Service and Maintenance Manual

Model
530LRT
SN E200000676 to Present,
Including 1200030223

3121781
September 03, 2018 - Rev A

AS/NZS
 INTRODUCTION

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

GENERAL MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the
Mobile Elevating Work Platform (MEWP). It is of utmost FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC-
importance that maintenance personnel pay strict TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR
attention to these warnings and precautions to avoid DEATH AND IS A SAFETY VIOLATION.
possible injury to themselves or others, or damage to
the equipment. A maintenance program must be fol- • No smoking is mandatory. Never refuel during electri-
lowed to ensure that the machine is safe to operate. cal storms. Ensure that fuel cap is closed and secure at
all other times.
• Remove all rings, watches and jewelry when perform-
MODIFICATION OF THE MACHINE WITHOUT APPROVAL BY JLG INDUS- ing any maintenance.
TRIES, INC. IS A SAFETY VIOLATION. • Do not wear long hair unrestrained, or loose-fitting
The specific precautions to be observed during mainte- clothing and neckties which are apt to become caught
nance are inserted at the appropriate point in the man- on or entangled in equipment.
ual. These precautions are, for the most part, those that • Observe and obey all warnings and cautions on
apply when servicing hydraulic and larger machine machine and in service manual.
component parts.
• Keep oil, grease, water, etc. wiped from standing sur-
Your safety, and that of others, is the first consideration faces and hand holds.
when engaging in the maintenance of equipment.
Always be conscious of weight. Never attempt to move • Use caution when checking a hot, pressurized coolant
heavy parts without the aid of a mechanical device. Do system.
not allow heavy objects to rest in an unstable position. • Never work under an elevated platform until it has
When raising a portion of the equipment, ensure that been safely restrained from any movement by block-
adequate support is provided. ing or overhead sling, or the safety prop has been
engaged.
• Before making adjustments, lubricating or performing
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER any other maintenance, shut off all power controls.
THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA
RESPONSIBILITY OF THE OWNER/OPERATOR. • Battery should always be disconnected during
replacement of electrical components.
HYDRAULIC SYSTEM SAFETY • Keep all support equipment and attachments stowed
It should be noted that the machines hydraulic systems in their proper place.
operate at extremely high potentially dangerous pres- • Use only approved, nonflammable cleaning solvents.
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any por-
tion of the system.

3121781 a
 INTRODUCTION

REVISION LOG
Original Issue A - September 03, 2018

b 3121781
 TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
SECTION 1 - SPECIFICATIONS
1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Generator Specifications (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Drive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Steering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Hydraulic Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Hydraulic Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Engine SPecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7 Platform Height/Tilt Limit Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.8 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance and Inspection Schedule Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footnotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Safety and Workmanship. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Lines and Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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TABLE OF CONTENTS

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.4 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Service Maintenance components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Setting Scissor Arm Safety Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
General Maintenance Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Scissor Arms - Sliding Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Hydraulic Charge Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Oil Change with Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Fuel/Water Separator Filter (Diesel) - Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Fuel Strainer (Diesel) - Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Fuel Filter (Gas) - Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.7 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS
3.1 Operating Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Leveling Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Tires, Wheels & Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Drive Hub (Fairfield) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Main Disassembly for Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Cover Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Re-Aligning Torque Hub Input Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

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3.4 Drive Motor (Sauer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Initial Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.5 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Front Axle Assembly (Fixed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Front Axle Assembly (Oscillating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.6 Leveling Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.7 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.8 Scissor Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Scissor Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3.9 Side Compartment Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Cover installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3.10 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Control Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Ground Control Station Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Options Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3.11 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.12 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.13 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.14 Kubota Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Engine Tray - Swing Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Dual Fuel/LPG System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Changing From Gasoline to LP Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Changing From LP Gas to Gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Using Liquid Petroleum (LP) Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.15 Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.16 Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Generator (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
DUAL FUEL - GAS/LPG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
DIESEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Engine Electrical Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Pump Coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

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SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.1 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Valves - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cylinders Without Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Oscillating AXLE - Lockout Cylinder Test (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Left Side Wheel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Right Side Wheel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 Drive Pump Pre-fill Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Pre-Fill of the Drive Pump Housing Without HOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Pre-Fill of the Drive Pump Housing With HOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Priming the Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.6 Drive Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.7 Hydraulic Component Start-Up Procedures & Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Tapered Thread Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Straight Thread Types, Tube and Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Straight Thread Types, Port Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Flange Connection Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Assembly And Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF)
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections . . . 4-11
Assembly Instructions for 37° (JIC) Flare Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Assembly Instructions for O-ring Face Seal (ORFS) Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS). . . . . . . . . . . . 4-19
Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Assembly Instructions for O-ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings . . . . . . . . . . . . . . . . . . . 4-31
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends. . . . . . . . . . . . . 4-38
Assembly instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Assembly Instructions for Flange Connections: (FL61 and FL62) . . . . . . . . . . . . . . . . . . . . . . . 4-47
Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
FFWR and TFFT Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
O-ring Installation (Replacement). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.9 Hydraulic Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Main Hydraulic Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Flow Divider Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Leveling Jack Directional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Leveling Jack Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Pressure Relief Valve - Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4.10 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Gear Pump Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

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4.11 Axial HI 45 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

General Repair Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Removing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Electric Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Shaft Seal, Roller Bearing & Shaft Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Charge Check/HPRV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Charge Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Pressure Limiter Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4.12 Charge Pump Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4.13 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4.14 Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Oscillating Axle Cylinder Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
4.15 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
SECTION 5 - JLG CONTROL SYSTEM
5.1 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
To Connect the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Analyzer Menu Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2 Diagnostic Troubleshooting codes (DTC’s) and Flash Codes Description . . . . . . . . . . . . . . . . . . . . 5-9
5.3 Chassis Tilt Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.4 Location Of Additional Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.5 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Chassis Tilt Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Oscillating Axle Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Set Stow Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.6 Service Mode Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
ECM Override (Dual Fuel Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Elevation Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
EEPROM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Allow Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Allow Leveling Jack Retract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.7 Machine Configuration and Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
SECTION 6 - LSS SETUP/CALIBRATION/SERVICE
6.1 Connecting the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Help Menu & Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.5 Machine Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.6 Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.7 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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6.8 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Min/Max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Resistance Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Continuity Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Current Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Continuity Measurement Over Long Distances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
7.3 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Installation of Dielectric Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
AMP Mate-N-Lok. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
DIN Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Brad Harrison / Phoenix Contact M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Engine Control unit connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Sealed Enclosures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
MIL-C-5015 SPEC Connector’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Molex CMC Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
7.4 Applying Silicone Dielectric Compound To Amp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
7.5 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
DT/DTP Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
HD30/HDP20 Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
7.6 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Basic check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Leveling Jacks Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Automatic Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
7.7 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

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LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-2. Hydraulic Oil Operating Temperature Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-3. Engine Oil Operating Temperature Specifications - Kubota (Dual Fuel Engine) . . . . . . . . . . . . . .1-7
1-4. Engine Oil Operating Temperature Specifications - Kubota (Diesel Engine) . . . . . . . . . . . . . . . . .1-8
1-5. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-6. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-7. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1-8. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1-9. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
2-1. Scissor Arm - Safety Prop Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-2. Safety Prop Actuator Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-3. Service Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-4. Kubota Dual Fuel (WG972-GL-E4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-5. Kubota Diesel (D1305-E3B - Stage IIIA and D1305-E4B - T4F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
3-1. Drive Assembly (Fairfield/Sauer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Drive Hub (Cross-Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-3. Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. Cluster Gear Punch Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-5. Drive Motor Cross Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-6. Removing the Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-7. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-8. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-9. Plugs, Fittings, and Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-10. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-11. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-12. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-13. Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-14. Shaft & Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-15. Swash Plate & Servo Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-16. Cylinder Kit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-17. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3-18. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3-19. Swash Plate and Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3-20. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3-21. Cylinder Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3-22. Servo Spring and Minimum Angle Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3-23. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-24. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-25. Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
3-26. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
3-27. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
3-28. Axle Assembly (Fixed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3-29. Axle Assembly (Oscillating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
3-30. Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
3-31. Axle Lockout Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3-32. Leveling Jack Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3-32. Leveling Jacks Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
3-33. Platform Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
3-34. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
3-35. Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-36. Scissor Arm - Hose and Wiring Routing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
3-37. Scissor Arm Component Assembly 1 of 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
3-38. Scissor Arm Component Assembly 2 of 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
3-39. Left Side - Engine Compartment Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48

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3-40. Right Side - Hydraulic/Fuel Compartment Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

3-41. Ground Control Station Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3-42. Ground Control Station Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-43. Optional Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-44. Battery Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-45. Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-46. Hydraulic Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3-47. Engine Swing Out Tray Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-48. Engine Tray In Swing Out Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-49. AC Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3-50. Exhaust System (Kubota Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3-51. Air Cleaner System (Kobota Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3-52. Radiator Installation (All Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3-53. Duel Fuel Engine - Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-54. Duel Fuel Engine Compartment - Electrical Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-55. Diesel Engine Compartment - Electrical Component Locations (T4F and CE) . . . . . . . . . . . . . . . . 3-63
3-56. Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-57. Pump Coupling Assembly (All Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-58. Engine Removal (All Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
4-1. NPTF thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-2. BSPT thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-3. JIC Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4. SAE Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-5. ORFS Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-6. MTBL-MBTS Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-7. Bulkhead Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-8. MFF-BSPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-9. ORB-MPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-10. Torque Wrench Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-11. Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4-12. FFWR Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
4-13. Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4-14. Hydraulic Compartment Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
4-15. Main Valve Port Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4-16. Flow Divider Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4-17. Leveling Jack Directional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4-18. Leveling Jack Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-19. Tandem Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4-20. Axial HI 45 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
4-21. Axial HI 45 Pump - Cross Section View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4-22. Charge Pump Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4-23. Lift Cylinder Holding Valve and Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4-24. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4-25. Lift Cylinder Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4-26. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4-27. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4-28. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4-29. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4-30. Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4-31. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-32. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-33. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-34. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4-35. Seating the Tapered Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4-36. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4-37. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4-38. Lift Cylinder (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4-39. Lift Cylinder (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

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4-40. Lift Cylinder Valve Cartridge Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-80

4-41. Oscillating Axle Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-81
4-41. Leveling Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-82
4-42. Leveling Jack Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-83
4-43. Oscillating Axle Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84
4-44. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-85
4-45. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-86
5-1. Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-2. Hand-Held Analyzer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-3. Analyzer Menu Flow Chart (Version P1.1) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4. Analyzer Menu Flow Chart (Version P1.1) - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-5. Analyzer Menu Flow Chart (Version P1.1) - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-6. Chassis Tilt Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-7. Chassis Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-8. Chassis Sensor Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
6-1. Load Sensing System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6-2. LSS Module Load Cell Connector Pinout (J5, J6, J7, J8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
6-3. LRT Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
7-2. Resistance Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
7-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
7-5. Application to Plug/Male Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
7-6. Use of Seal Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
7-7. Brad-Harrison M12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
7-8. Phoenix Contact M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
7-9. AMP Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
7-10. Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
7-11. Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
7-12. Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
7-13. Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
7-14. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
7-15. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
7-16. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
7-17. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
7-18. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
7-19. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
7-20. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
7-21. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
7-22. Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

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LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 7500W Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 4000W Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-6 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-9 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-10 Mobilfluid 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-11 Mobil DTE 10 Excel 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-12 UCon Hydrolube HP-5046. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-13 Mobil EAL 224H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-14 Mobil SHC Hydraulic EAL 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-15 Mobil EAL ENVIROSYN H 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-16 Main Control Valve Relief Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-17 Cylinder Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-18 Kubota Diesel (D1305-E4B - T4F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-19 Kubota (D1305-E3B - Stage IIIA - Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-20 Kubota (WG972-GL-E4 - Dual Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-21 Maximum Cutout Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-22 Tilt Cutout Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
2-1 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 Preventive Maintenance & Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2-3 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 Drive Hub Part Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-3 Excessive Noise and/or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-4 System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-5 Won’t Shift or Slow to Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-6 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-7 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3-8 Cylinder Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3-9 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-10 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-11 AC Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
4-1 NPTF Pipe Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4-2 BSPT Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4-3 37° Flare (JIC)Thread - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4-4 37° Flare (JIC)Thread - Aluminum/Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-5 45° Flare (SAE) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-6 45° Flare (SAE) - Aluminum/Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-7 O-ring Face Seal (ORFS) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4-8 O-ring Face Seal (ORFS) - Aluminum/Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4-9 DIN 24°Cone (MBTL & MBTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
4-10 Bulkhead Fittings (BH) - INCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
4-11 Bulkhead Fittings (BH) - METRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
4-12 O-ring Boss (ORB) - Table 1 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
4-13 O-ring Boss (ORB) - Table 2 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
4-14 O-ring Boss (ORB) - Table 3 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
4-15 O-ring Boss (ORB) - Table 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
4-16 O-ring Boss (ORB) - Table 5 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4-17 O-ring Boss (ORB) - Table 6 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
4-18 Metric Flat Face Port (MFF) - L Series - Table 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

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4-19 Metric Flat Face Port (MFF) - L Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

4-20 Metric Flat Face Port (MFF) - L Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-21 Metric Flat Face Port (MFF) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4-22 Metric Flat Face Port (MFF) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4-23 Metric Flat Face Port (MFF) - L Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4-24 Metric Pipe Parallel O-ring Boss (MPP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4-26 British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4-27 British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4-29 British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4-30 British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4-31 Flange Code (FL61 & FL62) -Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4-32 Flange Code (FL61 & FL62) - Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4-33 Main Valve Port Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4-34 Main Valve Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4-35 Main Valve Porting Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4-36 Leveling Jack Directional Valve Torque Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-37 Leveling Jack Valves Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-38 Gear Pump Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4-39 Gear Pump - Dual Fuel - Gas/LPG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4-40 Axial HI 45 Pump Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
5-1 DTC and Flash Code Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-2 Chassis Tilt Sensor Harness (SN3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-3 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-4 Machine Tilt Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-5 Machine Model Personality Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
6-1 LSS Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-4 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-5 LSS Troubleshooting Chart - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-6 LSS Troubleshooting Chart - Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-7 LSS Troubleshooting Chart - Measurement Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-8 LSS Troubleshooting Chart - Host System Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-9 LSS Module System Interface Connector - Power & Digital (J1 - Grey) . . . . . . . . . . . . . . . . . . . . . . . 6-11
6-10 LSS Module System Interface Connector – Communication (J1 - Black) . . . . . . . . . . . . . . . . . . . . . 6-11
6-11 LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

xii 3121781
 SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 SPECIFICATIONS Table 1-1. Operating Specifications

Model 530LRT
Operating Specifications Outside Turning Radius 19.76 ft. (6.023 m)
Table 1-1. Operating Specifications
Gross Vehicle Weight
Model 530LRT Dual Fuel/Diesel -
ANSI/ANSI Export/CSA/CE
Maximum Occupants 6 w/ One Extension: 17,000 lb. (7711 kg)
Maximum Workload (Capacity): w/Two Extensions: 17,300 lb. (7847 kg)
Main Platform: 1500 lb. (680 kg) w/Mega Deck: 17,800 lb (8074 kg)
Max. on Extension (Each): 500 lb. (227 kg)
Note: Certain options or country standards
Maximum Stowed Travel Grade - increase weight.
40% (22°)
Gradeability:
Maximum Stowed Travel Grade -
Sideslope:
5° Generator Specifications (If Equipped)
Maximum Platform Working Height 53 ft. (16.15 m) Table 1-2. 7500W Generator Specifications
Maximum Drive Height 32 ft. (9.8 m)
Type: Brush Type, Synchronous, Revolving Field
Maximum Drive Speed
Platform Lowered: High 3.5 mph (5.6 kph) Regulation:
Mid 1.5 mph (2.4 kph) 3 Phase: 240 Volt, 7.5 Kw, 18.3 Amps, 1.0 pf
Low 0.7 mph (1.1 kph) 1 Phase: 240 Volt, 6 K w, 26 Amps, 1.0 pf
(> 14 Ft.) Platform Elevated: 0.5 mph (0.8 kph) 1 Phase: 120 Volt, 6 Kw, 50 Amps, 1.0 pf
Lift Up Speed (No Load) Peak: 3 Phase - 8.5 Kw, - 1 Phase - 6.0 Kw
65 seconds Max Rated Temperature: 104 F (40C)
(Stowed to Full Height)
Lift Down Speed (No Load)
60 seconds
(Full Height to Stowed) Table 1-3. 4000W Generator Specifications
Maximum Wind Speed 28 mph (12.5 m/s)
Type: Brush Type, Synchronous, Revolving Field
Maximum Horizontal Manual Side Force:
ANSI/ANSI EXPORT: 300 lb force (1335 N) Regulation:
CE: 90 lb force (400 N) 1 Phase: 120/240 Volt, 4 Kw, 20 Amps, 1.0 pf
Peak: 4.0 Kw
Maximum Tire Load (Each) 5500 lb. (2500 kg)
Max Rated Temperature: 104 F (40C)
Ground Bearing Pressure
w/Standard tires 26.5 psi (1.86 kg/cm2)
Leveling Jack Bearing
Pressure 70 psi (4.92 kg/cm2)
Hydraulic System Pressure
Main Relief: 2700 psi (186 bar)
Steer Relief: 2500 psi (172 bar)
Electrical System Voltage 12 Volt
Inside Turning Radius 109.7 in (2.79 m)

3121781 1-1
 SECTION 1 - SPECIFICATIONS

Dimensional Data Tires

Table 1-6. Tire Specifications
Table 1-4. Dimensional Data
Ply Foam Fill Tire Wheel Nut
Size
530LRT Rating Assembly Rating Torque
Wheelbase 117 in. (297 cm) 12 x 16.5 90 PSI @
170 ft. lb.
Foam Filled (Non-Mark- 10 8,000 lb. (3700 kg) -
Ground Clearance (230 Nm)
14.1in (35.7cm) ing) Static Load
(center/platform stowed)
90 PSI @
Machine Height 12 x 16.5 170 ft. lb.
125 in. (317.5 cm) 10 8,000 lb. (3700 kg) -
(top of rails/platform stowed) Foam Filled (230 Nm)
Static Load
Machine Width 90.8 in. (230 cm)
IN395/45/D20 90 PSI @
Machine Length 170 ft. lb.
192.2 in. (488.3 cm) Foam Filled (Non- 14 14,740 lb. (6700 kg) -
(leveling jack to leveling jack) (230 Nm)
Marking) Static Load
90 PSI @
Capacities IN395/45/D20 170 ft. lb.
14 14,740 lb. (6700 kg) -
Foam Filled (230 Nm)
Static Load
Table 1-5. Capacities

Fuel Tank Capacity Diesel: 22 gal (83.3 L)

Critical Stability Weights
Gasoline: 22 gal (83.3 L)
LP Tank: 43.5 lb. (20 kg)
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF-
Hydraulic Tank 32.3 gal (122.2 L) FERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: FILLED TIRES,
ENGINE) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Drive Information Table 1-7. Critical Stability Weights

Model 530LRT Component 530LRT

High Drive, Forward, Range 4-5 (sec/25ft) Wheel and Tire (each)
High Drive, Reverse, Range 4-5 (sec/25ft) 12x16.5 - Foam Filled 328 lb. (149 kg)
395/45/D20 - Foam Filled 381 lb. (173 kg)
Elevation Drive, Platform Height 32 ft. (9.75 m)
Engine Only (Kubota - Diesel) 209 lb. (95.1 kg)
Elevated Drive, F/R, Range 34 (sec/25ft)
Engine Only (Kubota - Gas/LP) 171 lb. (77.7 kg)
Gradeability Requirement 40%
Battery 66 lb. (30 kg)

Steering Information Major Component Weights

Table 1-8. Major Component Weights
Model 530LRT
Toe In / Out, (+/-) Max 0.8 in. (20.32 mm) Component Weight
Steer Angle, Inside Tire 42-46 degrees Platform Single Ext: 993.6 lb. (450.7 kg)
Steer Angle, Outside Tire 32-34 degrees Dual Ext: 993.6 lb. (450.7 kg)
Mega: 1,172.2 lb. (531.7 kg)
Platform Extension (all) 300 lb. (136.1 kg)
Arms (with cylinders): 9,892.1 lb. (4491 kg)
Chassis: 3628 lb. (1645.7 kg)
Chassis Counterweight: 1000 lb. (456 kg)
Chassis with Foam Filled Tires: 5152 lb. (2337 kg)

1-2 3121781
 SECTION 1 - SPECIFICATIONS

1.2 SERIAL NUMBER LOCATIONS 1.3 LUBRICATION

For machine identification, a serial number plate is NOTE: Hydraulic oils must have anti-wear qualities at least
affixed to the machine. The plate is located at the rear of to API Service Classification GL-3, and sufficient
the machine on the center of the axle. In addition, chemical stability for mobile hydraulic system ser-
should the serial number plate be damaged or missing, vice.
the machine serial number is stamped onto the lip of
the rear axle.
NOTE: Aside from JLG recommendations, it is not advisable
to mix oils of different brands or types, as they may
not contain the same required additives or be of
comparable viscosities.

Table 1-9. Lubrication Specifications

KEY SPECIFICATIONS
Multipurpose Grease - Having a minimum dripping point
of 350° F. Excellent water resistance and adhesive qualities,
MPG
and being of extreme pressure type. (Timken OK 40 pounds
minimum.)
Extreme Pressure Gear Lube (oil) - Meeting API service clas-
EPGL
sification GL-5 or MIL-Spec MIL-L-2105.
EO Engine Oil (crankcase)
HO Hydraulic Oil

Hydraulic Oil Specifications

1 Table 1-10. Mobilfluid 424

1. Serial Number Plate Inspection Data Recommended Optional

2. Stamped Serial Number SAE Grade 10W-30 10W-20
Gravity, API 29.0 29.3
Figure 1-1. Serial Number Location
Density, LB/GAL, 60° F 7.35 7.3
Flash Point, ° F(° C) 442(228) 380(193)
Pour Point, ° F(° C) -46 (-43) -30(-34)
Viscosity
Brookfield, cP at -18° C 2700
Brookfield, cP at 0° F 2500
Viscosity, cST at 40°C 55 52.1
Viscosity, cST at 100°C 9.3 8.95
Viscosity Index 152 152
Viscosity, Sus at 100°F 26.0
Viscosity, Sus at 210°F 56.8
Color, ASTM D 1500 3.0

3121781 1-3
 SECTION 1 - SPECIFICATIONS

Table 1-11. Mobil DTE 10 Excel 32 Table 1-14. Mobil SHC Hydraulic EAL 46

ISO Viscosity Grade 32 ISO Viscosity Grade 46

Pour Point, °C Max. -54 Density@15° C 0.93
Flash Point, °C Min. 250 Pour Point, °C (°F), ASTM D 97 -33(-27)
Viscosity Flash Point, °C (°F), Min., ASTM D 97 298(568)
cSt @ 40° C 32.7 Operating Temp °C(°F) -29°(-20) to 93(200)
cSt @ 100° C 6.63 Viscosity
cSt @ 100° F 32.7 ASTM D 445 cST 40°C 43.3
cSt @ 212° F 6.63 ASTM D 445 cST 100°C 7.7
Viscosity Index 164 Viscosity Index 149
Density (Kg/l) @ 15°C 0.8468
Density (lb/in³) @ 60°F 0.0305 Table 1-15. Mobil EAL ENVIROSYN H 46

ISO Viscosity Grade 46

Table 1-12. UCon Hydrolube HP-5046
Density@15° C 0.874
pH 9.1 Pour Point, °C (°F), ASTM D 97 -45°C(-49)
Specific Gravity, 20/20°F 1.082 Flash Point, °C (°F), Min., ASTM D 97 260°C(500)
Pour Point, °C(°F) <-50(<58) Operating Temp °C(°F) -29°(-20) to 93(200)
Appearance Red Liquid Viscosity
Viscosity ASTM D 445 cST 40°C 48.8
at 0°C (32°F) 340cST(1600SUS) ASTM D 445 cST 100°C 7.8
at 40°C (104°F) 46cST(215SUS) Viscosity Index 145
at 65°C (150°F) 22cST(106SUS)
Viscosity Index 170 1.4 HYDRAULIC PRESSURE SETTINGS

Table 1-13. Mobil EAL 224H Table 1-16. Main Control Valve Relief Settings

Description 530LRT
Type Biodegradable Vegetable Oil
ISO Viscosity Grade 32/46 Main Relief 2700 psi (186 bar)
Specific Gravity 0.922 Steer Relief 2500 psi (172 bar)
Pour Point °C(°F) -32°(-25°)
Flash Point °C(°F) 220°(428°) 1.5 HYDRAULIC CYLINDER SPECIFICATIONS
Rust Protection, ASTM D 665A & BB Pass Color, ASTM D 1500 Max 2.0 Table 1-17. Cylinder Specifications
Operating Temp -17°-162°C (0-180°F) (Store above14°C (32°F)) Description Bore Stroke Rod Dia
Viscosity Lift Cylinders Upper: 3.90 in. 84.125 in. 3.30 in.
ASTM D445 cST 40°C 37 (100 mm) (2137 mm) (85 mm)
ASTM D445 cST 100°C 8.4 Lower: 4.70 in. 84.125 in. 3.5 in.
(120 mm) (2137 mm) (90 mm)
Viscosity Index, ASTM D 2270 213
Leveling Jack Cylinder 2.5 in. 27 in. 2 in.
(63 mm) (685.8 mm) (50 mm)
RAM Lockout Cylinder 3.62 in. 4 in. 3.5 in.
(Oscillating Axle) (92 mm) (101.6 mm) (88.9 mm)
Steer Cylinder 2.75 in. 8.94 in. 1.97 in.
(70 mm) (227.1 mm) (50 mm)

1-4 3121781
 SECTION 1 - SPECIFICATIONS

1.6 ENGINE SPECIFICATIONS Table 1-20. Kubota (WG972-GL-E4 - Dual Fuel)

Table 1-18. Kubota Diesel (D1305-E4B - T4F) Emissions U.S. EPA Phase 3 and CARB SSI
Fuel Type: Gasoline - 87 Octane minium
Emissions CARB and EPA Tier 4 Final - Ethanol/Gas Mix-10% max.
Fuel Type: Diesel: - Methanol/Gas Mix-5% max.
- Low Sulfur (<500 ppm) LP - Liquid Petrolium
- Ultra Low Sulfur (15 ppm) No. of Cylinders 3
(Recommended)
Oil Pan Capacity 0.90 Gal. (3.4 L)
- up to 5% biodiesel
Engine RPM Control Electronic - ECM
No. of Cylinders 3
Low RPM Set 1200 RPM
Oil Pan Capacity 1.51 Gal. (5.7 L)
High RPM Set 3500 RPM
Engine RPM Control Mechanical
Alternator 60 Amp, 12V, Belt Drive
Low RPM Set 1200 RPM
Battery 112 Amp-Hour, 950 Cold Cranking
High RPM Set 2600 RPM
Amps, 12 VDC
Alternator 60 Amp, 12V, Belt Drive
Fuel Consumption:
Battery 112 Amp-Hour, 950 Cold Cranking Amps,
12 VDC
Low RPM 0.38 gal/hr (1.45 L/hr) - Gas
Fuel Consumption: Low RPM 0.41 gal/hr (1.5 L/hr) 2.07 lb/hr (0.94 kg/hr) - LP
High RPM 2.0 gal/hr (7.6 L/hr)
Displacement 1.261 L (77 cu. in.) High RPM 1.76 gal/hr (6.66 L/hr) - Gas
Gross Power 24.8 Hp (18.5 Kw) @ 2600 RPM 9.77 lb/hr (4.43 kg/hr) - LP
Gross Torque 59.1 Ft. lb. (80.1 Nm) @ 1700 RPM Displacement 0.962L (58.7 cu. in.)
Gross Power GAS - 30.6 Hp (22.8 Kw) @ 3500 RPM
Table 1-19. Kubota (D1305-E3B - Stage IIIA - Diesel) LP - 30.0 Hp (21.6 Kw) @ 3500 RPM
Gross Torque GAS - 49.1 Ft.lb (66.6 Nm) @ 2400
Emissions China Stage III and EU Stage IIIA Certifica-
RPM
tion
LP - 48.8 Ft.lb (66.2 Nm) @ 1800 RPM
Fuel Type: Diesel:
- Low Sulfur (<500 ppm)
- Ultra Low Sulfur (15 ppm)
(Recommended)
- up to 5% biodiesel
No. of Cylinders 3
Oil Pan Capacity 1.51 Gal. (5.7 L)
Engine RPM Control Mechanical
Low RPM Set 1200 RPM
High RPM Set 3000 RPM
Alternator 60 Amp, 12V, Belt Drive
Battery 112 Amp-Hour, 950 Cold Cranking Amps,
12 VDC
Fuel Consumption:
Low RPM 0.41 gal/hr (1.5 L/hr)
High RPM 2.0 gal/hr (7.6 L/hr)
Displacement 1.261 L (77 cu. in.)
Gross Power 29.1 Hp (21.7 Kw) @ 3000 RPM
Gross Torque 59.1 Ft. lb. (80.1 Nm) @ 2000 RPM

3121781 1-5
 SECTION 1 - SPECIFICATIONS

1.7 PLATFORM HEIGHT/TILT LIMIT SETTINGS

The machine is equipped with the following limit
switches:
Rotary Position Sensor - High drive speed is cut out
when platform is raised above the preset heights listed in
Table 1-21, Maximum Cutout Height.

Table 1-21. Maximum Cutout Height

Model High Drive Cutout

530LRT 14 ft (4.26 m)

Tilt Alarm - An alarm sounds and a warning light is illu-

minated when the machine is operated on a slope that
exceeds the values in Table 1-22, Tilt Cutout Settings.
The lift and drive functions will cut out at these set
heights.
NOTE: Alarm only sounds when above elevation.
If the machine is operated beyond the specified
slope, with the platform completely lowered, only
the warning light is illuminated.

Table 1-22. Tilt Cutout Settings

Leveling Jacks Set Leveling Jacks NOT Set Lift Up is prevented

Drive is prevented
when elevated
when elevated
Market beyond the following
Front to Back Side to Side Front to Back Side to Side beyond the
heights without
following heights:
leveling jacks set:
ANSI,ANSI Exp., 5° to 32 ft (9.75 m) 3° to 32 ft (9.75 m)
1.5° to 53 ft (16 m) 1.5° to 53 ft (16 m) 32 ft 45 ft
CE, AUS, Korea 1.3° to 45 ft (13.7 m) 1.3° to 45 ft (13.7 m)
CSA 1.5° to 53 ft (16 m) 1.5° to 53 ft (16 m) 3° to 32 ft (9.75 m) 3° to 32 ft (9.75 m) 32 ft 32 ft

1-6 3121781
 SECTION 1 - SPECIFICATIONS

4150740_B_Hydraulic

Figure 1-2. Hydraulic Oil Operating Temperature Specifications

1001204714_A_Dual Fuel

Figure 1-3. Engine Oil Operating Temperature Specifications - Kubota (Dual Fuel Engine)

3121781 1-7
 SECTION 1 - SPECIFICATIONS

1001120075_C_Diesel

Figure 1-4. Engine Oil Operating Temperature Specifications - Kubota (Diesel Engine)

1-8 3121781
 SECTION 1 - SPECIFICATIONS

1.8 TORQUE CHARTS

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

3121781 1-9
 SECTION 1 - SPECIFICATIONS

Figure 1-6. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)

1-10 3121781
 SECTION 1 - SPECIFICATIONS

Figure 1-7. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)

3121781 1-11
 SECTION 1 - SPECIFICATIONS

Figure 1-8. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)

1-12 3121781
 SECTION 1 - SPECIFICATIONS

Figure 1-9. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)

3121781 1-13
 SECTION 1 - SPECIFICATIONS

NOTES:

1-14 3121781
 SECTION 2 - GENERAL

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND 3 months; or when purchased used. The frequency of
this inspection must be increased as environment,
MAINTENANCE severity and frequency of usage requires.

General Reference the JLG Pre-Delivery and Frequent Inspection

Form and the Inspection and Preventative Maintenance
This section provides the necessary information needed Schedule for items requiring inspection during the per-
by those personnel that are responsible to place the formance of these inspections. Reference the appropri-
machine in operation readiness and maintain its safe ate areas of this manual for servicing and maintenance
operating condition. For maximum service life and safe procedures.
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the Annual Machine Inspection
machine into service. With proper care, maintenance
and inspections performed per JLG's recommendations JLG recommends that an annual machine inspection be
with any and all discrepancies corrected, this product performed by a Factory-Certified Service Technician on
will be fit for continued use. an annual basis, no later than thirteen (13) months from
the date of the prior Annual Machine Inspection. JLG
Preparation, Inspection, and Maintenance Industries, Inc. recognizes a Factory-Certified Service
Technician as a person who has successfully completed
It is important to establish and conform to a compre- the JLG Service Training School for the subject JLG prod-
hensive inspection and preventive maintenance pro- uct model. Reference the machine Service and Mainte-
gram. The following table outlines the periodic machine nance Manual and appropriate JLG inspection form for
inspections and maintenance recommended by JLG performance of this inspection.
Industries, Inc. Consult your national, regional, or local
Reference the JLG Annual Machine Inspection Form and
regulations for further requirements for aerial work plat-
the Inspection and Preventative Maintenance Schedule
forms. The frequency of inspections and maintenance
for items requiring inspection during the performance
must be increased as environment, severity and fre-
of this inspection. Reference the appropriate areas of
quency of usage requires.
this manual for servicing and maintenance procedures.
Pre-Start Inspection For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated owner-
It is the User’s or Operator’s primary responsibility to
ship information for each machine. When performing
perform a Pre-Start Inspection of the machine prior to each Annual Machine Inspection, notify JLG Industries,
use daily or at each change of operator. Reference the Inc. of the current machine ownership.
Operator’s and Safety Manual for completion proce-
dures for the Pre-Start Inspection. The Operator and Preventative Maintenance
Safety Manual must be read in its entirety and under-
stood prior to performing the Pre-Start Inspection. In conjunction with the specified inspections, mainte-
nance shall be performed by a qualified JLG equipment
Pre-Delivery Inspection and Frequent Inspection mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of
The Pre-Delivery Inspection and Frequent Inspection
a recognized degree, certificate, extensive knowledge,
shall be performed by a qualified JLG equipment training, or experience, has successfully demonstrated
mechanic. JLG Industries, Inc. recognizes a qualified JLG the ability and proficiency to service, repair, and main-
equipment mechanic as a person who, by possession of
tain the subject JLG product model.
a recognized degree, certificate, extensive knowledge,
training, or experience, has successfully demonstrated Reference the Preventative Maintenance Schedule and
the ability and proficiency to service, repair, and main- the appropriate areas of this manual for servicing and
tain the subject JLG product model. maintenance procedures. The frequency of service and
maintenance must be increased as environment, sever-
The Pre-Delivery Inspection and Frequent Inspection ity and frequency of usage requires.
procedures are performed in the same manner, but at
different times. The Pre-Delivery Inspection shall be per-
formed prior to each sale, lease, or rental delivery. The
Frequent Inspection shall be accomplished for each
machine in service for 3 months or 150 hours (which-
ever comes first); out of service for a period of more than

3121781 2-1
 SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Prior to use each day; or
User or Operator User or Operator Operator and Safety Manual
Inspection At each Operator change.
Pre-Delivery Prior to each sale, lease, or Service and Maintenance Manual and
Owner, Dealer, or User Qualified JLG Mechanic
Inspection rental delivery. applicable JLG inspection form.
In service for 3 months or 150 hours, whichever
Frequent Service and Maintenance Manual and
comes first; or Out of service for a period of more Owner, Dealer, or User Qualified JLG Mechanic
Inspection applicable JLG inspection form.
than 3 months; or Purchased used.
Annual Annually, no later than 13 months from the date Factory-Certified Service
Service and Maintenance Manual and
Machine of the prior inspection. Owner, Dealer, or User Technician or a Qualified
applicable JLG inspection form.
Inspection JLG Mechanic
Preventative At intervals as specified in the Service and Main-
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance tenance Manual.

2.2 PREVENTIVE MAINTENANCE AND INSPECTION Maintenance and Inspection Schedule Codes
SCHEDULE 1. Check for proper and secure installation.
2. Visual inspection for damage, cracks, distortion, or
The preventive maintenance and inspection checks are excessive wear.
listed and defined in the following table. This table is
divided into two basic parts, the “AREA” to be inspected 3. Check for proper adjustment.
and the “INTERVAL” at which the inspection is to take 4. Check for cracked or broken welds.
place. Under the “AREA” portion of the table, the various 5. Operates properly.
systems along with the components that make up that
6. Returns to neutral or “off” position when released.
system are listed. The “INTERVAL” portion of the table is
divided into two columns representing the various 7. Clean and free of debris.
inspection time periods. The numbers listed within the 8. Interlocks function properly.
interval column represent the applicable inspection 9. Check for signs of leakage.
code for which that component is to be checked.
10. Decals installed and legible.
The checks and services listed in this schedule are not 11. Check for proper fluid level.
intended to replace any local or regional regulations
12. Check for chafing and proper routing.
that may pertain to this type of equipment nor should
the lists be considered as all inclusive. Variances in inter- 13. Check for proper tolerances.
val times may occur due to climate and/or conditions 14. Properly lubricated.
and depending on the location and use of the machine. 15. Torqued to proper specification.
16. No gouges, excessive wear, or cords showing.
17. Properly inflated and seated around rim.
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION
BE PERFORMED IN ACCORDANCE WITH THE "ANNUAL MACHINE 18. Proper and authorized components.
INSPECTION REPORT” FORM. 19. Fully charged.
20. No loose connections, corrosion, or abrasions.
NOTE: This machine requires periodic safety and mainte-
nance inspections by a JLG Dealer. A decal located 21. Verify.
on the frame affords a place to record (stamp) 22. Perform.
inspection dates. Notify dealer if inspection is over- 23. Sealed properly.
due. 24. Overrides platform controls.
25. Remove pump motor cover and blow away any
brush wear dust from cover, brushes, and brush
holder assembly.
26. Replace.

2-2 3121781
 SECTION 2 - GENERAL

Table 2-2. Preventive Maintenance & Inspection Schedule

INTERVAL

AREA ON MACHINE PRE-DELIVERY (a) ANNUAL (c)

OR FREQUENT (b) (YEARLY)
INSPECTION INSPECTION
FUNCTIONS/CONTROLS
Platform Controls 5, 6, 7 5, 6, 7
Ground Controls 5, 6 5, 6
Function Control, Guards, or Detents 5 5
Function Enable System 5, 8 5, 8
Emergency Stop Switches (Ground & Platform) 5 5
Manual Descent or Auxiliary Power 5 5
PLATFORM ASSEMBLY
Platform 1 1
Guard Rails 1, 2, 4 1, 2, 4
Gate 1, 5 1, 5
Floor 1, 2 1, 2
Lanyard Anchorage Point 1, 4, 10 1, 4, 10
SCISSOR ARMS
Scissor Arms 1, 2, 4 1, 2, 4
Arm Safety Prop 1, 5 1, 5
Cylinder Pins, Pivot Pins & Attaching Hardware 1, 2 1, 2
Arm Pins, Wear Pads & Attaching Hardware 1, 2 1, 2
CHASSIS ASSEMBLY
Side-Compartment Door Installation 1, 5,7 1, 5, 7
Static Strap 1 1
Wheel and Tire Assemblies 2, 15, 16 2, 15, 16
Drive Motors 1, 7, 9 1, 7, 9
Platform Ladder 1, 7 1, 7
Drive Brakes 1, 7 1, 7
Drive Torque Hubs 1, 7 1, 7
Engine Mounts 1 1
Battery 9 18
Engine Oil 5 5
Exhaust System 1, 5 1, 5
Fuel Tank 1, 9 1, 9
Air Cleaner**** 7 26

3121781 2-3
 SECTION 2 - GENERAL

Table 2-2. Preventive Maintenance & Inspection Schedule (Continued)

INTERVAL

AREA ON MACHINE PRE-DELIVERY (a) ANNUAL (c)

OR FREQUENT (b) (YEARLY)
INSPECTION INSPECTION
HYDRAULIC/ELECTRIC SYSTEM
Hydraulic Pump 1, 2, 9 1, 2, 9
Hydraulic Control Valves 1, 9 1, 9
Hydraulic Fluid*** 11 11
Hydraulic Filter* — 26
Hydraulic Hoses, Lines and Fittings 1, 9 1, 9
Hydraulic Oil Tank, Cap, and Breather 5, 7, 9 5, 7, 9
Hydraulic Cylinders (Steer and Lift) 2, 7, 9 2, 7, 9
GENERAL
Operation & Safety Manual in Storage Box 21 21
ANSI & AEM Handbooks in Storage Box (ANSI ONLY) 21 21
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
Annual Machine Inspection Due — 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21, 22
General Structural Condition and Welds 2, 4 2, 4
All Fasteners, Pins, Shields, and Covers 1, 2 1, 2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 22 22
Paint and Appearance 7 7
Notify JLG of change in Machine Ownership 22

* Replace Annually - JLG P/N - 70005423.

** Replace when system performance is degraded.
*** Every two years, drain and remove hydraulic oil reservoir, clean pick-up screen, refill with fresh hydraulic fluid.
**** Replace every six (6) months.

Footnotes
(a) Prior to each sale, lease, or delivery.
(b) In service for 3 months; or Out of service for 3
months or more; or Purchased used.
(c) Annually, no later than 13 months from the date of
the prior inspection.

2-4 3121781
 SECTION 2 - GENERAL

2.3 SERVICE AND GUIDELINES Component Disassembly and Reassembly

When disassembling or reassembling a component,
General complete the procedural steps in sequence. Do not par-
The following information is provided to assist you in tially disassemble or assemble one part, then start on
the use and application of servicing and maintenance another. Always recheck your work to assure that noth-
procedures contained in this book. ing has been overlooked. Do not make any adjustments,
other than those recommended, without obtaining
proper approval.
Safety and Workmanship
Your safety, and that of others, is the first consideration Pressure-Fit Parts
when engaging in the maintenance of equipment.
Always be conscious of weight. Never attempt to move When assembling pressure-fit parts, use an anti-seize or
heavy parts without the aid of a mechanical device. Do molybdenum disulfide base compound to lubricate the
not allow heavy objects to rest in an unstable position. mating surface.
When raising a portion of the equipment, ensure that
adequate support is provided. Bearings
Cleanliness 1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable
1. The most important single item in preserving the cleaning solvent and allow to drip dry. Compressed
long service life of a machine is to keep dirt and for- air can be used but do not spin the bearing.
eign materials out of the vital components. Precau- 2. Discard bearings if the races and balls (or rollers) are
tions have been taken to safeguard against this. pitted, scored, or burned.
Shields, covers, seals, and filters are provided to keep
air, fuel, and oil supplies clean; however, these items 3. If bearing is found to be serviceable, apply a light
must be maintained on a scheduled basis in order to coat of oil and wrap it in clean (waxed) paper. Do not
function properly. unwrap reusable or new bearings until they are
ready to install.
2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the openings 4. Lubricate new or used serviceable bearings before
and fittings themselves. As soon as a line or compo- installation. When pressing a bearing into a retainer
nent is disconnected, cap or cover all openings to or bore, apply pressure to the outer race. If the bear-
prevent entry of foreign matter. ing is to be installed on a shaft, apply pressure to the
inner race.
3. Clean and inspect all parts during servicing or main-
tenance, and assure that all passages and openings Gaskets
are unobstructed. Cover all parts to keep them clean.
Be sure all parts are clean before they are installed. Check that holes in gaskets align with openings in the
New parts should remain in their containers until mating parts. If it becomes necessary to hand-fabricate
they are ready to be used. a gasket, use gasket material or stock of equivalent
material and thickness. Be sure to cut holes in the right
Components Removal and Installation location, as blank gaskets can cause serious system
damage.
4. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains, Bolt Usage and Torque Application
cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being 1. Use bolts of proper length. A bolt which is too long
lifted. will bottom before the head is tight against its
related part. If a bolt is too short, there will not be
5. Should it be necessary to remove a component on an
enough thread area to engage and hold the part
angle, keep in mind that the capacity of an eyebolt or
properly. When replacing bolts, use only those hav-
similar bracket lessens, as the angle between the
ing the same specifications of the original, or one
supporting structure and the component becomes
which is equivalent.
less than 90°.
6. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc., have been
removed and that no adjacent parts are interfering.

3121781 2-5
 SECTION 2 - GENERAL

2. Unless specific torque requirements are given within 2.4 LUBRICATION AND INFORMATION
the text, standard torque values should be used on
heat-treated bolts, studs, and steel nuts, in accor- Hydraulic System
dance with recommended shop practices. (See
Torque Chart Section 1.) 1. The primary enemy of a hydraulic system is contami-
nation. Contaminants enter the system by various
Hydraulic Lines and Electrical Wiring means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
Clearly mark or tag hydraulic lines and electrical wiring,
etc., to enter when performing maintenance, or by
as well as their receptacles, when disconnecting or
permitting the pump to cavitate due to insufficient
removing them from the unit. This will assure that they
system warm-up or leaks in the pump supply (suc-
are correctly reinstalled.
tion) lines.
Hydraulic System 2. The design and manufacturing tolerances of the
component working parts are very close, therefore,
1. Keep the system clean. If evidence of metal or rubber even the smallest amount of dirt or foreign matter
particles are found in the hydraulic system, drain and entering a system can cause wear or damage to the
flush the entire system. components and generally results in faulty opera-
2. Disassemble and reassemble parts on clean work tion. Every precaution must be taken to keep hydrau-
surface. Clean all metal parts with non-flammable lic oil clean, including reserve oil in storage. Hydraulic
cleaning solvent. Lubricate components, as required, system filters should be checked, cleaned, and/or
to aid assembly. replaced as necessary, at the specified intervals
required in the Lubrication Chart in Section 1. Always
Lubrication examine filters for evidence of metal particles.

Service applicable components with the amount, type, 3. Cloudy oils indicate a high moisture content which
and grade of lubricant recommended in this manual, at permits organic growth, resulting in oxidation or cor-
the specified intervals. When recommended lubricants rosion. If this condition occurs, the system must be
are not available, consult your local supplier for an drained, flushed, and refilled with clean oil.
equivalent that meets or exceeds the specifications 4. It is not advisable to mix oils of different brands or
listed. types, as they may not contain the same required
additives or be of comparable viscosities. Good
Battery grade mineral oils, with viscosities suited to the
Clean battery, using a non-metallic brush and a solution ambient temperatures in which the machine is oper-
of baking soda and water. Rinse with clean water. After ating, are recommended for use.
cleaning, thoroughly dry battery and coat terminals NOTE: Metal particles may appear in the oil or filters of new
with an anti corrosion compound. machines due to the wear-in of meshing compo-
nents.
Lubrication and Servicing
Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section
1.

2-6 3121781
 SECTION 2 - GENERAL

Changing Hydraulic Oil 2.5 SERVICE MAINTENANCE COMPONENTS

1. Use of any of the recommended hydraulic oils elim-
inates the need for changing the oil on a regular Setting Scissor Arm Safety Prop
basis. However, filter elements must be changed
after the first 50 hours of operation and every 300
hours thereafter. If it is necessary to change the oil, THE SAFETY PROP MUST BE USED WHENEVER MAINTENANCE PER-
use only those oils meeting or exceeding the speci- FORMED ON THE MACHINE REQUIRES THE SCISSOR ARMS TO BE
fications appearing in this manual. If unable to RAISED.
obtain the same type of oil supplied with the
machine, consult local supplier for assistance in 1. To engage the safety props, raise the unloaded
selecting the proper equivalent. Avoid mixing platform high enough to allow the safety props to
petroleum and synthetic base oils. JLG Industries rotate vertically into position. (See Figure 2-1.)
recommends changing the hydraulic oil annually. 2. Rotate the rod keeper plate and release the safety
prop actuator rod at the front of the machine. (See
2. Use every precaution to keep the hydraulic oil Figure 2-2.)
clean. If the oil must be poured from the original
container into another, be sure to clean all possible 3. Lift the actuator rod (flat) up out of the slot in the
contaminants from the service container. Always keeper plate bracket and pull the actuator rod to
clean the mesh element of the filter and replace the align the safety props vertically with the scissor arm
cartridge any time the system oil is changed. center pins above and below the safety prop
mounting pins.
3. While the unit is shut down, a good preventive
maintenance measure is to make a thorough inspec- 4. Set the actuator rod (flat at the set position) into
tion of all hydraulic components, lines, fittings, etc., the slot on the keeper plate bracket and rotate the
as well as a functional check of each system, before keeper plate to lock the actuator rod in this posi-
placing the machine back in service. tion.

Lubrication Specifications 5. Lower the platform arms until the safety prop rests
on the scissor arm center pin mounts above and
Specified lubricants, as recommended by the compo- below the safety prop.
nent manufacturers, are always the best choice, how- Maintenance can now begin.
ever, multi-purpose greases usually have the qualities
which meet a variety of single purpose grease require-
ments. Should any question arise, regarding the use of
greases in maintenance stock, consult your local sup-
plier for evaluation. Refer to Section 1 for an explanation
of the lubricant key designations appearing in the Lubri-
cation Chart.
1

Figure 2-1. Scissor Arm - Safety Prop Assembly

1. Actuator Rod/Rod Keeper Plate. 3. Safety Prop in stowed position.
2. Safety Prop in set position.

To store the safety prop, raise the platform, release

the actuator rod from the keeper plate bracket, push
the safety prop rod so that the safety props are

3121781 2-7
 SECTION 2 - GENERAL

restored back to its stowed position. Lock the actua- General Maintenance Tips
tor rod in place with the keeper plate till next use.
NOTE: Be sure to lubricate like items on each side of
machine.
TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL MAINTE-
NOTE: Recommended lubricating intervals are based on
NANCE REQUIRING PLATFORM TO BE ELEVATED.
machine operations under normal conditions. For
machines used in multi-shift operations and/or
exposed to hostile environments or conditions,
lubrication frequencies must be increased accord-
ingly.

Operate hydraulic functions through one complete

cycle before checking hydraulic oil level in tank. Oil
should be visible in ADD sight window on hydraulic
tank. If oil is not visible, add oil until oil is visible in
both ADD and FULL sight windows on tank. Do not
1 overfill tank.

Any time the pump coupling is removed, coat

splines of coupling with Texaco Code 1912 grease
Figure 2-2. Safety Prop Actuator Rod prior to assembly.
1. Safety Prop Actuator 3. Rod Keeper Plate
Rod
2. Notch Flats on Rod

4 5
1 9 3
4

10
11 6
8 7 5
4 MAF04540

1. Fuel Tank - (Gasoline or Diesel) 5. Scissor Arm - Sliding Wear Pads 9. Fuel Filter/Fuel Pump - Kubota- Gasoline
2. Fuel Tank w/Shut-Off Valve - (LP Only) 6. Oil Change w/Filter - Kubota 10. Air Filter
3. Hydraulic Oil Tank 7. Fuel/Water Separator Filter - Kubota- Diesel 11. Engine Coolant
4. Drive Hubs 8. Hydraulic Charge Filter - Kubota - Diesel
Figure 2-3. Service Maintenance Components
NOTE: Platform ladders removed for illustrative purposes only.

2-8 3121781
 SECTION 2 - GENERAL

Fuel Tank Hydraulic Oil Tank

• Lube Point - Fill Cap/Fill Level

• Lube - HO - API service classification GL-3, Refer-
• Fuel - Diesel or Gasoline (Per Engine Type - Refer- ence - Figure 1-2., Hydraulic Oil Operating Temper-
ence Decal on Machine) ature Specifications
• Capacity - 22 gal (83.2 l) • Interval - Check oil every 10 hours of operation;
change oil every 2 years or 1200 hours of opera-
Drive Hub tion.

Hydraulic Charge Filter

• Lube Points - Fill Plugs (4)

• Lube - EPGL
• Interval - Every 2 years or 1200 hours

Scissor Arms - Sliding Wear Pads OAD00220

• Lube Points - 8 Sliding Wear Pads
• Lube - MPG • Lube Point(s) - Replaceable Element
• Interval - Every month or 50 hours. • Interval - Change after first 50 hours and after every
six months or 300 hours.

3121781 2-9
 SECTION 2 - GENERAL

Oil Change with Filter Fuel/Water Separator Filter (Diesel) - Kubota

Figure 2-4. Kubota Dual Fuel (WG972-GL-E4)

NOTE: Exhaust system shown removed for illustrative pur-

poses only. NOTE: Mounted inside engine cabinet on right-rear cabi-
• Lube Point(s) - Fill Cap/Spin-on Element net wall behind battery and exhaust pipe.
• Capacity - 0.9 Gal. (3.4 L) engine only • Lube Point(s) - Replaceable Element
• Lube - EO - Minimum API SL, Viscosity - See Figure • Interval (Filter) - Every Year or 600 hours of opera-
1-3., Engine Oil Operating Temperature Specifica- tion.
tions - Kubota (Dual Fuel Engine)
• Interval (Water Bowl) - Empty Daily. Loosen drain
• Interval - Every Year or 200 hours of operation cock on underside of fuel filter and allow all water
• Check oil level daily, maintain within marked level to drain into a container until clear fuel is visible.
(1)/Change in accordance with engine manual. Tighten drain.

Fuel Strainer (Diesel) - Kubota

Figure 2-5. Kubota Diesel (D1305-E3B - Stage IIIA and

D1305-E4B - T4F)
• Lube Point(s) - Fill Cap/Spin-on Element
NOTE: Mounted inside fuel/hydraulic cabinet on left-rear
• Capacity - 1.51 gal. (5.7 L) Engine Oil cabinet wall behind fuel tank.
• Lube - EO - Minimum API CF - Viscosity, See Figure
1-4., Engine Oil Operating Temperature Specifica- • Lube Point(s) - Replaceable Element
tions - Kubota (Diesel Engine)
• Interval - Every Year or 600 hours of operation
• Interval - Every Year or 200 hours of operation
• Check oil level daily, maintain within marked level
(1)/Change in accordance with engine manual.

2-10 3121781
 SECTION 2 - GENERAL

Fuel Filter (Gas) - Kubota Engine Coolant

NOTE: Mounted inside fuel/hydraulic cabinet on left-rear

cabinet wall behind fuel tank.
MAF06110

• Lube Point(s) - Replaceable Element • Lube Point - Fill Cap/Fill Level

• Interval - Every 6 months or 300 hours of opera- • Interval - Check coolant level daily. Ensure it is
tion between the “FULL” and “LOW” lines (1). If coolant
level is low, allow fluid to cool, then add as required.
Air Filter

• Lube Point(s) - Replaceable Primary Filter Element

(1) (Dry Type)
• Interval - Every 6 months or 300 hours of opera-
tion. Under severe operating conditions (such as a
very dusty work area) check condition of filter
more often.
• Once a week, squeeze the evacuator valve (2) on
bottom of air cleaner assembly to allow collected
debris to fall out of the air cleaner.

3121781 2-11
 SECTION 2 - GENERAL

2.6 CYLINDER DRIFT TEST 2.7 PINS AND COMPOSITE BEARING REPAIR
Maximum acceptable cylinder drift is to be measured GUIDELINES
using the following methods.
Filament wound bearings.

Platform Drift 1. Pinned joints should be disassembled and inspected if

the following occurs:
Measure the drift of the platform to the ground. Fully
a. Excessive sloppiness in joints.
extend the scissor arms from stowed position with the
rated load in the platform and power off. Maximum b. Noise originating from the joint during opera-
allowable drift is 2 in (5 cm) in 10 minutes. If the tion.
machine does not pass this test, proceed with the fol- 2. Filament wound bearings should be replaced if any
lowing. of the following is observed:

Cylinder Drift a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.
Table 2-3. Cylinder Drift c. Bearings that have moved or spun in their
housing.
MAX. ACCEPTABLE DRIFT
CYLINDER BORE DIAMETER d. Debris embedded in liner surface.
IN 10 MINUTES
3. Pins should be replaced if any of the following is
inches mm inches mm
observed (pin should be properly cleaned prior to
3 76.2 0.026 0.66 inspection):
3.5 89 0.019 0.48 a. Detectable wear in the bearing area.
4 101.6 0.015 0.38 b. Flaking, pealing, scoring, or scratches on the
5 127 0.009 0.22 pin surface.
6 152.4 0.006 0.15 c. Rusting of the pin in the bearing area.
7 177.8 0.005 0.13 4. Re-assembly of pinned joints using filament wound
bearings.
Drift is to be measured at the cylinder rod with a cali- a. Housing should be blown out to remove all
brated dial indicator. The cylinder oil must be at ambi- dirt and debris...bearings and bearing hous-
ent temperature and temperature stabilized. ings must be free of all contamination.
b. Bearing / pins should be cleaned with a sol-
The cylinder must have the normal load, which is the vent to remove all grease and oil...filament
normal platform load applied. wound bearing are a dry joint and should not
be lubricated.
If the cylinder passes this test, it is acceptable.
c. Pins should be inspected to ensure it is free of
NOTE: This information is based on 6 drops per minute cyl- burrs, nicks, and scratches which would dam-
inder leakage. age the bearing during installation and opera-
tion.

2-12 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS

3.1 OPERATING CHARACTERISTICS Lift

A proportional flow control valve allows for propor-
Leveling Jacks tional control of the lift up function. Proportional valves
The machine is equipped with auto leveling jacks. These on both the upper and lower cylinders allow for smooth
leveling jacks are operated through one switch unlike control of the lift down function.
the traditional four switch system. The leveling jacks are
operated by a bang bang valve. Drive
1. Activate the leveling jack button located on the plat- If driving at high drive up a grade and you hit an 8°
form control box. incline, the drive function will cut back to mid drive
2. Extend the jacks by moving the joystick forward. speed. The drive pump will shift back into high drive
once the incline decreases to 5°. There will be a 2 second
NOTE: Once all four jacks make contact with the ground the delay before the machine goes back into high drive.
system will go from set mode into level mode. At this
point the engine will return to idle.
3.2 TIRES, WHEELS & DRIVE ASSEMBLY
3. The tilt indicator will go out once the machine is
level. Tire Inflation
NOTE: If the machine is not level it will not lift. If you hit the
The air pressure for pneumatic tires must be equal to
end of stroke on any of the cylinders you cannot lift
the air pressure that is stenciled on the side of the JLG
the machine.
product or rim decal for safe and proper operational
NOTE: There is a limit switch on each cylinder that senses characteristics.
when the cylinder is fully retracted when all four are
fully retracted, the stowed light in the platform con- Tire Damage
trol box will light.
For pneumatic tires, JLG Industries, Inc. recommends
that when any cut, rip, or tear is discovered that exposes
If you receive a 2/5 flash code through the system
sidewall or tread area cords in the tire, measures must
fault light at the platform control station the
be taken to remove the JLG product from service imme-
machine is unable to level. You must reposition and
diately. Arrangements must be made for replacement of
try again.
the tire or tire assembly.
The jacks are operational (extend or retract) if the
For polyurethane foam filled tires, JLG Industries, Inc.
machine is in the stowed position. The armstack angle
recommends that when any of the following are discov-
tilt sensor and rotary sensor together must sense that
ered, measures must be taken to remove the JLG prod-
the machine is stowed. A failure of either sensor will pre-
uct from service immediately and arrangements must
vent the jacks from being activated.
be made for replacement of the tire or tire assembly.
Generator • a smooth, even cut through the cord plies which
exceeds 3 inches (7.5 cm) in total length
When the generator switch is activated, the engine RPM
will increase to high idle. • any tears or rips (ragged edges) in the cord plies
which exceeds 1 inch (2.5 cm) in any direction
When a function is selected for operation, which • any punctures which exceed 1 inch in diameter
requires a higher engine speed than the generator, the • any damage to the bead area cords of the tire
generator will automatically shut off during the opera- If a tire is damaged but is within the above noted crite-
tion of the function. Once the function has stopped, the ria, the tire must be inspected on a daily basis to ensure
generator will be active again. the damage has not propagated beyond the allowable
criteria.

Tire Replacement
JLG recommends a replacement tire be the same size,
ply and brand as originally installed on the machine.
Please refer to the JLG Parts Manual for the part number

3121781 3-1
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

of the approved tires for a particular machine model. If Tighten the lug nuts to the proper torque to prevent
not using a JLG approved replacement tire, we recom- wheels from coming loose. Use a torque wrench to
mend that replacement tires have the following charac- tighten the fasteners. If you do not have a torque
teristics: wrench, tighten the fasteners with a lug wrench, then
immediately have a service garage or dealer tighten the
• Equal or greater ply/load rating and size of original
lug nuts to the proper torque. Over-tightening will
• Tire tread contact width equal or greater than origi- result in breaking the studs or permanently deforming
nal the mounting stud holes in the wheels. The proper pro-
• Wheel diameter, width, and offset dimensions equal cedure for attaching wheels is as follows:
to the original 1. Start all nuts by hand to prevent cross threading. DO
• Approved for the application by the tire manufac- NOT use a lubricant on threads or nuts.
turer (including inflation pressure and maximum tire 2. Tighten nuts in the following sequence:
load)
Unless specifically approved by JLG Industries Inc., do
not replace a foam filled or ballast filled tire assembly
with a pneumatic tire. When selecting and installing a
replacement tire, ensure that all tires are inflated to the
pressure recommended by JLG. Due to size variations
between tire brands, both tires on the same axle should
be the same.

Wheel Replacement
The rims installed on each product model have been
designed for stability requirements which consist of
track width, tire pressure, and load capacity. Size
changes such as rim width, center piece location, larger
or smaller diameter, etc., without written factory recom-
mendations, may result in an unsafe condition regard-
ing stability.
3. The tightening of the nuts should be done in stages.
Wheel Installation Following the recommended sequence, tighten nuts
per wheel torque chart.
It is extremely important to apply and maintain proper
wheel mounting torque. Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE (DRY)

1st Stage 2nd Stage 3rd Stage
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER
TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE 40-50-ft. lb. 90-105 ft. lb. 170 ft. lb.
DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO (60-70 Nm) (125-150 Nm) (230 Nm)
USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.
4. Wheel nuts should be torqued after first 50 hours of
operation and after each wheel removal. Check
torque every 3 months or 150 hours of operation.

3-2 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Drive Assembly

1. Tire & Rim

2. Lugnut
3. Drive Hub
4. Bolt
5. Washer
6. Drive Motor (Sauer)
1 7. Gasket
8. Bolt
9. Washer
10. Nut
NOTE: Rear axle shown.

Figure 3-1. Drive Assembly (Fairfield/Sauer)

INSTALLATION
REMOVAL
1. Follow “Removal” procedures in reverse order.
2. Refer to Table 3-1, Wheel Torque Chart when torque-
ing Lugnuts (2).
SHUT MACHINE OFF, BRACE AXLES AND CHALK WHEELS TO PREVENT
MACHINE FROM MOVING DURING REPAIRS. NOTE: For detailed information on the Drive Hub and Drive
Motor, refer to Section 3.3, Drive Hub (Fairfield) and
1. Disconnect, cap and label all hydraulic lines attached Section 3.4, Drive Motor (Sauer).
to Drive Motor (6). If applicable, disconnect all electri-
cal wiring.
2. With axle raised and supported, remove the Tires (1)
from the Drive Hub (3) by removing the 9 Lugnuts
(2).
3. Remove the Drive Hub (3) and Drive Motor (6) from
the axle by removing the 6 Bolts (4) and Washers (5).
4. The Drive Motor (6) can be removed from the Drive
Hub (3) by removing the 2 Bolts (8), Nuts (10) and
Washers (9).

3121781 3-3
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.3 DRIVE HUB (FAIRFIELD) The following steps describe the proper procedure for
tightening and torquing bolts or socket head cap
Roll and Leak Testing screws in a bolt circle.
1. Tighten (but do not torque) bolt "A" until snug.
Always roll and leak test Drive-Hubs after assembly to
make sure that the unit’s gears and sealants are working 2. Go to the opposite side of the bolt circle and tighten
bolt "B" until equally snug.
properly. The following information briefly outlines
what to look for when performing these tests. 3. Continue around the bolt circle and tighten the
remaining bolts.
THE ROLL TEST 4. Now use a torque wrench to apply the specified
The purpose of a roll test is to determine if the unit’s torque to bolt "A".
gears are rotating freely and properly. You should be 5. Continue around the bolt circle and apply an equal
able to rotate the gears in your unit by applying a con- torque to the remaining bolts.
stant force to the roll checker. If you feel more drag in
the gears only at certain points, then the gears are not
Oil Information
rolling freely and you should examine them for
1. TYPE – EP90
improper installation or defects. Some gear packages
On normal applications, use EP90. On applications
roll with more difficulty than others. Do not be con- where the lubricant must meet special requirements,
cerned if the gears in your unit seem to roll hard as long the O.E.M. should be able to recommend a suitable
as they roll with consistency substitute.
THE LEAK TEST 2. OIL TEMPERATURE
Continuous – 160°F [70°C] Intermittent – 200°F [95°C]
The purpose of a leak test is to make sure the unit is air 3. OIL CHANGE
tight. You can tell if your unit has a leak if the pressure Initial – After 50 hours or 50,000 revolutions of opera-
gauge reading on your air checker starts to fall once you tion. Subsequent – After 1000 hours or (1) year,
have pressurized the unit. Leaks will most likely occur at whichever comes first.
the main seal or wherever o-rings or gaskets are located.
Usually you can detect the exact location of a leak by NOTE: Higher temperatures make it necessary to change oil
brushing a soap and water solution around the main more frequently.
seal and where o-rings or gaskets meet the exterior of 4. OIL FILL LEVEL AND VOLUME
the unit, then checking for air bubbles. If you detect a Unit mounted horizontal – half full
leak in a seal, o-ring, or gasket, replace the part immedi- Approximate volume - 17 oz. (0.5 ltr)
ately. 5. REAR BRAKES
Rear brakes require 2.7 oz. (0.08 ltr) of DTE 13M
Tightening and Torquing Bolts hydraulic fluid each to function properly.

“A”

“B”
If you use an air impact wrench to tighten bolts, take
extreme care to ensure that you do NOT tighten the
bolts beyond their indicated torque specification. Never
use an impact wrench to tighten shoulder bolts. Always
tighten all shoulder bolts by hand.

3-4 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Hub-Spindle Sub-Assembly 2. Internal Gear A. Cover C. Spring

A. Spindle 3. Carrier Sub-Assembly B. Cover Cap D. Spacer
B. Seal A. Carrier Housing C. Bolt 8. Input Gear
C. Bearing Cup B. Thrust Washer D. Disconnect Cap 9. Thrust Spacer
D. Bearing Cone C. Needle Roller E. Disconnect Rod 10. Bolt
E. Bearing Cup D. Spacer F. O Ring 11. Shoulder Bolt
F. Bearing Cone E. Planet Shaft G. O Ring 12. Coupling
G. Hub F. Cluster Gear 13. Flat Washer
H. Pipe Plug
H. Spacer G. Roll Pin 7. Input Shaft Sub Assembly
I. Retaining Ring 4. Ring Gear A. Input Shaft
J. Pipe Plug 5. O Ring B. Retaining Ring
N. Stud 6. Cover Sub-Assembly

Figure 3-2. Drive Hub (Cross-Section)

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 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

7B
7D 16
7C 29
7D
7 28
6F 30
6E 7A
10
6D
39 20
6C
6H 6G 2
6I 40
6 41
6G 6B
1I 37
1H 22
11 11
1F
6A
21

1E
1 24
5A

1G 21

4
15
24

5 3G 1J 19
3E
1D
34
33
1C
3
3A 27
1B
3B 1 36
14 3C 1A 35
3D
8 3C 25
38
13
3F
9
3B 12 26

32
23 31
23

17
18

Figure 3-3. Drive Hub

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 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTE: Refer to Figure 3-3., Drive Hub. Table 3-2. Drive Hub Part Description

Table 3-2. Drive Hub Part Description Item # Description

8 Sun Gear
Item # Description
9 Thrust Washer
1 Spindle/Housing Assembly
10 Bolt
1A Spindle
11 Dowell Pin
1B Seal
12 Coupling
1C Bearing Cone
13 Input Spacer
1D Bearing Cup
14 Input Spacer
1E Bearing Cup
15 Brake Assembly
1F Bearing Cone
16 O-Ring
1G Housing/Ring Gear
17 Threaded Rod
1H Thrust Washer
18 Nut 1/2”-13NC
1I Retaining Ring
BRAKE ASSEMBLY
1J Wheel Stud
19 Shaft
2 Internal Gear
20 Housing
3 Carrier Assembly
21 Friction Plate
3A Carrier
22 Pressure Plate
3B Retaining Ring
23 Gasket
3C Needle Bearing
24 Outer Plate
3D Thrust Washer
25 Gasket
3E Planet Shaft
26 Cylinder
3F Planet Gear
27 Piston
3G Rollpin
28 Ball Bearing
4 Ring Gear
29 Retaining Ring
5 O-Ring
30 Shaft Seal
5A O-Ring
31 Capscrew
6 Cover Assembly
32 Lockwasher
6A Thrust Spacer
33 O-Ring
6B Cover Plate
34 Back-up Ring
6C O-Ring
35 O-Ring
6D Disconnect Rod
36 Back-up Ring
6E Disengage Cap
37 Dowel Pin
6F Bolt 1/2"-20NC x 1/2”
38 Plug
6G Pipe Plug
39 Plug
6H Rivet
40 Spring Kit (Natural)
6I ID Plate
41 Spring Kit (Blue)
7 Input Shaft Assembly
7A Shaft
7B Retaining Ring
7C Spring
7D Thrust Spacer

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 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Main Disassembly for Drive Hub 17. At this point the main disassembly for drive hub is
complete.
NOTE: Refer to Figure 3-2. for part location and listing. Hub-Spindle Disassembly
1. Turn hub (1G) over onto its side. Remove coupling
(14) from the wide end of spindle (1A). NOTE: Start with large end of hub facing up, large end of
spindle facing down.
2. Mark location of shoulder bolt holes on outside of
ring gear and hub for easy re-alignment when
rebuilding. Remove the four shoulder bolts (13) and
twelve bolts (12) from cover (6). WEAR SAFETY GLASSES DURING THIS STEP.
3. Remove the sixteen flat washers (16) from cover (6).
4. Lift cover sub-assembly (6) off of ring gear (4), and 1. Remove retaining ring (1I) from around spindle (1A)
set cover on table, interior side facing up. in hub (1G).
2. Remove spacer (1H) from around spindle (1A) in hub
(1G).
CAUTION: BEWARE OF SHARP EDGES IN THE COUNTERBORE WHEN 3. Set hub (1G), small end/spindle facing down, up on
YOU REMOVE THE O-RING. something that will support the hub’s flange while it
lifts hub up so spindle is not resting on anything.
Carefully press or hammer spindle (1A) down and out
5. Remove o-ring (5) from the counterbore around the of hub (1G).
edge of cover (6A). Discard the o-ring.
NOTE: If seal (1B) and bearing cone (1D) come out of hub
NOTE: If o-ring is not in the cover counter- bore, it is in the
and rest on spindle, remove these parts from the
ring gear counterbore. Remove it from the hub and spindle and set them aside. Discard the seal.
discard it.
4. If seal and bearing cone did not come out of the
6. Remove thrust washer (11) from the counter- bore in small end of hub (1G) when spindle is pressed out of
top of carrier (3A). hub, remove seal (1B) and bearing cone (1D) from
7. Remove input gear (8) from the middle of carrier sub- the small end of hub. Discard the seal.
assembly (3). 5. Bearing cone (1F) should be lying loose in wide end
8. Lift ring gear (4) off of hub (1G). of hub (1G). Remove bearing cone (1F) from inside
9. Lift carrier sub-assembly (3) out of hub (1G). hub.
10. Remove thrust spacer (9) from input shaft (7) in the NOTE: If you use a punch and hammer, make sure you do
middle of spindle (1A). not strike the counterbore with the punch when you
11. Lift input shaft sub-assembly (7) out of middle of remove the bearing cup.
spindle (1A), and stand input shaft (7A) on its splined
end. 6. Remove bearing cup (1C) from the counterbore in
the small end of hub (1G).
NOTE: If using a punch and hammer, make sure to not
WEAR SAFETY GLASSES DURING THIS STEP, AND BE AWARE THAT strike the counterbore with the punch when remov-
SPRING AND SPACERS COMPRESSED BY RETAINING RING MAY POP ing the bearing cup.
SUDDENLY OFF SHAFT WHEN YOU REMOVE THE RETAINING RING. 7. Turn hub (1G) over and lift it out of the flange-sup-
port. Remove bearing cup (1E) from the counterbore
12. Using retaining ring pliers, remove retaining ring (7B) in the wide end of hub.
from the groove on input shaft (7A). 8. Turn hub (1G) over onto its small end. Remove two
13. Remove one spacer (7D), one spring (7C), and other pipe plugs (1J) from the two pipe plug holes in the
spacer (7D) from input shaft (7A). side of hub.
14. Remove thrust washer (11) from around spindle (1A). NOTE: If the unit does not have studs, skip this step:
15. Lift internal gear (2) out of hub (1G).
9. Press the nine studs (1N) out of the stud holes in hub
(1G).
10. At this point the hub-spindle disassembly is com-
BEWARE OF SHARP EDGES IN COUNTERBORE WHEN YOU REMOVE THE plete.
O-RING.

16. Remove o-ring (5) from the counterbore in hub (1G).

Discard the o-ring.

3-8 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Cover Disassembly Carrier Assembly

1. Remove the two bolts (6C) holding disconnect cap 1. Apply grease to the inside of one cluster gear (3F)
(6D) to cover (6A). and line one half of cluster gear with 16 needle roll-
2. Remove disconnect cap (6D) from top of cover cap ers (3C).
(6B) and cover (6A).
3. Remove the two bolts (6C) attaching cover cap (6B)
to cover (6A).
4. Remove cover cap (6B) from cover (6A).
5. Remove disconnect rod (6K) from cover cap (6B).
6. Pry o-ring (6F) out of the groove inside cover cap
(6B). Discard the o-ring.
7. Remove o-ring (6G) from the flange of cover cap (6B).
Discard the o-ring.
8. Remove pipe plug (6H) from cover (6A).
9. At this point the cover disassembly is complete.

Carrier Disassembly 2. Place one spacer (3D) inside cluster gear (3F) so that
it rests on top of the needle rollers.
NOTE: When removing the needle rollers from the cluster
gears, discard the old needle rollers and use new
ones during re-assembly.
1. Using a punch and hammer, drive roll pin (3G) into
planet shaft (3E).
NOTE: Be sure to drive the roll pin all the way into the planet
shaft. Failure to do so could result in damage to the
carrier when removing the planet shaft from the car-
rier.
2. Using a punch and hammer, drive the planet shaft
(3E) out of the planet shaft hole in the carrier housing
(3A).
3. Line the remaining half of cluster gear (3F) with 16
3. When removing the planet shaft (3E) from the carrier needle rollers.
housing, one thrust washer (38), one cluster gear
(3F), and one more thrust washer will come off of the
planet shaft and come to rest inside the carrier.
Remove these parts from inside the carrier.
4. Remove 16 needle rollers (3C) from inside one end of
cluster gear (3F). Discard the needle rollers.
5. Remove one spacer (3D) from inside cluster gear (3F).
6. Remove the remaining 16 needle rollers (3C) from
the other side of cluster gear (3F). Discard the needle
rollers.
7. Repeat steps 1-6 to remove and disassemble the two
remaining cluster gears.
8. At this point the carrier disassembly is complete.

3121781 3-9
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

4. Set carrier housing (3A) sideways on a table. Insert a 7. Following the cluster gear, place one more thrust
planet shaft (3E), roll pin hole last, into one of the washer (3B) onto planet shaft (3E) through the oppo-
planet shaft holes from roll-pin-holed side of carrier site planet shaft hole in carrier housing (3A).
housing.

8. Use an alignment punch or similar tool to align the

5. Place one thrust washer (3B) onto the end of planet roll pin holes in carrier housing (3A) and planet shaft
shaft (3E) inside carrier. Fit tang of thrust washer into (3E).
the slot on the inside edge of the planet shaft hole.

9. Drive roll pin (3G) down into the aligned roll pin
6. Following the thrust washer, place the cluster gear holes in carrier housing (3A) and planet shaft (3E).
(3F), large end toward roll pin hole in carrier housing,
onto the planet shaft (3E).

10. Repeat steps 1 thru 9 to assemble and install the two

remaining cluster gears.
11. Carrier sub-assembly is complete.

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 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Cover Sub-Assembly 4. Set cover (6A) on table, exterior side up. Place cover
cap (6B) onto cover (6A), aligning the pipe plug hole
1. Using the disconnect rod, push o-ring (6F) into the in the cover cap over the pipe plug hole in the cover.
groove inside the cover cap (6B).

5. Place two of the cover cap bolts (6C) into any two
2. Place the o-ring (6G) onto the cover cap (6B) so that it bolt holes that are 180° apart on the cover cap (6B)
rests against the flange of the cover cap. and tighten bolts.

3. Insert disconnect rod (6E) into cover cap (6B). 6. Using a torque wrench, apply 2.95 to 3.69 ft. lb. (4 to
5 Nm) of torque to both bolts (6C).

3121781 3-11
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

7. With the large end down, place the disconnect cap 10. Apply a light coat of “Never-Seize” to pipe plug (6H)
(6D) onto the cover cap (6B), aligning the pipe plug and tighten it into the pipe plug hole in the cover
hole in the disconnect cap over the pipe plug hole in (6A).
the cover cap.

11. Cover sub-assembly is complete.

8. Place the two remaining bolts (6C) into the bolt holes
in the disconnect cap (6D), and tighten the bolts. Hub-Spindle Sub-Assembly
NOTE: Make sure the cup sits square with the counterbore
before pressing.
1. Set hub (1G) onto its large end. Press bearing cup
(1C) into the counterbore in the small end of the hub
(1G).

9. Using a torque wrench, apply 2.95 to 3.69 ft. lb. (4 to

5 Nm) of torque to both bolts (6C).

2. Press the nine studs (1N) into the stud holes in hub
(1G).

3-12 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3. Apply a light coat of “Never-Seize” to two pipe plugs 6. Press seal (1B) into the small end of hub (1G).
(1J) and tighten them into the two pipe plug holes in
the side of the hub (1G).

7. Oil spindle, then lower hub (1G), small end down,

onto spindle (1A).
NOTE: Make sure the cup sits square with the counterbore
before pressing.
4. Turn hub (1G) over onto its small end. Press bearing
cup (1E) down into the counterbore in the deep end
of the hub (1G).

8. Press bearing cone (1F) onto spindle (1A) in hub (1G).

5. Set hub (1G) onto its large end. Place bearing cone
(1D) into bearing cup (1C).

9. Place spacer (1H) onto spindle (1A) in hub (1G).

3121781 3-13
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTE: Make sure the retaining ring is securely seated in the Main Assembly
groove.
10. Place retaining ring (1I) over the spacer onto spindle
(1A) in hub (1G).
BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE
O-RING

1. Grease o-ring (5) and place it into the counterbore in

hub (1G).
NOTE: O-ring may be stretched or pinched together to
make it fit the counterbore exactly.

11. At this point the hub-spindle sub-assembly is com-

plete.

2. Oil all exposed surfaces inside hub (1G).

3. Place internal gear (2) into hub (1G) so that its inter-
nal splines mesh with the external splines of spindle
(1A). Oil internal gear (2).

3-14 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

4. Place thrust washer (11) around spindle (1A) so it 7. Place other spacer (7D) onto the smooth end of input
rests on the bottom of the internal gear (2). shaft (7A).

5. Stand input shaft (7A) on its splined end. Place one

spacer (7D) onto the smooth end of input shaft (7A).
WEAR SAFETY GLASSES DURING THIS STEP, AND BE AWARE THAT
SPRING AND SPACERS, COMPRESSED BY RETAINING RING, MAY POP
SUDDENLY OFF SHAFT IF THE RING IS RELEASED BEFORE IT IS PROP-
ERLY IN PLACE.

8. Using retaining ring pliers, insert retaining ring (7B)

into the groove on input shaft (7A) by compressing
the spring and spacers together.

6. Place one spring (7C) onto the smooth end of input

shaft (7A).

9. With large splined end down, place input shaft sub-

assembly (7) into spindle (1A).

3121781 3-15
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

10. Place thrust spacer (9) onto input shaft (7). NOTE: You may lift the ring gear off the hub to align the
shoulder bolt holes. The ring gear and carrier are
installed together only to keep the punch marks on
the carrier in place.

11. Set carrier sub-assembly (3) on a flat work surface so

the large ends of cluster gears (3F) face up. Locate
the punch marks on the face of each cluster gear (3F)
and position them at 12 o’clock.
14. With the internal splines facing up (counterbore end
facing down), place input gear (8) into mesh with car-
rier sub-assembly (3).

Figure 3-4. Cluster Gear Punch Marks

12. With “X” marked side facing up, place the ring gear
(4) around cluster gears (3F). 15. Oil all exposed surfaces inside the hub (1G). Place
thrust washer (11) into the counterbore in top of the
NOTE: This will hold the punch marks in position while carrier.
installing the carrier into the hub.

13. Place the carrier sub assembly (3) and ring gear (4)
together into mesh with internal gear (2), aligning BEWARE OF SHARP EDGES IN THE COUNTERBORE WHEN YOU INSTALL
the “X” marked shoulder bolt hole in the ring gear (4) THE O-RING.
over one of the shoulder bolt holes in the hub. Mark
the location of shoulder bolt holes on the outside of
ring gear and hub. 16. Set the cover (6A) on table, interior side up. Grease o-
ring (5) and place it into the counterbore around the
edge of cover (6A).

3-16 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTE: The o-ring may be stretched or pinched together to 19. Place shoulder bolts (13) into the four shoulder bolt
make it fit the counterbore exactly. holes in cover (6) and tighten by hand.

20. Place the remaining 12 flat washers (16) onto the

17. Place cover sub-assembly (6) onto ring gear (4), remaining bolt holes in cover (6).
aligning the pipe plug holes according to the align-
ment prior to disassembly.

21. Place the 12 bolts into the remaining bolt holes in

cover (6) and tighten.
18. Place four flat washers (16) on top of the bolt holes in
the cover sub-assembly.

3121781 3-17
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

22. Torque the shoulder bolts (13) 18 to 25 ft. lb. (25 to 34 25. Leak test the unit at a pressure of 5 psi (0.34 bar) for 2
Nm). Torque bolts (12) 18 to 25 ft. lb. (25 to 34 Nm). to 3 minutes.

23. Turn hub (1G) over onto its side. Insert coupling (14) 26. At this point the main assembly is complete.
into the end of the spindle (1A).

24. Roll test the unit in both clockwise and counterclock-

wise directions. Perform the same number of turns in
each direction as the ratio of the unit. The ratio is the
last two digits of the model number on the unit’s ID
tag.

3-18 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Tool List 3. T-140433 ASSEMBLY PRESSING TOOL for CUP (1E)

6.625" (168.3 mm)
The following specialized tools are used to assemble
this unit. The tool diagrams included in this manual are
0.125" (3.1 mm) 6" (152.4 mm)
intended for the customer who may wish to have a tool 0.5" (12.7 mm)
made. All tools exist as one piece and must be made

3.510" (89.15 mm) Dia.

3.500" (88.90 mm) Dia.
3.280" (83.31 mm) Dia.
3.270" (83.05 mm) Dia.
from mild steel All dimensions are given in inches. 2.75" (69.8 mm)

1.5" (38.1 mm) Dia.

NOTE: In order to improve tool life, tools may be carburized
and hardened. If this is done, however, the tools must
be ground on all surfaces labeled with a “G” on the
tool diagram.
21 Copper Paint Knurl
1. T-118126 SEAL PRESSING TOOL for SEAL (1B). To Keep Handle Soft 3" (76.2 mm)
MAF04210

4. T-109691 ASSEMSLY PRESSING TOOL for CONE (1F)

* These tools are for specific seals, cups or cones. There

is a specific tool for each cup and cone.

Re-Aligning Torque Hub Input Coupling

2. T-138903 ASSEMBLY PRESSING TOOL for CUP (1C) The following procedure applies to torque hubs with
integral brakes.

EQUIPMENT REQUIRED
1. Hydraulic power supply (hand pump) capable of pro-
ducing 200 psi (13.8 bar).
2. Hydraulic fittings to adapt hydraulic supply to brake
release port on hub.
PROCEDURE
1. Using appropriate fittings, connect a line from the
hydraulic power supply to the brake port.
2. Pressurize the brake release port 155 to 200 psi (10.6
to 13.8 bar) to release the brake.
3. Verify that the brake is released by rotating the input
coupling or hub spindle.
4. Once the brake is released, the input coupling will be
free to re-align with the drive motor.
5. Install the drive motor on the hub, then release the
hydraulic pressure at the brake release port. The cou-
pling will remain in position.
6. Disconnect the hydraulic power supply and recon-
nect the line going into the brake release port.

3121781 3-19
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.4 DRIVE MOTOR (SAUER) Shaft Seal Replacement

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

Bias spring
Servo piston
Minimum
Angle Swashplate
Stop 1. Snap Ring
2. Support Washer
3. Shaft Seal
Output
Cylinder Shaft
Figure 3-6. Removing the Shaft Seal
Block
2. Remove the support washer (2).
3. Carefully pry out the shaft seal (3).
Shaft
Seal To avoid damaging the shaft during removal, install a
large sheet metal screw into the chuck of a slide
Piston hammer. Drive the screw into the seal surface and
Endcap Slipper Bearing
Valve plate use the slide hammer to pull the seal.
4. Discard the seal.
Figure 3-5. Drive Motor Cross Section

3-20 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

INSPECT THE COMPONENTS 4. Using pliers, remove centering springs (7, 8, and 9).
Inspect the new seal, the motor housing seal bore, and 5. Remove spring retaining washers (10 and 11).
the sealing area on the shaft for rust, wear, and contami- 6. Remove shift spool (12).
nation. Polish the shaft and clean the housing if neces- 7. Remove orifice poppet (13).
sary.
INSPECT THE COMPONENTS
INSTALLATION Inspect new O-rings and the sealing area for rust, wear,
1. Cover the shaft splines with an installation sleeve to or contamination. Also check springs and poppet for
protect the shaft seal during installation. wear.
2. Install a new shaft seal with the cupped side facing
the motor. Press seal into housing until it bottoms INSTALLATION
out. Press evenly to avoid binding and damaging the 1. Install orifice poppet (13).
seal. 2. Install shift spool (12).
3. Install seal support washer. 3. Install spring retaining washers onto springs (10 and
4. Install snap ring. 11).
5. Remove the installation sleeve. 4. Carefully install centering springs (7, 8, and 9).
5. Install new O-rings (6, 4, and 5).
Loop Flushing Valve
6. Using a 1/4 in hex wrench, torque plug (3) to 20 ft. lb.
(27 Nm).
REMOVAL
7. Using a 11/16 in internal hex, torque plugs (2 and 1)
1. Using a 11/16 in internal hex wrench, remove plug to 27 ft. lb. (37 Nm).
(1) and (2).

6
9
11
2
11/16 in
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)

1. Plug 6. O-ring 11. Washer

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

Figure 3-7. Loop Flushing Spool

2. Using a 1/4 in hex wrench, remove plug (3).

3. Remove O-rings (4, 5, and 6).

3121781 3-21
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Troubleshooting
Table 3-3. Excessive Noise and/or Vibration

Item Description Action

Check oil level in reservoir and Insufficient hydraulic fluid could lead to cavitation that would Fill the reservoir to the proper level and ensure that oil supply to
oil supply to the motor. cause system noise. the motor is adequate and the lines are unobstructed.
Check for air in the system. Air trapped within the system lines, or the motor itself, could result Ensure that all of the system lines and components are purged of
in cavitation that would cause system noise. air.
Inspect the output shaft cou- A loose or incorrect shaft coupling will produce vibrations that Ensure that the correct coupling is used and that it fits properly
plings. could result in system noise. onto the shaft.
Inspect the output shaft align- Misaligned shafts create excessive frictional vibration that could Ensure that the shafts are properly aligned.
ment. result in system noise.
Hydraulic oil viscosity above Viscosity above acceptable limits will result in cavitation that Replace hydraulic oil with appropriate fluid for operating condi-
limits. would lead to system noise. tions.

Table 3-4. System Operating Hot

Item Description Action

Check oil level in reservoir and Insufficient amount of hydraulic fluid will not meet the cooling Fill the reservoir to the proper level.
oil supply to the pump. demands of the system.
Inspect the heat exchanger, (if If the heat exchanger fails, or becomes obstructed, it may not meet Ensure that heat exchanger is receiving adequate air flow and that
so equipped). the cooling demands of the system. the heat exchanger is in good operating condition. Repair or
replace as necessary.
Check the system relief valves. If a system relief valve becomes unseated for an extended period of Repair or replace any malfunctioning relief valves as applicable
time or fails for any other reason, the system could become over- and verify that the loads on the machine are not excessive.
heated.

Table 3-5. Won’t Shift or Slow to Start

Item Description Action

Check the signal line to the Obstructed or restricted flow through the servo control signal lines Ensure that the signal lines are not obstructed or restricted and
servo control port. could result in slow shift or no shift conditions within the motor. that signal pressure is adequate to shift the motor.
Check that the correct supply Supply and drain orifices determine the shift rate of the motor. The Ensure that the proper control orifices are installed in the motor
and drain orifices are properly smaller the orifice, the longer the time it takes to shift the motor. and verify that they are not obstructed. Clean or replace as neces-
installed, and are not Obstruction will also increase shift times. sary.
obstructed.

3-22 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Disassembly
17
NOTE: Removal of the endcap voids warranty. 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.
14
It is recommended that all O-rings be replaced.
Lightly lubricate all O-rings with clean petroleum
jelly prior to assembly.

6 21
9
5 11
2
7
13 18
3

10 12
16
8
4 16

1
20

14. Lock Nut 18. Cavity Plug

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

1. Plug 5. O-ring 9. Spring 12. Shift Spool Figure 3-9. Plugs, Fittings, and Speed Sen-
2. Plug 6. O-ring 10. Washer 13. Orifice Poppet sor
3. Plug 7. Spring 11. Washer
4. O-ring 8. Spring 8. Remove all fittings from the unit. Discard any O-rings
on the fittings.
Figure 3-8. Loop Flushing Spool 9. Using an 11/16 in hex wrench, loosen the speed sen-
sor lock nut (14) if equipped. Then remove the speed
1. Using a 11/16 in wrench, remove plug (1) and (2). sensor using a 1/2 inch hex wrench. Units without
2. Using a 5/8 in hex wrench, remove plug (3). speed sensor have an O-ring plug (15) installed in
that location; remove it with a 1/4 inch internal hex
3. Remove O-rings (4, 5, and 6). wrench.
4. Using pliers, remove centering springs (7, 8, and 9). 10. Using a 1/4 in internal hex wrench, remove control
5. Remove spring retaining washers (10 and 11). line plugs (16, 17). Discard O-rings. Using a 3 mm hex
6. Remove shift spool (12). wrench, remove cavity plug (18, if equipped with
two-line control) from X2 cavity.
7. Remove orifice poppet (13).
11. Using a 5/16 in internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.
12. Using a 9/16 in internal hex wrench, remove work
port plugs (21, if equipped with axial ports). Discard
O-rings.

3121781 3-23
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

22 25

27
30

23 29
28
26
24
27

22. Screw
23. End Cap 25. Valve Plate
24. O-ring 26. End Cap
27. O-ring
28. Rear Shaft Bearing
Figure 3-10. End Cap 29. Minimum Angle Stop
13. Using an 8 mm internal hex wrench, remove the end- 30. Servo Spring
cap screws (22).
14. Remove the endcap (23). Remove O-ring (24) from
the housing or endcap. Figure 3-11. Valve Plate & Rear Shaft Bearing

When the endcap screws are removed, pressure from

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

Each displacement has a unique valve plate. For

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

The bearing may be difficult to remove with a puller.

Try this as an alternative: Pack the bearing cavity with
heavy grease. After the shaft is removed, insert it into
the bearing cavity and tap lightly with a soft mallet
on the splined end. The grease will force the bearing
out. Use caution not to drive the bearing past the
rear shaft journal as the bearing may become
trapped on the shaft and damaged.
18. Remove minimum angle stop (29) and servo spring
(30) from the housing.

3-24 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

20. Turn the housing over and remove the snap ring (32)
retaining the shaft seal and support washer. Remove
the support washer (33) and carefully pry out the
shaft seal (34). Discard the seal.

31
To avoid damaging the shaft during seal removal,
install a large sheet metal screw into the chuck of a
slide hammer. Drive the screw into the seal surface
and use the slide hammer to pull the seal.

36
31. Cylinder Kit Assembly 35
37

Figure 3-12. Cylinder Kit

38
19. Turn the housing on its side and remove the cylinder
kit assembly (31). Set the assembly aside, being care-
ful not to scratch the running surface.
NOTE: Grooves on the surface of the cylinder kit identify its
displacement:

Table 3-6. Displacement Identifiers 35. Inner Snap Ring

36. Snap Ring
# of Grooves Frame L Frame K
37. Bearing
1 25 38 38. Shaft
2 30 45
3 35 -- Figure 3-14. Shaft & Front Bearing
21. Remove the inner snap ring (35) and the shaft / bear-
ing assembly.
22. Remove the snap-ring (36) retaining the shaft front
32 bearing. Pull the bearing (37) off of the shaft (38).

33

34

32. Snap Ring

33. Support Washer
34. Shaft Seal

Figure 3-13. Shaft Seal

3121781 3-25
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Lift here
44
39
45

47
40
48
43
42 49
41

46

53

52

39. Swashplate 50
40. Servo Piston 51
41. Piston Seal
42. O-ring
43. Journal Bearings
44. Piston 49. Retaining Ring
Figure 3-15. Swash Plate & Servo Piston 45. Slipper Retainer 50. Block Spring Washer
46. Cylinder Block 51. Spiral Retaining Ring
23. Turn housing over and remove the swashplate (39) 47. Ball Guide 52. Block Spring
by lifting on the end opposite the servo lever.
48. Holddown Pins 53. Inner Block Spring Washer
24. Remove the servo piston (40). Remove the piston
seal (41) and O-ring (42) from the servo piston. Dis-
card the seal and O-ring. Figure 3-16. Cylinder Kit Disassembly
25. Remove the journal bearings (43) from the housing. 26. Remove pistons (44) and slipper retainer (45) from
If the bearings are to be reused, note the location the cylinder block (46).
and orientation of each bearing for reassembly.
The pistons are not selectively fitted, however units
with high hourly usage may develop wear patterns.
Number the pistons and bores for reassembly if they
are to be reused.
27. Remove the ball guide (47), hold-down pins (48), and
retaining ring (49) from the cylinder block.
NOTE: Most repairs do not require block spring removal.
Perform this procedure only if you suspect problems
with the block spring.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING

REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A
PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE
EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO
REMOVE THE SPIRAL RETAINING RING. RELEASE THE PRESSURE
SLOWLY AFTER THE RETAINING RING IS REMOVED.

3-26 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

28. Turn the block over. Using a press, apply pressure on SLIPPERS
the block spring washer (50) to compress the block Inspect the running surface of the slippers. Replace any
spring. Compress the spring enough to safely piston assemblies with scored or excessively rounded
remove the spiral retaining ring (51). While maintain- slipper edges. Measure the slipper foot thickness.
ing pressure, unwind the spiral retaining ring (51). Replace any piston assemblies with excessively worn
Carefully release the pressure and remove the outer
block spring washer (50), block spring (52), and inner slippers. Check the slipper axial end-play. Replace any
block spring washer (53) from the cylinder block. piston assemblies with excessive end-play.
Minimum slipper foot thickness and maximum axial
Inspection end-play are given in the table below.
After disassembly, wash all parts (including the end-cap
and housing) thoroughly with clean solvent and allow Table 3-7. Slipper Foot Thickness & End Play
to air dry. Blow out oil passages in the housing and end-
Measurement L Frame K Frame
cap with compressed air. Conduct inspection in a clean
area and keep all parts free from contamination. Clean Slipper Foot Thickness 2.71 4.07
and dry parts again after any rework or resurfacing. mm (0.11) (0.16)
Piston/Slipper End Play (in.) 0.15
PISTON
(0.006)
Inspect the pistons for damage and discoloration. Dis-
colored pistons may indicate excessive heat; do not
reuse. CYLINDER BLOCK
Measure the cylinder block height. Replace blocks worn
beyond the minimum height specification. Inspect the
Maximum end play
running surface of the cylinder block. Replace or resur-
face worn or scratched blocks. Blocks may be resurfaced
to the specifications shown in the drawing, provided
Minimum Slipper resurfacing will not reduce the block height below the
slipper foot
thickness minimum specification. Table 3-8, Cylinder Block Mea-
surements.

Table 3-8. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) mm 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
Cylinder Block Surface Flatness (in.) 0.002 0.002 0.002 0.002 0.002
(0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079)

3121781 3-27
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

BALL GUIDE AND SLIPPER RETAINER tion. Replace swashplate if the difference in thickness
Inspect the ball guide and slipper retainer for damage, from one side to the other exceeds specification.
discoloration, or excessive wear. A discolored ball guide
or slipper retainer indicates excessive heat. Do not
reuse. 0.0025 mm
[0.0001 in]

Slipper retainer
25.8 mm
LV [1.015 in]

KV 24.6 mm
[0.969 in]
Ball guide Thickness equality
side to side:
0.05 mm [0.002 in]

VALVE PLATE
The condition of the valve plate is critical to the effi-
ciency of the motor. Inspect the valve plate surfaces
carefully for excessive wear, grooves, or scratches.
Replace or resurface grooved or scratched valve plates.
Inspect the journal bearings for damage or excessive
Measure the valve plate thickness and replace if worn
wear. Replace journal bearings if scratched, warped, or
beyond the minimum specification. Valve plates may be
excessively worn. The polymer wear layer must be
resurfaced to the specifications shown in the drawing,
smooth and intact.
provided resurfacing will not reduce the thickness
below the minimum specification. SHAFT BEARINGS
3.83 mm [0.151 in] min.
Inspect bearings for excessive wear or contamination.
Rotate the bearings while feeling for uneven move-
0.025 mm
[0.001 in]
ment. Bearings should spin smoothly and freely.
Replace bearings that appear worn or do not rotate
smoothly.

0.0076 mm
[0.00030 in]
convex max

SWASHPLATE AND JOURNAL BEARINGS

Inspect the running face, servo ball-joint, and swash- SHAFT
plate journal surfaces for damage or excessive wear. Inspect the motor shaft. Look for damage or excessive
Some material transfer may appear on these surfaces wear on the output and block splines. Inspect the bear-
and is acceptable providing the surface condition meets ing surfaces and sealing surface. Replace shafts with
specifications shown. Measure the swashplate thickness damaged or excessively worn splines, bearing surfaces,
from the journals to the running face. Replace swash- or sealing surfaces.
plate if damaged or worn beyond minimum specifica-

3-28 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

SERVO PISTON AND MINIMUM ANGLE STOP Assembly

Inspect the minimum angle stop, servo piston head, and
servo piston ball-socket for damage or excessive wear. 1. Install new O-ring (1) and piston seal (2) to the servo
Replace if necessary. piston (3). Install the piston seal over the O-ring.

Installing the piston seal stretches it, making it diffi-

cult to install the servo piston in its bore. Allow 30
minutes for the seal to relax after installation. To
speed up seal relaxation, compress the seal by install-
ing the piston head into the servo cavity in the end-
cap and let it stand for at least five minutes.

2
3

LOOP FLUSHING SPOOL

1
Inspect the loop flushing spool. Check for cracks or
damage. Replace if necessary.

1. O-ring
2. Piston Seal
3. Servo Piston

Figure 3-17. Servo Piston

2. After piston seal has relaxed, lubricate and install
servo piston into the housing bore. Align the piston
with the ball socket facing the inside of the housing.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING

REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A
PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE
EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO
INSTALL THE SPIRAL RETAINING RING. RELEASE THE PRESSURE
SLOWLY AFTER THE RETAINING RING IS INSTALLED.

3121781 3-29
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3. Install the inner block spring washer (4), block spring 6. Install the journal bearings (13) into the housing
(5), and outer washer (6) into the cylinder block. seats. Use assembly grease to keep the bearings
Using a press, compress the block spring enough to seated during assembly. Ensure the locating nubs
expose the retaining ring groove. Wind the spiral drop into the cavities in the seats. If you're reusing
retaining ring (7) into the groove in the cylinder the bearings, install them in the original location and
block. orientation. Lubricate the journal bearings.

11 14
13
12

10

9
8
13

5
13. Journal Bearings
6 14. Swash Plate

7
Figure 3-19. Swash Plate and Journal Bear-
ing
7. Install the swashplate (14) into the housing. Tilt the
4. Block Spring Washer 9. Holddown Pins swashplate and guide the servo lever ball into its
5. Block Spring 10. Ball Guide socket in the servo piston rod. Ensure the swashplate
6. Outer Washer 11. Piston seats into the journal bearings and moves freely.
7. Spiral Retaining Ring 12. Slipper Retainer
Lubricate the running surface of the swashplate.
8. Retaining Ring

Figure 3-18. Cylinder Kit Assembly

4. Turn the block over and install the retaining ring (8),
hold-down pins (9), and ball guide (10) to the cylin-
der block.
5. Install the pistons (11) to the slipper retainer (12).
Install the piston/retainer assembly into the cylinder
block. Ensure the concave surface of the retainer
seats on the ball guide. If you're reusing the pistons,
install them to the original block bores. Lubricate the
pistons, slippers, retainer, and ball guide before
assembly. Set the cylinder kit aside on a clean surface
until needed.

3-30 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

19

15
16

19. Cylinder Kit

17
Figure 3-21. Cylinder Kit Installa-
18 tion

11. Lubricate and install the servo spring (20), and mini-
15. Front Shaft Bearing mum angle stop (21) into the housing bore.
16. Shaft
17. Snap Ring
18. Snap Ring

Figure 3-20. Shaft and Front Bearing

21
9. While holding the swashplate in place, turn the hous-
ing on its side. Install the install shaft/bearing assem-
20
bly into housing from the flange end. Install the
snap-ring (18).

20. Servo Spring

21. Minimum Angle Stop

Figure 3-22. Servo Spring and Minimum

Angle Stop

3121781 3-31
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

22

24
25

23

25. End Cap

22. Rear Shaft Bearing 26. Screw
23. Timing Pin
24. Valve Plate
Figure 3-24. End Cap
Figure 3-23. Valve Plate and Rear Bear- 16. Using an 8 mm internal hex wrench, tighten the end-
ing cap screws. Tighten the screws in opposite corners
slowly and evenly to compress the servo spring and
13. Install timing pin (23) into its bore in the endcap. properly seat the endcap. Torque endcap screws 35-
Install the pin with its groove facing toward or away 45 ft. lb. (47-61 Nm).
from the shaft. Press the pin until the end protrudes 17. Before installing the shaft seal, ensure the shaft turns
0.12 ±0.01 in (3 ±0.25 mm) above endcap surface. smoothly with less than 120 in.lbs. (13.5 Nm) of force.
14. Install the valve plate (24) onto the endcap. Install If the shaft does not turn smoothly within the speci-
the valve plate with the yellow surface toward the fied maximum force, disassemble and check the unit.
cylinder block. Align the slot in the valve plate with
the timing pin. Apply a liberal coat of assembly
grease to the endcap side of the valve plate to keep it
in place during installation.

3-32 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

18. Cover shaft splines with an installation sleeve. Install 19. Install remaining plugs and fittings to the housing.
a new shaft seal (27) with the cup side facing the Refer to the drawing below for wrench sizes and
motor. Press seal into housing until it bottoms out. installation torques.
Press evenly to avoid binding and damaging the seal.
Install seal support 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)

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

Figure 3-25. Shaft Seal 1/4 in

33 ft.lbs.
(45 Nm)

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

Figure 3-26. Plugs and Fittings Installation

3121781 3-33
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

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

3-34 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.5 AXLE INSTALLATION

Front Axle Assembly (Fixed)

9 10
11
10

10 8
9

7
10
9
6
5

3
4
2
9 3

13
1
12

MAF03740

1. Front Axle 5. Pin Keeper and Screw 8. Stop Block Pad Bracket 11. Nuts
2. Pivot Pin 6. Stop Block Pad 9. Hex Head Screws 12. Wear Pad
3. Pivot Pin Bushing 7. Stop Block Shims 10. Washers 13. Wear Pad Shims
4. Thrust Washer

Figure 3-28. Axle Assembly (Fixed)

REMOVAL ASSEMBLY
1. When installing the axle assembly, follow Removal
Steps in reverse.
SUPPORT THE FRAME AND AXLE BEFORE ATTEMPTING ANY REMOVAL 2. Shim both the stop block pad and the wear pad to
AND/OR ASSEMBLY PROCEDURES. achieve a maximum gap of 1/16 in. (1.5 mm)
between the pad and the axle machined surface.
1. Disable machine operation. Remove wheel and drive NOTE: Apply Loctite® #242 to bolts (9) attaching stop block
assemblies. pad (6), and wear pad (12).
2. Remove the bolt and pin keeper (5).
3. Push the axle pivot pin (1) out and remove the thrust
washer (4) and bearings (3).
4. Front axle (1) can now be moved away from the
frame.

3121781 3-35
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Front Axle Assembly (Oscillating)

11

10

9
12

3
4
8 2
3

7
1
6

MAF03750

1. Front Axle 5. Pin Keeper and Screw 8. Hex Head Screws 11. Spacers
2. Pivot Pin 6. Wear Pad 9. Osc. Axle Tilt Sensor 12. Mounting Bolts/Wash-
3. Pivot Pin Bushing 7. Wear Pad Shims Bracket ers/Nuts
4. Thrust Washer 10. Osc. Axle Tilt Sensor

Figure 3-29. Axle Assembly (Oscillating)

REMOVAL ASSEMBLY
1. When installing the axle assembly, follow Removal
Steps in reverse.
SUPPORT THE FRAME AND AXLE BEFORE ATTEMPTING ANY REMOVAL 2. If removed, shim the wear pad to achieve a maxi-
AND/OR ASSEMBLY PROCEDURES. mum gap of 1/16 in. (1.5 mm) between the pad and
the axle machined surface.
1. Disable machine operation. Remove wheel and drive NOTE: Apply Loctite® #242 to bolts (8) attaching wear pad
assemblies. (6) to the frame.
2. Unplug the axle tilt sensor electrical connection.
• Oscillating Axle Tilt Sensor - (item 10) If this sensor
3. Remove the bolt and pin keeper (5). is not wired correctly or if you have the wrong part
4. Push the axle pivot pin (1) out and remove the thrust number you will get CANBUS FAILURE - OSCILLATING
washer (4) and bearings (3). AXLE TILT SENSOR
5. Front axle (1) can now be moved away from the
frame.

3-36 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Steering Assembly

1. Steer Cylinder Assembly 6. Cyl. Attach Screws 11. Hex Flange Bolt
2. Tie-Rod Link 7. Washer 12. Tapered Kingpin Pin
3. Pivot Pins 8. Spindle Assembly 13. Hex Nut
4. Pin Keeper and Screw 9. Bushing Seal 14. Thrust Washer
5. Thrust Washer 10. Spindle Bushing
Figure 3-30. Steering Assembly

STEER CYLINDER REMOVAL the 2 tapered king pins (12), from the tapered king-
pin bores on the axle, and thrust washer (14) from
1. Disable machine operation and block all wheels. Dis-
lower axle. Remove spindle from axle.
connect, cap and label all hydraulic lines on steer cyl-
inder (1). ASSEMBLY
2. Remove the screws and pin keeper (4), and pin (3) 1. When assembling steer cylinder and spindle, follow
connecting cylinder rod to tie rod (2). Slide the tie Removal Steps in reverse.
rod out of the cylinder rod, capture the thrust washer
(5) on bottom of tie rod. NOTE: Apply Loctite® #242 to bolts (4, 6, 11).
3. Support steer cylinder. Remove 4 bolts (6) and wash- Torque flange bolt (11) to 108 ft. lb. (147 Nm).
ers (7) connecting cylinder to axle. Carefully remove Inspect spindle bushing seals (9), replace if damaged.
cylinder. Ensure large thrust washer (14) is installed between
spindle (8) and bottom of axle.
SPINDLE REMOVAL
Be certain spindle nut (13) is aligned and seated in the
4. Remove wheel and drive assembly prior to spindle machined groove on the axle before tightening.
(8) removal.
5. Disconnect tie rod (2) from spindle by removing
screw and pin keeper (4), and pin (3).
6. Support spindle. Remove spindle from axle by
removing flange bolts (11), from nuts (13). Remove

3121781 3-37
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Axle Lockout Cylinder

1. Axle Lockout Cylinder 2. Bolt 3. Washers

Figure 3-31. Axle Lockout Cylinder

REMOVAL INSTALLATION
1. Disable machine operation. 1. Attach cylinder to frame using four bolts (2) and
2. Disconnect, cap and label hydraulic lines on the axle washers (3).
lockout cylinder (1). NOTE: Make sure the shoulder on the lockout cylinder is
3. Remove the four bolts (2) and washers (3) connect- firmly against the bottom of the mounting plates on
ing the cylinder to the frame. the frame before torquing bolts.
4. Carefully remove cylinder from the frame. Apply Loctite® #242 and Loctite® Primer #7471 to
bolts (2).
2. Uncap and reconnect hydraulic lines to cylinder.
NOTE: Refer to Section 4.14, Cylinder Assemblies for axle
lockout cylinder breakdown and bleeding procedure.
3. Operate axle lockout cylinder function to ensure
proper functioning.

3-38 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.6 LEVELING JACKS

Cylinder Removal

1 1. Cover
10
2. Bolt
3. Flat washer
3
2 4. Tinnerman Nut
9 5. Jack Cover Attach Bracket
6. Bolt
7 7. Nut/Washer
8. Leveling Jack Cylinder
4 9. Bolt
8
10. Nut/Washer

MAF04230

Figure 3-32. Leveling Jack Cylinder Removal

REMOVAL INSTALLATION
1. Disable machine operation. 1. Follow Removal Steps in reverse.
2. Remove the three bolts (2 and 9), flat washers (3 and NOTE: Refer to Figure 4-30., Leveling Jack Cylinder for cylin-
10) and from cover (1). Carefully lift cover up and off der breakdown.
of machine.
3. Disconnect, cap and label all hydraulic lines and 2. Operate leveling jacks to ensure proper operation.
wires connected to the leveling jack cylinder (8).
4. Support cylinder. Remove the four bolts (6) and nuts
and washers (7) attaching cylinder to cylinder
mount. Remove jack cover attach bracket (5).
5. Carefully remove cylinder from mount.

3121781 3-39
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Assembly Removal
NOTE: Applies to both front and rear of machine.

2
5
4
6

4
3

MAF04240

1. Leveling Jacks Assembly 3. Bolt 5. Nut

2. Hydraulic Lines/Electrical Wiring 4. Washers (Hardened) 6. Doubler Plate

Figure 3-32. Leveling Jacks Assembly

REMOVAL INSTALLATION
1. Follow Removal Steps in reverse.
NOTE: Mount doubler plate on outside of frame rail.
SUPPORT THE LEVELING JACKS ASSEMBLY BEFORE ATTEMPTING ANY
REMOVAL AND/OR ASSEMBLY PROCEDURES. 2. Insert hoses and wiring into the leveling jack tube
assembly. Uncap and reconnect hydraulic lines and
electrical wires to cylinders and switches.
1. Disable machine operation and block all wheels.
3. Enable machine and unblock all wheels.
2. Remove covers from leveling jack cylinders (refer to
Figure 3-32., Leveling Jack Cylinder Removal). 4. Operate leveling jacks to ensure proper operation.
3. Disconnect, cap and label hydraulic lines (2) con-
nected to leveling jack cylinders. Disconnect and
label all electrical wiring attached to cylinder and
switches. Remove hoses and wiring from the leveling
jack tube assembly.
4. Remove the eight bolts (3), washers (4), nuts (5) and
doubler plate (6) through the frame.
5. Carefully lower assembly from the frame.

3-40 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.7 PLATFORM

1. Platform
2. Scissor Arms
3. Slide Block
4. Bolt
5. Locknut
6. Pin
1 7. Spacer Tube
8. Bolt
9. Locknut
3 10. Pin Keeper
11. Pin
4 3 7
8

9
10
11
5 3
6

MAF03770

Figure 3-33. Platform Removal

4. Detach the center attach link from the platform by

removing the bolt (8), locknut (9) pin keeper (10) and
NEVER WORK UNDER ELEVATED PLATFORM WITHOUT FIRST PROP- pin (11).
ERLY SUPPORTING THE PLATFORM AND BRACING/BLOCKING SCISSOR 5. With scissor arm assembly (2) braced, remove the
ARM ASSEMBLY. slide block (3) at each corner of the platform by
removing the bolt (4), locknut (5), pin (6) and spacer
REMOVAL tube (7).
6. Lift platform away from the machine.
1. Disable machine operation.
INSTALLATION
2. Place lifting straps at each end of the platform (1).
Using an overhead crane lift platform. 1. Follow Removal Steps in reverse.
NOTE: Use lifting straps and overhead crane capable of lift-
ing at least 6000 lbs (2722 kg).
TIGHTEN BOLTS (4) AND LOCKNUTS (5) TO JUST MAKE CONTACT WITH
3. Disconnect, cap and label hydraulic lines on deck THE SLIDE BLOCKS (3). DO NOT OVERTIGHTEN.
extension cylinders. Disconnect and label all electri-
cal wires going to platform.

3121781 3-41
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Platform Control Station

1 3

2 6
7
8
9

10

12
11

4
5

14 13
15
MAF04160

1. Mounting Bracket 5. Wiring Harness Connec- 9. Select Switch/Guard 13. Engine Start Switch
2. Control Box Plate tor 10. Stop Switch 14. Horn Switch
3. Joystick Controller 6. Function Decal 11. Fuel Select or Glow Plug 15. Blank Plug
4. Alarm Speaker 7. LED Indicator Switch/Guard
8. Leveling Jack Switch/ 12. Speed Select Switch
LEDS

Figure 3-34. Platform Control Station

ASSEMBLY
1. Follow Disassembly Procedures in reverse.
DO NOT SWITCH PLATFORM CONTROL BOXES FROM ONE MACHINE TO
ANOTHER. IF BOXES ARE SWITCHED, THE MACHINE WILL NOT POWER 2. Ensure electrical wires are properly and securely
attached to switches, buttons and bulbs.
UP IN PLATFORM MODE, AND THE SYSTEM DISTRESS INDICATOR ON
THE PLATFORM CONTROL BOX WILL REMAIN LIT. NOTE: Ensure wires are not pinched when installing the
loaded control box plate back onto the mounting
DISASSEMBLY bracket.
1. Disconnect the cable from the harness connector (5) 3. Reattach wiring cable to harness connector (4) on
on the underside of the platform control station. underside of platform control station.
2. Remove the control box plate (2) from the mounting 4. Mount control station to platform rail.
bracket (1) by removing the three bolts and washers.
5. Operate functions with platform control console to
3. Once loaded control box plate is removed, switches, ensure proper operation.
buttons and bulbs can be removed for replacement.
4. Remove the four screws and nuts to remove the joy-
stick controller (3).
5. The harness can be removed from the box by remov-
ing the harness connector terminal nut, and discon-
necting all the wiring inside the control box.

3-42 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Joystick Controller

Figure 3-35. Joystick Controller

Table 3-9. Joystick Specifications Table 3-10. Joystick Plug Loading Chart
Type Single Axis (Y Axis Only) Terminal Color Function
Input Voltage 5V 1 RED Handle COM
Current Consumption 10mA @ 12VDC 2 VIOLET Trigger N.O.
Centered Output Voltage 2.50VDC 3 Spare
Reverse Voltage 4.0VDC 4 YELLOW Rocker Right
Forward Voltage 1.0VDC 5 GREEN Rocker Left
6 Spare
7 White/RED +5VDC
8 White/BLACK Ground
9 BROWN SIG Output

3121781 3-43
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.8 SCISSOR ARMS Scissor Arm Assembly Removal

Lift Cylinder Removal
REMOVAL NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST
PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEMBLY.

REMOVAL
NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST
PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEMBLY. NOTE: Applies to all four corners.
1. Remove platform (refer to Figure 3-33., Platform
1. Remove platform (refer to Figure 3-33.). Removal).
2. Elevate the scissor arm assembly enough to gain 2. Disconnect, cap and label all hydraulic hoses and wir-
access to the upper and lower connection pins.
ing attached to scissor arms and lift cylinder.
Block/brace scissor arms and disable machine.
3. Support the scissor arm assembly with appropriate
3. Disconnect, cap and label all hydraulic lines con- lifting straps and overhead crane.
nected to the lift cylinder. Disconnect and label all
electrical wires connected to lift cylinder. 4. Disconnect the scissor arm assembly from the four
sliders by removing the bolts and nuts.
4. Attach lifting straps to overhead crane and lift cylin-
der and support cylinder before attempting to 5. Push pins out.
remove from arm assembly. 6. Carefully lift arm assembly up and away from chassis.
5. Remove the cylinder upper pin by removing the bolt, INSTALLATION
nut and collar. Push pin out. Follow Removal Steps in reverse.
6. Remove the lower pin by removing the bolt and nut.
Push pin out.
7. Carefully lift cylinder up and out of arm assembly.
INSTALLATION
1. Follow Removal Steps in reverse.
2. After assembly, operate lift cylinder to ensure proper
operation.
NOTE: Refer to Figure 4-28., Lift Cylinder for cylinder break-
down.

Scissor Arms Removal

NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST

PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEMBLY.

NOTE: Scissor arms can be removed individually or as an

entire assembly.
ARM REMOVAL
1. Remove platform (refer to Figure 3-33.) and lift cylin-
der (refer to Figure 3-37.).
2. Disconnect, cap and label all hydraulic hoses and wir-
ing attached to scissor arms.
3. Support the scissor arm(s) being removed.
4. Remove the pin from the scissor arm by removing
the two bolts, nuts and collar.
5. Push pin and bearing out from scissor arms.
6. Repeat at each connecting pin.
INSTALLATION
1. Follow Removal Steps in reverse.

3-44 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

F
G

MAF04270

NOTE: See Figure 3-37. and Figure 3-38. for letter detail views. Route hoses/wiring through wire rod on arm, behind safety prop.
Figure 3-36. Scissor Arm - Hose and Wiring Routing.

3121781 3-45
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

U DETAIL E

K
K
DETAIL A

K
K
J
DETAIL F
S
B
H
C
DETAIL B

K
P K
K

D
M

T
J DETAIL G
K
J
F
S
DETAIL C

L
A G
E

A
K
K
R

A
DETAIL H
A
DETAIL D
MAF03780

NOTE: Detail H - Do not overtighten safety rod keeper plate, it must rotate freely.
Detail A, C, D, F, G, and H - Apply Loctite #242 to threads.
Figure 3-37. Scissor Arm Component Assembly 1 of 2.

3-46 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

DETAIL P

DETAIL J

DETAIL K DETAIL U

DETAIL L

DETAIL R
DETAIL N

DETAIL M

DETAIL S DETAIL T
MAF04150

NOTE: Coat all pins (Detail: B, J, K, L, M, and V) with moly paste lubricant (example: Loctite #51049) before assembly.
Figure 3-38. Scissor Arm Component Assembly 2 of 2.

3121781 3-47
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.9 SIDE COMPARTMENT COVERS

7

1
8

5
MAF04330

Figure 3-39. Left Side - Engine Compartment Covers

1. Engine Main Compartment Cover 4. Ladder Assembly 7. Engine Exhaust Tube
2. Front Engine Door 5. Door Latch Assembly 8. Generator Shield
3. Rear Engine Door 6. Door Hinge Assembly

3-48 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

7
4

MAF04170

Figure 3-40. Right Side - Hydraulic/Fuel Compartment Covers

1. Hydraulic/Fuel Main Compartment Cover 4. Ladder Assembly 6. Door Hinge Assembly
2. Hydraulic Tank Door 5. Door Latch Assembly 7. Bracket Ladder Support
3. Fuel Tank Door

3121781 3-49
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Cover Removal 3.10 GROUND CONTROL STATION

NOTE: Procedures apply to both left and right side compart- Control Station Removal
ment hoods.
1. Elevate the platform to a height where, when
removed and lifted, the compartment covers clear
the underside of the platform. Engage the arm safety
prop and/or block the scissor arms to prevent lower-
ing.
2. Disable machine operation. 3
3. If removing the main compartment cover, the hinged
cover and any outer covers/doors must be removed 2
first.
4. Attach lifting straps to each end of the large com-
partment cover and support with an overhead lifting
device.
5. Remove the bolts on the hinges to remove the door
from the cover.
6. Remove the bolts and washers, from the front covers
or doors, remove and lay aside.
7. Remove the ladder from the support bracket by 1
removing the bolts, washers and nuts.
8. Remove the bolts and washers, from the front, top
and back of the large compartment cover. 3
NOTE: On engine side only, remove the exhaust pipe shield
from the cover by removing the bolts, washers, and
nuts. MAF04200

9. Carefully lift the main compartment cover up and

away from the machine. 1. Ground Control Box 3. Mounting Bolts, Nuts
2. Control Box Mount and Washers
Cover installation
Figure 3-41. Ground Control Station Removal
1. Follow Removal Steps in reverse.

REMOVAL
1. Disconnect and label the harnesses from the ground
control box (1).
2. Remove the ground control box from the control box
mount (2) by removing the four lower and two upper
bolts, nuts and washers (3).

INSTALLATION
1. Follow Removal Steps in reverse.

3-50 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Ground Control Station Components

4

3
2 1 MAF04180

1. Ground Control Box 4. Chassis Tilt Sensor

2. Lid 5. Machine Harness Connectors
3. Circuit Board

Figure 3-42. Ground Control Station Components

DISASSEMBLY ASSEMBLY
1. Disconnect the harnesses from the ground control 1. Reattach any wires and/or plugs.
box (1). 2. Close lid (2) and secure.
2. Open the lid (2) to gain access to components inside 3. Reattach machine harnesses to the ground control
the ground control box. box (5).
3. Disconnect any wires and/or plugs from damaged
components (3 or 4). NOTE: If Chassis tilt sensor or the ground control station
box is remo.ved and replaced, the Chassis tilt sensor
4. Remove and replace components if necessary.
must be calibrated (refer to Section 5.4, Location Of
Additional Sensors).

3121781 3-51
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Options Control Module

The Options Control Module provides additional machine harness connections for additional machine components
such as the Leveling Jacks and LSS control system. If determined faulty, this module is only replaceable and not service-
able.

3
2

9
6
1
8

5 4

MAF04520

1. Option Control Module 6. J2-Connector

2. Ground Control Station 7. J3-Connector
3. Station/Module Mounting Plate 8. J4-Connector
4. Module Mounting Bolts/Nuts/Washers 9. J5-Connector
5. J1-Connector

Figure 3-43. Optional Control Module

REMOVAL INSTALLATION
1. Tag and Disconnect the wiring harness(s) from the J- 1. Mount new module to the mounting plate using the
Connectors on the module. four bolts, nuts and washers (4)
2. Remove the four nuts and washers (4) from the 2. Reconnect the J-Connector wiring harness(s).
mounting bolts. 3. Power up machine and operate functions to check
3. Remove the module from the mounting plate. proper operation.

3-52 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.11 BATTERY INSTALLATION

1. Place battery in the seat. Negative battery terminal
(2) should be closest to outside of machine.
2. Secure battery in place with the hold-down bracket,
bolt, nut and washers (4).
3. Reconnect red battery cable to positive battery ter-
minal (3). Secure terminal cover in place over termi-
nal.
4. Reconnect black battery cable to negative battery
terminal (2).
(+) 5
(-) 5. If removed, secure auxiliary power block (5) to
2 machine using two bolts, nuts and washers. Recon-
nect cables.

3
4

1 MAF04190

Figure 3-44. Battery Removal

1. Battery 4. Bracket, Bolt, Nut &
2. Battery Terminal (-) Washers
3. Battery Terminal (+) 5. Auxiliary Power Block

REMOVAL
1. Disconnect the red battery cable from the positive
battery terminal (3).
2. Disconnect the black battery cable from the negative
(2) battery terminal.
3. Remove the bolts, nuts, and washers to remove the
hold-down bracket (4) securing the battery in place.
Remove battery.
4. With the positive battery cable disconnected, if nec-
essary, the auxiliary power block (5) can be removed
by first disconnecting the cables from the block.
Remove the bolts, washers and nuts securing the
block to the machine compartment cover.

3121781 3-53
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.12 FUEL TANK

5 4

MAF04220

1. Fuel Tank 4. Fuel Feed/Return and Vent Lines

2. Tank Drain (on bottom of tank) 5. Tank Mounting Bolts/Nuts and Washers
3. Tank Sending Unit

Figure 3-45. Fuel Tank Installation

REMOVAL INSTALLATION
NOTE: Outer cabinet, ladder and door shown removed for 1. Follow Removal Steps in reverse.
illustrative clarity only. NOTE: If removed, reuse or replace sending unit gasket, as
1. Disable machine operation. necessary. Before reinstalling, apply Loctite #222 to
threads of tank sending unit bolts.
2. Drain fuel from the fuel tank (1, 2). Store fuel in If removed, before reinstalling into tank insert apply
appropriate receptacle.
pipe sealant (Loctite® #567) to fuel and vent line fit-
3. Disconnect and cap the fuel and vent lines (4) tings on the fuel tank (1).
attached to the fuel tank. Apply (Loctite 567 PST thread sealant) to threads of
4. Remove the bolts, washers and nuts (5) from the bot- tank aluminum drain plug before installing. Do not
tom front and top rear of the fuel tank. over tighten.
5. Remove the fuel tank from the hydraulic compart-
ment. 2. Refill fuel tank with proper fuel.
6. If necessary, remove the tank sending unit (3) from
the tank.
ENSURE PROPER FUEL LINES ARE ATTACHED TO PROPER FITTING ON
FUEL TANK. FUEL TANK IS LABELED WITH RETURN LINE, SUPPLY LINE
AND VENT LINE.

3. Ensure there is no fuel leakage.

3-54 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.13 HYDRAULIC TANK

1. Hydraulic Tank 3. Tank Mounting Bolts/Nuts and Washers

2. Tank Drain

Figure 3-46. Hydraulic Tank Removal

REMOVAL INSTALLATION
NOTE: It is recommended to remove the side compartment 1. Follow Removal Steps in reverse.
cover before attempting to remove the hydraulic 2. Ensure drain plug (2) is tight. Refill hydraulic tank (1)
tank (refer to Section 3.9, Side Compartment Covers). with 34 gal (128.7 l) hydraulic fluid.

1. Disable machine operation.

2. Drain hydraulic fluid from hydraulic tank (1) by open-
ing the drain plug (2). Store hydraulic fluid in appro-
priate receptacle.
3. Disconnect, cap and label all hoses connected to
tank.
4. Remove the bolts, washers, and nuts (3) attaching
the hydraulic tank to the machine. Remove tank from
machine.
NOTE: Hydraulic tank has two lifting lugs on the top corners
for lifting.
Empty tank weighs approximately 105 lbs (47.6 kg).

3121781 3-55
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.14 KUBOTA ENGINE NOTE: When servicing components on the back side of the
engine, remove the tray (2) and ladder (3), bolts, nuts
Engine Tray - Swing Out and washers to swing the engine tray out for better
access (as shown below).

MAF04500

1. Tray Pivot Pin 3. Ladder To Cabinet - Bolt, Nut, and Washer

2. Tray to Frame - Bolt, Nut and Washer

Figure 3-47. Engine Swing Out Tray Components

MAF04510

Figure 3-48. Engine Tray In Swing Out Position

3-56 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Dual Fuel/LPG System 6. Do not store LPG tanks near heat or open flame. For
complete instructions on the storage of LPG fuels,
refer to ANSI/NFPA 58 & 505 or applicable standards.

IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER

WITHOUT ALLOWING THE ENGINE TO STOP. THE FOLLOWING INSTRUC- DO NOT USE AN LPG TANK THAT IS DAMAGED. A DAMAGED TANK MUST
TIONS MUST BE FOLLOWED. BE REMOVED FROM SERVICE. FROST ON THE SURFACE OF A TANK,
VALVES, OR FITTINGS INDICATES LEAKAGE. A STRONG ODOR OF LPG
Changing From Gasoline to LP Gas FUEL CAN INDICATE A LEAK.

NOTE: Before climbing onto the platform, open hand valve 3.15 PROPANE FUEL SYSTEM PRESSURE RELIEF
on LP gas supply tank by turning valve counterclock-
wise.
1. Start engine from platform control station.
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI
2. While engine is operating, place the dual fuel switch (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY,
at platform control station to the LPG position. Allow
engine to operate, without load, until engine begins RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICA-
to “stumble” from lack of gasoline. At this time the BLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS.
machine is allowing the LP fuel to be sent to the fuel
regulator. To relieve propane fuel system pressure:

Changing From LP Gas to Gasoline 1. Close the manual shut-off valve on the propane
fuel tank.
1. With engine operating on LP under a no-load condi-
tion, throw LPG/GASOLINE switch at platform control 2. Start and run the vehicle until the engine stalls.
station to GASOLINE position. 3. Turn the ignition switch OFF.
2. If engine “stumbles” because of lack of gasoline,
place switch to LPG position until engine regains
smoothness, then return switch to GASOLINE posi-
tion. RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM.
3. Close hand valve on LP gas supply by turning clock- ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DISCONNECT-
wise. ING ANY FUEL LINE.

Using Liquid Petroleum (LP) Gas 3.16 PROPANE FUEL SYSTEM LEAK TEST

CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT MORE THAN
NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK FOR PROPANE
MOMENTARILY.
FUEL SYSTEM LEAKS.
WHEN REFUELING LPG POWERED SCISSOR LIFTS, ALWAYS FOLLOW
MANUFACTURERS SPECIFICATIONS AND/OR APPLICABLE REGULA- Always inspect the propane fuel system for leaks after
TIONS. performing service. Check for leaks at the fittings of
the serviced or replaced component. Use a commer-
cially available liquid leak detector or an electronic
1. If machine is to be left overnight or longer, it must be
parked outside or the LPG tank removed and stored leak detector. When using both methods, use the
outside. electronic leak detector first to avoid contamination
by the liquid leak detector.
2. LPG is extremely flammable. No smoking.
3. Only trained and authorized personnel are permitted
to operate filling equipment.
4. Fill LPG tanks outdoors. Stay at least 50 ft (15 m) from
buildings, motor vehicles, electrical equipment or
other ignition sources. Stay at least 15 ft (5 m) from
LPG storage tanks.
5. During transfer of LPG, metal components can
become very cold. Always wear gloves when refilling
or changing tanks to prevent “freeze burns” to skin.

3121781 3-57
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Generator (if equipped)

1
3 4
2 5
MAF03540

1. Generator 4. Drive Pulley

2. Belt Tensioner 5. Bracket Assembly
3. Drive Belt
Figure 3-49. AC Generator Installation

Table 3-11. AC Generator Specifications

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- DESCRIPTION 7500 KW 4000 KW
ING. Voltage 120/240V AC±10% 120/240 V AC±10% - 60Hz
110/230V AC±5% - 50Hz
REMOVAL
Continuous 7.5 KW - 240V - 3 Phase
1. Disable machine operation. Rotate engine tray to 6.0 KW - 240V - 1 Phase 4.0 KW - 1 Phase
access back of engine. 6.0 KW - 120V - 1 Phase
2. Disconnect and label electrical wires attached to Peak 8.5 KW - 3 Phase
generator (1). 4.0 KW
6.0 KW - 1 Phase
3. Remove drive belt tension using the belt tensioner Amps Peak 18.3 Amps - 3 Phase
and remove belt from generator pulley.
26 Amps - 1 Phase 20 Amps
4. Remove the generator from the engine by removing 50 Amps - 1 Phase
the two upper bracket (5) bolts, nuts, and washers.
And the lower pivot, belt tensioner bolt, nut, and
washer. NOTE: The generator control box is mounted on the rear
wall of the Hydraulic/Fuel Tank cabinet just behind
5. Replace belt if damaged.
the ground control station.
The platform junction box is mounted under the
INSTALLATION platform deck on the Hydraulic/Fuel Tank cabinet
1. Follow Removal Steps in reverse. Ensure belt is tight side of the machine.
before securing generator with the bolts. See Section 6, Electrical Schematics generator elec-
NOTE: Apply Loctite® #242 to the threads of the generator trical configuration.
mounting bolts.

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 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Exhaust System

2 1

3 2
2

4 5

MAF04440 MAF04450

Dual Fuel - Gas/LPG Diesel

Figure 3-50. Exhaust System (Kubota Engine)
1. Tail Pipe 4. Mounting Bracket 1. Muffler 3. Mounting Bracket
2. O2 Sensor 5. Gasket 2. Gasket
3. Muffler 6. Exhaust Pipe

DUAL FUEL - GAS/LPG DIESEL

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC-
ING. ING.
REMOVAL REMOVAL
1. Disable machine operation. 1. Disable machine operation.
2. Disconnect the O2 Sensor (2) wiring. Disassemble the 2. Unbolt the muffler (1) from the mounting bracket (3),
tail pipe (1) from the muffler (3) by removing the two by removing the bolts, nuts, and washers from the
attaching bolts, washers, nuts, and gasket. rubber isolating mounts.
3. Disassemble the muffler (3) from the exhaust pipe (6) 3. Disassemble the muffler (1) from the exhaust mani-
removing by the four attaching bolts, nuts, washers fold by removing the four bolts, washers, and gasket
and gasket. Also remove the two bolts and washers (2) attaching it to the manifold.
attaching the muffler to the mounting bracket (4).
INSTALLATION
4. Disconnect the O2 Sensor (2) wiring. Disassemble the
exhaust pipe (6) from the engine exhaust manifold 1. Follow Removal Steps in reverse.
by removing the four bolts, nuts, washers and gasket
at the exhaust manifold.
INSTALLATION
1. Follow Removal Steps in reverse.
NOTE: Torque on O2 Sensors is 32±3.6 ft. lb. (44±4.9 Nm).

3121781 3-59
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Air Cleaner System

1
2 1
5 2

4
3 3
4
6
7 5

MAF04470
MAF04460

Dual Fuel - Gas/LPG Diesel

Figure 3-51. Air Cleaner System (Kobota Engine)

1. Inlet Hose 5. Intake Pipe 1. Inlet Hose 5. Intake Pipe
2. Clamp 6. Clamp 2. Clamp 6. Clamp
3. Air Cleaner Assy. 7. 90° Elbow 3. Air Cleaner Assy.
4. Clamp 8. Clamp 4. Clamp

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC-
ING. ING.
REMOVAL REMOVAL
1. Disable machine operation. If necessary, swing 1. Disable machine operation. If necessary, swing
engine tray out for better access to components. engine tray out for better access to components.
2. Loosen the clamp (4) and (8) attaching the intake 2. Loosen the clamp (4) and (6) attaching the intake
pipe to the air cleaner assembly (3) and engine pipe to the air cleaner assembly (3) and engine
intake manifold. Disconnect the intake pipe from the intake manifold. Disconnect the intake pipe from the
air cleaner assembly and remove the complete air cleaner assembly and remove the complete
intake pipe from the engine assembly. intake pipe from the engine assembly.
3. To remove the air cleaner assembly (3) from the air 3. To remove the air cleaner assembly (3) from the air
cleaner bracket clamp, Unscrew the main clamp cleaner bracket clamp, Unscrew the main clamp
screw on the clamp until the air cleaner is loose in screw on the clamp until the air cleaner is loose in
the bracket. Release the latches on the end and the bracket. Release the latches on the end and
remove the end cap from the air cleaner assembly. remove the end cap from the air cleaner assembly.
Slide the air cleaner assembly with inlet hose out of Slide the air cleaner assembly with inlet hose out of
the bracket clamp. the bracket clamp.
NOTE: The filter element can be removed from the air NOTE: The filter element can be removed from the air
cleaner by releasing the latches on the end of the air cleaner by releasing the latches on the end of the air
cleaner. Replace filter element as needed. See Section cleaner. Replace filter element as needed. See Section
1.8, Service Maintenance, 1.8, Service Maintenance,
INSTALLATION INSTALLATION
1. Follow Removal Steps in reverse. 1. Follow Removal Steps in reverse.

3-60 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Radiator

Figure 3-52. Radiator Installation (All Engines)

1. Radiator Mounting Plate 4. Fan Shroud Assembly
2. Mounting Plate Lower Support 5. Engine Tray
3. Radiator Assembly 6. Radiator Petcock Location

5. Re-check that all connections, hoses, etc. are discon-

nected and remove complete radiator mounting
ALLOW RADIATOR TO COOL DOWN BEFORE SERVICING. plate (1) assembly from the engine tray.
6. Dissemble the radiator shroud (3), and radiator
REMOVAL assembly (2) from the radiator mounting plate
assembly (1).
1. Disable machine operation. Swing engine tray out
for better access to components. INSTALLATION
2. Drain the coolant from the radiator into a suitable 1. Follow Removal Steps in reverse.
container by opening the petcock (6) on the bottom NOTE: Refill with fresh clean coolant properly balanced.
left corner of the radiator.
3. Disconnect the:
• upper and lower radiator hoses from the radiator.
• if necessary remove the air cleaner or disconnect the
intake pipe hose connector at the radiator mounting
plate
4. Support the radiator mounting plate assembly (1)
and remove the four large bolts holding the mount-
ing plate to the engine swivel tray (4), and the lower
support bracket (2)

3121781 3-61
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Engine Electrical Component Locations

1. Dual Fuel Engine 2. ECM Module

Figure 3-53. Duel Fuel Engine - Control Module Location

FC274
PWR RELAY RL13
FUSE ETV RELAY
FC273 RL11
ALT FUSE FC271 RL12
STRT FUSE LP SELECT RL
PWR RELAY
RL10
STRT

T7
ALT STUD MS153
ALTERNATOR ALT CONN
EC9
STRT SIG
EC8
BATT+
EC8
STRT POS

GND02
ENG GND FC270
MAIN MDL FUSE
MAF04480

Figure 3-54. Duel Fuel Engine Compartment - Electrical Component Locations

3-62 3121781
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

FC257 FC267 RL6 RL4

HOLD RL 2 SPD HOLD GLOW
FUSE FUSE RELAY PLUGS
FC260 FC259 FC258 RL5 RL2 RL3
ALT EXCITE PULL RL STRT PULL START 2 SPD
FUSE FUSE FUSE RELAY RELAY RELAY RL1
IGN
RELAY

TO OIL PRESSURE SENSOR

EC2
EC3
TO STARTER
SOLENOID
CONNECTOR

GND (2)
TO ENGINE BLOCK EC4
TO STARTER POWER
STUD

MAF04490

Figure 3-55. Diesel Engine Compartment - Electrical Component Locations (T4F and CE)

3121781 3-63
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Hydraulic Pump Installation

1. Tandem Gear Pump 3. Axial Hi 45 Pump

2. O-Ring 4. Pump Coupling

Figure 3-56. Hydraulic Pump Assembly

INSTALLATION
1. Follow Removal Steps in reverse.
ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC-
ING. NOTE: Apply grease to internal splines of pump coupling (1)
and external splines of axial pump (3) shaft prior to
REMOVAL installing pump.
Install a new o-ring (2) during installation.
1. Disable machine operation. Disconnect, cap and Apply Loctite® #242 to bolts.
label all hydraulic hoses connected to pumps (1, 3).
Disconnect and label all wiring connected to pumps. Torque mounting bolts to 50 - 55 ft. lb. (68 - 75 Nm)
for axial pump (3).
2. Remove the two bolts and washers attaching the
gear pump (1) to the axial pump (3). Carefully NOTE: Refer to Section 4.10, Gear Pump and Section 4.11,
remove the gear pump. Axial HI 45 Pump for more information on pumps.
3. Remove and discard the o-ring (2).
4. Remove the two bolts and washers attaching the
axial pump (3) to the coupling (4) of the motor. Care-
fully remove the axial pump.

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 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Pump Coupling Assembly

1. Coupler Housing 3. Engine Flywheel/Coupler Mounting Plate

2. Pump Coupler 4. Starter Bolts

Figure 3-57. Pump Coupling Assembly (All Engines)

INSTALLATION
1. Follow Removal Steps in reverse.
ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC-
ING. NOTE: Apply Loctite® #242 to bolts.
Torque coupling to flywheel bolts to 20 - 25 ft. lb.
REMOVAL (27.1 - 33.8 Nm).
Torque coupler housing to engine bolts to
1. Disable machine operation. Disconnect the battery 13 - 15 ft. lb. (17.6 - 20.3 Nm).
positive (+) terminal.
2. Remove exhaust system and pump assemblies, as
necessary.
3. Remove the five bolts, washers and nuts, plus the
two starter bolts holding the coupler housing (1) to
the engine block plate. Support starter, do not hang
by electrical wiring. Remove the coupler housing 1).
4. Remove the five pump coupler bolts to remove the
pump coupling from the engine flywheel/mounting
plate (3). Remove coupling plate (2).

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 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Engine Removal

1. Kubota Engine 4. Engine Isolator Mount

2. Engine Lifting Lugs 5. Swinging Engine Tray
3. Left/Right Side Engine Mounting Brackets

Figure 3-58. Engine Removal (All Engines)

REMOVAL
1. Disable machine operation. Disconnect battery posi-
ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- tive (+) terminal. Swing engine tray (5) out for access
ING. to both sides of engine.

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 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

2. Remove platform ladder and brackets, exhaust sys-

tem, air cleaner system, hydraulic pumps and radia-
tor cooling system, as necessary.
3. Disconnect, cap and label all hoses connected to
engine (1). Disconnect and label all electrical wiring
connected to engine.
4. Using the lifting lugs (2) at the front and rear corners
of the engine, support engine (1) with lifting device
capable of lifting 500 lbs (227 kg) (refer to engine
manual for proper lifting information).
5. Remove the four large bolts, nuts, and washers secur-
ing the left/right side engine mounting brackets (3)
to the isolator mounts (4) and tray.
6. Slowly lift the engine up and out of the engine com-
partment.

IF NOT REMOVED, BE CAREFUL NOT TO DAMAGE THE RADIATOR FAN

ON THE RADIATOR HOUSING WHEN LIFTING THE ENGINE.

INSTALLATION
1. Follow Removal Steps in reverse.
NOTE: Apply Loctite® #242 to the engine mount bolts.

3121781 3-67
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTES:

3-68 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

SECTION 4. BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.1 CYLINDERS - THEORY OF OPERATION alternate path for the continuing flow from the pump,
thus preventing rupture of the cylinder, hydraulic line or
Cylinders are of the double acting type. The steer sys- fitting. Complete failure of the system pump is also
tem incorporates a double acting cylinder. A double act- avoided by relieving circuit pressure. The relief valve is
ing cylinder is one that requires oil flow to operate the installed in the circuit between the pump outlet (pres-
cylinder rod in both directions. Directing oil (by actuat- sure line) and the cylinder of the circuit, generally as an
ing the corresponding control valve to the piston side of integral part of the system valve bank. Relief pressures
the cylinder) forces the piston to travel toward the rod are set slightly higher than the load requirement, with
end of the barrel, extending the cylinder rod (piston the valve diverting excess pump delivery back to the
attached to rod). When the oil flow is stopped, move- reservoir when operating pressure of the component is
ment of the rod will stop. By directing oil to the rod side reached.
of the cylinder, the piston will be forced in the opposite
direction and the cylinder rod will retract. Crossover Relief Valves
NOTE: The lift cylinder is a single acting cylinder which Crossover relief valves are used in circuits where the
takes hydraulic pressure to extend and gravity to actuator requires an operating pressure lower than that
retract. supplied to the system. When the circuit is activated and
the required pressure at the actuator is developed, the
A holding valve is used in the lift circuit to prevent
crossover relief diverts excess pump flow to the reser-
retraction of the cylinder rod should a hydraulic line
voir. Individual, integral relief’s are provided for each
rupture or a leak develop between the cylinder and its
side of the circuit.
related control valve.

4.2 VALVES - THEORY OF OPERATION 4.3 CYLINDER CHECKING PROCEDURE

NOTE: Cylinder check must be performed anytime a system
Solenoid Control Valves (Bang-Bang) component is replaced or when improper system
operation is suspected.
Control valves used are four-way three-position sole-
noid valves of the sliding spool design. When a circuit is Cylinders Without Counterbalance Valves
activated and the control valve solenoid energizes, the
spool is shifted and the corresponding work port opens 1. Using all applicable safety precautions, activate
to permit oil flow to the component in the selected cir- engine and fully extend cylinder to be checked. Shut
cuit, with the opposite work port opening to reservoir. down engine.
Once the circuit is deactivated (control returned to neu- 2. Carefully disconnect hydraulic hoses from retract
tral), the valve spool returns to neutral (center) and oil port of cylinder. There will be some initial weeping of
flow is then directed through the valve body and hydraulic fluid which can be caught in a suitable con-
returns to reservoir. A typical control valve consists of tainer. After the initial discharge, there should be no
the valve body, sliding spool, and two solenoid assem- further drainage from the retract port.
blies. The spool is machine fitted in the bore of the valve
body. Lands on the spool divide the bore into various 3. Activate engine and extend cylinder.
chambers, which, when the spool is shifted, align with 4. If cylinder retract port leakage is less than 6-8 drops
corresponding ports in the valve body open to common per minute, carefully reconnect hose to port and
flow. At the same time other ports would be blocked to retract cylinder. If leakage continues at a rate of 6-8
flow. The spool is spring-loaded to center position, drops per minute or more, cylinder repair must be
therefore when the control is released, the spool auto- made.
matically returns to neutral, prohibiting any flow 5. With cylinder fully retracted, shut down engine and
through the circuit. carefully disconnect hydraulic hose from cylinder
extend port.
Relief Valves 6. Activate engine and retract cylinder. Check extend
Main relief valves are installed at various points within port for leakage.
the hydraulic system to protect associated systems and 7. If extend port leakage is less than 6-8 drops per min-
components against excessive pressure. Excessive pres- ute, carefully reconnect hose to extend port, than
sure can be developed when a cylinder reaches its limit activate cylinder through one complete cycle and
of travel and the flow of pressurized fluid continues check for leaks. If leakage continues at a rate of 6-8
from the system control. The relief valve provides an

3121781 4-1
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

drops per minute or more, cylinder repairs must be 4.4 OSCILLATING AXLE - LOCKOUT CYLINDER TEST
made.
(IF EQUIPPED)
Cylinders With Single Counterbalance Valve

LOCKOUT CYLINDER SYSTEM TEST MUST BE PERFORMED QUARTERLY,

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER
SYSTEM OPERATION IS SUSPECTED.
1. Using all applicable safety precautions, activate
hydraulic system. NOTE: Ensure platform is fully lowered prior to beginning
lockout cylinder test, and that the surface used to
2. Shut down hydraulic system and allow machine to sit
approach the ramp is flat and level.
for 10-15 minutes. If machine is equipped with bang-
bang or proportional control valves, turn ignition
switch to on, move control switch or lever for appli-
Left Side Wheel Test
cable cylinder in each direction, then turn ignition 1. Place a 4 inch (10.16 cm) high block with ascension
switch to off. If machine is equipped with hydraulic ramp in front of left wheel of the oscillating axle.
control valves, move control lever for applicable cyl-
2. From platform control station, select LOW drive
inder in each direction. This is done to relieve pres-
speed.
sure in the hydraulic lines.
Carefully remove hydraulic hoses from appropriate 3. Set the DRIVE control switch into position and care-
cylinder port block. fully drive the machine up ascension ramp until left
oscillating axle wheel is on top of block.
3. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial 4. Verify the axle oscillates to maintain contact with the
discharge, there should be no further leakage from ground/ramp. (All four wheels on the ground).
the ports. If leakage continues at a rate of 6-8 drops 5. Raise machine platform above stowed position
per minute or more, the counterbalance valve is approximately 14 ft (4.26 m) on the 530LRT.
defective and must be replaced. 6. Carefully drive the machine back off the block and
4. To check piston seals, carefully remove the counter- ramp.
balance valve from the retract port. After initial dis- 7. Have an assistant check to see that the left oscillating
charge, there should be no further leakage from the axle wheel that was on the block is in position on the
ports. If leakage occurs at a rate of 6-8 drops per min- ground. The axle should oscillate so that all four
ute or more, the piston seals are defective and must wheels maintain contact with the ground.
be replaced.
8. In the current position (platform raised and all four
5. If no repairs are necessary or when repairs have been tires on flat and level surface), carefully drive
made, replace counterbalance valve and carefully machine up the ramp block again.
connect hydraulic hoses to cylinder port block.
9. Have an assistant check to verify that the axle did not
6. If used, remove lifting device supporting platform or oscillate and remained locked (one wheel is off of the
release and stow safety prop, activate hydraulic sys- ground).
tem and run cylinder through one complete cycle to
check for leaks. 10. Carefully drive the machine back off the block and
ramp.
11. Lower the machine platform; the lockout cylinder
should then release and allow wheel to rest on the
ground. It may be necessary to activate DRIVE to
release cylinders.
12. If the lockout cylinders do not function properly,
have qualified personnel correct the malfunction
prior to any further operation.

4-2 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Right Side Wheel Test 4.5 DRIVE PUMP PRE-FILL PROCEDURE

1. Place a 4 inch (10.16 cm) high block with ascension The drive pump should be pre-filled with recommended
ramp in front of right wheel of the oscillating axle. hydraulic fluid prior to machine start up.
2. From platform control station, select LOW drive Before starting this procedure inspect the unit for any
speed. damage incurred during shipping and handling. Make
3. Set the DRIVE control switch into position and care- certain all components are clean prior to filling with
fully drive the machine up ascension ramp until right hydraulic fluid.
oscillating axle wheel is on top of block.
The methods to pre-fill pump is as follows:
4. Verify the axle oscillates to maintain contact with the
ground/ramp. (All four wheels on the ground). Pre-Fill of the Drive Pump Housing Without HOC
5. Raise machine platform above stowed position
approximately 14 ft (4.26 m) on the 530LRT. These types of pumps should never be dry started.
Pre-fill the pump as follows:
6. Carefully drive the machine back off the block and
ramp.
1. The drive pump has 2 case drain ports. Both are SAE
7. Have an assistant check to see that the right oscillat- #12 ports. The lower port has a 3/4 in. hose going
ing axle wheel that was on the block is in position on back to tank. The other port has an SAE #12 plug in.
the ground. The axle should oscillate so that all four Using a 9/16 Allen wrench remove the plug.
wheels maintain contact with the ground.
2. Fill the hydraulic tank.
8. In the current position (platform raised and all four
tires on flat and level surface), carefully drive 3. Fluid from the hydraulic tank will back flush into the
machine up the ramp block again. pump housing through the 3/4 in. case drain hose.
Air will be forced out of the open port on the pump.
9. Have an assistant check to verify that the axle did not When oil starts flowing out of the open port, re-
oscillate and remained locked (one wheel is off of the install and tighten the plug. The pump case is now
ground). pre-filled.
10. Carefully drive the machine back off the block and
ramp. Pre-Fill of the Drive Pump Housing With HOC
11. Lower the machine platform; the lockout cylinder 4. The drive pump has both case drain ports filled by
should then release and allow the axle to oscillate. It hoses due to the HOC.
may be necessary to activate DRIVE to release cylin-
ders. 5. Repeat steps 1 to 3 as above, except instead of loos-
ening the SAE #12 plug, loosen the hose on the bot-
12. If the lockout cylinders do not function properly, tom of the case drain manifold, located near the
have qualified personnel correct the malfunction hydraulic tank. This is the hose connected to the
prior to any further operation. pump L2 port.

Priming the Gear Pump

1. Fill the hydraulic tank to the full mark.
2. Using a 2 in. wrench, loosen the pressure hose small
section of the gear pump (steering section). The hose
fitting does not need to be removed, just loosened
enough to let the air escape.
3. When oil leaks at the hose end, re-torque the hose
end. The pump is primed and the pumps are ready to
start.

3121781 4-3
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.6 DRIVE PUMP START-UP PROCEDURE MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL
START-UP.

Once charge pressure has been established, increase

THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PERFORMED WHEN speed to normal operating RPM. Charge pressure
STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN should be approximately 220 psi (15.5 bar) minimum. If
WHICH EITHER THE PUMP OR MOTOR HAVE BEEN REMOVED FROM charge pressure is incorrect, shut down and determine
THE SYSTEM. cause for improper pressure.

THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PERFORMED WHEN

STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN
WHICH EITHER THE PUMP OR MOTOR HAVE BEEN REMOVED FROM INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR’S ABIL-
THE SYSTEM. ITY TO CONTROL THE MACHINE.

THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DIS- Shut down prime mover and connect external control
ABLED (WHEELS RAISED OFF THE GROUND, DRIVE FUNCTION DISCON- input signal. Start prime mover, checking to ensure
NECTED, ETC.) WHILE PERFORMING THE PROCEDURE IN ORDER TO pump remains in neutral. With prime mover at normal
PREVENT INJURY TO TECHNICIAN AND OTHER PERSONNEL. TAKE NEC- operating speed, slowly check for forward and reverse
ESSARY SAFETY PRECAUTIONS BEFORE MOVING THE MACHINE. machine operation.
Charge pressure should remain at 220 psi to 240 psi
Prior to installing pump and/or motor, inspect unit(s) for
(15.5 bar to 16.9 bar) minimum during forward or
damage incurred during shipping and handling. Make
reverse operation. Continue to cycle slowly between
certain all system components (reservoir, hoses, valves, forward and reverse for at least five minutes.
fittings, heat exchanger, etc.) are clean prior to filling
with hydraulic fluid. Shut down prime mover, remove gauges, and plug
ports. Check reservoir level and add fluid if necessary.
Fill reservoir with recommended hydraulic fluid, which
should be passed through a 10 micron (nominal, no
bypass) filter prior to entering the reservoir. The use of
contaminated fluid will cause damage to components,
which may result in unexpected machine movement.
The inlet line leading from the reservoir to the pump
should be filled prior to start-up. Check inlet line for
properly tightened fittings and make sure it is free of
restrictions and air leaks.
Be certain to fill pump and/or motor housing with clean
hydraulic fluid prior to start-up. Fill housing by pouring
filtered oil into upper case drain port.
Install a 0 to 500 psi (0 to 35 bar) pressure gauge in the
charge pressure gauge port to monitor charge pressure
during start-up.
It is recommended that the external control input signal
electrical connections be disconnected at the pump
control until after initial start-up. This will allow the
pump to remain in its neutral position.
“Jog” or slowly rotate prime mover until charge pressure
starts to rise. Start prime mover and run at the lowest
possible RPM until charge pressure has been estab-
lished. Excess air may be bled from high pressure lines
through high pressure gauge ports.

DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL POSITION

(0 DEGREES SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PREVENT

4-4 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.7 HYDRAULIC COMPONENT START-UP that the pump is not being asked to draw an inlet
vacuum higher than it is capable of.
PROCEDURES & RECOMMENDATIONS
Be certain to fill the pump and/or motor housing with
From a hydrostatic component standpoint, the goal at clean hydraulic fluid prior to start up. Fill the housing by
system start up is to put into functional operation, the pouring filtered oil into the upper case drain port.
hydrostatic system in such a way as to preserve the
designed life span of the system. The following start-up NOTE: It is highly recommended to use the highest possible
procedure should be adhered to whenever a new pump case drain port, this ensures that the housing con-
or motor is initially installed into a machine, or a system tains as much oil as possible and offers the greatest
is restarted after either a pump or motor has been amount of lubrication to the internal components.
removed and/or replaced.
In initial start-up conditions, it may be convenient to
fill the housing, just prior to installing the case drain
line. Component, (especially motor), location may be
THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DIS- such that access to the case drain port after installa-
ABLED (WHEELS RAISED OFF THE GROUND, WORK FUNCTIONS DIS- tion is not realistic.
CONNECTED, ETC.) WHILE PERFORMING THE PROCEDURE IN ORDER
TO PREVENT INJURY. TAKE NECESSARY SAFETY PRECAUTIONS BEFORE Make certain that the oil being used to fill the com-
MOVING THE VEHICLE/MACHINE. ponent housing is as clean as possible. Store the fill
container in such a way as to prevent it from becom-
Prior to installing the pump and/or motor, inspect the ing contaminated.
unit(s) for damage that may have been incurred during
shipping and handling. Ensure all system components Install a 60 bar (or 1000 psi) pressure gauge in the
(reservoir, hoses, valves, fittings, heat exchanger, etc.) charge pressure gauge port in order to monitor the
are clean prior to filling with fluid. charge pressure during start-up.

Fill the reservoir with recommended hydraulic fluid. This It is recommended that the external control input sig-
fluid should be passed through a 10 micron (nominal, nal, (electrical connections for EDC), be disconnected at
no bypass) filter prior to entering the reservoir. The use the pump control until after initial start-up. This will
of contaminated fluid will cause damage to the compo- ensure that the pump remains in its neutral position.
nents, which may result in unexpected vehicle/machine
movement.
DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSI-
NOTE: If a pump or motor is being replaced due to internal
damage, the remaining units (pump or motors) need TION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PRE-
to be inspected for damage and contamination, and VENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING
INITIAL START-UP.
the entire hydraulic system will need to be flushed
and the fluid replaced. Failure to do so may cause
considerable damage to the entire system. "Jog" or slowly rotate the engine until charge pressure
starts to rise. Start the engine and run at the lowest pos-
The inlet line leading from the reservoir to the pump sible RPM until charge pressure has been established.
must be filled prior to start-up. Check the inlet line for Excess air should be bled from the system lines as close
property tightened fittings and make sure it is free of to the motors as possible.
restrictions and air leaks.
NOTE: With the engine on low idle, “crack”, (loosen-don't
NOTE: In most cases, the reservoir is above the pump inlet remove), the system lines at the motor(s). Continue
so that the pressure head created by the higher oil to run the engine at low idle and tighten the system
level helps to keep the inlet pressures within an lines as soon as oil is observed to leak from them.
acceptable range and prevent high vacuum levels. When oil is observed to “leak” at the motor, the line is
However, due to hose routing or low reservoir loca- full, the air has been purged, and the system hoses
tions, there may be air trapped within this line. It is should be retightened to their specified torque.
important to ensure that the air is bled from this line.
This can be accomplished by loosening the hose at Once charge pressure has been established, increase
the fitting closest to the pump. When oil begins to speed to normal operating RPM. Charge pressure
flow, the line is full, the air has been purged, and the should be as indicated in the pump model code. If
fitting can be retightened to its specified torque. If charge pressure is inadequate, shut down and deter-
the tank needs to be pressurized in order to start the mine the cause for improper pressure.
flow of oil, a vacuum reading should be taken at the
inlet of the pump during operation in order to verify

3121781 4-5
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR'S ABIL-

ITY TO CONTROL THE MACHINE.

Shut down the engine and connect the external control

input signal. Also reconnect the machine function(s), if
disconnected earlier. Start the engine, checking to be
certain the pump remains in neutral. With the engine at
normal operating RPM, slowly check for forward and
reverse machine operation.
Charge pressure may slightly decrease during forward
or reverse operation. Continue to cycle slowly between
forward and reverse for at least five minutes.
Shut down engine, remove gauges, and plug ports.
Check reservoir level and add filtered fluid if needed.
The machine is now ready for operation.

4-6 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.8 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512

TORQUE SPECIFICATION
Tapered Thread Types
NPTF = national tapered fuel (Dry Seal) per SAE J476/J512

Figure 4-4. SAE Thread

ORFS = o-ring face seal per SAE J1453

Figure 4-1. NPTF thread

BSPT = British standard pipe tapered per ISO7-1

Figure 4-5. ORFS Thread

MBTL = metric flareless bite type fitting, pressure rating L
(medium) per ISO 8434, DIN 2353
MBTS = metric flareless bite type fitting, pressure rating S
(high) per ISO 8434, DIN 2353

Figure 4-2. BSPT thread

Figure 4-6. MTBL-MBTS Thread

Straight Thread Types, Tube and Hose Connections BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
JIC = 37° flare per SAE J514

Figure 4-3. JIC Thread

Figure 4-7. Bulkhead Thread

3121781 4-7
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Straight Thread Types, Port Connections Flange Connection Types

ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162
MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162
6149, DIN 3852

Figure 4-9. ORB-MPP Thread

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. lb. (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.’

Figure 4-8. MFF-BSPP Thread

4-8 3121781
 SECTION 4 - BASIC HYDRAULIC 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 4-10. 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.

3121781 4-9
 SECTION 4 - BASIC HYDRAULIC 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 4-1,
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
the male pipe threads if not already applied. Ensure the NOTE: TFFT values provided in Table 4-1, NPTF Pipe Thread are
first 1 to 2 threads are uncovered to prevent system con- applicable for the following material configurations:
tamination.
• STEEL fittings with STEEL mating components
3. Assemble connection hand tight.
• STEEL fittings with ALUMINUM or BRASS mating compo-
4. Mark fittings, male and female. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR. mating components.

Table 4-1. NPTF Pipe Thread

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

4 1/4 - 18 0.54 13.61 2 to 3

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

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

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

* ØA thread dimension for reference only.

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

4-10 3121781
 SECTION 4 - BASIC HYDRAULIC 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 4-2,
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.
2. Apply a suitable thread sealant, such as Loctite 567, to NOTE: TFFT values provided in Table 4-2, BSPT Pipe Thread are
the male pipe threads if not already applied. Ensure the applicable for the following material configurations:
first 1 to 2 threads are uncovered to prevent system con-
tamination. • STEEL fittings with STEEL mating components
• 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.

NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN-

Table 4-2. BSPT Pipe Thread

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

4 1/4 - 19 0.52 13.16 2 to 3

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

8 1/2 - 14 0.83 20.96 2 to 3

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

16 1 - 11 1.31 33.25 1.5 to 2.5

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

* ØA thread dimension for reference only.

** See Appendix B for TFFT procedure requirements.

3121781 4-11
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table 4-3, 37° Flare
(JIC)Thread - Steel or Table 4-4, 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 4-3, 37° Flare
(JIC)Thread - Steel and Table 4-4, 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.

4-12 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-3. 37° Flare (JIC)Thread - Steel

Type/Fitting Identification Torque

Flats from
Thread Wrench
MATERIAL

ØA* ØB* [ft. lb.] [N-m]

Dash Size Size Resistance
(F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --
3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
STEEL FITTINGS WITH STEEL MATING COMPONENTS;

4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4

5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
UN-LUBRICATED THREADS

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

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

3121781 4-13
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-4. 37° Flare (JIC)Thread - Aluminum/Brass

TYPE/FITTING IDENTIFICATION Torque

Flats from
Thread Wrench
MATERIAL

ØA* ØB* [ft. lb.] [N-m]

Dash Size Size Resistance
(F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --
3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4

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

4-14 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 4-5, 45° Flare (SAE) - Steel
and Table 4-6, 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 4-5, 45° Flare (SAE) - Steel
and Table 4-6, 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.

3121781 4-15
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-5. 45° Flare (SAE) - Steel

TYPE/FITTING IDENTIFICATION Torque

Thread
MATERIAL

ØA* ØB* [ft. lb.] [N-m]

Dash Size Size
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19
STEEL MATING COMPONENTS;
UN-LUBRICATED THREADS
STEEL FITTINGS WITH

6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33

8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methodsfor FFWR procedure requirements.

Table 4-6. 45° Flare (SAE) - Aluminum/Brass

TYPE/FITTING IDENTIFICATION Torque

Thread
MATERIAL

ØA* ØB* [ft. lb.] [N-m]

Dash Size Size
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12
UN-LUBRICATED THREADS
MATING COMPONENTS;
OR ALUMINUM/BRASS
ALUMINUM/BRASS

6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20

FITTINGS

8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41

10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methods for TFFT procedure requirements.

4-16 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for O-ring Face Seal (ORFS) 5. Torque nut to value listed in Table 4-7, O-ring Face Seal
(ORFS) - Steel or Table 4-8, 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).
2. Ensure surface is smooth, free of rust, weld and brazing NOTE: Torque values provided in Table 4-7, O-ring Face Seal
splatter, splits, dirt, foreign matter, or burrs. If necessary (ORFS) - Steel and Table 4-8, O-ring Face Seal (ORFS) - Alu-
replace fitting or adapter. minum/Brass are segregated based on the material config-
uration of the connection.

ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING

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

Table 4-7. O-ring Face Seal (ORFS) - Steel

Flats from Wrench

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

Thread Size ØA* ØB* [ft. lb.] [N-m] Swivel &

Dash Size Tube Nuts
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Hose Ends

4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
STEEL MATING COMPONENTS;
UN-LUBRICATED THREADS
STEEL FITTINGS WITH

10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4

12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
20 111/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methodsfor FFWR procedure requirements.

3121781 4-17
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-8. O-ring Face Seal (ORFS) - Aluminum/Brass

Flats from Wrench

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

Dash Thread Size ØA* ØB* [ft. lb.] [N-m] Swivel &
Tube Nuts
Size (UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Hose Ends

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

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

UN-LUBRICATED THREADS

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

MATING COMPONENTS;
ALUMINUM/BRASS

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

12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
20 111/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
* ØA and ØB thread dimensions for reference only.
** See FFWR and TFFT Methods for FFWR procedure requirements.

4-18 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for DIN 24° Flare Bite Type

Fittings (MBTL and MBTS)

A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND

LEAKAGE.

1. Inspect the components to ensure free of contamina-

tion, external damage, rust, splits, dirt, foreign matter, or
burrs. Ensure tube end is visibly square. If necessary
replace fitting or tube.
2. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
3. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
4. Push the tube end into the coupling body.
5. Slide collet into position and tighten until finger tight.
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed in Table 4-9, DIN
24°Cone (MBTL & MBTS) while using the Double Wrench
Method. The tube must not turn with the nut.

3121781 4-19
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-9. DIN 24°Cone (MBTL & MBTS)

DIN 24° CONE FLARELESS BITE FITTING

TYPE/FITTING IDENTIFICATION
(With or Without o-ring)

Thread M Torque Flats from

MATERIAL

Tube O.D. ØA* ØB* C* ØD* Wrench

Size
TYPE

[ft. lb.] [N-m]

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

8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75

FFWR is the recommended
10 M16 x 1.5 14.50 16.00 7.00 10.20 1.5 to 1.75
method of fitting assembly.
12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
15 M22 x 1.5 20.50 22.00 7.00 15.20 Torque values are application 1.5 to 1.75
18 M26 x 1.5 24.50 26.00 7.50 18.20 specific due to variability in the 1.5 to 1.75
fitting supplier, coating,
22 M30 x 2 27.90 30.00 7.50 22.20 lubrication, and other physical 1.5 to 1.75
28 M36 x 2 33.90 36.00 7.50 28.20 1.5 to 1.75
STEEL FITTINGS WITH STEEL MATING COMPONENTS

characteristics of the connection.

35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
Refer to the specific procedure
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
in the
Thread M Torque Flats from
Tube O.D. ØA* ØB* C* ØD* Wrench
Size
TYPE

[ft. lb.] [N-m]

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

8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75

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

4-20 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for Bulkhead (BH) Fittings

1. Ensure threads and surface are free of rust, weld and
brazing splatter, splits, burrs or other foreign material. If
necessary replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
5. Torque nut onto fitting per Table 4-10 and Table 4-11
while using the Double Wrench Method.

3121781 4-21
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-10. Bulkhead Fittings (BH) - INCH

FASTENING JAM NUT

TYPE/FITTING IDENTIFICATION
for Bulkhead Connectors
Torque
MATERIAL

Thread Size
TYPE

Dash Size [ft. lb.] [N-m]

(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
O-RING FACE SEAL (ORFS)

8 13/16-16 55 58 61 75 79 83
BULKHEAD FITTING

10 1-14 85 90 94 115 122 127

12 1 3/16-12 135 142 149 183 193 202
14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Torque
Thread Size
TYPE

Dash Size [ft. lb.] [N-m]

STEEL FITTINGS

(UNF) Min Nom Max Min Nom Max

3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
37° FLARE (JIC) BULKHEAD FITTING

6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
10 7/8-14 85 90 94 115 122 127
12 1 1/16-12 135 142 149 183 193 202
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462

4-22 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-11. Bulkhead Fittings (BH) - METRIC

FASTENING JAM NUT

TYPE/FITTING IDENTIFICATION
for Bulkhead Connectors

Connecting Tube Torque

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

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

Connecting Tube Torque

Thread M Size
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING

O.D. [ft. lb.] [N-m]

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

3121781 4-23
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for O-ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 4-12
through Table 4-17 while using the Double Wrench
Fittings Method.
1. Inspect components to ensure that male and female a. The table headings identify the straight thread
port threads are free of rust, splits, dirt, foreign matter, or o-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 4-12 through Table
4-17 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.

4-24 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-12. O-ring Boss (ORB) - Table 1 of 6

HEX TYPE PLUGS & STUD ENDS

TYPE/FITTING IDENTIFICATION
with 37° (JIC) or L series DIN (MBTL) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
COMPONENTS; UN-LUBRICATED THREADS

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

STEEL FITTINGS WITH STEEL MATING

6 9/16-18 0.56 14.28 29 31 32 40 42 43

8 3/4-16 0.75 19.10 52 55 57 70 75 77
10 7/8-14 0.87 22.22 85 90 94 115 122 127
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
HEX TYPE PLUGS & STUD ENDS
TYPE/FITTING IDENTIFICATION
with 37° (JIC) or L series DIN (MBTL) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

4 7/16-20 0.44 11.11 14 15 16 19 20 22

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 15 16 17 20 22 23

6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

3121781 4-25
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-13. O-ring Boss (ORB) - Table 2 of 6

STUD ENDS
TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 26 27 28 35 37 38
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 30 32 33 40 43 45

STEEL FITTINGS WITH STEEL MATING

6 9/16-18 0.56 14.28 35 37 39 46 50 53

8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
STUD ENDS
TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

4 7/16-20 0.44 11.11 17 18 18 23 24 24

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 20 21 21 27 28 28

6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

4-26 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-14. O-ring Boss (ORB) - Table 3 of 6

ADJUSTABLE STUD END

TYPE/FITTING IDENTIFICATION
with 37° (JIC) or L series DIN (MBTL) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (60) (63) (66) 7 7 7
3 3/8-24 0.37 9.52 (100) (105) (110) 11 12 12
4 7/16-20 0.44 11.11 15 16 17 20 22 23
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 21 22 23 28 30 31

STEEL FITTINGS WITH STEEL MATING

6 9/16-18 0.56 14.28 29 31 32 40 42 43

8 3/4-16 0.75 19.10 52 55 57 70 75 77
10 7/8-14 0.87 22.22 85 90 94 115 122 127
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
ADJUSTABLE STUD END
TYPE/FITTING IDENTIFICATION
with 37° (JIC) or L series DIN (MBTL) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (39) (41) (43) 4 5 5
3 3/8-24 0.37 9.52 (65) (69) (72) 7 8 8
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

4 7/16-20 0.44 11.11 10 11 11 14 15 15

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 14 15 15 19 20 20

6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

3121781 4-27
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-15. O-ring Boss (ORB) - Table 4 of 6

ADJUSTABLE STUD END

TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 30 32 33 40 43 45

STEEL FITTINGS WITH STEEL MATING

6 9/16-18 0.56 14.28 35 37 39 46 50 53

8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
ADJUSTABLE STUD END
TYPE/FITTING IDENTIFICATION
with (ORFS) or S series DIN (MBTS) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

4 7/16-20 0.44 11.11 10 11 11 14 15 15

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 20 21 21 27 28 28

6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

4-28 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-16. O-ring Boss (ORB) - Table 5 of 6

TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
4 7/16-20 0.44 11.11 10 11 11 14 15 15
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 14 15 16 19 20 22

STEEL FITTINGS WITH STEEL MATING

6 9/16-18 0.56 14.28 34 36 38 46 49 52

8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

4 7/16-20 0.44 11.11 6 7 7 8 9 9

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 9 10 10 12 14 14

6 9/16-18 0.56 14.28 22 24 25 30 33 34
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

3121781 4-29
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-17. O-ring Boss (ORB) - Table 6 of 6

ZERO LEAK GOLD®

TYPE/FITTING IDENTIFICATION
HOLLOW HEX PLUGS
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 9 10 11 12 14 15

STEEL FITTINGS WITH STEEL MATING

6 9/16-18 0.56 14.28 11 12 13 15 16 18

8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
ZERO LEAK GOLD®
TYPE/FITTING IDENTIFICATION
HOLLOW HEX PLUGS
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS

4 7/16-20 0.44 11.11 7 8 9 9 11 12

MATING COMPONENTS; UN-LUBRICATED THREADS

5 1/2-20 0.50 12.70 9 10 11 12 14 15

6 9/16-18 0.56 14.28 11 12 13 15 16 18
8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.

4-30 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 4-18,
Table 4-19, Table 4-20, Table 4-21, Table 4-22, or Table 4-
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 4-18, Table 4-19,
care not to damage it. See O-ring Installation (Replace- Table 4-20, Table 4-21, Table 4-22, and Table 4-23 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.

3121781 4-31
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3

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

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with 37° (JIC) or L series DIN (MBTL) opposite end with 37° (JIC) or L series DIN (MBTL) opposite end

Thread M Connecting Torque Torque

MATERIAL Size Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
Thread M Connecting Torque Torque
MATERIAL Size Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450

4-32 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-19. Metric Flat Face Port (MFF) - L Series - Table 2 of 3

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

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with 37° (JIC) or L series DIN (MBTL) opposite end with 37° (JIC) or L series DIN (MBTL) opposite end

Thread M Connecting Torque Torque

MATERIAL Size Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
Thread M Connecting Torque Torque
MATERIAL Size Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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

3121781 4-33
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
TYPE/FITTING IDENTIFICATION
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS

Thread 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 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
Thread 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

4-34 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3

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

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end

Thread M Connecting Torque Torque

MATERIAL Size Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770
Thread M Connecting Torque Torque
MATERIAL Size Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

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

3121781 4-35
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3

FORM E (EOLASTIC SEALING RING)

FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE 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

Thread M Connecting Torque Torque

MATERIAL Size Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
Thread M Connecting Torque Torque
MATERIAL Size Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386

4-36 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-23. Metric Flat Face Port (MFF) - L Series - Table 3 of 3

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
TYPE/FITTING IDENTIFICATION
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS

Thread 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 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --
Thread 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 -- -- -- -- -- --

3121781 4-37
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 4-24
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 4-24 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.

4-38 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-24. Metric Pipe Parallel O-ring Boss (MPP)

STUD ENDS STUD ENDS

TYPE/FITTING IDENTIFICATION
with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end

Thread M Connectin Torque Torque

MATERIAL

Size g Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m]

(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
STEEL FITTINGS WITH STEEL MATING COMPONENTS;

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

M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING

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

3121781 4-39
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 4-25,
Table 4-26, Table 4-27, Table 4-28, Table 4-29, or Table 4-
(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 4-25, Table 4-26,
care not to damage it. See O-ring Installation (Replace- Table 4-27, Table 4-28, Table 4-29, and Table 4-30 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.

4-40 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3

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

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with 37° (JIC) or L series DIN (MBTL) opposite end with 37° (JIC) or L series DIN (MBTL) opposite end

BSPP 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 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
BSPP 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

3121781 4-41
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-26. 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

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 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594
BSPP 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

4-42 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-27. 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

3121781 4-43
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3

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

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end

BSPP 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 26 28 29 35 38 39 41 43 45 55 58 61
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP 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

4-44 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-29. 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

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 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594
BSPP 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

3121781 4-45
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-30. British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS

TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m] [ft. lb.] [N-m]
Size
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING

G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 Service Manual.
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [ft. lb.] [N-m] [ft. lb.] [N-m] [ft. lb.] [N-m]
Size
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS

G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 Service Manual.
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
* Typical for JLG Straight Male Stud Fittings
** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings

4-46 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly Instructions for Flange Connections:

(FL61 and FL62)
1. Make sure sealing surfaces are free of rust, splits,
scratches, dirt, foreign matter or burrs.
2. Install o-ring as per “O-ring Installation (Replacement)” .
3. Pre-lubricate the o-ring with Hydraulic Oil.
4. Position flange and clamp halves.
5. Place lock washers on bolt and bolt through clamp
halves.
6. Tighten all bolts by hand.
7. Torque bolts in diagonal sequence in two or more incre-
ments to the torque listed on Table 4-31and Table 4-32.

3121781 4-47
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-31. Flange Code (FL61 & FL62) -Inch Fasteners

STEEL 4-BOLT FLANGE SAE J518

TYPE/FITTING IDENTIFICATION
(INCH FASTENERS)

Bolt Fastener Torque for Flanges Equipped with 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)

20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101

24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Bolt Fastener Torque for Flanges Equipped with 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 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
CODE 62 SPLIT FLANGE (FL62)

12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66

16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
* A dimension for reference only.

4-48 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-32. Flange Code (FL61 & FL62) - Metric Fasteners

STEEL 4-BOLT FLANGE SAE J518

TYPE/FITTING IDENTIFICATION
(INCH FASTENERS)

Bolt Fastener Torque for Flanges Equipped with 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)

20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55

24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
Bolt Fastener Torque for Flanges Equipped with 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 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
CODE 62 SPLIT FLANGE (FL62)

12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77

16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
* A dimension for reference only.

3121781 4-49
 SECTION 4 - BASIC HYDRAULIC 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 4-11. for double wrench method require-
wrenches must be used; one torque wrench and one backup ments.
wrench. If two wrenches are not used, inadvertent component
rotation may occur which absorbs torque and causes
improper joint load and leads to leaks. For hose connections,

Figure 4-11. Double Wrench Method

4-50 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

FFWR and TFFT Methods Adjustable Stud End Assembly

For Adjustable Stud End Connections; the following assembly
FFWR (FLATS FROM WRENCH RESISTANCE METHOD)
steps are to be performed:
1. Tighten the swivel nut to the mating fitting until no lat-
1. Lubricate the o-ring with a light coat of hydraulic oil.
eral movement of the swivel nut can be detected; finger
tight condition. 2. Position #1 – The o-ring should be located in the groove
adjacent to the face of the backup washer. The washer
2. Mark a dot on one of the swivel hex nut flats and
and o-ring should be positioned at the extreme top end
another dot in line on the connecting tube adapter. See
of the groove as shown.
Figure B.1.
3. Position #2 – Position the locknut to just touch the
3. Use the double wrench method per Appendix A, turn
backup washer as shown. The locknut in this position
the swivel nut to tighten as shown in Figure 4-11. The
will eliminate potential backup washer damage during
nut is to be rotated clockwise the number of hex flats as
the next step.
defined by the applicable Table in Section 5.0.
4. Position #3 – Install the connector into the straight
4. After the connection has been properly tightened, mark
thread box port until the metal backup washer contacts
a straight line across the connecting parts, not covering
the face of the port as shown.
the dots, to indicate the connection has been properly
tightened. See Figure 4-12. 5. Position #4 – Adjust the connector to the proper posi-
tion by turning out (counterclockwise) up to a maxi-
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
Figure 4-12. FFWR Method flat against the face of the port.

TFFT (TURNS FROM FINGER TIGHT METHOD)

1. Tighten the swivel nut to the mating fitting until no lat-
eral movement of the swivel nut can be detected; finger
tight condition.
2. Mark a dot on one of the swivel hex nut flats and
another dot in line on the connecting tube adapter.
3. Use the double wrench method per Appendix A, turn
the swivel nut to tighten. The nut is to be rotated clock-
wise the number of turns as defined by the applicable
Table in Section 5.0.
4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering
the dots, to indicate the connection has been properly
tightened.

3121781 4-51
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Figure 4-13. Adjustable Stud End Assembly

O-ring Installation (Replacement) 4. In ORB; ensure o-ring is properly seated in groove. On

straight threads, ensure o-ring is seated all the way past
Care must be taken when installing o-rings over threads dur- the threads prior to installation.
ing replacement or installation. o-rings could become nicked
or torn. A damaged o-ring could lead to leakage problems. 5. Inspect o-ring for any visible nicks or tears. Replace if
found.
1. Inspect o-ring for tears or nicks. If any are found replace
o-ring.
2. Ensure proper o-ring to be installed. Many o-rings look
the same but are of different material, different hard-
ness, or are slightly different diameters or widths.
3. Use a thread protector when replacing o-rings on fit-
tings.

4-52 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.9 HYDRAULIC VALVES

1. Main Valve 4. Oscillating Axle Lock-Out Valve (If Equipped)

2. Flow Divider Valve 5. Hydraulic Tank
3. Leveling Jack Valve

Figure 4-14. Hydraulic Compartment Control Valves

REMOVAL INSTALLATION
1. Disconnect, cap and label all hydraulic hoses and any 1. Re-attach valve blocks to tray with bolts.
electrical harness connected to valves. 2. Re-connect all hydraulic lines and electrical harness.
2. Remove the valve blocks from the hydraulic tray by
removing the attaching bolts.

3121781 4-53
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Main Hydraulic Valve

L2 T4

P1
L1

S1
S2
B2
G

T2
11 2S2

17, 11
7, 14, 12
3, 15, 13
10

2, 15

1,15, 15

B1
2S1
8
5, 16
4, 16
20
OPTIONAL LOCATION SLOT 18
FOR MACHINING SET UP

T3

T1

P2 MP1

P3
PS
11

MS
6

1001234828-B
MAF04050B

Figure 4-15. Main Valve Port Identification

See Table 4-34 on page 4-55

4-54 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-33. Main Valve Port Identification

See Figure 4-15. on page 4-54
Port Functionality To Port
L1 To Lift Cylinder Lift Cylinder
L2 To Lift Cylinder Lift Cylinder
T4 Main RT Valve (Left Side) T - Outrigger Valve
P1 Main RT Valve (Left Side) Outlet - Tandem Gear Pump
S1 Main RT Valve (Left Side) Steer Cylinder
S2 Main RT Valve (Left Side) Steer Cylinder
G Main RT Valve (Left Side) (Tee at Port) P - Axle Lockout Valve
M3 - Axial Pump
2S2 Main RT Valve (Left Side) Union Tee
T2 Main RT Valve (Left Side) Return to Tank
P2 Main RT Valve (Right Side) LP - Leveling Jack Valve
PS Main RT Valve (Right Side) Outlet - Tandum Gear Pump
MS Main RT Valve (Right Side) Diagnostic Port
MP1 Main RT Valve (Right Side) Diagnostic Port

Table 4-34. Main Valve Torque Specs

See Figure 4-15. on page 4-54
Component Functionality Torque
1 Steer Valve 25 ft. lb.
2 Lift Up Valve 24 - 26 ft. lb.
3 Lift Pump Unloader Valve (Dump) 35 - 40 ft. lb.
4 Motors 2 Speed Control 40 ft. lb.
5 Hydraulic Brakes 40 ft. lb.
6 Steer Cylinder Relief Valve 19 - 21 ft. lb.
7 Flow Control 35 - 40 ft. lb.
8 Steer Cylinder Shuttle Valve 19 - 21 ft. lb.
18 Lift Cylinders Tank Port Check Valve 40 - 45 ft. lb.
20 Manifold Relief Valve 40 - 45 ft. lb.

Table 4-35. Main Valve Porting Specs

Port Size
L2, P1 & T1 SAE 10
L1 SAE 08
G, T4 & T2 SAE 06
All Others SAE 04

NOTE: For internal hydraulic circuits see Figure 4-44. on page 4-85.

3121781 4-55
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Flow Divider Valve

CV1
9 13 7 3

CV3
CV4
CV5

CV6

6 CV5 10 8

OR2 11 5,OR1

FD2
2 FD1
12

OR3 CV7 CV8 FD3

4

1001234828-B
MAF04310B

Figure 4-16. Flow Divider Valve

4-56 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Leveling Jack Directional Valve

OUTRIGGER CYLINDERS THERMAL RELIEF

S2, 2 RESET NON ADJUSTABLE

3
OUTRIGGER CYLINDER
EXTEND PRESSURE VALVE

OUTRIGGER CYLINDERS
EXTEND TANK VALVE

S3, 4
S1, 1

OUTRIGGER CYLINDERS
RETRACT VALVE

PA1 PB3
PB1 PB2

PA2
PA3 LP

T
PA4 PB4

1001217108-C
MAF04350C

Figure 4-17. Leveling Jack Directional Valve

NOTE: For valve torque specs see Table 4-36 on page 4-58.
For internal hydraulic circuits see Figure 4-44. on page 4-85.

3121781 4-57
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Table 4-36. Leveling Jack Directional Valve Torque Specs

See Figure 4-17. on page 4-57
Component Functionality Torque
S1 Leveling Jack Cylinders Retract Valve 18.5 - 22 ft. lb. (25-30 Nm)
S2 Leveling Jack Cylinders Extend Tank Valve 28 - 33 ft. lb. (38-45 Nm)
S3 Leveling Jack Cylinders Extend Pressure Valve 22 - 26 ft. lb. (30-35 Nm)
Coils S1-S3 Leveling Jack Cylinders Coils 12 VDC, 8.0 OHMS 3 - 4.5 ft. lb. (4 Nm)

Leveling Jack Valves

E
X
2 1

M1

3
1
B

A
2
B
A

MAF04340
NOTE: Applies to all four Leveling Jacks.
Figure 4-18. Leveling Jack Valves

Table 4-37. Leveling Jack Valves Torque Specs

Item Torque
1 3 to 4.5 ft. lb. (4.1 to 6.1 Nm)
2 18.5 to 22 ft. lb. (25.1 to 29.8 Nm)
3 18.4 to 22.1 ft. lb. (25-30 Nm)
4 16.2 ft. lb. (22 Nm)

4-58 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Pressure Relief Valve - Setting Procedures 3. Outrigger Jack Retract Relief Valve;
a. Install a pressure gauge, 3000 PSI or higher, at
Cold temperatures have a significant impact on pres- port MP1 of the main control valve.
sure readings. JLG Industries Inc. recommends operat-
ing the machine until the hydraulic system has warmed b. Start the engine and activate the auto level
to normal operating temperatures prior to checking function, then proceed to full extension by
pressures. JLG Industries Inc. also recommends the use using the rocker switch “trim” function.
of a calibrated gauge. Pressure readings are acceptable c. Next, fully retract leveling jacks. Repeat this
if they are within ± 5% of specified pressures. cycle four more times to bleed all air from cir-
cuit.
(See Main Valve Port Identification - Figure 4-15. on d. The relief valve is fixed type and the relief is set
page 4-54) at the vendor side. The relief valve is located on
the outrigger valve, the same face as the sole-
1. Main Relief;
noid valves.
a. Locate the lift up solenoid valve (SV1). It is the
middle solenoid on the main valve assembly.
b. Remove the coil nut and coil from the car-
tridge. Do not remove the wire out of the coil
plug.
c. Install a pressure gauge, 3000 PSI or higher, at
port MP1, located on the face 90 degrees
towards right.
d. Start the engine and activate lift up. The gauge
should read 2700 PSI.
e. The main relief (RV1/RV2) is located on the
same face as solenoid valve, and is the top
relief cartridge. Adjust clockwise to increase,
counter-clockwise to decrease.
f. Re-install the coil onto the lift up solenoid
valve (SV1) and torque coil nut to 5 ft. lb.s.
2. Steer Work Port Relief Valve;
a. Install a pressure gauge, 3000 PSI or higher, at
port MS, located on the top face (opposite face
to mounting hole).
b. Start the engine and activate steer right or left.
The gauge should read 2500 PSI.
c. The steer work port relief (RV2/RV3) is located
on the same face as port MP1, and is the low-
est relief valve. Adjust clockwise to increase,
counter-clockwise to decrease.
This one relief valve takes care of both right
and left.

3121781 4-59
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.10 GEAR PUMP

1. Inlet Port from Hydraulic Tank, 1-15/16-12 SAE STD 2. Outlet Ports, 7/8-14 SAE STD THD - SAE #10 ORB
THD - SAE #16 ORB

Figure 4-19. Tandem Gear Pump

Table 4-38. Gear Pump Specs Table 4-39. Gear Pump - Dual Fuel - Gas/LPG

Rotation (Viewing Drive End) Clockwise Rotation (Viewing Drive End) Clockwise

Displacement Front: 14.4 cc/rev Displacement Front: 8.4 cc/rev

13.3 GPM 8.9 GPM
Rear: 3.9 cc/rev Rear: 2.62 cc/rev
3.6 GPM 2.77 GPM

Max Rated Speed 3500 rpm Max Rated Speed 4000 rpm
(with max. fluid viscosity of 50mm2/sec.) (with max. fluid viscosity of 50mm2/sec.)

Rated Pressure 3045 psi Rated Pressure 3046 psi

(210 bar) (210 bar)

Minimum Speed at Rated Pressure 1000 rev/min Minimum Speed at Rated Pressure 1000 rev/min

4-60 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Gear Pump Priming

The gear pump is mounted with the suction hose up. Air
trapped in this area can cause an air lock on start up.
during this period, the pump is running dry, which can
cause gear wear, which affects the volumetric efficiency
of the pump.

To prime the pump:

1. Fill the hydraulic tank to the full mark.
2. Using a 2 in. wrench, loosen the suction hose fitting
at the gear pump. The hose fitting does not need to
be removed, just loosened enough to let the air
escape.
3. When oil leaks at the hose end, re-torque the hose
end to 115 ft. lb. (Nm). The pump is primed and the
machine is ready to start.

3121781 4-61
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.11 AXIAL HI 45 PUMP

2
4 5
3 12
11
1

10

9
MAF06320

1. Case Drain Port L2 (SAE#12) 5. Charge Pressure Filtration Port 9. Port A (SAE#16)
2. Deutsch DT04-2P Connector (to inlet on filter) 10. Charge Pump Suction Port
3. M5 Servo Gage Port (SAE#4) 6. MB Gage Port (SAE#6) (SAE#16)
4. Charge Pressure Filtration Port 7. M3 Charge Gage Port (SAE#6) 11. Port B (SAE#16)
(from outlet on filter) 8. M14 Gage Port (SAE#4) 12. Case Drain Port L1 (SAE#12)

Figure 4-20. Axial HI 45 Pump

Table 4-40. Axial HI 45 Pump Specs Table 4-40. Axial HI 45 Pump Specs

Rotation Clockwise 12 CC Charge Pump Pressure 348 psi (24 bar)

Max Pressure 6525 psi (450 bar) Max Operating Speed 3500 rpm

Displacement 2.75 in³ (45 cm³)

Control Current 755 mA Threshold
1640 mA Max Displacement

4-62 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

1 14

2
13

12

3 11

9
10
MAF06330

1. Electric Displacement Control 6. Shaft 11. Charge Pump

2. Swashplate Feedback Pin 7. Front Bearing 12. Rear Bearing
3. Piston 8. Swashplate Bearing 13. Valve Plate
4. Slipper 9. Swashplate 14. Servo Piston
5. Shaft Seal 10. Cylinder Block

Figure 4-21. Axial HI 45 Pump - Cross Section View

3121781 4-63
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

General Repair Instructions Start-Up Procedure

REMOVAL Follow this procedure when starting-up a new pump
installation or when restarting an installation in which
the pump has been removed and re-installed on the
machine. Ensure pump has been thoroughly tested on a
PRIOR TO PERFORMING REPAIRS, REMOVE THE UNIT FROM THE test stand before installing on a machine.
MACHINE. CHOCK WHEELS ON THE MACHINE TO INHIBIT MOVEMENT.
BE AWARE THAT HYDRAULIC FLUID MAY BE UNDER HIGH PRESSURE These pumps should never be dry started. The time it
AND/OR HOT. INSPECT THE OUTSIDE OF THE PUMP AND FITTINGS FOR takes for the charge pump to create a vacuum to draw
DAMAGE. CAP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION. in the fluid, send it out through the charge pump filter
and then back in to the pump may take 30-40 seconds.
KEEP IT CLEAN During this time the surface between the cylinder barel
Clean the outside of the pump thoroughly before disas- and valve plate are running dry. This can afec the volu-
sembly. Take care not to contaminate system ports. metric efficiency of the pump and cause premature fail-
Clean parts using a clean solvent wash and air dry. ure of the pump. Pre-filling the case also reduces the
time it takes fro the pump to create a vacuum to draw
fluid into the pump.

AS WITH ANY PRECISION EQUIPMENT, YOU MUST KEEP ALL PARTS

FREE OF FOREIGN MATERIAL AND CHEMICALS. PROTECT ALL EXPOSED TO PROTECT AGAINST UNINTENDED MOVEMENT, SECURE THE
SEALING SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MACHINE OR DISABLE/DISCONNECT THE MECHANISM WHILE SERVIC-
MATERIAL. IF LEFT UNATTENDED, COVER THE PUMP WITH A PROTEC- ING.
TIVE LAYER OF PLASTIC.

REPLACE ALL O-RINGS & GASKETS NOTE: Prior to installing the pump, inspect for damage that
may have occurred during shipping.
Replace all o-rings and seals during service. Lightly
lubricate o-rings with clean petroleum jelly prior to 1. Ensure that the machine hydraulic oil and system
assembly. components (reservoir, hoses, valves, fittings, and
heat exchanger) are clean and free of any foreign
SECURE THE UNIT material.
Place the unit in a stable position with the shaft point- 2. Install new system filter element(s) if necessary.
ing downward. It will be necessary to secure the pump Check that inlet line fittings are properly tightened
while removing and torquing fasteners and compo- and there are no air leaks.
nents. 3. Install the pump. Install a 1000 psi (50 bar) gauge in
the charge pressure gauge port M3.
4. Fill the housing by adding filtered oil in the upper
PERFORMING MINOR REPAIRS ACCORDING TO THIS SECTION WILL case drain port. If the control is installed on top, open
NOT AFFECT THE PUMP’S WARRANTY. MAJOR REPAIRS REQUIRING the construction plug in the top of the control to
THE REMOVAL OF THE UNIT’S CENTER SECTION, SERVO SLEEVES, OR assist in air bleed.
FRONT FLANGE VOIDS WARRANTY. 5. Fill the reservoir with hydraulic fluid of the recom-
mended type and viscosity. Use a 10-micron filler fil-
ter. Fill inlet line from reservoir to pump. Ensure
construction plug in control is closed after filling.
6. Disconnect the pump from all control input signals.
7. Close construction plug removed in step 4.

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 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

nected, plug each open port, to ensure that dirt and

contamination do not get into the pump.
AFTER START-UP, THE FLUID LEVEL IN THE RESERVOIR MAY DROP 3. Remove the pump and its auxiliary pump (if applica-
DUE TO SYSTEM COMPONENTS FILLING. DAMAGE TO HYDRAULIC COM- ble) as a single unit.
PONENTS MAY OCCUR IF THE FLUID SUPPLY RUNS OUT. ENSURE RES-
ERVOIR REMAINS FULL OF FLUID DURING START-UP. NOTE: Be careful, do not damage solenoids and electrical
AIR ENTRAPMENT IN OIL UNDER HIGH PRESSURE MAY DAMAGE connections when using straps or chains to support
HYDRAULIC COMPONENTS. CHECK CAREFULLY FOR INLET LINE LEAKS. the pump.
DO NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR
AND FLUID HAS BEEN THOROUGHLY FILTERED. INSPECTION
1. Ensure the work surface and surrounding area are
8. Disable the engine to prevent it from starting. Crank clean and free of contaminants such as dirt and
the starter for several seconds. Do not exceed the grime.
engine manufacturer’s recommendation. Wait 30
2. Inspect the system for contamination.
seconds and then crank the engine a second time as
stated above. This operation helps remove air from 3. Look at the hydraulic fluid for signs of system con-
the system lines. Refill the reservoir to recommended tamination, oil discoloration, foam in the oil, sludge,
full oil level. or metal particles.
9. When the gauge begins to register charge pressure, REASSEMBLY
enable and start engine. Let the engine run for a min-
imum of 30 seconds at low idle to allow the air to 1. Before replacing the pump, replace all filters and
work itself out of the system. Check for leaks at all drain the hydraulic system. Flush the system lines
line connections and listen for cavitation. Check for and fill the reservoir with the correct, filtered hydrau-
proper fluid level in reservoir. lic fluid.
10. When adequate charge pressure is established (as 2. Fill the pump with clean, filtered hydraulic fluid.
shown in model code), increase engine speed to nor- 3. Attach the pump to the prime mover. Torque mount-
mal operating rpm to further purge residual air from ing screws according to the manufacturers recom-
the system. mendation.
11. Shut off engine. Connect pump control signal. Start 4. Replace all hydraulic lines. Ensure the charge inlet
engine, checking to be certain pump remains in neu- line is filled with fluid.
tral. Run engine at normal operating speed and care-
fully check for forward and reverse control operation.
12. Continue to cycle between forward and reverse for at
least five minutes to bleed all air and flush system
contaminants out of loop.
NOTE: Normal charge pressure fluctuation may occur dur-
ing forward and reverse operation.
13. Check that the reservoir is full. Remove charge pres-
sure gauge. The pump is now ready for operation.

Removing the pump

CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID

THE MANUFACTURER’S WARRANTY.
TAKE PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOV-
ING AND INSTALLING SYSTEM LINES.

DISASSEMBLY
1. With the prime mover off, thoroughly clean all dirt
and grime from the outside of the pump.
2. Tag, disconnect, and cap each hydraulic line con-
nected to the pump. As hydraulic lines are discon-

3121781 4-65
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Electric Control Module

D050 (3X)
4 mm
4 ft.lbs. (5 Nm) D1

D025A D250
5 mm
10 ft.lbs.

D025A D050 (3X)

Torque sequence D084 4 mm

2 1 4 ft.lbs.
(5 Nm)
D150

6 5

F100 (2X)
4 3 3 mm
1.8 ft.lbs.
(2.5 Nm)
D300 (2X)

REMOVAL Control Solenoids

1. Using a 5 mm internal hex wrench, remove the six
cap screws (D250). REMOVAL
2. Remove the control module and gasket (D150). Dis- 1. Disconnect electrical connection and remove the
card the gasket. three cap screws (D050) using a 4 mm internal hex
3. If necessary, remove orifices (F100) using a 3 mm wrench.
internal hex wrench. Tag and number them for rein- 2. Remove the solenoid (D025) and O-ring (D025A). Dis-
stallation. card the O-ring.
3. If necessary, remove the coil using a 12 point 26 mm
INSPECTION
socket.
1. Inspect the machined surfaces on the control and
top of the pump. If you find any nicks or scratches, INSPECTION
replace the component. 1. Inspect the machined surface on the control. If you
find any nicks or scratches, replace the component.
REASSEMBLY
REASSEMBLY
NOTE: Ensure you install dowel pins (D300) in housing
before installing control. 1. Lubricate new O-ring (D025A) using petroleum jelly
and install.
1. Install a new gasket (D150).
2. Install solenoid with three cap screws (D050) using a
2. If you removed screen (D084), install a new one. 4 mm internal hex wrench. Torque screws to 5 Nm (4
Install with the mesh facing outward (see drawing). ft. lb.).
3. If previously removed, install orifices (F100) using a 3 3. Install coil using a 12 point 26 mm socket. Torque coil
mm internal hex wrench. Torque to 1.8 ft. lb. (2.5 nut to 3.7 ft. lb. (5 Nm).
Nm).
4. Reconnect electrical connections and test the pump
4. Install the control module and six cap screws (D250). for proper operation.
5. Using a 5 mm internal hex wrench, torque the cap
screws (D250) to 10 ft. lb. (13.5 Nm).

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 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Shaft Seal, Roller Bearing & Shaft Replacement (+0.12mm) or 0.0028 in (-0.72 mm) of the inside lip of
the carrier: see illustration.
NOTE: The shaft assembly is serviceable without disassem-
bling the pump. Orient the pump on the work sur- Positioning seal in seal carrier
face so the shaft is pointing to the side.
Press flush to this surface
REMOVAL 0.005 in (+0.12 mm) / 0.028 in (-0.72 mm)
1. Unwind the spiral ring (J300) from the housing to
release the shaft/seal/bearing subassembly.
2. Pry on the lip of the seal carrier (J275) to dislodge it Seal
from the pump. Remove the seal carrier. Remove and
discard O-ring (J260). Press the seal (J250) out of the
4. Cover the shaft with a protective sleeve while install-
carrier and discard.
ing the seal carrier. Hand press the seal carrier into
3. Pull the shaft (J100) with bearing (J150) out of the the housing. Ensure the seal carrier clears the spiral
pump. If necessary, tap lightly on the shaft to dis- ring groove in the housing. Remove the protective
lodge it from the cylinder block. sleeve.
4. Remove the retaining ring (J200) using retaining ring 5. Wind the spiral ring into the housing. Ensure the
pliers. Press the bearing off the shaft. inside diameter of the spiral ring is greater than 2.677
Shaft assembly in (68 mm) after installation.

Charge Pump
If the pump has an auxiliary pump attached, remove the
auxiliary pump and connecting shaft before removing
Protective the auxiliary pad.
J100 sleeve

J150 REMOVAL
J200
J250 1. Position pump so end cover or auxiliary pad is on
J150
J260 top.
J275
J300 2. If necessary, remove auxiliary pump (not shown), or
shipping cover (K300) and pad seal (K250) as shown
on following page.
3. Remove end cover/auxiliary pad screws (K400) using
a 10 mm internal hex wrench.
INSPECTION
NOTE: Alignment pins (G450) are in end cover. They may
1. Inspect the shaft journals for wear, scratching, and dislodge during disassembly.
pits. Check the splines for fretting; replace if dam-
aged. Rotate the bearing, if it does not rotate 4. Remove and discard gasket (K150).
smoothly, replace it. 5. Remove thrust washer (K500). Note thrust washer
orientation.
REASSEMBLY
6. Use a small hook to remove pressure balance plate
1. Press the bearing (J150) onto the shaft (J100) and (S200) and seal (S300). Note plate orientation. Dis-
replace the retaining ring (J200). Ensure the retaining card seal.
ring diameter is less than 1.53 in (38.84 mm) when 7. Remove coupling (K200). Use a small hook if neces-
installed on the shaft. sary.
2. Install the shaft/bearing assembly into the pump. 8. Remove the charge pump outer ring (S150), and
3. Lubricate and install a new O-ring (J260) onto seal gearset (S100).
carrier (J275). Press a new seal (J250) into the seal 9. Remove valve plate (S250) with seal (S300). Discard
carrier. Press the seal until it is flush within 0.005 in seal

3121781 4-67
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

INSPECTION
1. Inspect the components for wear, scratches or pit- Charge pump removal/installation
ting. Carefully inspect the valve and pressure-bal-
ance plates. Scratches on these components will
K400
cause a loss of charge pressure. If any component 8 mm
shows signs of wear, scratching or pitting, replace it.

REASSEMBLY
K100
1. Install new seals (S300) in the valve (S250) and pres-
G450
sure-balance (S200) plates.
2. Install valve plate (S250) in the same orientation as G450

removed. K150

3. Lubricate and install charge pump (S100) and outer

ring (S150). K500

4. Install charge pump coupling (K200).

S300
5. Install pressure balance plate (S200) in the same ori-
entation as removed.
S200
6. Install the thrust washer (K500). Coated side goes
toward charge pump coupling (K200).
K200
7. Install a new cover gasket. (K150). If removed, install
guide pins (K450).
8. Install the auxiliary pad or charge pump cover and S100

cap screws. Using a 10mm internal hex wrench,

torque the cap screws (K400) to 68 ft. lb. (92 Nm). S250
Torque in sequence below.
9. Reinstall auxiliary pump or pad seal (K250) and ship- S300
ping cover (K300).
Auxilliary pads

K350
(see table)
K300
Torque sequence

K250
K400
1 4 8 mm

SAE B SAE A

.
3 2 Cover Screw K350
Cover Pad Wrench Size; Torque
A 17 mm; 35 ft. lb. (48 Nm)
B, C 19 mm; 58 ft. lb. (77 Nm)

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 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Charge Check/HPRV Charge Pressure Relief Valve

REMOVAL Replace the charge pressure relief valve (V10) as a com-
plete unit. Do not attempt to repair the internal compo-
1. Using a 22 mm hex wrench, remove the HPRVs (L100/ nents of the valve. Torque to 38 ft. lb. (52 Nm).
L200). Remove and discard the O-rings (L060) and
backup rings (L068). REMOVAL
INSPECTION 1. Using a 22 mm wrench, remove the charge pressure
relief valve (V10). Discard seal (V024).
1. Inspect the sealing surfaces in the pump for nicks or
scratches. Check the valves for damage. Replace any INSPECTION
damaged components.
1. Inspect the sealing surfaces of the pump for nicks or
REASSEMBLY scratches.
1. Lubricate and install new backup rings (L068) and O- REASSEMBLY
rings (L060).
1. Lubricate and install new seal (V024).
2. Install HPRVs. Torque to the value in the illustration
below. 2. Install the charge pressure relief valve. Torque to 38
ft. lb. (52 Nm).
3. Operate the machine through full range of controls
to ensure proper operation. Check for leaks. 3. Operate machine through full range of controls to
ensure proper operation.

High Pressure Relief Valves (HPRVs)

Charge Pressure Relief Valve

L060

L068
V024

V10
L100 / L200
22 mm 22 mm
81 ft.lbs. 38 ft.lbs.
(110 Nm) (52 Nm)

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 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Pressure Limiter Valve Replacement 4.12 CHARGE PUMP FILTER

NOTE: Replace the pressure limiter valve as a complete unit.
Do not attempt to repair individual components.

REMOVAL
1. Using a 14 mm wrench, remove the pressure limiter 1
valves (L300/L400). Discard O-rings.

INSPECTION
1. Inspect the sealing surfaces of the pump for nicks or
scratches.

REASSEMBLY
1. Install new O-ring. Lubricate 0-ring with petroleum
jelly.
2. Replace pressure limiter valves. Torque to 22 ft. lb. (30
Nm).
3. Operate pump at full range of controls to ensure
proper machine operation.

Pressure Limiter

L300
14 mm
22 ft.lbs. (30 Nm)

L400
14 mm
22 ft.lbs. (30 Nm)

L022

1. Mounting Bracket 5. Inlet Hose from Port

2. Filter to Bracket F (Out) - Axial Pump
Bolts/Washers 6. Outlet Hose to Port E
3. Filter Assembly (Return) - Axial Pump
4. Filter Bowl 7. Rear Wall of Engine
Compartment

Figure 4-22. Charge Pump Filter

REMOVAL
1. Disconnect and cap the hydraulic lines (5 and 6) on
the filter assembly (3).
2. Remove the mounting bolts/washers (2) on top to
remove the filter assembly from the bracket.

INSTALLATION
1. Attach filter assembly (3) to mounting bracket (1)
using the mounting bolts/washers (2).
NOTE: Torque mounting bolts to 35 ft. lb. (48 Nm).
2. Uncap and reconnect the hydraulic lines (5 and 6) to
the filter.
NOTE: If removed and reinstalled, filter bowl torque is
30 ft. lb. (40 Nm).

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 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.13 CYLINDER REPAIR 4. Place the cylinder barrel into a suitable holding fix-
ture.
NOTE: The following are general procedures that apply to
all cylinders on this machine. Procedures that apply
to a specific cylinder will be so noted.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN

WORK SURFACE IN A DIRT FREE WORK AREA.

1. Connect a suitable auxiliary hydraulic power source

to the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT

CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. Figure 4-24. Cylinder Barrel Support
.
2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if appli-
cable.
3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Dis-
card o-rings.

Figure 4-25. Lift Cylinder Cap Screw Removal

NOTE: Steps 6 and 7 apply only to the steer cylinder.

5. Using a spanner wrench, loosen the spanner nut
retainer, and remove spanner nut from cylinder bar-
rel.
6. Being careful not to mar the surface of the rod, use a
punch or wooden dowel and hammer to drive the
rod guide about one inch down into the cylinder
bore. Using a screw driver, carefully push one end of
the round retaining ring back towards the inside of
MAF06130
the cylinder and then slip the screwdriver tip under
Figure 4-23. Lift Cylinder Holding Valve and Fitting that end. Pull the ring out of the groove toward the
Removal wall mouth. Once one end of the retaining ring is free
from the groove, the remainder can be easily pried
free using ones fingers or pliers.

3121781 4-71
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

13. Remove the bushing from the piston.

7. Attach a suitable pulling device to the cylinder rod

port block end or cylinder rod end, as applicable.

Figure 4-27. Tapered Bushing Removal

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER
ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, 14. Screw the piston counter-clockwise, by hand, and
WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BAR- remove the piston from cylinder rod.
REL SURFACES. 15. Remove and discard the piston o-rings, seal rings,
and backup rings.
8. With the barrel securely clamped, apply pressure to
16. Remove piston spacer, if applicable, from the rod.
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel. 17. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer plate, if applica-
ble. Discard the o-rings, back-up rings, rod seals, and
wiper seals.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.
2. Inspect the cylinder rod for scoring, tapering, ovallity,
or other damage. If necessary, dress rod with Scotch
Brite or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive dam-
age. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scor-
ing or other damage. Check inside diameter for
Figure 4-26. Cylinder Rod Support tapering or ovallity. Replace if necessary.
9. Using suitable protection, clamp the cylinder rod in a 5. Inspect threaded portion of barrel for damage. Dress
vise or similar holding fixture as close to the piston as threads as necessary.
possible. 6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
NOTE: Step 11 applies only to the steer cylinder. as necessary.
10. Loosen and remove the nut which attaches the pis- 7. Inspect threaded portion of piston for damage. Dress
ton to the rod, and remove the piston. threads as necessary.
11. Loosen and remove the cap screw(s), if applicable, 8. Inspect seal and o-ring grooves in piston for burrs
which attach the tapered bushing to the piston. and sharp edges. Dress applicable surfaces as neces-
12. Insert the cap screw(s) in the threaded holes in the sary.
outer piece of the tapered bushing. Progressively 9. Inspect cylinder head inside diameter for scoring or
tighten the cap screw(s) until the bushing is loose on other damage and for ovallity and tapering. Replace
the piston. as necessary.

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 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

10. Inspect threaded portion of head for damage. Dress 1. A special tool is used to install a new rod seal into the
threads as necessary. applicable cylinder head gland groove.
11. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring or
other damage and ovallity and tapering. Replace as
necessary.
13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs,
dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other dam-
age. If steel bushing is worn or damaged, rod/
barrel must be replaced.
c. Lubricate inside of steel bushing with WD40 Figure 4-29. Rod Seal Installation
prior to bearing installation.
d. Using an arbor of the correct size, carefully
press the bearing into steel bushing. WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS ARE
NOTE: Install pin into the Gar-Max bearing dry. Lubrication INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR
is not required with nickel plated pins and bearings. CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERA-
TION.
STEEL
COMPOSITE
BUSHING WHEN INSTALLING THE WIPER SEAL ON THE LOWER (TOWER) LIFT
BUSHING
CYLINDER, APPLY LOCTITE® #609 ON THE WIPER SEAL IN THREE
EVENLY SPACED PLACES TO AID IN RETENTION OF THE SEAL.

2. Use a soft mallet to tap a new wiper seal into the

applicable cylinder head gland groove. Install a new
wear ring into the applicable cylinder head gland-
ARBOR groove.

Figure 4-28. Bushing Installation

14. Inspect travel limiting collar or spacer for burrs and

sharp edges. If necessary, dress inside diameter sur-
face with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary. Figure 4-30. Poly-Pak Piston Seal Installation
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

Assembly
NOTE: Prior to cylinder assembly, ensure that the proper cyl-
inder seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components prior
to assembly.

3121781 4-73
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Figure 4-31. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable
outside diameter groove of the cylinder head.

Figure 4-33. Piston Seal Kit Installation

8. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to piston as
Figure 4-32. Installation of Head Seal Kit possible.
9. Carefully thread the piston on the cylinder rod hand
4. Install washer ring onto rod. Carefully install the head tight, ensuring that the o-ring and back-up rings are
gland on the rod, ensuring that the wiper and rod not damaged or dislodged.
seals are not damaged or dislodged. Push the head
10. Thread piston onto rod until it abuts the spacer end
along the rod to the rod end, as applicable.
and install the tapered bushing.
5. Carefully slide the piston spacer on the rod.
6. If applicable, correctly place new o-ring in the inner NOTE: When installing the tapered bushing, piston and
piston diameter groove. (The backup ring side facing mating end of rod must be free of oil.
the o-ring is grooved.) 11. Assemble the tapered bushing loosely into the pis-
7. If applicable, correctly place new seals and guide ton and insert JLG capscrews (not vendor capscrews)
lock rings in the outer piston diameter groove. (A through the drilled holes in the bushing and into the
tube, with I.D. slightly larger than the O.D. of the pis- tapped holes in the piston.
ton is recommended to install the solid seal.)
NOTE: The backup rings for the solid seal have a radius on
one side. This side faces the solid seal. [See magnified
insert in (See Figure 4-33.)] The split of seals and
backup rings must be positioned so as not to be in
alignment with each other.

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 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

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 BAR-
REL SURFACES.

18. With barrel clamped securely, and while adequately

supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.
19. Continue pushing the rod into the barrel until the
cylinder head gland can be inserted into the barrel
cylinder.
20. Secure the cylinder head gland using the washer ring
and socket head bolts.

Figure 4-34. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in
rotation to the specified torque value.
13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4” in diameter) as follows;
a. Place the shaft against the cylinder rod and in
contac t with the bushing in the spaces
between the capscrews.
b. Tap each space once; this means the tapered
bushing is tapped 3 times as there are 3 spaces
between the capscrews. Figure 4-36. Rod Assembly Installation
21. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
22. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable.
23. Push the piston onto the rod until it abuts the spacer
end and install the attaching nut.

WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE® #242 TO PISTON

NUT AND SETSCREW, THEN TORQUE PISTON NUT.

NOTE: The Steer Cylinder uses snap rings to secure piston.

Figure 4-35. Seating the Tapered Bearing 24. Prior to setscrew installation spot drill rod before
installing the setscrew(s) which secure the piston
14. Re-torque the capscrews evenly and progressively in attaching nut to the diameter groove.
rotation to the specified torque value.
25. Remove the cylinder rod from the holding fixture.
15. Remove the cylinder rod from the holding fixture.
26. Position the cylinder barrel in a suitable holding fix-
16. Place new guide locks and seals in the applicable ture.
outside diameter grooves of the cylinder piston. (See
Figure 4-33.)
17. Position the cylinder barrel in a suitable holding fix-
ture.

3121781 4-75
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

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 BAR-
REL SURFACES.

27. With barrel clamped securely, and while adequately

supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.
28. Continue pushing the rod into the barrel until the
cylinder head gland can be inserted into the barrel
cylinder.
29. If applicable, secure the cylinder head retainer using
a suitable chain wrench.
30. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
31. If applicable, install the cartridge-type holding valve
and fittings in the port block using new o-rings as
applicable.

4-76 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

4.14 CYLINDER ASSEMBLIES

Steer Cylinder

1. Barrel
2. Rod
3. Head - Torque to
434 ft. lb. (588 Nm)
4. Wiper
1
5. Road Seal
6. Back-up Ring
7. Dry Bearing
8. O-Ring
9. O-Ring
10. Piston Seal

Figure 4-37. Steer Cylinder

3121781 4-77
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

NOTE: SEE SCISSORS ARMS ASSEMBLY FOR CARTRIDGE

VALVES LOCATED IN VALVE BLOCK. DO NOT PUT CYLINDER
INTO SERVICE WITHOUT CARTRIDGE VALVE INSTALLED

6
1
Lift Cylinder (Lower)

5 1. Barrel
2. Rod
3. Head - Torque to
4
332 ft. lb. (450 Nm)
4. Piston - Torque to
107
108
1003 ft. lb. (1360 Nm)
107 5. Screw - Torque to
110 7 ft. lb. (10 Nm)
109
6. Bearing
101 101. Wear Ring
104 102. O-Ring
102 103. Back-up Ring
103
104. Rod Seal
105
105. O-Ring
3 106. Wiper Ring
101
107. Wear Ring
106
108. Piston Seal
2
109. O-Ring
110. Back-Up Ring
6

MAF04370

Figure 4-38. Lift Cylinder (Lower)

4-78 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

NOTE: SEE SCISSORS ARMS ASSEMBLY FOR CARTRIDGE

VALVES LOCATED IN VALVE BLOCK. DO NOT PUT CYLINDER
INTO SERVICE WITHOUT CARTRIDGE VALVE INSTALLED

7
6

Lift Cylinder (Upper)

1

5 1. Barrel
2. Rod
3. Head - Torque to 332 ft. lb.
4 (450 Nm)
107 4. Piston - Torque to 575 ft. lb.
108 (780 Nm)
107 5. Screw - Torque to
110
109 4 ft. lb. (5 Nm)
6. Bearing
101 7. LSS Transducers
104 (If Equipped)
102 101. Wear Ring
103 102. O-Ring
105 103. Back-up Ring
3 104. Rod Seal
101 105. O-Ring
106 106. Wiper Ring
107. Wear Ring
2 108. Piston Seal
109. O-Ring
110.Back-Up Ring
6

MAF04380

Figure 4-39. Lift Cylinder (Upper)

3121781 4-79
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

2 2
1
A

1
6

LOWER CYLINDER
7

UPPER CYLINDER

1
2

2
5
1
3

2 1

MAF04390

Item Torque
1 33 -37 ft. lb. (45 - 50 Nm)
2 3 - 4.5 ft. lb. (4 - 6 Nm)
3 18.5 - 22 ft. lb. (25 - 30 Nm)
4 5 - 7 ft. lb. (7 - 10 Nm)
5 75 - 85 ft. lb. (102 - 115 Nm)
6 4 - 5 ft. lb. (5.4 - 6.8 Nm)
7 33 -37 ft. lb. (45 - 50 Nm)

Figure 4-40. Lift Cylinder Valve Cartridge Torque Values

4-80 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

1. Barrel
2. Rod
3. Wiper Seal
4. Wear Ring
5. Rod Seal
6. Wear Ring
7. CounterBalance Valve
8. Bleeder Valve
9. Pilot Port
10. Valve Port
NOTE: Torque item #7 to 22 ft. lb.
(30 Nm)

THE CYLINDER ROD CAN SLIDE OUT OF THE CYLINDER IF

THE BLEEDER VALVE IS LOOSENED.

Figure 4-41. Oscillating Axle Cylinder

3121781 4-81
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

14
15

2 1. Head
1
2. Barrel
3. Rod
4. Jack Plate
5. Ring, Lock
6. Ring, Wear
7. Ring, Washer
8. Ring, Retaining
9. O-Ring
10. Screw
11. Capscrew
12. Seal
13. WIper
11 3 14. Ring, Back-Up
15. T-Seal
10 4 16. Jack Pad
13
12 5
9
6
8

4 7

MAF04290

Figure 4-41. Leveling Jack Cylinder

NOTE: Apply a light coat of grease to the Cylinder Rod (3) Apply Loctite® #242 to Capscrews (11) and torque to
before installing the Jack Pad (16). 30 ft. lb. (40.7 Nm).

4-82 3121781
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

E
X
2 1

M1

MAF04300

Item Description Torque

1 Solenoid Directional Valve 18.4 to 22.1 ft. lb. (25-30 Nm)
2 Straight Fitting 16.2 ft. lb. (22 Nm)
3 Straight Fitting 40 ft. lb. (54.2 Nm)

Figure 4-42. Leveling Jack Torques

3121781 4-83
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Oscillating Axle Cylinder Bleeding Procedure

1
1

1. Oscillating Axle Cylinder 2. Bleeder Valve

Figure 4-43. Oscillating Axle Cylinder Bleeding

1. Start the engine. NOTE: A fast stream of oil will exhaust the air out of the
2. Raise the arms high enough so that the left axle cyl- hoses and cylinder better than a slow stream of oil.
inder bleeder valve can be accessed. 8. Every 3-4 seconds, close the bleeder valve so that a
3. Let engine run at idle. slower stream of oil is being purged. When only oil
4. Position a suitable container [approximately 0.5 gal and no air is being purged, close the bleeder valve.
(1.9 l)] over the bleeder valve. 9. A new system can take 10-15 seconds per cylinder to
5. Using a 3/8” wrench, slowly open bleeder valve. bleed.
6. Keep the container close enough to the bleeder
valve to catch the aerated oil.
ANYTIME EITHER OF THE HOSES PLUMBING TO THE CYLINDERS ARE
7. Open the bleeder valve enough to get a fast stream
BROKEN INTO, AIR HAS BEEN INTRODUCED INTO THE SYSTEM. THE
of oil.
CYLINDERS MUST BE BLED.

4-84 3121781
 8 7 6 5 4 3 2 1

3121781
CHARGE FILTER
B5=> 1000
43 PSI BYPASS
M14
H V3 H

P PORT VALVE, AXLE

SV2 LOCKOUT (OPTION)
SV2
(NEXT PAGE)

F E M3
MA

RV1 A
CV2 RV1

SV1
G G

CV1
V1 V2
SV1 M5
V4
4.15 HYDRAULIC SCHEMATICS

STEERING
V1 V2
CYLINDER B
M4 S L1 MB
F F
MS
L1 L2 S1 S2 2S1 B1 B2

SV3 CV1 30 psi

2500 PSI
V17
P3
RV5

TO RAM 10 2 7 4 1
E TRACTION MANIFOLD E
LOCKOUT 11
SV6 6
CYLINDERS
(OPTION)
CV6 CV3
SV2 FD2
SV7 CV1

OR3 OR1
OR2
RV2 2700 PSI CV2 FD1
SV7
FD3
CV5 CV4
5
D D
P1 T1 PS T2 G
MP1 PP1

LEFT
COUPLED TO
AXLE PUMP LEFT A A
OR4

8 13 9 12 3
REAR AXLE FRONT
DRIVE MOTORS B B AXLE
DRIVE

Figure 4-44. Hydraulic Schematic

A MOTORS
A
C C
2 SPEED

B
RIGHT B
SV2 RIGHT
LEFT SV1 RIGHT
T LP 2 SPEED
FRONT FRONT
JACK RET 1 JACK
EXT 4

EXT 2

B B
PB1

PA1
PB2
2500 PSI
SV3
PA3 SV4
LEFT RIGHT
REAR REAR
JACK JACK

PB4 PB3 PA2 PA4

A A

LEVELING JACK SYSTEM

1001232921-B
8 7 6 5 4 3 2 1

MAF03720B

4-85
SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS
 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5 4 3 2 1

H H

G G

OPTION: AXLE
LOCKOUT VALVE

RAM LOCKOUT
CYLINDERS
AR AL P P
F CV1 CV1 F
CY1 V V CY1
R2P2W

RV1 RV1

R2P3W

T (4500 PSI) (4500 PSI)

P L2P2W

E E

L2P3W

D FROM PORT 11 D
TRACTION MANIFOLD

FROM PORT M3
DRIVE PUMP

C C

B B

A A

SHEET 2 1001232921-B
5 4 3 2 1
MAF03730B

Figure 4-45. Hydraulic Schematic

4-86 3121781
 SECTION 5 - JLG CONTROL SYSTEM

SECTION 5. JLG CONTROL SYSTEM

5.1 HAND HELD ANALYZER

men u:
Analyzer Display HELP:PRESS ENTER

Escape Key Enter Key

To return home or access Stores and selects Top Level, Sub
previous menu Level, and item menus

Up & Down Arrow Keys Left & Right Arrow Keys

Value Selector Used to move between Top Level,
Sub Level, and item menus

Figure 5-1. Hand Held Analyzer

To Connect the Hand Held Analyzer the PCB in the ground control station or at the plat-
form control station connector (2) X32 as shown.
1. Connect the four pin end of the cable supplied with Connect the remaining end of the cable to the ana-
the analyzer, to the four position connector (1) J6 on lyzer.

1 MAF05130

1. Ground Control Box - Analyzer Connector 2. Platform Control Box - Analyzer Connector
Figure 5-2. Hand-Held Analyzer Connections

3121781 5-1
 SECTION 5 - JLG CONTROL SYSTEM

NOTE: The cable has a four pin connector at each end; the If you press ENTER, at the HELP:PRESS ENTER display,
cable cannot be connected backwards. and a fault is present during power up, the analyzer dis-
play will scroll the fault across the screen. If there was no
3. Power up the Control System by turning the lower fault detected during power up, the display will read:
key to the platform position and pulling out both In platform mode, HELP: EVERYTHING OK,
emergency stop buttons.
In ground mode, GROUND MODE OK
Using the Analyzer If ENTER is pressed again, the display moves to the fol-
lowing display:
With the machine power on and the analyzer connected
properly, the analyzer will display the following:

hel p:
1: st ar t up ( 2/ 1)
MENU:
HELP:PRESS ENTER

LOGGED HELP

HELP: 1: STARTUP (2/1): (Or last recorded fault)

PRESS ENTER At this point, the analyzer will display the current fault, if
any are present. You may scroll through the fault logs to
At this point, using the RIGHT and LEFT arrow keys, you view what the last fifteen faults were. Use the right and
can move between the top level menu items. To select a left arrow keys to scroll through the fault logs. To return
displayed menu item, press ENTER. To cancel a selected to the beginning, press ESC two times.
menu item, press ESC; then you will be able to scroll
using the right and left arrow keys to select a different When a top level menu is selected, a new set of menu
menu item. items may be offered; If for example you choose Person-
alities:
The top level menus are as follows:
DRIVE
ACCESS LEVEL LIFT
PERSONALITIES GROUND MODE
MACHINE SETUP Pressing ENTER with any of the above displayed menus
CALIBRATIONS will display additional sub-menus within the selected
ACTIVATE TESTS menu. In some cases the next level is the parameter or
information to be changed. Refer to the flow chart for
HELP
what menus are available within the top level menus.
DIAGNOSTICS You may only view the personality settings for selected

5-2 3121781
 SECTION 5 - JLG CONTROL SYSTEM

menus while in access level 2. Remember, you may Once the correct password is displayed, press ENTER.
always cancel a selected menu item by pressing the ESC The access level should display the following, if the pass-
key. word was entered correctly:

Changing the Access Level of the Hand Held

Analyzer
When the analyzer is first connected, you will be in
access level 2 which enables you to only view most con-
figuration settings which cannot be changed until you MENU:
enter a password to advance to a lower level. This ACCESS LEVEL 1
ensures that a setting cannot be accidentally altered. To
change the access level, the correct password must be
entered. To enter the password, scroll to the ACCESS
LEVEL menu. For example:

MENU:
ACCESS LEVEL 2

MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings.

MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit
of the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the
password.
Use the UP or DOWN arrow key to enter the second
digit of the password which is 3.
Repeat this process until you have entered all five digits
of the password which is 33271.

3121781 5-3
 SECTION 5 - JLG CONTROL SYSTEM

Adjusting Parameters Using the Hand Held Machine Setup

Analyzer When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
Once you have gained access to level 1, and a personal-
ity item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR
MACHINE CAN RESULT IN IMPROPER OPERATION.

PERSONALITIES:
DRIVE ACCEL 3.0s
GROUND ALARM:
1=DESCENT

PERSONALITIES:
DRIVE ACCEL 3.0s
There will be a minimum and maximum for the value to GROUND ALARM:
ensure efficient operation. The value will not increase if
1=DESCENT
the UP arrow is pressed when at the maximum value
nor will the value decrease if the DOWN arrow is The effect of the machine digit value is displayed along
pressed and the value is at the minimum value for any with its value. The above display would be selected if
particular personality. If the value does not change the machine was equipped with a ground alarm and
when pressing the up and down arrows, check the you wanted it to sound when driving. There are certain
access level to ensure you are at access level 1. settings allowed to install optional features or select the
machine model.
When selecting the machine model to match the size of
the machine, the personality settings will return to
default settings.

5-4 3121781
 SECTION 5 - JLG CONTROL SYSTEM

NOTE: Refer to Table 5-3, Machine Configuration Program- NOTE: Flash codes are also displayed on the handheld ana-
ming Information and Table 5-5, Machine Model lyzer. For descriptions see Table 5-1, DTC and Flash
Personality Adjustment for default settings. Code Descriptions.

Password 33271 will give you access to level 1, which

will permit you to change all machine personalities
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/
and/or machine setup settings.
ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTI-
LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COM-
PONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM
CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFOR- PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12
MANCE OF YOUR MACHINE. INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/
ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE
The flash code is indicated on the face of the platform DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURA-
control box as shown: TION.

MAF06040

3121781 5-5
5-6
ANALYZER MENU
STRUCTURE
MENU: HELP: (001)
HELP:PRESS ENTER EVERYTHING OK

LOG: *(XXXXX)
X:XXXXXXXXXXXXXX

MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:

DIAGNOSTICS PLATFORM GROUND SYSTEM VALVES ELEV SENSOR LOAD TEMPERATURE ENGINE

PLATFORM: GROUND: SYSTEM: VALVES: ELEV SENSOR: LOAD: TEMPERATURE: ENGINE:

Analyzer Menu Flow Charts

DRIVE SEL OPEN LIFT UP OPEN GM BATTERY XX.XV FWD CMD XXXXMA READING X.XXV PLTLOAD ±XXXX KG AMBIENT: XXC START NOT ACTIVE

PLATFORM: GROUND: SYSTEM: VALVES: ARM SENSOR ANG: LOAD: LOW TEMPERATURE ENGINE:
LIFT SEL OPEN LIFT DN OPEN PM BATTERY XX.XV FWD FBK XXXXMA RAW XX.X DEG PLTGROS ±XXXX KG CUTOUT: NOT ACTIVE BATTERY XX.XV

PLATFORM: GROUND: SYSTEM: VALVES: ARM SENSOR ANG: LOAD: ENGINE:

HORN OPEN GLOW PLUG OPEN HORN OFF REV CMD XXXXMA CAL XX.X DEG OVERLOADED? NO COOLANT ±XXC
SECTION 5 - JLG CONTROL SYSTEM

PLATFORM: GROUND: SYSTEM: CHASSIS VALVES: PLATFORM HEIGHT: LOAD: ENGINE:

START OPEN START OPEN TILT +X.X +X.X REV FBK XXXXMA XXX.XIN CELL 1 ±XXXXX KG OIL PRS LOW

PLATFORM: SYSTEM: VALVES: TRANSPORT MODE: LOAD: ENGINE:

HI DRV SEL OPEN JACKS UNSET STEER LEFT OFF STOWED CELL 2 ±XXXXX KG FUEL SELECT GAS

PLATFORM: SYSTEM: VALVES: LOAD: ENGINE:

LOW DRV SEL OPEN FNT LFT XXX PSI STEER RIGHT OFF CELL 3 ±XXXXX KG FUEL LEVEL ERROR
LOWER LIFT DOWN
COMMAND: XXXXMA
PLATFORM: SYSTEM: VALVES: LOAD: ENGINE:
AUTO LEV OPEN FNT RHT XXX PSI DUMP OFF CELL 4 ±XXXXX KG GLOW PLUG OFF
LOWER LIFT DOWN
FBK: XXXXMA
PLATFORM : SYSTEM: VALVES: ENGINE:
GENERATOR OPEN REAR LT XXX PSI BRAKE OFF LP VALVE OFF
VALVES:
LOSC AXLE OFF
PLATFORM: SYSTEM: VALVES: ENGINE:
STR LEFT OPEN REAR RT XXX PSI 2 SPD OFF ACTUAL XXXX RPM
VALVLES:
ROSC AXLE OFF
PLATFORM: SYSTEM: VALVES: ENGINE:
STR RIGHT OPEN FNT LFT SW OPEN LIFT UP OFF TARGET XXXX RPM
VALVES:
FL L/J VLVE OFF DIAGNOSTICS: DIAGNOSTICS:
PLATFORM: SYSTEM: VALVES:
TRIGGER OPEN FNT RHT SW OPEN LIFT DN OFF DATALOG VERSIONS
VALVES:
FR L/J VLVE OFF DATALOG: VERSIONS:
PLATFORM: SYSTEM: VALVES:
JOYSTICK CENTER R LFT SW OPEN PROP LFT/LJ XXX% ENGINE XXh XXm GROUND PX.X
VALVES:
RL L/J VLVE OFF DATALOG: VERSIONS:
PLATFORM: SYSTEM: VALVES:
JOYSTICK X.XXV R RHT SW OPEN PROP LIFT XXX% DRIVE XXh XXm GROUND HW REV X
VALVES:
RR L/J VLVE OFF DATALOG: VERSIONS:
PLATFORM: SYSTEM: VALVES:
GLOW PLUG OPEN CANBUS TERM ON PROP LJ XXX% LIFT XXh XXm PLATFORM PX.X
VALVES:
L/J EXT OFF DATALOG: VERSIONS:
PLATFORM: SYSTEM: UPPER LIFT DOWN
FOOTSWITCH OPEN OSAX +X.X +X.X COMMAND: XXXXMA RENTAL XXh XXm I/O MOD PX.X
VALVES:
L/J RET OFF ERASE RENTAL? 1 VERSIONS:
SYSTEM: UPPER LIFT DOWN
DUSCUT XXXIN FBK: XXXXMA LSS MOD PX.X
VALVES:
LP VALVE OFF VERSIONS:
TO MENU: SYSTEM:
SYSTEM TEST GENERATOR OFF HIM MOD PX.X

VERSIONS:
ANALYZER VX.X 1001234738-C
MAF03040C

Figure 5-3. Analyzer Menu Flow Chart (Version P1.1) - Sheet 1 of 3

3121781
3121781
FROM MENU:
DIAGNOSTICS

MENU: ACTIVATE TEST:

SYSTEM TEST YES:ENTER,NO:ESC

MENU: ACCESS LEVEL:

ACCESS LEVEL X CODE XXXXX

MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

PERSONALITIES DRIVE LIFT LIFT (530LRT) LOAD JOYSTICK TEMP CUTOUT
(330/430LRT)
DRIVE: LIFT: LIFT: LOAD: JOYSTICK: LOW TEMPERATURE
ACCEL X.Xs ACCEL X.Xs UP ACCEL X.XS OVERLD XXXX KG FWD MAX X.XXV CUTOUT SET: ±XXC

DRIVE: LIFT: UP DECEL X.XS LOAD: JOYSTICK: TEMPERATURE

DECEL X.Xs DECEL X.Xs ACC'Y XXXX KG FWD MIN X.XXV OFFSET:XC

DRIVE: LIFT: LIFT: LOAD: JOYSTICK:

MIN FORWARD MIN UP XX% MIN UP XX% OVR DBNCE X.Xs REV MIN X.XXV
XXXXMA
DRIVE: LIFT: LIFT: LOAD: JOYSTICK:
HI DRV FWD MAX UP XXX% MAX UP XXX% OVR HOLD X.Xs REV MAX X.XXV
XXXXMA
DRIVE: LIFT: LIFT: LOAD:
MID DRV FWD MIN DOWN XX% UPR DN ACCL X.XS MIN CAL XXXX KG
XXXXMA
DRIVE: LOW DRV FWD LIFT: LIFT: LOAD:
XXXXMA MAX DOWN XXX% UPR DN DECL X.XS MAX CAL XXXX KG

DRIVE: MIN REVERSE LIFT:

XXXXMA UPR DN MIN XXXXMA

DRIVE: HI DRV REV LIFT:

XXXXMA UPR DN MAX
XXXXMA
DRIVE: MID DRV REV LIFT:
XXXXMA LWR DN ACCL X.XS

DRIVE: LOW DRV REV LIFT:

XXXXMA LWR DN DECL X.XS

DRIVE: ELEV FWD MAX LIFT:

XXXXMA LWR DN MIN XXXXMA

DRIVE: ELEV REV MAX LIFT:

XXXXMA LWR DN MAX XXXXMA

MENU: MODEL NUMBER: MARKET: ENGINE: GLOW PLUG: LEVELING JACKS: GENERATOR:
MACHINE SETUP 2=530LRT 0=ANSI USA 0=KUBOTA T4F 3=20 SEC GLOW 1=YES 0=NO

LOAD SYSTEM: GROUND ALARM: ENGINE SHUTDOWN: LOW TEMP CUTOUT: BEACON LIGHT: AXLE CONFIG:
TO MENU:
0=NOT INSTALLED 2=MOTION 1=YES 0=NO 0=NO 1=OSCILLATING
CALIBRATIONS

1001234738-C
MAF03050C

Figure 5-4. Analyzer Menu Flow Chart (Version P1.1) - Sheet 2 of 3

5-7
SECTION 5 - JLG CONTROL SYSTEM
5-8
FROM MENU: 1
MACHINE SETUP

MENU: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1

CALIBRATIONS CHASSIS TILT AXLE TILT SET STOW ELEV LOAD SENSING JOYSTICK

LEVEL VEHICLE: 1 LEVEL VEHICLE: 1 SET STOW ELEV: 1 LOAD SENSING: 1 JOYSTICK CAL: 1
YES:ENTER,NO:ESC YES:ENTER,NO:ESC YES:ENTER,NO:ESC YES:ENTER,NO:ESC YES:ENTER,NO:ESC

CHASSIS TILT 1 AXLE TILT CAL: 1 SET STOW ELEV: 1 LOAD SENSING: 1 JOYSTICK CAL: 1
CAL: COMPLETE! AXLE COMPLETE! COMPLETE! FORWARD & ENTER

CHASSIS TILT: 1 AXLE TILT CAL: 1 ARM SENSOR: 1 LOAD SENSE FAIL: 1 JOYSTICK CAL: 1
SENSOR FAILURE SENSOR FAILURE SENSOR NO COMM < MIN CAL CENTER & ENTER

CHASSIS TILT: 1 AXLE TILT FAIL: 1 ROTARY SENSOR: 1 LOAD SENSE FAIL: 1 JOYSTICK CAL: 1
SECTION 5 - JLG CONTROL SYSTEM

NOT LEVEL NOT LEVEL LOW NOT IN RANGE > MAX CAL REVERSE & ENTER

CHASSIS TILT: 1 AXLE TILT FAIL: 1 ARM SENSOR: 1 JOYSTICK CAL: 1

SENSOR NO COMM SENSOR NO COMM LOW NOT IN RANGE COMPLETE

CHASSIS TILT: 1 UNCALED TILT: 1 SET STOW ELEV: 1 JOYSTICK CAL: 1

RAW AXLE PLT NOT STOWED FAILED

TILT SENSOR: 1 SET STOW ELEV: 1

LEVEL VEHICLE? CAL ABORTED

TILT SENSOR: 1
CAL COMPLETE

TILT SENSOR: 1
CAL FAILED

MENU: 1 SERVICE MODE: 1 SERVICE MODE: 1 SERVICE MODE: 1 SERVICE MODE: 1 SERVICE MODE: 1
SERVICE ECM OVERRIDE ELEV SERVICE EEPROM RESET ALLOW DRIVE? ALLOW LJ RETRCT?

ECM OVERRIDE: 1 ELEV SERVICE: 1 EEPROM RESET: 1 ALLOW DRIVE? 1 ALLOW LJ RETRCT? 1
CODE XXXXX CODE XXXXX CODE XXXXX CODE XXXXX CODE XXXXX

ECM OVERRIDE: 1 ELEV SERVICE: 1 EEPROM RESET: 1 ALLOW DRIVE: 1 ALLOW LJ RETRCT: 1
PASSWORD FAILED PASSWORD FAILED PASSWORD FAILED PASSWORD FAILED PASSWORD FAILED

ECM OVERRIDE: 1 ELEV SERVICE: 1 EEPROM RESET: 1 ALLOW DRIVE? 1 ALLOW LJ RETRCT? 1
ALLOW FUNCTIONS? YES:ENTER,NO:ESC YES:ENTER,NO:ESC YES:ENTER,NO:ESC YES:ENTER,NO:ESC

ECM OVERRIDE: 1 ELEV SERVICE: 1 EEPROM RESET: 1 ALLOW DRIVE? 1 ALLOW LJ RETRCT? 1
FUNCTS ALLOWED COMPLETE! COMPLETE! PLATFORM STOWED? PLATFORM STOWED?

ALLOW DRIVE? 1 ALLOW LJ RETRCT? 1

L/J RETRACTED? RETRACT ALLOWED

ALLOW DRIVE? 1
DRIVE ALLOWED

1001234738-C
MAF03060C

Figure 5-5. Analyzer Menu Flow Chart (Version P1.1) - Sheet 3 of 3

3121781
 SECTION 5 - JLG CONTROL SYSTEM

5.2 DIAGNOSTIC TROUBLESHOOTING CODES (DTC’S) AND FLASH CODES DESCRIPTION

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
001 0 0 "Everything Ok" • No issues detected
004 0 0 "Driving At Cutback - Above Elevation" • The platform is determined to be elevated (Reference platform height
calculation section).
005 0 0 "Drive & Lift Up Prevented - Tilted & Elevated" • Platform is elevated, and machine tilt exceeds the model and market
specific limits.
009 0 0 "Drive Prevented - Elevated Above Drive Cutout Height" • Attempting to drive with the platform elevated to over 32 feet. The
control system prevents driving.
• Lower the platform to under 32 feet.
0041 0 0 "Front Left Leveling Jack At End Of Stroke" • Front Left Leveling Jack cylinder has reached end of stroke.
• Check if the cylinder is at end of stroke (normal operation).
• Check the wiring to the Front Left Leveling Jack end of stroke switch.
0042 0 0 "Front Right Leveling Jack At End Of Stroke" • Front Right Leveling Jack cylinder has reached end of stroke.
• Check if the cylinder is at end of stroke (normal operation).
• Check the wiring to the Front Right Leveling Jack end of stroke switch.
0043 0 0 "Rear Left Leveling Jack At End Of Stroke" • Rear Left Leveling Jack cylinder has reached end of stroke.
• Check if the cylinder is at end of stroke (normal operation).
• Check the wiring to the Rear Left Leveling Jack end of stroke switch.
0044 0 0 "Rear Right Leveling Jack At End Of Stroke" • Rear Right Leveling Jack cylinder has reached end of stroke.
• Check if the cylinder is at end of stroke (normal operation).
• Check the wiring to the Rear Right Leveling Jack end of stroke switch.
0045 0 0 "Engine Shutdown Commanded - Check Engine Sensors" • The engine coolant temperature is high or the oil pressure is low. The
control system shuts down the engine.
• DIESEL - Check the engine oil pressure and engine coolant temperature
sensors for damage.
• Check the engine oil pressure input J2-17 (should be low when not
overheating).
• Check the engine coolant input J2-25 (resistive).
211 2 1 "Power Cycle" • Power was cycled ON
212 2 1 "Keyswitch Faulty - Platform & Ground Active Together" • The Platform and Ground mode switches are both high.
• Check the Ground Module inputs for Ground Mode (J4-4) and Platform
Mode (J1-2).
221 2 2 "Function Problem - Horn Permanently Selected" • Horn switch input is closed during power up.
223 2 2 "Function Problem - Drive & Lift Active Together" • Drive and Lift Digital Inputs on the Platform Control Module are HIGH
simultaneously for 1000ms.
224 2 2 "Function Problem - Steer Left Permanently Selected" • Left steer select switch input is closed during power up.
225 2 2 "Function Problem - Steer Right Permanently Selected" • Right steer select switch input is closed during power up.
228 2 2 "Function Locked Out - Accelerator Not Centered" • Joystick is not centered during start-up of the machine. Joystick signal
must remain at neutral voltage for 1000 ms after start-up or fault will
activate.
229 2 2 "Function Problem - Trigger Permanently Closed" • The Trigger Switch CAN message and LRT Ground Module Trigger DI are
conflicting with each one another.

3121781 5-9
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
232 2 3 "Ground Lift Up/down Active Together" • Ground lift up and lift down inputs both closed. The control system
prevents lifting and lowering.
• Check if the Ground lift switch is damaged, obstructed, or jammed.
• Check Ground input J4-7 (should be low when lift up is not selected).
• Check Ground input J4-8 (should be low when lift down is not
selected).
241 2 4 "Ambient Temperature Sensor - Out Of Range Low" • The temperature is below the allowed minimum value. The control sys-
tem prevents lift up. The control system limits driving to turtle speed if
elevated.
• Check the wires to the Chassis Tilt Sensor.
• Replace the Chassis Tilt Sensor (also sends temperature).
242 2 4 "Ambient Temperature Sensor - Out Of Range High" • The temperature is above the allowed maximum value. The control
system prevents lift up. The control system limits driving to turtle
speed if elevated.
• Check the wires to the Chassis Tilt Sensor.
• Replace the Chassis Tilt Sensor (also sends temperature).
243 2 4 "Front Left Leveling Jack Pressure Transducer Failure" • Front Left Leveling Jack pressure transducer reading is outside of the
allowed range.
• Check the wiring to the Front Left Leveling Jack pressure transducer.
244 2 4 "Front Right Leveling Jack Pressure Transducer Failure" • Front Right Leveling Jack pressure transducer reading is outside of the
allowed range.
• Check the wiring to the Front Right Leveling Jack pressure transducer.
245 2 4 "Rear Left Leveling Jack Pressure Transducer Failure" • Rear Left Leveling Jack pressure transducer reading is outside of the
allowed range.
• Check the wiring to the Rear Left Leveling Jack pressure transducer.
246 2 4 "Rear Right Leveling Jack Pressure Transducer Failure" • Rear Right Leveling Jack pressure transducer reading is outside of the
allowed range.
• Check the wiring to the Rear Right Leveling Jack pressure transducer.
247 2 4 "Front Left Leveling Jack Stow Switch Faulty " • Front Left Outrigger stow switch is closed (digital input is high) while
all Leveling Jacks are set.
248 2 4 "Front Right Leveling Jack Stow Switch Faulty" • Front Right Outrigger stow switch is closed (digital input is high) while
all Leveling Jacks are set.
249 2 4 "Rear Left Leveling Jack Stow Switch Faulty" • Rear Left Outrigger stow switch is closed (digital input is high) while all
Leveling Jacks are set.
251 2 5 "Elev Angle Sensor Faulty - Not Mounted or Voltage Out Of Range" • Elevation angle sensor's voltage is > 4.85V or < 0.30V.
252 2 5 "Elev Angle Sensors Have Not Been Calibrated" • The EEPROM value for Arm Stack Arm Angle and Rotary Sensor values
for Stowed are default EEPROM values.
2111 2 1 "Engine Start Prevented - Platform Start Switch High At Power Up" • Start switch is closed during power up.
2210 2 2 "Trigger Closed Too Long While In Neutral" • Trigger has been squeezed for 10 seconds while the joystick was in the
center position.
• Check the Platform Trigger input J1-1 (should be high when trigger is
squeezed).
2232 2 2 "Function Locked Out - Drive & Lift Both Open" • The Platform Drive and Lift inputs are both open. The control system
prevents any function selects.
• Check Platform inputs J1-3 (should be high in drive mode) and J1-4
(should be high in lift mode).
2237 2 2 "Joystick Faulty - Steer Switches Active Together" • Steer switch inputs are both closed at the same time.

5-10 3121781
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
2239 2 2 "Function Locked Out - Joystick Calibration Faulty" • Joystick calibration is not valid. The control system prevents any func-
tion selects.
• Calibrate the Platform Joystick.
2267 2 2 "Joystick Faulty - Wiper Out Of Range" • Joystick Wiper is outside the acceptable voltage range.
• Check the wires to the joystick.
2269 2 2 "Function Problem - High Speed & Creep Active Together" • The High Speed and Low Speed Drive Inputs are active Simultaneously
for 1000ms.
2282 2 2 "Function Problem - Generator Permanently Selected" • Generator select switch input is closed during power up.
2284 2 2 "Function Problem - Trigger Switch Wiring Short to Ground" • CAN messages and DI on ground board are conflicting with one
another
22101 2 2 "Function Problem - Drive & Level Active Together" • Machine Setup Leveling Jacks is set to 1=YES

Drive and Level Digital Inputs on the Platform Control Module are HIGH
simultaneously for 1000ms
2299 2 2 "Function Problem - Lift and Level Active Together" • Machine Setup Leveling Jacks is set to 1=YES

Lift and Level Digital Inputs on the Platform Control Module are HIGH
simultaneously for 1000ms
22100 2 2 "Function Problem - Drive & Lift & Level All Open" • Machine Setup Leveling Jacks is set to 1=YES

The Lift/Level/Drive Mode Digital Inputs are LOW simultaneously for

1000ms.
22102 2 2 "Trigger Faulty" • Disagreement between the trigger input at the platform and the
ground.
Trigger reads low at the platform module
• Trigger reads high at the ground module
23245 2 3 "Elevation Sensors - Disagreement" • DTC 252 - ELEVATION ANGLE SENSORS NOT CALIBRATED is NOT Active
AND
Rotary Sensor Voltage > 1.5V (indicating elevated) and Adjusted Arm
Angle > -4 deg (indicating stowed) for 1000ms
OR
Rotary Sensor Voltage > 3V (indicating close to full height) and
Adjusted Arm Angle > -30 deg (indicating not close to full height) for
1000ms
2410 2 4 "Rear Right Leveling Jack Stow Switch Faulty" • Rear Right Outrigger stow switch is closed (digital input is high) while
all Leveling Jacks are set

3121781 5-11
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
2512 2 5 "Elev Angle Sensor Not Detecting Change" • DTC 6661, 8114, 8117 Not Active
ANDThe Platform Calculated Height is …
> 100 inches AND < 350 inches AND Model = 330LRT
OR
> 120 inches AND < 450 inches AND Model = 430LRT
OR
> 140 inches AND < 600 inches AND Model = 530LRT
AND
Lift Up/LJ Flow Control (530LRT) or Lift Flow Control (330/430LRT)
Command > LIFT UP MIN + 15%
AND
RDGFilteredAdjustedArmTiltAngle does not change more than 0.50
degrees for 5000mS
2555 2 5 "Function Prevented - Selected Before FSW" • Machine Setup Market == Korea
AND
Machine Setup Footswitch is 1=YES
AND
Footswitch is open while the joystick is not in the neutral/center posi-
tion
2568 2 5 "Temperature Cutout Active - Ambient Temperature Too Low" • The temperature is too low. The control system may prevent lift up,
drive, steer.
• Check the wires to the Chassis Tilt Sensor.
• Replace the Chassis Tilt Sensor (also sends temperature).
2580 2 5 "Lift Up Prevented - Leveling Jacks Not Set" • Attempting to lift up with the platform elevated too high with out the
leveling jacks set. The control system prevents lifting.
• Lower the platform to stowed. Set the leveling jacks.
2588 2 5 "Function Prevented - Leveling Jacks State Unknown" • One or more of the leveling jack's switches are not in the stowed posi-
tion and the jacks are not in the set position.
2590 2 5 "Functions Locked Out - ECM Lost" • MACHINE SETUP -> ENGINE = KUBOTA D/F ECM and CANbus communi-
cation is lost for 250mS
23107 2 3 "Function Problem - Lift Up Permanently Selected" • Ground lift up switch is closed during a power up.
23108 2 3 "Function Problem - Lift Down Permanently Selected" • Ground lift down switch is closed during a power up.
23153 2 3 "Function Problem - Engine Start Permanently Selected" • Ground start switch is closed during power up.
3517 3 5 "Front Left Leveling Jack Short To Ground" • The Front Left Leveling Jack is shorted to ground.
• Check the wiring to the Front Left Leveling Jack.
3518 3 5 "Front Left Leveling Jack Short To Battery" • The Front Left Leveling Jack is shorted to battery.
• Check the wiring to the Front Left Leveling Jack.
3519 3 5 "Front Left Leveling Jack Open Circuit" • The Front Left Leveling Jack is open circuit.
• Check the wiring to the Front Left Leveling Jack.
3520 3 5 "Front Right Leveling Jack Short To Ground" • The Front Right Leveling Jack is shorted to ground.
• Check the wiring to the Front Right Leveling Jack.
3521 3 5 "Front Right Leveling Jack Short To Battery" • The Front Right Leveling Jack is shorted to battery.
• Check the wiring to the Front Right Leveling Jack.
3522 3 5 "Front Right Leveling Jack Open Circuit" • The Front Right Leveling Jack is open circuit.
• Check the wiring to the Front Right Leveling Jack.
3523 3 5 "Rear Left Leveling Jack Short To Ground" • The Rear Left Leveling Jack is shorted to ground.
• Check the wiring to the Front Left Leveling Jack.

5-12 3121781
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
3524 3 5 "Rear Left Leveling Jack Short To Battery" • The Rear Left Leveling Jack is shorted to battery.
• Check the wiring to the Front Left Leveling Jack.
3525 3 5 "Rear Left Leveling Jack Open Circuit" • The Rear Left Leveling Jack is open circuit.
• Check the wiring to the Front Left Leveling Jack.
3526 3 5 "Rear Right Leveling Jack Short To Ground" • The Rear Right Leveling Jack is shorted to ground.
• Check the wiring to the Rear Right Leveling Jack.
3527 3 5 "Rear Right Leveling Jack Short To Battery" • The Rear Right Leveling Jack is shorted to battery.
• Check the wiring to the Rear Right Leveling Jack.
3528 3 5 "Rear Right Leveling Jack Open Circuit" • The Rear Right Leveling Jack is open circuit.
• Check the wiring to the Rear Right Leveling Jack.
3529 3 5 "Leveling Jack Extend Valve Short To Ground" • The Leveling Jack extend valve is shorted to ground.
• Check the wiring to the Leveling Jack extend valve.
3530 3 5 "Leveling Jack Extend Valve Short To Battery" • The Leveling Jack extend valve is shorted to battery.
• Check the wiring to the Leveling Jack extend valve.
3531 3 5 "Leveling Jack Extend Valve Open Circuit" • The Leveling Jack extend valve is open circuit.
• Check the wiring to the Leveling Jack extend valve.
3532 3 5 "Leveling Jack Retract Valve Short To Ground" • The Leveling Jack retract valve is shorted to ground.
• Check the wiring to the Leveling Jack retract valve.
3533 3 5 "Leveling Jack Retract Valve Short To Battery" • The Leveling Jack retract valve is shorted to battery.
• Check the wiring to the Leveling Jack retract valve.
3534 3 5 "Leveling Jack Retract Valve Open Circuit" • The Leveling Jack retract valve is open circuit.
• Check the wiring to the Leveling Jack retract valve.
33132 3 3 "Throttle Actuator - Short to Battery" • The Engine RPM is not commanded to high idle however the control
system detects high idle.
33280 3 3 "Glowplug - Short to Battery" • The platform or ground glow plug input is detected high at power up.
33318 3 3 "Drive Forward Valve - Short to Battery" • The HIM has detected a STB on the Drive Forward Valve output and
communicated it to the LRT Ground Module via CAN
33319 3 3 "Drive Forward Valve - Short to Ground" • The HIM has detected a STG on the Drive Forward Valve output and
communicated it to the LRT Ground Module via CAN
33317 3 3 "Drive Forward Valve - Open Circuit" • The HIM has detected a OC on the Drive Forward Valve output and com-
municated it to the LRT Ground Module via CAN

Only detectable when a function is active

33321 3 3 "Drive Reverse Valve - Short to Battery" • The HIM has detected a STB on the Drive Reverse Valve output and
communicated it to the LRT Ground Module via CAN
33322 3 3 "Drive Reverse Valve - Short to Ground" • The HIM has detected a STG on the Drive Reverse Valve output and
communicated it to the LRT Ground Module via CAN
33320 3 3 "Drive Reverse Valve - Open Circuit" • The HIM has detected a OC on the Drive Reverse Valve output and com-
municated it to the LRT Ground Module via CAN

Only detectable when a function is active

33750 3 3 "Upper Lift Down Valve - Short to Battery" • The HIM has detected a STB on the Upper Lift Down Valve output and
communicated it to the LRT Ground Module via CAN
AND
Machine Setup Model - 530LRT

3121781 5-13
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
33751 3 3 "Upper Lift Down Valve - Short to Ground" • The HIM has detected a STG on the Upper Lift Down Valve output and
communicated it to the LRT Ground Module via CAN
AND
Machine Setup Model - 530LRT
33752 3 3 "Upper Lift Down Valve - Open Circuit" • The HIM has detected a OC on the Upper Lift Down Valve output and
communicated it to the LRT Ground Module via CAN
Only detectable when a function is active
AND
Machine Setup Model - 530LRT
33753 3 3 "Lower Lift Down Valve - Short to Battery" • The HIM has detected a STB on the Lower Lift Down Valve output and
communicated it to the LRT Ground Module via CAN
AND
Machine Setup Model - 530LRT
33754 3 3 "Lower Lift Down Valve - Short to Ground" • The HIM has detected a STG on the Lower Lift Down Valve output and
communicated it to the LRT Ground Module via CAN
AND
Machine Setup Model - 530LRT
33755 7 8 "Lower Lift Down Valve - Open Circuit" • The HIM has detected a OC on the Lower Lift Down Valve output and
communicated it to the LRT Ground Module via CAN
Only detectable when a function is active
AND
Machine Setup Model - 530LRT
4381 4 3 "Fuel Sensor - Short to Battery" • The control system measures Fuel Sensor A2D value > 1023 counts
432 4 3 "Fuel Sensor Short To Ground" • The fuel sensor value is under the minimum allowed value.
• Check the fuel sensor input J2-34 (resistive).
4382 4 3 "Fuel Sensor - Open Circuity" • The control system measures Fuel Sensor A2D value > 768 counts
433 4 3 "Oil Pressure Short To Battery" • Engine oil pressure is high while the engine is not running for 30 sec-
onds.
• Check the engine oil pressure input J2-17 (should be low when not
overheating).
• Check the speed sensor wiring.
434 4 3 "Oil Pressure Short To Ground"
435 4 3 "Coolant Temperature Short To Ground"
437 4 3 "Engine Trouble Code " • Fault was reported by the engine controller.
• Check the engine.
438 4 3 "Engine Temperature High" • Engine temperature is over 110 degrees C.
441 4 4 "Battery Too Low - System Shut Down" • Battery voltage is under 9 Volts.
• Check the battery charge and cables.
442 4 4 "Battery Too High - System Shut Down" • Battery voltage is over 16 Volts.
• Check the battery charge and cables.
4310 4 3 "No Alternator Output" • The Alternator input is high after 15 seconds of engine running.
• Check alternator input J2-21 (should be low if engine is running).
4311 4 3 "Oil Pressure Low" • Engine oil pressure low after 10 seconds of running.
• Check engine oil pressure input J2-17 (should be high if engine is run-
ning).
4322 4 3 "Loss of Engine Speed Sensor" • Oil Pressure is present, Diesel Rpm is equal to zero and Speed Sensor
Loss Counter has timed out.

5-14 3121781
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
4323 4 3 "Speed Sensor Reading Invalid Speed" • The speed sensor reading is over the maximum allowed value.
• Check the speed sensor wiring.
4352 4 3 "Coolant Temp Sensor Out Of Range High" • Engine coolant temp value is over the maximum allowed value.
• Check the engine coolant input J2-25 (resistive).
4353 4 3 "Coolant Temp Sensor Out Of Range Low" • Engine coolant temp value is under the minimum allowed value.
• Check the engine coolant input J2-25 (resistive).
4430 4 4 "Battery Low" • Battery voltage is under 11 Volts.
• Check the battery charge and cables.
662 6 6 "Canbus Failure - Platform Module" • The control system failed to receive messages from the Platform Mod-
ule. All data from Platform Module is marked invalid.
• Check wiring to the Platform Module.
666 6 6 "Canbus Failure - Engine Controller" • MACHINE SETUP -> ENGINE = KUBOTA D/F ECM and CANbus communi-
cation is lost for 250mS.
663 6 6 "LSS Not Sending Can Messages" • LSS Module CANbus messages not received for 250mS
AND
LOAD CFG = LOAD PINS
AND
LOAD != NO
664 6 6 "Canbus Failure - Accessory Module" • Canbus communication with the accessory module port has been lost
for 1000ms
6649 6 6 "Canbus Failure - Temp/Tilt Sensor" • Ground module has lost communication with the tilt/temperature
(0xC1) sensor via Canbus for greater than or equal to 250ms AND Low
Temperature Cutout is configured
671 6 7 "Accessory Fault" • CAN faults reported by the Accessory Module.
6635 6 6 "Canbus Failure - Chassis Tilt Sensor" • The control system failed to receive messages from the Chassis Tilt Sen-
sor. The control system behaves tilted.
• The Chassis Tilt Sensor is located inside the left chassis cover. Check
wiring to the Chassis Tilt Sensor.
6650 6 6 "Canbus Failure - Oscillating Axle Tilt Sensor" • MACHINE SETUP ->AXLE = OSCILLATING AND MODEL = 330/430LRT
and MARKET = CE
OR
MACHINE SETUP MODEL = 530LRT and AXLE = OSCILLATING
AND
Ground module has lost communication with the oscillating axle tilt
sensor (0xC3) via CANbus for greater than or equal to 250ms .
6660 6 6 "Canbus Failure - Leveling Jacks Module" • CAN communication is lost with the leveling jacks module for 250ms.
6661 6 6 "Canbus Failure - Arm Stack Tilt Sensor" • Arm Stack Tilt Sensor CANbus messages not received for 250mS.
6671 "Canbus Failure - Hydraulics Improvement Module" • The LRT Ground Module has not received HIM messages for 250ms
813 8 1 "Chassis Tilt Sensor Not Calibrated" • The chassis tilt sensor has never been calibrated so the control system
assumes the vehicle is tilted. Control system determines that the chas-
sis tilt sensor EEPROM values have never been calibrated.
814 8 1 "Chassis Tilt Sensor Out Of Range" • The Chassis Tilt Sensor Raw X or Raw Y axis reads > +35 deg or < -35
deg.

3121781 5-15
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
818 8 1 "Tilt Sensor Stagnant" • If DTC's 6635, 813, 814 Not Active AND
Commanded Drive Fwd or Rev > Max Low Drive Forward or Max Low
Drive Reverse Personalities AND RDGChassisTilt(X) does not change by
0.01 deg within 5000ms OR
RDGChassisTilt(Y) does not change by 0.01 deg within 5000ms
825 8 2 "LSS Has Not Been Calibrated" • Machine Setup LOAD != NO AND the control system detects that LSS
has not been calibrated.
829 8 2 "Functions Cutout - Platform Overloaded" • Machine Setup -> LOAD != NO
• AND
• The platform load exceeds the "overload weight" value.
821 8 2 "LSS Cell #1 Error" • LOAD CFG = LOAD PINS and LOAD != NO
AND
LSS Module Reports Cell #1 DTC
822 8 2 "LSS Cell #2 Error" • LOAD CFG = LOAD PINS and LOAD != NO
AND
LSS Module Reports Cell #2 DTC
823 8 2 "LSS Cell #3 Error" • LOAD CFG = LOAD PINS and LOAD != NO
AND
LSS Module Reports Cell #3 DTC
824 8 2 "LSS Cell #4 Error" • LOAD CFG = LOAD PINS and LOAD != NO
AND
LSS Module Reports Cell #4 DTC
837 8 3 "Platform LSS Sensor 1 - Short To Battery" • Pressure Transducer Number 1 is reading higher then 3360PSI.
• Check Sensor wiring.
838 8 3 "Platform LSS Sensor 1 - Short To Ground Or Open Circuit" • Pressure Transducer Number 1 is reading lower then 0 PSI.
• Check Sensor wiring.
873 8 7 "Machine Safety System Override Occurred" • The Platform was moved while overloaded using the MSSO button.
• Can be reset only with an Analyzer, via the CALIBRATIONS > MSSO
RESET > MSSO RESET menu.
8113 8 1 "Axle Tilt Sensor Has Not Been Calibrated" • Ground module is indicating that the EEPROM which stores the axle tilt
sensor calibration is blank.
MACHINE SETUP ->AXLE = OSCILLATING AND MODEL = 330/430LRT
and MARKET = CE
OR
MACHINE SETUP MODEL = 530LRT and AXLE = OSCILLATING.
8114 8 1 "Arm Stack Tilt Sensor Out Of Range" • The Arm Stack Tilt Sensor Raw Arm Angle reading is < -90 degrees
(factors in max arm angle plus 40% grade) OR greater than 40 degrees
(conservatively assumes a minimum arm angle of 0 degrees plus a
downhill grade of 40%)
DTC 813 CHASSIS TILT SENSOR NOT CALIBRATED is not Active.
8115 8 1 "Axle Tilt Sensor Out Of Range" • The Axle Tilt Sensor Raw X or Raw Y axis reads:
530 LRT: > +25 deg or < -25 deg
330/430 LRT > +30 deg or < -30 deg
8118 8 1 "Axle Tilt Sensor Stagnant" • If DTC's 6650, 8113, 8115 Not Active AND
Commanded Drive Fwd or Rev > Max Low Drive Forward or Max Low
Drive Reverse Personalities AND
RDGAxleXTilt_SideSide does not change by 0.01 deg within 5000ms
OR
RDGAxleYTilt_FrontBack does not change by 0.01 deg within 5000ms

5-16 3121781
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-1. DTC and Flash Code Descriptions

DTC Flash
Description Item Check List
Code Code
991 9 9 "LSS Watchdog Reset" • LOAD CFG = LOAD PINS and LOAD != NO
LSS Module reports watchdog reset fault 0x40
992 9 9 "LSS EEPROM Error" • LOAD CFG = LOAD PINS and LOAD != NO
LSS Module reports EEPROM fault 0x40
993 9 9 "LSS Internal Error - Pin Excitation" • LOAD CFG = LOAD PINS and LOAD != NO
LSS Module reports excitation fault 0x01
994 9 9 "LSS Internal Error - DRDY Missing From A/D" • LOAD CFG = LOAD PINS and LOAD != NO
LSS Module reports DRDY fault 0x10
998 9 9 “EEPROM Failure - Check All Settings” • EEPROM checksum did not match saved checksum for a memory bank.
Bank (personalities, machine configuration, calibrations, or fault log)
reset to defaults.
• Replace controller.
9910 9 9 “Functions Locked Out - Platform Module Software • DTC 662 does not exist
Version Improper” AND
The LRT Ground Module software major version number does not
match the major version number of the platform module software
9979 9 9 “Functions Locked Out - Ground Module Software Version Improper” • Digital Input J4-10 = FALSE (indicating S299 control module has been
placed on a pre S299 machine)
99333 9 9 “Functions Locked Out - Him Module Software Version Improper” • DTC 6671 does not exist
AND
The LRT Ground Module software major version number does not
match the major version number of the HIM module software
99187 9 9 “LSS Internal Error - Driver Failure” • LOAD CFG = LOAD PINS and LOAD != NO
LSS Module reports driver fault 0x04

3121781 5-17
 SECTION 5 - JLG CONTROL SYSTEM

5.3 CHASSIS TILT SENSOR INSTALLATION

7
1
6
2
5

4
3

MAF04530
1 MAF04250

1. Ground Control Box 2. Chassis Tilt Sensor 1. Chassis Tilt Sensor 5. Stand-off Insulators
Assembly 2. Sensor Mount 6. Washers
3. Screws 7. Screws
Figure 5-6. Chassis Tilt Sensor Location 4. Washers 8. Harness Connector
Figure 5-7. Chassis Tilt Sensor Removal
NOTE: Refer to Figure 5-7., Chassis Tilt Sensor Removal for
numbers in parenthesis.
Table 5-2. Chassis Tilt Sensor Harness (SN3)
1. Disconnect the batteries.
2. Open the ground control box to gain access to the Wire Color Function Connector Pin
chassis tilt sensor assembly. White VCC 1
3. Disconnect the chassis tilt sensor wiring connector Yellow Ground 2
(SN3) from the (X03) harness connector on the side
of the box. Green CANH 3
4. Remove the four screws (3), lock washers (4), standoff Brown CANL 4
insulators (5) to remove the chassis tilt sensor (1) and
sensor mount (2) from the ground control box.
5. The chassis tilt sensor (1) can be removed from the
sensor mount (2) by removing the two screws (7) and
4 3 2 1 1 2 3 4
washers (6).
NOTE: Follow the above procedures in reverse order when
installing the chassis tilt sensor assembly. After FRONT BACK
MAF04260
installing, be sure to calibrate the chassis tilt sensor
(refer to Section 5.4, Location Of Additional Sensors).
Chassis Tilt Sensor - If this sensor is not wired correctly
or if you have the wrong part number you will get CAN-
BUS FAILURE - CHASSIS TILT SENSOR

5-18 3121781
 SECTION 5 - JLG CONTROL SYSTEM

5.4 LOCATION OF ADDITIONAL SENSORS

1 2 3 MAF04000

1. Oscillating Axle Tilt Sensor 3. Rotary Angle (Elevation) Sensor

2. Arm Stack Tilt Sensor

Figure 5-8. Chassis Sensor Locations

3121781 5-19
 SECTION 5 - JLG CONTROL SYSTEM

5.5 CALIBRATION PROCEDURES Some possible reasons that the tilt sensor will not cali-
brate are:
Chassis Tilt Sensor Calibration a. The surface the machine is sitting on is off level
by a few degrees (flat doesn’t imply level; park-
(Item 1, Figure 5-7.) ing lots are often not level).
1. Drive the machine onto a measured level surface b. The tilt sensor has failed one or both of the
(±0.5° for both x and y axis). channels (X axis and Y axis).
2. Using the Analyzer, go to MENU: CALIBRATION; TILT c. Tilt sensor has moisture intrusion that has
SENSOR. Press Enter. LEVEL VEHICLE will display. shifted its output.
Press Enter again to calibrate. d. Water and/or corrosion in the box has cor-
3. Both axis’ raw angles need to be within ±5.0°, other- rupted electrical connections or caused a tilt
wise the machine is not level and the software will sensor or ground control board failure
prohibit calibration. Should this occur, check for the (observe any cracks in the box).
following: e. The Ground Control Box, as mounted on the
a. Machine mounting and/or grade: machine, does not allow the tilt sensor to be
With a digital level, measure the top of the level.
Ground Control box for levelness. If unable to For the following troubleshooting steps, a bubble level
get a good reading, check the box’s mounting (smaller is better) will be needed and the machine must
surface for levelness. be on a level surface:
1. On the Analyzer, go to Diagnostics/System and read
the tilt angle. If either angle reports +20.0°, there is
2 an electrical/electronic failure (tilt sensor, control
board, electrical connections).
a. Open the Ground Control Box.
b. Disconnect the sensor and clean any corrosion
off of the tilt sensor and control board connec-
tions.
c. Reassemble and test. If fault persists, replace
tilt sensor.
2. If the Analyzer displays angles other than +20.0°,
attempt to calibrate. If machine will not calibrate,
note the reason displayed on Analyzer:
a. SENSOR FAILURE – tilt sensor internal fre-
quency is out of range (replace sensor).
b. NOT LEVEL - tilt sensor has either developed an
offset or it is too unlevel as mounted on the
machine.
1. Ground Control Box 2. Digital or Bubble
Level

b. Tilt sensor mounting on machine or wedged

crooked in control box:
If the machine mounting/grade appears
acceptable, open the Ground Control box care-
fully. Observe whether the tilt sensor is prop-
erly seated.
c. Tilt sensor has developed an offset shift:
Remove the tilt sensor from the Ground Con-
trol box, but keep both the tilt sensor and
Ground Control box electrically connected.
Level one axis of the tilt sensor and observe
the raw reading (should be within ±2.0°). Do
the same for the other axis. If either axis is
greater than ±2.0°, replace the tilt sensor.

5-20 3121781
 SECTION 5 - JLG CONTROL SYSTEM

Oscillating Axle Tilt Sensor 5.6 SERVICE MODE PROCEDURES

(Item 4, Figure 5-8.)
ECM Override (Dual Fuel Only)
1. Place machine on level surface This service menu may be utilized when ECM CAN
2. Start with machine in the stow position communication is lost on a machine equipped with
3. Go to CALIBRATIONS > AXLE TILT Dual Fuel, but Elevated Drive, Auto-Level, or Generator
function is needed. This service mode will bypass the
4. Select Enter ECM CAN loss DTCs and allow the machine to function
5. Analyzer says "Level Vehicle" as normal.
6. Select Enter
7. Analyzer will display the Axle Tilt Calibration Values 1. Using the Analyzer, navigate to SERVICE MODE >
ECM OVERRIDE.
8. Hit Escape to leave menu.
2. Input the pass code 22954 and select Enter.
Set Stow Elevation 3. The Analyzer will display ALLOW FUNCTIONS?
4. Select Enter.
1. Place machine on level surface
5. Analyzer will display FUNCTS ALLOWED.
2. Start with machine in the stow position
6. Select Escape to leave menu.
3. Go to CALIBRATIONS > SET STOW ELEV
4. Select Enter Elevation Service
5. Analyzer says "Calibrate Stow Elev Sensor?"
This procedure allows a service technician to elevate the
6. Select Enter platform when an active DTC is preventing elevation by
7. Analyzer will display "Complete" bypassing the DTC and allowing the platform to lift up.
8. Hit Escape to leave menu. This mode remains active until a power cycle occurs.
Once power is cycled, the DTC will become active again,
and Elevation Service mode must be reactivated to lift.

1. Using the Analyzer, navigate to SERVICE MODE >

ELEV SERVICE.
2. Input the pass code 87189 and select Enter.
3. Select Enter to activate the Elevation Service Mode.
4. 4.Analyzer will display COMPLETE!
5. Elevation Service is now active. Select Escape to
leave menu.

3121781 5-21
 SECTION 5 - JLG CONTROL SYSTEM

EEPROM Reset Allow Leveling Jack Retract

This procedure clears all the machine's calibrations and This mode allows a service technician to retract the lev-
returns the machine personalities and set-up to default eling jacks when an active DTC prevents normal leveling
settings. After Reset EEPROM, all calibration procedures jack functionality. Before initiating this service mode,
will need to be completed. Use this service mode when: the service technician must verify the platform is
a machine is having multiple issues and clearing the stowed before the leveling jacks can be retracted.
EEPROM may help to fix the problem; a service techni-
cian wants to clear all machine calibrations and return 1. Using the Analyzer, navigate to SERVICE MODE >
the machine to default settings; or a module is moved ALLOW LJ RETRCT.
from one machine to another and must be cleared and 2. Input the pass code 54749 and select Enter.
returned to default.
3. The Analyzer will display ALLOW LJ RETRCT? Select
1. Using the Analyzer, navigate to SERVICE MODE > Enter.
EEPROM RESET. 4. The Analyzer will display PLATFORM STOWED? Select
2. Input the pass code 35470 and select Enter. Enter.
3. Select Enter to activate EEPROM Reset. 5. The analyzer will display RETRCT ALLOWED. Select
Escape to leave menu.
4. Analyzer will display COMPLETE.
5. All settings will be reset. Select Escape to leave
menu.

Allow Drive
This mode allows a service technician to drive the
machine when an active DTC prevents normal drive
functionality. Before initiating this service mode, the ser-
vice technician must verify the platform is stowed and
the leveling jacks are retracted before drive function will
be enabled. Drive speed will only be allowed at elevated
speed.

1. Using the Analyzer, navigate to SERVICE MODE >

ALLOW DRIVE.
2. Input the pass code 82221 and select Enter.
3. The Analyzer will display ALLOW DRIVE? Select Enter
for YES.
4. The Analyzer will display PLATFORM STOWED? Select
Enter.
5. The Analyzer will display L/J RETRACTED? Select
Enter.
6. The analyzer will display RETRCT ALLOWED. Select
Escape to leave menu.

5-22 3121781
 SECTION 5 - JLG CONTROL SYSTEM

5.7 MACHINE CONFIGURATION AND PROGRAMMING SETTINGS

The Machine Configuration Programming must be completed before any Personality settings (Table 5-5) can be
changed. Changing the Personality settings first and then changing the Model of the Machine Configuration will cause
the Personality settings to return to default values.

Table 5-3. Machine Configuration Programming Information

Configuration Digit Setting Description Default Number
MODEL NUMBER: 0 330 LRT
1 1 430 LRT
2 530 LRT 2
MARKET: 0 ANSI USA 0
2 1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 KOREA
ENGINE: 0 KUBOTA T4F 0
3 1 KUBOTA T4I
2 KUBOTA D/F
GLOW PLUGS: 0 NO GLOW PLUGS
4 1 5 SEC GLOW
2 10 SEC GLOW
3 20 SEC GLOW 3
LEVELING JACKS: 0 No - Leveling Jacks not installed on vehicle.
5 1 YES - Leveling Jacks are installed on vehicle. 1
GENERATOR: 0 NO - Generator is not installed on vehicle. 0
6 1 YES - Generator is installed on vehicle.
LOAD SYSTEM: 0 NOT INSTALLED – No overload detection.
7* 1 CUTOUT PLT – Platform controls are disabled when overloaded. 1
2 CUTOUT ALL – Platform and Ground controls are disabled when overloaded.
NOTE: * Different Defaults by market: CE = 2
GROUND ALARM: 0 NOT INSTALLED – Vehicle alarm will function for Overload (if LOAD enabled).
8* 1 DESCENT – Vehicle alarm will function for Overload (if LOAD enabled) and during Lift Down
motion.
2 MOTION – Vehicle alarm will function for Overload (if LOAD enabled), during Drive 2
motion, and during Lift motion.
NOTE: * Different Defaults by market: CE = 0
ENGINE SHUTDOWN: 0 NO - The engine will not be automatically shutdown.
9 1 SHUTDOWN - The engine will automatically shutdown in the event of high engine 1
coolant temperature, low oil pressure, or a temperature sensor or oil pressure sen-
sor fault.
LOW TEMP CUTOUT: 0 NO - The machine will not have low temperature cutout functionality. 0
10 1 YES - The machine is equipped with low temperature cutout capability for the CE and ANSI
EXPORT markets.
BEACON LIGHT: 0 NO - The beacon light will never flash except for when being used by Electronic Arm 0
11* Guards (CE market). See footnote.
1 YES - The beacon light will flash at 1 Hertz all the time the machine is powered and not being
used by Electronic Arm Guards (CE market). See footnote.
NOTE: * The beacon light will ALWAYS be used for unique visual indi-
cation (flash at 1 Hertz for 2 seconds, then off for 1 second) for
the Electronic Arm Guards feature (only equipped on CE mar-
ket) regardless of the BEACON LIGHT setting.

3121781 5-23
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-3. Machine Configuration Programming Information

Configuration Digit Setting Description Default Number
AXLE CONFIG: 0 FIXED - The machine is not equipped with an oscillating axle. 0
12 1 OSCILLATING - The machine is equipped with an oscillating axle.
1001241348_C

NOTE: Bold Numbers indicate the default setting for that market. Plain text indicates another available selection. SHADED
CELLS indicates hidden menu or selection in that market.
CONFIG. DIGIT 1 2 3 4 5 6 7 8 9 10 11 12

ENGINE SHUTDOWN

LOW TEMP CUTOUT

MODEL NUMBER

GROUND ALARM
LEVELING JACKS

BEACON LIGHT
LOAD SYSTEM

AXLE CONFIG.
GLOW PLUG

GENERATOR
MARKET

ENGINE

530LRT

ANSI USA 2 0 0 1 2 0 1 2 3 0 1 0 1 2 0 1 X 0 1 2 0 1 0 X 0 1 0 1
ANSI EXPORT 2 1 0 1 2 0 1 2 3 0 1 0 1 2 0 1 X 0 1 2 0 1 0 1 0 1 0 1
CSA 2 2 0 1 2 0 1 2 3 0 1 0 1 2 0 1 X 0 1 2 0 1 0 X 0 1 0 1
CE 2 3 0 1 2 0 1 2 3 0 1 0 1 2 0 X 2 0 1 2 0 1 0 1 0 1 0 1
AUSTRALIA 2 4 0 1 2 0 1 2 3 0 1 0 1 2 0 1 X X X 2 0 1 0 X 0 1 0 1
KOREA 0 5 0 1 2 0 1 2 3 0 1 0 1 2 0 1 X 0 1 2 0 1 0 1 0 1 0 1
1001241348_C

Table 5-4. Machine Tilt Configuration

Lift Up and Drive prevented when Lift Up and Drive prevented when Drive prevented when Lift Up prevented when Elevated
Elevated and Tilted Front to Back Elevated and Tilted Side to Side Elevated beyond the fol- beyond the following heights with-
Model Market
beyond the following limits: beyond the following limits: lowing heights (regard- out outriggers deployed (regardless
less of tilt): of tilt):
±5° to 32 Feet ±3º to 32 Feet
ANSI USA ±1.3° to 45 Feet, Jacks Not Set ±1.3° to 45 Feet, Jacks Not Set 32 Feet 45 Feet
±1.5° to 53 Feet, Jacks Set ±1.5° to 53 Feet, Jacks Set
±5° to 32 Feet ±3º to 32 Feet
ANSI EXPORT ±1.3° to 45 Feet, Jacks Not Set ±1.3° to 45 Feet, Jacks Not Set 32 Feet 45 Feet
±1.5° to 53 Feet, Jacks Set ±1.5° to 53 Feet, Jacks Set
± 3° to 32 Feet ± 3° to 32 Feet
CSA 32 Feet 32 Feet
±1.5° to 53 Feet ± 1.5° to 53 Feet
530LRT ± 5° to 32 Feet ± 3° to 32 Feet
CE ± 1.3° to 45 Feet, Jacks Not Set ± 1.3° to 45 Feet, Jacks Not Set 32 Feet 45 Feet
± 1.5° to 53 Feet, Jacks Set ± 1.5° to 53 Feet, Jacks Set
± 5° to 32 Feet ± 3° to 32 Feet
AUSTRALIA ± 1.3° to 45 Feet, Jacks Not Set ± 1.3° to 45 Feet, Jacks Not Set 32 Feet 45 Feet
± 1.5° to 53 Feet, Jacks Set ± 1.5° to 53 Feet, Jacks Set
± 5° to 32 Feet ± 3° to 32 Feet
KOREA ± 1.3° to 45 Feet, Jacks Not Set ± 1.3° to 45 Feet, Jacks Not Set 32 Feet 45 Feet
± 1.5° to 53 Feet, Jacks Set ± 1.5° to 53 Feet, Jacks Set
1001241348_C

5-24 3121781
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-5. Machine Model Personality Adjustment

Model Default Values

Adjustment Adjustment Range
530LRT
DRIVE
Accel 0.1 - 5.0 (sec) 2.0
Decel 0.1 - 3.0 (sec) 2.0
Min Forward 500 - 800 mA 660
Hi Drv Fwd 1000 - 1800 mA 1400
Mid Drv Fwd 1100 - 1500 mA 1300
Low Drv Fwd 900 - 1100 mA 950
Min Reverse 500 - 800 mA 660
Hi Drv Rev 1000 - 1800 mA 1400
Mid Drv Rev 1100 - 1500 mA 1300
Low Drv Rev 900 - 1100 mA 950
Elev Fwd Max 700 - 1000 mA 860
Elev Rev Max 700 - 1000 mA 860
LIFT
Up Accel 0.1 - 5.0 (sec) 1.5
Up Decel 0.1 - 1.5 (sec) 0.5
Min Up 0 - 35% 17
Max Up 0 - 75% 55
Upr Dn Accel 0.1 - 5.0 (sec) 0.5
Upr Dn Decl 0.1 - 1.5 (sec) 0.1
Upr Dn Min 200 - 700 mA 450
Upr Dn Max 500 - 1600 mA 1550
Lwr Dn Accel 0.1 - 5.0 (sec) 1.5
Lwr Dn Decl 0.1 - 1.5 (sec) 1
Lwr Dn Min 200 - 700 mA 450
Lwr Dn Max 500 - 1600 mA 1550
LOAD
Overload 450 - 1225 kg 710
Accy 0 - 680 kg 0.0
Overload Dbnce 0 - 10.0 (sec) 3.0
Overload Hold 0.5 - 10.0 (sec) 5.0
JOYSTICK
Fwd Max 0.00 - 5.00V 1.1
Fwd Min 0.00 - 5.00V 2.25
Rev Min 0.00 - 5.00V 2.75
Rev Max 0.00 - 5.00V 3.9

3121781 5-25
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-5. Machine Model Personality Adjustment

Model Default Values

Adjustment Adjustment Range
530LRT
TEMP CUTOUT
Cutout Set -30 - 0 (C) -27
1001241349_A
NOTE: These settings may be changed in order to achieve optimal performance.

5-26 3121781
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

SECTION 6. LSS SETUP/CALIBRATION/SERVICE

6.1 CONNECTING THE JLG CONTROL SYSTEM 6.2 HELP MENU & FAULT CODES
ANALYZER The Help Menu is a troubleshooting tool to communi-
cate detected System Faults to the technician. The fol-
1. Connect the cable supplied with the Analyzer to the
host control system located at the ground controlsta- lowing table documents the Faults for the Load Sensing
tion. There is also an alternate connection on the System. To access the Help Menu, use the LEFT and
under side of the platform control station. Connect RIGHT arrow keys to select HELP: PRESS ENTER from the
the remaining end of the cable to the analyzer. Top Level Menu. Press the ENTER key to view the menu.
NOTE: The cable has a four-pin connector at each end of When accessing the Help Menu, the JLG Analyzer will
the cable; The cable cannot be connected back-
display EVERYTHING OK if the platform is not over-
wards. loaded and no difficulties are detected. Otherwise, the
2. Power-up the Control System by turning the key to JLG Analyzer will display OVERLOADED.
the Platform or Ground position and pulling both
emergency stop buttons. In the event of difficulty, the user can press ENTER again
to display Logged Help, which is a record of the last 16
Fault Messages. The following table lists each Help/
Logged Message, the Flash Code (for each Fault, the
module will flash the two-digit code on its LED) trig-
gered by the Fault, and a Description of the Situation
(cause).

Table 6-1. LSS Fault Codes

HELP/LOGGED FLASH
DESCRIPTION OF SITUATION
MESSAGE CODE
PLATFORM OVERLOADED 2-5 The platform load measured at the Load Sensing System is excessive. Functions from the platform control are prevented, and func-
tions from the ground control may be prevented, depending on machine.
BATTERY TOO HIGH 4-4 Incoming Supply Voltage >34.0 Vdc. The control system’s battery voltage is too high. This may be due to over-charging or improper
charger operation.
BATT TOO LOW 4-4 Incoming Supply Voltage <9.0 Vdc. The control system’s battery voltage is too low due to excessive electrical load or discharge. This
may compromise ability to predict weight. Recharge batteries or check for damaged batteries.
CANBUS FAILURE: LSS 6-6 The control system failed to receive messages from the LSS Module. Check wiring at the LSS Module and along scissor arms leading
MODULE up to platform.
CELL #1 ERROR 8-1 Cell #1’s Bridge <2V, >3V, or could not read Cell #1’s Internal Memory. This situation indicates damage to the sensor or its wiring.
CELL #2 ERROR 8-2 Cell #2’s Bridge <2V, >3V, or could not read Cell #2’s Internal Memory. This situation indicates damage to the sensor or its wiring.
CELL #3 ERROR 8-3 Cell #3’s Bridge <2V, >3V, or could not read Cell #3’s Internal Memory. This situation indicates damage to the sensor or its wiring.
CELL #4 ERROR 8-4 Cell #4’s Bridge <2V, >3V, or could not read Cell #4’s Internal Memory. This situation indicates damage to the sensor or its wiring.
WATCHDOG RST 9-1 Microprocessor’s Watchdog Timer Triggered. This is an indication that the LSS Module has been exposed to excessive electrical
noise, or has experienced a hardware difficulty.
EEPROM ERROR 9-2 Memory used to retain Personality/Machine Setup/Calibration has been corrupted and must be reset by verifying all entries and
re-calibrating. After resolution, re-cycle power to clear difficulty.
LSS NOT CALIBRATED 9-3 Calibration has not been successfully completed. A new LSS Module will display this message until properly calibrated.
LSS INTERNAL ERROR - PIN 9-9 Pin excitation <4.25 V. The sensors may be excessively loading the excitation supply, or the LSS Module may have hardware diffi-
EXCITATION culty.
LSS INTERNAL ERROR - 9-9 DRDY Interrupt from LSS Module’s A/D converter missing. This may indicate an LSS Module hardware difficulty.
DRDY MISSING FROM A/D

3121781 6-1
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

6.3 DIAGNOSTIC MENU NOTE: The Diagnostic, Load menu is not available when the
LSS is not enabled. (Machine Setup, Load is set to
NOTE: If necessary refer to Section 5 - Analyzer Menu Flow 0=Not Installed
Charts. Press the LEFT and RIGHT Arrow keys to view the load
The Diagnostic Load Menu is another troubleshooting sub-menus and press the enter key. Once in the load
tool for the Load Sensing System. Sensor and status sub-menu, press the LEFT and RIGHT arrow keys to view
information is presented in real-time for the technician. the various displays.
To access the Diagnostic Menu, use the LEFT and RIGHT The table below details the structure of the Diagnostic,
Arrow keys to select DIAGNOSTICS from the Top Level Load Menu, and describes the meaning of each piece of
Menu. Press the ENTER key to select the menu. information presented.

Table 6-2. Diagnostic Menu Descriptions

PARAMETER VALUE
DIAGNOSTICS MENU PARAMETER (DISPLAYED
(DISPLAYED ON DESCRIPTION
(DISPLAYED ON ANALYZER 1ST LINE) ON ANALYZER 2ND LINE)
ANALYZER 2ND LINE)
LOAD:
PLTLOAD +XXXX Kg Displays (Total Measured Force – Empty Platform
Calibration), in kilograms
PLTGROS +XXXX Kg Displays Total Measured Force (Sum of Pins 1 thru 4
LOAD) in kilograms
OVERLOADED? Yes / No Displays Current LSS Module Overload Status
CELL 1 +XXXX Kg Displays Calibrated Cell Reading in kilograms
CELL 2 +XXXX Kg Displays Calibrated Cell Reading in kilograms
CELL 3 +XXXX Kg Displays Calibrated Cell Reading in kilograms
CELL 4 +XXXX Kg Displays Calibrated Cell Reading in kilograms
ANALYZER VX.XXXX Displays Analyzer Software Version

6.4 PERSONALITIES
The following parameter in the PERSONALITIES, LOAD menu adjust performance of the LSS. All adjustments must be
made in Access Level 1 (33271).

Table 6-3. Personalities

SUBMENU (DISPLAYED ON PARAMETER (DISPLAYED ON

DESCRIPTION
ANALYZER1ST LINE) ANALYZER 2ND LINE)

LOAD: Displays/adjusts a derating for

ACC’Y XXXX KG
accessories.

Displays/ adjusts the debounce

OVR DBNCE 3 S
delay before an overload.

Displays/adjusts the minimum

OVR HOLD 5 S delay before an overload can be
released.

6-2 3121781
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

6.5 MACHINE SETUP MENU 6.6 CALIBRATION MENU

The LOAD submenu within the machine setup menu is The Load submenu within the Calibration Menu is used
used to configure the LSS. To access the Machine Setup, to zero the Empty Platform weight.
Load menu, use the Left and Right arrow keys to select
To access the Calibration Load Menu, use the LEFT and
MACHINE SETUP from the Top Level Menu. Press the
RIGHT Arrow keys to select CALIBRATION from the Top
ENTER key to select the menu. Press the Left and Right
Level Menu. Press the ENTER key to select the menu.
arrow keys to select LOAD from the MACHINE SETUP
Press the LEFT and RIGHT arrow keys to select LOAD
menu. Press the Enter key to view the submenu.
from the CALIBRATION menu. Press the ENTER key to
view the submenu.
The following table details the structure of the load sub-
menu and describes the meaning of the parameter. NOTE: The Calibration Menu is not available in Access Level
2.
Table 6-4. Machine Setup
Upon entry to the Calibration, Load Menu, the analyzer
will display the following:
SUBMENU PARAMETER
(DISPLAYED ON (DISPLAYED ON DESCRIPTION
ANALYZER 1ST LINE) ANALYZER 2ND LINE)

LOAD: 0 = NOT INSTALLED

Displays/adjusts
1 = CUTOUT PLT the LSS Module
2 =CUTOUT ALL

CALIBRATE:
YES:ENTER, NO:ESC

Pressing the ESC key will return the user to the top level
menu and not disturb the prior calibration information.

3121781 6-3
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

Pressing the ENTER key will confirm that the platform is If the empty platform weight is less than minimum cali-
empty (except for factory-installed options outside the bration value, the calibration attempt will be unsuccess-
Rated Load). The LSS Module will calculate the total of ful and the Analyzer will show the following:
all load cell readings and ensure that the total is greater
than minimum calibration value, but less than maxi-
mum calibration value. If successful, the Analyzer will
show the following:

CALIBRATE:
< MIN CAL
If the empty platform weight is greater than maximum
calibration value, the calibration attempt will be unsuc-
CALIBRATE: cessful and the Analyzer will show the following:
COMPLETE
Calibration values are as follows:
• Minimum Calibration: 485 lb. (220 kg)
• Maximum Calibration: 2205 lb. (1000 kg)

CALIBRATE:
> MAX CAL

6-4 3121781
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

6.7 SERVICE
Description
The system consists of the LSS Module, four Shear Pin Load Cells (sensors), Wire Harness, and various brackets and fas-
teners. The LSS Module is mounted beneath the platform on a bracket. The Shear Pin Load Cells mount between the
platform and the arm structure in such a way that all support force for the platform is applied through them (for mea-
surement). The four Shear Pin Load Cells plug directly into the LSS Module. The Wire Harness connects the LSS Module
to the Host Control System.
5

1 6

2 MAF04280

1. Slide Block/Load Cell (Left Front) 4. Slide Block/Load Cell (Right Rear)
2. Slide Block/Load Cell (Right Front) 5. Platform Interface Module
3. Slide Block/Load Cell (Left Rear) 6. LSS System Module
Figure 6-1. Load Sensing System Components

3121781 6-5
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

6.8 CALIBRATION Testing & Evaluation

Procedure Refer to the Troubleshooting section of this manual if
1. Plug the JLG Analyzer into the LSS Module on the the Load Sensing System fails to meet these guidelines.
Host Control System and enter the Access Level 1 1. Plug the JLG Analyzer into the Host Control System.
Password. Do not confuse the Host Control System
2. Park the vehicle on a level surface. The platform
and LSS Module’s Analyzer Connections. Proceed to
should be fully stowed and level within ± 5° (both
the ACCESS LEVEL menu and enter the Access Level 1
directions).
Password (33271).
3. Observe the Empty Platform Weight. Proceed to the
2. Park the vehicle on a level surface. The platform
DIAGNOSTICS, PLTLOAD sub-menu and observe the
should be fully stowed and level within ± 5° (both
measured platform load. All tools, debris, and cus-
directions).
tomer-installed devices shall be removed during
3. Configure the LSS Module for the proper model and evaluation. Ideally, the PLTLOAD should be zero but
Desired Units. Proceed to the LSS Module’s MACHINE can vary +15lbs (± 7kg). Further, the reading should
SETUP, MODEL sub-menu and select the applicable be stable and should not vary by more than +2lbs
model. Press the RIGHT ARROW to view the Units (±1kg) (unless there is heavy influence from wind or
Selection. Select “UNITS=LBS” for platform load mea- vibration).
surement in Pounds, and “UNITS=KG” for measure-
ment in Kilograms. 4. Use the Technician’s Weight to Evaluate. The techni-
cian should enter the platform and record the PLT-
LOAD reading while standing in the center of the
platform, and then each corner. The average of the
EARLY RT’S REQUIRE A CONFIGURATION TO THE LSS MODULE. PLUG readings should be the estimated weight of the tech-
THE JLG ANALYZER INTO THE MODULE’S CONNECTION BENEATH THE nician. The range of the readings should be no more
DECKAND ENTER THE ACCESS LEVEL 1 PASSWORD (33271). UNDER than 40lbs (18kg) (max PLTLOAD reading – min PLT-
MACHINE SETUP ENSURE THAT MODEL=260MRT. LOAD reading).
4. Remove everything except JLG Accessories from the 5. Confirm Host Control System Warnings and Inter-
Platform. Empty the platform to allow the Load Sens- locks. Using the vehicle’s key switch, select Platform
ing System to record its weight during calibration. All Mode and power-up. Start the vehicle’s engine (If
tools, debris, and customer-installed devices shall be equipped) and ensure that all controls are functional
removed. Permanently-fixed JLG Accessories shall and the Load Sensing System’s Overload Visual and
remain and their contribution toward Rated Load will Audible Warnings are not active. Simulate an Over-
be accounted for in the next step. load by unplugging the Shear Pin Load Cell con-
5. Configure the LSS Module for JLG Accessories. The nected to J5 on the LSS Module.The Overload Visual
contribution of each permanently-fixed JLG Acces- Warning should flash, and the Audible Warning (at
sory toward Rated Load must be determined. JLG Platform and Ground) should sound for 5 seconds
Accessories are decaled with their effective contribu- On, and 2 seconds Off. With the engine running (If
tion toward Rated Load. If this decal is missing, refer- equipped), all platform control should be prevented.
ence the appropriate manual for the JLG Accessory. Cycle the Platform EMS to stop the engine and then
Once determined, the contributions of all perma- power-up again. The Overload Visual and Audible
nently-fixed JLG Accessories mounted in the plat- Warning should continue. Install the disconnected
form of the vehicle shall be added together and Shear Pin Load Cell back in J5 on the LSS Module. The
entered in the Analyzer’s PERSONALITIES, ACC’Y dis- Overload Visual and Audible Warnings should cease
play (using the proper units). and normal control function should return. Switch
6. Execute a Calibration via the JLG Analyzer. Proceed to the vehicle’s key switch to Ground Mode and repeat
the Analyzer’s CALIBRATION top level menu and the above procedure. The Overload Visual Warning at
press ENTER. Press ESC to abort a calibration or the Ground Controls should flash, and the Audible
ENTER to calibrate (tare). If successful, the Analyzer Warning (at Platform and Ground) should sound for 5
will display “COMPLETE”. If unsuccessful, a message seconds On, 2 seconds Off. However, the controls
will be displayed that will help lead to a resolution should remain functional when using the engine (if
(reference the Troubleshooting section of this man- the Host Controls System’s MACHINE SETUP, LOAD is
ual). Press ESC to return to the top level menu. set to “2=CUTOUT PLT”. If set to “3=CUTOUT ALL”,
then Ground Controls will be prevented when using
the platform). Re-fit the Shear Pin Load Cell connec-
tor to J5 on the LSS Module and carefully tighten by
hand, and then with a small pair of locking pliers to
seat the O-ring seal.

6-6 3121781
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

6. Confirm Load Sensing System Performance with Cali-

brated Weights. Operate the vehicle from Ground
Control and place the platform in the fully stowed
position for safety. Place 120% of the machines rated
load in the center of the platform and ensure that the
overload visual and audible warnings are active.
Reduce the platform load to 100% rated load and
ensure that the warnings are not active. For vehicles
with multiple capacities, evaluate each operating
mode with the proper rated load.

3121781 6-7
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

6.9 TROUBLESHOOTING
The following tables are furnished to provide possible resolutions for common difficulties. Difficulties are classified as
General, Calibration, Measurement Performance, and Host System Functionality.
Also refer to Electrical Schematic in Section 7 for wiring circuit diagnostics.

Table 6-5. LSS Troubleshooting Chart - General

DIFFICULTY POSSIBLE RESOLUTION

JLG Analyzer does not display “HELP: The JLG Analyzer is failing to communicate with the LSS Module, but the LSS Module is powered (indicated by module’s
PRESS ENTER” when connected to LSS LED). Investigate JLG Analyzer serial communication and power supply connections.
Module’s connection, but the module’s 1. If the Analyzer displays “CONNECTING…” or “CONNECTION ERROR” after a short interval, examine the Analyzer
LED is lit or flashing. harness on J2. J2-2 should connect to Pin 3 on the Analyzer, and J2-11 should connect to Pin 2.
2. If the Analyzer does not display anything (and there is no backlighting), examine the Analyzer’s power supply.
Remove the harness connection from J2 and ensure that J2-1 has approximately 12V, and J2-12 is 0V. The harness
should connect J2-1 to Pin 1 on the Analyzer, and J2-12 to Pin 4 on the Analyzer.
3. The JLG Analyzer is suspect. Substitute to determine cause of failure.
4. The LSS Module is suspect. Substitute to determine cause of failure.
LED on LSS Module does not light. The LSS Module is un-powered, a short exists, or the device is damaged.
1. LSS Module’s power supply is improper. Check for the presence of approximately 12V on J1-1, and 0V on J1-2. The
module’s power supply comes from the Platform Console Box. Use to the Wiring Diagram to trace the conductors to
their source.
2. There is a short circuit on the reference voltage present on J5-J8. Unplug the connectors one at a time and observe
if the module begins to function after a particular connection is removed. If so, carefully inspect the wiring
between the module and that sensor.
3. There is a short circuit on the pre-regulated supply for the JLG Analyzer present on J2-1. Unplug J2’s connector and
observe whether the module begins to function. If so, examine the Analyzer harness for defect.
4. The LSS Module is suspect. Substitute to determine cause of failure.

Table 6-6. LSS Troubleshooting Chart - Calibration

Difficulty Possible Resolution

JLG Analyzer displays The LSS Module expected the empty platform to weight more for calibration.
“<MIN CAL” after attempt is made to Cali- 1. The platform is being supported by something other than the four Shear Pin Load Cells. This includes binding
brate. between the slide block/spacer bushing/arm tube assembly (bushing should be free enough to rotate by hand).
For proper operation, the platform’s entire weight must be transferred through the Shear Pin Load Cells and into
the arm support structure for an accurate calibration.
2. The wrong Model Selection was made under the LSS Module’s MACHINE SETUP, MODEL. This should be set to the
proper MODEL. Improper selection may lead the LSS Module to expect different empty platform weights.
3. The calibration difficulty may be a result of a Measurement Performance issue. Review the Possible Resolutions
under that category.
JLG Analyzer displays “>MAX CAL” after The LSS Module expects the empty platform to weigh less for calibration.
attempt is made to Calibrate. 1. Tools, debris, or customer-installed accessories have not been removed before calibration. The LSS Module must
tare an empty platform and its optional JLG Accessories.
2. The wrong Model Selection was made under the LSS Module’s MACHINE SETUP, MODEL. This should be set to
MODEL. Improper selection may lead the LSS Module to expect different empty platform weights.
3. The calibration difficulty may be a result of a Measurement Performance issue. Review the Possible Resolutions
under that category.

6-8 3121781
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

Table 6-7. LSS Troubleshooting Chart - Measurement Performance

DIFFICULTY POSSIBLE RESOLUTION

Empty Platform Weight (DIAGNOSTICS, The LSS Module is unable to properly measure the platform weight.
PLTLOAD) is not within +15lbs (±7kg) of 1. One of the Shear Pin Load Cells is not properly plugged into the LSS Module. Since the connectors seal with an O-ring
zero. and are located in a crowded area, it is possible that the connectors are threaded together, but poor electrical contact
or is made. Attempt to wiggle the molded portion of each connector on J5-J8. If properly tightened, the molded portion
should not move. Also, examined each Shear Pin Load Cell’s readings via the JLG Analyzer. Proceed to the DIAGNOS-
Platform Load readings (DIAGNOTICS, PLT- TICS, CELL 1-4, LOAD displays and determine if the readings are reasonable. Note that it is possible to have only two
LOAD) are unstable by more than +2lbs
sensors carrying all of the platform load due to fit between the platform and support structure (this is normal).
(±1kg) (without the influence of vibration
or wind). 2. Wiring leading to one of the Shear Pin Load Cells is damaged. Examine each sensor’s reading using the JLG Analyzer.
Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and determine if the readings are reasonable and responsive to
or slight downward pressure above the sensor being viewed. Carefully inspect sensor wiring where it passes through
There are large variations in Platform Load cable clamps for signs of damage. Inspect wiring where damage to the channel is apparent. If damage to the sensor’s
(DIAGNOSTICS, PLTLOAD) based on the cordset is found, replace the appropriate Shear Pin Load Cell since the cordset is not serviceable (connector is molded
location of the load. Tolerance to variations for moisture resistance; cordset is soldered into sensor beneath welded stainless steel cover). If damage to the sen-
is 40lbs (18kg) for an evaluation using the sors extension cordset is found, unplug both ends and fit a replacement.
technician’s weight, and +5% of Rated 3. One of the Shear Pin Load Cells was not assembled properly during installation. Examine each sensor’s reading using
Load when using calibrated weights. the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and determine if the readings are reasonable.
It is often helpful to apply slight downward pressure above the sensor being examined and observe that its output
increases (increasing force measurement; decreasing means the sensor is mounted upside-down). Compare the
order of assembly to the detail on the Installation Drawing and ensure that the only contact between the platform
and the support is through the sensor bodies (nothing else touches except wires). Re-assemble according to print if
necessary.
4. Damage to the platform or arm structure has occurred or one of the components is out-of-tolerance.Twists in the
platform, for instance, will cause huge off-axis forces to be applied to the Shear Pin Load Cells, disturbing their pri-
mary measurement axis readings. If Lift Up / Down is noisy or not smooth, examine this issue thoroughly. Resolution
is to replace the damaged or faulty component. Watch for Shear Pin Load Cell damage (yield) as a result of this diffi-
culty.
5. One of the Shear Pin Load Cells is contaminated by debris or moisture. Examine each sensor’s reading using the JLG
Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and determine if the readings are reasonable and sta-
ble (not changing by more than +2lbs (±1kg) (without the influence of vibration or wind). Lack of measurement
stability is a key indication of contamination. Unplug the appropriate connector (J5 is CELL 1, J6 is CELL 2, J7 is CELL 3,
and J8 is CELL 4) and inspect for dirt or moisture. Look carefully into the female connector on the sensor’s cordset for
evidence of contamination. Debris should be brushed away with a soft bristle brush (do not introduce any cleaners as
they will leave conductive residue). Moisture should be allowed to evaporate or accelerated with a heat-gun (use low
heat and be carefully to not melt connector materials). Moisture intrusion into the molded portion of the connector
(capillary action into the wire bundle) or the Shear Pin Load Cell itself will require replacement of the sensor.
6. One of the Shear Pin Load Cells has been mechanically damaged (yielded). Any Shear Pin Load Cell that is physically
deformed or has damage to one of the stainless steel covers should be replaced immediately. It is also possible to
have invisible mechanical damage resulting from an extreme overload (>4200lbs [>1900kg] for 1.25 in diam.;
>5700 lbs or 2600 KG for 2 inch diam.). This can be detected by supporting the platform with an overhead crane and
by removing the suspect sensor (no weight resting on the Shear Pin Load Cell). Examine the sensor’s reading using
the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and observe whether the unloaded sensors
read with +15lbs (±7kg) of zero (individually). Replace sensors that read excessive force when physically unloaded.
7. The LSS Module is suspect. Interchange the Shear Pin Load Cell connections (J5-J8) and observe the results via the
JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and observe the readings. If the problem seems to
remain with a particular sensor, carefully re-examine the issues above. If the problems seems to remain with a par-
ticular LSS Module channel, substitute another module.

3121781 6-9
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

Table 6-8. LSS Troubleshooting Chart - Host System Functionality

Difficulty Possible Resolution

The Visual and Audible Overload Warnings The Host Control System is failing to regard the overload signal from the LSS Module, or the signal is shorted.
fail to sound when platform is loaded 1. The Load Sensing System must be enabled within the Host Control System. Plug the JLG Analyzer into the Host Con-
beyond Rated Load, or when simulated by trol System, enter the Access Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu. The
unplugging a Shear Pin Load Cell from the selection “CUTOUT PLT” should be displayed for European Community compliance (platform controls prevented dur-
LSS Module. Controls remain functional at ing overload, ground controls remain operational). In country- or customer-specific circumstance, the selection
Platform and Ground Control positions. “3=CUTOUT ALL” is used (platform and ground controls prevented during overload).
2. The signal between the LSS Module and the Host Control System is shorted. The Platform Module’s J1-20 is an
input, and it connected to the J1-5 output on the LSS Module To examine the status of this signal, plug the JLG Ana-
lyzer into the Host Control System, enter the Access Level 1 password (33271), and examine the DIAGNOSTICS, SYS-
TEM, LOAD display. The display will indicate “OK” when the Platform Module’s input is energized (approximately
12V), and “OVERLOADED” when it is de-energized (0V). Refer to the Wiring Diagram for Load Sensing System for
details.
3. Observe the LSS Module’s assessment of overload using the JLG Analyzer plugged into the LSS Module’s connection.
Proceed to the DIAGNOSTICS, OVERLOADED? display. The display should indicate “OVERLOADED? N” when the plat-
form is empty, and “OVERLOADED? Y” when the platform is overloaded. If the assessment is improper, the difficulty
may be a result of a General or Measurement Performance issue. Review the Possible Resolutions under those cate-
gories.
4. If the LSS Module’s J1-5 Output does not appears to coincide with the DIAGNOSTICS, OVERLOADED? display, then the
LSS Module is suspect. Substitute to determine cause of failure.
The Visual and Audible Overload Warnings The LSS Module is un-powered, un-calibrated, or is experiencing a Measurement Performance difficulty. Alternately, the
sound even when the platform is empty. Host Control System is not receiving the proper signal from the LSS Module.
Controls are prevented in the same manner 1. Ensure that the LSS Module is powered. The LSS Module’s LED will be lit or flash if the module is powered. If not,
as when overloaded. ensure that approximately 12V is present between J1-1 and J1-2 on the LSS Module (J1-1 is positive). Trace the
Ignition and Ground supply wires into the Host Control System’s wiring harness using the wiring diagram to locate
the difficulty.
2. Plug a JLG Analyzer into the LSS Module’s connection and ensure that the Host Control System is powered-up. When
HELP:PRESS ENTER is displayed, press the ENTER key on the Analyzer. If “EVERYTHING OK” is displayed, it is probable
that the Overload Signal from the LSS Module is not reaching the Host Control System. This signal is present on LSS
Module’s J1-5 and is approximately 12V normally, and 0V during an overload. This signal eventually reaches the
Main Terminal Box to provide the overload signal. Refer to the Wiring Diagram for wire color, number, and terminal
information.
3. If the Analyzer displayed “OVERLOADED” in the previous step, press the ENTER key again. If “NO CAL” is displayed,
the Load Sensing System has not been properly calibrated. Refer to the Calibration portion of this manual.
4. If another fault is displayed, refer to the portion of this manual that describes Fault Messages and their causes.
5. The difficulty may be a result of a Measurement Performance issue. Review the Possible Resolutions under those
categories.
Controls remain functional at the Ground The Host Control System is configured to prevent platform controls only in the event of overload. Alternately, the Host Control
Control position during an overload, or System can be configured to prevent ground and platform controls for country- or customer-specific circumstances.
when simulated by unplugging a Shear Pin Plug the JLG Analyzer into the LSS Module’s connection and enter the Access Level 1 password (33271). Proceed to the
from the LSS Module. The Control at the MACHINE SETUP, LOAD sub-menu. Set this parameter to “CUTOUT PLT” to prevent platform controls in the event of overload.
Platform Control position are prevented. Set this parameter to “CUTOUT ALL” to prevent platform and ground controls in the event of overload.

6-10 3121781
 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE

Table 6-9. LSS Module System Interface Connector - Table 6-11. LSS Module Load Cell Connector Pinout (J5,
Power & Digital (J1 - Grey) J6, J7, J8)

PIN SIGNAL DESCRIPTION PIN SIGNAL DESCRIPTION

1 VBAT Positive Power Supply from Host Control System (12- 1 + Signal Positive Sensor Output (approx. 2.5V)
24V) 2 Cal Clock Serial Clock to Sensor’s Integrated Memory
2 GND Negative Power Supply from Host Control System (0V) 3 - Excitation Negative Sensor Supply Voltage (approx. 0V)
3 GND-2 Connects to GND 4 +Excitation Positive Sensor Supply Voltage (approx. 5V)
4 N/C Unused 5 - Signal Negative Sensor Output (approx. 2.5V)
5 DO1 Overload Indicator Output (Normal=VBAT / Over- 6 Cal Data Serial Data from Sensor’s Integral Memory
load=0V)
6 DO2 Warning Indicator Output (Normal=0V / Over-
loaded=VBAT for 5 Sec, 0V for 2 Sec)
7 DI3 Unused
8 DI2 Select OVERLD3 Personality Rating (No=0V /
Yes=VBAT)
9 DI1 Select OVERLD2 Personality Rating (No=0V /
Yes=VBAT)
10 GND-2 Connects to GND
11 VBAT-2 Connects to VBAT
12 VBAT-2 Connects to VBAT
NOTE: Physical connector as viewed looking into the
cable end
Table 6-10. LSS Module System Interface Connector – Figure 6-2. LSS Module Load Cell Connector
Communication (J1 - Black) Pinout (J5, J6, J7, J8)
PIN SIGNAL DESCRIPTION
1 APWR Pre-Regulated Supply for JLG Analyzer (Analyzer Pin
1; approx. 12V)
2 TX RS-232 for JLG Analyzer (Analyzer Pin 3)
3 TRP1 120 Ohm CANbus Terminator
4 CANH-1 CANbus Interface High
5 CANS-1 CANbus Shield Termination (Not same as GND)
6 CANH-2 Connects to CANH-1
7 CANL-2 Connects to CANL-1
8 CANS-2 Connects to CANS-1
9 CANL-1 CANbus Interface Low
10 TRP2 120 Ohm CANbus Terminator
11 RX RS-232 for JLG Analyzer (Analyzer Pin 2)
12 GND Ground for JLG Analyzer (Analyzer Pin 4)

3121781 6-11
3121781 6-12
Figure 6-3. LRT Wiring Diagram
GROUND CONTROL BOX
CONNECTED TO GROUND
POSITION AT ENOL_GND IN
L 06
LAMP
OVERLOAD
LRT

GROUND CONTROL BOX

CANH (J7-31)
MODULE
PLATFORM

CANL (J7-30)
IGN (J5-6)
ALT (J5-1)

TX (J6-3)
RX (J6-2)
GND (J5-5)

IGN (J6-1)
IGN (J3-1)

GND (J6-4)
GND (J3-4)

ENGTL (J5-4)
TILTY (J3-3)
TILTX (J3-2)

ENGOL (J5-3)
OVERLOAD (J5-2)

IGN (J2-33) J2-11

J6 J5 RECPTACLE J3 RECPTACLE
B+ (J4-1)
B+ (J2-1) GNDE (J4-2) GND (J2-25)
B+ (J2-2) GND (J4-6)
PLATFORM

GND (J2-39) HRMT (J4-15)

GND (J2-40) PLTS (J4-3)
ENGS (J2-27) GNDS (J4-4)
CONTROL BOX

IGN (J2-23) ENGS (J4-5)

E

GLWG (J4-13)
ALT (J2-21) UPG (J4-7)
J4 RECPTACLE

CHRP (J2-22) DNG (J4-8)

FDEG (J4-9)
ENGO (J2-24) FDRG (J4-10)
RDEG (J4-11)
SHIELD

ENGT (J2-25) RDRG (J4-12)

FPS (J2-29) AUXP (J4-14)
RED
BLACK

GACT (J2-26)
7
8
10
9

SPD (J2-19)
GND (J2-20) PLTS (J1-1) J4A
PLTE (J1-2)
RX485 (J2-31) QPRX (J1-3)
10

7
9

TX485 (J2-32) GND (J1-7)

J2 RECEPTACLE J4B
GND (J2-33) IGN (J1-8)
L 05
LAMP

CANH (J1-9)
GROUND ELECTRONICS
CANL (J1-13)
OVERLOAD

ISP1 (J2-18) GND (J1-14)

OPT VALVE (J2-16) GALR (J1-15)
GND (J1-16)
HRN (J1-4)
GND (J1-10)
AXPW (J2-35) GND (J1-24)
BLACK

J1 RECPTACLE
LPS/GLWS (J2-28) BSL2 (J1-22)
LP ASST (J2-30) BSL1 (J1-23)
FUEL (J2-34) APWR (J1-19)
CAN H (J2-36) ANGL (J1-20)
CAN L (J2-37) GND (J1-21)
GND (J2-38) IGN (J1-17)
BLACK

PROX (J1-18)
YEL/RED
CONTROL BOX

GENI (J2-17)
BUS BLOCK IN PLATFORM
CONNECTED TO GROUND

PLS (J1-6)

LTS (J2-5)
RTS (J2-6)
POSITION AT LAMP RETURN

BRS (J2-8)

RVS (J2-4)
DPS (J2-7)

FWS (J2-3)
LOSAX (J2-11)

ROSAX (J2-12)
LDHS (J1-5)

UPS (J2-10)
2SPD (J2-9)
GND (J1-12)
GND (J1-11)

GEN (J2-13)

GND (J2-14)
GND (J2-15)
PIN 5
PIN 9
PIN 4
PIN 9
PIN 8
PIN 7
J2

PIN 6
OVERLOAD

PIN 5
PIN 12
PIN 11
PIN 2
PIN 1
CONNECTORS THAT PLUG
INTO ADDED LSS MODULE

PIN 12
PIN 11
PIN 10

SHIELD
PIN 9

BLACK
WHITE
PIN 8

RED

GREEN
PIN 7

J1
PIN 6

OVERLOAD
PIN 5
PIN 4
PIN 3
PIN 2
PIN 1

PIN 4
PIN 3
PIN 2
PIN 1
CONNECTOR
ANALYZER

1001239852-A
MAF05430A
SECTION 6 - LSS SETUP/CALIBRATION/SERVICE
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

SECTION 7. GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL still attached to the contact and contacts are seated in
the connector.
This section contains schematics to be used for locating
and correcting most of the operating problems which Min/Max
may develop. If a problem should develop which is not
presented in this section or which is not corrected by Use of the “Min/Max” recording feature of some meters
listed corrective actions, technically qualified guidance can help when taking measurements of intermittent
should be obtained before proceeding with any mainte- conditions while alone. For example, you can read the
nance. voltage applied to a solenoid when it is only operational
while a switch, far from the solenoid and meter, is held
down.

IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- Polarity

TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- Finding a negative voltage or current reading when
TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A expecting a positive reading frequently means the leads
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO- are reversed. Check what reading is expected, the loca-
NENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING tion of the signal and that the leads are connected to
MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SAT- the device under test correctly. Also check that the lead
URATION. on the “COM” port goes to the ground or negative side
of the signal and the lead on the other port goes to the
positive side of the signal.
7.2 MULTIMETER BASICS
Scale
A wide variety of multimeters or Volt Ohm Meters
(VOM) can be used for troubleshooting your equip- M = Mega = 1,000,000 * (Displayed Number)
ment. A digital meter with reasonable accuracy (within
7%) is recommended for the measurements in these k = kilo = 1,000 * (Displayed Number)
procedures. This section shows diagrams of a common, m = milli = (Displayed Number) / 1,000
digital VOM configured for several different circuit mea-
surements. Instructions for your VOM may vary. Please μ = micro = (Displayed Number) / 1,000,000
consult the meter operator’s manual for more informa- Example: 1.2 kΩ = 1200 Ω
tion.
Example: 50 mA = 0.05 A
Grounding
“Grounding the meter” means to take the black lead
(which is connected to the COM (common) or negative
port) and touch it to a good path to the negative side of
the voltage source.

Backprobing
To “backprobe” means to take the measurement by
accessing a connector’s contact on the same side as the
wires, the back of the connector. Readings can be done
while maintaining circuit continuity this way. If the con-
nector is the sealed type, great care must be taken to
avoid damaging the seal around the wire. It is best to
use probes or probe tips specifically designed for this
technique, especially on sealed connectors. Whenever
possible insert probes into the side of the connector
such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a
closed connector by backprobing both sides of a con-
nector terminal and measuring resistance. Do this after
giving each wire a gentle pull to ensure the wires are

3121781 7-1
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Voltage Measurement Resistance Measurement

Figure 7-1. Voltage Measurement (DC) Figure 7-2. Resistance Measurement

• If meter is not auto ranging, set it to the correct • First test meter and leads by touching leads together.
range (See multimeter’s operation manual) Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads tance)
• Circuit power must be turned OFF before testing
resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct
range (See multimeter’s operation manual)
• Use firm contact with meter leads

7-2 3121781
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Continuity Measurement Current Measurement

Figure 7-3. Continuity Measurement Figure 7-4. Current Measurement (DC)

• Some meters require a separate button press to • Set up the meter for the expected current range
enable audible continuity testing • Be sure to connect the meter leads to the correct
• Circuit power must be turned OFF before testing jacks for the current range you have selected
continuity • If meter is not auto ranging, set it to the correct
• Disconnect component from circuit before testing range (See multi meter’s operation manual)
• Use firm contact with meter leads • Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity

3121781 7-3
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Continuity Measurement Over Long Distances 1. Disconnect all connections associated with the wire
under test and the two additional wires. If harness is
When trying to determine continuity of a harness or not completely isolated disconnect battery terminals
wire, longer than the reach of standard instrument also, as a precaution.
leads, is possible to perform the check without exces- 2. Measure continuity between all three wires, the wire
sively long leads. Using the other wires in the harness under test, wire #1 and wire #2. These should be
one can determine the condition of a particular wire in open. If not, repair the shorted wires or replace the
the harness. harness.
Requirements 3. On one side, jumper from contact of wire #1 and wire
#2.
• Harness with at least three separate wires including 4. Measure continuity between wire #1 and wire #2. If
the wire under test. there is continuity, both wires are good and can be
• These wires must be able to be isolated from other used for this test. If there is not continuity, either wire
wires, etc. could be bad. Check connections and measurement
• Jumper or method to connect contacts on one side setup. Redo measurement. If still no continuity, repair
of harness. wires or consult schematic for other wires to use for
test.
• Meter that can measure resistance or continuity.
5. Jumper from wire under test to wire #1.
Procedure 6. Measure continuity. If there is continuity, the wire
under test is good. Resistance of a wire increases as
Test multimeter leads resistance. Subtract this value the length increases and as the diameter decreases.
from the measured resistance of the wires to get a more
accurate measurement. One can find the continuity of two wires, here #1 and #2,
at once by following steps 1 through 4. If there is a prob-
Consult the circuit schematic to determine which wires lem the third wire is used to troubleshoot the other
to use in addition to wire under test, here called wire #1 wires. To find the problem, start at step 1 and use the
and wire #2, and how to isolate these wires. These wires entire procedure.
should appear in the same connectors as the wire under
test or are within reach of the jumper.

7-4 3121781
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.3 APPLYING SILICONE DIELECTRIC COMPOUND 3. Anderson connectors for the battery boxes and battery
chargers should have silicone grease applied to the con-
TO ELECTRICAL CONNECTIONS tacts only.
NOTE: This section is not applicable for battery terminals. NOTE: Curing-type sealants might also be used to prevent short-
ing and would be less messy, but would make future pin
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- removal more difficult.
RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.
When applied to electrical connections, dielectric grease helps
NOTE: Do NOT apply dielectric grease to the following connec- to prevent corrosion of electrical contacts and improper con-
tions: ductivity between contacts from moisture intrusion. Open and
sealed connectors benefit from the application of dielectric
• Main Boom Rotary sensor connections (on Celesco Sensor), grease.
• LSS Modules connections, Dielectric grease shall be applied to all electrical connectors at
• Deutz EMR 2 ECM connection. the time of connection (except those noted under Exclusions).

Silicone Dielectric Compound must be used on all electrical Installation of Dielectric Grease
connections except for those mentioned above for the follow-
ing reasons: Before following these instructions, refer to excluded connec-
tor types (See Exclusions below).
• To prevent oxidation at the mechanical joint between male
1. Use dielectric grease in a tube for larger connection
and female pins.
points or apply with a syringe for small connectors.
• To prevent electrical malfunction caused by low level con-
2. Apply dielectric grease to plug/male connector housing
ductivity between pins when wet.
which typically contains sockets contact/female termi-
Use the following procedure to apply Silicone Dielectric Com- nals (fill it approximately ½ full; see example below).
pound to the electrical connectors. This procedure applies to
all plug connections not enclosed in a box. Silicone grease 3. Leave a thin layer of dielectric grease on the face of the
should not be applied to connectors with external seals. connector.

1. To prevent oxidation, silicone grease must be packed 4. Assemble the connector system immediately to prevent
completely around male and female pins on the inside moisture ingress or dust contamination.
of the connector prior to assembly. This is most easily 5. Pierce one of the unused wire seals prior to assembly if
achieved by using a syringe. the connector system tends to trap air (i.e. AMP Seal)
and then install a seal plug.
NOTE: Over a period of time, oxidation increases electrical resis-
tance at the connection, eventually causing circuit failure.

2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connec-
tors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
should also be sealed.

NOTE: This condition is especially common when machines are

pressure washed since the washing solution is much more
conductive than water.

3121781 7-5
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Deutsch HD, DT, DTM, DRC Series

The Deutsch connector system is commonly used for harsh
environment interconnect. Follow the installation instructions.

Figure 7-6. Use of Seal Plugs

AMP Seal AMP Mate-N-Lok

The AMP Seal connector system is used on the Control ADE This connector system is widely used inside enclosures for
Platform and Ground Modules. general-purpose interconnect. Follow the general guidance
for installation.
Apply dielectric grease to the plug/male connector housing
which typically contains socket contacts/female terminals. If
trapped air prevents the connector from latching, pierce one
of the unused wire seals. After assembly, install a seal plug (JLG
#4460905) in that location to prevent moisture ingress.
Note that seal plugs may be installed by the wire harness man-
ufacturer if an unused wire seal becomes compromised (wire
inserted in the wrong cavity during assembly and then cor-
rected).

MAF01570

Figure 7-5. Application to Plug/Male Contacts

7-6 3121781
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

DIN Connectors Brad Harrison / Phoenix Contact M12

This connector is typically used on hydraulic valves. Follow the The connector uses gold contact material to resist corrosion
installation instructions. and an o-ring seal for moisture integrity. If dielectric grease is
mistakenly applied to this connector system, the low-force
contacts cannot displace the grease to achieve electrical con-
tact. Once contaminated, there is no practical way to remove
the dielectric grease (replacement of female contacts
required). The JLG Load Sensing System and 1250AJP Rotary
Angle Sensors are examples of components with the M12 con-
nector system.

MAF01580

Exclusions
A limited number of connectors do not benefit from dielectric
grease, or may be permanently damaged by application.
Dielectric grease may not be required in properly sealed
enclosures.

Figure 7-7. Brad-Harrison M12

Figure 7-8. Phoenix Contact M12

3121781 7-7
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Engine Control unit connectors MIL-C-5015 SPEC Connector’s

Many times, these types of connectors use back-seals for mois- Crown Connector Inc’s recommendation is to not use dielec-
ture integrity. However, the low-force contacts cannot displace tric grease for this series connector. For similar model series
dielectric grease and create electrical contact.It is possible to connectors, the manufacturer should be contacted for confir-
use solvents (i.e. contact cleaner or mineral spirits) for the mation before applying dielectric grease. A typical application
removal of improperly applied dielectric grease. The EMR4 for this connector is on David Clark Intercom connections in
engine control module from Deutz employs this connector Aerial Work Platforms.
system (for example).

MAF01610

Molex CMC Series Connectors

The CMC connector family is a sealed, high-density connec-
tion system using matte-seal technology for CP 0.635 and
1.50mm terminals. To guarantee IP6K7 and IP6K9 sealing, a
seal plug option is used. However the low-force contacts can-
not displace dielectric grease and create electrical contact. It is
possible to use solvents (i.e. contact cleaner or mineral spirits)
for the removal of improperly applied dielectric grease. The
Sealed Enclosures flexbox control modules from JDES employ this connector sys-
Application of dielectric grease is not required in properly tem (for example).
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.

MAF01600

7-8 3121781
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.4 APPLYING SILICONE DIELECTRIC COMPOUND around male and female pins on the inside of the
connector after the mating of the housing to the
TO AMP CONNECTORS header. This is easily achieved by using a syringe to
fill the header with silicone dielectric compound, to a
Silicone Dielectric Compound must be used on the AMP
point just above the top of the male pins inside the
connections for the following reasons:
header. When assembling the housing to the header,
it is possible that the housing will become air locked,
• To prevent oxidation at the mechanical joint thus preventing the housing latch from engaging.
between male and female pins.
2. Pierce one of the unused wire seals to allow the
• To prevent electrical malfunction caused by low level trapped air inside the housing to escape.
conductivity between pins when wet.
3. Install a hole plug into this and/or any unused wire
Use the following procedure to apply Silicone Dielectric
seal that has silicone dielectric compound escaping
Compound to the electrical connectors. from it.
1. To prevent oxidation and low level conductivity, sili-
cone dielectric grease must be packed completely

Figure 7-9. AMP Connector

3121781 7-9
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Assembly
Check to be sure the wedge lock is in the open, or as-
shipped, position (See Figure 7-10. Connector Assembly
(1 of 4)). Proceed as follows:

Figure 7-11. Connector Assembly (2 of 4)

Figure 7-10. Connector Assembly (1 of 4)

1. To insert a contact, push it straight into the appropri-
ate circuit cavity as far as it will go (See Figure 7-11.
Connector Assembly (2 of 4)).
2. Pull back on the contact wire with a force of 1 or 2
lbs. to be sure the retention fingers are holding the
contact (See Figure 7-11. Connector Assembly (2 of
4)).
3. After all required contacts have been inserted, the
wedge lock must be closed to its locked position.
Release the locking latches by squeezing them Figure 7-12. Connector Assembly (3 of 4)
inward (See Figure 7-12. Connector Assembly (3 of
4)).
4. Slide the wedge lock into the housing until it is flush
with the housing (See Figure 7-13. Connector Assem-
bly (4 of 4)).

Figure 7-13. Connector Assembly (4 of 4)

7-10 3121781
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Disassembly 2. Pry open the wedge lock to the open position.

3. While rotating the wire back and forth over a half
1. Insert a 4.8 mm (3/16”) wide screwdriver blade turn (1/4 turn in each direction), gently pull the wire
between the mating seal and one of the red wedge until the contact is removed.
lock tabs.

Figure 7-14. Connector Disassembly

NOTE: The wedge lock should never be removed from the
housing for insertion or removal of the contacts.

Wedge Lock
The wedge lock has slotted openings in the forward, or
mating end. These slots accommodate circuit testing in
the field, by using a flat probe such as a pocket knife. DO
NOT use a sharp point such as an ice pick.

3121781 7-11
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Service - Voltage Reading sharp point. This practice should be discouraged when
dealing with the AMPSEAL plug assembly, or any other
sealed connector system. The resulting pinholes in the
insulation will allow moisture to invade the system by
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. traveling along the wire strands. This nullifies the effec-
tiveness of the connector seals and could result in sys-
It has been common practice in electrical troubleshoot- tem failure.
ing to probe wires by piercing the insulation with a

Figure 7-15. Connector Installation

7-12 3121781
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.5 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly

A B
A B

C
C D
Figure 7-16. DT/DTP Contact Installation Figure 7-17. DT/DTP Contact Removal
1. Remove wedgelock using needle nose pliers or a
1. Grasp crimped contact about 25mm behind the contact hook shaped wire to pull wedge straight out.
barrel. 2. To remove the contacts, gently pull wire backwards,
2. Hold connector with rear grommet facing you. while at the same time releasing the locking finger
by moving it away from the contact with a screw-
3. Push contact straight into connector grommet until a driver.
click is felt. A slight tug will confirm that it is properly
3. Hold the rear seal in place, as removing the contact
locked in place.
may displace the seal.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. They may go in either way.

NOTE: The receptacle is shown - use the same procedure for plug.

3121781 7-13
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly

A B A B

C C
Figure 7-18. HD/HDP Contact Installation Figure 7-20. HD/HDP Contact Removal
1. Grasp contact about 25mm behind the contact
crimp barrel. 1. With rear insert toward you, snap appropriate size
extractor tool over the wire of contact to be
2. Hold connector with rear grommet facing you. removed.
3. Push contact straight into connector grommet until a 2. Slide tool along into the insert cavity until it engages
positive stop is felt. A slight tug will confirm that it is contact and resistance is felt.
properly locked in place.
3. Pull contact-wire assembly out of connector.

Figure 7-19. HD/HDP Locking Contacts Into Position Figure 7-21. HD/HDP Unlocking Contacts

NOTE: For unused wire cavities, insert sealing plugs for full envi- NOTE: Do Not twist or insert tool at an angle.
ronmental sealing.

7-14 3121781
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.6 SWITCHES Leveling Jacks Limit Switch

Limit switches are used to control movement or indicate
Basic check position. Mechanical limit switches are just like manu-
The following check determines if the switch is func- ally operated switches except that the moving object
tioning properly, not the circuit in which the switch is operates the switch. These switches can be tested the
placed. A switch is functioning properly when there is same way as a standard switch by manually operating
continuity between the correct terminals or contacts the sensing arm.
only when selected. Another type of limit switch used by JLG is the inductive
1. De-energize the circuit. proximity switch, also referred to as a “prox switch”.
Inductive proximity switches are actuated only by fer-
2. Isolate the switch from the rest of the circuit if possi-
rous metal (metal that contains Iron, such as steel) near
ble. If not possible, keep in mind it may affect read-
the switch. They do not require contact, and must be
ings.
energized to actuate. These types of switches can be
3. Access the terminals to the switch. used to detect boom or platform position, for example.
4. If the switch has two terminals: These switches have a sensing face where the switch
a. Measure resistance across the terminals. can detect ferrous metal close to it. To find the sensing
face, take note how the switch is mounted and how the
b. Change the switch position. mechanisms meet the switch. Test this type of switch as
c. Measure resistance again with the leads in the follows:
same positions. If the meter was reading short,
it should read an open. If the meter was read- 1. Remove prox switch from its mount.
ing open it should read short. 2. Reconnect harness if it was disconnected for step a,
5. If the switch has more than two terminals, consult and turn on machine.
the schematic or switch diagram to determine what 3. Hold switch away from metal and observe switch
terminals will be connected. The test is similar to state in the control system diagnostics using the
testing a switch with two terminals. Analyzer. See vehicle or control system documenta-
a. Place one meter lead on the common contact tion on how to do this.
and the other on a different contact in the 4. Place sensing face of switch on the object to be
same circuit. sensed by the switch. If that is not available, use a
b. Cycle through all positions of the switch. The piece of ferrous metal physically similar to it. The
meter should read short only when the switch switch state in the control system diagnostics should
connects the two terminals and open other- change.
wise. 5. When reinstalling or replacing switch be sure to fol-
c. If the switch has more than one common con- low mounting instructions and properly set the gap
tact repeat the process for that circuit. between the switch and object sensed.

3121781 7-15
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Automatic Switches Switch Wiring - Low Side, High Side

If the switch is actuated automatically, by temperature When controlling a load, a switch can be wired between
or pressure for example, find a way to manually actuate the positive side of the power source and the load. This
the switch to test it. Do this either by applying heat or switch is called a “high side” switch. The switch supplies
pressure, for example, to the switch. These switches may the power to the load. When a switch is wired between
need to be energized to actuate. the negative side of the power source and the load, it is
a “low side” switch. The switch provides the ground to
1. Connect instrumentation to monitor and/or control
the load.
the parameter the switch is measuring.
2. Observe switch state in control system with the Ana- A low side switch will allow voltage to be present on the
lyzer. See vehicle or control system documentation load. No power is applied because the switch is stop-
on how to do this. ping current flow. This voltage can be seen if the mea-
surement is taken with one test lead on the load and the
3. Operate system such that the switch actuates. This
other on the battery negative side or grounded to the
could be going over a certain pressure or tempera-
vehicle. What is actually being measured is the voltage
ture, for example. The state indicated in the control drop across the switch. This could mislead a technician
system should change.
into thinking the load is receiving power but not operat-
ing. To produce an accurate picture of power or voltage
applied to the load, measure voltage across the load’s
power terminals. Also, the technician can measure the
voltage at both power terminals with respect to battery
ground. The difference between those two measure-
ments is the voltage applied to the load.

7-16 3121781
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.7 ELECTRICAL SCHEMATICS

530LRT ELECTRICAL SCHEMATIC

SHEET 2: GROUND CONTROL
HARNESS,GROUND MODULE
HARNESS,GROUND CONTROL BOX

SHEET 3: CHASSIS, ARM STACK & OPTIONS

HARNESS,CHASSIS WIRING
CABLE,ARM STACK
CABLE,ARM STACK
CABLE,ARM STACK
HARNESS,CHASSIS WIRING
CABLE,ARM STACK,UPR AUX
CABLE,ARM STACK,LWR AUX
CABLE,ARMS LSS
HARNESS,OSCILLATING AXLE OPTION
HARNESS,ARM STACK TILT SENSOR
WIRE,LEVELING JACK HARNESS
OIL COOLER HARNESS OPTION

SHEET 4: PLATFORM CONTROL

HARNESS,PLATFORM I/O MODULE

SHEET 5: PLATFORM CONTROL BOX

HARNESS,PLATFORM BOX

SHEET 6: DIESEL ENGINE

HARNESS,ENGINE KUBOTA,DIESEL
CABLE,BATTERY KIT
WIRE,10 GA FUSIBLE LINK

SHEET 7: GAS ENGINE CHASSIS

HARNESS,HYDRUALIC COMPARTMENT

SHEET 8: GAS ENGINE

HARNESS,ENGINE KUBOTA,DUAL FUEL

SHEET 9: GENERATOR & LIGHT OPTIONS

HARNESS,4000W GEN CONTROL
HARNESS,4000W GEN CONTROL
CABLE,4000W GEN POWER
HARNESS,7500W GEN CONTROL
HARNESS,7500W GEN CONTROL
CABLE,7500W GEN POWER
HARNESS,BOX SWITCH
HARNESS,HEAD/TAIL LIGHTS
HARNESS,WORK LIGHTS
HARNESS,FLOOD LIGHT SWITCH

SHEET 10: LOAD SENSE

HARNESS,LOAD SENSE
1001236134-A
MAF03620A

Figure 7-22. Electrical Schematic

3121781 7-17
7-18
1 2 3 4 5 6 7 8

GROUND CONTROL BOX

LRT GROUND CONTROL MODULE

J1 J2

1 PLATFORM SELECT CONTROL SYSTEM GROUND 40

H 2 PLATFORM EMS CONTROL SYSTEM GROUND 39 H
3 TRIGGER SWITCH INPUT CANBUS SHIELD 38
4 HORN OUTPUT CANBUS LOW 37
5 LIFT DOWN VALVE (330/430 ONLY) CANBUS HIGH 36
6 PROP LIFT UP/LJ (530 ONLY) HOLD RELAY OUTPUT 35
7 GROUND FUEL LEVEL SENSOR 34
8 IGNITION POWER (+12V) RS-485 SHIELD 33
9 CANBUS HIGH RS-485 LOW 32
10 GROUND RS-485 HIGH 31
TO CONNECTOR C02-J1 11 GROUND 2-SPEED THROTTLE 30
12 GROUND FUEL PUMP OUTPUT 29
ON SHEET 3 (G1) 13 CANBUS LOW LP VALVE/GLOW PLUG SOLENOID 28
14 CANBUS SHIELD ENGINE START OUTPUT 27
HARNESS 15 GROUND ALARM OUTPUT SPARE 26
16 GROUND COOLANT TEMPERATURE INPUT 25
(SEE SHEET 3-G1) C02-J2 CONNECTOR TO HARNESS
17 IGNITION POWER (+12V) SPARE 24
18 SPARE IGNITION POWER (+12V) 23
19 ROTARY POSITION EXCITE OSCILLATING AXLE OPTION INPUT 22
C02-J2 SHEET 6-E2
G G
20 ROTARY POSITION INPUT ALTERNATOR LAMP LINE INPUT 21
21 GROUND GROUND 20
(DIESEL ENGINE) OR
22 BOOTSTRAP 1 ENGINE SPEED SENSOR INPUT 19
C02-J2 SHEET 7-F1 (GAS ENGINE)
23 BOOTSTRAP 2 SPARE 18
24 OSCILLATING AXLE RELAY OIL PRESSURE SWITCH INPUT 17
BEACON LIGHT 16
J5
LB7 CO2-J5 GROUND 15
YEL 47-1 IGN PWR YEL 47-1 IGN PWR
ALT IND 1 6 1 IGNITION POWER (+12V) GROUND 14
BRN 2-4 ALT IND BRN 2-4 ALT IND
2 1 2 ALTERNATOR LAMP OUTPUT GENERATOR/SKYWELDER OUTPUT 13
BRN 47-3 ENG TEMP IND
3 3 ENG OIL PRES LAMP OUTPUT RIGHT OSCILLATING AXLE VALVE 12
BRN 47-2 ENG OIL IND
4 4 ENG COOLANT TEMP LAMP OUTPUT LEFT OSCILLATING AXLE VALVE 11
BLK 32 GND
5 5 GROUND LIFT UP ENABLEVALVE 10
BRN 47-4 OVERLOAD IND
2 6 CHARGE PRES LAMP OUTPUT 2 SPEED VALVE 9
LB8
BRN 47-3 ENG TEMP IND BRAKE VALVE 8
ENG TEMP 1 J3
BLK 32-2 GND DUMP VALVE 7
2
1 8V SENSOR SUPPLY STEER RIGHT VALVE 6
2 SPARE STEER LEFT VALVE 5
F 3 SPARE SPARE 4
F
4 GROUND PROP FUEL RACK ACTUATOR 3
LB9 CONTROL SYSTEM SUPPLY (+12) 2
BRN 47-2 ENG OIL IND
ENG OIL 1 CONTROL SYSTEM SUPPLY (+12) 1
BLK 32-1 GND
2
J6

IGNITION POWER (+12V) 1

S48 RS-232 SERIAL RECEIVE 2
RS-232 SERIAL TRANSMIT 3
LB10 GROUND 4
BRN 47-4 OVERLOAD IND
OVERLOAD 1
BLK 32-3 GND
2

J4
CNTL SYSTEM SUPPLY (+12V)
GROUND EMS
PLATFORM SELECT
GROUND SELECT
ENGINE START SWITCH INPUT
GROUND
UP SWITCH INPUT
DOWN SWITH INPUT
SPARE
S299 CONFIG
SPARE
SPARE
GLOW PLUG SWITCH INPUT
SPARE
HOURMETER OUTPUT
E E
X03 SN3

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
RED 11-2-1 PWR RED 11-2-1 PWR
1 1 PWR
BLK 001-2-1 GND BLK 001-2-1 GND
2 2 GND

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
YEL J1939 CANH YEL J1939 CANH CHASSIS TILT SENSOR
3 3 CANH
X03 TO CONNECTOR GRN J1939 CANL GRN J1939 CANL

CO2-J4
4 4 CANL
X03 ON HARNESS YEL/BLK 2-3-3 GND MODE
5
(SEE SHEET 3-C4) YEL/RED 124 OIL COOLER SW
6
OR 7
(SEE SHEET 10-F3) 8
9
YEL/RED 2-8 GND EMS
10

RED 1-3 +12V

RED 1-3 +12V

BLK 33 GND

YEL 2-2 PLTS

RED 1-1 +12V

11

BLU 52-1 HRMT

YEL 2-3-1 GNDS

TAN 3-1 LIFT UP
12

YEL 2-1-1 GND EMS

TAN 4-1 LIFT DOWN

WHT 48-1 ENG START

WHT 48-2 GLOW PLUG
D D
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

HARNESS AND HARNESS

Figure 7-22. Electrical Schematic

INSTALLED IN GROUND

C CONTROL BOX YEL 2-1-2 GND EMS

C
YEL 2-1-1 GND EMS
S64

YEL/RED 124 OIL COOLER SW

YEL 2-1-2 GND EMS

YEL/BLK 2-3-3 GND MODE

BLK 33 GND
YEL 2-3-2 GND PWR
YEL 2-3-2 GND PWR

BLU 52-1 HRMT

WHT 48-1 ENG START
SW13-B
WHT 48-2 GLOW PLUG
YEL/RED 2-8 GND EMS

YEL 2-3-2 GND PWR

YEL 2-3-2 GND PWR
YEL 2-3-2 GND PWR

YEL 2-2 PLTS

RED 1-2 +12V
RED 1-1 +12V

RED 1-2 +12V

YEL 2-3-2 GND PWR

YEL 2-3-1 GNDS
YEL 2-1-3 GND EMS

1
1

SW13-3
1
SW12-2

1
1
1
1
1
1
1
1
1
2
1
1

CB1-2
CB1-1

SW13-4
SW13-2
SW13-3
SW13-1
SW15-1
SW15-2
SW12-1
SW12-2

SW13-B
1

1
1
1
1
SW13-B1

GD1-2
GD1-1
SW16-1
SW16-2
A2 SW14-2

B B
15A
BOX CIRCUIT
GLOW PLUG SWITCH
LIFT SWITCH

HOUR METER START SWITCH

EMS
A3
A1
1
1

KEY SWITCH
SW14-3
SW14-1
TAN 3-1 LIFT UP

TAN 4-1 LIFT DOWN

A A

1001236134-A
1 2 3 4 5 6 7 8

MAF03630A

3121781
 1 2 3 4 5 6 7 8
YEL J1-1-1 IGN YEL J1-1 IGN
4 1 IGN PWR (7-33V)
X599 CONNECTOR TO BLK J1-2-1 GND BLK J1-2 GND
S602

3121781
3 2 GROUND
ENGINE HARNESS X599 WHT J1-7 FWD S601
1 3 DIGITAL INPUT 0
(SEE SHEET 6-G3) WHT J1-8 REV
2 4 DIGITAL INPUT 1
X16 OSC OPT PWR CONNECTOR TO
(SEE SHEET 7-H3) X599 5 DIGITAL INPUT 2
BLK 00-24-2 ANLG GND X15 ANALOG PWR CONNECTOR TO HARNESS
HARNESS X16 CONNECTOR 2 6 DIGITAL INPUT 3
RED 82-1-1 ANLG PWR X15 CONNECTOR WHT J1-7 FWD
SEE B3 (WHEN EQUIPPED) 1 7 PWM OUTPUT 0
(SEE SHEET 6-H6) HORN WHT J1-8 REV
X16 X15 8 PWM OUTPUT 1
WHT 60-1-3 UPR HLD VAL
1 9 PWM OUTPUT 2
WHT 60-1-2 LWR HLD VAL
H 2 GROUND ALARM 10 PWM OUTPUT 3 H
SN1 11 PWM OUTPUT 4
RED 82-1-2 ANLG PWR
A 12 PWM OUTPUT 5

1
1
WHT 30-1 OSC AXLE WHT 76-1 ROT ANG
24 B X594 X593 CO589-J1
BLK 00-24-1 ANLG GND 1060978 RED WHT J2-1 PWR
23 C 1 1 1 ANALOG +5V OUT

AH3-1
AH3-2
S11 1060978 WHT WHT J2-2 UPR B SIG
22 2 2 2 ANALOG INPUT 0

2
1
BLK 00-24 ANLG GND 1060978 BLK WHT J2-3 GND

ROTARY SENSOR
21 S595 3 3 3 ANALOG GROUND

AH4
WHT 76-1 ROT ANG S10 YEL J1-4 PWR WHT J2-4 PWR
HYDRAULICS MODULE

20 4 4 4 ANALOG +5V OUT

RED 82-1 ANLG PWR 1060780 YEL/BLK WHT J2-5 LWR R SIG
19 CABLE S596 5 5 5 ANALOG INPUT 1
BLK J1-6 GND WHT J2-6 GND
18 6 6 6 ANALOG GROUND
1060780 BLU/RED WHT J2-7 LWR B SIG
17 7 7 7 ANALOG INPUT 2
GROUND CONTROL BLK 00-22 ALARM GND BLK 00-22 ALARM GND
16 8 8 8 N/A
WHT 65-1 ALARM SIG WHT 65-1 ALARM SIG

BLK 00-20-1 GND

YEL CANH CANH
15 X597 9 CANBUS HIGH

WHT 71-2 HORN SIG

MODULE C02-J1 SHIELD SHIELD SHIELD YEL J1-1-2 IGN GRN CANL CANL
14 S5 D1 1 10 CANBUS LOW
GRN CANL CANL WHT J2-11 TX WHT J2-11 TX
13 S4 3 11 ANALYZER TRANSMIT
CONNECTOR BLK 00-21 GND WHT J2-12 RX WHT J2-12 RX
12 2 12 ANALYZER RECEIVE
BLK 00-3 GND BLK J1-2-2 GND
11 4 CO589-J2
(SEE SHEET 2-G4) BLK 00-20 GND CABLE
10 HV11 UPR PRI HLD VAL SV1
YEL CANH CANH BLK 00-3-4 GND BLK 00-3-4 - BLK 00-3-4 -

1060978 BLK
1060978 RED
1060978 WHT
9 S3 2 2 2 RIGHT FRONT LEFT FRONT RETRACT EXTEND 1 LEFT REAR RIGHT REAR EXTEND 2
RED 11-1 PWR S9 WHT 60-1-3 UPR HLD VAL WHT 60-1-3 - WHT 60-1-3 - ON UPPER

1060780 YEL/BLK

1060780 BLU/BLK
1060780 BRN/BLK
1060780 BLK/RED
1060780 BLU/RED

1060780 ORG/BLK
8 1 1 1
BLK 00-1 GND S7 S6 CYLINDER
7 X14 X14
G WHT 64-1 PROP VAL G
6 X13 X13

A
B
A
B
A
B

C
C
C

SN592
SN591
SN590
WHT 60-1-2 LWR HLD VAL WHT 60-1-2 - WHT 60-1-2 -
5 1 1 1 LWR PRI HLD VAL SV1
WHT 71-1 HORN SIG BLK 00-3-3 GND BLK 00-3-3 - BLK 00-3-3 -
4 2 2 2

1
2
1
2
1
2
1
2
1
2
1
2
1
2

BLU 6-1 TRIG SW INPUT ON LOWER

HV10

SIG
SIG
SIG
3

GND
GND
GND

PWR
PWR
PWR
CYLINDER

HV16
HV17
HV18
HV19
HV20
HV21
HV22

ORG 5-1 PLAT EMS

2 CABLE
RED 2-2-3 PLAT EMS OUT WHT 64-1 PROP VAL
1 1
S49 S606 BLK 00-21 GND ON MAIN HYDRAULIC PRES TRANS PRES TRANS PRES TRANS
CO2-J1 2
S607 MANIFOLD UPPER BARREL LOWER ROD LOWER BARREL
HV9

LEVEL / LIFT UP FLOW CONTROL

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

WHT 64-1 PROP VAL

1
BLK 00-21 GND
2

DIODE
FC276 MS605

ORG/WHT 55-21 -
ORG/WHT 55-20 -
ORG/WHT 55-25 -
ORG/WHT 55-22 -
ORG/WHT 55-23 -

RED 115 PWR

ORG/WHT 55-24-1 -
ORG/WHT 55-24-2 -

B
RED 115 B+
A

5A
FC277
ORG 111 PWR

UNIVERSAL TELE
B
RED 111 B+
A

10A
RED 115 B+ SN10
1 RED - RED_1

PLAT OPT PWR

PWR A
T2+ BLK - BLACK_1
GND B

RED 2-2-2 PLAT EMS OUT

RED 11-4 PWR
BLK 00-1-3 GND
RED 115 PWR
YEL 2-3-3 GND MODE
SHIELD SHIELD SHIELD
GRN CANL CANL
YEL CANH CANH
BLK 00-1-2 GND
RED 11-2 PWR
YEL 2-3-3 GND MODE
SHIELD SHIELD SHIELD
GRN CANL CANL
YEL CANH CANH
BLK 00-112 GND
BLU 6-1 TRIG SW INPUT
ORG 111 PWR
BLK 00-1-1 GND
ORG 5-1 PLAT EMS
RED 11-3 PWR
RED 2-2-1 PLAT EMS OUT
RED 111 B+ T2+ TO POSITIVE (+) TERMINAL
1 WHT - WHITE_1
F T2+ TO POSITIVE (+) TERMINAL ON SIG C F
T2+ ON AUXILIARY BATTERY BLOCK

PRESSURE
FRONT LEFT
AUXILIARY BATTERY BLOCK

TRANSDUCER

X02
X49

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

T
F

X
V
S
P
K
E
B
A

U
R
N
H
D
C

MS300
BLK 00-112 GND T2- TO NEGATIVE (-) TERMINAL ON OPTIONS MODULE
1

8
7
6
5
4
3
2
1
X
W W
V
U
T
S
R
P
N
M M
L
K
J
H
G
F
E
D
C
B
A
SN11
T2- AUXILIARY BATTERY BLOCK RED - RED_2
MS300 UNIVERSAL PWR A CO3-J3

X02
X49
BLK - BLACK_2 RED - RED_1
TELE CONNECTOR GND B 1 12
WHT - WHITE_2 WHT - WHITE_1
S60

SIG C 2 11
ADAPTOR PORT BLK - BLACK_1

PRESSURE
3 10

FRONT RIGHT

TRANSDUCER
RED - RED_2 IGN PWR YEL/RED 2-20 -
4 9
WHT - WHITE_2

YEL CANH
GRN CANL
SN12 5 8
RED - RED_3 BLK - BLACK_2

RED 11-2 PWR

PWR A 6 7

BLK 00-1-2 GND

BLK - BLACK_3 RED - RED_3

SHIELD SHIELD
GND B 7 6

YEL - CABLE
YEL - CABLE
BLK - CABLE

BLU - CABLE
WHT - WHITE_3 WHT - WHITE_3

BRN - CABLE
RED - CABLE

GRN - CABLE
ORG - CABLE
ORG - CABLE
SIG C 8 5
BLK - BLACK_3 RETRACT ORG/WHT 55-25 -

PRESSURE
REAR LEFT
9 4

YEL/BLK - CABLE
TRANSDUCER

BLU/BLK - CABLE
RED/BLK - CABLE

ORN/BLK - CABLE
BLK/WHT - CABLE
RED - RED_4 EXTEND ORG/WHT 55-24 -
10 3

YEL/BLK 2-3-3 GND MODE

WHT - WHITE_4 REAR-RT VALVE OUT ORG/WHT 55-23 -

S12
SN13 11 2
X50 RED - RED_4 BLK - BLACK_4 REAR-LT VALVE OUT ORG/WHT 55-22 -
RED/BLK - CABLE PWR A 12 1
A BLK - BLACK_4
RED - CABLE GND B CO3-J5
B WHT - WHITE_4

S13
ORG - CABLE SIG C
C

PRESSURE
REAR RIGHT
BLK - CABLE
BLK 2 -
BLK 3 -
BLK 4 -
BLK 5 -
BLK 6 -
BLK 7 -
BLK 1 -
BLK 8 -

TRANSDUCER
D
ORG - CABLE
E E E
BLU - CABLE X50 PLAT GND CONNECTOR 8
F IGN SPLICE
BLK/WHT - CABLE 7
G
YEL - CABLE TO HARNESS 6
H
1
2
3
4
5
6
7
8
9

MS305

5
10
11
12

GRN - CABLE
J
X50 CONNECTOR 4
K
6
5
4
3
2
1

YEL/BLK - CABLE 3
L
YEL - CABLE (SEE SHEET 4-D1) 2
MS306

M
ORN/BLK - CABLE 1 GND SPLICE
N
BLU/BLK - CABLE CO3-J4
P
BRN - CABLE

YEL CANH
GRN CANL
R

SHIELD SHIELD
S
CO3-J1
T FRONT-RT OUTPUT ORG/WHT 55-21 -

B
A

C
1 12

MS200-2
U FRONT-LT OUTPUT ORG/WHT 55-20 -
CABLE 2 11
V
3 10
W C03-J1 CONNECTOR TO DIESEL YEL/RED 2-21 -
4 9
X X578 X578 CABLE ENGINE HARNESS (SEE SHEET REAR-RT STOW BLK - BLACK4
5 8
3 3 HV24 UPR AUX HLD VAL SV2 REAR-LT STOW BLK - BLACK3 WHT - WHITE1
6-G6) OR GAS ENGINE CHASSIS 6 7

A
B
C
A
B
C
BLK 00-30 GND BLK BLK ON UPPER
2 2 2 FRONT-RT STOW BLK - BLACK2
WHT 60-12 AUX HLD VAV WHT WHT HARNESS (SEE SHEET 7-G5) 7 6
1 1 1 CYLINDER FRONT-LT STOW BLK - BLACK1 BLK - BLACK1
8 5

MS200-3
MS200-1
L.F. LIMIT

D 9 4 D
X579 X579 HV23 GND BLK 1 -
WHT 60-13 AUX HLD VAV WHT WHT 10 3
1 1 1 LWR AUX HLD VAL SV2

SHIELD
S575 BLK 00-31 GND BLK BLK 11 2 WHT - WHITE2
2 2 2 ON LOWER
12 1
HARNESS 3 3 CYLINDER

YEL CANH
YEL CANH

GRN CANL
GRN CANL
CO3-J2 BLK - BLACK2
CABLE
R.F. LIMIT

X03

SHIELD SHIELD
RED 11-2-1 PWR
1
BLK 001-2-1 GND
2
YEL CANH WHT - WHITE3
3
GRN CANL
4 X03 GND CNTL BLKHD
YEL/BLK 2-3-3 GND MODE BLK - BLACK3
5 HARNESS
L.R. LIMIT

YEL/RED 124 OIL COOL

(SEE SH3-B6) 6 TO GROUND CONTROL
7
8
LEVELING JACKS HARNESS
BOX CONNECTOR X03 WHT - WHITE4
9

WHT 60-11 AUX HLD VAV

YEL/RED 2-9 GND EMS

10 (SEE SHEET 2-E1) BLK - BLACK4
R.R. LIMIT

11

1
1

SW19-1
SW19-2
12

Figure 7-22. Electrical Schematic

YEL/RED 2-9 GND EMS

C WHT/RED 31-1 LT AXL ENBL 87 C

87
WHT 30-2 OSC RL PWR 30
AUX DESCENT SW 30
87a
87A

SHIELD SHIELD
BLK 00-19-1-2 GND 85

YEL CANH
GRN CANL
85
OSC LT RL

ORG 55-3 OSC STR LT ORG 55-3-1 LT AXL UNLK 86

86
S31
RL7 YEL/RED 124 OIL COOL

A
B
C
1

MS201-1
YEL/RED 123 OIL COOL
ORG 55-4 OSC STR RT 2
FC278
S32 RED 121 PWR MS302

BLK 00-1-2-3 GND

RED 11-2-3 PWR
BLK 00-1-2-2 GND
RED 11-2-2 PWR
WHT/RED 32-1 RT AXL ENBL 87 B
87 RED 120 PWR
WHT 30-3 OSC RL PWR 30 A
15A
OIL COOLER

X17
X20
30

2
1
2
1
OIL COOLER

87a
87A
S33

2
1
C
B
A
C
B
A
2
1
BLK 00-19-1-3 GND 85
85
OSC RT RL

ORG 55-4-1 RT AXL UNLK 86 T2+ TO POSITIVE (+) TERMINAL

X17
X20
86
HARNESS X42 CONNECTOR TO ENGINE HARNESS X42
RL8
ORG 55-3 OSC STR LT ON AUXILIARY BATTERY BLOCK

MS201-2
MS201-3
1
X42 CONNECTOR (SEE SHEET 7-D5 ORG 55-4 OSC STR RT RED 120 PWR
ARM STACK TILT SENSOR 2 1 RED 122 PWR
BLK 00-19 GND 1
FOR GAS ENGINE OR SHEET 6-G5 3 X03-6 TO X03 T2+ BLK 00-25-2 GND M
2
FOR DIESEL ENGINE) 4 ORG 55-3-2 LT AXL UNLK CONNECTOR YEL/RED 124 OIL COOL
1 1 MS303
BLK 00-19-5 GND

SHIELD
POSITION 6

SHIELD
2 X03-6
OIL COOLER FAN

YEL CANH
YEL CANH

GRN CANL
GRN CANL
X16 CONNECTOR TO 2 HV12 (SHEET 3-3D) BLK 00-25 GND
UNLK LT

B WHT 30-1 OSC AXL PWR 1 B

1 S63 RED 122 PWR 87
HARNESS X16

RED 11-2-4 PWR

RED 11-2-3 PWR
S34 T2- 87

BLK 00-1-2-3 GND

X16 WHT/RED 31-1 LT AXL ENBL RED 121 PWR 30

BLK 001-1-2-4 GND

CONNECTOR (SEE H2) 1 30
BLK 00-19-4 GND T2- TO NEGATIVE 87a
SN4 2
RED 11-2-4 PWR (-) TERMINAL ON BLK 00-25-1 GND 85
PWR 1 HV13 HARNESS 85
BLK 001-1-2-4 GND
ENABLE LT

AUXILIARY YEL/RED 123 OIL COOL 86

OIL COOLER

GND 2 SN8 86
ARM STACK TILT SNSR YEL CANH RED 11-2-3 PWR
CANH 3 1 PWR ORG 55-4-2 RT AXL UNLK BATTERY BLOCK OIL COOLER OPTIONS RL14
GRN CANL BLK 00-1-2-3 GND 1
CANL 4 2 GND BLK 00-19-3 GND
YEL CANH OSC AXL SNSR 2
3 CANH HARNESS (WHEN EQUIPPED)
GRN CANL HV14
UNLK RT

4 CANL

WHT/RED 32-1 RT AXL ENBL

1
BLK 00-19-2 GND
2
HV15
ENABLE RT

HARNESS
BLK 00-19-5 GND
BLK 00-19-4 GND
BLK 00-19-3 GND
BLK 00-19-2 GND
BLK 00-19-1 GND
BLK 00-19 GND

OSCILLATING AXLE OPTION

A HARNESS SCHEMATIC
A
6
5
4
3
2
1
MS157

GND CONN

1001236134-A
1 2 3 4 5 6 7 8

MAF03640A

7-19
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7-20
1 2 3 4 5 6 7 8

HARNESS

H H
TO LOAD SENSE

BLK 001-1 GND

RED 11-3 PWR
Connector J4B
on sheet 10-C2

1
2
BOX RECEPT

CO1-J8

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

J4A
CO1-J1 X01
WHT 1 ANALYZER TX
34 28 1
WHT 2 ANALYZER RX
33 30 2
WHT 3 ANALYZER PWR
29 GROUND RETURN 29 3
ORG 12 STR LT WHT 4 ALARM GND
28 STEER LEFT 8 4
BLU 10 STR RT WHT 5 ALARM
27 STEER RIGHT 9 5

YEL CANH -3
GRN CANL -3

YEL J2-33 IGN

BLU 6 LAMP RETURN

BLK J2-25 GND

26 10 6
BLU 7 LEVEL JACK UP

MODULE POWER
25 11 7

MODULE GROUND
BLU 8 LEVEL JACK DOWN
24 12 8
BLU 9 TRIGGER BLU 9 TRIGGER
22 TRIGGER INPUT 1 9
BLU 10 STR RT
21 13 10
ORG 11 +5V
18 27 11
G ORG 12 STR LT G
17 15 12
ORG 13 DRV
16 16 13
ORG 14 GND X01 BOX RECEPT TO
15 17 14
ORG 15 AUTO LVL ORG 15 AUTO LVL
13 LEVELING JACKS 2 15
YEL 16 PWR YEL 16 PWR HARNESS
10 SWITCH POWER 18 16
YEL 17 SYS IND
8 19 17
20
YEL 18 PLAT EMS OUT X01 CONNECTOR
35 18
ORG 11 +5V YEL 19 EMS IN
12 +5 ANALOG EXCITATION 21 19
YEL 20 LOW FUEL (SEE SHEET 5-F1)
7 22 20
TAN 21 TILT IND
6 23 21
TAN 22 OVLD IND
5 24 22
TAN/BRN 23 LFT SEL TAN/BRN 23 LFT SEL
14 ANALOG GROUND RETURN LIFT 4 23
TAN/BRN 24 DRV SEL TAN/BRN 24 DRV SEL
23 DRIVE 3 24
TAN 25 GEN SW PWR
11 +5 ANALOG EXCITATION 25 25
SHIELD SHIELD SHIELD PNK 26 GEN SW
32 CAN SHIELD 26 26
S609 GRN CANL CANL PNK 27 HORN PNK 27 HORN
30 CAN LOW HORN 31 27
S610 YEL CANH CANH PNK 28 ENG START PNK 28 ENG START
31 CAN HIGH START 14 28
ORG 5-1 PLAT EMS PNK 29 SPD LOW PNK 29 SPD LOW
3 PLATFORM EMS TO GROUND MODULE SPEED LOW 5 29
YEL 2-3-3 GND MODE PNK 30 SPD HI PNK 30 SPD HI
1 GROUND MODE SPEED HI 6 30
PNK 26 GEN SW PNK 31 GLOW PLUG/FUEL SEL PNK 31 GLOW PLUG/FUEL SEL
9 GENERATOR ON SIGNAL FUEL/GLOW PLUG 7 31
TAN 25 GEN SW PWR
F 4 GENERATOR SWITCH POWER 32 F
WHT 4 ALARM GND
20 ALARM RETURN 33
WHT 5 ALARM
19 PLATFORM ALARM 34
YEL 19 EMS IN
2 PLATFORM EMS 35
CO1-J7

8 GROUND RETURN
ORG 14 GND
7 DRIVE/STEER JOYSTICK RETURN PLATFORM CONTROL MODULE
6
5
4
ORG 13 DRV
3 DRIVE SIGNAL
2
1
CO1-J6

8 GROUND RETURN
7
6
5
E 4 E
WHT 126 FOOT SW 3
2
RED 125 PWR 2
1
1
SW588

FOOT SW
CO1-J5

SWITCH POWER
BATTERY VOLTAGE
BATTERY VOLTAGE
BATTERY VOLTAGE
BATTERY VOLTAGE
ANALYZER GND (N/C)
BATTERY VOLTAGE
FOOT SWITCH
TRIGGER SWITCH REDUNDANCY
ANALYZER TX
ANALYZER RX
ANALYZER POWER
LAMP RETURN
LEVELING JACKS EXTENDED
LEVELING JACKS STOWED
SYSTEM DISTRESSED INDICATOR
LOW FUEL INDICATOR
CHASSIS TILT INDICATOR
PLAT OVERLOAD IND

35
34
33
32
31
30
27
25
24
23
22
19
17
16
15
14
13
7
5
4
3
2
1
20
12
29
28
26
18
10
9
8
21
6
11
MS301 CONNECTOR TO HARNESS
4
MS301 CONNECTOR

CO1-J2
WORK & FLOODLIGHT OPTIONS 3
BLK 00-112 GND
(WHEN EQUIPPED) 2
ORG 111 PWR
(SEE SHEET 9-E6) 1
MS301

YEL J2-33 IGN

BLK J2-25 GND
RED 125 PWR
X

YEL 17 SYS IND

TAN 21 TILT IND
W

TAN 22 OVLD IND

YEL 20 LOW FUEL

WHT 126 FOOT SW

V

WHT 1 ANALYZER TX
BLU 6 LAMP RETURN

WHT 2 ANALYZER RX
BLU 7 LEVEL JACK UP
U

WHT 3 ANALYZER PWR

BLU 6-1 TRIG SW INPUT

D T
D

BLU 8 LEVEL JACK DOWN

S
R
P
N
M
ORG 111 PWR
E
BLK 00-112 GND
X50 PLAT GND CONNECTOR TO G
RED 11-3 PWR
B
MAIN ARM CABLE BLK 001-1 GND
D
X50 CONNECTOR SHIELD SHIELD SHIELD
K
(SEE SHEET 3-E4) GRN CANL CANL
J
YEL CANH CANH
H
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

ORG 5-1 PLAT EMS

C
YEL 2-3-3 GND MODE
L
BLU 6-1 TRIG SW INPUT
F
YEL 18 PLAT EMS OUT
A

Figure 7-22. Electrical Schematic

X50

PLAT GND CONN

C C

B B

A A

1001236134-A
1 2 3 4 5 6 7 8

MAF03650A

3121781
 1 2 3 4 5 6 7 8

3121781
H H
PLATFORM BOX HARNESS

DRIVE/LEVEL/LIFT SELECT
START
DUAL FUEL GLOW PLUGS 3-SPD SEL GENERATOR OPTION
USE DUAL FUEL SWITCH
IN PLACE OF GLOW PLUG
HORN
SWITCH ON GAS
MACHINES

1
1
1
1
1
1
1
1
1
1
1
1
1
1

SW9-3
SW9-2
SW2-2
SW2-1
SW8-3
SW8-2
SW5-3
SW5-2
SW5-4
SW5-6

SW10-1
SW10-3
SW10-1
SW10-3
SW11-3
SW11-2
SW11-1
G G

WHT 2-1-9 PWR

WHT 2-1-8 PWR
WHT 2-1-7 PWR
WHT 2-1-6 PWR
WHT 2-1-5 PWR

ORG 55-9 HORN

BLK 55-12 SPD HI

BLU 55-5 LFT SEL

BLK 55-8 GEN SW

ORG 55-6 DRV SEL
ORG 2-7 AUTO LVL

BLU 55-11 SPD LOW

YEL 55-10 ENG START
RED 55-7 GEN SW PWR
X11
WHT 2-1-5 PWR

BLK 55-13 GLW/FUEL SEL

2
WHT 2-1-6 PWR
3
WHT 2-1-7 PWR
4
WHT 2-1-8 PWR
5
BLK 55-13 GLW/FUEL SEL WHT 2-1-9 PWR
31 6

PWR1 SPLICE
BLK 55-12 SPD HI WHT 2-1-3 PWR
30 1
BLU 55-11 SPD LOW
29
YEL 55-10 ENG START
28
F 27
ORG 55-9 HORN F
BLK 55-8 GEN SW
26
RED 55-7 GEN SW PWR
25
ORG 55-6 DRV SEL
24
BLU 55-5 LFT SEL
23
BLU 55-4 OVLD IND
22
YEL 55-3 TILT IND
21
X01 PLAT BOX RECEPT TO BRN 55-2 FUEL LOW
20
RED 2-2 EMS IN BLK 00-2-4 GND
19 2
HARNESS X01 RED 2-2-1 EMS OUT BLU 55-4 OVLD IND OVERLOAD IND
18 1
BRN 55-1 SYS IND
17 LB6
CONNECTOR (SEE SHEET 4-G7) RED 2-1 PWR
16
ORG 2-7 AUTO LVL
15
BLK 57-3 GND
14
BRN 57-1 DRV
13
YEL 10-1 STR LT BLK 00-2-4 GND
12 2
RED 57-2-2 +5V YEL 55-3 TILT IND TILT IND
11 1
E ORG 9-1 STR RT E
10 LB3
BLU 2-16 TRIGGER
9
BRN 49-4 LEVEL JACK DOWN
8
BLU 49-3 LEVEL JACK UP
7

RED 2-1-2 PWR

RED 2-2-1 EMS OUT
BLK 00-1 LAMP RETURN

RED 2-1 PWR

WHT 2-1-3 PWR
RED 2-2 EMS IN
6
YEL 49-1 ALARM BLK 00-2-2 GND
5 2
BLK 49-2 ALARM GND BRN 55-2 FUEL LOW LOW FUEL IND
4 1
RED 2-7-2 ANALYZER PWR LB2
3

1
1

SW1-1
SW1-2
ORG 49-6 ANALYZER RX

X09
2

6
5
2
3
4
1
BRN 49-5 ANALYZER TX
1
X01

BLK 00-2-1 GND

X32 2
BRN 49-5 ANALYZER TX PWR0 SPLICE E-STOP BRN 55-1 SYS IND SYSTEM IND
ANALYZER 3 1

BLK 00-1-1 GND

BLU 49-3 LEVEL JACK UP
BLK 00-1-2 GND
BRN 49-4 LEVEL JACK DOWN
RED 2-1-2 PWR
BLU 2-16 TRIGGER
ORG 9-1 STR RT
YEL 10-1 STR LT
RED 57-2-2 +5V
BRN 57-1 DRV
BLK 57-3 GND
ORG 49-6 ANALYZER RX
2 LB1
CONNECTOR RED 2-7-2 ANALYZER PWR

YEL 49-1 ALARM

1
PORT BLK 00-1-3 GND
4
D X08
D
BLK 00-1 LAMP RETURN

JS1

LB4
LB5
1

2
1
2
1
1
2
3
4
5
6
7
9
8
BLK 00-2-1 GND
2

1
1
AH1-2
AH1-1
BLK 00-2-2 GND
3
R L BLK 00-2-4 GND
4
BLK 00-2-4 GND
5

LAMP RETURN
6

OUTPUT
ALARM T
BLK 00-1-3 GND LVL JACK UP LVL JACK DN
6 PLATFORM JOYSTICK
BLK 00-1 LAMP RETURN
5
BLK 00-1-1 GND
2
BLK 00-1-2 GND
3
BLK 00-1 LAMP RETURN
4

GND1 SPLICE

Figure 7-22. Electrical Schematic

1
X10

C C

B B

A A

1001236134-A
1 2 3 4 5 6 7 8

MAF03660A

7-21
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7-22
1 2 3 4 5 6 7 8

WHT 86-3 ALT EXCT

A

20A
WHT 86-2 ALT EXCT
B
BLK 00-24-1-2 ANLG GND
2 X15 ANALOG PWR CONNECTOR TO HARNESS FC260
RED 82-1-1 ANLG PWR

ALT EXCITE
MS100 1 X15 CONNECTOR (SEE SHEET 3-H3)
BLK 00-6 GND
1 X15
BLK 00-19 GND
10
BLK 00-10 GND RED 82-1-1 ANLG PWR
3 A Vcc
BLK 00-11 GND BLK 00-24-1-2 ANLG GND WHT 86-2 ALT EXCT
4 C Vout 1
BLK 00-18 GND WHT 82-1 SPD SN WHT 86-1-2 HOLD RL

SPEED
H 9 B GND 2 H

SENSOR
SPD SNSR
BLK 00-14 GND

DIODE
7 SN6 D1
BLK 00-12 GND
5

4460837
BLK 00-8 GND BLK 00-1-4 GEN CNTL BOX GND
2 C
BLK 00-15-1 GND ORG 52-1 GEN ON X18 CONNECTOR TO HARNESS
8 B

GND SPLICE BLOCK

BLK 00-13-1 GND YEL 2-1-2 GEN CNTL BOX PWR GENERATOR OPTION (SEE SHEET 9)
6 A
BLK 000-20 GND
11 X18
BLK 000-21 GND
12

MS152
ORG 2-7-4 BCN PWR
MS150 1 BEACON
BLK 00-1-2 BCN GND
3 2 2920146
WHT 86-3 ALT EXCT
2
WHT 89-1 ALT LMP IN FORWARD RVS VALVE STR LT STR RT DUMP BRAKE 2 SPEED LIFT UP
1

LAMP IGN
X599 CONNECTOR TO

KUBOTA
X42 CONNECTOR TO OSCILLATING AXLE
HARNESS X42 CONNECTOR (SEE SHEET 3-B3)
CHASSIS HARNESS X599
DIESEL ENGINE HARNESS
1

B+
ALTERNATOR
1
2
3
4
T6 (SEE SHEET 3-H6)
TO ENGINE EC4 10AWG FUSIBLE LINK TO ALT STUD T6 S24

X42
1 1

1
2
3
4
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
STARTER STUD (G3)
HARNESS

HV1
HV2
HV3
HV4
HV5
HV6
HV7
HV8

X599
(C2) WIRE,10 GA FUSIBLE LINK AND
AND TO ALT STUD T7 BLK 00-1-5 OPT MDL GND
G 4
G
TO ENGINE EC8 (SHEET 8-G3)
12
STARTER STUD 11
C03-J1 CONNECTOR TO
(SHEET 8-G4) DIESEL & DUAL FUEL (GAS) ENGINE HARNESSES 10

BLK 00-19 GND

9 OPTIONS MODULE C03-J1
3

YEL 2-1-5 IGN

BLK 000-20 GND
BLK 00-8 GND
PORT (SEE SHEET 3-D6)

BLK 00-12 GND

BLK 00-14 GND
BLK 00-18 GND
BLK 00-11 GND
BLK 00-10 GND

ORG 8-1-1 RVS VAL

2

ORG 7-1-1 FWD VAL

TAN 3-1 UP VAL

BLK 00-13-1 GND

BLK 00-15-1 GND
FC261

ORG 55-3 OSC AXLE LF

ORG 55-4 OSC AXLE RT
MAIN MDL FUSE RED 1-2-5 PWR 12AWG 1

ORG 8-1-1 RVS VAL

B YEL CANH HI

ORG 7-1-1 FWD VAL

ORG 55-2 2 SPD VAL

WHT 50-1 DUMP VAL

S14 6

YEL 9-1 STR LFT VAL

RED 1-2-4 PWR 12AWG

ORG 55-1 BRAKE VAL

A GRN CANL LO

YEL 10-1 STR RHT VAL

20A
7
SHIELD CANSHIELD SHIELD
8
YEL 2-1-1 OPT MDL PWR
5
CO2-J2 CO3-J1
RED 1-1 MDL PWR
1
RED 1-2 MDL PWR RED 1-2-1 MDL PWR
2
RED 1-2-2 PWR S18
22
WHT 80-1 THROTTLE ACT T1-1-
3
S25 BLK 00-17-1 GND
4 GND TO ENG 1
YEL 9-1 STR LFT VAL 87 YEL 2-1 IGN PWR
5 87 GROUND STUD
YEL 10-1 STR RHT VAL 30 RED 1-2-3 PWR
6 30
WHT 50-1 DUMP VAL 87a
F 7 S20 F
ORG 55-1 BRAKE VAL 85 BLK 00-17-2 IGN RL GND
8 85

IGN RELAY
ORG 55-2 2 SPD VAL 86 YEL 2-7-1 IGN RL
9 86
TAN 3-1 UP VAL
10 RL1
ORG 55-3 OSC AXLE LF
11
ORG 55-4 OSC AXLE RT
12
BLK 00-6 GND
15 R1
C02-J2 WHT 89-1 ALT LMP IN YEL 2-1-3 IGN PWR
21 EC2 1
WHT 82-1 SPD SN WHT 83-3 ENG OIL PRS WHT 83-2 ENG OIL PRS
19 1 2

KUBOTA
OIL PRES
ORG 52-1 GEN ON S19 620 OHM
OIL PRES RSTR
CONNECTOR TO 13
BLK 00-1 GND LBL 83-1 ENG OIL PRS
14
GROUND MODULE ORG 2-7-4 BCN PWR
16 SN5
YEL CANH HI WHT 87-1 CLNT SNSR TEMP SENSOR
36 1
CONNECTOR GRN CANL LO S59 BLK 00-1-6 CLNT SNSR GND COOLANT
37 2
SHIELD CANSHIELD S58
38
C02-J2 (SHEET YEL 2-7-1 IGN RL S57
23
LBL 83-1 ENG OIL PRS
17
2-G4) 25
WHT 87-1 CLNT SNSR
ORG 46-1 FUEL PUMP PWR ORG 46-1 FUEL PUMP PWR
29 1
BRN 47-9 FUEL LVL SN M BLK 00-1-7 FUEL PUMP GND
34 2
BLK 00-17 GND
40 MS151

FUEL PUMP
E 20 E
BRN 47-9 FUEL LVL SN
18 1
24 T8
WHT 85-1 2 SPD RL BLK 00-1-8 FUEL SN GND
30 1

FUEL LEVEL
31 T9
32
33
BLK 00-16 GND
39
WHT 86-1 HOLD RL
35
WHT 84-1 GLW PLG RL
28
26
WHT 1-3 ENG STRT RL
27
S17
S23

S16
S15
WHT 80-1 THROTTLE ACT
1
BLK 000-21 GND
2
D HV604
D
RL 86-1-1 HOLD RL

GENERIC
WHT
YEL 2-1-4 IGN
CANSHIELD SHIELD
GRN CANL LO
YEL CANH HI
RED 91-4 12V+
BLK 00-16-8 GND
RED 91-4 12V+
RED 91-3 12V+

THROTTLE ACTUATOR
WHT 1-3-1 ENG STRT RL
BLK 00-17-3 GND
RED 1-10-3 STRT RL PWR
WHT 45-4 STRT ENG
RED 1-10-2 PWR
RED 1-10-1 PWR
RED 10-1 PWR 10AWG
WHT 85-1 2 SPD RL
BLK 00-16-6 GND
RED 1-10-6 2 SPD RL PWR
WHT 88-1 2 SPD ACT
WHT 88-1 2 SPD ACT
BLK 00-16-7 GND
RED 1-10-6 2 SPD RL PWR
RED 1-10-5 PWR
WHT 84-1 GLW PLG RL
BLK 00-16-4 GND
RED 1-10-4 GLW PLG RL PWR
WHT 84-2 GLW PLG ENGD
WHT 84-2 GLW PLG ENGD
WHT 1-3-2 PULL RL
BLK 00-16-3 GND
RED 91-1-2 PULL RL PWR
YEL 91-1-3 PULL ACT
YEL 91-1-3 PULL ACT
WHT 91-2-3 HOLD ACT
RED 91-1-2 PULL RL PWR
RED 91-1-1 BATT PWR
RED 91-2-1 BATT PWR
RED 91-2-2 HOLD RL PWR
WHT 91-2-3 HOLD ACT
RED 91-2-2 HOLD RL PWR
BLK 00-16-2 GND
WHT 86-1-1 HOLD
J
F
X534

E
B
A
B
A

H
D
C

G
FC533

CLEARSKY
DIAGNOSTIC

T4
T5

RL2
RL3
RL4
RL5
RL6

10A

EC1
EC5

1
1
1
1
2

B
A
B
A
B
A
A
B

FC258
FC267
FC259
FC257

86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
87
30
85
86

CONNECTOR DIAG PWR FUSE

87A
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
87
30
85
86

87a
87a
87a
87a
87a

S22

40A 30A 40A 4A

START FUSE 2 SPD FUSE PULL RL FUSE HOLD RL
PULL
HOLD

2 SPD
KUBOTA

Figure 7-22. Electrical Schematic

START RELAY 2 SPEED RL GLOW PLUGS GLOW PLUGS PULL RELAY HOLD RELAY
STOP SOL
KUBOTA
KUBOTA

C GND TO ENGINE T2+ TO AUX BLOCK RED 91-1 B+

C
1
BLK 00-16-5 GND GROUND STUD POWER TERMINAL
T2+
1 S26 BLK 00-16-1 GND
1 T1-
S21
WHT 45-4 STRT ENG
1
EC3
RED 10-1 PWR 10AWG
M 1
RED 1-2-5 PWR 12AWG

ENGINE STARTER
EC4

B B

GD
BLK - MAIN GND
1 TO ENGINE GROUND
BLK - MAIN GND
GD
BLK - AUX GND BLK - AUX GND
1 1 TO AUX BLOCK GROUND
BT1-

0400075
EC4-1

BATTERY
RED - MAIN PWR RED - MAIN PWR
1 1 TO ENGINE STARTER
RED - AUX PWR
BT1+
RED - AUX PWR
1TO AUX BLOCK POWER
T2+

BATTERY CABLE KIT

A A

1001236134-A
1 2 3 4 5 6 7 8

MAF03670A

3121781
 1 2 3 4 5 6 7 8

3121781
IGN RL

H H
X599 CONNECTOR TO
CHASSIS HARNESS X599

86
85
87a
30
87
(SEE SHEET 3-H6)
HARNESS

86
85
3
30
87
1
2
3
4

RL9
X599
GAS ENGINE CHASSIS HARNESS

TO ENGINE STARTER RED 95-2-2 MDL PWR

1
+ TERMINAL STUD
EC8

ORG 8-1 RVS VAL

ORG 7-1 FWD VAL
BLK 00-3-10 GND
YEL 44-7 IGN PWR

BLK 00-1-3 GND

RED 95-2-3 PWR

YEL 2-7-1 IGN RL

YEL 44-2 IGN PWR
FC270
RED 95-2-2 MDL PWR
B
RED 95-2-4 MDL PWR
A

20A
MAIN MDL FUSE
CO2-J2
RED 95-1 MDL PWR

S38
1
G RED 95-2 PWR S35 G
2
RED 95-2-2 PWR S36
22
YEL 2-7-1 IGN RL
23
BLK 00-1-1 GND YEL 44-1 IGN PWR
39 2
BLK 00-1-2 GND S37 BLK 00-1 GND
40 11
RED 25-1 ENG STRT RL RED 25-1 ENG STRT RL
27 1
WHT 26-1 LP VAL WHT 26-1 LP VAL X54 CONNECTOR TO GAS ENGINE
28 12
BLU 6-1 ALT LMP LN BLU 6-1 ALT LMP LN
21 3
ORG 7-1 FWD VAL HARNESS
3 7
ORG 8-1 RVS VAL
4 9
36
YEL CANH CANH BLK 00-3-7 GND CONNECTOR X54
10
GRN CANL CANL S60 BLK 00-3-5 GND
37 8
SHIELD CANSHIELD S61 SHIELD CANSHIELD (SHEET 8-F1)
38 6
S62 GRN CANL CANL
18 5
YEL CANH CANH
19 4
C02-J1 CONNECTOR TO ORG 52-1 GEN ON
13 X54
20
GROUND MODULE J
24 YEL 44-6 IGN PWR
H
25
CONNECTOR C02-J2 G CLEARSKY
26
F
29 SHIELD CANSHIELD SHIELD DIAGNOSTIC C 12
F (SHEET 2-G4) E F
30 GRN CANL CANL CONNECTOR MS202-1 B 11
D YEL CANH CANH
31 RED 95-2-4 DIAG PWR YEL CANH CANH A A 10
A C GRN CANL CANL C03-J1 CONNECTOR

10A
32 RED 95-2-5 DIAG PWR RED 95-2-5 DIAG PWR B MS202-2 9
B B SHIELD CANSHIELD SHIELD CANSHIELD SHIELD CANSHIELD
33 BLK 00-2-5 GND C C 8
FC552 A GRN CANL CANL GRN CANL CANL TO OPTIONS MODULE

DIAG PWR
35 B 7
X551 YEL CANH CANH YEL CANH CANH
17 A 6
BRN 47-9 FUEL LVL C03-J1 PORT
34 MS202-3 1
BLK 00-2 GND YEL 44-3 IGN PWR
14 5
ORG 2-7-4 BCN PWR BLK 00-2-1 GND (SEE SHEET 3-D6)
16 4
ORG 55-3 OSC AXLE LF
11 3
ORG 55-4 OSC AXLE RT
12 X18 2
TAN 3-1 UP VAL YEL 44-5 GEN BOX PWR X18 CONNECTOR TO HARNESS
10 A CO3-J1
ORG 55-2 SPD VAL ORG 52-1 GEN ON GENERATOR OPTION (SEE SHEET 9-H1
9 B
ORG 55-1 BRAKE VAL BLK 00-2-3 GND
8 C OR SHEET 9-D1)
WHT 50-1 DUMP VAL
7
YEL 10-1 STR RT VAL
6
YEL 9-1 STR LT VAL
5
BLK 00-3 GND
15
BRN 47-9 FUEL LVL
1
T10-1
BLK 00-2-4 GND
E 1 E

FUEL LEVEL
T11-2
MS101
BLK 00-3 GND
1
BLK 00-3-7 GND
8
BLK 00-3-5 GND S39 BLK 00-2-2 GND
6 2
BLK 00-3-9 GND ORG 2-7-4 BCN PWR BEACON
10 1
BLK 00-3-1 GND
2 MS155
BLK 00-3-4 GND
5
BLK 00-3-6 GND
7

4460837
GND BUS
BLK 00-3-8 GND
9
BLK 00-3-3 GND
4
BLK 00-3-2 GND
3 X42
BLK 00-3-10 GND ORG 55-3 OSC AXLE LF
11 1 X42 CONNECTOR TO OSCILLATING AXLE
ORG 55-4 OSC AXLE RT
12 2
BLK 00-3-9 GND HARNESS X42 CONNECTOR (SEE SHEET 3-B3)
3
4

BLK 00-3-1 GND

YEL 9-1 STR LT VAL
BLK 00-3-4 GND
YEL 10-1 STR RT VAL
BLK 00-3-6 GND
WHT 50-1 DUMP VAL
BLK 00-3-8 GND
ORG 55-1 BRAKE VAL
BLK 00-3-3 GND
ORG 55-2 SPD VAL
BLK 00-3-2 GND
TAN 3-1 UP VAL
D D

HV3
HV4
HV5
HV6
HV7
HV8

2
1
2
1
2
1
2
1
2
1
2
1
STR LT STR RT DUMP BRAKE 2 SPEED LIFT UP

Figure 7-22. Electrical Schematic

C C

B B

A A

1001236134-A
1 2 3 4 5 6 7 8

MAF03680A

7-23
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7-24
1 2 3 4 5 6 7 8

H KUBOTA KUBOTA H
KUBOTA POST O2 SNSR PRE O2 SNSR
DUAL FUEL ENGINE HARNESS
STARTER
KUBOTA START

M
HARNESS ALTERNATOR DIODE
ALT FUSE START T12- TO
5A 40A AUX BLOCK
IGN LAMP B+

87
30
87a
85
86
HEATER
POWER
SIGNAL
GROUND
HEATER
POWER
SIGNAL
GROUND
GROUND STUD

A
B
3
2
1
1
1
1
1
A
B
87
30
85
86
1
2
D
C
B
A
D
C
B
A
T12-

T7
D5

EC8
EC9
EC6
EC7

RL10

FC273
FC271

MS153
BLK 34-1 GND

RED 26-1 PWR

RED 26-1 PWR
GRN 17 STRT RL
BLK 54-1 SN GND
YEL 30 PRE 02 SN
GRN 54-2 SN GND

BLK 2 PRE 02 HTR

YEL 44-3 IGN PWR

YEL 44-4 IGN PWR
YEL 44-4 IGN PWR
BLU 6-1 ALT LMP IN
WHT 45-4 STRT SIG
WHT 45-4 STRT SIG
BLK 3 POST 02 HTR
GRN 31 POST 02 SN
G S41 G

ORG 60-7 PRE 02 PWR

RED 26-2 STRT RL PWR

RED 26-2 STRT RL PWR
ORG 60-6 POST 02 PWR

RED 25-4 ENG STRT SIG

RED 25-4 ENG STRT SIG
RED 25-3 ENG STRT SIG
EC10
BLK 34-2 GND
1
BLK 34-3 GND
2
GRN 54-2 SN GND
22
YEL 30 PRE 02 SN
21
BLK 2 PRE 02 HTR
3
BLK 54-1 SN GND
24
GRN 31 POST 02 SN
23
BLK 3 POST 02 HTR
X54 4
RED 25-1 ENG STRT RL S46 RED 25-2 ENG STRT
1 9
BLU 6-1 ALT LMP IN GRN 17 STRT RL
3 19
YEL 44-1 IGN PWR YEL 44-2 IGN PWR EC10 CONNECTOR TO
2 7
YEL CAN HI S44 YEL CAN HI
4 28
X54 CONNECTOR TO GAS CHASSIS GRN CAN LO GRN CAN LO GAS ENGINE ECU
5 34
SHIELD CANSHIELD SHIELD WHT 26-3 LP VAL
6 31
HARNESS CONNECTOR WHT 26-1 LP VAL BLK 176 LP VAL RL CONNECTOR
12 41
BLK 00-1 GND S47 S42 ORG 60-1 PWR
11 10
X54 (SHEET 7-G5) ORG 7-1 FWD VAL ORG 60-2 PWR
7 11
BLK 00-3-5 GND
F 8 8 F
ORG 8-1 RVS VAL
9 S43 13
BLK 00-3-7 GND
10 15
16
BLK 1 FUEL PUMP
12
14
BLK 99-1 PWR RL
20
BLK 177 ETV RL
6
YEL 5 ETV PWR SIG
5
S45
17
18
25
26
27

BLK 00-1 GND

29
30

ORG 8-1 RVS VAL

BLK 00-3-7 GND
ORG 7-1 FWD VAL
BLK 00-3-5 GND
32
33

HV2
HV1
35

1
2
1
2
1
GD02
36
GD02 TO 37
E 38 E
ENGINE BLOCK
39
GROUND STUD
40
REVERSE FORWARD
42

WHT 26-2 LP VAL

BLK 176 LP VAL RL
ORN 60-10 LP VAL PWR
RED 175 LP VAL ACT
RED 175 LP VAL ACT
BLK 34-4 LP VAL GND
ORG 60-3 FUEL PUMP PWR
BLK 1 FUEL PUMP
RED 72-1 B+
RED 72-1 B+
RED 72-2 PWR RL
RED 72-3 PWR RL ACT
BLK 99-1 PWR RL
RED 72-4 PWR RL IN
RED 60-5 PWR RL OUT
RED 60-8 ETV SIG PWR
BLK 177 ETV RL
ORN 60-9 ETV RL PWR
YEL 5 ETV PWR SIG

T12+

RL11
RL12
RL13

1
2
1
2
1
3

A
B
FC274

MS156
MS154

86
85
30
87
86
85
30
87
86
85
30
87
T12+ TO AUX

86
85
30
87
86
85
30
87
86
85
30
87
BLOCK POWER

87a
87a
87a

M
STUD 30A
PWR RL
FUEL SELECT FUEL PUMP
KUBOTA KUBOTA
LP SELECT POWER ETV

D D
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-22. Electrical Schematic

C C

B B

A A

1001236134-A
1 2 3 4 5 6 7 8

MAF03690A

3121781
 1 2 3 4 5 6 7

3121781
GFCI HARNESS HEAD & TAIL LIGHTS OPTION
TO EMS SWITCH OUTPUT YEL/RED 2-1-3 GNDE
1
SW12-2

H HARNESS GEN CNTL BOX

HARNESS H
X18 CONNECTOR X18 MS158
YEL/RED 2-1-3 GNDE
TO ENGINE HARNESS A A 1
ORN 52-1 GEN ON ORN 52-1 GEN ON
B B SW19-1

4360336
(SHEET 7-E5 FOR GAS BLK 00-1-4 GEN CNTL BOX GND BLK 00-1-4 GEN CNTL BOX GND YEL/ORG 122-1 LIGHT SIG YEL/ORG 122-1 LIGHT SIG YEL/ORG 122-1 LIGHT SIG
C C 1 1 1
SHEET 6-H6 FOR DIESEL)

HEAD/TAIL LIGHTS
SW19-2 X03-12 X03-12 RL14
YEL/ORG 122-1 LIGHT SIG
86

BLK - 10
GRN - 10
WHT - 10
GENERATOR BLK 00-113-1 LIGHT GND 86

RED/BLK - 10

BLK/WHT - 10
WHT/BLK - 10
MS160 MS159 85
85
4000W 1 HARNESS A
RED 120-2 PWR 87a
LIGHTS

2 B 6 30
WHT 53-1 - WHT 53-1 - WHT 121-1 LIGHT PWR WHT 121-1 LIGHT PWR 30
3 C 5 87
BLK 53-2 - BLK 53-2 - WHT 121-5 LIGHT PWR 87
4 D 4
WHT 121-4 LIGHT PWR
5 E 3

S4
S5
S6
4460892
WHT 121-3 LIGHT PWR
6 F 2

S1
S2
S3
POWER BUS
WHT/BLK - 10 WHT 121-2 LIGHT PWR
1 1 FC279
RED 120-2 PWR
T1-G MS170 B
RED/BLK - 10 RED 120-1 PWR
LIGHT

1 A
10A

T2-Y LB14

BLK - 10
GRN - 10
WHT - 10
BLK/WHT - 10 WHT 121-2 LIGHT PWR
1 1
BLK - 10
1 T3-X 2 T2+
240V RECEPTACLE RED 120-1 PWR TO AUX BLOCK +
T1 3 1

2920113
G BRN - 10 BLK 00-113-3 LIGHT GND G
1 4

RT TAIL LIGHT
BLK - 10 BLK - 10
T2 1 1 T2-
BLU - 10 BLK 00-113 LIGHT GND TO AUX BLOCK -
1 T1-1 T1 T1-2 1
BRN - 10 WHT - 10
T3 1 1
GRN/YEL - 10 BLK - 12
1 T2-1 T2 1 LB13
WHT 121-3 LIGHT PWR
T3 T2-2 1 MS180
BLK - 12 BLK 00-113 LIGHT GND
T3 1 2 4
BLU - 10 WHT - 12 BLK 00-113-3 LIGHT GND
1 1 CB1-1 3 1

2920113
BLK - 12 BLK - 12 BLK 00-113-4 LIGHT GND BLK 00-113-4 LIGHT GND
T4-1 T4 T4-2 1 4 2

4360070
LT TAIL LIGHT
GRN/YEL - 10 GRN - 10 WHT - 12
B 120V
BLK 00-113-1 LIGHT GND

15A
1 1 CB1-2 W 6
GRN - 12 GRN - 12 RECEPTACLE BLK 00-113-5 LIGHT GND
T5-1

CIRCUIT BREAKER
T5 1 G 5
BLK 00-113-6 LIGHT GND
GROUND BUS

CABLE T5-2 3
T6
LB11
WHT 121-4 LIGHT PWR
LT HEADLIGHT 1
BLK 00-113-5 LIGHT GND
2

PLATFORM JUNCTION
BOX OR (CE MACHINES)

F F
LB12
WHT 121-5 LIGHT PWR
RT HEADLIGHT 1
BLK 00-113-6 LIGHT GND
2

WORK LIGHT OPTION

BLK 00-112-3 GND

2 2
WHT 111-3 PWR WORKLIGHT 2
1 LB15 & LB16 CONNECTOR 1
LB16 LB16
TO WORK LIGHT 1 & 2

4 WITH WORK LIGHT OPTION

MS301 CONNECTOR TO HARNESS
3 OR HARNESS
MS301 CONNECTOR BLK/WHT 00-112-1 GND
2 X55 CONNECTOR WHEN
(SEE SHEET 4-E1) ORG 111-1 PWR S54
1
S55 BLK 00-112-2 GND FLOOLIGHTS ARE EQUIPPED
E MS301 2 2 E
WHT 111-2 PWR WORKLIGHT 1
1 1
GEN CNTL LB15 LB15
5A
HARNESS

A
B
FC275
FLOOD LIGHT OPTION (QUANTITY 2 PER MACHINE)
X55 CONNECTOR TO
HARNESS BLK 00-112-5 GND
2
BLK 00-112-4 GND WHT 112-1 FLD LT FLOODLIGHT 1
LB15 AND LB16 CONNECTOR 2 1
D GFCI WHT 111-4 PWR S56 D
X56

YEL 200 GEN CNTL BOX PWR

1
(WHEN FLOOLIGHTS
X55
ARE EQUIPPED)

YEL 2-1-2/44-5 GEN CNTL BOX PWR

HARNESS 0861572 HARNESS
X18 CONNECTOR GEN CNTL BOX
X18 MS161
YEL 2-1-2/44-5 GEN CNTL BOX PWR YEL 200 GEN CNTL BOX PWR
TO ENGINE HARNESS A A
ORN 52-1 GEN ON ORN 52-1 GEN ON
B B
(SHEET 7-E5 FOR GAS BLK 00-1-4 GEN CNTL BOX GND BLK 00-1-4 GEN CNTL BOX GND
C C 1
SHEET 6-H6 FOR DIESEL) WHT 111-4 PWR
2
WHT 112-1 FLD LT
3

BLK - 10
GRN - 10
WHT - 10
HARNESS WHT 112-2 FLD LT

RED/BLK - 10

BLK/WHT - 10
WHT/BLK - 10
MS162 MS163 4
4360336

WHT 21B - WHT 21B -

1 A 5
WHT 22B - WHT 22B -
2 B 6
FLOOD LIGHT SW

WHT 5B - WHT 5B -
3 C PLATFORM SW20
WHT 6B - WHT 6B -
4 D
WHT 12A - WHT 12A - RECEPTACLE
5 E

S4
S5
S6
WHT 13A - WHT 13A -
6 F

S1
S2
S3
WHT/BLK - 10

Figure 7-22. Electrical Schematic

1
T1-G
RED/BLK - 10
1 240V RECEPTACLE X57
WHT 112-2 FLD LT
T2-Y 1
C FLOODLIGHT 2 C

BLK - 10
PLATFORM JUNCTION

GRN - 10
WHT - 10
BLK/WHT - 10 BLK 00-112-6 GND
1 2
BOX
T3-X
CABLE BLK - 10
1
BLK - 8 BLK - 8 BLK - 10
1 1 1
T1 T1-1 T1 T1-2
WHT - 10
1
BLK - 8 BLK - 8 BLK - 12
1 1 1
WHT - 10
T2 T2-1 T2 1
T2-2
BRN - 8 BRN - 8 RED - 10
1 1 1
BLK - 12
T3 T3-1 T3 T3-2 1
BLU - 8 BLU - 8 WHT - 12 BLK - 12
1 1 1 CB1-1 B
BLK - 12 WHT - 12
T4 T4-1 T4 T4-2 1
4360070

GRN - 10 GRN - 12
W 120V RECEPTACLE
15A

1 CB1-2 G
GRN/YEL - 8 GRN/YEL - 8 GRN - 12
CIRCUIT BREAKER

1 1 1
GRN - 10
T5 T5-1 T5 1
T5-2

T6
B B

BLK - 10
WHT - 10
Z
RED - 10
Y
GRN - 10
X WELDER PLUG
G

A A

1001236134-A
1 2 3 4 5 6 7 8

MAF03700A

7-25
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7-26
1 2 3 4 5 6 7 8

Load Sense Harness

Cable
D X550 D
RED CABLE
1 J2
WHT CABLE RED CABLE
2 1
Analyzer Port Connector 3
GRN CABLE GRN CABLE
2
BLK CABLE
4 3
SHIELD SHLD YEL CAN HI
4
5
6
7
LSS MODULE
8
GRN CAN LO
9
10
WHT CABLE
11
BLK CABLE
12
SHIELD SHLD

12
11
10
J4B 9
1 8
2 7
3 6
LSS MODULE
4 5
To connector J4A 5 4
6 3
on sheet 4-H2 7
BLK J1-1 GND BLK J1-1 GND
C 2 C
WHT J1-2 POWER WHT J1-2 POWER
8 1
YEL CAN HI
9 J1
GRN CAN LO
10
11
12

B B
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-22. Electrical Schematic

A A

1001236134-A
1 2 3 4 5 6 7 8
MAF03710A

3121781
 3121781

Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417

Visit our website for JLG Worldwide Locations.

www.jlg.com