Professional Documents
Culture Documents
Models
G5-18A & 2505H
Agrovector
25.5
S/N 0160053000 & After including
0160051045, 0160051047, 0160051049,
0160051194 & 0160051359
31200926
Original
May 9, 2013
EFFECTIVITY PAGE
May 9, 2013 - A - Original Issue Of Manual
31200926
Machine Configuration
Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur
Fuel Decal (1) as indicated below.
If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as
Ultra Low Sulfur (ULS) from this point forward.
If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to
as Low Sulfur (LS) from this point forward.
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
1001125387 A
OAH2300
31200926
SECTION CONTENTS
Section
Subject
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Page
1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-2
1-2
1-3
1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.1
2.2
2.3
2.4
2.5
2.6
Section 3
Boom
2-2
2-3
2-11
2-13
2-16
2-19
...........................................................
3-1
3-2
3-3
3-3
3-3
3-9
3-10
3-11
3-12
3-13
3-15
...........................................................
4-1
4-2
4-3
4-3
4-3
4-10
4-11
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
Section 4
Cab
4.1
4.2
4.3
4.4
4.5
4.6
Section
Subject
Page
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5-1
5-2
5-3
5-3
5-3
5-9
5-10
5-11
5-11
5-12
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.1
6.2
6.3
6.4
6.5
6-2
6-3
6-3
6-3
6-3
...........................................................
7-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7-4
7-7
7-7
7-8
7-10
7-11
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
Section 7
Engine
7.1
7.2
7.3
7.4
7.5
7.6
7.7
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
ii
8-3
8-4
8-4
8-4
8-4
8-5
8-7
8-10
8-11
8-12
8-13
8-26
Section
Subject
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
Page
9-1
9-3
9-4
9-4
9-7
9-15
9-17
9-18
9-19
9-21
9-22
9-26
9-32
9-34
9-39
iii
Section
iv
Subject
Page
Section 1
Safety Practices
Contents
PARAGRAPH
1.1
1.2
1.3
1.4
1.5
1.6
1.7
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.1
Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1
Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2
Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.3
General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.4
Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-4
1-4
1-1
Safety Practices
1.1
INTRODUCTION
1.4
1.5
SAFETY INFORMATION
1.5.1
1.2
DANGER
WARNING
DISCLAIMER
1.3
CAUTION
1-2
Safety Practices
1.6
SAFETY INSTRUCTIONS
1.6.1
Personal Hazards
1.6.2
Equipment Hazards
1.6.3
General Hazards
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.
1-3
Safety Practices
1.6.4
Operational Hazards
1.7
SAFETY DECALS
1-4
Section 2
General Information and Specifications
Contents
PARAGRAPH
2.1
2.2
2.3
2.4
2.5
2.6
TITLE
PAGE
2-2
2-3
2-3
2-7
2-10
2-11
2-11
2-11
2-11
2-12
2-12
2-13
2-13
2-15
2-16
2-16
2-17
2-18
2-19
2-19
2-1
2.1
MY8350
2-2
2.2
2.2.1
TORQUE CHARTS
SAE Fastener Torque Chart
Tensile
Clamp Load
Stress Area
Torque
Lubricated
Torque
Loctite 242 or 271
OR
Vibra-TITE 111 or 140
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
380
420
580
610
900
940
1120
1285
2020
2320
8
9
16
18
30
31
43
49
96
120
0.9
1.0
1.8
2.0
3.4
3.5
4.8
5.5
10.8
13.5
6
7
12
13
22
23
32
36
75
86
0.7
0.8
1.4
1.5
2.5
2.6
3.5
4
9
10
105
135
12
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
FT-LB
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
[N.m]
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983
FT-LB
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
[N.m]
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224
FT-LB
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
[N.m]
26
29
48
54
75
82
116
136
163
184
224
258
388
449
646
707
918
1000
1142
1258
1598
1768
2074
2380
2754
3128
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
Torque
Loctite 262
OR
Vibra-TITE 131
IN-LB
[N.m]
FT-LB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
[N.m]
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
JLG P/N
Loctite P/N
ND Industries P/N
0100011
0100019
0100071
242TM
271TM
262TM
Vibra-TITE TM 121
Vibra-TITE TM 140
Vibra-TITE TM 131
Description
Medium Strength (Blue)
High Strength (Red)
Medium - High Strength (Red)
MY4650J
2-3
Torque
Loctite 242 or 271
OR
Vibra-TITE 111 or 140
K=.18
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
1320
1580
1800
2860
3280
43
60
68
143
164
5
7
8
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
770
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1045
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
2-4
Tensile
Clamp Load
Stress Area
Torque
Loctite 262
OR
Vibra-TITE 131
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
Clamp Load
See Note 4
Torque
(Dry) K = .17
Torque
Loctite 242 or 271
OR
Vibra-TITE 111 or 140
OR Precoat 85
K=0.16
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
122
139
14
16
114
131
13
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
20
25
35
40
60
65
90
100
130
145
180
205
320
355
515
570
730
845
1095
1225
1545
1710
2025
2300
2690
3020
[N.m]
25
35
50
55
80
90
120
135
175
195
245
280
435
485
700
775
995
1150
1490
1665
2100
2325
2755
3130
3660
4105
FT-LB
20
20
35
40
55
60
85
95
125
135
170
190
300
335
485
535
685
795
1030
1155
1455
1610
1905
2165
2530
2845
[N.m]
25
25
50
55
75
80
115
130
170
185
230
260
410
455
660
730
930
1080
1400
1570
1980
2190
2590
2945
3440
3870
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
Loctite 262
OR
Vibra-TITE 131
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
2-5
Clamp Load
See Note 4
Torque
(Loctite 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85
K=0.18
Torque
(Dry)
K = .20
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
143
164
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
775
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1055
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
(Loctite 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
2-6
Size
PITCH
Tensile
Stress
Area
Sq mm
Clamp
Load
Torque
(Dry or Loctite
263TM)
Torque
(Lub)
KN
[N.m]
[N.m]
Torque
Loctite
Torque
Loctite 262 242 or 271
OR
OR
Vibra-TITE 131 Vibra-TITE
111 or 140
[N.m]
[N.m]
0.5
5.03
2.19
1.3
1.0
1.2
1.4
3.5
0.6
6.78
2.95
2.1
1.6
1.9
2.3
0.7
8.78
3.82
3.1
2.3
2.8
3.4
0.8
14.20
6.18
6.2
4.6
5.6
6.8
20.10
8.74
11
7.9
9.4
12
28.90
12.6
18
13
16
19
1.25
36.60
15.9
26
19
23
28
10
1.5
58.00
25.2
50
38
45
55
12
1.75
84.30
36.7
88
66
79
97
14
16
2
2
115
157
50.0
68.3
140
105
126
154
219
164
197
241
18
2.5
192
83.5
301
226
271
331
20
2.5
245
106.5
426
320
383
469
22
2.5
303
132.0
581
436
523
639
24
353
153.5
737
553
663
811
27
459
199.5
1080
810
970
1130
30
3.5
561
244.0
1460
1100
1320
1530
33
3.5
694
302.0
1990
1490
1790
2090
36
817
355.5
2560
1920
2300
2690
42
4.5
1120
487.0
4090
3070
3680
4290
2-7
Size
PITCH
Tensile
Stress
Area
Clamp
Load
Torque
Lube OR Loctite
242 or 271
OR
Vibra-TITE
111 or 140
K= 0.18
Torque
Loctite 262
OR
Vibra-TITE 131
[N.m]
[N.m]
[N.m]
Torque Dry
or
Loctite 263
K = 0.20
Sq mm
KN
K=0.15
0.5
5.03
3.13
3.5
0.6
6.78
4.22
0.7
8.78
5.47
0.8
14.20
8.85
20.10
12.5
28.90
18.0
25.2
22.7
18.9
1.25
36.60
22.8
36.5
32.8
27.4
10
1.5
58.00
36.1
70
65
55
12
1.75
84.30
52.5
125
115
95
14
16
2
2
115
157
71.6
97.8
200
180
150
315
280
235
18
2.5
192
119.5
430
385
325
20
2.5
245
152.5
610
550
460
22
2.5
303
189.0
830
750
625
24
353
222.0
1065
960
800
27
459
286.0
1545
1390
1160
30
3.5
561
349.5
2095
1885
1575
33
3.5
694
432.5
2855
2570
2140
36
817
509.0
3665
3300
2750
42
4.5
1120
698.0
5865
5275
4395
2-8
Magni Coating*
CLASS 12.9 SOCKET HEAD CAP SCREWS
M6 AND ABOVE*
Size
PITCH
Tensile
Stress
Area
Clamp Load
See Note 4
Sq mm
kN
Torque
Lube OR Loctite
Torque
Torque Dry
242 or 271 Loctite 262
or
OR
OR
Loctite 263
Vibra-TITE Vibra-TITE 131
111 or 140
K = .17
K = .16
K = .15
[N.m]
[N.m]
[N.m]
0.5
3.5
0.6
5.03
6.78
0.7
8.78
0.8
14.20
20.10
12.5
13
12
11
28.90
18.0
21
20
19
27
1.25
36.60
22.8
31
29
10
1.5
58.00
36.1
61
58
54
12
1.75
84.30
52.5
105
100
95
14
16
2
2
115
157
71.6
170
160
150
97.8
265
250
235
18
2.5
192
119.5
365
345
325
20
2.5
245
152.5
520
490
460
22
2.5
303
189.0
705
665
625
24
353
220.0
900
845
790
27
459
286.0
1315
1235
1160
30
3.5
561
349.5
1780
1680
1575
33
3.5
694
432.5
2425
2285
2140
36
817
509.0
3115
2930
2750
42
4.5
1120
698.0
4985
4690
4395
2-9
Torque Wrench:
1. Identify the appropriate application and refer to the
above chart for the correct torque value.
2. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 3 lb-ft (4 Nm).
Size
ORFS
JIC
Flats Method
13 lb-ft
(18 Nm)
13 lb-ft
(18 Nm)
1.5 to 1.75
23 lb-ft
(31 Nm)
23 lb-ft
(31 Nm)
1 to 1.5
40 lb-ft
(54 Nm)
40 lb-ft
(54 Nm)
1.5 to 1.75
10
60 lb-ft
(81 Nm)
60 lb-ft
(81 Nm)
1.5 to 1.75
12
136 lb-ft
(100 Nm)
136 lb-ft
(100 Nm)
1.0 to 1.5
16
115 lb-ft
(156 Nm)
115 lb-ft
(156 Nm)
0.75 to 1.0
20
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
0.75 to 1.0
24
200 lb-ft
(271 Nm)
200 lb-ft
(271 Nm)
0.75 to 1.0
32
N/A
270 lb-ft
(366 Nm)
0.75 to 1.0
2-10
Flats Method:
1. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 3 lb-ft (4 Nm).
2. Mark a dot on one of swivel nut flats and another dot
in line on hex of adapter its connecting to.
3. Use double wrench method while tightening to avoid
hose twist.
4. After connection has been properly tightened, mark
a straight line across the connecting parts, not
covering dots indicating that connection has been
properly tightened.
2.3
SPECIFICATIONS
2.3.1
Travel Speed
Tires
Approximate Speed
1216.50 (305/70D16.5)
1417.50 (355/70D17.5)
10.518
2.3.2
Note: Machine with no load, engine at full throttle, hydraulic oil above 15.6 C (60 F) minimum, engine at
operating temperature.
Approximate Times (sec.)
Function
ANSI
CE & AUS
6.7
6.7
Boom Retract
3.8
3.5
Boom Lift
6.8
6.6
Boom Lower
4.6
8.2
Quick AttachUP
2.0
1.8
Quick AttachDOWN
2.5
2.3
2.3.3
Electrical System
Note: Refer to Section 9.3, Fuses and Relays, for more information.
Battery
Type, Rating
950
1190
185
Group/Series
Alternator
Group 31
14V, 95 Amps
2-11
Engine Make/Model
Deutz TD L4
Displacement
177 in (2.9 L)
Low Idle
High Idle
Horsepower
Peak Torque
Fuel Delivery
Fuel Injection
Air Cleaner
2.3.5
Tires
Note: Standard wheel lug nut torque is 220 lb-ft (300 Nm).
Note: Pressures for Foam filled tires are for initial fill ONLY.
Size
Tire Type
Minimum Ply/
Star Rating
1216.50 (305/70D16.5)
Duraforce
DT
Bias 12 Ply
1417.50 (355/70D17.5)
Outrigger
Bias 14 Ply
MPT-01 TL
Bias 16 Ply
10.518
33x1220
2-12
Fill Type
Pressure
Pneumatic
NonMarking (White)
2.4
2.4.1
Fluids
Engine Crankcase
Axle Differential*
and Wheel End
Hydraulic System
Viscosities
Min
Max
Min
Max
SAE 0W-30
-20
-29
-18
SAE 5W-30
-15
70
-26
21
SAE 10W-30
-9
70
-22
21
SAE 15W-40
120
-15
49
MobilFluid 424
10W-30
15
120
-10
49
MobilFluid 424
10W-30
15
120
-10
49
MobilFluid DTE-13
32
-8
80
-21
27
-20
120
-29
49
MobilFluid 424
10W-30
15
120
-10
49
Mystik Tetrimoly
NLGI Grade 2
-4
104
-20
40
Cylinder Grease
Multipurpose Grease
NLGI Grade 2
-22
104
-30
40
Axle Grease
Multipurpose Grease
NLGI Grade 3
-22
104
-30
40
Ethylene Glycol
and Water
50/50 Mix
Standard
Engine Coolant
60/40 Mix
Cold Weather
#2 Diesel
Fuel
Air Conditioning
Standard
Ultra Low Sulfur
(S 15 mg/kg)
Cold Weather
Tetrafluoroethane
Note: Friction Modifier required for axle differentials, refer to Section 2.4.2, Capacities.
2-13
Engine Crankcase
Axle Differential*
and Wheel End
Hydraulic System
Viscosities
Min
Max
Min
Max
SAE 0W-30
-20
-29
-18
SAE 5W-30
-15
70
-26
21
SAE 10W-30
-9
70
-22
21
SAE 15W-40
120
-15
49
MobilFluid 424
10W-30
15
120
-10
49
MobilFluid 424
10W-30
15
120
-10
49
MobilFluid DTE-13
32
-8
80
-21
27
-20
120
-29
49
MobilFluid 424
10W-30
15
120
-10
49
Mystik Tetrimoly
NLGI Grade 2
-4
104
-20
40
Cylinder Grease
Multipurpose Grease
NLGI Grade 2
-22
104
-30
40
Axle Grease
Multipurpose Grease
NLGI Grade 3
-22
104
-30
40
Ethylene Glycol
and Water
50/50 Mix
Standard
Engine Coolant
60/40 Mix
Cold Weather
#2 Diesel
Fuel
Air Conditioning
Standard
Low Sulfur
(S 500 mg/kg)
Cold Weather
Tetrafluoroethane
Note: Friction Modifier required for axle differentials, refer to Section 2.4.2, Capacities.
2-14
Capacities
9.6 qt (9,1 L)
Fuel Tank
Capacity
24 gal (91 L)
Cooling System
System Capacity
14 qt (13,2 L)
Hydraulic System
System Capacity
24 gal (91 L)
16 gal (61 L)
Brake System
System Capacity
0.7 qt (0,7 L)
Axles
Differential Housing Capacity
Friction Modifier (Front Axle Only)
3.5 qt (3,3 L)
5.4 oz (0,16 L)
24 oz (0,7 L)
21 oz (0,6 L)
1.7 lb (771 g)
2-15
2.5
2.5.1
MAINTENANCE SCHEDULE
10,1st 50 & 50 Hour Maintenance Schedule
EVERY
10
Check Fuel
Level
Check Engine
Oil Level
Check Hydraulic
Oil Level
Check Tire
Condition &
Pressure
Additional
Checks Section 8
Check
Air Filter
Check
Battery
Check Brake
Fluid Level
1st
50
LB/F
T (N
m)
Check Wheel
Lug Nut
Torque
EVERY
50
Drain Fuel/
Water
Separator
Check Engine
Coolant Level
Check Washer
Fluid Level
(if equipped)
OAH2341
2-16
1st
250
Change Axle
Differential Oil
Change Wheel
End Oil
Change Front
Axle Drop
Box Oil
EVERY
250
Check Axle
Differential Oil
Level
Check Wheel
End Oil Levels
Check Enclosed
Cab Air Filter
(if equipped)
Lubrication
Schedule
Check Front
Axle Drop
Box Oil Level
Check
Fan Belt
Check Boom
Wear Pads
EVERY
500
LB/F
T (N
m)
Change Engine
Oil and Filter
Change
Air Filter
Elements
Check LSI
Calibration
(CE & AUS)
Check Wheel
Lug Nut
Torque
OAH2211
2-17
EVERY
1000
Change Axle
Differential Oil
Change Wheel
End Oil
Change
Transmission
Filter
Change Front
Axle Drop
Box Oil
Change
Hydraulic
Fluid & Filters
Check
Hydraulic Tank
Cap
EVERY
1500
Change
Engine Coolant
OAH2220
2-18
2.6
2.6.1
LUBRICATION SCHEDULE
250 Hour Lubrication Schedule
EVERY
250
OAL1980
2-19
2-20
Section 3
Boom
Contents
PARAGRAPH
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
TITLE
PAGE
3-2
3-3
3-3
3-3
3-3
3-3
3-4
3-5
3-6
3-7
3-9
3-9
3-9
3-9
3-10
3-10
3-10
3-11
3-11
3-12
3-12
3-12
3-13
3-13
3-14
3-15
3-1
Boom
3.1
COMPENSATING
CYLINDER
FIRST
BOOM
SECTION
SECOND
BOOM
SECTION
PIVOT PIN
LIFT/LOWER
CYLINDER
TILT
CYLINDER
EXTEND/RETRACT
CYLINDER
AUXILIARY HYDRAULIC
QUICK CONNECTS
MY8380
3-2
Boom
3.2
SAFETY INFORMATION
3.4.1
WARNING
DO NOT service the machine without following all
safety precautions as outlined in the Safety Practices
section of this manual.
3.3
3.3.1
WARNING
3.4
MY8570
3-3
Boom
16. Lower boom to a level position and place a suitable
support under rear of boom. Reposition slings to
each end of boom.
3
MY8580
3.4.2
5
6
MY8590
3-4
Boom
10. Uncap and reconnect extend/retract cylinder fittings
and plugs to extend/retract cylinder tubes and
tighten until wrench-tight. Mark fitting, then torque to
specification. Refer to Section 2.2.3, Hydraulic
Hose Torque Chart.
11. Uncap and reconnect tilt hoses and (if equipped)
auxiliary hoses. Attach both sets to their appropriate
fittings until wrench-tight. Mark fitting, then torque to
specification. Refer to Section 2.2.3, Hydraulic
Hose Torque Chart.
3.4.3
MY8570
12. Remove top and side wear pads from rear of second
boom section.
Note: Tag each pad, backing plate, shim and bolts from
each location.
16. Check the hydraulic fluid level in tank and add fluid
as required.
17. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
11
MY1960
3-5
Boom
16. Pull second boom section out of first boom section
approximately 6 in to 8 in (15 cm to 20 cm).
17. Pull tilt hoses and (if equipped) auxiliary hydraulic
hoses through rear of boom.
18. Remove top, side and bottom wear pads from front
of first boom section.
Note: Tag each pad, backing plate, shim and bolts from
each location.
3.4.4
Note: The use of two slings will allow for better stability.
11
MY1960
Boom
12. Start engine and operate all boom functions several
times to bleed any air out of hydraulic system. Check
for fluid leaks. Check hydraulic fluid level in tank and
add fluid as required.
3.4.5
12
MY2000
13
MY2680
3-7
Boom
15
18
14
19
17
MY2670
16
MY8610
3-8
Boom
3.4.6
3.5
3.5.1
Ma2070
3.5.2
15. Check the hydraulic fluid level in tank and add fluid
as required.
16. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
17. Close and secure the engine cover.
18. Remove Do Not Operate Tags from both ignition key
switch and the steering wheel.
19. Install previously removed attachment to quick
attach assembly.
MAM1390
Boom
The number of shims can vary at each shim point.
3.6
3.6.1
3.5.3
8
9
6
7
MY2660
3-10
Boom
3.6.2
3.7
FORKS
12
15
16
13
14
11
10
18
21
19
20
MH6460
3-11
Boom
3.8
3.8.1
NOTICE
Prop Installation
WARNING
A raised boom can fall if a hydraulic component is
removed. Remove any load, retract the boom and
install the boom prop or a suitable supporting stand
before working under a raised boom.
1. Park the machine on a firm, level surface. Place the
transmission control lever in (N) NEUTRAL, engage
the park brake switch.
2. Raise the boom to an angle of approximately 20
degrees. Shut engine OFF.
3.8.2
Prop Removal
3
2
1
2
MAM1280
3-12
Boom
3.9
WARNING
To avoid instability of the machine, the extend/retract
cylinder MUST BE fully retracted prior to retracting
the lift cylinder. If circumstances prevent retraction of
the extend/retract cylinder first, lower the lift cylinder
the minimum amount necessary and resume
retraction of the extend/retract cylinder as soon as
possible.
WARNING
Properly support the boom before attempting to
proceed with the emergency boom lowering
procedure.
3.9.1
NOTICE
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Supply hydraulic oil must be compatible with hydraulic
oil shown in Section 2.4, Fluids, Lubricants and
Capacities.
Hoses:
Two Hydraulic Hoses - Approximately 10 ft
(3,0 m) each, with a minimum I.D. of
0.375 in. (9,5 mm) and a minimum rating of
4000 psi (275,8 bar).
Fittings:
WARNING
If possible, safely remove and/or secure the load on
the machine before starting the boom lowering
procedure. If load cannot be removed, the machine
load chart MUST be followed.
3-13
Boom
3.9.2
Lowering Procedure
4&5
MAP0040
7
MY3000
3-14
Boom
3.10
TROUBLESHOOTING
Problem
1. Boom will not extend or
retract.
Possible Causes
Remedy
1. Insufficient lubrication.
2. Worn bushing(s).
4. Replace bushing.
3-15
Boom
Problem
6. Rapid boom pad wear.
3-16
Possible Causes
Remedy
3. Contaminated, corroded or
rusted wear pad sliding
surfaces.
Section 4
Cab
Contents
PARAGRAPH
4.1
4.2
4.3
4.4
4.5
4.6
TITLE
PAGE
4-2
4-3
4-3
4-3
4-3
4-3
4-3
4-4
4-5
4-6
4-7
4-7
4-7
4-8
4-8
4-9
4-10
4-11
4-1
Cab
4.1
LSI INDICATOR
(2505H & 25.5)
ACCESSORY CONTROL LEVER
(IF EQUIPPED)
FRAME LEVEL
INDICATOR
POWER OUTLET
JOYSTICK
RIGHT HAND
CONSOLE
HORN BUTTON
LONGITUDINAL LEVEL
INDICATOR (AUS)
STEERING WHEEL
POWER
OUTLET
INSTRUMENT
PANEL
IGNITION SWITCH
ACCELERATOR PEDAL
MY8850
4-2
Cab
4.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in the Safety Practices
section of this manual.
4.3
4.3.1
OPERATOR CAB
Operator Cab Description
4.4
CAB COMPONENTS
4.4.1
Steering Wheel
WARNING
DO NOT weld, grind, drill, repair or modify the cab in
any way. Any modification or damage to cab structural
components requires cab replacement.
To help ensure optimum safety, protection and
performance, replace cab if it is damaged. Refer to
appropriate parts manual for ordering information.
4.3.2
MAH0430
4-3
Cab
4.4.2
6
5
7
9
8
MY2440
4-4
Cab
4.4.3
11
10
MY8860
4-5
Cab
4.4.4
12
MY8870
4-6
Cab
4.4.5
4.4.6
Joystick Replacement
a. Joystick Removal
4.4.7
15
16
14
MY2410
4-7
Cab
4.4.8
a. Removal
1. Park machine on a hard, level surface.
2. Fully retract boom, lower boom, place transmission
control lever in (N) NEUTRAL.
b. Installation
1. Install heater assembly (18) to original orientation.
4.4.9
17
18
MY2430
Cab
4.4.10
MY9020
4-9
Cab
4.5
CAB REMOVAL
WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners or correct size and grade, and torqued to
their specified value.
1
1
2
MY2420
4-10
Cab
4.6
CAB INSTALLATION
21. Turn engine off and wait for engine to cool and check
coolant level. Add coolant as required to bring
coolant to proper level.
22. Install protective cover to front of cab.
23. Install mirrors and all other components as needed,
if removed.
24. Unblock wheels
25. Close and secure engine cover.
26. Start engine and test joystick for proper functions.
27. Remove a Do Not Operate Tag on both ignition key
switch and steering wheel.
WARNING
Avoid breathing exhaust fumes, and prevent engine
operation from becoming a cause of toxic emissions.
NOTICE
When the engine is initially started, run it briefly at low
idle and check the machine for any visual sign of fluid
leakage. STOP the engine immediately if any leakage
is noted, and make any necessary repairs before
continuing.
20. If equipped with optional heater, operate engine until
operating temperature is achieved ensuring that
thermostat has opened.
G5-18A, 2505H, 25.5
4-11
Cab
4-12
Section 5
Axles, Drive Shafts, Wheels and Tires
Contents
PARAGRAPH
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
TITLE
PAGE
5-2
5-3
5-3
5-3
5-3
5-3
5-3
5-3
5-4
5-5
5-6
5-9
5-9
5-9
5-9
5-9
5-9
5-10
5-10
5-11
5-11
5-11
5-11
5-12
5-12
5-13
5-1
5.1
FRONT AXLE
ASSEMBLY
DRIVE SHAFT
REAR STEERING
CYLINDER
FRONT STEERING
CYLINDER
REAR AXLE
ASSEMBLY
MY8880
5-2
5.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in the Safety Practices
section of this manual.
5.3
GENERAL INFORMATION
5.4
5.4.1
AXLE ASSEMBLIES
Axle Serial Number Plate
5.4.4
Axle Maintenance
5.4.2
Axle Specifications
5.4.3
5-3
Axle Removal
WARNING
5
MY8890
1
5
5-4
MY2091
Axle Installation
4. Position the axle under the frame, and align with the
holes in the frame.
5. Install the axle with capscrews, locknuts and the axle
plates. Torque the front and rear axles to 420 lb-ft
(569 Nm).
6. Install the drive shaft assemblies. (Refer to Section
5.5.5, Drive Shaft Installation.)
7. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle
according to the alignment marks made earlier. If
installing a new axle, note the position of the
driveshaft yoke at the transmission. Align the
driveshaft yoke on the axle in the same plane as the
yoke on the transmission.
8. Tighten the axle oil drain plug (4), loosen and
remove the axle oil fill plug (5). Tighten the drop box
oil drain plug (4), loosen and remove the drop box oil
fill plug (5). Fill axle with the appropriate oil. Refer to
Section 2.4, Fluids, Lubricants and Capacities, for
proper oil and capacities.Rotate wheel hubs 90
degrees so the drain plug (4) becomes the fill plug.
Fill wheel hubs with the appropriate oil. Refer to
Section 2.4, Fluids, Lubricants and Capacities, for
proper oil and capacities.
9. Install the wheel and tire assemblies. (Refer to
Section 5.6.2, Installing Wheel and Tire Assembly
onto Machine.)
10. Carefully remove the jack, hoist or overhead crane
and sling supporting the axle.
5-5
Problem
1. Excessive axle noise while
driving.
5-6
Possible Causes
Remedy
Problem
4. Oil leaking from axle
(differential housing and/or
axle housings).
Possible Causes
Remedy
2. Tighten fittings.
2. Replace o-ring.
1. Tighten fittings.
5-7
Problem
7. Axle overheating.
5-8
Possible Causes
Remedy
5.5
DRIVE SHAFTS
TO REAR AXLE
5.5.1
4
2
2
1
MY8900
TO FRONT AXLE
5.5.2
5.5.4
5.5.3
5.5.5
5-9
5.6
WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.
It is recommended that a replacement tire to be the same
size, ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using an approved replacement tire, It is recommended
that replacement tires have the following characteristics:
MZ6020
5-10
5.6.1
5.7
5.8
5.8.1
BRAKES
Brake Disc Inspection
MAH0460
1
8
7
2
6
4
OAH0990
5-11
5.9
5.9.1
NOTICE
WARNING
MACHINE HAS NO TOWING BRAKES. Towing
vehicle must be able to control machine at all times.
On highway towing is NOT permitted.
WARNING
BLOCK ALL FOUR WHEELS TO PREVENT
MACHINE FROM MACHINE ROLL AWAY. Failure
to follow instructions could cause death or serious
injury.
5-12
Towing Procedure
4 (Not Shown)
MY2050
5-13
5-14
Section 6
Transmission
Contents
PARAGRAPH
6.1
6.2
6.3
6.4
6.5
TITLE
PAGE
6-2
6-3
6-3
6-3
6-3
6-3
6-3
6-4
6-4
6-1
Transmission
6.1
TRANSMISSION ASSEMBLY
COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the
operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following
illustration identifies the components that are referred to throughout this section.
HYDROSTATIC
TRANSMISSION
FORWARD
RELIEF
VALVE
SHUTTLE VALVE
REVERSE
RELIEF
VALVE
DIRECTIONAL
CONTROL VALVE
6-2
MY8920
Transmission
6.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in the Safety Practices
section of this manual.
6.3
TRANSMISSION DESCRIPTION
6.4
6.4.1
TRANSMISSION SPECIFICATIONS
Transmission Maintenance
6.5
TRANSMISSION REPLACEMENT
6.5.1
Transmission Removal
6-3
Transmission
15. Vertically secure transmission and implement pump
with a lifting strap or chain. Use a suitable hoist or
overhead crane. Operate hoist or crane to remove
slack from chain, but DO NOT raise transmission at
this time.
16. Remove two bolts that attach transmission to engine.
WARNING
The transmission may move while hoisting it out of
the chassis. Carefully move the transmission and
adjust the sling as needed. Keep fingers, hands, legs
and other body parts clear of the transmission.
17. Carefully remove transmission and pump from the
machine. Avoid causing damage to transmission or
surrounding parts.
18. Lift transmission and pump clear of machine, and
lower it onto suitable supports or secure it to a stand
built especially for transmission or engine service.
Secure transmission and pump so that it will not
move or fall.
6.5.2
Transmission Disassembly
6.5.3
Transmission Installation
NOTICE
DO NOT use flushing compounds for cleaning
purposes.
11. Run engine for two minutes at idle to help bleed any air
from hydraulic system.
12. Operate all boom functions to ensure any air is
removed from hydraulic system.
13. Retract and level boom, recheck level of the fluid in
the reservoir.
14. Add oil as necessary to bring fluid level up until it
reaches FULL mark on reservoir. Recheck oil level
when it reaches operating temperature 180200 F
(8394 C).
15. Recheck all drain plugs, lines, connections, etc., for
leaks, and tighten where necessary.
16. Close and secure the engine covers.
17. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling. Failure to follow the safety practices
could result in death or serious injury.
1. Use a lifting strap or chain attached to a hoist or
overhead crane to position transmission and pump
within the chassis.
2. Insert the two bolts that attach transmission to
engine. Torque to 154 lb-ft (210 Nm).
3. Remove hoist or overhead crane and sling.
4. Uncap and reconnect previously labeled hoses and
electrical connections to their appropriate locations.
5. Remove fill port screw and pre-fill transmission to
top of fill port. Install screw and torque to 398 lb-ft
(540 Nm).
6. Install front fender support bar.
6-4
Section 7
Engine
Contents
PARAGRAPH
7.1
7.2
7.3
7.4
7.5
7.6
7.7
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3
Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . .
7.1.4
Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1
Surge Tank Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2
Radiator/Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2
Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3
After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.1
Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.2
Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.1
Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.2
Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.1
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.2
Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . .
7.7.3
Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
7-2
7-2
7-2
7-2
7-3
7-4
7-4
7-4
7-7
7-7
7-7
7-7
7-8
7-8
7-8
7-9
7-10
7-10
7-10
7-11
7-11
7-12
7-12
7-1
Engine
7.1
7.1.1
INTRODUCTION
Disclaimer and Scope
7-2
7.1.2
7.1.3
Engine
7.1.4
Component Terminology
THERMOSTAT
FUEL PUMP
FUEL FILTER
OIL FILTER
ALTERNATOR
TURBOCHARGER
STARTER
MY8930
7-3
Engine
10
10
3 9
7.2
7.2.1
7.2.2
MY8970
Engine
29. Loosen and remove the lower hydraulic oil cooler
hose. Cap all fittings and openings to keep dirt &
debris from entering the hydraulic system.
19. Loosen the mounting bolts and move the surge tank
(4) to access the cooling package lifting eye mounts.
20. Remove the top radiator hose (7) and hose from the
surge tank attached to the radiator. Cap all fittings
and openings to keep dirt & debris from entering the
cooling system.
14
14
14
14
MY8940
15
13
11
12
MY9000
MY8950
7-5
Engine
Note: Retain the key located on the fan motor shaft.
16
16
2. Install the fan motor to the fan guard. The fan motor
can only be installed one way.
7-6
Engine
28. Install and secure the battery cover.
7.4
FUEL SYSTEM
7.3
7.4.1
Diesel Fuel
7.4.2
7-7
Engine
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
7.5
7.5.1
ULS
c. Inspection
Note: If a leak is suspected between the fuel and hydraulic
oil tank, contact the local JLG dealer.
1. Inspect the fuel/hydraulic oil tank thoroughly for any
cracks, slices, leaks or other damage.
2. Plug all openings except one elbow fitting. Install the
elbow fitting, and apply approximately 1-1.5 psi
(0.07-0.10 bar) of air pressure through the elbow.
Check the tank for leaks by applying a soap solution
to the exterior and look for bubbles to appear at the
cracked or damaged area.
1
LS
7.4.3
MY8980
Engine
7.5.2
7-9
Engine
7.6
CAUTION
7.6.1
7.6.2
MY9010
7-10
Engine
7.7
ENGINE REPLACEMENT
3
2
MY8970
7.7.1
Engine Removal
16. Remove the four motor mount bolts that attach the
engine to the frame.
17. Carefully lift the engine from the machine. Avoid
causing damage to the surrounding parts.
18. Lift the engine clear of the machine, and lower it onto
suitable supports or stand. Secure the engine so
that it will not move or fall.
7-11
Engine
7.7.2
7.7.3
Engine Installation
NOTICE
During the full throttle check:
DO NOT operate any hydraulic function.
DO NOT steer or apply any pressure to the
steering wheel.
Keep the transmission in NEUTRAL (N).
15. Check for leaks from the engine, main hydraulic pump
and lines, transmission, hydraulic reservoir and fuel
tank. Check the levels of all fluids and lubricants. Fill
as required.
16. Purge the hydraulic system of air by operating all
boom functions through their entire range of motion
several times. Check the hydraulic oil level.
17. Check for proper operation of all components.
20. Install the engine cover. Close and secure the cover.
7-12
Section 8
Hydraulic System
Contents
PARAGRAPH
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
TITLE
PAGE
8-3
8-4
8-4
8-4
8-4
8-4
8-4
8-5
8-5
8-5
8-6
8-6
8-6
8-6
8-7
8-10
8-10
8-10
8-10
8-11
8-11
8-11
8-11
8-12
8-12
8-12
8-13
8-13
8-14
8-16
8-17
8-18
8-18
8-19
8-21
8-22
8-23
8-24
8-1
Hydraulic System
8.12
8-2
Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.1
General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.2
General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.3
Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.4
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.5
General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.6
General Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.7
Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.8
Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
8-26
8-26
8-26
8-27
8-27
8-27
8-28
8-28
8-29
Hydraulic System
8.1
HYDRAULIC COMPONENT
TERMINOLOGY
COMPENSATING
CYLINDER
HYDRAULIC RESERVOIR AND
LIFT/LOWER CYLINDER
(UNDER BOOM)
MAIN CONTROL
VALVE
EXTEND/RETRACT
CYLINDER
TILT CYLINDER
HYDRAULIC
FILTER
HYDROSTATIC
DRIVE PUMP
IMPLEMENT
PUMP
FRONT AXLE
DRIVE MOTOR
STEERING
CYLINDER
MY8690
8-3
Hydraulic System
8.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in the Safety Practices
section of this manual.
8.4
8.5
8.3
GENERAL INFORMATION
8-4
SPECIFICATIONS
8.5.1
Replacement Considerations
8.5.2
Hydraulic System
NEVER replace a hydraulic hose or other component
with a part not specifically designed for this machine. Use
only factory approved parts for best performance and
safety.
Removal and replacement of hoses, tube lines, fittings,
etc. usually involves straightforward procedures. When
removing a hydraulic hose or other component, be aware
that o-rings are used throughout the hydraulic system.
ALWAYS replace a used o-ring with a new part.
8.6.2
8.6
8.6.1
MY8640
1. Attach 5000 psi (345 bar) gauge to the test port (1)
at the rear of the implement pump to check the
system pressure. Make sure the gauge is visible
from inside the cab.
2. See Section 8.6, Hydraulic Pressure Diagnosis, for
start up procedure. Check the main control pressure
with the park brake on and the service brake off at
full throttle. Retract a boom circuit function until the
cylinder bottoms. The main control valve pressure
should be 3585-3665 psi (247-252,7 bar) at full
throttle. Repeat for each boom circuit to verify the
correct main control valve pressure.
2
MY2110
8-5
Hydraulic System
8.6.3
8.6.5
4
3
5
6
MY8640
MY8650
8.6.4
1. Attach 5000 psi (345 bar) gauge to the test port (5)
at the rear of the implement pump to check the
system pressure. Make sure the gauge is visible
from inside the cab.
2. See Section 8.6, Hydraulic Pressure Diagnosis, for
start up procedure. Check the boom function
pressure with the park brake on and the service
brake off at full throttle. Retract each boom circuit
function until the cylinder bottoms. Each circuit
function pressure should be 3585-3665 psi
(247-252,7 bar) at full throttle.
Note: With the machine at operating temperature, the
3585-3665 psi (247-252,7 bar) pressure reading at the
main control valve is 125 psi (13,3 bar) HIGHER than the
3450-3550 psi (237,8-244,7 bar) of each individual valve
section function. DO NOT adjust the main control valve
relief pressure below 3585-3665 psi (247-252,7 bar).
To check individual valve section pressures, install a tee
and test port between the cylinder being checked and
the corresponding valve section on the main control
valve.
8.6.6
8-6
3.45 BAR
FILTER, RETURN
VALVE, STEER
SELECT
CYLINDER, LIFT
FRONT STEERING
CYLINDER
CF
STEERING
ORBITAL
LS
EF
CYLINDER, TILT
LS
1B 1A
VALVE, PRIORITY
1a
1b
2a
2b
2B 2A
3a
3b
3B 3A
FRONT AUX
CYLINDER, CROWD
11 CC
11 CC
STANDARD-VARIABLE
SPEED FAN DRIVE
FILTER, CHARGE
3.45 BAR
4B 4A
11 CC
4a
4b
DR
DR
DR
T2
X1
T1
T2
X2
3A
3B
DRIVE
PUMP
Yst
MH
P2
TELE
P1
26.2 BAR
PS
Fa
P3
AUX
JOYSTICK
TILT
P4 P5
31.8
CC
MA
MB
P6
JS4
14.3
CC
JS2
IMPLEMENT
PUMP
FRONT AXLE
PARK BRAKE
Vg min
M1
Vg max
MASTER CYLINDER
Sa
T1
T2
INCHING VALVE
FRONT AXLE
SERVICE BRAKE
VALVE, PARK
BRAKE RELEASE
DRIVE
MOTOR
8.7
CYLINDER
REAR STEERING
Hydraulic System
HYDRAULIC SCHEMATIC
MAL2710B
8-7
2.41 BAR
241 BAR
8-8
3A
FRONT AUX
3B
1ST
3A
2ND
-ELECTRIC-
FRONT AUXILIARY
3A
2ND
FRONT AUX
1ST
3B
REAR AUX
FRONT AUX
OPTIONAL SECOND
AUXILIARY
OPTIONAL REAR
3B
REAR AUX
AUXILIARY OPTIONS
Hydraulic System
G5-18A
MAL2720B
3A
FRONT AUX
3A
2ND
OPTIONAL SECOND
FRONT AUXILIARY
-ELECTRIC-
3B
1ST
FRONT AUX
OPTIONAL REAR
AUXILIARY
3B
REAR AUX
3A
1ST
2ND
FRONT AUX
STEERING
3B
REAR AUX
LS
CF
EF
P1
AUXILIARY OPTIONS
TO IMPLEMENT VALVE
Hydraulic System
MAL2730B
8-9
Hydraulic System
8.8
HYDRAULIC RESERVOIR
8.8.3
8.8.1
8.8.2
8-10
Hydraulic System
8.9
8.9.1
8.9.3
MY8640
Pump Test
8.9.2
8-11
Hydraulic System
8.10
8.10.2
1. Install the motor onto the front axle and secure with
the four previously removed bolts (4). Torque to
72 lb-ft (97 Nm). Use only new seals.
8.10.1
3. Fill the motor with hydraulic fluid through the fill plug
(5) before starting the machine.
4. Refill the hydraulic reservoir and inspect for leaks
around the machine.
5. Properly connect the battery.
6. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
7. Inspect for leaks and check all fluid levels.
8. Close and secure the battery and engine covers.
9. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
4
5
3
MY8660
8-12
Hydraulic System
8.11
8.11.1
CONTROL VALVES
NOTICE
1
MY2110
FRONT OF MACHINE
8-13
Hydraulic System
e. Main Control Valve Assembly
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
Assemble each Valve Section
8.11.2
f.
8-14
Hydraulic System
7. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without
moving the machine or operating any hydraulic
functions.
1
2
MY2161
8-15
Hydraulic System
3. DO NOT open the brake bleeder without holding the
tubing firmly on the bleeder. There is pressure at the
brakes. Have an assistant depress the brake pedal.
Carefully open the bleeder with a 12 mm wrench.
Close the brake bleeder when air bubbles no longer
appear in the oil. Release the brake pedal. Remove
the tubing from the brake bleeder.
4. If bleeding the service brake circuit, install a vacuum
pump on the brake reservoir and remove the
remainder of the trapped air from the brake system.
8.11.3
The park brake valve is located in the cab, below the seat.
a. Park Brake Valve Removal
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the battery and engine covers. Allow the
system fluids to cool.
4. Properly disconnect the battery.
5. Remove the four capscrews holding the cover below
the seat. The park brake valve is mounted on the
backside of the cover.
6. Label, disconnect and cap the hydraulic hoses on
each side and bottom of the park brake valve.
Disconnect and cap all hoses, fittings, etc.
7. Remove the two capscrews, and two lockwashers
mounting the park brake valve to the cover.
8-16
MY2150
Hydraulic System
4. Properly connect the battery.
5. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without
moving the machine or operating any hydraulic
functions.
8.11.4
8-17
Hydraulic System
6. Inspect the hand brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
7. Install the hand brake cover with the two capscrews.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
9. Close and secure the battery and engine covers.
10. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
5
4
7
ANSI
MU7720
CE & AUS
8-18
8.11.6
8.11.5
Hydraulic System
c. Pilot Select Valve Installation
8.11.7
Inching Valve
1
MY2330
8-19
Hydraulic System
4. Inspect the cartridge for proper operation. Check by
shifting the spool to ensure that it is functioning
properly. Check that the spring is intact. Inspect the
cartridge interior for contamination.
5. Inspect internal passageways of the inching valve for
wear, damage, etc. If inner surfaces of the manifold
DO NOT display an ultra-smooth, polished finish, or
components are damaged in any way, replace the
manifold or appropriate part. Often, dirty hydraulic
fluid causes failure of internal seals and damage to
the polished surfaces within the unit.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
6. Install the cartridge in the inching valve housing.
c. Inching Valve Installation
1. Attach the inching valve to the mounting plate on the
frame using the socket head capscrews.
2. Connect the hydraulic hoses, fittings, etc., to the
inching valve.
3. Check the routing of all hoses and wiring for sharp
bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all hose clamps.
4. Properly connect the battery.
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the
machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the battery and engine covers.
9. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
MY2330
8-20
Hydraulic System
8.11.8
Priority Valve
MY2971
8-21
Hydraulic System
8.11.9
8-22
Hydraulic System
8. Close and secure the battery and engine covers.
9. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
d. Steering Test
8.11.10
MY8670
8-23
Hydraulic System
6. Install the solenoid valve and cartridge in the quick
attach valve housing.
c. Quick Attach Installation
1. Attach the quick attach valve to the fittings on the
boom head.
2. Connect the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the quick attach.
2
VARIABLE SPEED
REVERSING FAN
(if equipped)
1
2
8.11.11
8-24
MY8680
Hydraulic System
4. Inspect the solenoid cartridge for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
5. Inspect internal passageways of the variable speed
fan valve for wear, damage, etc. If inner surfaces of
the manifold DO NOT display an ultra-smooth,
polished finish, or components are damaged in any
way, replace the manifold or appropriate part. Often,
dirty hydraulic fluid causes failure of internal seals
and damage to the polished surfaces within the unit.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
6. Install the solenoid valve and cartridge in the variable
speed fan valve housing.
c. Variable Speed Fan Valve Installation
1. Connect the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the variable fan valve.
2. Refer to Section 7.2.2, Radiator/Oil Cooler
Replacement, for detailed installation instructions.
3. Properly connect the battery.
4. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the
machine or operating any hydraulic functions.
5. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
6. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
7. Close and secure the battery and engine covers.
8. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
d. Variable Speed Fan Valve Test
1. Turn the ignition switch to the ON position, activate
the variable speed fan switch to the ON position.
2. Place a piece of paper over the face of the radiator
core. If the paper is held in place, the fan is rotating
in the right direction.
3. If further troubleshooting is required, refer to Section
8.7, Hydraulic Schematic, or Section 9.4, Electrical
System Schematics.
8-25
Hydraulic System
8.12
HYDRAULIC CYLINDERS
1
2
8.12.1
8.12.2
NOTICE
Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the
cylinder tube.
3. If applicable, remove the counterbalance valve from
the side of the cylinder barrel.
8-26
2
6
MAH0160
NOTICE
DO NOT tamper with or attempt to adjust the
counterbalance valve cartridge. If adjustment is
necessary, replace the counterbalance valve with a
new part.
4. Extend the rod (5) to allow access to the base of the
cylinder.
NOTICE
Protect the finish on the rod at all times. Damage to the
surface of the rod can cause seal failure.
5. Using a pin spanner wrench, unscrew the head
gland (6) from the barrel (1). A considerable amount
of force will be necessary to remove the head gland.
Carefully slide the head gland down along the rod
toward the rod eye end, away from the cylinder
barrel.
Hydraulic System
NOTICE
When sliding the rod and piston assembly out of the
tube, prevent the threaded end of the tube from
damaging the piston. Keep the rod centered within the
tube to help prevent binding.
6. Carefully pull the rod assembly along with the head
gland out of the cylinder barrel.
7. Fasten the rod end in a soft-jawed vise, and put a
padded support under and near the threaded end of
the rod to help prevent damage to the rod.
8. Remove the set screw (3) from the piston (4).
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod
before the piston can be removed.
Some cylinder parts are sealed with a special organic
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic
oil, then heat the part(s) uniformly to break the bond. A
temperature of 300-400 F (149-204 C) will destroy the
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal
while the parts are still hot. The sealant often leaves a
white, powdery residue on threads and other parts, which
must be removed by brushing with a soft brass wire brush
prior to reassembly.
8.12.4
Cylinder Inspection
8.12.5
9. Remove the piston head (4) from the rod (5) and
carefully slide the head gland (6) off the end of the
rod.
10. Remove all seals, back-up rings and o-rings (2) from
the piston head and all seals, back-up rings and orings from the head gland.
Note: The head gland bearing will need to be inspected
to determine if replacement is necessary.
2
6
8.12.3
MAH0160
8-27
Hydraulic System
Note: The Crowd cylinder has a spacer that MUST be
installed over the rod AFTER the head gland and
BEFORE the piston head.
3. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod (5) to prevent any damage to the rod.
8.12.6
NOTICE
NOTICE
Avoid using excessive force when clamping the
cylinder barrel in a vise. Apply only enough force to
hold the cylinder barrel securely. Excessive force can
damage the cylinder barrel.
5. Place the cylinder barrel (1) in a soft-jawed vise or
other acceptable holding equipment if possible.
NOTICE
When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the
cylinder barrel from damaging the piston head. Keep
the cylinder rod centered within the barrel to prevent
binding.
8.12.7
Steering Cylinders
8-28
Hydraulic System
8.12.8
Piston
CB Valve
Valve Screw
FC Valve
Set Screw
300-400 lb-ft
(406-542 Nm)
1800-2000 lb-ft
(2440-2712 Nm)
45-50 lb-ft
(61-67,7 Nm)
20-25 lb-ft
(27-33,8 Nm)
30-35 lb-ft
(40,6-47,5 Nm)
b. Extend/Retract Cylinder
Head
Piston
Valve
Valve Screw
Set Screw
200-250 lb-ft
(271-339 Nm)
200-240 lb-ft
(271-325 Nm)
44 lb-ft
(60 Nm)
10-12 lb-ft
(14-16 Nm)
60-69 lb-ft
(81-94 Nm)
Head
Piston
Valve
Valve Screw
Set Screw
300-400 lb-ft
(406-542 Nm)
1400-1500 lb-ft
(1898-2034 Nm)
44 lb-ft
(60 Nm)
10-12 lb-ft
(14-16 Nm)
Head
Piston
Valve
Valve Screw
Set Screw
300-400 lb-ft
(406-542 Nm)
1400-1500 lb-ft
(1898-2034 Nm)
44 lb-ft
(60 Nm)
10-12 lb-ft
(14-16 Nm)
c. Tilt Cylinder
d. Compensating Cylinder
8-29
Hydraulic System
8-30
Section 9
Electrical System
PARAGRAPH
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
TITLE
PAGE
9-3
9-4
9-4
9-4
9-4
9-5
9-6
9-7
9-15
9-15
9-17
9-17
9-18
9-18
9-18
9-19
9-19
9-20
9-20
9-21
9-21
9-22
9-22
9-23
9-23
9-24
9-24
9-25
9-26
9-26
9-27
9-28
9-29
9-31
9-32
9-1
Electrical System
9.12
9.13
9.14
9-2
9-32
9-32
9-33
9-34
9-34
9-34
9-39
9-39
Electrical System
9.1
ELECTRICAL COMPONENT
TERMINOLOGY
DIAGNOSTIC
CONNECTION
CAB FUSE BOX
INSTURMENT
CLUSTER
BACK-UP ALARM
FRAME HARNESS
HORN
FRAME HARNESS
RELAYS
FUSE BOX
ENGINE DIAGNOSTIC
CONNECTION
ENGINE HARNESS
BATTERY
MY8700
9-3
Electrical System
9.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in the Safety
Practices section of this manual.
9.3
9.3.1
MY8710
There are seven relays and one buss bar located on the
frame, mounted on a bracket behind the battery. The
relays control the auxiliary (1), ignition (2), fuel pump (3),
Cut Out (4), Auxiliary (5) and Joystick (6 & 7).
9.3.2
MY2480
9-4
Electrical System
9.3.3
MAP0030
Fuse/Relay
Function
Amp Rating
F1
Drive Cut-Out
15
F2
Auxiliary Circuit
15
F3
Display
F4
Joystick
F5
System Module
15
F6
ClearSky
F7
15
F8
Beacon
10
F9
LSI System
10
F10
ECM
15
F11
Key
10
F12
ClearSky
F13
15
F14
Front Worklights
10
F15
Boom Worklights
10
F16
Rear Worklights
10
R1
Worklights
35
R2
35
9-5
Electrical System
9.3.4
MY2470
Fuse/Relay
Amp Rating
F21
Hazard
10
F22
F23
Dome Light
10
F24
Analyzer
F25
15
F26
20
F27
Front Wiper
20
F28
HVAC Switch
30
F29
Spare
F30
Spare
F31
7.5
F32
7.5
F33
7.5
F34
7.5
F35
7.5
F36
7.5
F37
15
F38
15
F39
Radio
15
F40
HVAC Switch - AC
10
R11
35
R12
35
Flasher
10
X1
9-6
Function
9-7
MY8720B
A
DIAGNOSTIC
RS-232
PWR MGT
NA MACHINES
PARK BRAKE
QUICK COUPLER
1
X159
SW08
8
1
YEL 062-14 IGN
SW09
8
SW01
8
LB02-1
1B
1A
LB02-2
2B
2A
RED CAN HI
X41
A
BLK CAN LO
B
C
TO
SEAT SW 1
&
SEAT SW 2
Sheet3-[8,B]
Sheet3-[8,A]
Sheet3-[2,C]
Sheet3-[6,C]
Sheet3-[1,A]
Sheet3-[7,D]
Sheet3-[8,D]
Sheet3-[1,B]
Sheet3-[6,C]
FNR LEVER
Sheet3-[8,B]
Sheet3-[1,C]
RED CAN HI
CAN LO
GND
CAN HI
2
3
IGN RUN
FUEL SENSE
4
6
7
8
Sheet3-[8,D]
BLK CAN LO
BLK 000-8-5 GND
Sheet3-[2,C]
WHT 048-9 FUEL SENSE
Sheet3-[8,C]
RED CABLE 1 CAN HI
BLK CABLE 1 CAN LO
Sheet3-[8,D]
GAUGE
Sheet3-[8,B]
IP68
Sheet3-[8,B]
Sheet3-[8,B]
4
3
2
1
X166
1
2
3
4
5
6
SW10
Sheet3-[6,C]
Sheet3-[6,C]
CAN HI
CAN LO
PARK BRAKE
STEERING PRES
4W CRAB STEER
12
4W STEER
11
2W STEER
10
13
2
RED 061-8-2 B+
14
NC
GD167
CAN SHLD
WHT 071-16 BU LP
Sheet3-[8,B]
S208
1A
1B
LB03-1
2A
2B
LB03-2
REAR
Sheet3-[8,C]
3
4
5
6
7
8
SW05
Sheet3-[6,D]
Sheet3-[6,B]
Sheet3-[6,B]
S270
IP69
FRONT
Sheet3-[6,D]
Sheet3-[8,D]
Sheet3-[6,D]
SW06-I
1
GRY
SW06-F
1
X291
X211
YEL
1 1
2 2
3 3
4 4
RED
6 6
SW06-S
1
X215
1
F
I
B
S
FC73-L1
ON FRAME
SHEET 5
8
SW14
MS290-1
A
B
B
A
MS290-2
Sheet3-[1,B]
F21_A
F21_B
F22_A
F22_B
F23_B
F24_A
F24_B
Sheet3-[1,A]
Sheet3-[6,D]
Sheet3-[8,D]
F25_A
F25_B
F26_A
F26_B
F27_A
F27_B
F28_A
F28_B
F29_A
F29_B
F30_A
F30_B
F31_A
F31_B
F32_A
F32_B
F33_A
F33_B
TO CAB ROOF
TO CAB ROOF
F34_A
F34_B
F35_A
F35_B
F36_A
F36_B
F37_A
F37_B
F38_A
R11_85
R11_86
R11_87
R11_30
R11_87a
Sheet3-[5,B]
R12_85
Sheet3-[8,A]
WHT 071-12 LH SD LP
WHT 071-1-4 LIGHTING
Sheet3-[8,A]
F38_B
F39_A
F39_B
F40_A
F40_B
Sheet3-[8,C]
Sheet3-[8,D]
R12_86
R12_87
R12_30
R12_87a
31
X1_31
49
49a
X1_49a
C1
X1_C1
FLASHER
Sheet3-[1,B]
Sheet3-[8,B]
Sheet3-[8,B]
Sheet3-[8,B]
WHT 071-11 RH SD LP
WHT 071-1-3 LIGHTING
S213
Sheet3-[8,B]
Sheet3-[8,B]
SHIELD LSI S
RED 061-7 B+
RED 061-8 B+
Sheet3-[8,B]
RED 061-6-2 B+
S67
RED 061-6-3 B+
Sheet3-[8,D]
Sheet3-[3,D]
X1_49
Sheet3-[6,C]
C2
X1_C2
TO X17
TO X65.
NO CONNECTOR REQUIRED
TO X66.
TO
TPS
Sheet3-[8,B]
X206
A
Sheet3-[2,A]
Sheet3-[1,C]
Sheet3-[5,A]
Sheet3-[1,C]
TO FRAME
SHEET 5
RL72-R
Sheet3-[8,C]
1
X216
Sheet3-[2,A]
Sheet3-[8,B]
S288
WHT 058-8 APS GND
S221
S220
10A
35A
RELAY, FLASHER
15A
15A
15A
10A
35A
FUSE, RADIO
7.5A
7.5A
FUSE, AC
7.5A
7.5A
7.5A
7.5A
EMPTY
15A
20A
20A
30A
FUSE, HVAC
EMPTY
10A
5A
10A
RATING
5A
FUSE,ANALYZER
DESCRIPTION
FUSE, HAZARDS
FUSE, LSI
X1
R12
F37
F38
F39
R11
F40
F35
F36
F30
F31
F32
F33
F34
F25
F26
F27
F28
F29
F23
F24
F21
F22
Sheet3-[8,B]
Sheet3-[8,B]
FC07
NAME
Sheet3-[8,A]
Sheet3-[8,B]
RED 061-6-1 B+
RED 061-9 B+
S212
WHT 073-4 AC
WHT 077-2 PK BRK
Sheet3-[5,B]
Sheet3-[6,C]
Sheet3-[1,B]
1
2
3
4
1
2
3
F23_A
TO IGNITION RELAY
SW06-B
1
5 5
S280
IGNITION SWITCH
HORN
Sheet3-[2,D]
Sheet3-[7,D]
WH12
Sheet3-[8,C]
2
WH13-F
2
WH13-R
5
4
1
2
LOW HD
HIGH HD
5
6
7
RIGHT
INDICATOR, TRAILER
4
3
SN11
Sheet3-[8,C]
Sheet3-[8,C]
SIDE LT
LIGHT PWR
FLASH PWR
LEFT
TURN PWR
C
BLK CABLE 2 CAN LO
RED CABLE 2 CAN HI
Sheet3-[8,C]
Sheet3-[8,C]
A
MS290-3
Sheet3-[7,D]
S214
Sheet3-[8,B]
Sheet3-[8,B]
12
11
10
8
7
6
5
4
3
2
1
X15
WHT 073-5 AC
Sheet3-[1,A]
Sheet3-[1,A]
8
7
6
5
4
3
2
1
X16
4
3
2
1
X17
X65
062-2-2 YEL 16AWG
X66
062-2-2 YEL 16AWG
062-4-4 YEL 16AWG
9.4
STUD
TO
X22
1
S218
1
X217
Sheet2-[7,D]
Sheet2-[5,D]
Sheet2-[7,D]
Sheet2-[5,D]
Sheet2-[7,D]
Sheet2-[7,D]
Sheet2-[2,C]
STUD
GROUND
FRAME
TO
Sheet2-[2,D]
X22
HARNESS
WORKLIGHT 4
ROOF
CAB
TO
STUD
GROUND 1
X82
CAB
WHT 073-5 AC
WHT 073-4 AC
WHT 051-7 RR WK LP
BLK 000-8-2 GND
WHT 051-6 FR WK LP
TO
TO
CAB
GROUND
STUD
FAN
Sheet2-[8,C]
AC
S186
Sheet2-[2,B]
SWITCH, HAZARD
S205
3
STEER SELECT SWITCH
12
1
YEL 051-3 BM WK LP
BEACON
HVAC FAN
AC
11
14
6
FRONT WIPER
Sheet2-[7,B]
Sheet2-[7,B]
Sheet2-[2,B]
CE + AUS MACHINES
Sheet2-[2,D]
Sheet2-[2,D]
Sheet2-[2,D]
S115
S113
NA MACHINES ONLY
PARK BRAKE
FRONT WASHER
1
WHT 074-4 WPR P 14AWG
Sheet2-[2,D]
S219
Sheet2-[8,C]
Sheet2-[8,C]
FRAME
1
GROUND X81
1
X266
HI
LOW
PWR
Sheet2-[2,B]
1
YEL 062-15-2 IGN
2
WHT 101-1 FAN CYCLE
3
YEL 062-15-2 IGN
4
YEL 062-15-1 IGN
5
WHT 101-2 FAN DEMAND
6
BLK 000-8-18 GND
7
WHT 070-1-9 LIGHTING
8
WHT 070-1-10 LIGHTING
SW145
BLK 000-8-19 GND
MED.
WHT 073-6 AC
MS18
1
RED 061-2-1 R PWR
S143
Sheet2-[3,D]
WHT 073-5 AC
C
SW32-AC
1
Sheet2-[8,C]
RED 061-8-3 FLASHER
Sheet2-[4,B]
WHT 071-4-1 FLASHER
POWER SOCKET
7
8
13
WHT 065-1-1 LOCK OUT
6
Sheet2-[5,B]
7
17
8
SW19
18
15
3
16
10
SW20
Sheet2-[7,B]
BLK 000-8-28 GND
7
FAN REVERSE
8
SW26
WHT 070-1-14 LIGHTING
BLK 000-8-23 GND
8
SW21
WHT 070-1-13 LIGHTING
WHT 073-4 AC
C
SW32-F
AC
Sheet2-[4,D]
Sheet2-[8,C]
LOW
2
GND
YEL 051-2 FR WK LP
WHT 073-3 FAN L 14AWG
WHT 073-2 FAN M 14AWG
3
WHT 051-6 FR WK LP
4
WH34-F
MED
WHT 073-6 AC
YEL 051-4 RR WK LP
WHT 077-2 PK BRK
Sheet2-[7,D]
8
SW29
WHT 070-1-16 LIGHTING
BLK 000-8-25 GND
3
WHT 051-7 RR WK LP
8
SW23
WHT 070-1-15 LIGHTING
WHT 077-2-4 PK BRK
4
BLK 000-8-30 GND
Sheet2-[4,A]
1
WHT 074-6 FR WASH
Sheet2-[3,A]
8
SW30
S112
9-8
Sheet2-[4,A]
1
7
Sheet2-[2,B]
Sheet2-[6,D]
Sheet2-[6,D]
Sheet2-[6,D]
Sheet2-[6,D]
Sheet2-[6,D]
Sheet2-[6,D]
Sheet2-[3,D]
Sheet2-[3,A]
Sheet2-[2,B]
Sheet2-[8,C]
Sheet2-[8,B]
Sheet2-[6,B]
Sheet2-[2,C]
Sheet2-[6,B]
Sheet2-[6,B]
Sheet2-[8,B]
Sheet2-[8,B]
Sheet2-[6,B]
Sheet2-[2,A]
Sheet2-[2,A]
Sheet2-[2,D]
Sheet2-[6,B]
Sheet2-[6,B]
Sheet2-[4,D]
Sheet2-[4,D]
Sheet2-[8,C]
Sheet2-[3,D]
Sheet2-[7,D]
Sheet2-[5,A]
Sheet2-[2,D]
Sheet2-[5,A]
Sheet2-[5,A]
Sheet2-[2,A]
Sheet2-[2,A]
Sheet2-[2,C]
Sheet2-[2,C]
Sheet2-[3,A]
Sheet2-[7,B]
Sheet2-[5,D]
Sheet2-[7,B]
WHT 071-12 LH SD LP
WHT 071-16 BU LP
WHT 008-2-2 BU LP
SHIELD LSI S
RED LSI 1
BLK LSI 2
YEL 051-3 BM WK LP
YEL 051-4 RR WK LP
YEL 051-2 FR WK LP
WHT 008-2-2 BU LP
1
2
3
X28
X27
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
8
SW31
TO
BASE
FRAME
ROOF/REAR WIPER
X188
HARNESS
FRAME
OPTION
TO
X119
HARNESS
Electrical System
MY8730B
9-9
MY8740B
A
SHEET 2
6
X264
TO
FRAME
HARNESS
S245
SHEET 5
1
BLK LSI CABLE 2
SHIELD LSI S
RED LSI CABLE
PRESSURE SW
8
X223
TO CAB
1
12
X298
10
11
HARNESS
X16
X15
SHEET 2
TO CAB
HARNESS
S128
SN123-2
WHT 073-8-4 AC COMP
1
SN123-1
WHT 073-9 AC PRES
1
5
4
3
2
1
X268
RL267
WHT 073-8-3 AC COMP
5
2
3
GD237
1
2
3
4
5
TO
COND
FAN 2
TO
COND
FAN 1
RADIO (EUROPE)
6
YEL 062-13-1 IGN
7
BLK 000-7-9 GND
8
MS242-GRY
PWR
GND
SWITCHED OUT
SENSOR 1 -VE
SENSOR 2 -VE
SENSOR VE+
CAN L
CAN H
7
NC
1
2
3
4
5
6
LB238+
LSI PASSIVE
CUSTOMER SUPPLIED
S285
S246
3
4
S247
LSI DISPLAY
1
4
CONDENSER FAN
86
85
87a
30
87
2
1
X269
X284
WHT 108-1-2 COND FAN 14AWG
1
BLK 000-1-1 GND 14AWG
2
LB238-
8
MS242-BRN
CUSTOMER SUPPLIED
CUSTOMER SUPPLIED
S249
1
WH240-G
W
P
W
P
SPEARKERS(EUROPE)
1
LB239-G
1
WH240-P
SPEARKERS(EUROPE)
1
MS243-
1
MS244-
LIGHT, DOME
LB239
1
S248
1
MS244+
4
2
025-2 GRN
025-2-1 GRN
S148
026-4 GRN
026-4 GRN
014-1-2 GRN
070-1-22 BLU
014-1 GRN
014-1-1 GRN
S149
026-5 GRN
026-5 GRN
062-3-3 YEL
000-4-13 BLK
025-2-2 GRN
000-4-14 BLK
1
2
3
4
5
6
7
8
9
S146
055-2 GRN
10
SW120
1
3
4
5
6
7
8
X27
TO CAB
HARNESS
X98
SHEET 5
1
2
3
4
5
6
7
072-1 BLU
000-8-1 BLK
2
MS109
WORKLIGHT
FRONT RIGHT
WORKLIGHT
FRONT LEFT
1
2
LB
WORKLIGHT
BLUE
BLACK
X
2
LB104
1
2
LB105
REAR RIGHT
BLACK
BLACK
2
LB106
BLACK
REAR LEFT
2
X103
BLUE
2
X104
BLUE
1
2
X106
BLUE
1
2
X105
WORKLIGHT
1
2
X104
1
2
X106
1
2
X105
051-7-1 BLU
000-8-29 BLK
S112
000-8-27 BLK
S110
LIGHT BEACON
062-3-3 YEL
055-2 GRN
000-4-15 BLK
070-1-22 BLU
8
SW145
057-7-2 BLU
000-8-30 BLK
S113
051-6-2 BLU
000-8-28 BLK
051-6-1 BLU
S111
072-1 BLU
000-8-1 BLK
051-7 BLU
000-8-2 BLK
051-6 BLU
000-8-3 BLK
X22
HARNESS
X22
SHEET 3
TO CAB
8
A
Electrical System
TO
1
X124
10
11
12
13
14
15
16
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
YEL 051-4 RR WK LP
YEL 051-2 FR WK LP
S146
TO RL71-B+
Sheet6-[4,D]
Sheet6-[4,D]
Sheet6-[5,D]
Sheet6-[2,C]
Sheet6-[2,C]
Sheet6-[2,C]
Sheet6-[2,C]
Sheet6-[4,B]
Sheet6-[4,B]
S278
SHEET 7
X56
HARNESS
ENGINE
TO
SHEET 3
X27
HARNESS
CAB
BASE
X119
1
BUSS BAR 1
X279
1
RL71
1
BUSS BAR 2
RL71-Y
1
RED 061-1 B+ 10AWG
RL71-B+
YEL 062-1-1 KEY I
1
BLK 000-5-9 GND
2
Sheet6-[3,B]
RL71-R
TO RL71-R
X268
SHEET 4
HARNESS
TO AC
F10
F9
F8
TO
ENGINE
X151
TO
ENGINE
X180
FRAME
RL72
1
GROUND
RL72-Y
1
STUD
F7
F11
F1
F2
F3
F4
F5
F6
A7
S316
FRAME
GROUND
STUD
F12
F13
F14
F15
C4
JUMPER
ON SHEET 8
MACHINES X226
F16
R1
R2
HORN
S127
IP307
S129
RELAY, CUTOUT
30
D8
S110
S121
ON PAGE 8
OPTION FRAME
X104 CAP
MACHINES HAVE
1.MORTH AMERICAN
FUEL
LEVEL
FUEL SENDER
PWR
OUT
BUSS BAR 1
5
ALARM, REVERSE
1
BLK 000-6 GND 12AWG
Sheet9-[2,B]
RED 001-2 BATT 6AWG
A6
Sheet6-[3,B]
1
RED 061-1-3 B+ 10AWG
WHT 073-8-2 AC COMP
BLK 000-6 GND 12AWG
3
X120
WHT 073-9 AC PRES
4
A5
Sheet6-[6,B]
RL72-B+
1
YEL 062-3-4 IGN
1
X274
RL72-R
2
BUSS BAR 2
L1
FC73-L1
YEL 62-9-5 ECM IGN
A10
YEL 062-19 LSI IGN
A9
YEL 062-9 BEACON
A8
1
X149
A4
YEL 062-8 BK UP
YEL 062-7 IGN
A3
A2
A1
S131
BLK 000-3 GND 10AWG
D1
C2
87
4
S122
D2
C3
RED 061-1-3 B+ 10AWG
D3
YEL 051-2 FR WK LP
D4
C5
YEL 051-3 BM WK LP
D5
C6
YEL 051-4 RR WK LP
S138
B7
B9
YEL 062-8 BK UP
B10
C8
WHT 008-1-2 FNR-R
C1
1
X116
S137
B8
D6
Sheet6-[3,B]
WHT 52-3 HORN
D9
S132
S135
D7
2
2
S125
GRN 026-2 FT
85
2
86
5
RL75
87a
D10
HV108
WHT 007-2 FNR-F
1
BLK 000-3-15 GND
2
C10
FC73
1
AH74
S118
WHT 008-1-1 FNR-R
2
2
GRN 079-3 FT
1
WHT 026-1 TOGGLE
2
S126
1
AH74-G
BLK 000-3-12 GND
WHT 008-1-4 FNR-REV
1
X305
1
X306
GND
GRN 079-2 FT
GRN 025-1 AUX
BLK 000-3-7 GND
Sheet6-[3,B]
HV78
1
WHT 065-3-1 4W STR
4
JS76
BLK 000-3-4 GND
C
C
HV79
1
BLK 000-4-6 GND
Sheet6-[1,B]
2
BLK 000-3-6 GND
3
SN77
S296
BLK 000-3-19 GND
Sheet6-[1,B]
BLU 008-2-1 BU WRN
RL97
BLK 000-5-7 GND
5
GRN 025-1 AUX
2
86
GRN 079-4 FT
3
85
HV80
1
GRN 026-3 FT
30
4
87
1
87a
8
DESCRIPTION
FUSE, ECM
FUSE, KEYSWITCH
GRN 026-3 FT
TO
6
7
86
85
87a
30
87
X27
SHEET 4
LOADER SW
FRAMER/
87
86
85
87a
30
3
4
5
5
RL96
X98
RL95
5
SHEET 9
QK CPLR X93
TO
SHEET 9
WORK LP X90
TO
X163A
1
1
2
HV85
1
X94
X89
X83
ON SHEET 8
YEL 080-1 FCN L/O
YEL 062-19 LSI IGN
YEL
35A
35A
10A
10A
10A
RELAY, WORKLIGHTS
RELAY, REVERSE CIRCUIT
R1
R2
15A
10A
15A
5A
JUMPER
FUSE, BOOM WL
FUSE, REAR WL
F15
F16
F10
F11
F12
F13
F14
5A
15A
10A
10A
FUSE, CLEARSKY
FUSE, REVERSE CIRCUIT
FUSE, BEACON
FUSE, LSI SYSTEM
F7
F6
15A
15A
5A
5A
15A
F8
F5
RATING
F9
F2
F3
F4
F1
NAME
9-10
RELAY, SPDT, 12V, 20/40 AMP
Electrical System
MY8750B
9-11
MY8760B
A
1/2W 1%
Sheet5-[3,A]
Sheet5-[7,D]
Sheet5-[7,D]
METAL FILM
28
27
26
25
24
23
WHT 048-23 IVS2
22
21
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
WHT 084-3 PWR MGT XMIT
1
X153
Sheet5-[2,A]
Sheet5-[5,D]
S04
Sheet5-[1,B]
Sheet5-[1,B]
Sheet5-[1,B]
CAB
X28
TO
Sheet5-[1,B]
FAN SPEED
IF OPTION FRAME
IS NOT USED
PLUG X154
INTO X152
1
X152
12
11
10
X187
OPTION
20
19
18
17
12
11
10
1
X154
FRAME
TO
499 OHM
IP155
RL315
5
2
3
1
4
30
87
GROUND
NC
FAN DEMAND
9
10
Sheet5-[3,D]
Sheet5-[6,A]
Sheet5-[1,C]
Sheet5-[1,C]
11
WHT 52-3-1 HORN A
12
CO299-J1
WHT 102-1 HYD TMP
1
WHT 102-3 HYD TMP
3
HYDRAULIC TEMP
10
CANBUS LOW
CANBUS HIGH
NC
NC
ANALOG GROUND
NC
Sheet5-[1,B]
MS265
1
3
4
Sheet5-[1,B]
11
12
Sheet5-[1,B]
10
3 x 4 Buss Bar
11
ANALYZER TRANSMIT
N/C
CO299-J2
6
8
FAN CONTROL
FAN REVERSE
D
31
30
29
B
A
HV140
2
1
HV141
86
85
87a
FAN CYCLE
NC
+5V OUT
ANALOG GROUND
12
ANALYZER RECEIVE
2
1
HV157
SENSOR
SPEED
SENSOR, SPEED
SN207
BLK 102-9 VEH SPD GND 18AWG
3
WHT 052-2 VEH SPD SEN 18AWG
2
WHT 052-3 VEH SPD 5V 18AWG
1
GND
Vout
Vcc
MS295-3
A
B
Sheet5-[6,A]
ATTACH
DUST CAP
1001106736
TO
CLEARSKY
MS295-2
RED CABLE 14 CAN HI
A
Sheet5-[4,D]
C
D
F
G
Sheet5-[3,D]
J
X185
7
ALL WIRES ARE 16 GA. UNLESS NOTED OTHERWISE.
8
A
Electrical System
TO
ECM
TO
ECM
X37
33
16
NC
73
26
15
68
94
93
88
87
86
85
82
78
76
75
64
63
62
61
57
54
53
52
46
45
44
35
29
28
16
13
X38
1
35
23
60
59
44
43
40
29
28
27
26
25
24
20
19
54
39
52
37
46
32
18
FUEL PUMP
X39
62
35
42
60
59
58
57
51
50
46
17
26
23
28
27
24
29
25
31
22
48
47
32
21
15
13
14
19
20
41
40
61
38
37
TO
PLUG X319
TO EC169
SHEET 7
S49
WATER/FUEL
ENGINE
S48
COOLANT LEVEL
S312
1
RL60-2
RED 001-11 GLOW PLUG 8AWG
1
RL60
2
BLK 000-40-2 GP RLY 0.75mm
YEL 69-9-5-4 IGN
X281
1
001-11-1 FUSIBLE LINK 12 GA
4
1
RL60-1
WHT 048-22-2 GP SENSE 12AWG
WHT 048-22 GLOW PLG 8AWG
BLK 000-64 GND
SHIELD CABLE 6 CAN S 18AWG
48
SHEET 9
S117
3 x 4 Buss Bar
BLK CAN LO
10
TO ALTERNATOR
EC57-B+
RED CAN HI
12
7.5A
ATO FUSE
S51
2
FC61
GLOW PLUG
TO
X111
1
WHT 048-22-3 GLOW PLG 8AWG
AC COMPRESSOR
1
MS302
WHT 078-8-2 AC COMP
9-12
S292
S54
BLK CAN 4 LO
RED CAN 4 HI
BLK CAN 3 LO
RED CAN 3 HI
RED CAN HI
RED CAN 2 HI
BLK CAN LO
BLK CAN 2 LO
S55
3
2
K
L
X43
1
SHEET 5
SHEET 7
TO X319
PLUG EC169
FRAME X182
TO
SHEET 5
FRAME X124
TO
SHEET 5
FRAME X149
TO
DIAGNOSTIC
GROUND
ENGINE
TO
X158
A
B
C
B
C
X62
A
B
C
B
C
X156
A
X45
X46
NC
2
EC169
1
X180
X56
10
11
12
13
14
15
16
1
X151
RL148
1
RL148-1
1
RL148-2
1
FUEL PUMP
f.
GENERIC
Electrical System
Engine Schematic
MY8770B
9-13
MY8780B
A
FRAME
X152
TO
BASE
CAB
X28
TO
MAIN
FRAME X226
TO BASE
SHIELD LSI S
WHT 008-2-2 BU LP
WHT 071-16 BU LP
WHT 071-12 LH SD LP
WHT 071-11 RH SD LP
10
11
12
X187
1
21
15
20
28
29
30
31
22
23
26
27
17
18
19
16
12
14
13
24
25
10
11
X188
6
RL193
5
2
3
1
30
1 x 8 Buss Bar
WHT 071-12-1 LH SD LP
WHT 071-5-2 LH TRN
BLK 000-9-4 GND
6
2
3
HIGH
4
5
SIDE
6
2
3
HIGH
4
SIDE
TURN
ON
PAGE 5
X183
S194
PLUGS
INTO
X103
S203
S202
S200
S201
S199
LSI
RS-232
DIAGNOSTIC
STOP
6
5
4
TURN
3
2
1
LB162
BACK
TAIL
7
WHT 071-16-3 LH STOP
WHT 071-5-3 LH TRN
WHT 008-2-4 LH BU
WHT 071-12-2 LH TAIL
STOP
6
5
4
TURN
3
2
1
LB163
BLK CAN 1 LO
RED CAN 1 HI
A
MS114-3
NC
C
RED CAN 2 HI
B
BLK CAN 2 LO
A
MS114-2
NC
BACK
TAIL
1
MS164-1
BLK CAN 1 LO
TRAILER CONNECTOR
NC
DRIVE REVERSE
MS114-1
BLK CABLE 13 CAN LO
A
RED CABLE 13 CAN HI
B
LSI CUTOUT
JS CUTOUT
+5V OUT
MODULE CONFIG
RED CAN 1 HI
NC
10
5
LSI MAIN MODULE
1
2
LB165
S195
LIGHT, LICENSE
1
2
SN172-1
SHIELD LSI S
RED LSI 1 LSI
BLU LSI PWR
BLK LSI 2 LSI
NC
A
B
C
SN297
LSI SENSOR
8
RED CAN 2 HI
9
BLK CAN 2 LO
10
WHT 084-1 TRANSMIT 18AWG
11
WHT 084-2 RECEIVE 18AWG
12
CO301-J2
NC
NC
12
CO300-J1
NC
S190
YEL 062-20 IGN 18AWG
1
BLK 00-9-13 GND 18AWG
2
WHT 076-9 LSI O/R 18AWG
3
WHT 025-2 TELE CMD 18AWG
4
WHT 007-3 DR FWD 18AWG
5
WHT 081-1 BM STATE 1 18AWG
6
WHT 082-1 LFT MODE 18AWG
7
WHT 082-2 LFT DWN 18AWG
8
WHT 083-1 TELE OUT 18AWG
9
WHT 083-2 TELE MODE 18AWG
10
WHT 080-1 FCN L/O 18AWG
11
WHT 085-1 LSI LP 18AWG
12
CO301-J1
WHT 086-1 +5V PRES SEN 18AWG
1
NC
ON PAGE 5
TURN
1
LB161
GROUND
10
NC
NC
NC
CANBUS LOW
12
CO300-J2
ANALYZER RECEIVE
DRIVE FORWARD
BOOM TELE STATE 1
+5V OUT
NC
NC
ANALYZER RECEIVE
MACHINES X184
1
LB160
LOW
YEL 062-25 IGN
WHT 071-8 LH HDLP HI
B
A
X183
86
85
87a
87
2
1
X222
8
7
6
5
4
3
2
1
MS189
LOW
YEL 062-19 IGN
2
1
X184
7
X294
YEL 062-25 IGN
1
WHT 084-2 RECEIVE 18AWG
2
3
4
11
NC
CANBUS HIGH
SEAT SWITCH 2
1
MS164-2
BLK 000-10-2 GND
1
MS164-3
WHT 071-6-4 RH TRN
1
MS164-4
WHT 071-11-3 RH TAIL
1
MS164-5
WHT 071-16-2 STOP
1
MS164-6
WHT 071-12-3 LH TAIL
1
MS164-7
11
ANALYZER TRANSMIT
ANALOG GROUND
PRESSURE SENSOR
SEAT SWITCH 1
CANBUS HIGH
CANBUS LOW
ANALYZER TRANSMIT
S198
S197
X160
YEL 062-23
1
BLK 000-10-5
WHT 081-1
YEL 062-22
BLK 000-10-6
WHT 081-2
INTO HV102
FRAME
GROUND
STUD
SHEET 5
SIG
GND
X178
1
PWR
SN177
1
X179
1
HV176
1
HV175
1
HV174
1
HV173
1
GND
PWR
SIG
PWR
GND
SN44
YEL 062-22
1
BLK 000-10-6
WHT 081-2
LIFT DOWNVALVE
SIG
SN178
YEL 062-23
1
BLK 000-10-5
2
WHT 081-1
3
S196
X170
YEL 062-23 IGN
1
PRESSURE SENSOR
Electrical System
FRAME
STUD
GROUND
1
X44
1
X181
ENGINE
BLOCK
GROUND
X191
1
150A
IP105
ALTERNATOR
ALTERNATOR
EC57-B+ 1
X106
1
B+
BT70+
1
RED 001-1 BATT POS 2/0AWG
EC57-D+
1
D+
BT701
BLK 000-1 BATT NEG 2/0AWG
Sheet5-[3,D]
EC57-W
1
W
CASE GROUND
STARTER
EC58
1
STUD
GROUND
ENGINE
1
X304
BLK 000-1 GND 12AWG
GROUND
A/C COMP
1
X303
9-14
M
1
4
X90
1
2
X93
1
000-4-3 BLK
051-5 BLU
051-5-2 BLU
000-4-7 BLK
000-4-8 BLK
051-5-1 BLU
S92
S91
HV86
1
2
LB88
2
LB87
Electrical System
MY8790B
EC58-B-
Electrical System
9.5
9.5.1
Starter
MY8810
Electrical System
16. Remove the top bolt securing the starter to the
engine.
Starter Installation
9-16
Electrical System
9.6
CHARGING CIRCUIT
3
MY8820
9.6.1
Alternator
a. Alternator Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the battery and engine covers. Allow the
engine to cool.
4. Properly disconnect the battery.
5. Label and disconnect the wires attached to the
alternator.
Note: Record how the alternator is installed to ensure
correct installation later.
9-17
Electrical System
9.7
ELECTRICAL SYSTEM
COMPONENTS
9.7.1
a. Removal
NOTICE
Back-up Alarm
9.7.2
Gauge Cluster
MY8830
9-18
Electrical System
9.8
9.8.1
WINDOW WIPER/WASHER
Windshield Wiper Motor
b. Disassembly
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.
c. Inspection and Replacement
Inspect the motor terminals for continuity. Replace motor
if continuity is not found.
d. Installation and Testing
1. Install all required hardware to the motor assembly.
2. Align motor with the mounting holes and bolt the
motor to the mounting bracket.
3. Connect the wiper linkage to the wiper motor shaft.
MY2220
a. Removal
Note: It may be necessary to remove several hydraulic
hoses from under the dash in order to remove and install
the wiper motor housing.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
Note: Align the wiper linkage arm with the flat on the
motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area.
4. Connect the cab harness connectors to windshield
wiper motor connectors.
5. Properly connect the battery.
6. Turn ignition key switch to the RUN position, and
operate windshield wiper in both LOW and HIGH
speeds to ensure proper operation and that correct
wiper travel is achieved.
7. Install right side defroster hose to the dash panel
hose connector.
8. If previously removed, install hydraulic hoses under
the dash.
9. Install the lower dash panel.
9-19
Electrical System
9.8.2
MY2520
a. Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the battery and engine covers. Allow the
engine to cool.
9.8.3
a. Removal
b. Disassembly
9-20
Electrical System
7. Rotate the washer reservoir, label and remove the
cab harness connectors from the washer reservoir
connectors.
8. Remove the windshield washer hoses from the
reservoir.
b. Disassembly
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective.
c. Installation and Testing
1. Connect the windshield washer hoses to the
reservoir.
2. Connect the cab wiring harness connectors to the
reservoir connectors.
3. Install the reservoir tank onto the mounting studs.
4. Install the lockwashers and nuts and secure.
5. Fill the washer fluid reservoir with washer fluid.
6. Properly connect the battery.
7. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed
on the windshield.
8. Close and secure the battery and engine covers.
9. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
9.9
9.9.1
9-21
Electrical System
c. Installation and Testing
9.10
9.10.1
MY2340
Electrical System
d. Ignition Switch Installation
1. Connect the ignition key switch to the cab harness
connectors.
2. Reach up and under the dash to work the ignition
switch into the ignition switch-mounting hole on the
lower right side of the dash.
3. Align the ignition switch so that when it is in the OFF
position, the key slot is positioned vertically (straight
up and down). Install the hex nut securing the
ignition switch to the dash. DO NOT overtighten.
4. Install the lower dash panel.
5. Properly connect the battery.
6. Turn the ignition key switch to the START position to
verify proper operation.
d. Switch Installation
1. Connect the switch to the cab harness connector.
2. Position the switch over the rectangular switch bezel
and snap into position.
3. Replace the frame into the dash.
4. Properly connect the battery.
5. Start the machine and check the replaced switch for
proper function.
6. Close and secure the battery and engine covers.
7. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
9.10.3
9.10.2
Dash Switches
a. Switch Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the battery and engine covers. Allow the
engine to cool.
4. Properly disconnect the battery.
5. Pull the frame out of the dash, disconnect the
harness connector to the switch in question and
push the switch out of the frame.
b. Disassembly
DO NOT disassemble the dash switch. Replace a
defective switch with a new part.
c. Inspection and Replacement
Inspect the switch terminals for continuity in both the
engaged and disengaged positions. Replace a defective
or faulty switch with a new switch.
Electrical System
5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator
wiring at the cab, fuse and relay panel, ignition key
switch and from the fuel level sender on the fuel tank
through the wiring in the cab.
7. Check the fuel level sender. The resistance of the
fuel level sender is 31 ohms for a full tank of fuel,
101 ohms for 1/2 tank and 255 ohms for an empty
tank. A defective fuel level sender in the fuel tank
may also prevent the fuel level indicator from
moving.
9.10.4
Hourmeter
9.10.5
9-24
Electrical System
9.10.6
3
MY8820
9-25
Electrical System
9.11
WARNING
3
9.11.1
1
MAM2900
9-26
The LSI axle sensor (1) is bolted on the top left of the rear
axle.
Note: If the rear axle is removed or replaced, the LSI
Sensor must be installed AFTER the rear axle is
installed and setting on all four wheels.
Electrical System
a. LSI Axle Sensor Removal
9.11.2
MAM2910
The LSI sensors (2) are bolted on the left inside of the first
boom section.
9-27
Electrical System
b. LSI Sensor Boom Installation
1. Mount the LSI sensor to the side of the first boom
section with the previously removed hardware. Do
Not tighten the mounting bolts at this time.
2. Shim the LSI sensor within 2-3 mm (0.08-0.11in) of
the second boom section. Tighten and torque the
mounting bolts as required.
3. Plug the electrical connector into the sensor
assembly.
4. Properly connect the battery.
5. Close and secure the battery and engine covers.
6. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
9.11.3
LSI Modules
3
MAM2920
The LSI modules (3) are bolted to the frame at the inside
left rear corner.
a. LSI Module Removal
1. Remove any fork carrier or attachment from the
machine.
2. Park the machine on a firm, level surface, level the
machine, fully retract the boom, fully raise the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
4. Open the battery and engine covers. Allow the
engine to cool.
5. Properly disconnect the battery.
6. Disconnect the LSI modules electrical connectors.
9-28
Electrical System
9.11.4
a. Standard Calibration
To calibrate the LSI, certain conditions must be met:
The sensors must be installed according to Section
9.11.1, LSI Axle Sensor, and Section 9.11.2, LSI
Boom Sensors.
The machine control system must be powered on for
at least 10 minutes before calibration.
The operator must remain in the cab.
The calibration shall be conducted with the standard
carriage and forks attached and weights as
necessary (a range of 60 - 80% of maximum weight
capacity).
The machine must be on a level surface with the
wheels steered straight and park brake off, with
straight driving over a distance of at least 2 m (6.5 ft)
being the last movement before entering a
calibration point.
While utilizing the LSI override button, 10 times lift
and lower the boom stopping suddenly to induce the
rear axle to bounce.
Position the rear tires centrally on the scales.
9-29
Electrical System
b. Field Calibration
To calibrate the LSI, certain conditions must be met:
The sensor must be installed according to Section
9.11.1, LSI Axle Sensor, and Section 9.11.2, LSI
Boom Sensors.
Market
Test
Weight
(W)
Xtip (1)
Xcal (2)
CE &
AUS
2000 kg
(4408 lb)
1225 mm
(48.25 in)
978 mm
(38.5 in)
CE &
AUS
2000 kg
(4408 lb)
1200 mm
(47.25 in)
952 mm
(37.5 in)
MU7740
9-30
MU7740
Electrical System
8. Press the SYSTEM CHECK button on the LSI
display and release. As the calibration point is
recorded, buzzer sounds and the LEDs will flash and
perform a sequence until all are flashing.
9. Perform the LSI- CAN Check PT to finalize the
calibration. Refer to Section 9.11.5, LSI-CAN Check
PT.
Note: The following procedure MUST BE performed to
finalize the LSI System Calibration.
9.11.5
LSI-CAN Check PT
9-31
Electrical System
9.11.6
9.12
2
3
4
ESC
MY2480
ENTER
MY8200
1. Cable Connector.
2. Analyzer Display Screen.
3. Escape Key: To return home or access previous
menu.
4. Enter Key: Stores and selects Top Level, Sub Level
and Items Menus.
5. Up/Down Arrow Keys: Change adjustable values.
6. Left and Right Arrow Keys: Used to move between
Top Level, Sub Levels and Item Menus.
9.12.1
Analyzer Usage
9-32
Electrical System
9.12.2
NOTE: THE LAYOUT SHOWS ALL POSSIBLE ANALYZER SCREENS. PLEASE NOTE, SOME SCREENS MAY NOT BE AVAILABLE DEPENDING UPON MACHINE CONFIGURATION.
MENU :
HELP : PRESS ENTER
HELP :
( 001 )
EVERYTHING OK
LOG : (xxx )
x : xxxxxxxxxxx
DIAGNOSTICS :
CAB INPUTS
DIAGNOSTICS :
BOOM FUNCTIONS
DIAGNOSTICS :
FAN
DIAGNOSTICS :
SYSTEM
DIAGNOSTICS :
LOAD MOMENT
DIAGNOSTICS :
CAN STATISTICS
DIAGNOSTICS :
CALIBRATION DATA
DIAGNOSTICS :
VERSIONS
LSI CANCEL SW :
ENGAGED
LIFT DN OUTPUT :
XXX %
POWER MODULE :
VOLTAGE : XX . XV
LOAD MOMENT
STATUS :
STABLE
CAN 1 STATISTICS
RX/ SEC : XXX
CALIBRATION DATA
XXXX
LSI CELL A :
POWER MODULE
SOFTWARE : PX . X
TELE MODE SW :
ENGAGED
LIFT DN OUTPUT
CURRENT : XXXMA
ENGINE COOLANT
TEMP : XX C
GROUND MODULE :
VOLTAGE : XX . XV
LOAD MOMENT
OVERRIDE : YES
CAN 1 STATISTICS
TX / SEC : XXX
CALIBRATION DATA
LSI CELL B : XXXX
GROUND MODULE
SOFTWARE : PX . X
F / R DRIVE CUTOUT
ENGAGED
LIFT DN PILOT
SENSOR : X. XV
LIFT DN FDBK mA
XXXmA
REMOTE IO MODULE
VOLTAGE : XX . XV
LOAD MOMENT %:
XXX %
CAN 1 STATISTICS
BUS OFF : XXX
LIFT DN PILOT
PRESSURE : XXXPSI
LIFT ENABLE
ENGAGED
CAN 1 STATISTICS
PASSIVE :
XXX
JOYSTICK LOCK :
ENGAGED
TELE OUT %:
XXX %
FAN REVERSE
VALVE : ENGAGED
CAN 1 STATISTICS
MSG OVERRUN : XXXX
TELE OUT
CURRENT :
DIAGNOSTICS :
DRIVE
MENU :
DIAGNOSTICS
MENU :
ACCESS LEVEL :
CODE XXXXXX
ACCESS LEVEL
MENU :
PERSONALITIES
PERSONALITIES :
LIFT DOWN
LIFT DN ZN
1
OMD< 50 : XX %
LIFT DN ZN
1
50 < OMD< 75 : XX %
LIFT DN ZN
1
OMD>75 : XX %
LIFT DN ZN
2
OMD< 50 : XX %
LIFT DN ZN
2
50 < OMD< 75 : XX %
LIFT DN ZN
2
OMD> 75 : XX %
XXXMA
CELL DISAGREE %:
XXX %
MIDBOOM # 1 SW :
OPEN
TELE ENABLE
ENGAGED
MIDBOOM # 2 SW :
OPEN
FUNCTION ENABLE
ENGAGED
OPERATING MODE :
ACTIVE
X. X
2
ANALYZER :
ANALYZER VER 6 . 2
2
SEAT SW 1
ENGAGED
2
SEAT SW 2
ENGAGED
2
CREEP :
XX %
MARKET :
CE
MENU :
MACHINE SETUP
FAN CONFIG :
FAN SPD & REV
TIRE :
LARGE - 273 . 05 CM
SPEED UNIT :
KPH
TEMP UNIT :
CELCIUS
MENU :
OPERATOR TOOLS
FAN REVERSE
INTERVAL : XX MIN
PERFORM LSI
SYSTEM CHECK?
FAN REVERSE
TIMER : XX MIN
REMOVE WEIGHTS
AND ATTACHMENTS
TELESCOPE IN AND
FULLY LIFT UP
**** STOP ****
WAIT 1 MINUTE
PRESS ENTER TO
START TEST : ---MENU :
CALIBRATION TOOLS
2
LSI CHECK POINT
2
EMULATE AXL LOAD
EMULATE
YES / NO
60 % :
EMULATE
YES / NO
80 % :
MY8840
9-33
Electrical System
9.13
9.13.1
8
7
MY9030
Fault codes will appear in the display area (7) of the gauge (8).
9.13.2
Fault Codes
Help Message
DTC
System OK
Power Cycle
211
Load Moment
Shutoff Input Invalid Signal
2336
Trigger / Possible
Actions
Symptom
The Ground Module detects
no problems exist
Power was cycled on
Default machine to LSI
Cutout (if not in passive
LSI Cancel Switch
mode and not in LSI
depressed at Startup or for
calibration mode) and
longer than 40seconds
disregard LSI Cancel
Switch Input override
Latch / Reset
Condition
Latched. Check wiring to
Pin J1-3 on the Ground
Module and integrity of
mechanical switch
335
336
Telescope Out
Valve - Short to
Battery
33123
33159
33160
9-34
Electrical System
Trigger / Possible
Symptom
Help Message
DTC
33161
33186
33188
33407
33438
33443
33444
33439
33440
33441
33442
Telescope Out
Valve - Open
Circuit
Telescope Out
Valve - Short to
Ground
Lift Down Valve Short to Ground
Function Enable
Output Short to
Battery
Function Enable
Output Short to
Ground
Telescope Enable
Valve Short to
Ground
Telescope Enable
Valve Open
Circuit
Telescope Enable
Valve - Short to
Battery
Passive Mode
Indicator Short to
Ground
Passive Mode
Indicator Short to
Battery
Battery Voltage
Low System
Shutdown
Battery Voltage
Too High - System
Shutdown
Lift Valve
Pressure Sensor
Voltage Out of
Range
Latch / Reset
Condition
Latched. Check wiring to
Deactivate Lift Enable
Pin J1-7 on the Ground
Output
Module
Latched. Check wiring to
Deactivate Telescope
Pin J1-9 on the Ground
Out Output
Module
Latched. Check wiring to
Deactivate Telescope
Pin J1-9 on the Ground
Out Output
Module
Latched. Check wiring to
Deactivate Lift Down
Pin J1-8 on the Ground
Output
Module
Latched. Check wiring to
Deactivate Function Enable Pin J1-11 on the Ground
Module
Latched. Check wiring to
Deactivate Function Enable Pin J1-11 on the Ground
Module
Latched. Check wiring to
Deactivate Telescope
Pin J1-10 on the Ground
Enable Output
Module
Latched. Check wiring to
Deactivate Telescope
Pin J1-10 on the Ground
Enable Output
Module
Latched. Check wiring to
Deactivate Telescope
Pin J1-10 on the Ground
Enable Output
Module
Latched. Check wiring to
Deactivate Indicator Output Pin J1-12 on the Ground
Module
Actions
441
Not Latched
Revert to normal
operation when battery
voltage greater than or
equal to 11V for at least
1000mS
442
Latched
Fix supply voltage
4578
9-35
Electrical System
Help Message
Conflicting Drive
Direction Signals
DTC
462
6638
6642
8514
8516
8517
9-36
Trigger / Possible
Symptom
This fault can only be
present if the machine is
configured for the CE
market. Both passive mode
inputs (fwd/park brake off
AND rev/park brake off) are
present concurrently
Ground Module lost CAN
bus communication with LSI
module and no messages
have been received for a
period of
1 second
Actions
Default machine to
Active Mode
Machine automatically in
LSI Cutout with operation
only available via LSI
LSI module detects condition
Cancel Switch (Creep
and OMD reading is 100%
Mode operation)
Permit LSI-CAN display to
control its internal alarm
Machine automatically in
LSI Cutout with operation
only available via LSI
LSI module detects condition
Cancel Switch (Creep
and OMD reading is 100%
Mode operation)
Permit LSI-CAN display to
control its internal alarm
Latch / Reset
Condition
Latched. Check wiring to
Pins J1-5 on Ground
Module and Pin J1-4 on
Remote IO Module
Not Latched
Revert to normal
operation when CAN
bus communication is
re-established
Not Latched
Revert to normal
operation when CAN
bus communication is
re-established
Electrical System
Help Message
LSI Cutout Output Short to Battery or
Open Circuit
LSI Out of
Calibration
Functions Locked
Out Remote Input
Module Software
Version Improper
DTC
8518
Trigger / Possible
Symptom
Actions
Machine automatically in
LSI Cutout with operation
LSI module detects condition
only available via LSI
and OMD reading is 100%
Cancel Switch (Creep
Mode operation)
Latch / Reset
Condition
Latched. Check LSI
gauge and sensor wiring
8519
99152
99153
99154
99161
Deactivate all
Module Outputs
9-37
Electrical System
Help Message
Seat Switch
Disagreement
Ground Module
Parameters not
Received from
Power Module
9-38
DTC
Trigger / Possible
Symptom
Actions
Latch / Reset
Condition
23119
6643
Electrical System
9.14
9.14.1
Fault
Codes
SPN
Codes
FMI
Codes
132
11
2
3
4
9
34
35
36
37
38
39
40
45
46
47
48
132
132
132
172
523006
523006
523923
523924
523925
523926
523927
168
168
168
168
11
11
11
2
3
4
3
3
3
3
3
3
4
2
2
49
597
55
56
57
58
59
60
61
62
63
64
523910
524013
524020
523911
523911
523911
523911
523911
523911
523912
14
7
14
0
12
3
3
4
11
2
66
523912
69
523912
72
523912
73
523912
74
523913
Deutz Description
Air flow sensor load correction factor exceeding the maximum drift limit; plausibility
error
Air flow sensor load correction factor exceeding drift limit; plausibility error
Air flow sensor low idle correction factor exceeding the maximum drift limit
Air flow sensor load correction factor exceeding the maximum drift limit
Sensor ambient air temperature; plausibility error
Controller mode switch; short circuit to battery
Controller mode switch; short circuit to ground
UB1; Short circuit to battery error of actuator relay 1
UB2; Short circuit to battery error of actuator relay 2
UB3; Short circuit to battery error of actuator relay 3
UB4; Short circuit to battery error of actuator relay 4
UB5; Short circuit to battery error of actuator relay 5
Sensor error battery voltage; signal range check high
Sensor error battery voltage; signal range check low
High battery voltage; warning threshold exceeded
Low battery voltage; warning threshold exceeded
Break lever main switch and break lever redundancy switch status
not plausible
Air pump doesn't achieve air mass flow set point
Burner flame unintentional deleted
Engine power; Not enough oxygen for regeneration
Burner dosing valve (DV2); over current at the end of the injection phase
Burner dosing valve (DV2); powerstage over temperature
Burner dosing valve (DV2); short circuit to battery
Burner dosing valve (DV2); short circuit to battery on high side
Burner dosing valve (DV2); short circuit to ground
Burner dosing valve (DV2); short circuit high side powerstage
Burner dosing valve (DV2) downstream pressure sensor; plausibility error
Physical range check high for burner dosing valve (DV2) downstream pressure; shut
off regeneration
Physical range check low for burner dosing valve (DV2) downstream pressure; shut
off regeneration. When burner injector is actuated, the measured pressure does not
rise above ca. 1250mbarabs
(expected; ca. 2400mbar).
Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range
check high
Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range
check low
Sensor error glow plug control diagnostic line voltage; signal range
check high
9-39
Electrical System
Fault
Codes
SPN
Codes
FMI
Codes
75
523913
76
77
78
79
82
84
85
86
88
89
96
97
98
99
101
523914
523914
523914
523914
1235
639
1231
1235
102
102
110
110
110
110
111
5
12
3
4
14
14
14
14
2
2
3
4
0
0
1
109
523929
110
523930
111
523931
112
523932
113
523933
114
523934
115
523929
116
523930
117
523931
118
523932
119
523933
120
523934
121
122
125
126
1109
523698
523717
523603
2
11
12
9
9-40
Deutz Description
Sensor error glow plug control diagnostic line voltage; signal range
check low
Glow plug control; open load
Glow plug control; powerstage over temperature
Glow plug control; short circuit to battery
Glow plug control; short circuit to ground
CAN Bus error passive; warning CAN C
CAN-Bus 0 "BusOff-Status"
CAN-Bus 1 "BusOff-Status"
CAN-Bus 2 "BusOff-Status"
Charged air pressure above warning threshold
Charged air pressure above shut off threshold
Sensor error coolant temperature; signal range check high
Sensor error coolant temperature; signal range check low
High coolant temperature; warning threshold exceeded
High coolant temperature; shut off threshold exceeded
Coolant level too low
Fuel Balance Control integrator injector 1 (in firing order); maximum
value exceeded
Fuel Balance Control integrator injector 2 (in firing order); maximum
value exceeded
Fuel Balance Control integrator injector 3 (in firing order); maximum
value exceeded
Fuel Balance Control integrator injector 4 (in firing order); maximum
value exceeded
Fuel Balance Control integrator injector 5 (in firing order); maximum
value exceeded
Fuel Balance Control integrator injector 6 (in firing order); maximum
value exceeded
Fuel Balance Control integrator injector 1 (in firing order); minimum
value exceeded
Fuel Balance Control integrator injector 2 (in firing order); minimum
value exceeded
Fuel Balance Control integrator injector 3 (in firing order); minimum
value exceeded
Fuel Balance Control integrator injector 4 (in firing order); minimum
value exceeded
Fuel Balance Control integrator injector 5 (in firing order); minimum
value exceeded
Fuel Balance Control integrator injector 6 (in firing order); minimum
value exceeded
Engine shut off demand ignored
Shut off request from supervisory monitoring function
Time out Error of CAN-Transmit-Frame AmbCon; Weather environments
Time out Error of CAN-Receive-Frame AMB; Ambient Temperature Sensor
Electrical System
Fault
Codes
SPN
Codes
FMI
Codes
127
3224
128
3224
129
3224
130
3224
133
523938
134
523939
135
523940
137
3234
138
3234
139
3234
140
523941
141
523942
142
523943
168
169
171
179
523935
523936
523212
523240
12
12
9
9
198
523216
202
523793
203
212
281
282
283
284
285
291
523794
523803
523766
523767
523768
523769
523770
523776
9
9
9
9
9
9
9
9
Deutz Description
DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor (SCR-system upstream
cat; DPF-system downstream cat); length of frame incorrect
Time out Error of CAN-Receive-Frame AT1IG1; NOX sensor upstream
DLC Error of CAN-Receive-Frame ATllGlVol NOX Sensor (SCR-system upstream
cat; DPF-system downstream cat); length of frame incorrect
Time out Error of CAN-Receive-Frame ATllGlVol; NOX sensor (SCR-system
upstream cat; DPF-system downstream cat)
Time out Error (BAM to packet) for CAN-Receive-Frame ATllGCVoll information;
factors & Sensor calibration for NOX Sensor (SCR-system upstream cat; DPFsystem downstream cat)
Time out Error (BAM to BAM) for CAN-Receive-Frame ATllGCVoll information;
factors & Sensor calibration for NOX Sensor (SCR-system upstream cat; DPFsystem downstream cat)
Time out Error (PCK2PCK) for CAN-Receive-Frame ATllGCVoll information; factors
& Sensor calibration for NOX Sensor (SCR-system upstream cat; DPF-system
downstream cat)
Time out Error of CAN-Receive-Frame AT1OG1; NOX sensor (SCR-system
downstream cat; DPF system downstream cat)
DLC Error of CAN-Receive-Frame ATlOlVol NOX Sensor (SCR-system
downstream cat; DPF-system downstream cat); length of frame incorrect
Time out Error of CAN-Receive-Frame ATlOGlVol; NOX sensor (SCR-system
downstream cat; DPF-system downstream cat)
Time out Error (BAM to packet) for CAN-Receive-Frame ATlOGCVol2 information;
factors & Sensor calibration for NOX Sensor (SCR-system downstream cat; DPFsystem downstream cat)
Time out Error (BAM to BAM) for CAN-Receive-Frame ATlOGCVol2 information;
factors & Sensor calibration for NOX Sensor (SCR-system downstream cat; DPFsystem downstream cat)
Time out Error (PCK2PCK) for CAN-Receive-Frame ATlOGCVol2 information;
factors & Sensor calibration for NOX Sensor (SCR-system downstream cat; DPFsystem downstream cat)
Time out Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages
Time out Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages
Time out Error of CAN-Receive-Frame ComEngPrt; Engine Protection
Time out CAN-message FunModCtl; Function Mode Control
Time out Error of CAN-Receive-Frame PrHtEnCmd; pre-heat
command, engine command
Time out Error of CAN-Receive-Frame UAA10; AGS sensor
service message
Time out Error of CAN-Receive-Frame UAA11; AGS sensor data
Time out Error of CAN-Receive-Frame RxEngPres; Status burner air pump
Time out Error of CAN-Receive-Frame Active TSC1AE
Time out Error of CAN-Receive-Frame Passive TSC1AE
Time out Error of CAN-Receive-Frame Active TSC1AR
Time out Error of CAN-Receive-Frame Passive TSC1AR
Time out Error of CAN-Receive-Frame Passive TSC1DE
Time out Error of CAN-Receive-Frame TSC1TE - active
9-41
Electrical System
Fault
Codes
292
293
294
299
300
301
305
306
SPN
Codes
523777
523778
523779
523788
523605
523606
898
520
FMI
Codes
9
9
9
12
9
9
9
9
322
523867
12
360
361
376
377
378
381
383
384
385
386
387
388
389
390
391
412
413
417
418
419
420
421
422
423
424
425
426
427
450
451
452
453
455
456
523982
523982
630
630
630
411
2791
2791
2791
2791
523612
190
190
190
190
108
108
171
171
190
190
190
190
190
703
703
703
703
975
975
975
975
975
975
0
1
12
12
12
4
5
12
3
4
12
0
0
11
14
3
4
3
4
8
12
2
8
12
5
12
3
4
5
12
3
4
5
12
9-42
Deutz Description
Passive Time out Error of CAN-Receive-Frame TSC1TE; Set point
Active Time out Error of CAN-Receive-Frame TSC1TR
Passive Time out Error of CAN-Receive-Frame TSC1TR
Time out Error of CAN-Transmit-Frame TrbCH; Status Wastegate
Time out Error of CAN-Receive-Frame TSC1AE; Traction Control
Time out Error of CAN-Receive-Frame TSC1AR; Retarder
Time out Error of CAN-Receive-Frame TSC1TE; Set point
Time out Error of CAN-Receive-Frame TSC1TR; Set point
Time out Error of CAN-Transmit-Frame UAA1 on CAN 2; Burner Air
Pump Control
Powerstage diagnosis disabled; high battery voltage
Powerstage diagnosis disabled; low battery voltage
Access error EEPROM memory (delete)
Access error EEPROM memory (read)
Access error EEPROM memory (write)
Physical range check low for EGR differential pressure
Actuator EGR Valve; open load
Actuator EGR Valve; powerstage over temperature
Actuator EGR Valve; short circuit to battery
Actuator EGR Valve; short circuit to ground
Internal software error ECU; injection cut off
Overspeed detection in component engine protection
Engine speed above warning threshold (FOC-Level 1)
Engine speed above warning threshold (FOC-Level 2)
Engine speed above warning threshold (Overrun Mode)
Sensor error ambient air pressure; signal range check high
Sensor error ambient air pressure; signal range check low
Sensor error environment temperature; signal range check high
Sensor error environment temperature; signal range check low
Sensor camshaft speed; disturbed signal
Sensor camshaft speed; no signal
Offset angle between crank- and camshaft sensor is too large
Sensor crankshaft speed; disturbed signal
Sensor crankshaft speed; no signal
Engine running lamp; open load
Engine running lamp; powerstage over temperature
Engine running lamp; short circuit to battery
Engine running lamp; short circuit to ground
Digital fan control; open load
Digital fan control; powerstage over temperature
Digital fan control; short circuit to battery
Digital fan control; short circuit to ground
Fan actuator (PWM output); open load
Fan actuator (PWM output); powerstage over temperature
G5-18A, 2505H, 25.5
Electrical System
Fault
Codes
457
458
460
461
462
463
464
465
472
473
474
475
481
482
488
500
501
502
503
504
505
506
SPN
Codes
975
975
1639
1639
523602
523602
97
97
94
94
94
94
174
174
523619
523915
523915
523915
523915
523915
523915
523916
FMI
Codes
3
4
0
1
0
0
3
4
3
4
1
1
0
0
2
0
12
3
3
4
11
2
508
523916
511
523916
514
515
516
523916
523916
523917
3
4
2
518
523917
521
523917
524
525
526
523917
523917
523918
3
4
2
528
523918
531
523918
534
535
543
544
545
523918
523918
676
676
729
3
4
11
11
5
Deutz Description
Fan actuator (PWM output); short circuit to battery
Fan actuator (PWM output); short circuit to ground
Sensor error fan speed; signal range check high
Sensor error fan speed; signal range check low
High fan speed; warning threshold exceeded
High fan speed; shut off threshold exceeded
Sensor error water in fuel; signal range check high
Sensor error water in fuel; signal range check low
Sensor error low fuel pressure; signal range check high
Sensor error low fuel pressure; signal range check low
Low fuel pressure; warning threshold exceeded
Low fuel pressure; shut off threshold exceeded
High low fuel temperature; warning threshold exceeded
High Low fuel temperature; shut off threshold exceeded
Physical range check high for exhaust gas temperature up stream (SCR-CAT)
HCI dosing valve (DV1); over current at the end of the injection phase
HCI dosing valve (DV1); powerstage over temperature
HCI dosing valve (DV1); short circuit to battery
HCI dosing valve (DV1); short circuit to battery high side
HCI dosing valve (DV1); short circuit to ground
HCI dosing valve (DV1); short circuit high side powerstage
Sensor HCI dosing valve (DV1) downstream pressure; plausibility error
Physical range check high for HCI dosing valve (DV1) downstream pressure; shut
off regeneration
Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off
regeneration
Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high
Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low
Sensor DV1 & DV2 upstream pressure; plausibility error
Physical range check high for DV1 & DV2 upstream pressure;
shut off regeneration
Physical range check low for DV1 & DV2 upstream pressure;
shut off regeneration
Sensor error DV1 & DV2 upstream pressure; signal range check high
Sensor error DV1 & DV2 upstream pressure; signal range check low
Sensor DV1 & DV2 upstream temperature; plausibility error
Physical range check high for DV1 & DV2 upstream temperature;
shut off regeneration
Physical range check low for DV1 & DV2 upstream temperature; shut off
regeneration
Sensor error DV1 & DV2 upstream temperature; signal range check high
Sensor error DV1 & DV2 upstream temperature; signal range check low
Cold start aid relay error.
Cold start aid relay open load
Cold start aid relay open load
9-43
Electrical System
Fault
Codes
547
SPN
Codes
729
FMI
Codes
12
559
523895
13
560
523896
13
561
523897
13
562
523898
13
563
523899
13
564
523900
13
565
566
567
568
569
570
571
572
573
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
604
605
606
607
608
523350
523352
523354
651
652
653
654
655
656
651
652
653
654
655
656
651
652
653
654
655
656
523615
523615
523615
523615
523615
523615
1323
1324
1325
1326
1327
4
4
12
5
5
5
5
5
5
3
3
3
3
3
3
4
4
4
4
4
4
5
12
3
4
3
4
12
12
12
12
12
9-44
Deutz Description
Cold start aid relay; over temperature error
Check of missing injector adjustment value programming (IMA) injector 1
(in firing order)
check of missing injector adjustment value programming (IMA) injector 2
(in firing order)
check of missing injector adjustment value programming (IMA) injector 3
(in firing order)
check of missing injector adjustment value programming (IMA) injector 4
(in firing order)
check of missing injector adjustment value programming (IMA) injector 5
(in firing order)
check of missing injector adjustment value programming (IMA) injector 6
(in firing order)
Injector cylinder-bank 1; short circuit
Injector cylinder-bank 2; short circuit
Injector powerstage output defect
Injector 1 (in firing order); interruption of electric connection
Injector 2 (in firing order); interruption of electric connection
Injector 3 (in firing order); interruption of electric connection
Injector 4 (in firing order); interruption of electric connection
Injector 5 (in firing order); interruption of electric connection
Injector 6 (in firing order); interruption of electric connection
Injector 1 (in firing order); short circuit
Injector 2 (in firing order); short circuit
Injector 3 (in firing order); short circuit
Injector 4 (in firing order); short circuit
Injector 5 (in firing order); short circuit
Injector 6 (in firing order); short circuit
High side to low side short circuit in the injector 1 (in firing order)
High side to low side short circuit in the injector 2 (in firing order)
High side to low side short circuit in the injector 3 (in firing order)
High side to low side short circuit in the injector 4 (in firing order)
High side to low side short circuit in the injector 5 (in firing order)
High side to low side short circuit in the injector 6 (in firing order)
Metering unit (Fuel-System); open load
Metering unit (Fuel-System); powerstage over temperature
Metering unit (Fuel-System); short circuit to battery high side
Metering unit (Fuel-System); short circuit to ground high side
Metering unit (Fuel-System); short circuit to battery low side
Metering Unit (Fuel-System); short circuit to ground low side
Too many recognized misfires in cylinder 1 (in firing order)
Too many recognized misfires in cylinder 2 (in firing order)
Too many recognized misfires in cylinder 3 (in firing order)
Too many recognized misfires in cylinder 4 (in firing order)
Too many recognized misfires in cylinder 5 (in firing order)
G5-18A, 2505H, 25.5
Electrical System
Fault
Codes
609
610
612
613
614
615
616
617
618
619
620
621
623
624
625
627
628
637
648
649
732
733
734
735
736
737
738
739
740
741
743
744
745
746
747
750
751
752
753
755
758
761
762
763
SPN
Codes
1328
1322
523612
523612
523612
523612
523612
523612
523612
523612
523612
523612
523612
523612
523612
523612
523612
523612
523008
523008
100
100
100
100
100
100
175
175
175
175
175
175
175
175
1237
107
107
107
523919
523919
523919
523919
523919
523920
FMI
Codes
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
1
2
3
4
0
0
1
1
2
2
0
1
3
4
0
0
2
3
4
0
2
0
1
3
4
2
Deutz Description
Too many recognized misfires in cylinder 6 (in firing order)
Too many recognized misfires in more than one cylinder
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Internal ECU monitoring detection reported error
Manipulation control was triggered
Time out error in Manipulation control
Sensor error oil pressure; signal range check high
Sensor error oil pressure sensor; signal range check low
High oil pressure; system reaction initiated
High oil pressure; shut off threshold exceeded
Low oil pressure; warning threshold exceeded
Low oil pressure; shut off threshold exceeded
Sensor oil temperature; plausibility error
Sensor oil temperature; plausibility error oil temperature too high
Physical range check high for oil temperature
Physical range check low for oil temperature
Sensor error oil temperature; signal range check high
Sensor error oil temperature; signal range check low
High oil temperature; warning threshold exceeded
High oil temperature; shut off threshold exceeded
Override switch; plausibility error
Sensor error air filter differential pressure; short circuit to battery
Sensor error air filter differential pressure; short circuit to ground
High air filter differential pressure; warning threshold exceeded
Sensor air pump pressure; plausibility error
Physical range check high for air pump pressure; shut off regeneration
Physical range check low for air pump pressure; shut off regeneration
Sensor error air pump pressure; signal range check high
Sensor error air pump pressure; signal range check low
Sensor exhaust gas back pressure; plausibility error
9-45
Electrical System
Fault
Codes
SPN
Codes
FMI
Codes
765
523920
768
523920
770
771
776
777
791
792
793
794
795
796
805
807
523920
523920
102
102
411
411
411
411
411
411
524025
3253
3
4
3
4
0
1
11
2
3
4
14
2
809
3251
812
3251
814
815
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
3253
3253
523009
523470
523470
523470
523470
523470
523470
523470
523009
523906
523906
523906
523906
523450
523450
523450
3
4
9
2
2
12
12
14
11
11
10
5
12
3
4
3
4
2
841
523451
842
523451
843
844
845
523451
523452
523452
2
3
4
9-46
Deutz Description
Physical range check high for exhaust gas back pressure burner; shut
off regeneration
Physical range check low for exhaust gas back pressure burner; shut
off regeneration
Sensor error exhaust gas back pressure burner; signal range check high
Sensor error exhaust gas back pressure burner; signal range check low
Sensor error charged air pressure; signal range check high
Sensor error charged air pressure; signal range check low
Physical range check high for differential pressure Venturi unit (EGR)
Physical range check low for differential pressure Venturi unit (EGR)
Sensor differential pressure Venturi unit (EGR); plausibility error
Sensor differential pressure Venturi unit (EGR); CAN signal invalid
Sensor error differential pressure Venturi unit (EGR); signal range check high
Sensor error differential pressure Venturi unit (EGR); signal range check low
Particulate filter; regeneration not successful
Sensor differential pressure (DPF); plausibility error regarding signal offset
Physical range check high for differential pressure (DPF); shut
off regeneration
Physical range check low for differential pressure (DPF); shut
off regeneration
Sensor error differential pressure (DPF); signal range check high
Sensor error differential pressure (DPF); signal range check low
Pressure Relief Valve (PRV) reached maximum allowed opening count
Pressure Relief Valve (PRV) forced to open; performed by pressure increase
Pressure Relief Valve (PRV) forced to open; performed by pressure shock
Open Pressure Relief Valve (PRV); shut off condition
Open Pressure Relief Valve (PRV); warning condition
Pressure Relief Valve (PRV) is open
The PRV can not be opened at this operating point with a pressure shock
Rail pressure out of tolerance range
Pressure relief valve (PRV) reached maximum allowed open time
Electrical fuel pre - supply pump; open load
Electrical fuel pre - supply pump; power stage over temperature
Electrical fuel pre - supply pump; short circuit to battery
Electrical fuel pre - supply pump; short circuit to ground
Multiple Stage Switch constant speed; short circuit to battery
Multiple Stage Switch constant speed; short circuit to ground
Multiple Stage Switch constant speed; plausibility error
Multiple Stage Switch engine speed control parameter; short circuit
to battery
Multiple Stage Switch engine speed control parameter; short circuit
to ground
Multiple Stage Switch engine speed control parameter; plausibility error
Multiple Stage Switch engine torque limitation curve; short circuit to battery
Multiple Stage Switch engine torque limitation curve; short circuit to ground
G5-18A, 2505H, 25.5
Electrical System
Fault
Codes
846
849
850
856
SPN
Codes
523452
1176
1176
523613
FMI
Codes
2
3
4
0
857
523613
858
523613
859
523613
860
861
862
864
876
877
878
881
523613
523613
523613
523613
523470
157
157
523633
0
1
0
2
7
3
4
11
882
523633
11
883
523633
11
887
889
892
893
894
896
897
898
899
900
903
905
906
908
3234
3224
4345
4343
4374
523723
523632
523632
523632
523632
4365
3241
3241
3361
11
1
11
11
13
11
16
18
0
1
0
0
1
7
914
523720
915
523720
916
523721
917
523721
918
919
925
523981
523330
523720
11
14
8
Deutz Description
Multiple Stage Switch engine torque limitation curve; plausibility error
Sensor error pressure sensor upstream turbine; signal range check high
Sensor error pressure sensor downstream turbine; signal range check high
Maximum positive deviation of rail pressure exceeded (RailMeUnO)
Maximum positive deviation of rail pressure in metering unit
exceeded (RailMeUnl)
Rail system leakage detected (RailMeUnlO)
Maximum negative deviation of rail pressure in metering unit
exceeded (RailMeUn2)
Negative deviation of rail pressure second stage (RailMeUn22)
Minimum rail pressure exceeded (RailMeUn3)
Maximum rail pressure exceeded (RailMeUn4)
Set point of metering unit in overrun mode not plausible
Maximum rail pressure in limp home mode exceeded (PRV)
Sensor error rail pressure; signal range check high
Sensor error rail pressure; signal range check low
Nox conversion rate insufficient (SCR-Cat defect, bad AdBlue quality)
Nox conversion rate insufficient (SCR-Cat defect, bad AdBlue quality); temperature
range 1
Nox conversion rate insufficient (SCR-Cat defect, bad AdBlue quality); temperature
range 2
Nox Sensor downstream of SCR Catalysator; plausibility error "stuck in range"
Nox sensor upstream of SCR Catalysator; low signal not plausible
Sensor back flow line pressure (SCR); plausibility error
General pressure check error (SCR)
Pressure stabilization error dosing valve (SCR)
Detection of AdBlue filled SCR system in Init-State
Pump pressure SCR metering unit too high
Pump pressure SCR metering unit too low
Pressure overload of SCR-System
Pressure build-up error SCR-System
Urea tank temperature too high
Sensor SCR catalyst upstream temperature too high; plausibility error
Sensor SCR catalyst upstream temperature too low; plausibility error
AdBlue dosing valve blocked (SCR)
Sensor urea supply module heater temperature; plausibility error
(normal condition)
Sensor urea supply module heater temperature; plausibility error
(cold start condition)
Sensor urea supply module temperature; plausibility error (normal condition)
Sensor urea supply module temperature; plausibility error
(cold start condition)
Urea-tank without heating function (heating phase)
Immobilizer status; fuel blocked
Urea supply module heater temperature; duty cycle in failure range
9-47
Electrical System
Fault
Codes
926
927
928
929
930
931
932
935
936
937
940
941
942
943
944
945
946
947
948
956
957
958
959
960
961
963
965
967
969
970
971
972
973
974
975
976
980
981
982
983
984
986
989
994
9-48
SPN
Codes
523720
523721
523722
523722
523721
523721
29
91
29
29
91
29
523921
3532
523921
3532
1079
1080
523601
677
677
677
677
677
677
523922
523922
523922
624
624
624
624
523612
523612
523612
91
523550
172
172
172
523921
523921
523921
105
FMI
Codes
8
11
8
8
8
8
3
3
3
4
4
4
3
3
4
4
13
13
13
3
4
5
12
3
4
5
3
4
5
12
3
4
14
14
14
11
12
3
4
2
11
0
1
3
Deutz Description
Urea supply module heater temperature; duty cycle in invalid range
Urea supply module temperature measurement not available
Urea supply module PWM signal; period outside valid range
Detect faulty PWM signal from Supply Module
Urea supply module temperature; duty cycle in failure range
Urea supply module temperature; duty cycle in invalid range
Hand throttle idle validation switch; short circuit to battery
Sensor error accelerator pedal; signal range check high
Sensor error hand throttle; signal range check high
Hand throttle idle validation switch; short circuit to ground
Sensor error accelerator pedal; signal range check low
Sensor error hand throttle sensor; signal range check low
Sensor error burner temperature; signal range check high
Sensor error urea tank level; signal range check high
Sensor error burner temperature; signal range check low
Sensor error urea tank level; signal range check low
Sensor supply voltage monitor 1 error (ECU)
Sensor supply voltage monitor 2 error (ECU)
Sensor supply voltage monitor 3 error (ECU)
Starter relay high side; short circuit to battery
Starter relay high side; short circuit to ground
Starter relay; no load error
Starter relay; power stage over temperature
Starter relay low side; short circuit to battery
Starter relay low side; short circuit to ground
Burner shut off valve; open load
Burner shut of valve; short circuit to battery
Burner shut of valve; short circuit to ground
SVS lamp; open load
SVS lamp; power stage over temperature
SVS lamp; short circuit to battery
SVS lamp; short circuit to ground
Software reset CPU SWReset 0
Software reset CPU SWReset 1
Software reset CPU SWReset 2
Plausibility error between APPl and APP2 or APPl and idle switch
T50 start switch active for too long
Sensor error intake air; signal range check high
Sensor error intake air sensor; signal range check low
Intake air sensor; plausibility error
Sensor burner temperature; plausibility error
Physical range check high for burner temperature
Physical range check low for burner temperature
Sensor error charged air temperature; signal range check high
G5-18A, 2505H, 25.5
Electrical System
Fault
Codes
995
996
997
1007
1008
1009
1011
1012
1013
SPN
Codes
105
105
105
412
412
412
523960
523960
523960
FMI
Codes
4
0
0
3
4
2
0
1
11
1014
51
1015
51
1016
51
1017
51
1018
51
12
1019
1020
1021
51
51
51
3
4
12
1022
51
1023
51
1024
51
1025
51
1026
1029
1032
1034
1035
1036
1039
1042
4769
4766
4766
4769
4769
4768
4765
4765
2
0
1
3
4
2
0
1
1044
4768
1045
4768
1047
1066
3248
1180
4
11
1067
1180
Deutz Description
Sensor error charged air temperature; signal range check low
High charged air cooler temperature; warning threshold exceeded
High charged air cooler temperature; shut off threshold exceeded
Sensor error EGR cooler downstream temperature; signal range check high
Sensor error EGR cooler downstream temperature; signal range check low
Sensor exhaust gas temperature Venturi unit (EGR); plausibility error
Physical range check high for EGR cooler downstream temperature
Physical range check low for EGR cooler downstream temperature
Sensor exhaust gas temperature Venturi unit (EGR); plausibility error
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check
high
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check
low
Actuator position for EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8)
not plausible
Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); open load
Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); power stage
over temperature
EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery
EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground
Mechanical actuator defect EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8)
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check
high
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check
low
Position sensor error of actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8);
signal range check high
Position sensor error actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal
range check low
Sensor exhaust gas temperature downstream (DOC); plausibility error
Physical range check high for exhaust gas temperature downstream (DOC)
Physical range check low for exhaust gas temperature downstream (DOC)
Sensor error exhaust gas temperature downstream (DOC); signal range check high
Sensor error exhaust gas temperature downstream (DOC); signal range check low
Sensor exhaust gas temperature upstream (DOC); plausibility error
Physical range check high for exhaust gas temperature upstream (DOC)
Physical range check low for exhaust gas temperature upstream (DOC]
Sensor error exhaust gas temperature upstream (DOC); signal range
check high
Sensor error exhaust gas temperature upstream (DOC); signal range
check low
Sensor error particle filter downstream temperature; signal range check low
Sensor exhaust gas temperature upstream turbine; plausibility error
Sensor error exhaust gas temperature upstream turbine; signal range
check high
9-49
Electrical System
Fault
Codes
SPN
Codes
FMI
Codes
1068
1180
1069
1070
4360
4360
0
1
1072
4360
1073
4360
1074
1077
1078
1079
1080
1081
1082
1083
1084
1085
1086
1087
1088
1089
1090
1092
1093
1094
1096
1097
1098
1099
1100
1101
1102
1104
1105
1106
1108
1109
1110
1111
1112
1113
1118
1120
1761
3361
3361
3361
3361
4345
4366
4343
4366
4366
4341
523719
4366
4243
4345
4345
4345
4343
4343
4343
523718
523718
523718
523718
4341
4341
4341
523719
523719
523719
4366
4366
4366
4366
4375
4375
14
3
3
4
4
5
5
5
5
5
5
5
5
11
5
3
4
5
3
4
5
12
3
4
5
3
4
5
3
4
5
12
3
4
5
3
9-50
Deutz Description
Sensor error exhaust gas temperature upstream turbine; signal range
check low
Physical range check high for urea catalyst upstream temperature
Physical range low for urea catalyst upstream temperature
Sensor error urea catalyst exhaust gas temperature upstream; signal range check
high
Sensor error urea catalyst exhaust gas temperature upstream; signal range check
low
Urea tank level; warning threshold exceeded
Urea dosing valve; short circuit to battery on high side
Urea dosing valve; short circuit to battery or open load on high side
Urea dosing valve; short circuit to ground or open load on low side
Urea dosing valve; short circuit on high side
SCR heater relay urea return line secondary side; open load
SCR main relay (secondary side); open load
SCR heater relay urea pressure line secondary side; open load
SCR main relay (secondary side); Shortcut to battery
SCR main relay (secondary side); shortcut to ground
SCR heater relay urea supply line secondary side; open load
SCR heater relay urea supply module secondary side; open load
SCR Tank heating valve secondary side; open load
SCR system heater diagnostic reports error; shut off SCR-system
SCR heater relay urea return line primary side; open load
SCR heater urea return line; short circuit to battery
SCR heater urea return line; short circuit to ground
SCR heater relay urea pressure line primary side; open load
SCR heater urea pressure line; short circuit to battery
SCR heater urea pressure line; short circuit to ground
SCR main relay (primary side); open load
SCR main relay (primary side); powerstage over temperature
SCR main relay (primary side); short circuit to battery
SCR main relay (primary side); short circuit to ground
SCR heater relay urea supply line primary side; open load
SCR-heater urea supply line; short circuit to battery
SCR-heater urea supply line; short circuit to ground
SCR heater relay urea supply module primary side; open load
SCR heater urea supply module; short circuit to battery
SCR heater urea supply module; short circuit to ground
SCR tank heating valve primary side; open load
SCR-heater relay urea tank powerstage output; over temperature
SCR Tank heating valve; short circuit to battery
SCR Tank heating valve; short circuit to ground
Urea pump motor; open load
Urea pump motor; short circuit to battery
G5-18A, 2505H, 25.5
Electrical System
Fault
Codes
1121
1122
1123
1124
1125
1127
1128
1129
1130
1131
1132
1135
1136
1138
1139
1157
1158
1159
1160
1161
1162
1163
1164
1165
1166
1167
1168
1169
1170
1171
1173
1174
1175
1176
1177
1178
1180
1181
1182
1183
1187
1192
1193
1194
SPN
Codes
4375
4334
4334
4334
4334
4334
4334
4376
4376
4376
4376
3031
3031
3031
3031
97
523946
523947
523948
523949
523950
523951
523946
523947
523948
523949
523950
523951
523612
175
523973
523974
523975
523976
523977
523978
168
168
172
172
523980
523922
1180
1180
FMI
Codes
4
0
1
0
1
3
4
5
12
3
4
0
1
3
4
12
0
0
0
0
0
0
1
1
1
1
1
1
12
2
14
14
14
14
14
14
0
1
0
1
14
12
0
1
Deutz Description
Urea pump motor; short circuit to ground
Physical range check high for Urea Pump Pressure
Physical range check low for Urea Pump Pressure
Urea pump pressure sensor; high signal not plausible
Urea pump pressure sensor; low signal not plausible
Sensor error urea pump pressure; signal range check high
Sensor error urea pump pressure; signal range check low
SCR reversing valve; open load
SCR reversing valve; over temperature
SCR reversing valve; short circuit to battery
SCR reversing valve; short circuit to ground
AdBlue-Tank temperature; maximum exceeded
DEF-Tank temperature; below minimum
Sensor error urea tank temperature; short circuit to battery
Sensor error urea tank temperature; short circuit to ground
Water in fuel level prefilter; maximum value exceeded
Zero fuel calibration injector 1 (in firing order); maximum value exceeded
Zero fuel calibration injector 2 (in firing order); maximum value exceeded
Zero fuel calibration injector 3 (in firing order); maximum value exceeded
Zero fuel calibration injector 4 (in firing order); maximum value exceeded
Zero fuel calibration injector 5 (in firing order); maximum value exceeded
Zero fuel calibration injector 6 (in firing order); maximum value exceeded
Zero fuel calibration injector 1 (in firing order); minimum value exceeded
Zero fuel calibration injector 2 (in firing order); minimum value exceeded
Zero fuel calibration injector 3 (in firing order); minimum value exceeded
Zero fuel calibration injector 4 (in firing order); minimum value exceeded
Zero fuel calibration injector 5 (in firing order); minimum value exceeded
Zero fuel calibration injector 6 (in firing order); minimum value exceeded
Internal software error ECU
Customer oil temperature; signal un-plausible
SCR Tamper detection; derating timer below limit 1
SCR Tamper detection; derating timer below limit 2
Urea quality; derating timer below limit 1
Urea quality; derating timer below limit 2
Urea tank level; derating timer below limit 1
Urea tank level; derating timer below limit 2
Physical range check high for battery voltage
Physical range check low for battery voltage
Physical range check high for intake air temperature
Physical range check low for intake air temperature
Bad quality of reduction agent detected
Over temperature error on burner shut of valve
Physical range check high for exhaust gas temperature upstream turbine
Physical range check low for exhaust gas temperature upstream turbine
9-51
Electrical System
Fault
Codes
1216
1217
SPN
Codes
523914
523914
FMI
Codes
5
11
1219
524018
14
1220
524022
14
1221
1222
1223
1224
1225
1226
1227
1228
1229
524023
190
51
51
51
51
51
51
51
14
14
5
6
12
3
3
4
4
1230
51
1231
51
11
1232
51
1239
1240
1243
1244
1245
1246
1247
1248
1249
1250
1251
1252
1253
1254
1255
1256
1257
1258
1259
1260
1261
1262
1263
1264
523984
523985
523988
523988
523988
523988
524019
523910
523910
523910
523910
523910
523911
524014
524013
523915
523915
524016
524016
524016
523910
523922
524021
523922
3
3
5
12
3
4
11
9
7
12
0
0
7
1
7
7
7
11
2
2
6
7
11
7
9-52
Deutz Description
Glow plug control release line; short circuit error
Glow plug control; internal error
DPF wasn't regenerated, power reduction phase 1 (manual
regeneration request)
DPF wasn't regenerated, power reduction phase 2 (manual
regeneration request)
DPF wasn't regenerated, warning condition (manual regeneration mode)
Camshaft- and Crankshaft speed sensor signal not available on CAN
Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); open load
Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over current
Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over temperature
EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery (A02)
EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery (A67)
EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground (A02)
EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground (A67)
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Overload by shortcircuit
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Power stage over
temperature due to high current
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); Voltage
below threshold
UB6; Short circuit to battery error of actuator relay 7
UB7; Short circuit to battery error of actuator relay
Charging lamp; open load
Charging lamp; over temperature
Charging lamp; short circuit to battery
Charging lamp; short circuit to ground
Air Pump; air lines blocked
Air Pump; CAN communication lost
Air pump; CAN communication interrupted no purge function available
Air Pump; internal error
Air Pump; power stage over temperature
Air Pump; operating voltage error
Burner dosing valve (DV2); blocked closed
Air pressure glow plug flush line; below limit
Burner operation is interrupted too often
HCI dosing valve (DV1); blocked closed
HCI dosing valve (DV1); blocked open
HFM sensor; electrical fault
Amount of air is not plausible to pump speed
Calculated amount of air is not plausible to HFM reading
Air Pump; over current
Burner Shut Off Valve; blocked closed
Burner fuel line pipe leak behind Shut Off Valve
Burner Shut Off Valve; blocked open
G5-18A, 2505H, 25.5
Electrical System
Fault
Codes
1265
1266
SPN
Codes
524017
524017
FMI
Codes
12
12
1267
523989
1268
523990
1269
523989
1270
523990
1279
1283
523992
523993
9
9
1285
524038
1286
524039
1287
524040
1288
524041
1289
524042
1290
524043
1291
524045
1292
524046
1293
524047
1294
1295
1297
1298
1299
1300
524048
524049
523788
523788
523788
523788
9
9
0
0
0
0
1302
524024
11
1324
523995
13
1325
523996
13
1327
1328
1329
1330
1333
523998
523999
524000
524001
524000
4
12
5
5
3
Deutz Description
Spark plug control unit (SPCU); electrical fault
Spark plug control unit (SPCU); internal error
Fuel Balance Control integrator injector 7 (in firing order); maximum
value exceeded
Fuel Balance Control integrator injector 8 (in firing order); maximum
value exceeded
Fuel Balance Control integrator injector 7 (in firing order); minimum
value exceeded
Fuel Balance Control integrator injector 8 (in firing order); minimum
value exceeded
Time out Error of CAN-Receive-Frame DM19Voll; NOX sensor upstream
Time out Error of CAN-Receive-Frame DM19Vol2; NOX sensor downstream
Time out error of CAN-Receive-Frame ComMS_SyslTO (error memory Slave);
Master-Slave internal CAN message
Time out error of CAN-Receive-Frame ComMS_Sys2TO (error memory Slave);
Master-Slave internal CAN message
Time out error of CAN-Receive-Frame ComMS_Sys3TO (error memory Slave);
Master-Slave internal CAN message
Time out error of CAN-Receive-Frame ComMS_Sys4TO (error memory Slave);
Master-Slave internal CAN message
Time out error of CAN-Receive-Frame ComMS_Sys5TO (error memory Slave);
Master-Slave internal CAN message
Time out error of CAN-Receive-Frame ComMS_Sys6TO (error memory Slave);
Master-Slave internal CAN message
Master-Slave CAN; Message-Counter-Error of CAN-Receive-Frame
ComMSMoFOvR
Master-Slave CAN; Checksum-Error of CAN-Receive-Frame ComMSMoFOvR
Master-Slave CAN; Messsage-Length-Error of CAN-Receive-Frame
ComMSMoFOvR
Time out error CAN message ComMSMoFOvRlTO error memory Slave
Message copy error in the Master/ Slave data transfer
CAN-Transmit-Frame ComTrbChActr "BusOff-Satus"; Wastegate
CAN-Transmit-Frame ComTrbChActr disable error; wastegate
CAN-Transmit-Frame ComTrbChActr plausibility error; wastegate
Time out Error of CAN-Transmit-Frame ComTrbChActr; Wastegate
Deviation of the exhaust gas temperature set point to actual value downstream
(DOC) too high
check of missing injector adjustment value programming (IMA) injector 7 (in firing
order)
check of missing injector adjustment value programming (IMA) injector 8 (in firing
order)
Injector cylinder bank 2 slave; short circuit
Injector powerstage output Slave defect
Injector 7 (in firing order); interruption of electric connection
Injector 8 (in firing order); interruption of electric connection
Injector 7 (in firing order); short circuit
9-53
Electrical System
Fault
Codes
1334
1335
1336
SPN
Codes
524001
524000
524001
FMI
Codes
3
4
4
1337
2797
1338
2798
1339
1340
1341
1342
1343
1344
2798
2798
524035
524036
524004
524005
4
4
12
12
12
12
1345
524069
1357
524052
11
1368
524052
11
1378
1379
1380
1381
1389
1390
1392
1395
1398
1399
1400
1401
523919
523920
3253
164
523922
523922
523922
523921
1136
1136
1136
1136
2
2
2
2
5
12
4
2
0
1
3
4
1402
4769
1403
4769
1404
3248
1405
3248
1406
3248
1407
3248
1408
3248
1409
3248
9-54
Deutz Description
Injector 8 (in firing order); short circuit
High side to low side short circuit in the injector 7 (in firing order)
High side to low side short circuit in the injector 8 (in firing order)
Injector diagnostics; time out error of short circuit to ground measurement cyl.
Bank 0
Injector diagnostics; time out error of short circuit to ground measurement cyl.
Bank 1
Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 0
Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 1
Injector diagnostics; time out error in the SPI communication
Injector diagnostics Slave; time out error in the SPI communication
Too many recognized misfires in cylinder 7 (in firing order)
Too many recognized misfires in cylinder 8 (in firing order)
Time out Error of CAN-Receive-Frame MSMon_FidFCCTO; Master-Slave CAN
communication faulty
Error memory Slave reports FID MSMonFC2; Shut-Off Path test error of fuel
injection system
Error memory Slave reports FID MSMonFC3; time out of engine state messages
(ComMS_Sysl-7) from master ECU
Sensor air pump airpressure; plausibility error
Sensor exhaust gas back pressure burner; plausibility error
Sensor differential pressure (DPF); plausibility error
Rail pressure safety function is not executed correctly
Burner Shut Off Valve; open load
Burner Shut Off Valve; powerstage over temperature
Burner Shut Off Valve; short circuit to ground
Sensor burner temperature; plausibility error
Physical range check high for ECU temperature
Physical range check low for ECU temperature
Sensor error ECU temperature; signal range check high
Sensor error ECU temperature; signal range check low
Sensor exhaust gas temperature OxiCat downstream (normal operation); plausibility
error
Sensor exhaust gas temperature OxiCat downstream (regeneration); plausibility
error
Sensor exhaust gas temperature downstream DPF; plausibility error
Physical range check high for exhaust gas temperature particulate
filter downstream
Physical range check high for exhaust gas temperature particulate
filter downstream; shut off regeneration
Physical range check high for exhaust gas temperature particulate
filter downstream; warning
Physical range check low for exhaust gas temperature particulate
filter downstream
Physical range check low for exhaust gas temperature particulate filter downstream;
shut off regeneration
G5-18A, 2505H, 25.5
Electrical System
Fault
Codes
SPN
Codes
FMI
Codes
1410
3248
1411
1412
1413
1414
1415
1416
1417
1418
1419
1420
1421
1422
1431
1188
1188
1188
1188
1188
1188
1188
1188
524011
524012
524011
524012
524028
11
11
13
2
7
11
11
11
0
0
1
1
2
1432
524029
1436
1437
1438
1439
1440
1441
1442
1443
1444
1445
1446
1447
1448
1449
1453
1454
524034
524034
524034
524034
524030
524031
524032
524033
2621
2621
2621
2621
175
175
411
411
5
12
3
4
7
13
2
7
5
12
3
4
0
0
0
1
1455
3711
12
1457
524055
1458
523960
1459
523960
1460
1460
1461
1461
1462
1180
1180
1180
1180
1180
0
0
1
1
0
Deutz Description
Physical range check low for exhaust gas temperature particulate filter downstream;
warning
Wastegate actuator; internal error
Wastegate actuator; EOL calibration not performed correctly
Wastegate actuator calibration deviation too large, re-calibration required
Wastegate; status message from ECU missing
Wastegate actuator; blocked
Wastegate actuator; over temperature (> 145C]
Wastegate actuator; over temperature (> 135C]
Wastegate actuator; operating voltage error
Zero fuel calibration injector 7 (in firing order); maximum value exceeded
Zero fuel calibration injector 8 (in firing order); maximum value exceeded
Zero fuel calibration injector 7 (in firing order); minimum value exceeded
Zero fuel calibration injector 8 (in firing order); minimum value exceeded
CAN message PROEGRActr; plausibility error
Time out Error of CAN-Receive-Frame ComEGRActr - exhaust gas recirculation
positioner
Disc Separator; open load
Disc Separator; power stage over temperature
Disc separator; short circuit to battery
Disc separator; short circuit to ground
EGR actuator; internal error
EGR actuator; calibration error
EGR actuator; status message "EGRCust" is missing
EGR actuator; due to overload in Save Mode
Flush valve burner (EPV DPF-System); open load
Flush valve burner (EPV DPF-System); powerstage over temperature
Flush valve burner (EPV DPF-System); short circuit to battery
Flush valve burner (EPV DPF-System); short circuit to ground
High customer oil temperature; warning threshold exceeded
High customer oil temperature; shut off threshold exceeded
Differential pressure Venturi unit (EGR); warning threshold exceeded
Differential pressure Venturi unit (EGR); shut off threshold exceeded
Regeneration temperature (PFItRgn LigtOff) not reached;
regeneration aborted
Spark Plug Control Unit (SPCU); short circuit to ground
High exhaust gas temperature EGR cooler downstream; warning
threshold exceeded
High exhaust gas temperature EGR cooler downstream; shut off
threshold exceeded
Turbocharger Wastegate CAN feedback; warning threshold exceeded
Turbocharger Wastegate CAN feedback; warning threshold exceeded
Turbocharger Wastegate CAN feedback; shut off threshold exceeded
Turbocharger Wastegate CAN feedback; shut off threshold exceeded
Exhaust gas temperature upstream turbine; warning threshold exceeded
9-55
Electrical System
Fault
Codes
1462
1463
1463
1474
1474
1475
1475
1477
1477
1478
1478
1479
1479
1480
1480
1481
1482
1483
1484
1484
1485
1485
1486
1487
1487
1488
1488
1489
1489
1490
1490
1491
1491
1493
1493
1494
1494
1495
1495
1496
1496
1505
1505
1523
9-56
SPN
Codes
1180
1180
1180
524037
524037
34
84
524037
524037
524037
524037
524062
524062
524062
524062
524025
524044
523632
524068
524068
524052
524052
523718
523718
523718
523718
523718
523718
523718
4376
4376
4376
4376
4376
4376
2659
2659
2659
2659
2659
2659
524057
524057
2659
FMI
Codes
0
1
1
5
5
2
2
3
3
4
4
12
12
12
12
5
9
2
2
2
11
11
5
12
12
3
3
4
4
5
5
12
12
4
4
0
0
1
1
11
11
2
2
2
Deutz Description
Exhaust gas temperature upstream turbine; warning threshold exceeded
Exhaust gas temperature upstream turbine; shut off threshold exceeded
Exhaust gas temperature upstream turbine; shut off threshold exceeded
Ash lamp; open load
Ash lamp; open load
Sensor vehicle speed; plausibility error
Sensor vehicle speed; plausibility error
Ash lamp; short circuit to battery
Ash lamp; short circuit to battery
Ash lamp; short circuit to ground
Ash lamp; short circuit to ground
Regeneration inhibit switch not available; ComlnhSwtNA
Regeneration inhibit switch not available; ComlnhSwtNA
Regeneration release switch not available; ComRegSwtNA
Regeneration release switch not available; ComRegSwtNA
DPF system; operating voltage error
CAN message ComMS_Sys7 not received from slave
Metering control is not performed in time error
Master ECU and Slave ECU have been identified as the same types
Master ECU and Slave ECU have been identified as the same types
Master ECU and Slave ECU data sets or software are not identical
Master ECU and Slave ECU data sets or software are not identical
SCR main relay; open load (only CV56B)
SCR main relay; powerstage over temperature (only CV56B)
SCR main relay; powerstage over temperature (only CV56B)
SCR main relay; short circuit to battery (only CV56B)
SCR main relay; short circuit to battery (only CV56B)
SCR main relay; short circuit to ground (onlyCV56B)
SCR main relay; short circuit to ground (only CV56B)
SCR reversing valve; open load
SCR reversing valve; open load
SCR reversing valve; over temperature
SCR reversing valve; over temperature
SCR reversing valve; short circuit to ground
SCR reversing valve; short circuit to ground
Physical range check high for EGR mass flow
Physical range check high for EGR mass flow
Physical range check low for EGR mass flow
Physical range check ow for EGR mass flow
Exhaust gas recirculation; EGR mass flow; shut off demand
Exhaust gas recirculation; EGR mass flow; shut off demand
Electric fuel pump; fuel pressure build up error
Electric fuel pump; fuel pressure build up error
Exhaust gas recirculation AGS sensor; plausibility error
G5-18A, 2505H, 25.5
Electrical System
Fault
Codes
1523
1524
1524
1525
1525
1526
1526
1527
1527
1615
1615
SPN
Codes
2659
2659
2659
2659
2659
2659
2659
2659
2659
3699
3699
FMI
Codes
2
0
0
1
1
12
12
2
2
14
14
1616
3699
1616
3699
1617
1617
1659
1659
1660
1660
1661
1661
1662
1662
1663
1663
1664
1664
1665
1665
1666
1666
1667
1667
1668
1668
1669
1669
1670
1670
1671
1671
1672
3699
3699
524114
524114
524115
524115
524116
524116
524117
524117
524097
524097
524098
524098
524099
524099
524100
524100
524101
524101
524105
524105
524108
524108
524110
524110
524112
524112
524118
2
2
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
Deutz Description
Exhaust gas recirculation AGS sensor; plausibility error
Physical range check high for EGR exhaust gas mass flow
Physical range check high for EGR exhaust gas mass flow
Physical range check low for EGR exhaust gas mass flow
Physical range check low for EGR exhaust gas mass flow
Exhaust gas recirculation; AGS sensor has "burn off" not performed
Exhaust gas recirculation; AGS sensor has "burn off1' not performed
AGS sensor temperature exhaust gas mass flow; plausibility error
AGS sensor temperature exhaust gas mass flow; plausibility error
Maximum stand-still-duration reached; oil exchange required
Maximum stand-still-duration reached; oil exchange required
DPF differential pressure sensor and a further sensor or actuator CRT system
defective
DPF differential pressure sensor and a further sensor or actuator CRT system
defective
Temperature sensor us. and ds. DOC simultaneously defect
Temperature sensor us, and ds, DOC simultaneously defect
Time out error of CAN-Transmit-Frame A1DOC
Time out error of CAN-Transmit-Frame A1DOC
Time out error of CAN-Transmit-Frame AT1S
Time out error of CAN-Transmit-Frame AT IS
Time out error of CAN-Transmit-Frame SCR2
Time out error of CAN-Transmit-Frame SCR2
Time out error of CAN-Transmit-Frame SCR3
Time out error of CAN-Transmit-Frame SCR3
Time out error of CAN-Transmit-Frame DPFBrnAirPmpCtl
Time out error of CAN-Transmit-Frame DPFBrnAirPmpCtl
Time out error of CAN-Transmit-Frame ComDPFBrnPT
Time out error of CAN-Transmit-Frame ComDPFBrnPT
Time out error of CAN-Transmit-Frame ComDPFCl
Time out error of CAN-Transmit-Frame ComDPFCl
Time out error of CAN-Transmit-Frame ComDPFHisDat
Time out error of CAN-Transmit-Frame ComDPFHisDat
Time out error of CAN-Transmit-Frame ComDPFTstMon
Time out error of CAN-Transmit-Frame ComDPFTstMon
Time out error of CAN-Transmit-Frame ComEGRMsFlw
Time out error of CAN-Transmit-Frame ComEGRMsF Iw
Time out error of CAN-Transmit-Frame ComEGRTVActr
Time out error of CAN-Transmit-Frame ComEGRTVActr
Time out error of CAN-Transmit-Frame ComETVActr
Time out error of CAN-Transmit-Frame ComETVActr
Time out ComlTVActr
Time out ComlTVActr
Time out error of CAN-Receive-Frame ComRxCMl
9-57
Electrical System
Fault
Codes
1672
1673
1673
1674
1674
1675
1675
1676
1676
1677
1677
1678
1678
1679
1679
1680
1680
1681
1681
1682
1682
1683
1683
1684
1684
1685
1685
1686
1686
1687
1687
14S1
14S2
14S3
I486
9-58
SPN
Codes
524118
524119
524119
524102
524102
524103
524103
524104
524104
524106
524106
524107
524107
524109
524109
524111
524111
524113
524113
524120
524120
524121
524121
524122
524122
524123
524123
524124
524124
524125
524125
524025
524044
523632
523718
FMI
Codes
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
5
9
2
5
Deutz Description
Time out error of CAN-Receive-Frame ComRxCMl
Time out error of CAN-Receive-Frame ComRxCustSCR3
Time out error of CAN-Receive-Frame ComRxCustSCR3
Time out error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl
Time out error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl
Time out error of CAN-Receive-Frame ComRxDPFBrnAirPmp
Time out error of CAN-Receive-Frame ComRxDPFBrnAirPmp
Time out error of CAN-Receive-Frame ComRxDPFCtl
Time out error of CAN-Receive-Frame ComRxDPFCtl
Time out error of CAN-Receive-Frame ComRxEGRMsFlwl
Time out error of CAN-Receive-Frame ComRxEGRMsFlwl
Time out error of CAN-Receive-Frame ComRxEGRMsFlw2
Time out error of CAN-Receive-Frame ComRxEGRMsFlw2
Time out error of CAN-Receive-Frame ComRxEGRTVActr
Time out error of CAN-Receive-Frame ComRxEGRTVActr
Time out error of CAN-Receive-Frame ComRxETVActr
Time out error of CAN-Receive-Frame ComRxETVActr
Time out error of CAN-Receive-Frame ComRxlTVActr
Time out error of CAN-Receive-Frame ComRxlTVActr
Time out error of CAN-Receive-Frame ComRxSCRHtDiag
Time out error of CAN-Receive-Frame ComRxSCRHtDiag
Time out error of CAN-Receive-Frame ComRxTrbChActr
Time out error of CAN-Receive-Frame ComRxTrbChActr
Time out error of CAN-Receive-Frame ComRxUQSens
Time out error of CAN-Receive-Frame ComRxUQSens
Time out error of CAN-Receive-Frame ComSCRHtCtl
Time out error of CAN-Receive-Frame ComSCRHtCt
Time out error of CAN-Receive-Frame ComTxATllMG
Time out error of CAN-Receive-Frame ComTxATllMG
Time out error of CAN-Receive-Frame ComTxTrbChActr
Time out error of CAN-Receive-Frame ComTxTrbChActr
DPF system; operating voltage error
CAN message ComMS_Sys7 not received from slave
Metering control is not performed in time error
SCR main relay; open load (only CV56B)
31200926
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: +48 (0)914 320 245
Fax: +48 (0)914 358 200
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal, Barcelona
Spain
Phone: +34 93 772 4 700
Fax: +34 93 771 1762
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
Phone: +46 (0)850 659 500
Fax: +46 (0)850 659 534
www.jlg.com