder rod port
Adequately support the cylinder rod, if applicable. block end or cylinder rod end, as applicable.
3. Remove the proportional valve, lift holding valve, relief
valve, check valve and plugs. Discard o-rings.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
4. Place the cylinder barrel into a suitable holding fixture. HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
ROD SUPPORT
PROTECTED ROD CLAMP 7. With the barrel clamped securely, apply pressure to the
rod pulling device and carefully withdraw the complete
BARREL CLAMP rod assembly from the cylinder barrel.
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
5-72 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
18
18
22
21
23**
21 21
22
20
16*
19 15
10
12 11
9
13
12
13
10
11
14
7
8
6
3 17***
5
4
* Torque to 30 ft. lbs. (41 Nm)
18 ** Torque to 4-5 ft. lbs. (5.5-7 Nm)
2 ***Torque to 302 ft. lbs. (410 Nm)
18
1001228028-A
MAE33610A
3121631 5-73
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
14***** 16
16
1
10
6
13**
6
6 15****
10
9*
7
5
17
11
4
20
19
20
17
18
12
22
23
21
8***
3
24
25 * Torque to 30 ft. lbs. (41 Nm)
** Torque to 4-5 ft. lbs. (6- 7 Nm)
***Torque to 302 ft. lbs. (410 Nm)
2 **** Torque to 35 ft. lbs. (47.4 Nm)
*****Torque to 33-37 ft. lbs. (44.7-50.2 Nm)
16
1001228029-A
MAE33620A
16
5-74 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove capscrews from drilled holes.
2. Inspect the cylinder rod for scoring, tapering, ovality or
10. Insert the capscrews in the threaded holes in the outer other damage. If necessary, dress rod with Scotch Brite
piece of the tapered bushing. Progressively tighten the or equivalent. Replace rod if necessary.
capscrews until the bushing is loosen on the piston.
3. Inspect threaded portion of rod for excessive damage.
11. Remove the bushing from the piston. Dress threads as necessary.
.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
5. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
essary.
6. Inspect threaded portion of piston for damage. Dress
threads as necessary.
7. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
8. Inspect cylinder head inside diameter for scoring, taper-
ing, ovality or other damage. Replace if necessary.
Figure 5-65. Tapered Bushing Removal 9. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
12. Screw the piston counterclockwise by hand and remove 10. Inspect cylinder head outside diameter for scoring,
the piston from cylinder rod. tapering, ovality or other damage. Replace if necessary.
13. Remove and discard the piston o-rings, seal rings, wear 11. If applicable, inspect rod and barrel bearings for signs of
rings and backup rings. correct excessive wear or damage. Replace if necessary.
14. Remove piston spacer from the rod. a. Thoroughly clean hole, (steel bushing) of burrs, dirt
15. Remove the rod from the holding fixture. Remove the etc. to facilitate bearing installation.
cylinder head gland. Discard the o-rings, backup rings, b. Inspect steel bushing for wear or other damage. If
rod seals, wear rings and wiper seals. steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to bear-
ing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
3121631 5-75
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
BACKUP
RING
O-R ING SEAL
WEAR RING WIPER
SEAL
5-76 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston
cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the
ring into the applicable cylinder head gland groove. bushing and into the tapped holes in the piston.
PISTON
TAPERED
BUSHING
ROD
CAPSCREW
3. Place a new o-ring and backup ring in the applicable Figure 5-71. Tapered Bushing Installation
outside diameter groove of the cylinder head.
11. Tighten the capscrews evenly and progressively in rota-
tion to 30 ft. lbs. (41 Nm).
12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4 in. diameter) as follows:
a. Place the shaft against the cylinder rod and in con-
tact with the bushing in the spaces between the
capscrews.
b. Tap each space once; this means the tapered bush-
ing is tapped 3 times as there are 3 spaces between
the capscrews.
8. Carefully thread the piston on the cylinder rod hand Figure 5-72. Seating the Tapered Bearing
tight, ensuring that the o-ring and backup rings are not
damaged or dislodged.
3121631 5-77
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
PISTON
ROD
SPACER
HEAD
BARREL
ROD
MAE33630 CA1SCREW
Figure 5-73. Piston Seal Kit Installation (800S)
5-78 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Main Boom Lift Cylinder (860SJ) (SN B300002484 to 5. Mark cylinder head and barrel with center punch marks
for later realignment. Using a pin-face spanner wrench,
Present) unscrew the cylinder head from the barrel.
DISASSEMBLY
2. Operate the hydraulic power source and extend the cyl- Mark For Reassembly
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. Remove the proportional valve, lift holding valve, relief
valve, check valve and plugs. Discard o-rings.
4. Place the cylinder barrel into a suitable holding fixture. Figure 5-77. Cylinder Head Removal
ROD SUPPORT
6. Attach a suitable pulling device to the cylinder rod port
PROTECTED ROD CLAMP block end or cylinder rod end, as applicable.
BARREL CLAMP
SUPPORT TABLE
3121631 5-79
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
10
24
10
1
22*
20
21**
8
9
21**
13
22 23
24 19
3
6***
13
24 15
15
5
16
18
14
14
14
11
17 12
4****
2
7
*Torque to 34-38 ft. lbs. (46-52 Nm)
**Torque to 10-11 ft. lbs. (14-15 Nm)
7 *** Torque to 1991-2434 ft. lbs. (2700-3300 Nm)
****Torque to 663-811 ft. lbs. (900-1100 Nm)
10 1001230373-A
MAE33660A
10
5-80 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove locknut from the piston rod.
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.
ROD
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 nec-
essary.
PISTON
6. Inspect threaded portion of piston for damage. Dress
NUT threads as necessary.
MAE33670 7. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
Figure 5-80. Piston Removal 8. Inspect cylinder head inside diameter for scoring, taper-
ing, ovality or other damage. Replace if necessary.
10. Screw the piston counterclockwise by hand and remove 9. Inspect seal and o-ring grooves in head for burrs and
the piston from cylinder rod. sharp edges. Dress applicable surfaces as necessary.
11. Remove and discard the piston o-rings, seal rings, wear 10. Inspect cylinder head outside diameter for scoring,
rings and backup rings. tapering, ovality or other damage. Replace if necessary.
12. Remove piston spacer from the rod. 11. If applicable, inspect rod and barrel bearings for signs of
13. Remove the rod from the holding fixture. Remove the correct excessive wear or damage. Replace if necessary.
cylinder head gland. Discard the o-rings, backup rings, a. Thoroughly clean hole, (steel bushing) of burrs, dirt
rod seals, wear rings and wiper seals. etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inner side of steel bushing prior to bear-
ing installation.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
3121631 5-81
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
ROD SEAL
O-RING BACKUP
RING
MAE33750
5-82 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli-
cable cylinder head gland groove. Install a new wear
ring into the applicable cylinder head gland groove.
ROD
PISTON
NUT
MAE33670
Figure 5-84. Wiper Seal Installation
Figure 5-86. Piston Installation
3. Place a new o-ring and backup seal in the applicable
outside diameter groove of the cylinder head.
9. Remove the cylinder rod from the holding fixture.
10. Place new seal and wear rings in the outer piston diame-
ter groove. (A tube, with I.D. slightly larger than the O.D.
of the piston is recommended to install the solid seal).
WEAR RING
STOPT RING
O-RING
"O" RING
BACK-UP
RING
CYLINDER
HEAD
MAE33680
3121631 5-83
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
BARREL
. .
PUNCH
MARKS
CYLINDER
HEAD
MAE34080
14. Screw the cylinder head into the barrel using a pin-face
spanner wrench and torque cylinder head to 663-811 ft.
lbs. (900-1100 Nm).
15. 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.
16. Install the new o-rings and plugs into the cylinder port-
block and torque plug as shown in Figure 5-79., Main
Boom Lift Cylinder (860SJ).
17. Install the proportional valve, lift holding valve, relief
valve, check valve and plugs, using new O-rings as appli-
cable.
5-84 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Platform Level Cylinder (800S) (SN 0300182743 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
through 0300183962, SN 0300193127 through inder head retainer capscrews and remove capscrews
0300198300, SN 0300198661 through 0300243278 from cylinder barrel.
& SN B300001092 through B300002584), BARREL
(860SJ) (SN 0300182743 through 0300244707, SN
B300001092 through B300002483) CAPSCREW
DISASSEMBLY WASHER
RING
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER 6. Attach a suitable pulling device to the cylinder rod port
SLIGHTLY TO AVOID TRAPPING PRESSURE. block end or cylinder rod end, as applicable.
SUPPORT TABLE
3121631 5-85
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
7 22**
23** 3
1
2*
11
18
9
13
14
13
18
11
21
12
15
10
4
16
17
19
20***
3
* Torque to 9 ft. lbs. (12 Nm)
** Torque to 50-55 ft. lbs. (68-75 Nm)
5
***Torque to 55 ft. lbs. (75 Nm)
3
1684189 F
1684136 G
MAE33380
5-86 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove capscrews from drilled holes.
10. Insert the capscrews in the threaded holes in the outer 2. Inspect the cylinder rod for scoring, tapering, ovality, or
piece of the tapered bushing. Progressively tighten the other damage. If necessary, dress rod with Scotch Brite
capscrews until the bushing is loosen on the piston. or equivalent. Replace rod if necessary.
11. Remove the bushing from the piston. 3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
3121631 5-87
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
BACKUP
O-RING RING
ROD SEAL
WEAR RING
ROD WIPER
SEAL
5-88 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston
cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the
rings into the applicable cylinder head gland groove. bushing and into the tapped holes in the piston.
PISTON
TAPERED
BUSHING
ROD
CAPSCREW
8. Carefully thread the piston on the cylinder rod hand Figure 5-100. Seating the Tapered Bearing
tight, ensuring that the o-ring and backup rings are not
damaged or dislodged.
3121631 5-89
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
13. Rotate the capscrews evenly and progressively in rota- 17. With barrel clamped secured and adequately support-
tion to 9 ft. lbs (12 Nm). ing the rod, insert the piston end into the barrel cylinder.
Ensure that the piston loading o-ring and seal ring are
14. Remove the cylinder rod from the holding fixture. not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. REFER TO HYDROLOCK PISTON SEAL INSTALLATION
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. PISTON
ROD
SPACER
HEAD
BARREL WASHER RING
ROD
CA1SCREW
Figure 5-101. Hydrolock Piston Seal Installation
5-90 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Platform Level Cylinder 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
(800S) (SN 0300243279 to Present, inder head retainer capscrews and remove capscrews
SN B300002585 to Present) from cylinder barrel.
(860SJ) (SN 0300244708 to Present) BARREL
DISASSEMBLY
CAPSCREW
WASHER
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK RING
SURFACE IN A DIRT FREE WORK AREA.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER Figure 5-105. Capscrew Removal
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate the hydraulic power source and extend the cyl- 6. Attach a suitable pulling device to the cylinder rod port
inder. Shut down and disconnect the power source. block end or cylinder rod end, as applicable.
Adequately support the cylinder rod, if applicable.
3. Remove the counterbalance valves and fittings from the
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
cylinder port block. Discard o-rings.
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
4. Place the cylinder barrel into a suitable holding fixture. CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
ROD SUPPORT 7. With the barrel clamped securely, apply pressure to the
rod pulling device and carefully withdraw the complete
PROTECTED ROD CLAMP
rod assembly from the cylinder barrel.
BARREL CLAMP
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
3121631 5-91
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
17**
22 19
22
18**
22
19
23
22
22 1
20*
15
11
10
9
13
13 12
10
11
14
6
7
5
8
4
3
16
21***
19
1001228027-A
1001228022-A
MAE33690A
1. Barrel 6. Wear Ring 11. Wear Ring 16. Washer Ring 21. Plug
2. Rod 7. O-ring 12. O-ring 17. Cartridge valve 22. Plug
3. Head 8. Backup Ring 13. Backup Ring 18. Bushing
4. Wiper Seal 9. Piston 14. Tube Spacer 19. Capscrew
5. Rod Seal 10. T-Seal 15. Tapered Bushing 20. Capscrew
5-92 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove capscrews from drilled holes.
10. Insert the capscrews in the threaded holes in the outer 2. Inspect the cylinder rod for scoring, tapering, ovality, or
piece of the tapered bushing. Progressively tighten the other damage. If necessary, dress rod with Scotch Brite
capscrews until the bushing is loosen on the piston. or equivalent. Replace rod if necessary.
11. Remove the bushing from the piston. 3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
3121631 5-93
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
BACKUP
O-RING RING
ROD SEAL
WEAR RING
ROD WIPER
SEAL
5-94 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston
cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the
rings into the applicable cylinder head gland groove. bushing and into the tapped holes in the piston.
PISTON
TAPERED
BUSHING
ROD
CAPSCREW
8. Carefully thread the piston on the cylinder rod hand Figure 5-115. Seating the Tapered Bearing
tight, ensuring that the o-ring and backup rings are not
damaged or dislodged.
3121631 5-95
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE 17. With barrel clamped secured and adequately support-
INSTALLED PROPERLY. REFER TO HYDROLOCK PISTON SEAL INSTALLATION ing the rod, insert the piston end into the barrel cylinder.
FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD Ensure that the piston loading hydrolock seals, guide-
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. lock rings are not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
PISTON
ROD
SPACER
HEAD
BARREL WASHER RING
Figure 5-116. Hydrolock Piston Seal Installation
15. Place new hydrolock seal and guidelock rings in the ROD
outer piston diameter groove. (A tube, with I.D. slightly
larger than the O.D. of the piston is recommended to
install the solid seal).
CA1SCREW
+<'52/2&.
5,1* %$&.83
*8,'(/2&. 5,1* Figure 5-118. Rod Assembly Installation
5,1*
25,1* 19. Secure the cylinder head gland using the washer ring
and capscrews. Torque capscrews to 55 ft. lbs. (75 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. 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).
5-96 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Platform Level Cylinder 5. Mark cylinder head and barrel with center punch marks
for later realignment. Using a pin-face spanner wrench,
(860SJ) (SN B300002484 to Present) unscrew the cylinder head from the barrel..
DISASSEMBLY
BARREL CLAMP EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
3121631 5-97
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
19*
21
21
20*
8
21
22
21
21
7**
1
12
10
13 12
5
16
18
18
6
15
9 17
11
2
14
4*** 8
6 * Torque to 50-55 ft. lbs. (68-75 Nm)
** Torque to 498-608 ft. lbs. (675-825 Nm)
***Torque to 332-405 ft. lbs. (450-550 Nm)
8
1001230372-A
MAE33700A
1. Barrel 6. Locking Piece 11. Wiper Seal 16. O-ring 21. Plug
2. Rod Assembly 7. Locknut 12. Wear Ring 17. Backup Ring 22. Plug
3. Piston 8. Bushing 13. O-ring 18. Wear Ring
4. Head 9. Rod Seal 14. O-ring 19. Counterbalance Valve
5. Tube Spacer 10. Seal 15. O-ring 20. Counterbalance Valve
5-98 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove locknut from the piston rod..
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.
10. Screw the piston counterclockwise by hand and remove 7. Inspect seal and o-ring grooves in piston for burrs and
the piston from cylinder rod. sharp edges. Dress applicable surfaces as necessary.
11. Remove and discard the piston hydrolock seals, guide- 8. Inspect cylinder head inside diameter for scoring, taper-
lock rings. ing, ovality or other damage. Replace if necessary.
12. Remove piston spacer from the rod.
9. Inspect seal and o-ring grooves in head for burrs and
13. Remove the rod from the holding fixture. Remove the sharp edges. Dress applicable surfaces as necessary.
cylinder head gland. Discard the o-rings, backup rings,
rod seals, wear rings and wiper seals. 10. Inspect cylinder head outside diameter for scoring,
tapering, ovality or other damage. Replace if necessary.
3121631 5-99
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
5-100 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli-
cable cylinder head gland groove. Install a new wear
rings into the applicable cylinder head gland groove.
ROD
PISTON
NUT
MAE33710
Figure 5-127. Wiper Seal Installation
Figure 5-129. Piston Installation
3. Place a new o-ring and backup seal in the applicable
outside diameter groove of the cylinder head. 9. Remove the cylinder rod from the holding fixture.
"O" RING
BACK-UP
RING
CYLINDER
HEAD
MAE33680
3121631 5-101
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
WEAR RING
SEAL
. .
MARK FOR
REASSEMBLY
MAE34150
WEAR RING
MAE33770 14. Screw the cylinder head into the barrel using a pin-face
spanner wrench and torque cylinder head to 332-405 ft.
lbs. (450-550 Nm).
Figure 5-131. Piston Seal Kit Installation 15. 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.
11. Position the cylinder barrel in a suitable holding fixture.
16. 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).
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
5-102 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Platform Level Cylinder (SN 0300183963 through 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using a pin-face spanner wrench,
0300193126 & SN 0300198301 through 300198660) unscrew the cylinder head from the barrel.
DISASSEMBLY
. .
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
Mark For Reassembly
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. Remove the cartridge-type counterbalance valves and
plugs from the cylinder port block. Discard o-rings. Figure 5-134. Cylinder Head Removal
4. Place the cylinder barrel into a suitable holding fixture. 6. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable
ROD SUPPORT
ROD SUPPORT
3121631 5-103
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
22
18***
18*** 9**
20*****
19**** 22
21**
19****
18*** 20*****
1
7
6
3
6
8
17
10
11
13
4*
12
14
15
16
23
23
1. Barrel 6. Wear Ring 11. Backup ing 16. O-ring 21. Counterbalance Valve
2. Rod 7. Seal 12. Seal 17. Spacer 22. Bushing
3. Head 8. O-ring 13. O-ring 18. Plug 23. Bushing
4. Piston 9. Counterbalance Valve 14. Wiper Seal 19. Plug
5. Retainer 10. O-ring 15. Retaining Ring 20. Plug
Figure 5-136. Platform Level Cylinder (SN 0300183963 through 0300193126 and SN
0300198301 through 300198660)
5-104 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove the retainer from rod end.
2. Inspect the cylinder rod for scoring, tapering, ovality, or
10. Screw the piston counterclockwise by hand and remove other damage. If necessary, dress rod with Scotch Brite
the piston from cylinder rod. or equivalent. Replace rod if necessary.
11. Remove and discard the piston o-rings, seal rings and
3. Inspect threaded portion of rod for excessive damage.
backup rings.
Dress threads as necessary.
12. Remove piston spacer from the rod.
4. Inspect inner surface of cylinder barrel tube for scoring
13. Remove the rod from the holding fixture. Remove the or other damage. Check inside diameter for tapering or
cylinder head gland. Discard the o-rings, backup rings, ovality. Replace if necessary.
rod seals, retaining ring and wiper seals.
5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
11. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
3121631 5-105
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
8*1&34&"-
30%4&"-
5-106 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 10. Place new seals in the outer piston diameter groove. (A
cable cylinder head gland groove. Install a new wear tube, with I.D. slightly larger than the O.D. of the piston
ring into the applicable cylinder head gland groove. is recommended to install the solid seal).
3121631 5-107
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Steer Cylinder (SN 0300182743 to Present, SN 4. Using a hook Spanner, loosen the spanner nut retainer
and remove spanner nut from cylinder barrel.
B300001092 through B300002483)
DISASSEMBLY
CYLINDER BARREL
SPANNER NUT
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA.
HOOK SPANNER
1. Connect a suitable auxiliary hydraulic power source to
the cylinder port block fitting.
2. Operate the hydraulic power source and extend the cyl- Figure 5-144. Spanner Nut Removal
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
5. Attach a suitable pulling device to the cylinder rod port
3. Place the cylinder barrel into a suitable holding fixture. block end or cylinder rod end, as applicable.
ROD SUPPORT
PROTECTED ROD CLAMP EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
BARREL CLAMP CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
ROD SUPPORT
5-108 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1001150539 F
3121631 5-109
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
8. Loosen and remove setscrew which attaches the piston
to the rod. 2. Inspect the cylinder rod for scoring, tapering, ovality or
9. Screw the piston counterclockwise by hand and remove other damage. If necessary, dress rod with Scotch Brite
the piston from cylinder rod. or equivalent. Replace rod if necessary.
10. Remove and discard the piston o-rings, seal rings. 3. Inspect threaded portion of rod for excessive damage.
11. Remove the rod from the holding fixture. Remove the Dress threads as necessary.
cylinder head gland. Discard the o-rings, backup rings,
rod seals, c-ring and wiper seal. 4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
5-110 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
BACKUP
RING O-R ING
C-RING
ROD SEAL
WIPER
SEAL
3121631 5-111
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 9. Place new seal and wear ring in the outer piston diame-
cable cylinder head gland groove. ter grooves. (A tube, with I.D. slightly larger than the O.D.
of the piston is recommended to install the solid seal).
WEAR
RING SEAL
WEAR
RING
5-112 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Steer Cylinder (SN B300002484 to Present) 4. Using a hook Spanner, loosen the spanner nut retainer
and remove spanner nut from cylinder barrel.
DISASSEMBLY
ROD SUPPORT
Figure 5-154. Cylinder Head Removal
PROTECTED ROD CLAMP
ROD SUPPORT
SUPPORT TABLE
3121631 5-113
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
7
1
6**
3
11
15
8
4
14
9 10
14
12
13
5
1001230375-A
MAE33550A
5-114 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
8. Remove locknut from the piston rod.
9. Screw the piston counterclockwise by hand and remove 2. Inspect the cylinder rod for scoring, tapering, ovality or
the piston from cylinder rod. other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
10. Remove and discard the piston o-rings, seal rings.
11. Remove the rod from the holding fixture. Remove the 3. Inspect threaded portion of rod for excessive damage.
cylinder head gland. Discard the o-rings, backup rings, Dress threads as necessary.
rod seals, c-ring and wiper seal.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
3121631 5-115
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
WEAR RING
ROD SEAL
WIPER
SEAL
5-116 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 9. Place new seal and wear ring in the outer piston diame-
cable cylinder head gland groove. ter grooves. (A tube, with I.D. slightly larger than the O.D.
of the piston is recommended to install the solid seal).
WEAR RING
CYLINDER
HEAD
SEAL MAE33580
3121631 5-117
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
CYLINDER BARREL
CYLINDER HEAD
ROD
STEEL ROPE
MAF10710
. .
MARK FOR
REASSEMBLY
MAE34150
5-118 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Telescope Cylinder (800S) (SN 0300196955 through 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
0300243278, SN B300001097 through B300002584) inder head retainer capscrews and remove capscrews
(860SJ) (SN 0300196955 through 0300244707, (SN from cylinder barrel.
B300001097 through B300002587)
:$6+(5
DISASSEMBLY 5,1*
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER &$36&5(:
SLIGHTLY TO AVOID TRAPPING PRESSURE.
&</,1'(5
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source. Figure 5-166. Capscrew Removal
Adequately support the cylinder rod, if applicable.
6. Attach a suitable pulling device to the cylinder rod port
3. If applicable, remove the cartridge type holding valve block end or cylinder rod end, as applicable.
and fittings from the cylinder port block. Discard o-
rings.
4. Place the cylinder barrel into a suitable holding fixture EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
ROD SUPPORT
7. With the barrel clamped securely, apply pressure to the
PROTECTED ROD CLAMP
rod pulling device and carefully withdraw the complete
rod assembly from the cylinder barrel.
BARREL CLAMP
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
3121631 5-119
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
15 1*
2
6
20 17
16 14
6
8
8 10
22
9
11
7 18
3 21**
12
9
13
27
1001177317-B
26 1001181588-C
24 MAE33540
5-120 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove capscrews from drilled holes
10. Insert the capscrews in the threaded holes in the outer 2. Inspect the cylinder rod for scoring, tapering, ovality, or
piece of the tapered bushing. Progressively tighten the other damage. If necessary, dress rod with Scotch Brite
capscrews until the bushing is loosen on the piston. or equivalent. Replace rod if necessary.
11. Remove the bushing from the piston. 3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
15. Remove the rod from the holding fixture. Remove the 11. If applicable, inspect rod and barrel bearings for signs of
cylinder head gland. Discard the o-rings, backup rings, correct excessive wear or damage. Replace as necessary.
rod seals, wear rings and wiper seals.
a. Thoroughly clean hole (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
3121631 5-121
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
5-122 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- NOTE: When installing the tapered bushing, piston and mating
cable cylinder head gland groove. Install a new wear end of rod must be free of oil.
rings into the applicable cylinder head gland groove.
10. Assemble the tapered bushing loosely into the piston
and insert capscrews through the drilled holes in the
bushing and into the tapped holes in the piston.
PISTON
TAPERED
BUSHING
ROD
CAPSCREW
Figure 5-173. Wiper Seal Installation
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:
9. Thread piston onto rod until it abuts the spacer end and Figure 5-176. Seating the Tapered Bearing
install the tapered bushing.
3121631 5-123
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
CA1SCREW
5-124 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Telescope Cylinder (800S) SN 0300243279 to 5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the cyl-
Present, SN B300002585 to Present), (860SJ) (SN inder head retainer capscrews and remove capscrews
030024708 to Present, SN B300002588 to Present) from cylinder barrel.
DISASSEMBLY
CYLINDER
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA.
2. Operate the hydraulic power source and extend the cyl- CAPSCREW
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
MAE33480
3. If applicable, remove the cartridge type holding valve
and fittings from the cylinder port block. Discard o- Figure 5-180. Capscrew Removal
rings.
4. Place the cylinder barrel into a suitable holding fixture 6. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.
ROD SUPPORT
ROD SUPPORT
SUPPORT TABLE
SUPPORT TABLE
Figure 5-179. Cylinder Barrel Support
3121631 5-125
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
22
11
10
11 14
12 18*
16
15
22 9
6 13
7 13
8
3
5
6
4
19**
5-126 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
vise or similar holding fixture as close to the piston as
possible. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Remove capscrews from drilled holes
10. Insert the capscrews in the threaded holes in the outer 2. Inspect the cylinder rod for scoring, tapering, ovality, or
piece of the tapered bushing. Progressively tighten the other damage. If necessary, dress rod with Scotch Brite
capscrews until the bushing is loosen on the piston. or equivalent. Replace rod if necessary.
11. Remove the bushing from the piston. 3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
ROD
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
PISTON
ovality. Replace if necessary.
14. Remove setscrew from the piston spacer. Remove a. Thoroughly clean hole (steel bushing) of burrs, dirt
spacer from the rod. etc. to facilitate bearing installation.
15. Remove the rod from the holding fixture. Remove the b. Inspect steel bushing for wear or other damage. If
cylinder head gland. Discard the o-rings, backup rings, steel bushing is worn or damaged, rod/barrel must
rod seals, wear rings and wiper seals. be replaced.
3121631 5-127
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
5-128 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
2. Use a soft mallet to tap a new wiper seal into the appli- 8. Carefully thread the piston on the cylinder rod hand
cable cylinder head gland groove. Install a new wear tight, ensuring that the o-ring and backup rings are not
rings into the applicable cylinder head gland groove. damaged or dislodged.
9. Thread piston onto rod until it abuts the spacer end and
install the tapered bushing.
ROD
CAPSCREW
BACK-UP RING
O-RING
CYLINDER HEAD
MAE33500
MAE33510
3121631 5-129
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
12. After the screws have been torqued, tap the tapered the O.D. of the piston is recommended to install the
bushing with a hammer (16 to 24 oz.) and brass shaft solid seal).
(approximately 3/4 in. diameter) as follows:
a. Place the shaft against the cylinder rod and in con- BACK-UP
WEAR
tact with the bushing in the spaces between the RING T-SEAL
RING
capscrews.
b. Tap each space once; this means the tapered bush-
ing is tapped 3 times as there are 3 spaces between-
the capscrews.
5-130 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
PISTON
ROD
SPACER
HEAD
BARREL
ROD
CA1SCREW
19. Secure the cylinder head gland using the capscrews. For
Torque capscrews Refer Figure 5-182., Telescopic Cylin-
der.
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. Install the valve assembly. For Torque capscrews Refer
Figure 5-182., Telescopic Cylinder.
3121631 5-131
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1. Main Valve 3. Dual Flow Divider (4WD) 5. Platform Valve 7. Dual Select Valve
2. Platform Valve Filter 4. Auxiliary Pump 6. Hydraulic Filter 8. Flow Divider (2WD)
5-132 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5.4 PRESSURE SETTING PROCEDURE 3. There are (2) adjustments at the top of the pump. They
are located on the pump compensator which has (4)
Cold temperatures have a significant impact on pressure read- bolts mounting it to the pump. The stand by adjustment
ings. JLG Industries Inc. recommends operating the machine is at the top. To adjust this, a 4 mm and 6 mm allen
until the hydraulic system has warmed to normal operating wrench will be needed. The adjustment screw is facing
temperatures prior to checking pressures. JLG Industries Inc. the front of the pump, or toward the engine.
also recommends the use of a calibrated gauge. Pressure read-
a. First, using the 4 mm wrench, loosen the setscrew
ings are acceptable if they are within ± 5% of specified pres-
on the side of the compensator (facing you) which is
sures.
in line with the adjustment screw. This is a jam nut
screw which holds the main adjustment from turn-
To ensure all pressures are set correctly, the following proce-
ing. Loosen it 1 turn.
dures must be followed in order.
1. All applicable steps in Section 5.5, Start Up Procedures
must be followed.
2. Set up of the function pump.
3. Adjustments made at the main valve block.
4. Adjustments made at the platform valve.
3121631 5-133
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5-134 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1
3
1001154598-C
Table 5-33. Main Valve Coil Resistance MAE33730C
1. Main Dump Valve (Coil Resistance 7.1 Ohms @ 20oC) (53 ft. lb. (71 Nm)) 3. Tele Solenoid Valve (Coil resistance 8.8 Ohms @ 20oC) (20 ft. lb. (27 Nm))
2. Steer Valve (Coil Resistance 7.1 Ohms @ 20oC) (25 ft. lb. (34 Nm)) 4. Lift Valve (Coil resistance 8.8 Ohms @ 20oC) (20 ft. lb. (27 Nm))
5. Swing Valve (Coil Resistance 7.1 Ohms @ 20oC) (25 ft. lb. (34 Nm))
Figure 5-194. Main Valve Identification
3121631 5-135
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1001154598 C
5-136 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1001154600 C
3121631 5-137
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
4, A
5, A
3, B
6
2
1001154600 C
Table 5-36. Cartridge Torque Values Table 5-37. Coil Torque Values
Ft-Lbs. Nm Ft-Lbs. Nm
1 NA NA A 5 6.7
2 20 27.1 B 6 8
3 25 33.9
4 20 27.1
5 20 27.1
5-138 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1001154599 D
3121631 5-139
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
1001154599 D
Table 5-38. Cartridge Torque Values Table 5-39. Coil Torque Values
Ft-Lbs. Nm Ft-Lbs. Nm
1 25 33.9 A 5 6.7
2 20 27.1 B 6 8
3 20 27.1
4 20 27.1
5 20 27.1
6 20 27.1
7 20 27.1
8 20 27.1
5-140 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5.5 START UP PROCEDURES return filter cap at the top of the tank, lift out the ele-
ment making sure the canister stays in the tank. Hold
the hose end down in the canister and start the machine
Start Up After Overhaul or Replacement of and let it run approx. 10 seconds. Re-install the filter and
Components re-hose the machine.
NOTE: **If using a shop vac to create suction on the oil tank while
PRE-FILL OF BOTH THE DRIVE AND FUNCTION PUMP
doing maintenance, both steps “1” and “2” will need done.
Machine without oil cooler: When filling the oil tank, fill it to
the very top of the tank. This will give you enough head pres- NOTE: **If installing a new drive pump, step “1” will need done.
sure 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 NOTE: **If installing a new function pump, step “1” and “2” will
top case port on the outside of the drive pump has a 3/4” tee need done.
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 NOTE: **If installing a new function pump and the suction hose is
is done. Next, go the function pump, using a 3/8” allen wrench capped without draining a lot of oil out of the hose, which
remove the plug on the inside of the pump next to the turn- creates a large air void, step “2” will not need to be done.
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 NOTE: **When operating a function such as Lift Up, if the function
causes the pumps to start dry, and reduces the efficiency of pump makes a loud noise and the lift up stops and starts,
the pump and can cause premature failure. that is a sign of cavitation, air going through the pump at
high pressure. This will in a short time destroy the pump
Machine with oil cooler: When filling the oil tank, fill it to the and contaminate the entire system. Make sure all suction
very top of the tank. This will help give you enough head pres- hoses are tight and free of leaks at the tank and pump. A
sure from the tank to gravity fill the case on both pumps. The suction hose does not leak when the engine is running, it
top case port on the outside of the pump has a 3/4” tee fitting. will allow air to be drawn into the pump causing cavita-
Remove the cap from the center of the tee. You should see oil tion. After the machine is shut down, then you will see a
in 1-2 minutes. If not, depending on hose routing, the drive very slow leak.
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 func-
tion pump, using a 3/8” 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 pre-
mature 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 inch 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” 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” hose from port “P1”, using a #12 male
union add approx. 30” of 3/4” hose to it. Remove the
3121631 5-141
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
SHEET 1
5-142 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
SHEET 1 1001167259 B
3121631 5-143
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
SHEET 2
5-144 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
SHEET 2 1001167259 B
3121631 5-145
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
SHEET 3
5-146 3121631
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
SHEET 3 1001167259 B
3121631 5-147
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
NOTES:
5-148 3121631
SECTION 6 - JLG CONTROL SYSTEM
6.1 JLG CONTROL SYSTEM ANALYZER KIT viewing and adjusting the various personality settings for
smooth control of: acceleration, deceleration, creep, min
INSTRUCTIONS speed, and max.-speed for all boom, drive, and steering func-
tions.
Introduction
The main lift, swing, and drive are controlled by individual joy-
sticks, with steering being controlled by a rocker switch built
into the top the drive joystick. To activate Drive, Lift, and Swing
WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT simply pull up on the slide lock location on the joystick and
WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER move the handle into the direction desired.
MACHINE CONFIGURATION, INCLUDING OPTIONS.
The control system will control the voltage output to the
valves and pump, as programmed for smooth operation and
maximum cycle time. Ground control speeds for all boom
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- functions can also be programmed into the control system.
TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- The JLG Control System controller has a built in LED to indicate
TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A any faults. The system stores recent faults which may be
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO- accessed for troubleshooting. Optional equipment includes a
NENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING soft touch system, head and tail lights, and ground alarm.
MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SAT- These options may be added later but must be programmed
URATION. into the control system when installed.
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub
To return home or access pre-
Level, and item menus
vious menu
3121631 6-1
SECTION 6 - JLG CONTROL SYSTEM
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.
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
6-2 3121631
SECTION 6 - JLG CONTROL SYSTEM
ACCESS LEVEL:
CODE 33271
MENU:
When the correct password is displayed, press ENTER to
ACCESS LEVEL 3
confirm it; the access level will change to match the password
3121631 6-3
SECTION 6 - JLG CONTROL SYSTEM
GROUND ALARM:
2 = DRIVE
PERSONALITIES:
DRIVE ACCEL 1.0s The effect of the machine digit value is displayed along with
its value; there will only be certain settings allowed to ensure
There will be a maximum and minimum for the value to
safe operation.
6-4 3121631
SECTION 6 - JLG CONTROL SYSTEM
3121631 6-5
SECTION 6 - JLG CONTROL SYSTEM
6-6 3121631
SECTION 6 - JLG CONTROL SYSTEM
3121631 6-7
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal-
ity settings first and then changing the model number of the machine configuration will cause the personality settings
to return to default values.
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
6 GB
6-8 3121631
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
14 PERKINS ECM
15 CAT ECM
*This menu item is only visible if Deutz engine selections 3 or 4 are selected.
3121631 6-9
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start 0
6 can be attempted at any time during pre-glow.
1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permit-
ted until pre-glow is finished.
FUEL CUTOUT 0 RESTART: Engine allowed to be restarted multiple times when very low fuel level is reached. 0
7*
1 ONE RESTART: Engine allowed to be restarted once for 2 minutes when very low fuel level is reached.
2 ENGINE STOP: Engine not able to restart when very low fuel level is reached.
* This menu item is only visible if non dual fuel engines are selected.
6-10 3121631
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more 1
9* than 5 degrees and above elevation; also reduces drive speed to creep.
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.
5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 3
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
6 5 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 5
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
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
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.
Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the machine is also above elevation.
3121631 6-11
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
14*
1 MOTION CUTOUT: Motion cutout in platform mode only.
6-12 3121631
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
sec ON, 2 sec OFF).
4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform
alarm beeps (5 sec ON, 2 sec OFF).
LOAD SENSOR: 0 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the Leveling Platform
18* Module.
* Only visible if Load Sensor Menu selection is not 0 and under certain market selections.
* Certain market selections will limit load sensor options.
3 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
3121631 6-13
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
DRIVE CONTROL: 0 NORMAL: Drive coils are energized from the Ground Module.
24
1 PROPULSION: Drive coils are energized from the Propulsion Module.
2 ENHANCED: Drive coils are energized from the Ground Module and the ground side of the 2
drive coils are brought back to current feedback returns.
DRIVE PUMP 0 SAUER DANFOSS: Machine equipped with Sauer Danfoss drive pump 0
25*
1 EATON: Machine equipped with Eaton drive pump
BOOM CONTROL: 0 NORMAL: Boom function coils are energized from the Ground Module. 0
26
1 ENHANCED: Boom function are energized from the Ground Module and the ground side of the drive coils
and brought back to current feedback returns.
6-14 3121631
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
FUNCTION SPEED KNOB 0 YES: Machine is equipped with Function Speed Knob. 0
27
1 NO: Machine is equipped with Operation Speed Switch.
ALERT / BEACON: 0 OFF FOR CREEP: Alert beacon will not flash while in Creep. 0
32
1 20FPS FOR CREEP: Alert beacon will flash at 20FPS while in Creep.
PLAT LVL OVR CUT: 0 NO: Platform Level Override will always be functional. 0
34
1 YES: Platform Level Override will only be functional when In Transport.
3121631 6-15
SECTION 6 - JLG CONTROL SYSTEM
Default
Configuration Digit Number Description
Number
6-16 3121631
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. 800S Machine Configuration Programming Table 6-3. 800S Machine Configuration Programming
Settings (Software Version P6.22) Settings (Software Version P6.22)
ANSI Export
ANSI Export
Australia
ANSI USA
Australia
ANSI USA
800 S
Japan
800 S
Japan
CSA
GB
CSA
CE
GB
CE
Model Number 10 10 10 10 10 10 10 Load System 0 0 0 0 0 0 0
Market 0 1 2 3 4 5 3 X 1 X X X 1 X
Engine 12 12 12 12 12 12 12 X 2 X 2 2 2 2
Flywheel Teeth 0 0 0 0 0 0 0 X 3 X 3 X 3 3
1 1 1 1 1 1 1 X 4 X X X 4 X
Glow Plugs 0 0 0 0 0 0 0 Load Sensor X 0 X 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 X 2 X 2 2 2 2
Starter Lockout 0 0 0 0 0 0 0 Function Cut- 0 0 0 0 0 0 0
out X 1 1 1 1 1 1
1 1 1 1 1 1 1
Fuel Cutout 0 0 0 0 0 0 0 2 2 2 X 2 2 2
1 1 1 1 1 1 1 X 3 3 X 3 3 3
2 2 2 2 2 2 2 Ground Alarm 0 0 0 0 0 0 0
Engine Shut- 0 0 0 0 0 0 0 1 1 1 1 1 1 1
down 2 2 2 2 2 2 2
1 1 1 1 1 1 1
Tilt 1 1 1 X X 1 X 3 3 3 3 3 3 3
2 2 2 X 2 2 X Drive Type 0 0 0 0 0 0 0
3 3 3 X 3 3 X 1 1 1 1 1 1 1
4 4 4 4 4 4 4 2 2 2 2 2 2 2
5 5 5 5 5 5 5 Display Units 0 0 0 0 0 0 0
6 6 6 X X 6 X 1 1 1 1 1 1 1
7 7 7 X X 7 X Leveling Mode 0 0 0 0 0 0 0
8 8 8 8 8 8 8 1 1 1 1 1 1 1
9 9 9 9 9 9 9 Drive Control 0 0 0 0 0 0 0
Jib 0 0 0 0 0 0 0 1 1 1 1 1 1 1
4 Wheel Steer 0 0 0 0 0 0 0 2 2 2 2 2 2 2
Soft Touch/ 0 0 0 0 0 0 0 Drive Pump 0 0 0 0 0 0 0
Skyguard 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 X X X X X X X
3 3 3 3 3 3 3 X X X X X X X
Gen Set / 0 0 0 0 0 0 0 Boom Control 0 0 0 0 0 0 0
Welder 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Gen Set Cutout 0 0 0 0 0 0 0 Function Speed 0 0 0 0 0 0 0
Knob 1 1 1 1 1 1 1
1 1 1 1 1 1 1
Head & Tail- 0 0 0 0 0 0 0 Clearsky 0 0 0 0 0 0 0
lights 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Cable Break 0 0 0 0 0 0 0 Cribbing 0 0 0 0 0 0 0
Switch Option 1 1 1 1 1 1 1
1 1 1 1 1 1 1
Fuel Tank Size 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Alarm / Horn 0 0 0 0 0 0 0
1 1 1 1 1 1 1
3121631 6-17
SECTION 6 - JLG CONTROL SYSTEM
Australia
ANSI USA
ANSI Export
800 S
Japan
Australia
ANSI USA
CSA
860 SJ
GB
CE
Japan
CSA
GB
CE
Alert Beacon 0 0 0 0 0 0 0
1 1 1 1 1 1 1 Model Number 10 10 10 10 10 10 10
Temp Cutout X 0 X 0 X X 0 Market 0 1 2 3 4 5 3
X 1 X 1 X X 1 Engine 12 12 12 12 12 12 12
Plat Lvl Ovr Cut 0 0 0 0 0 0 0 Flywheel Teeth 0 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1 1 1
Water In Fuel X 0 X X X X 0 Glow Plugs 0 0 0 0 0 0 0
Sensor X 1 X X X X 1 1 1 1 1 1 1 1
Dual Capacity 0 0 0 0 0 0 0 2 2 2 2 2 2 2
1 1 1 1 1 1 1 Starter Lockout 0 0 0 0 0 0 0
BOLD TEXT indicates the default setting. Plain text indicates another available selec- 1 1 1 1 1 1 1
tion.RED ITALIC TEXT indicates the default when option is factory installed. SHADED Fuel Cutout 0 0 0 0 0 0 0
CELLS indicate hidden menu or selection. 1 1 1 1 1 1 1
2 2 2 2 2 2 2
Engine Shut- 0 0 0 0 0 0 0
down 1 1 1 1 1 1 1
Tilt 1 1 1 X X 1 X
2 2 2 X 2 2 X
3 3 3 X 3 3 X
4 4 4 4 4 4 4
5 5 5 5 5 5 5
6 6 6 X X 6 X
7 7 7 X X 8 X
8 8 8 8 8 8 8
9 9 9 9 9 9 9
Jib 1 1 1 1 1 1 1
4 Wheel Steer 0 0 0 0 0 0 0
Soft Touch/ 0 0 0 0 0 0 0
Skyguard 1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3
Gen Set / 0 0 0 0 0 0 0
Welder 1 1 1 1 1 1 1
Gen Set Cutout 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Head & Tail- 0 0 0 0 0 0 0
lights 1 1 1 1 1 1 1
Cable Break 0 0 0 0 0 0 0
Switch 1 1 1 1 1 1 1
6-18 3121631
SECTION 6 - JLG CONTROL SYSTEM
Table 6-4. 860SJ Machine Configuration Programming Table 6-4. 860SJ Machine Configuration Programming
Settings (Software Version P6.22) Settings (Software Version P6.22)
ANSI Export
ANSI Export
Australia
Australia
ANSI USA
ANSI USA
860 SJ 860 SJ
Japan
Japan
CSA
CSA
GB
GB
CE
CE
Load System 0 0 0 0 0 0 0 Cribbing 0 0 0 0 0 0 0
X 1 X X X 1 X Option 1 1 1 1 1 1 1
X 2 X 2 2 2 2 Fuel Tank Size 0 0 0 0 0 0 0
X 3 X 3 X 3 3 1 1 1 1 1 1 1
X 4 X X X 4 X Alarm / Horn 0 0 0 0 0 0 0
Load Sensor X 0 X 0 0 0 0 1 1 1 1 1 1 1
1 1 1 1 1 1 1 Alert Beacon 0 0 0 0 0 0 0
X 2 X 2 2 2 2 1 1 1 1 1 1 1
Function Cut- 0 0 0 0 0 0 0 Temp Cutout X 0 X 0 X X 0
out X 1 1 1 1 1 1 X 1 X 1 X X 1
2 2 2 X 2 2 2 Plat Lvl Ovr Cut 0 0 0 0 0 0 0
X 3 3 X 3 3 3 1 1 1 1 1 1 1
Ground Alarm 0 0 0 0 0 0 0 Water In Fuel X 0 X X X X 0
1 1 1 1 1 1 1 Sensor X 1 X X X X 1
2 2 2 2 2 2 2 Dual Capacity 0 0 0 0 0 0 0
3 3 3 3 3 3 3 1 1 1 1 1 1 1
Drive Type 0 0 0 0 0 0 0 BOLD TEXT indicates the default setting. Plain text indicates another available selec-
1 1 1 1 1 1 1 tion.RED ITALIC TEXT indicates the default when option is factory installed. SHADED
2 2 2 2 2 2 2 CELLS indicate hidden menu or selection.
Display Units 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Leveling Mode 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Drive Control 0 0 0 0 0 0 0
1 1 1 1 1 1 1
2 2 2 2 2 2 2
Drive Pump 0 0 0 0 0 0 0
1 1 1 1 1 1 1
X X X X X X X
X X X X X X X
Boom Control 0 0 0 0 0 0 0
1 1 1 1 1 1 1
Function Speed 0 0 0 0 0 0 0
Knob 1 1 1 1 1 1 1
Clearsky 0 0 0 0 0 0 0
1 1 1 1 1 1 1
3121631 6-19
SECTION 6 - JLG CONTROL SYSTEM
6.2 MACHINE PERSONALITY SETTINGS AND NOTE: Personality settings can be adjusted within the adjustment
range in order to achieve optimum machine performance.
FUNCTION SPEEDS
STEER MAXimum speed 1 to 100% 100 100 100 100 100 100
Engine RPM 800 to 2900 1800 1800 1800 1800 1800 1800
MAIN LIFT ACCELeration 0.1 to 5.0s 2.5 2.5 2.5 2.5 2.5 2.5
DECELeration 0.1 to 3.0s 1.5 1.5 1.5 1.5 1.5 1.5
MINimum UP speed 0 to 60% 15 15 15 15 15 15
MAXimum UP speed 0 to 100% 80 80 80 80 80 80
CREEP maximum UP speed 0 to 65% 30 30 30 30 30 30
MINimum DOWN speed 0 to 60% 15 15 15 15 15 15
MAXimum DOWN speed 0 to 100% 80 80 80 80 80 80
CREEP maximum DOWN speed 0 to 75% 30 30 30 30 30 30
Engine RPM 800 to 2900 1800 1800 1800 1800 1800 1800
SWING ACCELeration 0.1to 5.0s 2.8 2.8 2.8 2.8 2.8 2.8
DECELeration 0.1 to 3.0s 1.7 1.7 1.7 1.7 1.7 1.7
MINimum LEFT speed 0 to 50% 14 14 14 14 14 14
MAXimum LEFT speed 0 to 100% 65 65 65 65 65 65
CREEP maximum LEFT speed 0 to 65% 43 43 43 43 43 43
MINimum RIGHT speed 0 to 50% 14 14 14 14 14 14
MAXimum RIGHT speed 0 to 100% 68 68 68 68 68 68
CREEP maximum RIGHT speed 0 to 65% 49 49 49 49 49 49
Engine RPM 800 to 2900 1800 1800 1800 1800 1800 1800
6-20 3121631
SECTION 6 - JLG CONTROL SYSTEM
PLATFORM LEVEL ACCELeration 0.1to 5.0s 0.1 0.1 0.1 0.1 0.1 0.1
DECELeration 0.1to 3.0s 0.1 0.1 0.1 0.1 0.1 0.1
MINimum UP speed 0 to 65% 48 48 48 48 48 48
MAXimum UP speed 0 to 100% 100 100 100 100 100 100
MlNimum DOWN speed 0 to 65% 48 48 48 48 48 48
MAXimum DOWN speed 0 to 100% 100 100 100 100 100 100
Medium Speed 0.01 to 1.00 0.10 0.10 0.10 0.10 0.10 0.10
Engine RPM 800 to 2900 1800 1800 1800 1800 1800 1800
PLATFORM ACCELeration 0.1to 5.0s 0.1 0.1 0.1 0.1 0.1 0.1
ROTATE DECELeration 0.1to 3.0s 0.1 0.1 0.1 0.1 0.1 0.1
MlNimum LEFT speed 0 to 65% 69 69 69 69 69 69
MAXimum LEFT speed 0 to 100% 90 90 90 90 90 90
MINimum RIGHT speed 0 to 65% 69 69 69 69 69 69
MAXimum RIGHT speed 0 to 100% 90 90 90 90 90 90
Medium Speed 0.01 to 1.00 0.30 0.30 0.30 0.30 0.30 0.30
Engine RPM 800 to 2900 1800 1800 1800 1800 1800 1800
JIB LIFT Lift ACCELeration 0.1 to 5.0s N/A 3.3 3.3 N/A 3.3 3.3
Lift DECELeration 0.1 to 3.0s N/A 0.8 0.8 N/A 0.8 0.8
MINimum UP speed 0 to 65% N/A 43 43 N/A 43 43
MAXimum UP speed 0 to 100% N/A 80 80 N/A 80 80
MINimum down 0 to 65% N/A 40 40 N/A 40 40
MAXimum Down 0 to 100% N/A 75 75 N/A 75 75
Medium Speed 0.01 to 1.00 N/A 0.60 0.60 N/A 0.60 0.60
Engine RPM 800 to 2900 N/A 1800 1800 N/A 1800 1800
3121631 6-21
SECTION 6 - JLG CONTROL SYSTEM
Note: Ground Mode speed are automatically limited to being lower than platform speed for a given function.
4150384-L
6-22 3121631
SECTION 6 - JLG CONTROL SYSTEM
3121631 6-23
SECTION 6 - JLG CONTROL SYSTEM
6.4 CANBUS COMMUNICATIONS Interlocks: Any device that sends an electrical input. (For an
example a limit switch, proximity switch, etc).
CANbus: CAN (Control Area Network) is a two wire differential
serial link between the Platform Module, Jib Module, Ground Platform Level: The GROUND MODULE stores the default val-
Module, Boom Length Angle Module and the Chassis Module ues and handles interlocks. The PLATFORM MODULE reads the
providing bi-directional communications. sensors mounted on the platform assembly and controls the
Level Up / Down valves to maintain setpoint sent from the
Two-wire: One wire (red) is driven high (5v) and the other low GROUND MODULE.
(black) (0v) to send a signal; both wires ”float” (2.5v) when no
signal is being sent. Steer: The GROUND MODULE stores crack points and sends
desired drive direction, steering mode and axle extend/retract
Differential: Any electrical line noise can affect the high or the commands. The PLATFORM MODULE reports the steering
low wires but never both, so communications is not corrupted. switch position to the GROUND MODULE.
Serial Link: Messages are being sent bit by bit along the wires; Drive: The GROUND MODULE stores crack points, sends com-
the high bus speed allow all modules to be constantly mands for each drive pump. (Command is computed from
updated around 20 times per second. Typical traffic is 300 - drive joystick input, interlocks, wheel angle, etc).
500 messages per second.
Lift, Tele, & Swing: The GROUND MODULE stores default val-
A complete CANbus circuit is approximately 60 ohms, which ues and handles interlocks and calibration information. Lift,
can be verified at the ”T” fitting inside the ground station or Telescope and Swing commands are dependent upon inter-
below the BLAM. Each individual circuit from the modules is locks through out the machine. Boom angle, length and swing
approximately 120 ohms. are controlled by the GROUND MODULE.
The GROUND MODULE (UGM) is the master system controller.
Most functions are dispatched and coordinated from this
module, The PLATFORM MODULE handle sub-tasks. All charac-
terized information (values) are stored into the ground mod-
ule (i.e., Personalities or Calibrations).
6-24 3121631
SECTION 6 - JLG CONTROL SYSTEM
:
: PRESS ENTER EVERYTHING OK
G :(xxx)
x:xxxxxxxxxxx
: : :
:
BOOM FUNCTIONS
LEFT TRACK V. A : E
: : % C :
RIGHT TRACK V. A : E
: % : % :
: CRIBBING MODE : : :
SYSTEM TEST %
1001103790-Q
MAE33180Q
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be
available depending upon machine configuration and software versions.
Figure 6-3. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 1 of 9
3121631 6-25
SECTION 6 - JLG CONTROL SYSTEM
: : :
: :
BOOM FUNCTIONS
Y : PLATFORM MODULE :
.XV T Y : .XV : XX.X
C UGM TEMP :
: F F : XX.X
C : A Y S
ENGINE OIL
: : :
A CHARGE PUMP T .
: F : : :
CABLE BREAK S S 1 A
: CL F
S S 2 W
: CL : C
: :
T : :
.X
1001103790-Q
MAE33190Q
NOTE: The layout shown includes all possible analyzer screens. Please note that some
screens may not be available depending upon machine configuration and soft-
Figure 6-4. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 2 of 9
6-26 3121631
SECTION 6 - JLG CONTROL SYSTEM
: : : : :
:
C G
Y C G : GROUND MODULE
: / :X O : : h XXm : .XX
Y C G : GROUND MODULE
: CL / :X 500 : : h XXm C . D A : .XX
C 1 G : GROUND MODULE
E : P :X : : h XXm S /N:
G : PLATFORM MODULE
: : h XXm W : .
G : PLATFORM MODULE
: h XXm : X
G : PLATFORM MODULE
: F S /N:
G : PROPULSION MODE
: F W : .
G : U
: .XV W : XX .
G : U
: h XXm : X
CLEAR RENTAL : G : U
S: ,NO : ERASE RENTAL ? S /N :
Y
W : .
Y
: X
:
.XX
1001103790-Q
MAE33200Q
NOTE: The layout shown includes all possible analyzer screens. Please note that
some screens may not be available depending upon machine configura-
tion and software versions.
Figure 6-5. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 3 of 9
3121631 6-27
SECTION 6 - JLG CONTROL SYSTEM
: SYSTEM TEST :
SYSTEM TEST E ?
: ACCESS LEVEL :
ACCESS LEVEL C
: : : : :
:
PERSONALITIES LEFT TRACK RIGHT TRACK :
M
: LEFT TRACK : K :
X . % X . X .
LEFT TRACK : K :
X . X . X .
LEFT TRACK : K :
MIN FORWARD % W % MIN FORWARD %
: LEFT TRACK : K :
W % W % W %
: LEFT TRACK : K :
MIN REVERSE % % MIN REVERSE %
: LEFT TRACK : K :
MAX REVERSE % E % E %
: LEFT TRACK : K :
V. % % %
: LEFT TRACK : K :
% % %
LEFT TRACK : K :
% %
LEFT TRACK : K :
% %
:
% 1001103790-Q
MAE33210Q
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration and software versions.
Figure 6-6. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 4 of 9
6-28 3121631
SECTION 6 - JLG CONTROL SYSTEM
: : : : :
:
M TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE
RIGHT TRACK
M : :
% %
M : :
% CREEP RIGHT %
: : : : : :
PLATFORM LEVEL JIB LIFT T / TEMPERATURE CUT
:
TOWER TELE : %
:
TOWER UP : %
:
TOWER DOWN : %
:
JIB LIFT : %
:
JIB SWING : % 1001103790-Q
MAE33220Q
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration and software versions.
Figure 6-7. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 5 of 9
3121631 6-29
SECTION 6 - JLG CONTROL SYSTEM
:
400S
450A
510A
:
600S
600A
601S
740A
800A
800S
1001103790-Q
MAE33230Q
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration and software versions.
Figure 6-8. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 6 of 9
6-30 3121631
SECTION 6 - JLG CONTROL SYSTEM
1001103790-Q
MAE33240Q
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration and software versions.
Figure 6-9. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 7 of 9
3121631 6-31
SECTION 6 - JLG CONTROL SYSTEM
1001103790-Q
MAE33250Q
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration and software versions.
Figure 6-10. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 8 of 9
6-32 3121631
SECTION 6 - JLG CONTROL SYSTEM
1001103790-Q
MAE33260Q
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration and software versions.
Figure 6-11. Analyzer Flow Chart - Diagnostics (Software Version P6.22) - Sheet 9 of 9
3121631 6-33
SECTION 6 - JLG CONTROL SYSTEM
GROUND
6-34 3121631
SECTION 6 - JLG CONTROL SYSTEM
PLATFORM CONNECTION
3121631 6-35
SECTION 6 - JLG CONTROL SYSTEM
6-36 3121631
SECTION 6 - JLG CONTROL SYSTEM
1001103667-Y
MAE33350Y
3121631 6-37
SECTION 6 - JLG CONTROL SYSTEM
6-38 3121631
SECTION 6 - JLG CONTROL SYSTEM
1001141138-E
MAE33270E
3121631 6-39
SECTION 6 - JLG CONTROL SYSTEM
6-40 3121631
SECTION 6 - JLG CONTROL SYSTEM
DRIVE
ACCEL Displays/adjusts drive acceleration
DECEL Displays/adjusts drive deceleration
MIN FORWARD Displays/adjusts minimum forward drive speed
MAX FORWARD Displays/adjusts maximum forward drive speed
MIN REVERSE Displays/adjusts minimum reverse drive speed
MAX REVERSE Displays/adjusts maximum reverse drive speed
ELEVATED MAX Displays/adjusts maximum drive speed
NOTE: used when elevation cutout switches are limiting maximum speed
CREEP MAX Displays/adjusts maximum drive speed
NOTE: used when creep switch on pump pot is active
STEER MAX Displays/adjusts the maximum steer speed
LIFT
ACCEL Displays/adjusts 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
NOTE: used when creep switch on pump pot is active
SWING
ACCEL Displays/adjusts swing acceleration
DECEL Displays/adjusts swing deceleration
MIN LEFT Displays/adjusts minimum swing left speed
MAX LEFT Displays/adjusts maximum swing left speed
CREEP LEFT Displays/adjusts maximum swing left speed
NOTE: used when creep switch on pump pot is active
MIN RIGHT Displays/adjusts minimum swing right speed
MAX RIGHT Displays/adjusts maximum swing right speed
CREEP RIGHT Displays/adjusts maximum swing right speed
NOTE: used when creep switch on pump pot is active
MAIN TELESCOPE
ACCEL Displays/adjusts telescope acceleration
DECEL Displays/adjusts telescope deceleration
MIN IN Displays/adjusts minimum telescope in speed
3121631 6-41
SECTION 6 - JLG CONTROL SYSTEM
6-42 3121631
SECTION 6 - JLG CONTROL SYSTEM
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
NOTE: demand is controlled by the pump pot
JIB UP … Displays jib lift switch direction & demand
NOTE: demand is controlled by the pump pot
Not displayed if JIB = NO
JIB LEFT … Displays jib swing switch direction & demand
NOTE: demand is controlled by the pump pot
Not displayed if JIB = NO
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
3121631 6-43
SECTION 6 - JLG CONTROL SYSTEM
6-44 3121631
SECTION 6 - JLG CONTROL SYSTEM
3121631 6-45
SECTION 6 - JLG CONTROL SYSTEM
6-46 3121631
SECTION 6 - JLG CONTROL SYSTEM
3121631 6-47
SECTION 6 - JLG CONTROL SYSTEM
6-48 3121631
SECTION 6 - JLG CONTROL SYSTEM
33122 33 SWING LEFT VALVE - SHORT TO GROUND Check Harness for damage.
33123 33 TELESCOPE OUT VALVE - SHORT TO BATTERY Check Harness for damage.
3121631 6-49
SECTION 6 - JLG CONTROL SYSTEM
33331 33 DRIVE - CURRENT FEEDBACK READING TOO LOW The UGM shall suspend Drive
Forward and Reverse command and revert to Open Current loop control for
Drive;
The UGM shall limit Drive Forward and Reverse to Creep
speed after controls initialized
33410 33 DRIVE - CURRENT FEEDBACK READING LOST The UGM shall suspend Drive
Forward and Reverse command and revert to Open Current loop control for
Drive;
The UGM shall limit Drive Forward and Reverse to Creep
speed after controls initialized
33412 33 SWING VALVES - SHORT TO BATTERY Check Harness for damage.
33414 33 SWING - CURRENT FEEDBACK READING TOO LOW Check wiring and coil.
33415 33 FLOW CONTROL VALVE - CURRENT FEEDBACK READING TOO The UGM shall suspend Flow
LOW Control and revert to Open
Current loop control for Flow
Control.
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 LOST Check wiring and coil.
6-50 3121631
SECTION 6 - JLG CONTROL SYSTEM
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 GROUND Deutz engine only.
436 43 FORD FAULT CODE ##
3121631 6-51
SECTION 6 - JLG CONTROL SYSTEM
6-52 3121631
SECTION 6 - JLG CONTROL SYSTEM
8641 86 FRONT LEFT STEER VALVE - SHORT TO GROUND Check Harness for damage.
8642 86 FRONT RIGHT STEER VALVE - OPEN CIRCUIT Check Harness for damage.
8643 86 FRONT RIGHT STEER VALVE - SHORT TO BATTERY Check Harness for damage.
8644 86 FRONT RIGHT STEER VALVE - SHORT TO GROUND Check Harness for damage.
8645 86 REAR LEFT STEER VALVE - OPEN CIRCUIT Check Harness for damage.
8646 86 REAR LEFT STEER VALVE - SHORT TO BATTERY Check Harness for damage.
8647 86 REAR LEFT STEER VALVE - SHORT TO GROUND Check Harness for damage.
8648 86 REAR RIGHT STEER VALVE - OPEN CIRCUIT Check Harness for damage.
8649 86 REAR RIGHT STEER VALVE - SHORT TO BATTERY Check Harness for damage.
8650 86 REAR RIGHT STEER VALVE - SHORT TO GROUND Check Harness for damage.
3121631 6-53
SECTION 6 - JLG CONTROL SYSTEM
6-54 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
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 cir-
cuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around
the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gen-
tle pull to ensure the wires are still attached to the contact and Figure 7-1. Voltage Measurement (DC)
contacts are seated in the connector. • If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual).
Min/Max
• Use firm contact with meter leads.
Use of the "Min/Max" recording feature of some meters can
help when taking measurements of intermittent conditions
while alone. For example, you can read the Voltage applied to
a solenoid when it is only operational while a switch, far from
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, the location of the signal and
that the leads are connected to the device under test correctly.
3121631 7-1
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7-2 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE-
RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.
3121631 7-3
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
3. Anderson connectors for the battery boxes and battery Deutsch HD, DT, DTM, DRC Series
chargers should have silicone grease applied to the con-
tacts only. The Deutsch connector system is commonly used for harsh
environment interconnect. Follow the installation instructions.
NOTE: Curing-type sealants might also be used to prevent short-
ing and would be less messy, but would make future pin
removal more difficult.
7-4 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
DIN Connectors
This connector is typically used on hydraulic valves. Follow the
installation instructions.
AMP Mate-N-Lok
This connector system is widely used inside enclosure for gen-
eral-purpose interconnect. Follow the installation instructions.
3121631 7-5
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
SEALED ENCLOSURES
Figure 7-7. Brad-Harrison M12 Application of dielectric grease is not required in properly
sealed enclosures. To meet criteria, the enclosure must be
rated to at least IP66 (dust tight; protected from powerful jets
of water). The enclosure must be fitted with a high quality,
continuous gasket and all wiring must pass through cable
entrances.
7-6 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
3121631 7-7
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7-8 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-13.).
Release the locking latches by squeezing them inward
(See Figure 7-12.).
3121631 7-9
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7-10 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
3121631 7-11
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
A B
A B
C
C D
Figure 7-16. DT/DTP Contact Installation Figure 7-17. DT/DTP Contact Removal
NOTE: The receptacle is shown - use the same procedure for plug.
7-12 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
A B A B
C C
Figure 7-18. HD/HDP Contact Installation Figure 7-20. HD/HDP Contact Removal
3121631 7-13
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
GATEWAY MODULE
DIAGNOSTICS PLUG
Telematics-Ready (TCU) Plug
The telematics-ready (TCU) plug is a standard 12-pin Deutsch
connector. Pin-out locations are shown below:
12 1 - BATTERY
11 2 - GROUND
CAN-HI 2 - 10 3
CAN-LO 2 - 9 4 - IGNITION
8 5
7 6
TELEMATICS-READY PLUG
7-14 3121631
3121631
MS1619-3 MS1619-1
MS1619-2
X1609
MS1620-1
S1614
MS1618-2
S1615
MS1620-3
MS1620-2
MS1618-3
CO1613-J2
CO1613-J1
X1606
7-15
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
1 RED 1-0 BAT 16 AWG GXL X1606 (B) A YEL CANH2 18 AWG GXL CO1613-J2 (10)
2 BLK 0-0 GND 16 AWG GXL S1615 (1) B GRN CANL2 18 AWG GXL CO1613-J2 (9)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 2 ORN 2-2 IGN 16 AWG GXL CO1613-J1 (12)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 2 BLK 0-1 GND 16 AWG GXL X1606 (A)
A YEL CANH2 18 AWG GXL MS1620-2 (A) 2 BLK 0-2 GND 16 AWG GXL CO1613-J1 (11)
MS1618-2 (CAN-T 1)
CO1613-J1 (GATEWAY 1)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
A YEL CANH1 18 AWG GXL CO1613-J1 (10)
9 GRN CAN1 18 AWG GXL MS1618-2 (B)
B GRN CANL1 18 AWG GXL CO1613-J1 (9)
10 YEL CANH1 18 AWG GXL MS1618-2 (A)
7-16 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
FROM TO
WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE PIN REFERENCE PIN
3121631 7-17
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
PLATFORM
FLOODLIGHTS
FOOTSWITCH
7500W
GENERATOR
GENERATOR PLATFORM
SWITCH BOX
J7
J1
PLATFORM
WORK LIGHTS
J5 J6
J2
ABOVE HORIZONTAL
LIMIT SWITCH
J8
BOOM CAPACITY
ANGLE
LIMIT SWITCH
BOOM CAPACITY
LENGTH
LIMIT SWITCHES
DPF BOOM TRANSPORT
LENGTH
TILT LIMIT SWITCHES
#2 SENSOR
PLATFORM
CONTROL BOX #1
JIB VALVE
GROUND BOOM
PROX.
CONTROL BOX SWITCH
J8
J1
J12 J7
J2
J3 J4
HEADLIGHTS
DIAGNOSTIC
ANALYZER TAILLIGHTS
MAE19760
7-18 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
OR
25000W
GENERATOR
RELAY
25000W
GENERATOR
CONTROL BOX
75000W
25000W GENERATOR
GENERATOR CONTROL BOX 75000W 75000W
GENERATOR SKYPOWER
RELAYS GENERATOR
BOSCH FUEL
REGULATOR
ENGINE (GM)
CONTROL EGR VALVE
ENGINE (DEUTZ D2011) SWITCH
TO FUEL WATER IN (DEUTZ
CONTROL PUMP FUEL IND. OR D2011)
(DEUTZ TD2.9L4) ECU
ENGINE MODULE
HARNESS GM
(DEUTZ D2011)
DEUTZ TD2.9L4
COMPONENTS TO GLOW PLUGS
TO ENGINE EIC (FORD
ENGINE)
FUEL
TO COOLANT REGULATOR AUX
LEVEL IND. (GM HARNESS) PUMP
RELAY
(DEUTZ BOLT ON
POWER D2011) ENGINE
START
MODULE RELAY BATTERY
RELAY GLOW
PLUGS
STROBE 2 SPEED
LIGHT & BRAKE
VALVE
GLOW START
PLUGS RELAY
HYDRAULIC RELAY (DEUTZ)
PUMPS
AUX
RELAY
STARTER
ALTERNATOR
(DEUTZ DRIVE
TD2.9L4) ORIENTATION GENERATOR
SWITCH HOURMETER
REAR MAIN
CONTROL
STEER VALVE
HORN
FUEL
LEVEL
SENSOR MAIN LIFT
ALARM
CYLINDER MAE19750
3121631 7-19
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
A B C D
SHEET 1
A B C D
7-20 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
E F G H
SHEET 2 1001131992 A
E F G H
3121631 7-21
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
8 7 6 5 4
YEL/RED 2-12-1
H SEE SHT 7 ZONE F1
OR RED
SEE SHT 6 ZONE G6 BLACK
1 RED 1 33
5 SEE ZONE A5 BLUE 102-1
2 BLU 2 ORN/RED 49-63 25 21 RED/WHT 50-2-1 5 BLUE 5
AMP YEL/RED 2-40-9
BLK 3 ORN/RED 49-68 PINK 26-3-1 7 BROWN (18) 7
3
PINK 25-3-1 9 RED/BLK (18) 9 MAIN TELE IN
MAIN TELE OUT
STROBE LIGHT ROTATE RIGHT
5
6
7
ROTATE LEFT
TO BATTERY NEG.
15 YEL/BLK(18) 15 BLU/ORN 52-11 1
LEVEL UP
PINK 26-3-2
PINK 25-3-2
1 RED 15 LEVEL DOWN
RED/WHT 50-2-3
RED 1-90
15 AMP 2
C.B. START SWITCH
PINK 26-3-3
2 YEL 16 ORN/RED 49-80 26 MTB
PINK 25-3-3
BLU/ORN 52-11
SELECT AUX POWER/ENABLE
3 BLK 17 YEL/RED
ORN/RED 49-81 2-5-1
SWITCH
G
YEL/RED YEL/RED
13 ORN/BLK 13 2-5 MTB
MAIN TELE IN BROWN 13-1 5 2-5 JIB UP
16 EMS
MAIN TELE OUT 6 YEL/RED JIB DOWN
BROWN 14-1 15 ORN(12) YEL/RED 2 B1 YEL/RED
ORN/RED 49-103 2-2(12) 10 10 2-2(12) MAIN LIFT UP
ROTATE RIGHT GRAY 24-1 7
4 2-4 (12) MAIN LIFT DOWN
ROATE LEFT GRAY 23-1 8 PLATFORM DUMP PLATFORM SEE YEL/RED 2-2-2
24 EMS SHT 1 1 B YEL/RED
LEVEL UP PINK 25-1 9 UP LEVEL SWING RIGHT
22 ZONE G1 2-1(12)
J7 (BLACK)
YEL/RED 2-3(16)
ZONE C4
ZONE C4
ZONE B4
ZONE C4
ZONE C4
ZONE B4
JIB DOWN BLUE 28-1 12 6 GRAY 24-3 9 RIGHT ROTATE SEE
25 BLUE 27-3 10 YEL/RED YEL/RED SHT 1
FUEL SELECT BLU/ORN 52-20 33 UP JIB
2-30-4 2-1-3 ZONE G1
Ref.V RED/ORN 4 RED/WHT 55-30 34 26 BLUE 28-3 11 DOWN JIB
PUMP (12)
WIPER GREEN 6 RED/WHT 55-31 35 29 BLACK 12 X1001 BRN/WHT 47-9
POTENTIOMETER
GND BRN/BLK 5 BLACK 13 10
SEE SHT 7 ZONE F1 30 HOURMETER
CREEP 2 ORN/RED 49-11 32 13 OR 86 85
19 14 SEE SHT 6 ZONE E2 87a ENGINE LOW
87
F OIL PRESSURE
ORN/YEL
BLACK
22 32 CAN SHIELD SHIELD NO CHARGE
C 1 1
EMS PTF TO MTB output YEL/RED 2-3-1 SYSTEM
23 3 4 ORANGE (18) 4
3 24 1 GND MODE DISTRESS
YEL/RED 2-30-1
J1 (WHITE)
BLACK (10)
ORN 55-52 2 PTF EMS X1002
18 27 ORN/RED 49-104
J1-19
1 28 ORN/RED 49-105 PLATFORM
OVERLOAD
YEL/RED 2-1-1(12)
2
FOOTSWITCH 2
3 8 ORN/RED 49-70 7 CRIBBING ENABLED
BLACK
YEL/RED 2-10
4 4 ORN/RED 49-71 8 WHITE 7 GREEN 6 YELLOW(18) 6 GLOW PLUG
{
16
17 ORN/RED 49-69-1 SEE SHT 7 ZONE F1
17
CAN SHIELD
YEL/RED 2-75
J2 (GRAY)
BLACK 18
FULL BRN/WHT 47-4 35 MAIN BOOM ELEVATION
FUEL GAGE
SWING
3/4 BRN/WHT 47-3 23 CABLE SERVICE BROWN 2
1/2 BRN/WHT 47-2 24 5K SWITCH (CE ONLY) 4 1 BLACK 3
1/4 6 A B C
BRN/WHT 47-1 22
{
BRN 15-1
J5 (WHITE)
4 BOOM ANGLE
TO ALARM GROUND 1 GRN/YEL 1 2 BLACK 6
BRN 16-1 PROX. SWITCH
2 2 GREEN
TO J7-20
SEE SHT 4, ZONE G2
SEE SHT 4, ZONE B5
SEE SHT 2, ZONE F7
GRY CAN LO
J6 (BLACK)
30
WHT 2-18-2
SHIELD (18)
SHIELD (18)
BLK CAN HI
BLK CAN HI
BLACK (18)
BLACK (18)
BLU 0-27-2
MS509
ANALYZER GROUND
ANALYZER RECEIVE
ANALYZER POWER
CANBUS
SHEET 1
8 7 6 5 4
7-22 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
5 4 3 2 1
SEE
SHT 1
ZONE B2 GROUND CONTROL BOX
30 AMP
BLK/WHT (12) 18 BLACK (12)
RED 1-2(10)
J4 (BLUE)
2-5 JIB UP BLUE 27-2 19
EMS 19 YELLOW 9-1 LEFT FRONT STEER
JIB DOWN BLUE 28-2 8 9
YEL/RED 2 B1 YEL/RED
10 ORN(12) 10 MAIN LIFT UP TAN 3-2 23
2-2(12) 20
4 2-4 (12) MAIN LIFT DOWN
J2 (GRAY)
SEE YEL/RED 2-2-2 TAN 4-2 33
1 14 BLACK
SHT 1 B YEL/RED SWING RIGHT WHITE 22-2 35
ZONE G1 13 RED/WHT 50-6 MAIN DUMP
2-1(12) SWING LEFT WHITE 21-2 34
3 4 BROWN 13-3 IN MAIN TELE
10 16 BROWN 14-3 OUT MAIN TELE
21
ZONE C4
ZONE C4
ZONE B4
15 18 BLACK
PLATFORM
OVERLOAD ORN/RED 49-100 14 24
CRIBBING ENABLED 28 SPARE-GND 4 LED
BRN/WHT 47-75 1
25 BRN/WHT 47-12 FUEL SENSOR (SIGNAL) 1 FUEL GAGE IN
6 GLOW PLUG WHT/YEL 48-6 3 6 BLACK SENSOR (GROUND) 2 PLATFORM.
BLACK 31
{ SEE SHT 4, ZONE D7
SEE SHT 2, ZONE E6
8 32 1
GND FROM BATTERY 2
1 3 ORANGE 7-2 DRIVE FORWARD WHT/BLK 58-1-1
MTB EMS input E
2 6 ORANGE 8-2 DRIVE REVERSE WHT/BLK 58-1-2
GND TO PLATFORM
J8 (BLACK)
8 34
MAIN BOOM ELEVATION 32 B+
28
BROWN 2 ORN/RED 49-87 32 33 ORN 100-1
CABLE SERVICE
19
SWITCH (CE ONLY) 4 1 BLACK 3 ORN/RED 49-88 12
A B C 35 CRIBBING
{
BLUE 3 2 ENABLE C
BATTERY
1
SWITCH
12 VDC
ORN/RED 49-94 31 1
BROWN 5
BOOM ANGLE 8 BLU/ORN 52-75 13 12 YEL/RED 2-75 SEE
PROX. SWITCH 1 2 BLACK 6 ORN/RED 49-95 35
9 OPTION SHT 1
J3 (BLACK)
SEE SHT 4, ZONE G2
ZONE
SEE SHT 4, ZONE B5
SEE SHT 2, ZONE F7
6 5
ZONE F5 7 C6
34 WHT/BLK 58-3
ZONE F6 13
22
ZONE C8 11 ORN 100-2
ZONE F5 17
ZONE H8 12
ZONE F6 19 10
14 WHT/BLK 33-7
ZONE F5 27 4 WHT/BLK 11-1
GRY CAN LO
GRY CAN LO
ZONE F6 20
WHT 2-18-2
SHIELD (18)
SHIELD (18)
6 WHT/BLK 12-1
BLK CAN HI
BLK CAN HI
BLACK (18)
BLACK (18)
BLU 0-27-2
COMPONENTS LOCATED
SW1003
RED (18)
RED (18)
IN PLATFORM BOX 3
ORN 101-1 ORN 100-3
5 1 CE MARKET ONLY
AMP 2 BLACK A
MSSO
3 CAN HI C
8 7 6 5 10 9 4 3 12 11 2 1 4 CAN LO D B
J12
HEST IND
BLACK (18) 3
REGEN IND
INHIBIT IND
RED (18) 4
5
6
SEE ZONE H4 BLUE 102-1 1
BROWN 103-1
A
2
SHEET 1
5 4 3 2 1
MAE19890M
3121631 7-23
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
8 7 6 5 4
87a
30
RED 1-2-2 WHT/YEL 48-8
1
87
J1-7 ON SHEET 1, ZONE C3 WHT/YEL 48-15
86
J1-17 ON SHEET 1, ZONE C3 BLACK
PUMP
FUEL
85
G FUEL PUMP RELAY
(LOCATED IN M.T.B.)
BLACK
2
BATTERY +
SHEET 1
SEE ZONE D1
SHEET 1
ZONE C5
STARTER
MOTOR
1 YEL/RED 2-1-99 (16)
2 WHT/YEL 48-3 J1-11 ON SHEET 1 ZONE D3
F
VEHICLE INTERFACE
SEE SHT3 D2
3
4
5
6
RED CAN HI
BLK CAN LO
BRN/WHT 47-8-1 SHIELD } SEE SHEET 1, ZONE C5
120 OHM
BRN/WHT 47-8
SEE VENDOR
87 SCHEMATIC DETAIL
BLU/ORN 52-5 87a
14 SHEET 3
BRN/WHT 47-8-2
REGULATOR
JLG WIRING W
FOR
CAT ENGINE
GENERATOR
PLUG
C
SHEET 2
8 7 6 5 4
7-24 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
5 4 3 2 1
GENERATOR
CONTROL
7500 W GENERATOR BOX
(MACHINES BEFORE CN 147965) B A C
BLU/ORN 52-6
G
YEL/RED 2-20
87 87a
A
GENERATOR BLU/ORN 52-5 86 85
PLUG 30
BATTERY + B
SHEET 1 87 87a
ZONE D1
BRN/WHT 47-8-2 86 85
30
STARTER
RED
MOTOR 5 AMP
RED RED
POWERMITE F
2500 W GENERATOR GENERATOR
(DEUTZ TIER IVF MACHINES)
SEE VENDOR B+
SCHEMATIC DETAIL
E
SHEET 3
D+
ZONE E/G2 GENERATOR
CONTROL
7500 W GENERATOR BOX
REGULATOR
W BLU/ORN 52-6
YEL/RED 2-20
A 5 AMP
GENERATOR
PLUG BRN/WHT 47-8-2 D
B
GENERATOR
CONTROL
7500 W GENERATOR BOX
(DEUTZ TIER IVF MACHINES) B A C
4000 W GENERATOR
GENERATOR
CONTROL
BOX BLU/ORN 52-5
YEL/RED 2-20
B A C
A GENERATOR CONNECTIONS AT
BLU/ORN 52-5 VEHICLE INTERFACE 2
GENERATOR
SEE SHT 5 E-1
PLUG
BLACK
B 5 AMP
C
3
5 YEL/RED 2-20
6 BLACK
SHEET 2
5 4 3 2 1
MAE19900M
3121631 7-25
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
8 7 6 5 4
VENDOR SCHEMATIC
CAT ENGINE HARNESS
PURPLE/LT GREEN 18
1 SENSOR OUT
BLACK/LT GREEN 18
2 5V RTN
TAN/ORANGE 18
3 DBW + F3
PINK/WHITE 18
4 DBW - 10A
LT GREEN/RED 18
5 5V EXT
GLOW
BOSCH_872-860-521 CONN
PLUGS
BOSCH_C-TAB 2 99 00 49262 2 TERMINAL
OIL BOSCH_1 99 00 44435 2 SEAL
PRESSURE
BLACK/LT GREEN 18 2
LT BLUE 18
1
F RED/BLACK 18 2
DEUTSCH_DT06-2S CONN
DEUTSCH_0462-201-16141 TERMINAL BLACK/RED 18 3
AMP23 DEUTSCH_W2S LOCK
RED 18 5
DBW + 1 PINK/WHITE 18 PINK/TAN 18 1
DBW - 2 TAN/ORANGE 18 4
STARTER LOCKOUT 3
RED/BLACK 18
GLOW CONTROL 4
WHITE/BLACK 18
SHUT OFF CONTROL 5
6 GROUND
7
BLACK 14 13MM RING W/
8
STAR WASHER
9
BLACK 16 BLACK 18
GROUND 10
VBAT 11 RED/TAN 16
TPS 12 PURPLE/LT BLUE 18
E 13
LT BLUE 18
OIL PRESSURE 14
PINK/TAN 18 PINK/TAN 18
VSW 15
5V EXT 16 LT GREEN/RED 18
17
TAN/WHITE 18
ECT 18
BLACK/LT GREEN 18 ECM
5V RTN 19
BLUE/PINK 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH RED/TAN 16 F2 RED 16
CAN + 20
BLUE/WHITE 18 10A
CAN - 21
CRANK - 22 WHITE/PURPLE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CRANK + 23 PURPLE/WHITE 18
TAN/WHITE 18 A 30
WHITE 16
AMP_770680_1 CONNECTOR
AMP_770520_1 TERMINAL (TIN PLATED)
BLACK/LT GREEN 18 B ECT
LT BLUE/PINK 18
PED_12162193 CONNECTOR
PED_12124075 TERMINAL
D BLACK 18
DEUTSCH_DT06-2S CONN
DEUTSCH_0462-201-16141 TERMINAL
DEUTSCH_W2S LOCK
SHEET 3
8 7 6 5 4
7-26 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
5 4 3 2 1
GLOW PLUG
PURPLE/LT GREEN 18
BLACK/LT GREEN 18
1 SENSOR OUT
SOLENOID ALTERNATOR
2 5V RTN
TAN/ORANGE 18
3 DBW + F3 BLACK/RED 18 UNUSED
PINK/WHITE 18 1
4 DBW - 10A BROWN/WHITE 18 CAT 1073134 CONNECTOR
LT GREEN/RED 18 2
5 5V EXT BROWN/WHITE 18 CAT 1073135 TERMINAL
GLOW 5MM RING 3
BOSCH_872-860-521 CONN
PLUGS
BOSCH_C-TAB 2 99 00 49262 2 TERMINAL
BOSCH_1 99 00 44435 2 SEAL
18-22 GAUGE INSULATED BUTT CONNECTOR
RED/BLACK 18 2 F
STARTER B+
BLACK/RED 18 3
RED 14 10MM RING
RED 18 5 RED 8
PINK/TAN 18 1
4
GLOW CONTROL
GROUND ALTERNATOR +
BLACK 14 13MM RING W/ RED 8 7MM RING
STAR WASHER
BLACK 18
E
PINK/TAN 18 F1 PINK 18
5A
VSW
ECM VEHICLE INTERFACE
RED/TAN 16 F2 RED 16 RED 16 PINK 18 1
VSW
10A LT BLUE/PINK 18 2
START
BLUE/PINK 18 3 ENGINE CONNECTOR
CAN + SEE SHT 2 F8
87a BLUE/WHITE 18 4
30 CAN -
TAN/WHITE 18 A WHITE 16 BROWN/WHITE 18 5
87 RED 16 ALT. EXCITE
6
BLACK/LT GREEN 18 B ECT UNUSED
WHITE/BLACK 18 2
SHUT OFF SOLENOID
BK/W 18 F4 BLACK/WHITE 18 3 C
CRANK SENSOR TYCO_172128-1 CONNECTOR 10A
TYCO_63648-1 TERMINAL RED 18 5
WHITE/PURPLE 18
2 CRANK -
SHUT OFF PINK/TAN 18 1
PURPLE/WHITE 18
1 CRANK + 4
SHEET 3
5 4 3 2 1
MAE19910M
3121631 7-27
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
8 7 6 5 4
H
RECTIFER
B+ FUSIBLE
STATOR LINK
RED 1-1(10)
STARTER ALTERNATOR
MOTOR
SOL. REGULATOR
STARTER SENSING AND
MOTOR SWITCHING
CIRCUITS D+
WHT/YEL 48-12(12)
BRN/WHT 47-8-1
IN HEAD GLOW PLUGS
A
BLU/ORN 52-5
WHT/YEL 48-9
GENERATOR
RECEPTACLE BRN/WHT 47-8-2 ENGINE
B
CONNECTOR
{
SEE J1-11
SHEET 1
ZONE D3 J1-12
B+
E SHEET 1
87 87a ZONE D1
COOLANT 2 8 GRD(TempAll)
86 85
TEMPERATURE 1 9 ADC7(TEMP3) 1
30
ENGINE 2 13 SPEED 2
SPEED
1 12 GRD (SPEED)
MTB TO EMR2 ENGINE CONTROL
CAMSHAFT 10
EMR2 ENGINE CONTROL TO ENGINE
4 RackMeasSignal
5 18 RackMeasRef
120 OHM
RESISTOR
BLACK (16)
CAN SHIELD
CAN LO
CAN HI
BLACK 0-1
ORN/RED 49-199
YEL/RED 2-1-99
ORN/RED 49-198
YEL/RED 2-1-98
C
BLACK (18)
RED (18)
J1-8
{
DEUTZ
DIANOSTICS
SEE SHEET 1
ZONE C5
PLUG
SEE SHEET 1, ZONE E3
SHEET 4
8 7 6 5 4
7-28 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
5 4 3 2 1
H
RECTIFER
B+ FUSIBLE
STATOR LINK
RED 1-1(10)
ALTERNATOR
REGULATOR
SENSING AND
SWITCHING
CIRCUITS D+
SEE
SHEET 1
ZONE C5
BRN/WHT 47-8-1
}
ENGINE N RED CAN HI
CONNECTOR P BLK CAN LO SEE SHEET 1, ZONE C5
R SHIELD
S
BRN/WHT 47-8
E
87 87a
14 BLU/ORN 52-5
YEL/RED 2-6-2 86 85
BRN/WHT 47-8-2
30
J1-10
BLACK
J1-22
ON
ON
SHEET 1
120 OHM
RESISTOR
TERMINAL B
MTB STATION
BLACK (16)
CAN SHIELD
SELECT SWITCH
CAN LO
CAN HI
SHEET 1, ZONE G5
BLACK 0-1
ORN/RED 49-199
YEL/RED 2-1-99
ORN/RED 49-198
JLG SCHEMATIC
YEL/RED 2-1-98
C
FOR
BLACK (18)
GM/PSI ENGINE
RED (18)
B L K A
C
B
A
J1-8
{
DEUTZ
DIANOSTICS
SEE SHEET 1
ZONE C5
PLUG
SEE SHEET 1, ZONE E3
SHEET 4
5 4 3 2 1
MAE19920M
3121631 7-29
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
8 7 6 5 4
ECM-J2 EIC BUSSMANN DIODE PACK
BLK 248-33 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT)
33 62 (BLUE)
BLK 248-16 INJECTOR 1 1.5mm² YELLOW CONNECTOR
16 35
BLK 248-48 INJECTOR 4 1.5mm² GENERIC
48 42
BLK 248-18 INJECTOR 4 1.5mm² RELAY, POWER MODULE
18 37
BLK 248-32 INJECTOR 3 1.5mm²
32 38
BLK 248-2 INJECTOR 3 1.5mm² 5A 10A
2 61
BLK 248-46 INJECTOR 2 1.5mm²
46 40
BLK 248-3 INJECTOR 2 1.5mm²
3 41
6 2
H 5
BLK 248-5 MPROP ACTUATOR 1.5mm²
20
MS932
RL930-B+
BLK 248-4 MPROP ACTUATOR 1.5mm²
RL930-1
RL930-2
D
H
G
A
C
B
1
2
1
E
F
4 19
RL930
BLK 248-37 ENGINE SPEED CAMSHAFT 0.75mm²
37 14
BUSBAR
BLK 248-52 ENGINE SPEED CAMSHAFT 0.75mm²
S946
23 16
24
BLK 248-24 BOOST PRESSURE / TEMP 0.75mm²
22 EIC (ENGINE INTERFACE CONNECTION)
BLK 248-25 RAIL PRESSURE FUEL 0.75mm²
25 31
BLK 248-26 RAIL PRESSURE FUEL 0.75mm²
26 25
BLK 248-27 BOOST PRESSURE / TEMP 0.75mm²
27 29
BLK 248-28 COOLING TEMPERATURE 0.75mm²
28 24
BLK 248-29 OIL PRESSURE 0.75mm²
29 27
30 33
31 60
BLK 148-61 FUEL LOW PRESSURE 0.75mm²
34 17
BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²
35 18
36 58
1 30
BLK 248-40 AIR INLET TEMP 0.75mm² BLK 248-40 AIR INLET TEMP 0.75mm²
40 28
BLK 148-56 AIR INLET TEMP 0.75mm²
41 34
42 36
BLK 248-43 OIL PRESSURE 0.75mm²
43 23
BLK 248-44 OIL PRESSURE 0.75mm²
44 26
45 39
F 47 43
49 44
50 45
BLK 148-85 EHXAUST GAS RECIRCULATION 0.75mm²
51 46
BLK 148-72 THROTTLE FLAP 3 0.75mm²
55 49
BLK 148-44 EHXAUST GAS RECIRCULATION 0.75mm²
56 50
BLK 148-38 THROTTLE FLAP 4 0.75mm²
57 52
BLK 148-82 EHXAUST GAS RECIRCULATION 0.75mm²
58 51
59 53
60 54
55
56
ECM-J1
1.5MM (7,29,51,73) 7
8
9
10
11
12
E 13
BLK 148-13 COOLANT LEVEL SIG 0.75mm²
S951
14
BLK 148-15-68 CLUTCH SWITCH
15
16
17
S952
18
19
20
21
22
23
24
25
26 BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²
27
BLK 148-28 START RELAY CONTROL GND 0.75mm²
28
1.5MM (7,29,51,73) 29 BLK 148-29 COOLANT LEVEL PWR 0.75mm²
30
31
32
D 33
34
BLK 148-35-2 START 0.75mm²
35
36
37
BLK 148-38 THROTTLE FLAP 4 0.75mm²
38
39
40
41
42
43
BLK 148-44 EHXAUST GAS RECIRCULATION 0.75mm²
44
45
46
47
48
49
50
1.5MM (7,29,51,73) 51
52
GRN CAN 2 LO DIAG CAN LOW S968
53
C 54
YEL CAN 1 HI CUSTOMER CAN HIGH
55 S953
BLK 148-56 AIR INLET TEMP 0.75mm²
56
BLK 148-57 WATER IN FUEL SW RTN 0.75mm²
57
K [J1] 58 X965
YEL CAN 2 HI DIAG CAN HIGH 120 OHM
59 A A
ECM CONNECTOR 60
GRN CAN 2 LO DIAG CAN LOW
B B
61 BLK 148-61 FUEL LOW PRESSURE 0.75mm² C C
62 X966
63
BLK 148-64 WATER IN FUEL SW 0.75mm²
64
65
66
67 X955
BLK 148-15-68 CLUTCH SWITCH YEL CAN 1 HI CUSTOMER CAN HIGH 120 OHM
68 A A
GRN CAN 1 LO CUSTOMER CAN LOW
69 B B
70 C C
71 X956
BLK 148-72 THROTTLE FLAP 3 0.75mm²
72
1.5MM (7,29,51,73) BLK 148-73 START RELAY IGN 0.75mm²
73
74
B 75
YEL CAN 2 HI DIAG CAN HIGH S969
GRN CAN 1 LO CUSTOMER CAN LOW
76
77 S954
78
79
80
81
BLK 148-82 EHXAUST GAS RECIRCULATION 0.75mm²
82
83
84
BLK 148-85 EHXAUST GAS RECIRCULATION 0.75mm²
85
86
87 BLK 148-87 COOLANT LEVEL GND 0.75mm²
BLK 148-88 IGNITION 0.75mm²
88
89
90
91
92
93
94
RED 148-5 ECM PWR 2.5mm²
A 5
RED 148-3 ECM PWR 2.5mm² S944
3
RED 148-1 ECM PWR 2.5mm²
1
2.5MM (1-6) BLK 148-2 ECM GND 2.5mm²
2 S945
BLK 148-4 ECM GND 2.5mm²
4
BLK 148-6 ECM GND 2.5mm²
6
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
NC
SHEET 5
8 7 6 5 4
7-30 3121631
C
B
A
3121631
X956
120 OHM
SHEET 5
5
5
MS932
B
A
C
D
BLK 248-23 GLOW SENSE 0.75mm²
E
5A
(BLUE)
S951
S952
4
4
RL930-B+
BUSBAR 1
RL930
YEL 2-48-4 IGNITION 18AWG
1
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²
2
RL930-1
GENERIC
RL930-2
RELAY, POWER MODULE
RL931-87
ORG 248-23-1 GLOW SENSE 18AWG
1
RL931-87
RED 48-14 GLOW 8AWG
1
RL931-87
RED 48-13 GLOW 8AWG 87
1
150A
BUSBAR RL931-30
30
1
150 AMP
GLOWPLUG SOLENOID
7-31
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
8 7 6 5 4
PLATFORM SENSOR
H
ORN/RED 49-69
SEE 3 YEL/RED P1 ZONE D6
SHT 1
ZONE E6 YEL/RED 2-63
6 YEL/RED P8 PLATFORM SENSOR
13
YEL/RED P9 ZONE D6
YEL/RED P2 ZONE E2
OR SEE SHEET 7
ZONE E1
PLATFORM SENSOR
WHT ORN/RED P4
4
BLK ORN/RED P5
3
E BLK BLK P6
2
WHT YEL/RED P10
1
YEL/RED P1
D
YEL/RED P9
SHEET 6
8 7 6 5 4
7-32 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
5 4 3 2 1
PLATFORM SENSOR
YEL/RED P3 YEL/RED P3 87
1
YEL/RED P9-1 30
1
RELAY, 12V
87a F
1
ORN/RED P5 85
1
ORN/RED P5-1
ORN/RED P4 86
1
PLATFORM SENSOR ORN/RED P4-1
WHT ORN/RED P4
4
BLK ORN/RED P5
3
BLK P6 SEE
BLK 2 SHT 1
E
WHT YEL/RED P10 YEL/RED P2 ZONE F7
1
18 ohm 25W
YEL/RED P1 YEL/RED P1 87
1
YEL/RED P9 YEL/RED P9 D
YEL/RED P9-1 30
1
RELAY, 12V
87a
1
ORN/RED P5-1 85
1
P-J8A ORN/RED P4-1 86
1
YEL/RED EMS GND 2-1-3
X3
CONNECT TO P8
2 C
BLK GND
(MATING CONNECTOR OF J8)
1
NOTE:
MOLEX SHT 1 ZONE D-7 SKYGUARD RELAYS LOCATED ON THE RIGHT SIDE OF THE CONTROL PLATFORM BOX.
042818-0212 IF SKYGUARD RELAYS ARE ON THE LEFT SIDE, SEE SHEET 7.
X4
B
A
CONNECT TO X1002
C SHT 1 ZONE F-6
B
DEUTSCH
JLG PN 4460536
X5
B
CONNECT TO X1001
A
C SHT 1 ZONE F-6
DEUTSCH
JLG PN 4460539
SHEET 6
5 4 3 2 1
MAE19940M
3121631 7-33
7-34
F
B
C
A
G
H
D
BEACON MODULE
8
8
12
WHT - CAN SHIELD
11
BLK - CAN LOW
10
RED - CAN HIGH
9
8
7
6
5
4
3
2
1
X2
X5
RED - CAN HIGH
1
BLK - CAN LOW
3
WHT - CAN SHIELD
5
2
1
RED - CAN HIGH
2
X3
BLK - CAN LOW
4
WHT - CAN SHIELD
6
RED - CAN HIGH
7
7
11
BLK - CAN LOW
9
WHT - CAN SHIELD
7
RED - CAN HIGH
12
BLK - CAN LOW
ALERT BEACON OPTION
10
WHT - CAN SHIELD
8
BLK - GROUND
RED - BEACON PWR
B
BLK - GROUND
A
X9
CAN TERMINATOR
6
6
X7
G
F
WHT - CAN SHIELD
E
BLK - CAN LOW
D
RED - CAN HIGH
C
BLK - GROUND
RED - BATTERY
WHT - IGNITION
B
RED - BEACON PWR
BLK - GROUND S2
A
X4
X1
1
2
3
4
5
6
7
8
9
10
11
12
5
5
WHT P1 87
WHT P9-1 30
87a
WHT P5-1 85
RELAY #1
WHT P4-1 86
PLTFM SNSR
RL503
4
4
IP144
18 OHM
RL502
WHT P4-2
WHT P5-2 86
85
HARNESS,GEN 2
SHEET 7
3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
5 4 3 2 1
12
11
10
9
8
RED - BEACON PWR
7 PLTFM SNSR
6
BEACON MODULE PLTFM SNSR PLTFM SNSR
5 RELAY #1 RELAY #2
4
3
BLK - GROUND
2
WHT - IGNITION
1
X1
87a
87a
87
30
85
86
86
85
30
87
4
3
2
1
G
RL503
RL502
X500
4
3
2
1
WHT P1
WHT P9-1
WHT P5-1
WHT P4-1
WHT P4-2
WHT P5-2
WHT P9-2
WHT P3
WHT P5
WHT P4
WHT P6
WHT P10
NOTE:
6 PIN CONNECTOR AND RELAYS LOCATED
ON THE LEFT SIDE OF THE CONTROL PLATFORM BOX.
IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE, SEE SHEET 6.
S191 INTERFACE
S2
X5B KL
S192
WHT P6 BLACK SK 2 F
2 SEE SHT 1 ZONE F7
WHT - CAN SHIELD
RED - BATTERY
BLK - GROUND
YEL/RED P2
3 SEE SHT 6 ZONE F6 OR G6
E
D
C
B
A
SHEET 7
5 4 3 2 1
MAE19950M
3121631 7-35
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
1 2 3 4
18 BLACK FUEL
5 WHT/YEL 48-8 PUMP
}
ENGINE 28 RED CAN HI
C CONNECTOR 29 BLK CAN LO SEE SHEET 1, ZONE C5 C
SHIELD
BRN/WHT 47-8
87 87a
14 BLU/ORN 52-5
BRN/WHT 47-8-2
YEL/RED 2-6-2 86 85
30
J1-10
BLACK
J1-22
ON
ON
SHEET 1
YEL/RED 2-4-1 (12)
SHEET 1
A B ZONE D3
ZONE D3
B B
GENERATOR
RECEPTACLE
SEE
SHEET 1
ZONE E5
TERMINAL B
MTB STATION
SELECT SWITCH
SHEET 1, ZONE G5
A JLG SCHEMATIC A
FOR
FORD ENGINE
SHEET 8
1 2 3 4
MAE19960M
7-36 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
3121631 7-37
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
8 7 6 5 4
HDGCP90
Value
SHEET 9
8 7 6 5 4
7-38 3121631
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
5 4 3 2 1
ALTERNATOR
Value
NOTES:
ALL WIRE IS SAE J1128 TXL TYPE
HARNESS TO BE LABELED WITH ECI PART NUMBER AND REVISION
SHEET 9
5 4 3 2 1
MAE19970M
3121631 7-39
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
NOTES:
7-40 3121631
3121631
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