Service - JLG Telehandler Service Manual - English

Service Manual
Models
G10-55A
&
G12-55A
AccuPlace
31200452
Original
January 20, 2009
An Oshkosh Corporation Company

EFFECTIVITY PAGE
January 20, 2009 - A - Original Issue Of Manual
31200452 G10-55A & G12-55A AccuPlace i

EFFECTIVITY PAGE
-ii G10-55A & G12-55A AccuPlace 31200452

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Section 3
Boom ........................................................... 3.1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.4 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.5 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.6 Hydraulic Sub-Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.7 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.8 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.9 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operators Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
G10-55A & G12-55A AccuPlace i

Section Subject Page
5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Section 7
Engine ........................................................... 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.5 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.6 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.7 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.8 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.5 Hydraulic System Schematics and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.7 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.8 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.9 Hydraulic Piston Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
8.10 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.5 Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.6 Electrical System Schematics And Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.11 Solenoids, Senders and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
9.14 Engine Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38
9.15 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.39
ii G10-55A & G12-55A AccuPlace

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
G10-55A & G12-55A AccuPlace 1.1

Safety Practices
1.1 INTRODUCTION 1.2 DISCLAIMER

This service manual provides general directions for All information in this manual is based on the latest
accomplishing service and repair procedures. Following product information available at the time of publication.
the procedures in this manual will help assure safety and JLG reserves the right to make changes and
equipment reliability. improvements to its products, and to discontinue the
Read, understand and follow the information in this manufacture of any product, at its discretion at any time
manual, and obey all locally approved safety practices, without public notice or obligation.
procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in
the equipment, procedures, or processes described, nor 1.3 OPERATION & SAFETY MANUAL
provide directions for meeting every possible contingency
during operation, maintenance, or testing. When additional The mechanic must not operate the machine until the
information is desired consult the local JLG distributor. Operation & Safety Manual has been read & understood,
training has been accomplished and operation of the
Many factors contribute to unsafe conditions: carelessness, machine has been completed under the supervision of an
fatigue, overload, inattentiveness, unfamiliarity, even experienced and qualified operator.
drugs and alcohol, among others. For optimal safety,
encourage everyone to think, and to act, safely. An Operation & Safety Manual is supplied with each
machine and must be kept in the manual holder located
Appropriate service methods and proper repair in the cab. In the event that the Operation & Safety
procedures are essential for the safety of the individual Manual is missing, consult the local JLG distributor before
doing the work, for the safety of the operator, and for the proceeding.
safe, reliable operation of the machine. All references to
the right side, left side, front and rear are given from the
operators seat looking in a forward direction.
Supplementary information is available from JLG in the
1.4 DO NOT OPERATE TAGS
form of Service Bulletins, Service Campaigns, Service
Place Do Not Operate Tags on the ignition key switch and
Training Schools, the JLG website, other literature, and
the steering wheel before attempting to perform any
through updates to the manual itself.
service or maintenance. Remove key and disconnect
battery leads.
1.2 G10-55A & G12-55A AccuPlace

Safety Practices
1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

To avoid possible death or injury, carefully read, Following are general safety statements to consider before
understand and comply with all safety messages. performing maintenance procedures on the telehandler.
In the event of an accident, know where to obtain medical Additional statements related to specific tasks and
assistance and how to use a first-aid kit and fire procedures are located throughout this manual and are
extinguisher/fire suppression system. Keep emergency listed prior to any work instructions to provide safety
telephone numbers (fire department, ambulance, rescue information before the potential of a hazard occurs.
squad/paramedics, police department, etc.) nearby. If For all safety messages, carefully read, understand and
working alone, check with another person routinely to follow the instructions before proceeding.
help assure personal safety.
1.6.1 Personal Hazards
1.5.1 Safety Alert System and Signal Words PERSONAL SAFETY GEAR: Wear all the protective
clothing and personal safety gear necessary to perform
DANGER the job safely. This might include heavy gloves, safety
glasses or goggles, filter mask or respirator, safety shoes
or a hard hat.
DANGER indicates an imminently hazardous situation LIFTING: NEVER lift a heavy object without the help of at
which, if not avoided, will result in death or serious injury. least one assistant or a suitable sling and hoist.
1.6.2 Equipment Hazards

WARNING LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
that it is of the proper capacity, in good working order, and
WARNING indicates a potentially hazardous situation is properly attached.
which, if not avoided, could result in death or serious
NEVER stand or otherwise become positioned under a
injury.
suspended load or under raised equipment. The load or
equipment could fall or tip.
CAUTION DO NOT use a hoist, jack or jack stands only to support
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
CAUTION indicates a potentially hazardous situation HAND TOOLS: Always use the proper tool for the job;
which, if not avoided, may result in minor or moderate keep tools clean and in good working order, and use
injury. special service tools only as recommended.

Safety Practices
1.6.3 General Hazards appropriate container and dispose of in accordance with

prevailing environmental regulations.
SOLVENTS: Only use approved solvents that are known
to be safe for use. RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
HOUSEKEEPING: Keep the work area and operators
injury. To prevent personal injury, NEVER remove the
cab clean, and remove all hazards (debris, oil, tools, etc.).
radiator cap while the cooling system is hot. Wear safety
FIRST AID: Immediately clean, dress and report all injuries glasses. Turn the radiator cap to the first stop and allow
(cuts, abrasions, burns, etc.), no matter how minor the pressure to escape before removing the cap completely.
injury may seem. Know the location of a First Aid Kit, and Failure to follow the safety practices could result in death
know how to use it. or serious injury.
CLEANLINESS: Wear eye protection, and clean all FLUID FLAMABILTITY: DO NOT service the fuel or
components with a high-pressure or steam cleaner hydraulic systems near an open flame, sparks or smoking
before attempting service. materials.
When removing hydraulic components, plug hose ends NEVER drain or store fluids in an open container. Engine
and connections to prevent excess leakage and fuel and hydraulic fluid are flammable and can cause a
contamination. Place a suitable catch basin beneath the fire and/or explosion.
machine to capture fluid run-off.
DO NOT mix gasoline or alcohol with diesel fuel. The
Check and obey all Federal, State and/or Local mixture can cause an explosion.
regulations regarding waste storage, disposal and
PRESSURE TESTING: When conducting any test, only
recycling.
use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
1.6.4 Operational Hazards manner, and make changes or repairs as indicated by the
ENGINE: Stop the engine before performing any service test procedure to achieve the desired result.
unless specifically instructed otherwise. LEAVING MACHINE: Lower the forks or attachment to
VENTILATION: Avoid prolonged engine operation in the ground before leaving the machine.
enclosed areas without adequate ventilation. TIRES: Always keep tires inflated to the proper pressure
SOFT SURFACES AND SLOPES: NEVER work on a to help prevent tipover. DO NOT over-inflate tires.
machine that is parked on a soft surface or slope. The NEVER use mismatched tire types, sizes or ply ratings.
machine must be on a hard level surface, with the wheels Always use matched sets according to machine
blocked before performing any service. specifications.
FLUID TEMPERATURE: NEVER work on a machine MAJOR COMPONENTS: Never alter, remove, or
when the engine, cooling or hydraulic systems are hot. substitute any items such as counterweights, tires,
Hot components and fluids can cause severe burns. batteries or other items that may reduce or affect the
Allow systems to cool before proceeding. overall weight or stability of the machine.
FLUID PRESSURE: Before loosening any hydraulic or BATTERY: DO NOT charge a frozen battery.Charging a
diesel fuel component, hose or tube, turn the engine frozen battery may cause it to explode. Allow the battery
OFF. Wear heavy, protective gloves and eye protection. to thaw before jump-starting or connecting a battery
NEVER check for leaks using any part of your body; use charger.
a piece of cardboard or wood instead. If injured, seek
medical attention immediately. Diesel fluid leaking under
1.7 SAFETY DECALS
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause Check that all safety decals are present and readable on
infection, gangrene and other serious personal injury. the machine. Refer to the Operation & Safety Manual
Relieve all pressure before disconnecting any supplied with machine for information.
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.1 ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.2 ASTM Fastener Torque Chart (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.3 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.3 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.4 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.1 10, 1st 100 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.2 250, 500, 1000 & 1500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

2.1 REPLACEMENT PARTS AND

WARRANTY INFORMATION
Before ordering parts or initiating service inquiries, make
note of the machine serial number. The machine serial
number plate (1) is located as indicated in the figure.
MY1000
1
Note: The replacement of any part on this machine with

any other than JLG authorized replacement parts can
adversely affect the performance, durability, or safety of
the machine, and will void the warranty. JLG disclaims
liability for any claims or damages, whether regarding
property damage, personal injury or death arising out of
the use of unauthorized replacement parts.
A warranty registration form must be filled out by the JLG
distributor, signed by the purchaser and returned to JLG
when the machine is sold and/or put into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the distributor
has returned the business reply card of the warranty
registration form to JLG.

2.2
2.2.1
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
STRESS LOCTITE LOCTITE
TORQUES
SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
G10-55A & G12-55A AccuPlace

IN SQ. IN. LB. IN-LB IN-LB IN-LB IN-LB LB. IN-LB. IN-LB IN-LB IN-LB LB. IN-LB IN-LB
40 0.00604 380 8 6 540 12 9
4 0.1120
48 0.00661 420 9 7 600 13 10
32 0.00909 580 16 12 820 23 17
6 0.1380
40 0.01015 610 18 13 920 25 19
32 0.01400 900 30 22 1260 41 31
8 0.1640
36 0.01474 940 31 23 1320 43 32
24 0.01750 1120 43 32 1580 60 45
10 0.1900
32 0.02000 1285 49 36 1800 68 51
20 0.0318 2020 96 75 105 2860 144 108 160 3180 160 168
1/4 0.2500
28 0.0364 2320 120 86 135 3280 168 120 185 3640 168 178
IN SQ. IN. LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB
18 0.0524 3340 17 13 16 19 4720 25 18 22 30 5240 25 28
5/16 0.3125
24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30
16 0.0775 4940 30 23 28 35 7000 45 35 40 50 7750 45 50
ASTM Fastener Torque Chart (English)
3/8 0.3750
24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55
14 0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77
7/16 0.4375
20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82
13 0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120
1/2 0.5000
20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127
12 0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170
9/16 0.5625
18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182
11 0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231
5/8 0.6250
18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242
10 0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400
3/4 0.7500
16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440
9 0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645
7/8 0.8750
14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700
8 0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950
1 1.0000
12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000
7 0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365
1-1/8 1.1250
12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520
7 0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925
1-1/4 1.2500
12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070
6 1.1550 64100 1460 1100 1322 1525 104000 2380 1780 1907 2625 115500 2320 2550
1-3/8 1.3750
12 1.3150 73000 1680 1260 1506 1750 118100 2720 2040 2165 3000 131500 2440 2685
6 1.4050 78000 1940 1460 1755 2025 126500 3160 2360 2530 3475 140500 3040 3345
1-1/2 1.5000
12 1.5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 3600
Note: These torque values do not apply to cadmium plated fasteners.
2.3
2.4
2.2.2
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
40 0.00604 380 .8 .8 540 1.4 1.0
4 0.1120
48 0.00661 420 1.0 .8 600 1.5 1.0
32 0.00909 580 1.8 1.4 820 2.6 2.0
6 0.1380
40 0.01015 610 2.0 1.6 920 2.8 2.2
32 0.01400 900 3.4 2.4 1260 4.6 3.4
8 0.1640
36 0.01474 940 3.4 2.6 1320 5 3.6
24 0.01750 1120 5 3.6 1580 7 5
10 0.1900
32 0.02000 1285 6 4 1800 8 6
20 0.0318 2020 11 8 12 2860 16 12 18 3180 18 19
1/4 0.2500
28 0.0364 2320 14 10 15 3280 19 14 21 3640 19 20
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
18 0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38
5/16 0.3125
24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41
16 0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68
3/8 0.3750
24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75
ASTM Fastener Torque Chart (Metric)
14 0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104

7/16 0.4375
20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111
13 0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163
1/2 0.5000
20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172
12 0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230
9/16 0.5625
18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247
11 0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313
5/8 0.6250
18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328
10 0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542
3/4 0.7500
16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597
9 0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874
7/8 0.8750
14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949
8 0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288
1 1.0000
12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356
7 0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851
1-1/8 1.1250
12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061
7 0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 2712 96900 2373 2610
1-1/4 1.2500
12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 2983 107300 2549 2807
6 1.1550 64100 1979 1491 1792 2068 104000 3227 2413 2586 3559 115500 3145 3457
1-3/8 1.3750
12 1.3150 73000 2278 1708 2042 2373 118100 3688 2766 2935 4067 131500 3308 3640
6 1.4050 78000 2630 1979 2379 2745 126500 4284 3200 3430 4711 140500 4122 4535
1-1/2 1.5000
12 1.5800 87700 2983 2224 2676 3118 142200 4827 3606 3856 5322 158000 4433 4881

2.2.3 Metric Fastener Torque Chart

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY
CLASS 8.8 METRIC BOLTS & CLASS 10.9 METRIC BOLTS &
CLASS 8 METRIC NUTS CLASS 10 METRIC NUTS
TORQUE TORQUE
TENSILE
CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE
SIZE PITCH LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR
AREA 262 262
263 271 263 271
sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m
3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1
3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3
4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8
5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7
6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17
7 1 28.9 12.6 18 13 16 19 18 25 19 20 28
8 1.25 36.6 15.9 25 19 23 28 22.8 37 27 29 40
10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79
12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139
14 2 115 50.0 140 105 126 154 71.6 200 150 160 220
16 2 157 68.3 219 164 197 241 97.8 313 235 250 344
18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473
20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671
22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915
24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170
27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690
30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310
33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860
36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020
42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440
METRIC CLASS 8.8 METRIC CLASS 10.9

2.3 SPECIFICATIONS
2.3.1 Travel Speeds
G10-55A G12-55A
First Gear 3.4 mph (5,4 km/h) 3.5 mph (5,6 km/h)
Second Gear 6.1 mph (9,8 km/h) 6.3 mph (10,1 km/h)
Third Gear 13.8 mph (22,2 km/h) 14.1 mph (22,7 km/h)
Fourth Gear 20.0 mph (32,2 km/h) 20.4 mph (32,8 km/h)
2.3.2 Electrical System
Battery:
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Quantity 1
Reserve Capacity 1,000 Cold Cranking Amps @ 0 F (-18 C)
Group/Series Group 31
Alternator 12V, 95 Amps
2.3.3 Engine Performance Specifications
Description G10-55A G12-55A

Engine Make/Model Perkins 1104D - 125HP Perkins 1104D - 142 HP
Displacement 269 in (4,4 liters) 269 in (4,4 liters)
Low Idle 1000 rpm 900 rpm
High Idle 2,400 to 2,650 rpm 2,400 to 2,650 rpm
Horsepower 125 HP (93 kW) @ 2400 rpm 142 HP (104 kW) @ 2400 rpm
Peak Torque Not Available at Publication 410 lb-ft (556 Nm) @ 1400 rpm
Fuel Delivery Fuel Injection Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Dry Type, Replaceable Primary and
Safety Elements Safety Elements

2.3.4 Tires
Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm).
a. G10-55A
Size Tire Type Minimum Ply/ Fill Type Pressure

Star Rating
14.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply Pneumatic 65 psi (4,5 bar)
approx. 720 lb foam
14.00 x 24 G-3/L-3 Bias Ply Rock 12 Ply Pneumatic 65 psi (4,5 bar)
approx. 720 lb foam
14.00 x 24 G-2/L-2 Radial 1 Star Pneumatic 70 psi (4,8 bar)
approx. 720 lb foam
14.00 x 24 Solid N/A Solid Rubber N/A
approx. 785 lb foam
approx. 785 lb foam
approx. 785 lb foam
b. G12-55A
Size Tire Type Minimum Ply/ Fill Type Pressure

Star Rating
14.00 x 24 Solid N/A Solid Rubber N/A
approx. 785 lb foam
approx. 785 lb foam
approx. 785 lb foam

2.4 FLUID AND LUBRICANT CAPACITIES
Engine Crankcase Oil

Capacity with Filter Change - Perkins 7 quarts (6,5 liters)
Oil Type 15W-40 CE
Fuel Tank
Capacity 38 gallons (144 liters)
Type of Fuel Low Sulfur Diesel #2
Cooling System
System Capacity - Perkins 20.5 quarts (19,4 liters)
Overflow Bottle Capacity 3 quarts (2,8 liters)
Type of Fluid 50/50 ethylene glycol & water
Coolant Conditioner (refer engine manual) 0.5 quarts (0,47 liters)
Transmission
Capacity with Filter Change 4.23 gallons (16 liters)
Type of Fluid Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46)
Transfer Case
Capacity 1.5 quarts (1,4 liters)
Axles
Differential Housing Capacity Front Axle - 15.8 quarts (15 liters)
Rear Axle - 16.9 quarts (16 liters)
Wheel End Capacity 2 quarts (1,9 liters)
Hydraulic System
System Capacity G10-55A - 63 gallons (238 liters)
G12-55A - 65 gallons (246 liters)
Reservoir Capacity 38 gallons (144 liters)
Auxiliary Hydraulic Circuit Max Flow 16 gpm (72,7 lpm)
Type of Fluid Mobilfluid 424 Tractor Hydraulic Fluid

2.5 SERVICE AND MAINTENANCE

SCHEDULES
2.5.1 10, 1st 100 & 50 Hour
EVERY
10
Check Fuel Check Tire Air Filter Check Engine Check Hydraulic
Level Pressure Restriction Oil Level Oil Level
Indicator
Check Check Hydraulic Check Auto-

Transmission Return Filter Sway Function
Oil Level Indicator
1st
100
Change Change Wheel Change Engine Change Change

Axle Oil End Oil Oil & Filter Transmission Transfer
Oil & Filter Case Oil
LB/F
T (N
m)
Check Wheel Check Boom

Lug Nut Chain Tension
Torque
EVERY
50
Drain Fuel/ Check Engine Check Lubrication

Water Coolant Level Battery Schedule
Separator
MY1731

2.5.2 250, 500, 1000 & 1500 Hour
EVERY
250
Change Engine Check Axle Check Wheel Air Filter Check

Oil and Oil Level End Oil Levels Vacuator Fan Belt
Filter* Valve
Check Boom Check Boom Check Transfer Check Rear Axle

Chain Bearing Case Oil Level Stabilization
Tension Pads (if equipped)
EVERY
500
LB/F
T (N
m)
Change Fuel Check Wheel

Filter Lug Nut
Torque
EVERY
1000
Change Change Change Change Wheel

Transmission Transfer Case Axle Oil End Oil
Oil & Filter Oil
EVERY
1500
Change Change Change

Engine Coolant Hydraulic Hydraulic Tank
Fluid & Filters Breather
MY0090
Note: Engine oil & filter service interval can be extended. See Engine Manual for details.

2.6 LUBRICATION SCHEDULES
a. 50 Hour
EVERY
50
OY1630

b. 250 Hour
EVERY
250
OW1210

Section 3
Boom
Contents

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.2 Second, Third & Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . 3.4
3.3.3 Third & Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3.4 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.3.5 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.3.6 Third & Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.3.7 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.3.8 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.4 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.4.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.4.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.4.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.4.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.4.5 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.4.6 Retract Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.4.7 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.4.8 Extend Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.5 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.6 Hydraulic Sub-Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.6.1 Hydraulic Sub-Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.6.2 Assembling the Hydraulic Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
3.6.3 Hydraulic Sub-Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
3.7 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.7.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.7.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.7.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.8 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.8.1 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.8.2 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.9 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19

Boom
3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY
The following illustrations identify the components that
are referred to throughout this section.
EXTEND
CHAINS
THIRD BOOM
FOURTH BOOM SECTION SECOND BOOM
SECTION SECTION
FIRST
BOOM
SECTION
ELECTRICAL
CONNECTION
ATTACHMENT
TILT CYLINDER
ATTACHMENT BOOM HYDRAULIC

QUICK SWITCH ASSEMBLY
(Inside Boom) RETRACT
CHAINS
EXTEND/RETRACT
CYLINDER
(Underside Of Boom)
HOSE
SHEAVES
MAP0500

Boom
3.2 BOOM SYSTEM - FOUR SECTION 3.3.1 Boom Removal

1. Remove any attachment from the quick switch
3.2.1 Boom System Operation assembly.
The four section boom consists of the first, second, third Note: If replacing the fourth section boom, remove the
and fourth assemblies with double third and fourth quick switch from the fourth section. Refer to Section
section extend chains, a double third section retract chain 3.8.1, Quick Switch Removal.
and a single fourth section retract chain.
2. Park the machine on a hard, level surface, level the
As the extend/retract cylinder, which is anchored at the machine, fully retract the boom, raise the boom,
front of the second boom section, and the rear of the first place the transmission control lever in
boom section begins to extend, it forces the second boom (N) NEUTRAL, engage the park brake and shut the
section out of the first boom section. engine OFF.
The boom sections are connected by extend and retract 3. Place a Do Not Operate Tag on both the ignition key
chains. These chains are routed around sheaves on the switch and the steering wheel, stating that the
second and third boom sections. As the second section is machine should not be operated.
forced out hydraulically, the third and fourth boom
4. Open the engine cover. Allow the system fluids to
sections are pulled out by the extend chains.
cool.
As hydraulic pressure is applied to the retract port on the
5. Remove the battery negative (-) cable from the
extend/retract cylinder, the second boom section is pulled
battery negative (-) terminal.
back into the first boom section, and the retract chain
pulls the third and fourth boom sections back into the 6. Support the front of the boom by placing a sling
second boom section. behind the boom head.
This mechanical linkage formed by the chains and 7. Label, disconnect and cap all hydraulic hoses for the
supporting hardware, extends and retracts the third and extend/retract and tilt circuits. Cap all fittings and
fourth boom sections at the same rate. openings to keep dirt & debris from entering the
hydraulic system.
The boom section lifts and lowers via action of the lift/
lower cylinder. 8. Support the lift cylinder on the left side of the
machine. Remove the lock bolt and rod end pin.
3.3 BOOM ASSEMBLY MAINTENANCE Lower the lift cylinder onto the frame rails. Repeat
this step for the right side lift cylinder.
These instructions must be completed in sequence. The 9. Lower the boom to a level position and place a
second, third and fourth boom sections are removed from suitable support under the boom head. Reposition
the first boom section. The third and fourth boom sections the slings to each end of the boom.
are removed from the second boom section. The fourth 10. Remove the boom angle sensors from both the left
boom section is removed from the third boom section. and right side of the boom. Refer to Section 9.11.12,
Before beginning, conduct a visual inspection of the Boom Angle Sensors.
machine and work area, and review the task about to be 11. Remove the bolt securing the boom pivot pin. Pull
undertaken. Read, understand and follow these out the boom pivot pin.
instructions.
12. Lift the complete boom off machine and set on level
ground or supports.
WARNING
NEVER weld or drill the boom unless approved in
writing by JLG. The structural integrity of the boom
will be impaired if subjected to any repair involving
welding or drilling. Failure to comply can result in
death or severe personal injury.

Boom
3.3.2 Second, Third & Fourth Boom Section hose ends and tube ends to prevent dirt and debris
Removal from entering the hydraulic system.
1. Set the complete boom on level ground and by 9. Disconnect the top front chains (3) from the chain
repositioning the slings, turn boom over on to the top clevis on the first and second boom section.
side. Set the complete boom on suitable stands to 10. Release the chain tension from the front top chains.
begin tear down.
11. Remove the front top chain rollers from the second
Note: With the complete boom setting upside down, the and third boom sections.
removal and replacing of each boom section, hoses,
12. Remove the chain adjustment block (4) from the first
extend and retract chains and hose carrier are made
boom section.
much easier.
13. Remove all wear pads from the front of the first
2. Remove the extend/retract cylinder support from the boom section. Tag each pad, backing plate, shim
front of the boom. and bolts from each location.
3. Support the extend/retract cylinder with a suitable 14. Carefully pull the second, third and fourth boom
sling. Remove the lock bolt and pin from both ends sections together from the first boom section and
of the cylinder. Remove the cylinder. place on suitable support for further separation.
4. Unhook the latch on the Boom Length Sensor cable
from the third boom section. Refer to Section 3.3.3 Third & Fourth Boom Section Removal
9.11.13, Boom Length Sensor.
1. Loosen and remove the bottom rear and side wear
5. At the boom head, attach a sling through the rod end pads from the third boom section. Tag each pad,
of the tilt cylinder. Remove both hoses from the tilt backing plate, shim and bolts from each location.
cylinder. Plug the hose ends and cap the tilt cylinder
2. Remove the standard and optional hose sheaves
fittings to prevent dirt and debris from entering the
from the rear of the second boom section.
hydraulic system. Remove the pin from the barrel
end of the tilt cylinder and remove the cylinder from 3. Remove the chain and chain clevis (5) from the rear
the boom head. of the second boom section.
6. Loosen and remove the bottom rear wear pads and
rear side bearing pads from the second boom
section. Tag each pad, backing plate, shim and bolts 5
from each location.
7. Release tension from the hoses on the hose take-up
weldment (1). 6
1 2 MAP0670
4
4. Remove the hydraulic sub-assembly bracket (6) and
hardware from the rear of the third boom section.
5. Pull the hydraulic sub-assembly partially out through
the rear of the boom to access the hoses.
6. Loosen and remove the hoses from the rear of the
hydraulic sub-assembly.
7. Release the tension on the clevis before proceeding.
3 MAP0660 8. Loosen and remove the chain adjustment block from
the bottom of the boom.
8. Loosen the hydraulic hoses (2) and electrical cables
if equipped on the hose take-up weldment. Plug the

Boom
9. Loosen and remove all the wear pads from the front 4. Loosen and remove the front wear pads and
of the second boom section. Tag each pad, backing supports from the third boom section. Tag each pad,
plate, shim and bolts from each location. backing plate, shim and bolts from each location.
10. Place a sling around the third boom section, lift and 5. Carefully pull the fourth boom section out of the third
slowly pull the third and fourth boom sections (7) boom section, taking care to protect the chains.
approximately half way out of the second boom 6. Disconnect the chains when the boom sections are
section. Lower the third and fourth boom sections free from each other.
onto a suitable support.
7. Place the fourth boom section onto suitable
11. Relocate the sling or using two slings for better supports.
stability, balance the two boom sections and slowly
pull them out of the second boom section being If the hydraulic sub-assembly (11) is going to be
careful not to damage any surrounding components. removed:
11
MX0390
8. Remove the guide bracket from the front of the

hydraulic sub-assembly.
7 9. Remove the hardware securing the hydraulic sub-
assembly to the front of the boom.
8
10. Install a sling on the hydraulic sub-assembly at the
rear of the boom. Slowly pull it loose from the bottom
MY1690 bracket located on the bottom plate of the fourth
boom section.
12. Remove the chain (8) from the second boom section
to the third boom section after the boom sections are 11. When the sub-assembly is approximately 25% free
free from each other. of the boom, fasten the two hose carriers together
(using nylon tie-wraps or nylon straps) to prevent
13. Lower the third and fourth boom sections onto a them from separating.
suitable support.
Note: Do not wrap the hose carrier since it will not
3.3.4 Fourth Boom Section Removal prevent the two hydraulic carriers from moving apart
sideways.
1. Remove the bottom rear and side bearing pads from
the fourth boom section. Tag each pad, backing 12. Continue to withdraw the sub-assembly, fastening
plate, shim and bolts from each location. the hydraulic carriers together as they are removed.
2. Loosen and remove the 3/4 in. chain (9) through the 13. When the hydraulic carrier is approximately 75% tied
rear of the fourth boom section. together, pull the assembly free of the boom.
10 9
3.3.5 Fourth Boom Section Installation
1. Clean and lubricate the inside of the boom sections
where the hydraulic sub-assembly rides
(if removed).
2. Using a sling, lift the balanced hydraulic sub-
assembly and slowly insert it into the fourth boom
section.
3. As the first tie wrap nears the boom, remove the tie
MX0380 wrap and continue inserting the sub-assembly and
removing each tie wrap until the sub-assembly is
3. Loosen and remove the retract chain roller (10) at fully inserted.
the rear of the third boom section.

Boom
Note: Be certain the hydraulic sub-assembly locks into 2. Grease the inside of the second boom section on
place on the pin bracket at the bottom of the fourth boom areas where the third section wear pads will slide.
section. 3. Install the grease fittings for the wear pad and chain
4. Reconnect the hydraulic hoses and any optional roller assembly.
circuits. 4. Install the chain clevis to the rear of the third boom
5. Install the guide bracket and hardware to secure the section.
hydraulic sub-assembly to the front of the boom. 5. Install the chain roller (1) at the bottom rear of the
6. Reinstall the hose take-up compression spring. boom.
Torque the jam nut to 100 lb-ft. There should be a 6. Install the chain roller at the top front of the boom.
1 in. (25 mm) gap from the back of the jam nut to the
7. Lay out and lubricate the retract chain. Make sure
end of the threads on the hose take-up weldment.
the chain has been inspected and meets the
7. Install the wear pads, backing plates and shims to adjustment parameters in Section 3.4.1, Boom
the top, bottom and sides of the fourth boom section. Chain Inspection.
Do not shim or tighten the bolts at this time.
8. Connect the retract chain (2) to the clevis at the rear
8. Attach the chain clevis and the keeper plate to the of the fourth boom section.
inside rear of the boom. 2
1
9. Install the grease fitting extensions for the bottom
rear wear pads.
10. Lubricate the extend chain completely. Make sure
the chain is inspected and is in good working
condition. See Section 3.4.4, Chain Lubrication.
11. Attach the chain to the chain clevis.
12. Attach the chain clevis to the top of the fourth boom
section.
MX0380
13. Grease the inside of the third boom section on areas
where the fourth boom section wear pads will slide. 3
14. Using a suitable sling, balance the fourth boom 9. Connect the chain to the chain clevis and the clevis
section and carefully slide 3-4 ft (1-1,5 m) into the to the chain adjustment block. Adjust the nut until the
front of the third boom section. Set the fourth boom gap between the nut and the washer is 1/8 in.
section head onto suitable supports and reset sling (3,175 mm). Torque the locknut to 100 lb-ft
under the boom head. Carefully slide the fourth (135 Nm).
boom section into the third boom section. Leave
6-8 in (15-20 cm) of the fourth boom section out to 10. Lay out and lubricate the two extend chains. Make
be able to install wear pads on the front of the third sure the chains have been inspected and meets the
boom section. adjustment parameters in Section 3.4.1, Boom
Chain Inspection.
15. With the boom head still supported, install the top
wear pads, washers and bolts in the front of the third 11. Attach the rear chain clevis to the chain.
boom section. Remove the boom head from 12. Using a suitable sling, balance the fourth and third
supports and install the remaining wear pads inside boom sections and carefully slide 3-4 ft (1-1,5 m)
the third boom section. Do not shim or tighten the into the front of the second boom section. Set the
bolts at this time. fourth and third boom sections onto suitable
16. Install the grease fittings for the wear pad and chain supports and reset the sling under the boom head.
roller assembly. Carefully slide the fourth and third boom sections
into the second boom section. Leave 6-8 in
3.3.6 Third & Fourth Boom Section (15-20 cm) of the third boom section out to be able to
Installation install the wear pads on the front of the second
section.
1. Install the top, bottom and side rear wear pads onto
13. With the boom still supported, install the top wear
the third boom section. Do not shim or tighten the
pads in the front of the second boom section.
bolts at this time.

Boom
Remove the boom from supports and install the 9. Connect the chain clevis (5) to the second boom
remaining wear pads to the second boom section. section.
Do not shim or tighten bolts at this time. 10. Assemble the rear bottom chain roller to the second
14. Install the grease fittings for the wear pad and chain boom section.
roller assembly. 11. Shim all wear pads needed to obtain the minimum
gap of 1/16 in (1,6 mm). Tighten all wear pad bolts to
3.3.7 Second Boom Section Installation the correct values. Refer to Section 3.7, Boom Wear
1. Install the top, bottom and side rear wear pads onto Pads.
the second boom section. Do not shim or tighten the 12. Install the hose sheave to the second boom section.
bolts and this time.
13. Attach the hoses, and optional auxiliary hoses and
2. Lubricate the inside of the first boom section on electrical cable to the hose carrier at the rear of the
areas where the second boom section wear pads boom.
will slide.
14. At the rear of the boom, install the bracket (6) to the
3. Attach the chain clevis (3) to the rear of the third back of the hose carrier.
boom section.
4. Using a suitable sling, balance the second, third and
fourth boom sections and carefully slide 3-4 ft into
the front of the first boom section. Set the second, 6
third and fourth boom sections on a suitable support 5
and reset the sling under the boom head of the
fourth boom section. Carefully slide the three boom
sections into the first boom section. Leave 6-8 in of
the two boom sections out to be able to install the
wear pad block and the wear pads in the front of the
first boom section.
5. Install the chain adjustment block (4) to the bottom of
the boom.
MAP0670
4
15. Install the hose guide bracket for the electric and
hydraulic options at the rear of the boom.
16. Attach the chain clevis to the chain.
17. Install the hoses to the hose carrier at the rear of the
boom.
18. Install the hose guide bracket to the rear of the
second boom section.
19. Install the optional hydraulics and electrical cables if
MX0440 equipped.
20. Connect the hose assembly to the take-up
6. With the boom still supported, install the top wear weldment.
pads in the front of the first boom section. Remove 7
the boom from supports and install the remaining
wear pads to the first boom section. Do not shim or
tighten bolts at this time.
7. Lubricate the retract chain on the bottom of the
second boom section.
8. Install the lube fittings to the wear pad and chain
roller assembly. MY1720

Boom
21. Install the top front chain roller (7) to the second and 3.3.8 Boom Installation
third boom sections. 1. Park the machine on a hard, level surface, place the
transmission control lever in (N) NEUTRAL, engage
the park brake, chock the wheels and shut the
engine OFF.
2. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the
MAP0740 frame pivot bore with the boom assembly pivot bore.
8
Install the boom pivot pin.
22. Install the cushion clamps around the hoses on the 3. With the sling still in place, install the compensation
first boom section. cylinder, pins and bolts.
23. Connect the top front chain clevises to the chains, 4. With the sling still in place, install the rod end of the
then connect the chains to the first and second left lift/lower cylinder, pin and lock bolt. Repeat for
boom sections. the right side lift/lower cylinder.
24. Adjust the retract chain (8) at the bottom front of the Note: Raising the boom up or down with the sling may
first boom section to 2 7/8 in. (73 mm) for the initial be necessary so the boom, compensation and lift/lower
setup. cylinder bores can be aligned for easier pin installation.
25. Install the auxiliary hydraulic hoses and electrical Note: Grease the boom pivot bore, compensation
cables to the boomhead of the fourth boom section. cylinder rod ends, lift/lower cylinder rod end and pins
26. Using a suitable sling, install the tilt cylinder to the before installing.
front of the boom.
5. Uncap and reconnect the previously labeled
27. Using a suitable sling, install the extend/retract hydraulic hoses to the extend/retract cylinder.
cylinder and support to the second and first boom 6. Uncap and connect any remaining hydraulic fittings
section. to their appropriate locations.
28. Reconnect the latch on the Boom Length Sensor
7. Recheck the wear pad gaps to ensure they meet the
cable to the third boom section. Refer to Section
minimum gap requirement. Shim if necessary.
9.11.13, Boom Length Sensor.
8. Ensure that the boom chains are properly adjusted.
Refer to Section 3.5, Boom Section Separation
Adjustment.
9. Install and reconnect the boom angle sensors to
both the left and right side of the boom. Refer to
Section 9.11.12, Boom Angle Sensors.
10. Connect the battery negative (-) cable to the battery
negative (-) terminal.
11. Start the engine and operate all boom functions
several times. Check for leaks, and check the
hydraulic fluid level in the reservoir; add fluid if
required.
12. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
13. Close and secure the engine cover.

Boom
3.4 BOOM EXTEND AND RETRACT Following are some examples of dynamic shock loading
which can impose abnormal loads above the endurance
CHAINS
limit of a leaf chain.
High velocity movement of load, followed by
3.4.1 Boom Chain Inspection sudden, abrupt stops.
Carrying loads in suspension over irregular
WARNING surfaces such as railroad tracks, potholes, and
rough terrain.
Worn pins, stretched or cracked links or corrosive
Attempting to inch loads which are beyond the
environments can cause chain failure. A chain failure
rated capacity of the vehicle.
could result in uncontrolled boom movement, loss of
load or machine instability, and could cause death or The above load cycles and environmental conditions
serious injury and/or property damage. make it impossible to predict chain life. It is therefore
necessary to conduct frequent inspections until
Under normal operating conditions the boom chains will replacement life can be predicted.
need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every The boom chains normal life expectancy can be
1000 hours of operation. Environmental conditions and expressed as a maximum percent of elongation. This is
dynamic impulse/shock loads can drastically affect generally 3%. As the chain flexes back and forth over the
normal operating conditions and require more frequent sheave, the bearing joints (pins and inside link plates)
inspection intervals. gradually incur wear due to articulation.
Environments in which material handling vehicles 3.4.2 Inspection Guidelines

operate can vary widely from outdoor moisture to
temperature to mildly corrosive or highly corrosive 1. Park the machine on a firm, level surface, raise the
industrial atmospheres, in addition to abrasive boom to a horizontal (level) position, place the
exposures such as sand and grit. Some effects can be transmission control lever in (N) NEUTRAL, engage
as follows: the park brake switch.
Moisture - Corrosive rusting reduces chain 2. Fully extend the boom until the extend chain is taut.
strength by pitting and cracking. Shut the engine off.
Temperature - Low temperature reduces chain 3. The extend chains will be visible for inspection with
strength by embrittlement. Going in and out of the vehicle in this state.
cold storage results in moisture from
4. While doing the chain inspection, check all chain
condensation.
clevis ends for distortion or cracking and sheaves for
Chemical Solutions or Vapors - Corrosive attack bearing wear or grooving from the chain.
on the chain components and/or the mechanical
connections between the chain components. 5. Inspect the retract chains every 1000 hours of
Cracking can be (and often is) microscopic. operation.
Going from microscopic cracking to complete 6. Inspect the chains for the following conditions:
failure can be either abrupt or may require an
extended period of time.
Abrasives - Accelerated wearing and scoring of
the articulating members of the chain (pins and
plates), with a corresponding reduction in chain
strength. Due to the inaccessibility of the bearing
surfaces (pin surfaces and plate apertures),
wear and scoring are not readily noticeable to
the naked eye.

Boom
Edge Wear Distorted or Battered Link Plates

Check the chain for wear on the link plate edges Distorted or battered link plates (5) on a leaf chain can
caused by running back and forth over the sheave. cause tight joints and prevent flexing.
The maximum reduction of material should not
exceed 5%. Measure and compare to a normal link
plate height by measuring a portion of chain that 85
does not run over the sheave. If the measured plate
height (1) is 5% less than the normal plate height
(2), discard and replace the chain.
MZ1466
1 2
Turning or Protruding Pins
Highly loaded chain, operating with inadequate
lubrication can generate abnormal frictional forces
MZ1463 between pin and link plates. When chain is allowed
to operate in this condition, a pin or series of pins,
can begin to twist out of a chain, resulting in failure.
Elongation
Examine the pin head rivets to determine if the
It is important to measure the chain in the section VEE flats are still in correct alignment (6). Chain
that moves over the sheaves because it receives the with rotated/displaced heads (7) or abnormal pin
most frequent articulation. Measuring the chain near protrusion (8) should be replaced immediately.
its clevis terminals could give an inaccurate reading.
The ends of the chains, near the clevis terminal, will DO NOT attempt to repair the chain by welding or
not have flexed as frequently, if at all, as the middle driving the pin(s) back into the chain. Once the press
of the chains. fit integrity between outside plates and pins has
been altered, it cannot be restored.
It is best to measure in 12 pin increments from pin
center to pin center. For example, if the links are one Any wear pattern on the pin heads or the sides of the
inch from pin center to pin center, the distance link plates indicates misalignment in the system.
should be 12 in (305 mm). If the links are 3/4 in This condition damages the chain as well as
apart, the distance after 12 pins should be 9 in. increases frictional loading and should be corrected.
If the distance measured (3) is 3% greater than the
normal length (4), discard and replace the chain.
4 7
6
3 8
MZ1465
MY1360

Boom
Cracked Plates 3.4.3 Expose Chains for Inspection

Inspect the chains very carefully, front and back as
c. Extend Chains
well as side to side, for any evidence of cracked
plates. If any one crack is discovered, the chain 1. Park the machine on a firm, level surface. Place the
should be replaced in its entirety. transmission control lever in (N) NEUTRAL, engage
It is important, however to determine the cause of the park brake switch and raise the boom to a
the crack before installing a new chain so the horizontal (level) position.
condition does not repeat itself. 2. Fully extend the boom until both extend chains are
The types of cracks are: taut. Shut the engine OFF.
Fatigue Cracking - The extend chains will be visible for inspection with the
Fatigue cracks (9) are a machine in this state.
9
result of repeated While doing the chain inspection, check all chain clevis
cyclic loading beyond MZ1467
ends for distortion or cracking and sheaves for bearing
the chains endurance
wear or grooving from the chain.
limit.
If during the inspection, any chain is found to be damaged
Stress Corrosion
or stretched, the chain must be replaced. It is
Cracking - The
10 recommended that when any chain is replaced, that all
outside link plates
are particularly MZ1468
the chains and clevises be replaced at the same time.
susceptible to stress
corrosion cracking (10). d. Retract Chains
Corrosion Fatigue Cracking - Corrosion The three retract chains are only partially visible through
fatigue cracks are very similar to fatigue the rear of the boom with all the sections retracted. It is
cracks in appearance. Corrosion fatigue is the possible to see a section of the retract chain as the boom
combined action of an aggressive is slowly extended. If there is ANY question that one or all
environment and cyclic stress. the retract chains are damaged, the boom should be
Other Modes of Failure removed and disassembled with the retract chains being
inspected and replaced if necessary.
Ultimate Strength Failure -
These types of failures are Note: DO NOT attempt to repair a chain. Replace a
caused by overloads far in 1 stretched or damaged chain with a new part. Always
excess of the design load. MZ1469 replace both the chain and the clevis. It is recommended
Either fractured plates (1) or 2 that when any chain is replaced, that all chains and
enlarged holes (2) can clevis be replaced at the same time.
occur. If either of these
MZ1470
failures occurs, the chain
should be replaced immediately.
Tight Joints
- All joints in
the chain
should flex
freely. Tight
3 MZ1471
joints (3)
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or
bent pins, replace the chain.

Boom
3.4.4 Chain Lubrication 5. Remove the rod end pin and lower the cylinder onto
the frame rails. Lowering the extend/retract cylinder
After inspection and before being returned to service,
chains must be lubricated with a quality chain lubricant will allow access to the chains.
(LUBRIPLATE Chain & Cable Fluid, LPS3 or 6. Remove tension from the chain by backing off the
equivalent). jam nut and adjusting nut (1).
The lubricant must penetrate the chain joint to prevent 4
wear. Applying lubricant to the external surfaces will
prevent rust, but the chains should be articulated to
make sure the lubricant penetrates to the working
surfaces between the pins and links.
To prepare the chain for lubrication, the chain plates MX0510
should be brushed with a stiff brush or wire brush to 1 3

clear the space between the plates so that lubricant can 2
penetrate to the working surfaces.
7. Remove the four bolts (2) from the chain adjustment
Lubricant may be applied with a narrow paint brush or block.
directly poured on, but the chain should be well flooded
with lubricant and the boom should be extended and 8. Remove the chain from the clevis (3) at the block.
retracted to be sure that the lubricant penetrates to the 9. Install a nylon tie wrap through the holes of the
working surfaces. All surplus lubricant should be wiped removed chain, making a loop with a tie wrap and tie
away from the external surfaces. DO NOT use a solvent a rope to the loop.
for this wiping operation.
10. At the rear of the boom, pull the chain to the rear to
Regular application of lubricant is necessary to make allow slack for removal.
sure that all working surfaces are adequately lubricated.
In extremely dusty conditions, it may be necessary to 11. Remove the chain from the clevis and drop it free
lubricate the chains more often. from the boom.
Lubrication of chains on vehicles working consistently in 12. Holding a rope at the front adjustment block,
extreme hot or cold conditions requires special carefully pull the chain out through the back of the
consideration. It is important that a reputable lubrication boom.
specialist, a JLG Distributor or the vehicle distributor be 13. Untie the rope and leave it in place for reinstallation
consulted for guidance. of the chain.
3.4.5 Retract Chain Removal To remove the 3/4 in. retract chain from the fourth to
second boom sections:
The following section explains the removal of the retract
chains without removing the boom assemblies. 1. Remove the jam nut (4) from the chain clevis
installed in the chain adjustment block.
Note: The retract chain on the bottom of the boom must
2. Back off the adjusting nut fully on the chain clevis.
be removed to gain access to the inner retract chain.
Do not remove the nut from the clevis.
To remove the 1 in. retract chain from the third to first 3. Remove the chain from the clevis, install a nylon tie-
boom sections: wrap through the holes in the chain, making a loop
1. Park the machine on level ground. Place the with the tie-wrap and tie a rope to the loop.
transmission control lever in (N) NEUTRAL, engage 4. Move to the back of the boom and pull the chain to
the parking brake switch, level the boom and shut the rear to allow slack for removal.
the engine OFF.
5. Remove the chain from the clevis and drop it free
2. Place a Do Not Operate Tag on both the ignition key from the boom.
switch and the steering wheel, stating that the
machine should not be operated. 6. Holding the rope at the front, carefully pull the chain
out through the back of the boom until its free.
battery negative (-) terminal. 7. Untie the rope and leave it in place for reinstallation
of the chain.
4. Attach a suitable sling to the extend/retract cylinder.
Remove the extend/retract cylinder support.

Boom
3.4.6 Retract Chain Installation 2. Place a Do Not Operate Tag on both the ignition key
Inspect and lubricate chains thoroughly before
machine should not be operated.
installation. Articulate the chains to make sure all working
surfaces are thoroughly lubricated. 3. Remove the battery negative (-) cable from the
Note: If the inner retract chain was removed, it must be
installed first. 4. Secure the boom sections together to prevent
uncontrolled boom run out when the extend chains
1. Fasten a rope to the end of the 3/4 in. chain in order are removed.
to pull it back into the boom.
5. On the chain being removed, loosen and remove the
2. Attach the chain to the chain clevis at the rear of the jam nut from the rear chain clevis and back off the
boom. adjusting nut on the chain clevis to the end of the
3. Carefully pull the chain into the boom until it can be threads. Do not completely remove the nut.
fastened to the chain clevis. 6. Remove the chain clevis pin and retaining ring to
4. Remove the rope. free the chain.
5. Fasten the chain into the clevis by installing the pin 7. Install the nylon tie wrap through the holes in the
and retaining ring. chain, making a loop with the tie wrap and tie a rope
to the loop.
6. Apply Loctite 242 to the jam nut threads and torque
to 100 lb-ft (135 Nm). 8. Pull the slack to the chain clevis at the front of the
boom.
To install the outer retract chain:
9. Remove the clevis pin and the retaining ring from the
1. Fasten a rope to the end of the chain in order to pull
chain and chain clevis.
it back into the boom.
10. Install a nylon tie wrap through the chain holes,
2. Attach the chain to the chain clevis at the rear of the
forming a loop and tie a rope to the loop.
boom.
11. Carefully pull the chain out of the boom.
3. Carefully pull the chain into the boom until it can be
fastened to the chain clevis. 12. Untie the rope and leave it in place for reinstallation
of the chain.
4. Remove the rope.
5. Fastened the chain into the clevis by installing the 3.4.8 Extend Chain Installation
pin and cotter pin.
The following section explains the installation of the
6. Install the chain adjustment block and mounting retract chains without removing the boom assemblies.
bolts. Torque the chain adjustment block mounting
bolts to 360-390 lb-ft (475-530 Nm). Inspect and lubricate chains thoroughly before
installation.
7. Install the extend/retract cylinder and cylinder
support. 1. Fasten the previously used rope to the end of the
extend chain.
8. Adjust the retract chains as needed. Refer to Section
3.5, Boom Section Separation Adjustment. 2. Carefully pull the chain into the boom to the chain
clevis anchor.
negative (-) terminal. 3. Fasten the chain to clevis with a pin and cotter pin.
4. At the other end of the chain, connect the chain to
3.4.7 Extend Chain Removal the clevis fastening the chain to the clevis with a pin
and retaining ring.
The following section explains the removal of the extend
chains without removing the boom assemblies. 5. Install the chain clevis fastening and adjusting
hardware on both ends.
1. Park the machine on level ground. Place the
transmission control lever in (N) NEUTRAL, engage 6. Remove any clamping devises being used to keep
the parking brake switch, level the boom, extend the the boom sections from moving.
boom far enough to access the chain anchor and the 7. Adjust the extend chains as needed. Refer to
clevis through the top rear access hole, shut the Section 3.5, Boom Section Separation Adjustment.
engine OFF.

Boom
3.5 BOOM SECTION SEPARATION

ADJUSTMENT 1
1. Park the machine on level ground. Place the

the parking brake switch and raise the boom to a
horizontal (level) position.
2. Extend the boom 4 ft to 5 ft, then fully retract the
boom.
3. Measure the gap between the flat washer at the
extend chain anchor on the top front of the first boom MY1320
section and the second boom section. If the gap is 2
greater that 3/8 in. (9.52 mm), the boom chains will
3. Loosen the retract chain lock nut and adjusting nut
need to be adjusted.
as far as possible.
While doing the chain inspection, check all chain clevis
4. Tighten the retract chain adjusting nut until the
ends for distortion or cracking and sheaves for bearing
proper distance is obtained and proper access hole
wear or grooving from the chain.
alignment is obtained.
4. If during the inspection, any chain is found to be
5. Torque the lock nut to 100 lb-ft (135 Nm).
damaged or stretched, the chain must be replaced. It
is recommended that when any chain is replaced, 6. Recheck the extend chain adjustments and readjust
that all the chains and clevises be replaced at the if necessary.
same time. 7. Measure the distance between the third boom
Adjust the extend chain as follows: section and fourth boom section (2). The dimension
should be 18.5 in, + 0.25 in - 0.0 in
1. Loosen the lock nut on each of the extend chains.
(469,9 mm, + 6,75 mm - 0,0 mm)
2. Tighten the adjusting nut on the first boom section
8. Tighten the retract chain adjusting nut until the
until the gap between the flat washers and boom is
proper distance is obtained and proper access hole
3/8 in. (9,52 mm) maximum. The gap must be equal
alignment is obtained.
on both chains. Torque the lock nut to 100 lb-ft
(135 Nm). 9. Torque the lock nuts to 100 lb-ft (135 Nm).
3. Tighten the adjusting nut on the second boom 10. Re-adjust the extend chain as needed.
section until the gap between the washer and boom
is 3/8 in. (9,52 mm) maximum. Torque the lock nut to 3.6 HYDRAULIC SUB-ASSEMBLY
100 lb-ft (135 Nm). REMOVAL/INSTALLATION
4. After adjusting, check to see that the boom sections
and access holes are aligned. If they are not, the The hydraulic sub-assembly is located primarily in the
retract chain will need to be adjusted as well. fourth boom section. It is fastened at the bottom front of
the fourth boom section and at the rear of the third boom
Adjust the retract chain as follows:
section.
1. Fully retract the boom.
2. Measure the distance between the second boom 3.6.1 Hydraulic Sub-Assembly Removal
section and the third boom section (1). The 1. Remove any attachment from the quick switch
dimension should be 0.500 in, + 0.250 in - 0.0 in assembly.
(12,7 mm, + 6,75 mm - 0.0 mm).
Note: Allow adequate room in front of the machine
when removing and installing the hydraulic sub-
assembly.

Boom
2. Park the machine on a hard, level surface, level the 10. Loosen and remove the sub-assembly bracket (4) at
machine, fully retract the boom, level the boom, the rear of the third boom section.
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
4
cool. 1
MY2720
6. Label and disconnect the tilt and auxiliary hydraulic
hoses attached to the sub-assembly at the rear of 11. Install a sling around the sub-assembly at the front of
the boom and at the front of the boom head. Plug the boom. With a suitable lifting device, slowly pull
and cap the hose ends to prevent dirt and debris the sub-assembly loose from the bottom bracket (5)
from entering the hydraulic system. located approximately halfway in the fourth boom
7. If equipped, label and disconnect any electrical section.
connections at the front and rear of the boom
assembly.
FRONT
Note: Tag or identify each hose to the corresponding
fitting it was removed from.
8. Loosen and remove both cap screws and locknuts
(2) from the sub-assembly bracket at the front of the
fourth boom section.
MY2700
5
3
12. When the sub-assembly is pulled approximately
25% out of the boom, fasten the two hydraulic
carriers together using plastic tie wraps or nylon
straps to keep them from separating.
1 Note: Do Not wrap the hose carrier since it will not
prevent the two hydraulic carriers from moving apart
sideways.
MY2710
13. Continue withdrawing the sub-assembly, fastening
2 the two hydraulic carriers together.
14. With the two hose carriers tied together, remove the
9. Loosen and remove the guide bracket (3) from the
sub-assembly and set on the ground or proper
front of the fourth boom section.
supports.

Boom
3.6.2 Assembling the Hydraulic Sub- 3. Fully collapse the hose carriers and secure together
Assembly using plastic tie wraps or nylon straps to keep them
from separating.
The following procedure is described with the assumption
that all components have been removed and assembly 4. Install a sling around the balance point of the sub-
proceeding from the beginning. assembly. With a suitable lifting device, slowly insert
the sub-assembly into the front of the fourth boom
section.
5. Remove the first plastic tie wrap or nylon strap as the
hydraulic sub-assembly is being inserted into the
front of the fourth boom section.
6. Continue inserting the hydraulic sub-assembly and
removing the plastic tie wraps or nylon straps until
the sub-assembly is fully inserted into the boom.
7. Verify that the bottom bracket (2) on the sub-
assembly is in place on the bottom plate (3) of the
fourth boom section.
MY2730
1. Place both sections on a suitable stand or support.

FRONT
2. Install the wear pad to the bottom of the upper
hydraulic carrier.
3. Install the bulkhead fittings to each hydraulic carrier.
4. Install the tube assemblies to the bulkhead fittings
on each hydraulic carrier.
5. Install the cushion clamps to the tube assemblies MY2700
and secure to each hydraulic carrier. 2 3
6. Install the hose carrier to each hydraulic carrier and
8. Install the cap screws, washers and nuts to the sub-
install each tilt hose and auxiliary hose to the proper
assembly bracket at the rear of the third boom
fitting or tube connection.
section.
7. Tie wrap the hydraulic hoses together where they
9. Install both cap screws and locknuts to the sub-
extend from each end of the hose carrier.
assembly bracket at the front of the fourth boom
8. Fasten the two hydraulic carriers together using section.
plastic tie wraps or nylon straps for stability.
10. Uncap and reconnect the previously labeled tilt and
auxiliary hydraulic hoses to the proper fittings at the
3.6.3 Hydraulic Sub-Assembly Installation rear of the hydraulic sub-assembly.
1. Clean and lubricate the side surfaces where the 11. Uncap and reconnect the previously labeled tilt and
hydraulic sub-assembly rides. auxiliary hydraulic hoses to the proper fittings at the
2. Install the guide bracket (1) on the front of the front of the fourth boom section.
hydraulic sub-assembly. 12. If equipped, reconnect any electrical connections at
the front and rear of the boom assembly.
MY2740

Boom
3.7 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear
pads with metal inserts.
A total of 42 wear pads are installed on the boom.
3.7.1 Wear Pad Inspection

Inspect all wear pads for wear. If the angle indicators (3)
on the ends of the wear pads are visible, the wear pads
can be reused. If the pads show uneven wear (front to
back), they should be replaced. Replace pads as a set if
worn or damaged.
4
3 3
Ma2070
3.7.2 Boom Wear Pad Replacement

When replacing a wear pad on the boom, replace both MY0630
wear pads on that side of the boom; e.g.: replace top front
left and top front right wear pads at the same time.
5
Usually, shimming will remain the same when installing
new wear pads. Some wear pads are secured to the
boom using different bolts and washers. Keep bolts and
washers with the same wear pad that is being replaced.
When installing new wear pads, apply Loctite 242 to all
wear pad mounting bolts and torque to required
specifications.
Wear pad bolt torques are:
3/8 in. bolt: 32-37 lb-ft (43-50 Nm)
1/2 in. bolt: 76-86 lb-ft (103-117 Nm)
Hollow 3/8 in. bolt: 15-17 lb-ft (20-23 Nm)
Hollow 1/2 in. bolt: 45-50 lb-ft (61-68 Nm) 3.7.3 Boom Wear Pad Lubrication
Note: The first shim next to a wear pad always needs to The boom has been factory lubricated for proper wear pad
have the two hole configuration. The remaining pads (4) break-in and will normally require minor further
may have the large slot configuration. lubrication. However, after replacing any wear pad(s), or
after prolonged periods of inoperation, light lubrication of
Use shims under the wear pads as required to maintain a
the boom wear surfaces with a factory authorized grease
maximum gap of 1/16 in (1,6 mm) (5) between the wear
is recommended to keep the boom wear surfaces
pad on the front and sides of the boom. The gap at the
lubricated properly. Light lubrication of the boom wear
rear of the boom should be no more than 3 mm (0.12).
surfaces is also recommended when the machine is
Shims are available in a 0.06 in (1,5 mm) thickness. stored, to help prevent rusting.

Boom
3.8 QUICK SWITCH ASSEMBLY 3.9 FORKS

Forks should be cleaned and inspected prior to being
3.8.1 Quick Switch Removal attached to carriage. If the following criteria is not met,
1. Remove the lock bolt holding the tilt cylinder rod end forks must be removed from service immediately.
pin to the quick switch assembly. Remove the Tilt Daily Inspection
Cylinder pin.
1. Inspect forks (6) for cracks, paying special attention
2. Support the quick switch assembly.Remove the to heel (7) and mounting tubes (8).
capscrew and locknut securing the head pin to the
boom head. 2. Inspect forks for broken or bent tips (9) and twisted
blades (10) and shanks (11).
3. Inspect the above pins for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion. Yearly Inspection
If damaged or if it cannot be repaired, the pin must 1. Straightness of the upper face of blade (10) and the
be replaced. front face of shank (11) should not exceed 0.5
percent of the length of blade or height of shank.
3.8.2 Quick Switch Installation 2. Angle (12) between upper face of blade and front
1. Assemble the quick switch to the boom head. Line face of shank should not exceed 93 degrees.
up the quick switch between the mounts on the 3. Thickness of blade (15) and shank (16) should not
boom head. The quick switch should be centered in be reduced to 90 percent of original thickness.
the boom head.
4. Ensure fork length (14) is adequate for intended
2. Coat the quick switch head pin with an anti-seize loads.
compound. Insert the quick switch head pin through
5. Fork markings should be legible, re-stamp if
the quick switch and boom head. Secure with the
required.
previous capscrew and locknut.
6. Compare fork tips (13) when mounted on a carriage.
Align the quick switch with the tilt cylinder rod end and
Maximum difference in height of fork tips is 3 percent
insert the tilt cylinder pin. Align the tilt cylinder pin and
of the length of the blade (15).
screw in the locking bolt. Torque as required.
8
11
12 9
10
7
6
16
15 13
14 MH6460

Boom
3.10 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.
Problem Cause Remedy

1. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s)
retract. tube(s) and/or connections or tube(s), tighten connections.
leaking.
2. Extend/retract hydraulic system 2. Refer to Section 8.4, Hydraulic

not operating properly. Circuits.
3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section
8.10.1, General Cylinder
Removal Instructions.
4. Electronic control function not 4. Check for DTC. Refer to Section

operating properly. 9.15.8, Diagnostic Trouble
Code (DTC) Table.
2. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.7.2, Boom
Wear Pad Replacement.
3. Excessive boom pivot pin 1. Insufficient lubrication. 1. Lubricate at regular intervals.

noise and/or wear. Refer to Section 2.6,
Lubrication Schedules.
Replace worn pins as needed.
2. Worn bearing(s). 2. Replace bearing(s) and

lubricate at regular intervals.
Refer to Section 2.6,

Boom

4. Drooping chain, or jerky 1. Chain(s) tension not properly 1. Adjust chain(s).
boom extend or retract adjusted.
functions.
2. Chain(s) stretched or binding. 2. Replace chains as needed.
Refer to Section 3.5, Boom
Section Separation Adjustment.
3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to

excessively worn or damaged. Section 3.7.2, Boom Wear Pad
Replacement.
4. Contaminated, corroded or 4. Remove contamination and/or

rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Extend/Retract hydraulic system 5. Refer to Section 8.4, Hydraulic

not operating properly. Circuits.
6. Damaged boom section. 6. Replace the damaged boom

section. Refer to Section 3.3,
Boom Assembly Maintenance.

Code (DTC) Table.
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8.4, Hydraulic

operating properly. Circuits.
3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

8.10.1, General Cylinder
Removal Instructions.
4. Seized boom pivot pin bearing. 4. Replace bearing.

Code (DTC) Table.
6. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

pivot pin noise and/or wear. Refer to Section 2.5, Service
and Maintenance Schedules.
Replace worn pins as needed.
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and

lubricate at regular intervals.
Refer to Section 2.6,

Boom

7. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.7.2, Boom Wear Pad
Replacement.
2. Rapid cycle times with heavy 2. Reduce cycle times.

loads.
3. Contaminated, corroded or 3. Remove contamination and/or

rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be
reconditioned, replace the boom
section(s).
4. Operating in extremely dusty/ 4. Clean equipment frequently.

abrasive conditions.
8. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.4, Hydraulic
operate. operating properly. Circuits.

Code (DTC) Table.
9. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer
to Section 3.4.1, Boom Chain
Inspection.- Replace chains as
needed.
2. Chain sheave(s) not properly 2. Lubricate chain sheave. Refer to

lubricated. Section 2.5, Service and
Maintenance Schedules.
3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer to

freely. Section 2.5, Service and
Maintenance Schedules.
Repair or replace chain
sheave(s) as needed.
4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.5, Service
and Maintenance Schedules.
Replace chains as needed.

Boom
This Page Intentionally Left Blank

Section 4
Cab and Covers
Contents

4.1 Operators Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.3 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.3.4 Boom Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.3.5 Frame Level, Auxiliary Hydraulic and Outrigger Joysticks . . . . . . . . . . . . 4.6
4.3.6 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.7 Heater/Defroster System (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

Cab and Covers
4.1 OPERATORS CAB AND COVERS

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 machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.
FRAME LEVEL INDICATOR
STEERING WHEEL
BOOM JOYSTICK
INSTRUMENT PANEL
FRAME LEVEL JOYSTICK

TRANSMISSION CONTROL
LEVER AUXILIARY HYDRAULIC JOYSTICK
HEATER AND AC OUTRIGGER JOYSTICKS

CONTROLS (optional)
IGNITION SWITCH
MY2780
SERVICE BRAKE PEDAL
ACCELERATOR PEDAL

Cab and Covers
4.2 OPERATORS CAB 3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the battery negative (-) cable at the battery
WARNING negative (-) terminal.
DO NOT service the machine without following all Note: It may be necessary to remove the main dash
safety precautions as outlined in the Safety Practices panel to gain access to the appropriate hydraulic hoses.
section of this manual. Failure to follow the safety Refer to Section 9.12.1, 3-N-1 Digital Gauge.
practices could result in death or serious injury. 5. Label, disconnect and cap the four hoses from the
side of the steering valve (1). Cap the fittings on the
4.2.1 Cab Safety steering valve. Label, disconnect and plug the load
sense hose at the front of the steering valve. Cap the
fitting on the steering valve.
WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural 2
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners of correct size and grade, and torqued to
their specified value.
DO NOT weld, grind, drill, repair or modify the cab in any
way. Any modification or damage to cab structural 3
components requires cab replacement. The lives of the
operator and others are potentially at stake.
To help ensure optimum safety, protection and
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
4
4.2.2 Serial Number Decal
The cab serial number decal is located on the left side of
the cab, behind the seat. Information specified on the
serial number plate includes the cab model number, the 1
cab serial number and other data. Write this information
down in a convenient location to use in cab
correspondence.
4.3 CAB COMPONENTS
MY0120
4.3.1 Steering Column and Orbitrol Valve
6. Remove the steering wheel (2), disconnect and
a. Orbitrol Valve Removal
remove the travel select lever (3), disconnect the
1. Park the machine on a firm, level surface, level the instrument panel harness connector (4).
machine, fully retract the boom, lower the boom, 7. Remove the steering assembly through the dash
place the travel select lever in the (N) NEUTRAL panel opening.
position, engage the parking brake and turn the
engine OFF. 8. Support the steering valve, and remove the four hex-
head capscrews and four lockwashers.
switch and the steering wheel, stating that the Note: DO NOT disassemble the orbitrol valve. The
machine should not be operated. orbitrol valve is not serviceable and must be replaced in
its entirety, if defective.

Cab and Covers
b. Orbitrol Valve Installation b. Service Brake Pedal Removal

1. Secure the steering valve to the steering column 1. Park the machine on a firm, level surface, level the
with four hex-flange capscrews and four machine, fully retract the boom, lower the boom,
lockwashers. Apply Loctite 242 threadlock to the place the travel select lever in the (N) NEUTRAL
capscrews threads before tightening. position, engage the parking brake and turn the
2. Install the steering column through the dash panel engine OFF.
opening. Position steering valve to its original 2. Place a Do Not Operate Tag on both the ignition key
orientation in the cab. switch and steering wheel, stating that the machine
3. Install the travel select lever. Torque the capscrews to should not be operated.
30-35 lb-in (3,4-4 Nm). Connect the instrument panel 3. Open the engine cover. Allow the system fluids to
harness connector and install the steering wheel cool.
assembly. Torque the steering wheel nut to 29-34 lb-ft 4. Disconnect the battery negative (-) cable at the
(39-46 Nm). battery negative (-) terminal.
4. Install new o-rings into the steering valve fittings.
Lubricate the o-rings with clean hydraulic oil.
5. Uncap and connect the previously labeled load
sense hose to the steering valve.
6. Uncap and connect the remaining previously labeled
four hoses to the steering valve.
Note: If necessary, install the main dash panel. Refer to
Section 9.12.1, 3-N-1 Digital Gauge.
7. Connect the battery negative (-) cable at the battery 2 3
1
8. Carefully examine all connections one last time
before engine start-up. Rectify any faulty conditions.
9. Start the engine and check the operation of steering
system. Check for hydraulic fluid leaks. Check the
hydraulic fluid level in the tank and add fluid as
required.
c. Steering Test
Conduct a pressure check of the steering hydraulic MAP0270
circuits at the hydraulic manifold valve. Refer to Section Note: If necessary, remove the dash from the cab by
8.3.1, Pressure Checks and Adjustments. removing the three bolts, nuts and washers.
4.3.2 Service Brake Pedal 5. Remove the bolt and lockwasher (1) securing the
service brake pedal pivot pin (2).
a. Brake Valve Removal/Installation 6. Pull the pivot pin from the service brake pedal
Refer to Section 8.8.7, Service Brake Valve, for removal bracket (3).
information. 7. Remove the service brake pedal from the cab.
c. Service Brake Pedal Installation

1. Position the service brake pedal in its mounting
location within the cab.
2. Apply Loctite Moly Paste #51049 to the pivot pin.
Secure the brake pedal into position with the pivot pin.

Cab and Covers
3. Be sure the brake pedal has the correct range of motion. 1. Position the throttle pedal in its mounting location
Secure pivot pin with bolt and lockwasher. Apply Loctite within the cab.
242 threadlock to the bolt threads before tightening. 2. Secure the throttle pedal into position with the pivot
Note: If necessary, install the dash to the cab by pin.
installing the three bolts, nuts and washers. 3. Install the throttle pedal ball joint to the throttle pedal.
4. Connect the battery negative (-) cable to the battery 4. Connect the battery negative (-) cable to the battery
negative (-) terminal. negative (-) terminal.
5. Close and secure the engine cover. 5. Close and secure the engine cover.
4.3.3 Throttle Pedal 4.3.4 Boom Joystick Assembly
a. Throttle Pedal Removal a. Boom Joystick Assembly Removal

1. Park the machine on a firm, level surface, level the 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the position, engage the parking brake and turn the
engine OFF. engine OFF.
2. Place a Do Not Operate Tag on both the ignition key 2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine switch and steering wheel, stating that the machine
should not be operated. should not be operated.
3. Disconnect the battery negative (-) cable at the 3. Disconnect the battery negative (-) cable at the
battery negative (-) terminal. battery negative (-) terminal.
4. Disconnect the electrical harness connector (4). 4. Remove the plastic right hand panel (7) to gain
5. Remove the bolts (5) securing the throttle pedal to access to the underside of the boom joystick.
the throttle pedal bracket (6). 5. Disconnect the electrical harness connector from the
6. Remove the throttle pedal assembly from the cab. joystick.
6. Remove the bolts (8) on the underside of the joystick
b. Throttle Pedal Installation securing the boom joystick to the cab.
7. Lift the boom joystick from its mounting position.
8. Remove the boom joystick assembly.
8
6
MY2770
MY0940

Cab and Covers
b. Boom Joystick Assembly Installation 5. Label and disconnect the electrical connector to the
joystick (10).
1. Connect the electrical harness connector to the
joystick. 6. Remove any hardware securing the joystick to the
dash panel.
2. Ensure the rubber sleeve at the base of the joystick
is secured over all four corners of the base of the 7. Remove the joystick.
joystick. If necessary, carefully pull the rubber sleeve
over the four corners. b. Joystick Installation
3. Place the joystick into the mount and install the bolts 1. Install the joystick to the RH panel.
securing the boom joystick to the cab. Ensure the 2. Connect the previously labeled electrical connector
rubber sleeve on the joystick stays in place when to the joystick.
tightening the bolts.
3. Install the RH panel to its original position with the
4. Place the plastic right hand panel into position and previously used hardware.
secure with bolts. Ensure the rubber sleeve on the
joystick remains under the panel. 4. Connect the battery negative (-) cable to the battery
negative (-) terminal. 5. Test the complete range of the joystick functions:
6. Test the joystick functions. 6. Close and secure the engine cover.
7. Close and secure the engine cover. 4.3.6 Windshield Wiper Assembly
4.3.5 Frame Level, Auxiliary Hydraulic and Refer to Section 9.9, Window Wiper/Washer Windshield
Outrigger Joysticks Wiper Motor, for removal and installation information.
4.3.7 Heater/Defroster System (If equipped)
a. Heater Assembly Removal

10
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
9 place the travel select lever in the (N) NEUTRAL
position, engage the park brake and shut the engine
OFF.
MY2770 3. Open the engine cover. Allow the system fluids to
cool.
a. Joystick Removal 4. Disconnect the battery negative (-) cable at the
1. Park the machine on a firm, level surface, level the battery negative (-) terminal.
machine, fully retract the boom, lower the boom, 5. Place a suitable container beneath the radiator.
place the travel select lever in the (N) NEUTRAL Slowly turn the radiator cap to the first stop, and
position, engage the parking brake and turn the allow any pressure to escape. Remove the radiator
engine OFF. cap.
2. Place a Do Not Operate Tag on both the ignition key 6. Place a funnel at the base of the radiator to channel
switch and steering wheel, stating that the machine the drained coolant into the container. Loosen the
should not be operated. drain petcock and allow the coolant to drain.
3. Disconnect the battery negative (-) cable at the 7. Transfer the coolant to a container with a cover, and
battery negative (-) terminal. label as Used Antifreeze. Dispose of the used
4. Remove the screws securing the RH panel (9) to the coolant at an approved recycling facility.
cab. Remove the RH panel. 8. Tighten the radiator drain petcock.

Cab and Covers
9. Remove the bolts that secure the seat to the cab. 4. Install the seat riser weldment.
Remove the seat. 5. Install the front plate to the seat riser weldment.
6. Install the cab seat.
7. Fill the cooling system completely with a 50/50
mixture of ethylene glycol and water, allowing time
for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.4, Fluid and
Lubricant Capacities.
12 negative (-) terminal.
Note: 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
11
before continuing.
MY0190
9. Wait for the engine to cool and check the coolant
10. Remove the bolts securing the front plate (11) to the level. Add coolant as required to bring the coolant to
seat riser weldment (12). the proper level.
11. Remove the bolts securing the seat riser weldment
to the cab. Remove the riser weldment. 4.4 CAB REMOVAL
12. Loosen the hose clamps, label and disconnect the
heater hoses (13). Cap or plug the hoses to prevent
debris from entering the heater system. 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 of correct size and grade, and torqued to
their specified value.
Note: To help ensure safety and optimum performance,

replace the cab if it is damaged. Refer to the appropriate
parts manual for ordering information.
Inspect the cab, its welds and mounts. If modification,
13
damage, a cracked weld and/or fatigued metal is
discovered, replace the cab. Contact the JLG distributor or
MY2790 the JLG Service Department with any questions about
13. Label and disconnect any electrical connections. the suitability or condition of a cab.
14. Remove the bolts securing the heater assembly to Note: Remove and label cab components as needed
the cab. Remove the heater assembly. before removing the cab from the machine. Label,
disconnect and cap hydraulic hoses. Transfer cab parts
b. Heater Assembly Installation to the replacement cab after the replacement cab is
securely mounted on the machine.
1. Position the heater assembly to its original orientation
in the cab. Secure with the previous hardware. 1. Park the machine on a firm, level surface. Allow
sufficient overhead and side clearance for cab
2. Connect the previously labeled electrical
removal. Level the machine, fully retract the boom,
connections.
lower the boom, place the travel select lever in the
3. Connect the previously labeled heater hoses to their (N) NEUTRAL position, engage the park brake and
appropriate locations. shut the engine OFF.

Cab and Covers
2. Block all four wheels to help prevent the machine the cab so they do not become damaged during cab
from moving. Ensure that there is sufficient overhead removal.
and side clearance for cab removal. 18. Remove the fuel tank from the cab. Refer to Section
3. Open the engine cover. Allow the system fluids to 7.4.2, Fuel Tank.
cool. 19. Route a sling with a suitable lifting capacity under
4. Disconnect the battery negative (-) cable at the the inner six braces (14) and behind the center cross
battery negative (-) terminal. support above the wind shield.
5. Place a funnel at the base of the radiator to channel 14
the drained coolant into the container. Loosen the
drain petcock and allow the coolant to drain.
6. Transfer the coolant to a container with a cover, and
label as Used Antifreeze. Dispose of the used
coolant at an approved recycling facility.
7. Tighten the radiator drain petcock.
8. Disconnect the cab heater hoses. Refer to Section
4.3.7, Heater/Defroster System (If equipped).
9. Remove the necessary dash panels to gain access
to the electrical wiring connections. Label and
disconnect the harnesses. Push the harness
connectors through the opening in the cab. MY0610
10. Remove the boom joystick from the mounting 20. Remove the two cab side-mount bolts, washers,
position. Refer to Section 4.3.4, Boom Joystick isolators and nuts (15) in the cab.
Assembly. Label and disconnect the electrical
21. Remove the four lower cab-to-frame bolts, washers
harness attached to the boom joystick.
and nuts (16).
11. Remove the frame level and attachment tilt and
auxiliary hydraulic joysticks. Refer to Section 4.3.5,
Frame Level, Auxiliary Hydraulic and Outrigger
Joysticks. Label and disconnect the electrical
harnesses attached to the joysticks.
15
12. Label, disconnect and cap all hydraulic hoses
attached to the steering orbitrol valve. Cap all fittings
and openings to keep dirt and debris from entering
the hydraulic system.
attached to the steering orbitrol valve. Cap all fittings
attached to the service brake valve. Cap all fittings
15. Push all the hydraulic hoses through the opening in
the cab. 16 MAP0160
16. Disconnect the throttle cable from the throttle
assembly. Refer to Section 4.3.3, Throttle Pedal. 22. Remove the mirrors and all other cab components
as needed, if not previously removed.
17. Disconnect the engine air filter and hydraulic oil
reservoir breather from their brackets at the top of 23. Carefully begin to lift the cab. Stop and check that all
the cab. Move the air filter and breather clear from wiring, hydraulic hoses and fasteners are
disconnected or removed.

Cab and Covers
24. When all wiring, hydraulic hoses and fasteners are 11. For machines equipped with the heater option,
disconnected or removed, carefully and slowly lift the reconnect the heater hoses to the cab heater. Refer
cab and remove it from the frame. Readjust the to Section 4.3.7, Heater/Defroster System (If
position of the sling as needed to help balance the equipped).
cab during removal. 12. Install the fuel tank to the cab. Refer to Section 7.4.2,
25. When the cab is completely clear of the machine, Fuel Tank.
carefully lower it to the ground. Block up or support 13. Fill the cooling system completely with a 50/50 mixture
the cab so that it does not move or fall. Ensure that of ethylene glycol and water, allowing time for the
no personnel enter the cab while it is being removed coolant to fill the engine block. The cooling system
from the machine. capacity is listed in Section 2.4, Fluid and Lubricant
26. Inspect the condition of the fittings, clamps, hydraulic Capacities.
hoses, etc. Replace parts as indicated by their 14. Connect the battery negative (-) cable to the battery
condition. negative (-) terminal.
27. Inspect and replace other machine parts that are 15. Carefully examine all cab components, fasteners,
exposed with the cab removed. Repair or replace as etc., one last time before engine start-up. Rectify any
required. faulty conditions.
16. Start the engine and check the operation of all controls.
4.5 CAB INSTALLATION
Check for hydraulic fluid leaks. Check the hydraulic
1. Block all four wheels to help prevent the machine fluid level in the tank and add fluid as required.
from moving. Ensure that there is sufficient overhead Note: When the engine is initially started, run it briefly at
and side clearance for cab installation. low idle and check the machine for any visual sign of
2. Route a sling with a suitable lifting capacity around fluid leakage. STOP the engine immediately if any
the inner six braces (13) and behind the center cross leakage is noted, and make any necessary repairs
support above the wind shield. before continuing.
3. Use a hoist or overhead crane and sling attached to 17. Wait for the engine to cool and check the coolant
the cab. Carefully begin to align the cab with the level. Add coolant to the overflow bottle as required
mounting holes in the frame. Stop and check that to bring the coolant to the proper level.
wiring, hydraulic hoses, cables, etc., will not be 18. Install the mirrors and all other cab components as
pinched or damaged as the cab is positioned. needed, if removed.
Readjust the position of the sling as needed to help
balance the cab during installation. 19. Unblock the wheels.
4. Install the four lower cab-to-frame mount bolts, 20. Close and secure the engine cover.
washers and nuts to 280-305 lb-ft (380-414 Nm).
5. Install the two cab side mount bolts, washers,
isolators and nuts to 680-720 lb-ft (922-976 Nm).
6. Install the engine air filter and hydraulic oil reservoir
breather to their brackets at the top of the cab.
7. Install the throttle cable to the throttle pedal
assembly. Refer to Section 4.3.3, Throttle Pedal.
8. Pull all the hydraulic hoses and electrical wires
through the cab.
9. Uncap and reconnect the previously labeled
hydraulic hoses to their appropriate locations.
10. Reconnect the previously labeled electrical
connections to their appropriate locations.

Cab and Covers

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5.6
5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.10
5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5.11
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

5.1 AXLE, DRIVE SHAFT AND WHEEL

locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
components that are referred to throughout this section.
REAR STEERING
ASSEMBLY
REAR DRIVE SHAFT
REAR AXLE
ASSEMBLY
TRANSMISSION
DROPBOX
REAR AXLE HUBS (2)
FRONT STEERING
CYLINDER
FRONT DRIVE SHAFT
FRONT AXLE FRONT AXLE WHEEL HUBS (2)

ASSEMBLY
MAP0170

5.2 GENERAL INFORMATION 5.3.3 Axle Internal Service

Detailed axle service instructions (covering the axle,
differential, brakes and wheel-end safety, repair,
WARNING disassembly, reassembly, adjustment and
troubleshooting information) are provided in the
DO NOT service the machine without following all
MO213S10 213 Dana Axle Repair Manual
safety precautions as outlined in Section 1, Safety
(JLG P/N 31200240).
Practices, of this manual. Failure to follow the safety
practices could result in death or serious injury.
5.3.4 Axle Maintenance
Note: To help ensure optimum performance, the drive CLEANING: Clean parts with machined or ground
shaft assemblies are specially balanced as a unit at the surfaces (such as gears, bearings and shafts) with
factory. When servicing any flange yoke, slip yoke or emulsion cleaners or petroleum-based cleaners. DO
drive shaft tube, order a complete assembly if NOT steam clean internal components and the interior of
components are bent or damaged. Refer to the the planetary hub and axle housing. Water can cause
appropriate parts manual for ordering information. corrosion of critical parts. Rust contamination in the
Before performing any inspection, maintenance or lubricant can cause gear and bearing failure. Remove old
service operation, thoroughly clean the unit. The axles gasket material from all surfaces.
and drive shafts should be checked and repaired only by DRYING: Use clean, lintless towels to dry components
experienced service technicians who are aware of all after cleaning. DO NOT dry bearings by spinning them
safety instructions and particular component features. with compressed air; this can damage mating surfaces
Use suitable products to thoroughly clean all due to lack of lubrication. After drying, lightly coat
disassembled mechanical parts to help prevent personal components with oil or a rust-preventive chemical to help
injury to the worker and prevent damage to the parts. protect them from corrosion. If storing components for a
Carefully inspect the integrity of all moving parts prolonged period, wrap them in wax paper.
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners PERIODIC OPERATION REQUIREMENT: Every two
(nuts, bolts, washers, etc.) as they are subject to major weeks, drive the machine far enough to cause the drive-
stress and wear. Always replace elastic locknuts and any train components to make several complete revolutions.
damaged, worn, cracked, seized or otherwise improper This will help ensure that internal components receive
parts that could affect the safe and proper functioning of lubrication to minimize deterioration caused by
the machine, axles and drive shafts. environmental factors such as high humidity.
SUBMERSION: If the machine has been exposed to
5.3 AXLE ASSEMBLIES water deep enough to cover the hubs, disassemble the
wheel ends and inspect for water damage and
5.3.1 Axle Serial Number Plate contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent
The front and rear axle serial number plate is located on tube (breather), drain the axle and inspect internal parts
a mounting pad on the front side of the center section of for water damage and contamination. Before assembling
each axle. Information on the serial number plate is and refilling the unit with the specified lubricant(s), clean,
required in correspondence regarding the axle. examine and replace damaged parts as necessary.
Supply information from the axle serial number plate
when communicating about an axle assembly or axle Note: Use a suitable puller for bearing removal. Clean,
components. inspect and lubricate all bearings just prior to
reassembly. If replacement of a damaged bearing cup or
5.3.2 Axle Specifications cone is necessary, replace the cup and cone as a set.
General axle specifications are found in Section 2.4,

Fluid and Lubricant Capacities.

5.3.5 Axle Removal 8. Block the front and rear of both tires on the axle that
is not being removed. Ensure that the machine will
The front and rear axle assemblies differ in that the front
remain in place during axle removal before
axle assembly is equipped with a parking brake
proceeding.
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal 9. Raise the machine using a suitable jack or hoist.
procedure, suitable for either the front or the rear axle Place suitable supports under both sides of the
assembly. frame and lower the machine onto the supports.
Ensure that the machine will remain in place during
Cleanliness is extremely important. Before attempting to
axle removal.
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the stabilizer 10. Support the axle that is being removed with a suitable
solenoids and other electrical components. If using a jack, hoist or overhead crane and sling. DO NOT
steam cleaner, seal all openings before steam cleaning. raise the axle or the machine.
Note: Clear the work area of all debris, unnecessary 11. Remove both wheel and tire assemblies from the
personnel, etc. Allow sufficient space to raise the axle that is being removed. Refer to Section 5.5.1,
machine and to remove the axle. Removing Wheel and Tire Assembly from Machine.
1. Park the machine on a firm, level surface, level the Note: The wheel and tire assemblies must be re-installed
machine, fully retract the boom, lower the boom, later with the directional tread pattern arrows facing in
place the travel select lever in the (N) NEUTRAL the direction of forward travel.
position, engage the parking brake, straighten all 12. Remove the drive shaft assembly. Refer to Section
wheels and shut the engine OFF. 5.4.3, Drive Shaft Removal.
2. Place a Do Not Operate Tag on both the ignition key 13. Remove the bolts and locknuts securing the axle to
switch and steering wheel, stating that the machine the frame.
should not be operated.
14. Remove the axles from the machine using the jack,
3. Open the engine cover. Allow the system fluids to hoist or overhead crane and sling supporting the
cool. axle. DO NOT raise or otherwise disturb the machine
4. Remove the battery negative (-) cable from the while removing the axle. Balance the axle and
battery negative (-) terminal. prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
5. Remove the optional fender assembly.
axle on a suitable support or holding stand.
6. If the axle will be disassembled after removal, place
a suitable receptacle under the axle (1) and wheel 5.3.6 Axle Installation
hubs drain plugs. Remove the drain plugs and allow
the axle oil to drain into the receptacle. Transfer the 1. Before proceeding, ensure that the machine will
used axle oil into a suitable covered container, and remain in place during axle installation. Block the
label the container as Used Oil. Dispose of used oil front and rear of both tires on the axle that is already
at an approved recycling facility. installed on the machine.
2. If applicable, raise the machine using a suitable jack
or hoist. Place suitable supports beneath the frame
and lower the machine onto the supports, allowing
enough room for axle installation. Ensure that the
machine will remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and
sling, remove the axle from its support or holding
stand. Balance the axle and prevent it from tipping,
turning or falling while positioning it beneath the
2 machine. DO NOT raise or otherwise disturb the
1 machine while installing the axle. Keep the axle
MY0840 (in rear) supported and balanced on the jack, hoist or
overhead crane and sling throughout the installation
7. Label, disconnect and cap the steering and brake procedure.
lines at the axle. Wipe up any spilled oil.

4. Position the axle under the frame, and align the axle Note: ALWAYS use new o-rings when servicing the
housings with the holes in the frame. machine.
5. Install the four axle bolts and nuts. Apply Loctite 242 16. Install new o-rings into the fittings. Lubricate the
threadlock to the bolt threads and torque to 530-565 lb- o-rings with clean hydraulic oil.
ft (718-766 Nm).
17. Uncap and connect the steering and brake lines at
6. Move the cylinder into position on the axle cylinder their axle fittings.
anchor. Insert a cylinder-mount pin through the
18. Check the hydraulic reservoir oil level.
cylinder and cylinder anchor. Secure the cylinder-
mount pin with one capscrew and a new locknut. 19. Start the engine. Turn the steering wheel several
times lock to lock, operate the frame tilt function
7. Apply multi-purpose grease through the self-tapping
several times in both directions and check the
lube fitting to lubricate the self-align bearing and the
function of the brakes. Check for hydraulic leaks, and
cylinder-mount pin.
tighten or repair as necessary.
8. Install the drive shaft assemblies. Refer to Section
20. Install the optional fender assembly.
5.4.5, Drive Shaft Installation.
9. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle Note: The service brake circuit will need to be bled after
according to the alignment marks made earlier. If axle installation. Refer to Section 8.8.8, Brake Test.
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.
10. Tighten the axle oil drain plug, loosen and remove
the axle oil fill plug (2). Refer to Section 2.4, Fluid
and Lubricant Capacities, for proper oil and
capacities.
11. Rotate wheel hubs 90 degrees so the drain plug
becomes the fill plug (3). Refer to Section 2.4, Fluid
and Lubricant Capacities, for proper oil and
capacities.
MT0220
12. Install the wheel and tire assemblies. Refer to

Section 5.5.2, Installing Wheel and Tire Assembly
onto Machine.
13. Carefully remove the jack, hoist or overhead crane
and sling supporting the axle.
14. Carefully raise the machine using a suitable jack or
hoist. Remove the supports from beneath the frame
and lower the machine to the ground.
15. Remove the blocks from the front and rear of both
tires on the other axle.

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.4, Fluid and
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level
low. with Mobilfluid 424
(ISO 46). Refer to Section 2.4,
3. Incorrect alignment of ring and 3. Correct alignment by adding or

pinion gears. removing shims as needed.
4. Incorrect pinion (input) shaft 4. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end

housings and fill to correct level
with Mobilfluid 424 (ISO 46).
Refer to Section 2.4, Fluid and
8. Axle housing damaged. 8. Replace damaged parts.

2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal
traveling. damaged. joints as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.
3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
2. Drive shaft universal joint(s) 2. Repair or replace universal
worn or damaged. joints as needed.
3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as

unbalanced. needed.


4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged tighten plugs to 96 lb-ft
axle housings). or missing. (130 Nm).
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint

missing and/or worn or coupling fork shaft (axle shaft).
damaged shaft sealing
surfaces.
4. Input shaft multi-seal ring 4. Replace o-rings as needed and

damaged or missing and/or tighten plugs to 96 lb-ft
worn or damaged pinion (input) (130 Nm).
shaft sealing surfaces.
5. Axle casing to brake housing 5. Replace o-rings and seals.

and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.
6. Axle housing mounting nuts and 6. Tighten housing nuts and

capscrews loose. capscrews to 288 lb-ft
(390 Nm).
7. Differential and/or axle 7. Replace housing(s) as needed.

housing(s) damaged.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 96 lb-ft
(130 Nm).
2. O-ring between hub and 2. Replace o-ring.

housing (planet carrier)
damaged or missing.
3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

and/or worn or damaged shaft shaft.
sealing surfaces.
4. Housing capscrews loose. 4. Tighten housing capscrews to

41 lb-ft (55 Nm).
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).
6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or 3. Replace piston rod seal.

damaged.
4. Cylinder tube damaged. 4. Replace cylinder tube.


7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with
Mobilfluid 424 (ISO 46). Refer
to Section 2.4, Fluid and
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level
filled with incorrect oil or oil with Mobilfluid 424 (ISO 46).
contaminated or oil level low. Refer to Section 2.4, Fluid and
3. Dragging park brake. 3. Adjust park brake cable as

needed.
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, Hydraulic
2. Excessive joint housing swivel 2. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
3. Worn or damaged swivel 3. Replace swivel bearings as

bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, Hydraulic
2. Steering cylinder leaking 2. Repair or replace steering

internally. cylinder as needed.
10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to Section 2.4, Fluid and
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.8.8, Brake
operating properly. Test.
2. Brake piston o-rings and seals 2. Replace o-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to Section 2.4, Fluid and
reduced. Lubricant Capacities.
2. Brake (hydraulic) system not 2. Refer to Section 8.8.8, Brake

operating properly. Test.
3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).

5.4 DRIVE SHAFTS 7. Remove the four capscrews and two straps securing
the bearing cross to the transmission output shaft
flange.
5.4.1 Drive Shaft Inspection and Service
8. Remove the four capscrews and two straps securing
Whenever servicing the machine, conduct a visual the bearing crosses to the axle.
inspection of the drive shafts and cross and bearing
assemblies (universal joints, or U-joints). A few moments 9. Remove the front drive shaft assembly.
spent doing this can help prevent further problems and 10. Repeat the above procedure on the second front
down time later. drive shaft and rear drive shaft.
Inspect areas where the drive shaft flange yokes and slip
To Transmission
yokes mount to the drive shafts. Attempt to turn each
drive shaft in both directions. Look for excessive
looseness, missing parts, cracks or other damage. Worn
or damaged drive shafts and cross and bearing
assemblies may cause an excessive amount of vibration
or noise.
5.4.2 Drive Shaft Maintenance

Refer to Section 2.4, Fluid and Lubricant Capacities, for
information regarding the lubrication of the grease fittings
on the drive shafts.
To Axle MT0350
5.4.3 Drive Shaft Removal
Note: The drive shaft assemblies are balanced 5.4.4 Drive Shaft Cleaning and Drying
assemblies. Mark the yoke and axle, transmission,
transfer case, and the shaft and slip yoke so that these 1. Disassemble and clean all parts using an approved
components can be returned to their original positions cleaning fluid. Allow to dry.
when reinstalled. Yokes at both ends of the drive shaft 2. Remove any burrs or rough spots from all machined
must be in the same plane to help prevent excessive surfaces. Re-clean and dry as required.
vibration.
5.4.5 Drive Shaft Installation
1. Raise the drive shaft assembly into position. The
slip-yoke end of the drive shaft mounts toward the
place the transmission control lever in (N) NEUTRAL,
axle. If reinstalling a drive shaft previously removed,
engage the park brake and shut the engine OFF.
align the flange yokes according to the alignment
2. Place a Do Not Operate Tag on both the ignition key marks made during removal.
switch and steering wheel, stating that the machine
2. Install the four capscrews and two straps securing
the bearing crosses to the transmission.
cool. Note: Do not re-torque strap capscrews. Replace old
capscrews with new capscrews and torque to 55-60 lb-ft
4. Disconnect the battery negative (-) cable from the (75-81 Nm). Apply Loctite 242 threadlock to capscrew
battery negative (-) terminal. threads before tightening.
5. Block the wheels.
3. Install the four capscrews and two straps securing
6. The drive shaft assembly is a balanced assembly. the bearing crosses to the axle.
Mark the yoke and axle, transmission and the shaft
4. Repeat the above procedure on the remaining front
and slip yoke so that these components can be
drive shaft and rear drive shaft.
returned to their original positions when reinstalled.
Yokes at both ends of the drive shaft must be in the 5. Connect the battery negative (-) cable to the battery
same plane to help prevent excessive vibration. negative (-) terminal.
7. Unblock the wheels.
5.5 WHEELS AND TIRES 4
WARNING
Risk of death or serious personal injury. Mismatched
tire sizes, ply ratings or mixing of tire types (radial tires
with bias-ply tires) may compromise machine stability
and could cause machine to tip over.
JLG recommends 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 a JLG approved replacement tire, JLG
recommends that replacement tires have the following
characteristics:
Equal or greater ply/load rating and size of original.
Tire tread contact width equal or greater than
original.
Wheel diameter, width and offset dimensions equal
to the original.
Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load).
The rims installed have been designed for stability MAH0890
requirements which consist of track width, tire pressure
and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc., 5.5.1 Removing Wheel and Tire Assembly
without written factory recommendations, may result in from Machine
unsafe condition regarding stability.
1. Park the machine on a firm, level surface, fully
Foam filled tires have a positive effect on the weight, retract the boom, lower the boom, place the
stability and handling characteristics of the machine, transmission control lever in (N) NEUTRAL, engage
especially under load. JLG does not recommend the use the park brake and shut the engine OFF.
of hydrofill as a tire-fill substance because of possible
environmental impact. 2. Place an Do Not Operate Tag on both the ignition
key switch and steering wheel, stating that the
Large-bore valve stems are used to help expedite tire machine should not be operated.
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation 3. Loosen but DO NOT remove the lug nuts on the
pressures when the tires are cold. When mounting a tire wheel and tire assembly to be removed.
on the wheel, the tire must be mounted on the wheel 4. Place a suitable jack under the axle pad closest to
respective of the directional tread pattern of the tire; this the wheel being removed. Raise the machine and
produces a left or right tire and wheel assembly. position a suitable support beneath the axle. Allow
The wheel and tire assemblies must be installed with the sufficient room to lower the machine onto the
directional tread pattern arrows (4) facing in the support and to remove the wheel and tire assembly.
direction of forward travel. 5. Lower the machine onto the support.
6. Remove lug nuts and lug washers in an alternating
pattern.
7. Remove the wheel and tire assembly from the
machine.

5.5.2 Installing Wheel and Tire Assembly 5.6 BRAKES

onto Machine
Check the brake disks for wear every 1,000 hours of
Note: The wheel and tire assemblies must be installed
operation or yearly.
with the directional tread pattern arrows facing in the
direction of forward travel. For more information on brake disk inspection, refer to
the appropriate axle repair manual.
5.7 TOWING A DISABLED MACHINE

Tread arrows must point
forward
Towing a disabled machine should only be attempted as
a last resort, after exhausting all other options. Make
every effort to repair the machine, and move it under its
own power, before using the emergency towing
procedures outlined below.
IMPORTANT: Block the wheels of the machine
BEFORE attempting to release the park brake. Once
the park brake is released, the machines park brake
AND service brakes are inoperable.
5.7.1 Manually Releasing the Park Brake

5
Install tires onto wheels

to rotate in proper direc-
tion
MAH0460
1. Position wheel onto studs on wheel end of axle.

MZ1020
2. Install wheel lug washers.
3. Start all nuts by hand to prevent cross threading. DO
1. Loosen the nuts of the screws (5) for the manual
NOT use a lubricant on threads or nuts.
release of the braking units. Draw the nuts back
4. Tighten lug nuts in an alternating pattern as approximately 6 mm.
indicated in figure. Torque to 350-400 lb-ft
2. Tighten the screws until they are gently seated on
(475-542 Nm).
the driving plate
3. Carefully tighten each release screw a 1/4 turn at a
time in sequence until all have been turned on full
3 5 turn 360.
1 7
4. Repeat steps 1 thru 3 for the other side of the
differential.
10 9 Note: After the machine has been towed to a secure
location, reactivate the parking brake. Carefully follow
8 2 the procedures from start to finish. Consult your local
JLG distributor or the JLG Service Department if you are
6 4
unsure about any part of the procedure, or for specific
OY1220 instructions concerning your particular situation.
5. Remove machine from supports.

5.7.2 Manually Resetting the Park Brake

Note: Block the wheels of the machine BEFORE
attempting to reset the machines park brake. Once the
park brake is released, the machines park brake AND
service brakes are inoperable.
1. Loosen each release screw, only 1/4 turn at a time,
in sequence, until each screw has lost contact with
the guide pin.
2. Remove the screws along with the nuts and seals.
Replace the seals, lubricate the screws with a
silicone-based grease and re-install the screws
along with the nuts.
3. Adjust the nut of the screw heads in relation to the
arm by 30 mm (1.18 in).
4. Repeat steps 1 thru 3 for the other side of the
differential.
5. After repairs to the machine have been made, start
the machine and check the park brake and service
brakes for proper function.

Section 6
Transmission
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.2 Transmission Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.5.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6.5
6.5.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
6.5.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.6.1 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

Transmission
6.1 TRANSMISSION ASSEMBLY

locations of the major assemblies of the transmission.
The following illustration identifies the components that
are referred to throughout this section.
TRANSMISSION
FILTER
OIL DRAIN PLUG
OIL FILLER PLUG
TRANSFER CASE
BREATHER
OIL FILL TUBE AND DIPSTICK
TRANSMISSION BREATHER
SHIFT SOLENOIDS PARK BRAKE SOLENOIDS
OIL DRAIN PLUG
MAP0680

Transmission
6.4.2 Transmission Maintenance Schedule

WARNING Complete transmission maintenance information is
located in the appropriate Operation & Safety Manual.
At ten hour intervals, check the transmission oil
level. Refer to the appropriate Operation & Safety
Manual.
When the machine completes its first 50 hours of
6.2 TRANSMISSION DESCRIPTION use, change the transmission filter and oil. Refer
to the appropriate Operation & Safety Manual.
Instructions in this section pertain mainly to general At 1,000 hour intervals, change the transmission
specifications, towing, maintenance information, and oil and filter. Refer to the appropriate Operation &
transmission removal and installation procedures. for Safety Manual.
internal transmission service instructions and detailed Periodically, depending on operating conditions and
specifications contact your local JLG distributor for a copy other factors, back flush the transmission oil cooler,
of the ZF Repair Manual P/N 5872 135 002 which is located in or behind the radiator. ALWAYS back
(JLG P/N 31200241). flush the transmission oil cooler after removing the
transmission for repair or replacement.
6.3 TRANSMISSION SERIAL NUMBER
The transmission oil cooler outlet hose, routed to the
The transmission serial number plate is located on the lower oil cooler fitting, is located on the top of the
front of the transmission case behind the oil dipstick. transmission. The transmission oil cooler inlet hose,
Information specified on the serial number plate includes routed to the upper oil cooler fitting, is located on the top
the transmission model number, the transmission serial of the transmission. (Refer to Section 7.2.3, Radiator
number and other data. Information on the serial number Replacement.)
plate is required in correspondence regarding the Disconnect and back flush the oil cooler portion of the
transmission. radiator or the oil cooler (located behind the radiator) with
oil and compressed air until all foreign material is
6.4 TRANSMISSION SPECIFICATIONS removed. If necessary, remove the radiator or oil cooler
from the machine, and clean the oil cooler circuit using oil,
compressed air and steam.
6.4.1 Transmission Maintenance
IMPORTANT: DO NOT use flushing compounds for
Cleanliness is of extreme importance. Before attempting cleaning purposes.
any repairs, thoroughly clean the exterior of the
transmission to help prevent dirt from entering while 6.5 TRANSMISSION REPLACEMENT
performing maintenance checks and procedures.
Section 6.4.2, Transmission Maintenance Schedule, Note: Contact the JLG Service Department if internal
provides a suggested maintenance schedule with transmission repair is required during the warranty
references to pertinent procedures and instructions in this period.
manual. To help prevent transmission problems before
Note: To help ensure safety and optimum performance,
they occur, follow the maintenance schedule.
replace the transmission if it is damaged. Refer to the
Note: Lubrication and Maintenance chart decals are appropriate parts manual for ordering information.
located inside the engine compartment access door.
Cleanliness is of extreme importance. Before attempting
These decals contain a general maintenance schedule
to remove the transmission, thoroughly clean the exterior
that should be followed to maintain the machine in good
of the transmission to help prevent dirt from entering
operating condition. Refer to Section 2, General
during the replacement process. Avoid spraying water or
Information and Specifications. The same schedule
cleaning solution onto or near the transmission shift
information is presented in the appropriate Operation &
solenoids and other electrical components.
Safety Manual, with a detailed account of how to perform
the procedures.

Transmission
6.5.1 Transmission Removal 9. Transfer the used transmission oil into a suitable,
covered container, and label the container as Used
Oil. Dispose of used oil at an approved recycling
WARNING facility. Clean and reinstall the transmission drain
plug.
Risk of severe personal injury. NEVER lift a
transmission alone; enlist the help of at least one 10. Remove the transmission-to-axle drive shafts. Refer
assistant or use a suitable hoist or overhead crane and to Section 5.4.3, Drive Shaft Removal.
sling. 11. Remove air cleaner unit and intake tubes.
1. Park the machine on a firm, level surface, level the 12. Remove the hydraulic pump. Refer to Section 8.7.3,
machine, fully retract the boom, lower the boom, Pump Replacement.
place the transmission control lever in (N) 13. Label and disconnect the transmission temperature
NEUTRAL, engage the park brake and shut the switch connector and shift solenoid wiring harness
engine OFF. connectors.
2. Place a Do Not Operate Tag on both the ignition key 14. Label, disconnect and cap the transmission oil
switch and steering wheel, stating that the machine cooler inlet and outlet hoses at the transmission.
15. Remove the access plug from the bottom of the
3. Open the engine cover. Allow the system fluids to cool. engine bell housing. This will allow access to remove
4. Remove engine cover to allow easier access to the the four bolts holding the torque convertor
transmission. diaphragm to the engine flywheel.
5. Drain the hydraulic oil reservoir. Refer to Section 16. Turn the engine over slowly by hand and align each
8.6.1, Hydraulic Oil Reservoir Draining. of the four torque convertor diaphragm bolts to be
accessed. Remove them one at a time.
6. Disconnect the (+) positive and (-) negative battery
cables and remove the battery. 17. Wipe up any spilled hydraulic and transmission oil.
7. Thoroughly clean the transmission and surrounding 18. Connect a lifting strap or chain to the lifting eye at
area, including all hoses and fittings, before the top of the transmission, and to a suitable hoist or
proceeding. overhead crane. Operate the hoist or crane to
remove slack from the chain, but DO NOT raise the
8. Place a suitable receptacle under the transmission
transmission at this time.
drain plug (1). Remove the transmission drain plug,
and allow the transmission oil to drain into the 19. Place blocks under rear of engine for support
receptacle. Repeat drain procedure with the drop BEFORE transmission mounts are removed.
box (2). 20. Place blocks under the transmission to help support
it during removal.
21. Remove both rear transmission mount bolts and
lockwashers securing the transmission mount to the
frame.
22. Remove the twelve bolts and washers holding the
transmission to the engine.
23. Remove the capscrews and lockwashers securing
each rear transmission mount to the transmission.
24. Carefully remove the transmission from the machine.
Avoid causing damage to the transmission or
surrounding parts.
25. Lift the transmission clear of the machine, and lower
MY0980 it onto suitable supports or secure it to a stand built
1
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.

Transmission
26. Remove any external transmission components as orientation with one hole at 6 oclock on the engine
required, including the transmission temperature and the transmission.
switch, and inlet and outlet cooler hose fittings. 6. Install the twelve bolts and washers and torque to
Cover all transmission openings. 53 lb-ft (72 Nm). Remove the two alignment studs
and install and torque the last two transmission
mounting bolts.
3
7. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite 242 threadlock to the transmission mount
bolts and torque to 125-140 lb-ft (169-190 Nm).
8. Turn the engine over slowly by hand and align each
2 of the four torque convertor diaphragm bolts through
the access plug in the bell housing. Install them one
MAP0690
at a time. DO NOT fully tighten until all of the
27. Remove the transmission oil filter (3) and dispose of capscrews and locknuts are in place. Torque to
properly. Clean the filter mounting surface. Cover or 26-29 lb-ft (35-39 Nm). Replace access plug.
cap the oil filter mount. 9. Remove the hoist or overhead crane and sling.
28. If transmission oil is suspect to contamination or 10. Connect the transmission temperature switch
torque converter is damaged, remove the converter connector and shift solenoid wiring harness
and flex plate from the transmission. connectors.
29. Remove the bolt and washers holding the converter 11. Secure the wiring harness to the transmission
to the flex plate. housing.
12. Connect the transmission oil cooler inlet and outlet
6.5.2 Transmission Inspection and Internal hoses at the transmission.
Repair
13. Install the hydraulic pump. Refer to Section 8.7.3,
Refer to the ZF Transmission Repair Manual Pump Replacement.
PN- 5872 135 002 (JLG P/N 31200241) which can be
14. Install the transmission-to-axle drive shafts. Refer to
obtained by calling your local JLG distributor.
Section 5.4.5, Drive Shaft Installation.
If replacing the entire transmission, transfer the
15. Install the air cleaner and tubing.
transmission temperature switch to the replacement
transmission. The gear shift solenoids are included with a 16. Clean the transmission oil filter mounting surface.
new transmission. 17. Apply a thin film of clean Mobilfluid 424
(ISO Grade 46) to the new transmission filter gasket.
6.5.3 Transmission Installation Install the new filter and torque to 20-25 lb-ft
1. Install both rear transmission mounts on the (27-34 Nm).
transmission. Torque capscrews to 125-140 lb-ft 18. Transmission oil may be added through the oil fill
(170-190 Nm). tube. Remove the plug and add Mobilfluid 424
2. Install two guide studs near the top of the bell (ISO Grade 46). Check the oil level by taking
housing holes. intermittent dipstick readings as outlined in the
appropriate Operation & Safety Manual. DO NOT
3. Ensure there are no burrs on the flywheel mounting overfill. Reinstall the oil fill tube plug and dipstick
face and nose pilot bore. Clean the drive plate when finished.
surface with solvent.
19. Install the engine cover.
4. Ensure the bolts securing the flex plate to the torque
converter are torqued to 26-29 lb-ft (35-39 Nm). 20. Connect the battery negative (-) cable at the battery.
5. Use a hoist or overhead crane and sling attached to 21. Close and secure the engine cover.
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
Make sure the engine flywheel and transmission flex
plate hole patterns are aligned and in the same

Transmission
6.5.4 After Transmission Service or

Replacement
Refer to the ZF Transmission Repair Manual
PN- 5872 135 002 (JLG P/N 31200241) which can be
obtained by calling your local JLG distributor.
In general:
1. Check the transmission oil level and add oil as
required.
2. Install a new transmission filter.
3. Check the torque on the drive shaft yoke capscrews.
MAP0690
4. Wear suitable eye protection. When an overhauled 4
or repaired transmission is installed, thoroughly
clean the oil cooler lines to and from the transmission. 10. Run the engine for two minutes at idle to help prime the
5. Drain and flush the entire system. torque converter and the transmission oil lines.
6. Disconnect and clean all transmission cooler hoses. 11. Recheck the level of the fluid in the transmission with
When possible, remove transmission lines from the the engine running at idle.
machine for cleaning. 12. Add Mobilfluid 424 (ISO Grade 46) as necessary to
7. Thoroughly clean transmission filter screens and bring the fluid level up until it reaches the FULL mark
cases, and replace transmission filter elements. on the dipstick. Recheck the oil level when it reaches
operating temperature 180-200 F (83-94 C).
CAUTION 13. Recheck all drain plugs, lines, connections, etc., for
leaks, and tighten where necessary.
DO NOT exceed 165 psi (11,4 bar) when back flushing
the oil cooler. Applying too much pressure may
damage the oil cooler/radiator.
8. Back flush the transmission oil cooler portion of the

radiator or the oil cooler (located behind the radiator)
with oil and compressed air until all foreign material
is removed. Flushing in the direction of normal oil
flow does not adequately clean the cooler. If needed,
remove the radiator or oil cooler from the machine.
Note: DO NOT use flushing compounds for cleaning
purposes.
9. Reassemble all components and fill the transmission
with clean, fresh Mobilfluid 424 (ISO Grade 46)
through the oil fill tube opening (4). Check the level
by taking intermittent dipstick readings as outlined in
the appropriate Operation & Safety Manual. DO NOT
overfill. Reinstall the oil fill tube plug and dipstick
when finished.

Transmission
6.6 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that may occur during
operation of the transmission.
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.
The transmission should be checked, serviced and

repaired only by experienced service technicians who are
aware of all safety instructions and particular component
features.
6.6.1 Transmission Troubleshooting

1. Transmission will not engage 1. Oil level too high or low. 1. Fill transmission to correct level
or will not shift properly. with Mobilfluid 424
(ISO Grade 46). Refer to
Section 2.4, Fluid and
2. Transmission control lever not 2. Refer to Section 9.6, Electrical
functioning properly and/or a System Schematics And
fault in the wiring Diagrams.
harness.Transmission control
lever not functioning properly
and/or a fault in the wiring
harness.
3. Transmission valve body 3. Refer to Section 9.6, Electrical

solenoids not functioning System Schematics And
properly. Diagrams.
4. Pilot-operated shift valves not 4. Clean the valve spool and

operating properly. housing. Replace return spring
as needed.
5. Pump output pressure low. 5. Refer to Section 6.6.1,
Transmission Troubleshooting,
Problem 2. Low or no pump
flow or pressure.
6. Clutch piston o-rings damaged. 6. Replace o-rings.
7. Clutch discs worn or damaged. 7. Replace clutch discs.
8. Coupling shafts or gear teeth 8. Replace couplings.

damaged.

Transmission

2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level
pressure. with Mobilfluid 424
2. Transmission filled with incorrect 2. Drain transmission and fill to

oil, or oil contaminated. correct level with Mobilfluid 424
3. Pump suction pipe screen 3. Clean, repair and/or replace

clogged. suction pipe.
4. Central shaft damaged. 4. Replace central shaft.
5. Pump worn or damaged. 5. Repair or replace pump

assembly.

Code (DTC) Table.
Refer to Section 9.15.2, Debug
Functionality.
3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level
with Mobilfluid 424
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.
3. Broken or worn coupling shaft or 3. Replace coupling and/or o-rings.

piston o-rings.
4. Pressure reducing valve stuck 4. Clean the valve spool and

open. housing.

Transmission

4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.4, Hydraulic
Circuits.
2. Low engine rpm causes 2. Adjust the engine rpm to
converter stall. specifications. Refer to Engine
Service Manual.
3. Pump output pressure is low. 3. Refer to Section 6.6.1,

Problem 2. Low or no pump
flow or pressure.
4. Clutch discs worn or damaged. 4. Replace clutch discs.
5. Transmission overheating. 5. Refer to Section 6.6.1,

Problem 5. Transmission
overheating (oil above 120 C
(248 F)).
5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level
(oil above 120 C (248 F)). with Mobilfluid 424
2. Clogged radiator. 2. Remove debris from the

radiator.

oil, or oil contaminated. correct level with Mobilfluid 424
4. Excessive roading. 4. Stop and idle the engine.
5. Restriction in oil cooler hoses. 5. Replace cooler hoses.
6. Pump worn or damaged. 6. Repair or replace pump

assembly.
7. Engine thermostat stuck. 7. Replace engine thermostat.

Refer to Section 7.2.2,
Thermostat Replacement.

Transmission

6. Grinding or clunking noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.4, Fluid and

oil. correct level with Mobilfluid 424
3. Incorrect clutch engagement. 3. Refer to Section 9.11.8,

Transmission Solenoid Valves.
4. Internal damage. 4. Repair or replace parts as

needed.
5. Broken diaphragm (torque 5. Replace diaphragm (torque

convertor). convertor). Refer to Section
7.8.1, Torque Convertor
Diaphragm Removal.
6. Loose diaphragm (torque 6. Tighten capscrews.

convertor) mounting capscrews.

Transmission

7. Oil leaking from transmission. 1. Oil leaking from vent (high oil 1. Remove drain plug and drain oil
level). as needed, until oil is at correct
level. Refer to Section 2.4,
Replace o-rings as needed and
tighten plugs to 96 lb-ft (130 Nm).
2. Drain plug loose and/or o-rings 2. Replace o-rings as needed and
damaged or missing. tighten plug to 26 lb-ft (35 Nm).
3. Hose fittings loose. 3. Tighten fittings.
4. Oil leaking at valve bodies 4. Replace gaskets and/or tighten

(possible valve body gaskets capscrews to 7 lb-ft (9,5 Nm).
damaged or missing and/or
mounting capscrews not tight).
5. Housing capscrews loose. 5. Tighten capscrews to 34 lb-ft

(46 Nm).
6. Oil leaking at pump (possible 6. Replace o-rings and/or tighten
pump-to-housing o-rings capscrews to 85 lb-ft (115 Nm).
missing or damaged, and/or
pump mounting capscrews not
tight).
7. Oil leaking at converter bell 7. Replace converter and/or input

(possible converter leak and/or shaft seal.
input shaft seal damage).
8. Oil leaking at output shaft 8. Replace output shaft seal.

(output shaft seal damaged).
9. Housing damaged. 9. Replace housing as needed.

Transmission

Section 7
Engine
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.1.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 7.4
7.2 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.2.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.2.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.2.3 Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.3 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.4.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.4.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.4.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.5 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.5.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.5.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.6 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.6.1 Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.6.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.7 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.7.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.7.2 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.8 Torque Convertor Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.8.1 Torque Convertor Diaphragm Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.8.2 Torque Convertor Diaphragm Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

Engine
7.1 INTRODUCTION
7.1.1 Disclaimer and Scope

These instructions are written for worldwide use. In
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine,
engine operation does not violate local regulations.
Note: These instructions cover only the routine
maintenance, removal, installation and troubleshooting
of the engine. Refer to the local Engine Distributor and
the applicable Engine Service Manual for assistance
with comprehensive engine diagnosis, repair and
component replacement. A gradual running-in (break-in)
of a new engine is not necessary. Full load can be
applied to a new engine as soon as the engine is put into
service and the coolant temperature is at least
140 F (60 C). Extended light-load operation during the
early life of the engine is not recommended. DO NOT run
the engine at high, no-load speeds. DO NOT apply an
overload to the engine.

Engine
7.1.2 Component Terminology

locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.
THERMOSTAT
FUEL FILTER
OIL FILTER STARTER
MAL0260
ALTERNATOR
MAL0270

Engine
7.1.3 Engine Serial Number a. Thermostat Removal

The Perkins 1104D serial number is stamped on top of 1. Park the machine on a firm, level surface, level the
the engine. Information contained in the serial number is machine, fully retract the boom, lower the boom,
required in correspondence with the engine place the travel select lever in the (N) NEUTRAL
manufacturer. position, engage the parking brake, and shut the
engine OFF.
7.1.4 Specifications and Maintenance 2. Place a Do Not Operate Tag on both the ignition key
Information switch and steering wheel, stating that the machine
For engine, coolant and oil specifications, and should not be operated.
maintenance information, refer to Section 2, General 3. Open the engine cover. Allow the system fluids to
Information and Specifications. cool.
Detailed Perkins engine service instructions (covering 4. Remove the battery negative (-) cable from the
disassembly, inspection, internal repair, assembly, battery negative (-) terminal.
adjustment and troubleshooting information) are
5. Slowly turn the radiator cap to the first stop and allow
provided in the appropriate Perkins engine service
any pressure to escape. Remove the radiator cap.
manual.
6. Place a funnel at the base of the radiator to channel
7.2 ENGINE COOLING SYSTEM the drained coolant into the container. Loosen the
drain plug and slowly remove to allow the coolant to
drain. Transfer the coolant into a properly labeled
7.2.1 Radiator Pressure Cap container. Dispose of properly if coolant needs to be
For a 210 F (99 C) system, use a 13 psi (90 kPa) replaced. Replace the radiator drain plug.
radiator cap. An incorrect or malfunctioning cap can
result in the loss of coolant and a hot-running engine. 1
7.2.2 Thermostat Replacement

Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
If the engine seems to take a long time to warm
up, the thermostat may be stuck in the open
position and requires replacement.
If the engine runs hot, check the temperature of
the upper radiator hose.
If the hose is not hot, the thermostat may be MY2750
stuck in the closed position.
7. Disconnect the Engine Water Temperature Sender.
If the engine has overheated, performance may
suffer, indicating other damage including a 8. Remove the two capscrews securing the thermostat
leaking cylinder head gasket, cracked cylinder housing (1) to the engine.
head or block, and/or other internal engine 9. Remove the thermostat housing, old gasket and
damage. thermostat. Clean all gasket surfaces. DO NOT let
any debris into the thermostat opening.
Note: ALWAYS use the correct thermostat and install a
new gasket. NEVER operate the engine without a
thermostat, or engine damage will result.

Engine
b. Thermostat Installation 7. Place a funnel at the base of the radiator to channel

the drained coolant into a container. Loosen the
1. Install the engine thermostat, thermostat gasket and
drain cock and slowly remove to allow the coolant to
thermostat housing. Secure with the two capscrews.
drain. Transfer the coolant into a properly labeled
2. Connect the Engine Water Temperature sender. container. Dispose of properly if coolant needs to be
3. Connect the battery negative (-) cable to the battery replaced. Tighten the radiator drain cock.
negative (-) terminal. 8. Label, disconnect and cap the hose attached to the
4. Open the radiator cap, and fill the radiator coolant recovery tank. Remove the coolant recovery
completely with a 50/50 mixture of ethylene glycol tank.
and water. Replace and tighten the radiator cap. Add 9. Loosen the clamps on the hoses attached to the
coolant to the overflow bottle until the bottle is 1/4 to radiator. Work the hoses off the radiator. Position the
1/2 full. This overfilling will compensate for any air hoses out of the way to allow radiator removal, or
trapped in the cooling system. remove the hoses from the engine. Inspect the
5. Run the engine to operating temperature. Visually hoses, and replace if necessary.
check for leaks with the engine running. Check the 10. Loosen the clamps on the hoses attached to the oil
coolant level in the overflow bottle and fill, or drain, cooler. Work the hoses off the oil cooler. Position the
as necessary. hoses out of the way to allow radiator removal, or
remove the hoses from the engine. Inspect the
7.2.3 Radiator Replacement hoses, and replace if necessary.
Before considering radiator replacement for other than 11. Remove the radiator fan shroud.
obvious damage, conduct a cooling system pressure test, 12. Remove the nuts and washers from the radiator and
check the coolant specific gravity, coolant level, fan belt oil cooler mounts.
tension and dash panel temperature indicator.
13. Carefully lift the radiator and oil cooler out of the
If the engine runs hot, check the temperature of engine compartment.
the upper radiator hose.
Note: If more clearance is needed to remove the
If the hose is not hot, the thermostat may be
radiator, the engine fan may be removed for easier
stuck in the closed position.
access.
If the engine has overheated, performance may
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
a. Radiator Removal
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
15
engine OFF.
cool.
5. Slowly turn the radiator cap to the first stop and allow
MY1040
any pressure to escape. Remove the radiator cap.
6. Place a suitable container beneath the radiator
drain.

Engine
b. Radiator Installation Note: Due to the precise tolerances of diesel injection

systems, keep the fuel clean, and free of dirt and water.
1. Install the isolator mounts to the bottom of the
Dirt and water in the fuel system can cause severe
radiator. Place the radiator in the engine
damage to both the injection pump and the injection
compartment at its original orientation. Secure with
nozzles. Use ASTM #2 diesel fuel with a minimum Cetane
the previously used hardware.
rating of 40. #2 diesel fuel gives the best economy and
Note: Ensure there is adequate clearance between the performance under most operating conditions. Fuels with
radiator and the engine fan. Cetane numbers higher than 40 may be needed in high
altitudes or extremely low ambient temperatures to help
2. If necessary, install the engine fan.
prevent misfiring and excessive smoking.
3. Install the radiator fan shroud.
Inform the owner/operator of the machine to use #2
4. Uncap and connect the previously labeled hoses to diesel fuel, unless ambient temperatures are below
the radiator and oil cooler. 32 F (0 C). When temperatures are below 32 F (0 C),
5. Install the coolant recovery tank. Uncap and connect a blend of #1 diesel and #2 diesel fuels (known as
the previously removed hose. winterized #2 diesel) may be used.
6. Open the radiator cap and fill the radiator completely Note: #1 diesel fuel may be used, however, fuel
with a 50/50 mixture of ethylene glycol and water. economy will be reduced.
Replace and tighten the radiator cap. Refer to
Section 2.4, Fluid and Lubricant Capacities, for Use a low-sulfur content fuel with a cloud point (the
proper capacities. temperature at which wax crystals form in diesel fuel) at
least 10 below the lowest expected fuel temperature.
7. Connect the battery negative (-) cable to the battery The viscosity of the fuel must be kept above
negative (-) terminal. 1.3 centistrokes to provide adequate fuel system
8. Run the engine to operating temperature. Visually lubrication.
check for leaks with the engine running. Check the
coolant level in the overflow bottle and fill, or drain,
as necessary.
7.3 ENGINE ELECTRICAL SYSTEM

The engine electrical system, including the starter,
alternator and primary wiring, is described in Section 9.6,
Electrical System Schematics And Diagrams.
7.4 FUEL SYSTEM
7.4.1 Diesel Fuel

Fuel represents a major portion of machine operating
costs and therefore must be used efficiently. ALWAYS
use a premium brand of high-quality, clean diesel fuel.
Low cost, inferior fuel can lead to poor performance and
expensive engine repair.
Note: Use only diesel fuel designed for diesel engines.
Some heating fuels contain harmful chemicals that can MAP0180
seriously affect engine efficiency and performance.

Engine
7.4.2 Fuel Tank To clean the fuel tank:

Note: The fuel tank is a one piece unit. It is located on the 1. Have a dry chemical (Class B) fire extinguisher near
rear of the cab. If it is determined that the fuel tank must be the work area.
removed, the fuel must be drained before tank removal. 2. Remove the fuel or oil tank drain plug, and safely
Always dispose of fuel properly. drain any fuel into a suitable container. Dispose of
a. Fuel Tank Removal fuel properly.
3. Clean the fuel tank with a high-pressure washer, or
flush the tank with hot water for five minutes and
drain the water. Dispose of contaminated water
properly.
engine OFF. 4. Add a diesel fuel emulsifying agent to the tank. Refer
to the manufacturers instructions for the correct
emulsifying agent-to-water mixture ratio. Refill the
tank with water, and agitate the mixture for 10
minutes. Drain the tank completely. Dispose of
3. Open the engine cover. Allow the system fluids to contaminated water properly.
cool.
5. Refill the fuel tank with water until it overflows.
4. Remove the battery negative (-) cable from the Completely flush the tank with water. Empty the fuel
battery negative (-) terminal. tank, and allow it to dry completely.
Note: If replacing the tank, remove all internal and
external components from the old tank, and retain for d. Assembly
use on the replacement tank. The fuel level indicator can be removed and reused on the
Note: Have a dry chemical (Class B) fire extinguisher new replacement tank. Dispose of the old tank according
near the work area. to local regulations concerning hazardous materials
disposal regulations.
5. Remove fuel tank drain plug, and drain fuel into an
approved and suitable container. Dispose of fuel e. Inspection
properly.
Note: If a leak is suspected in the fuel tank, contact the
6. Label, disconnect and cap the fuel lines from the JLG Service Department.
bottom of the fuel tank.
1. Inspect the fuel tank thoroughly for any cracks,
7. Disconnect the fuel gauge harness. slices, leaks or other damage.
8. Remove screws securing fuel sender to the tank. 2. With the fuel tank removed from the machine, plug
Remove fuel sender from tank. all openings except one elbow fitting. Install the
9. Remove the bolts on the fuel tank hold down bar. elbow fitting, and apply approximately 1-1.5 psi
10. Lift the empty fuel tank from the rear of the cab. (7-10 kPa) of air pressure through the elbow. Check
the reservoir for leaks by applying a soap solution to
b. Disassembly the exterior and look for bubbles to appear at the
cracked or damaged area.
The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed and f. Fuel Tank Installation
reused on the new replacement tank. Dispose of the old
tank according to local regulations concerning hazardous 1. Set fuel tank in its original orientation at the rear of
materials disposal. the cab.
2. Install the fuel tank hold down bar.
c. Cleaning and Drying 3. Install the fuel sender with new gasket into the fuel
If contaminated fuel or foreign material is in the tank, the tank and secure with screws. DO NOT overtighten.
tank can usually be cleaned. 4. Connect the previously labeled fuel hoses to their
Note: If a leak is suspected in the fuel tank, contact JLG appropriate locations. Secure with clamps.
Service Department. 5. Connect the fuel gauge harness.

Engine
6. Fill the fuel tank according to specifications. Refer to 7.5.2 Exhaust System Installation
Section 2.4, Fluid and Lubricant Capacities.
Note: Keep all clamps loosened until entire exhaust
7. Check fuel tank for leaks. system is in place.
7.4.3 After Fuel System Service

1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Operation &
Safety Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as required.
7.5 ENGINE EXHAUST SYSTEM
7.5.1 Exhaust System Removal

position, engage the parking brake, and shut the MAP0190
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key 1. Install the exhaust pipe with a new seal to the
switch and steering wheel, stating that the machine exhaust manifold.
should not be operated. Note: Replace the nuts and the exhaust manifold studs
3. Open the engine cover. Allow the system fluids to if damaged.
cool. 2. Install the exhaust pipe clamp.
4. Remove the battery negative (-) cable from the 3. Install the muffler to the exhaust pipe and bolt the
battery negative (-) terminal. muffler to the frame.
5. Remove the heat shield attached to the engine. 4. Install the clamp securing the muffler to the exhaust
6. Loosen and remove the clamp from the exhaust pipe pipe.
at the exhaust manifold. 5. Install the clamp securing the muffler to the tail pipe.
7. Disconnect and remove the clamp attaching the 6. Adjust the muffler, exhaust and tail pipes for proper
exhaust pipe to the frame. clearance then tighten all clamps.
8. Disconnect and remove the clamp connecting the 7. Install the heat shield attached to the engine.
muffler and the exhaust pipe.
9. Disconnect and remove the clamp connecting the negative (-) terminal.
tail pipe to the muffler and remove the tail pipe.
9. Start engine and check for exhaust leaks at all
10. Loosen and remove the bolts at the front and rear of exhaust connections. Adjust or repair as needed.
the muffler, remove the muffler.

Engine
7.6 AIR CLEANER ASSEMBLY 7.7 ENGINE REPLACEMENT
7.7.1 Engine Removal

CAUTION Note: The radiator and oil cooler must be removed from
NEVER run the engine with only the inner safety the machine before engine removal. Refer to Section
element installed. 7.2, Engine Cooling System. Several additional
components must be removed before engine removal.
Note: Refer to the appropriate Operation & Safety They will be addressed in the following procedures.
Manual for your machine for the correct element change
procedure. 1. Park the machine on a firm, level surface, level the
7.6.1 Air Cleaner Assembly Removal place the travel select lever in the (N) NEUTRAL
1. Park the machine on a firm, level surface, level the engine OFF.
place the travel select lever in the (N) NEUTRAL 2. Place a Do Not Operate Tag on both the ignition key
position, engage the parking brake, and shut the switch and steering wheel, stating that the machine
engine OFF. should not be operated.
2. Place a Do Not Operate Tag on both the ignition key 3. Open the engine cover. Allow the system fluids to
switch and steering wheel, stating that the machine cool.
should not be operated. 4. Disconnect the (+) positive and (-) negative battery
3. Open the engine cover. Allow the system fluids to cables and remove the battery.
cool. 5. Remove the engine cover. Mark the position of the
4. Remove the battery negative (-) cable from the cover to help with cover adjustment when being
battery negative (-) terminal. reinstalled.
5. Remove the clamp securing the air intake elbow to 6. Remove the oil pan cover underneath the engine
the air cleaner assembly. Lift the air intake elbow off compartment.
the air cleaner. 7. Drain and remove the radiator assembly. Refer to
6. Remove the capscrews and nuts securing the air Section 7.2.3, Radiator Replacement.
cleaner mounting bracket to the air cleaner mounting 8. Remove the heater hoses attached to the engine (if
plate. Remove the air cleaner assembly. equipped).
Note: The engine harness is routed and attached to the
7.6.2 Air Cleaner Assembly Installation
engine using hold-down clamps and plastic wire ties at
Note: Apply Loctite 242 threadlock to the capscrew various places on the engine. Before removing engine,
threads before installation. ensure that the harness has been completely separated
(disconnected) from the engine. Move the harness clear
1. With the air cleaner assembly attached, install the air
of the engine, and with the help of an observer, ensure
cleaner mounting bracket using capscrews and nuts.
that the engine clears the harness during removal.
2. Place the loosened clamps over the air outlet elbow
and install elbow on the air cleaner assembly. 9. Label and disconnect all electrical wire connections
on the engine.
3. Adjust and tighten both clamps to 30 lb-in (3 Nm)
before starting the machine. 10. Label and disconnect all electrical wire connections
on the power distribution bracket.
negative (-) terminal. 11. Remove the power distribution bracket.
5. Close and secure the engine cover. 12. Disconnect and cap the fuel inlet line at the fuel filter
head.
13. Disconnect and cap the fuel return line from the fuel
filter head.

Engine
7.7.2 Engine Installation

1. Attach a lifting chain to the front and rear engine lift
brackets, and lift engine clear of the ground.
Note: Apply Loctite 242 threadlock to the engine
mount bracket capscrew threads before installation.
2. Install two guide studs in the bell housing holes.
3. Lift the engine and slowly push and lower into the
engine bay. Have an assistant ensure that the
engine clears the frame, hose and harness
components during engine installation. Position
engine brackets over the front frame mounts.
MY1030
4. Push the engine towards the transmission aligning
the guide studs and the torque convertor shaft with
1
the corresponding holes.
14. Remove the exhaust pipe from the exhaust manifold. 5. Push the engine against the transmission and install
Refer to Section 7.5.1, Exhaust System Removal. eight of the ten bolts and washers. Remove both
15. Loosen the clamps on the sleeve reducer at the guide studs and replace with the remaining two bolts
engine and on the air suction pipe. and washers. Torque bolts to 53-58 lb-ft (72-79 Nm).
16. Remove the air cleaner assembly. Refer to Section 6. Remove the support from under the transmission
7.6.1, Air Cleaner Assembly Removal. and lower the engine the remainder of the way onto
17. Remove the access plug (1) from bottom of the the frame. Align the motor mount holes and install
engine bell housing. This will allow access to remove the bolts. Apply Loctite 242 threadlock to the motor
the bolts holding the torque convertor diaphragm to mount bolts and torque to 125-140 lb-ft
the engine flywheel. (169-190 Nm).
18. Turn the engine over slowly by hand and align each 7. Turn the engine over slowly by hand and align each
of the four torque convertor diaphragm bolts to be of the four torque convertor diaphragm bolts through
accessed. Remove them one at a time. the access plug in the bell housing. Install them one
at a time. DO NOT fully tighten until all of the
19. Secure the engine with a lifting strap or chain from
capscrews and locknuts are in place. Torque to
the appropriate lifting points. Use a suitable hoist or
26-39 lb-ft (35-59 Nm). Replace access plug.
overhead crane.
8. Install the exhaust pipe. Refer to Section 7.5.2,
20. Place a support or jack under the transmission to
Exhaust System Installation.
hold the transmission in place while engine is being
removed. 9. Install the complete air cleaner assembly. Refer to
Section 7.6.2, Air Cleaner Assembly Installation.
21. Remove the bolts and washer securing the engine
mounts. 10. Connect the fuel inlet line to the fuel filter head.
22. Remove the ten bolts holding the transmission to the 11. Connect the fuel return line to the fuel filter head.
engine. Slightly lift and pull the engine out of the 12. Install the Power Distribution bracket.
machine. Have an assistant ensure that the engine
13. Connect all the previously labeled electrical wire
clears all frame components during removal.
connections on the Power Distribution bracket.
23. Place engine on a flat, level surface.
14. Connect all the previously labeled electrical wire
connections on the engine.
15. Install both heater hoses to the engine and tighten
clamps (if equipped).
16. Install the complete radiator assembly. Refer to
Section 7.2.3, Radiator Replacement.
17. Install the engine cover and adjust.

Engine
18. Install the battery and connect the (+) positive and 7.8 TORQUE CONVERTOR DIAPHRAGM
(-) negative cables.
19. Check that all hydraulic system, electrical system, 7.8.1 Torque Convertor Diaphragm Removal
cooling system, fuel system and exhaust system
connections are correct and connected tightly. 1. Park the machine on a firm, level surface, level the
20. From within the cab, lightly depress the throttle pedal place the travel select lever in the (N) NEUTRAL
to full-throttle position. As needed, adjust the limit- position, engage the parking brake, and shut the
stop screw until it touches the pedal bracket. engine OFF.
Note: Have an assistant stand by with a Class B fire Note: In order to remove the engine drive plates, the
extinguisher. engine and transmission must be separated.
21. Start the engine and run to normal operating 2. Refer to Section 6.5.1, Transmission Removal, or
temperature then shut off the engine. While the Section 7.7.1, Engine Removal.
engine is cooling, check for leaks.
22. Allow the engine to cool. Check the radiator coolant
3 4
level, and top off with a 50/50 mixture of ethylene
glycol and water. Replace the radiator cap. 2
23. 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.
Note: 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 (N) NEUTRAL.
3. Remove the four bolts holding the diaphragms to the
24. Obtain and connect an appropriate engine analyzer flywheel.
or tachometer. Check the engine rpm at full throttle. 4. With the drive plates and torque converter removed,
25. Purge the hydraulic system of air by operating all loosen and remove the four bolts (2) and eight lock
boom functions through their entire range of motion washers holding the two diaphragms (3) to the
several times. Check the hydraulic oil level. torque converter (4).
26. Check for proper operation of all components. 5. Replace both diaphragms if damaged.
27. Turn the engine OFF.
7.8.2 Torque Convertor Diaphragm
28. Install the oil pan cover underneath the engine Installation
compartment.
1. Install the two new diaphragms on the torque
converter and install the four bolts with lock washers.
2. Mount the diaphragm/converter assembly to the
transmission.
3. Refer to Section 6.5.3, Transmission Installation, or
Section 7.7.2, Engine Installation, for the remainder
of the installation.

Engine
7.9 TROUBLESHOOTING
Trouble Possible Causes (see key, below)

Low Cranking Power 1, 2, 3, 4
Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12
Key to Possible Causes
1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks

Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.5 Hydraulic System Schematics and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.5.1 Chassis Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.5.2 Boom Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.5.3 Hydraulic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.6.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.6.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.6.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 8.12
8.7 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.7.1 Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.7.2 Pump Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.7.3 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.8 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.8.1 Lift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.8.2 ISP Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
8.8.3 Stabilizer Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8.8.4 Auxiliary Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.8.5 Telescope Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.8.6 Tilt Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.8.7 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.8.8 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.8.9 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.8.10 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.8.11 Valve Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
8.9 Hydraulic Piston Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
8.9.1 Accumulator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
8.9.2 Accumulator Pre-Charge & Check Procedure . . . . . . . . . . . . . . . . . . . . . 8.23
8.10 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24
8.10.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24
8.10.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
8.10.3 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
8.10.4 Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
the operator/mechanic be familiar with the name and
location of the hydraulic components of the machine. The
following illustration identifies the components that are
referred to throughout this section.
EXTEND/RETRACT ISP VALVE

CYLINDER (engine compartment)
AUXILIARY VALVE & HYDRAULIC OIL LIFT/LOWER LIFT VALVE

STABILIZER
TILT VALVE RESERVOIR CYLINDER(S)
VALVE
TILT CYLINDER
MAP0330
OUTRIGGER STABILIZER
CYLINDER HYDRAULIC MANIFOLD HYDRAULIC PISTON
SWAY CYLINDER CYLINDER
(engine compartment) ACCUMULATOR
(behind tire) (behind tire)
STEERING SELECT
VALVE

Hydraulic System
8.2 SAFETY INFORMATION Whenever you disconnect a hydraulic line, coupler, fitting
or other component, slowly and cautiously loosen the part
involved. A hissing sound or slow seepage of hydraulic
WARNING fluid may occur in most cases. After the hissing sound
has ceased, continue removing the part. Any escaping oil
DO NOT service the machine without following all should be directed into an appropriate container. Cap or
safety precautions as outlined in Section 1, Safety otherwise block off the part to prevent further fluid seepage.
Practices, of this manual. Failure to follow the safety Hydraulic system maintenance will, at times, require that
practices could result in death or serious injury. the engine be operated. Always follow safety precautions.
Petroleum-based hydraulic fluids are used in this A major cause of hydraulic component failure is
machine. The temperature of hydraulic fluid increases contamination. Keeping the hydraulic fluid as clean as
during the operation of various hydraulic functions. A possible will help avoid downtime and repairs. Sand, grit
heated petroleum-based hydraulic fluid presents a fire and other contaminants can damage the finely machined
hazard, especially when an ignition source is present. surfaces within hydraulic components. If operating in an
Hydraulic fluid has a flash point that ranges from exceptionally dirty environment, change filters and
300-600 F (150-318 C) and an auto-ignition temperature inspect the fluid more often. When servicing the system,
of 500-750 F (262-402 C). cap or plug hydraulic fittings, hoses and tube assemblies.
Accordingly, periodically inspect all hydraulic system Plug all cylinder ports, valves and the hydraulic reservoir,
components, hoses, tubes, lines, fittings, etc. Carefully and pump openings until installation occurs. Protect
examine any deterioration and determine whether any threads from contamination and damage.
further use of the component would constitute a hazard. Some hydraulic functions are actuated by interfacing with
If in doubt, replace the component. electrical system components (switches, solenoids and
Operate the hydraulic controls after the engine has sensors). When the hydraulic system is not functioning
stopped to relieve trapped pressure. properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.6, Electrical System
Note: Residual pressure may remain in hydraulic Schematics And Diagrams, in this manual.
cylinders, hoses, valve bodies, components, etc. If the
hydraulic lines going to or coming from a component are
taut, slowly and cautiously relieve (bleed off) pressure.

Hydraulic System
8.3 HYDRAULIC PRESSURE DIAGNOSIS 8.3.1 Pressure Checks and Adjustments

When diagnosing trouble in the hydraulic system, use the
JLG Parts Department has a kit available to use for
hydraulic testing information in Section 8.4.1, Hydraulic
hydraulic system maintenance and troubleshooting: the
Pressures.
JLG Pressure Test Kit. The kit is contained in a durable
polyethylene carrying case for demanding field service In general, follow the steps below whenever conducting
conditions. pressure checks and performing adjustments:
1. Park the machine on a firm, level surface. Engage
Pressure Test Kit the park brake, place the travel select lever in (N)
The hydraulic pressure test kit is used to pressure test the NEUTRAL, level the boom and turn the engine OFF.
various hydraulic components in the hydraulic system. 2. The test ports are located on the hydraulic manifold
The kit includes: in the engine compartment. Install a pressure gauge
Gauges for testing high and low pressure circuits capable of measuring at least 10% more pressure
than that which the circuit being checked operates
Fittings, couplers and hoses under.
3. Start the engine. Operate machine functions several
times to allow hydraulic oil to reach operating
temperature. The hydraulic oil temperature should
be between 100-120 F (38-49 C). If a temperature
gauge or thermometer is unavailable, the hydraulic oil
reservoir should be warm to the touch.
4. Refer to Section 8.4.1, Hydraulic Pressures, for
testing procedures.
5. Fully depress the accelerator pedal if required. Place
and hold the joystick in the position needed to
operate the particular machine function being
checked. Continue holding the joystick in position
until pressure readings are taken.
6. Check the pressure gauge reading. It should read as
specified in the Pressure Range column of the
MZ1460
charts found in Section 8.4.1, Hydraulic Pressures.
If the reading is not as specified, turn the engine
Contact JLG Parts Department at 717-485-6472 for
OFF and check other components in the system.
ordering information.
Verify that all related hydraulic components and
Part Description Approximate Price and electrical switches, sensors, solenoids, etc. are
Number Weight Availability operating correctly.
70000652 Hydraulic Pressure 10 lbs. Consult Factory
Test Kit 7. Adjust the relief valve by turning the adjustment
70000101 Digital Hydraulic 7 lbs. Consult Factory
screw. Turning clockwise will increase the pressure;
Pressure Test Kit turning the screw counterclockwise will decrease the
pressure.
8. Start the engine and check the pressure again. Turn
the engine OFF. If there is pressure reading in the
gauge, bleed it off then disconnect or remove the
pressure gauge from the machine.

Hydraulic System
8.4 HYDRAULIC CIRCUITS machine off, install the safety cap and remove the
gauge from the test port.
This section covers the hydraulic circuits and includes 4. If the proper pressure cannot be set, use the
listings for all hydraulic function pressures, where and accompanying hydraulic schematic and/or the
how to check those pressures and a hydraulic schematic. electrical schematic to help troubleshoot and correct
Electrical and hydraulic functions are often related. Verify the problem.
that the electrical components of the circuit are
functioning properly whenever troubleshooting the
1
hydraulic circuit. 2
Always check the following before beginning to
troubleshoot a circuit that is not functioning correctly.
1. Check the hydraulic oil level in the reservoir. Oil level
should be to the middle of the sight glass with all
cylinders retracted.
2. Check hoses, tubes, fittings and other hydraulic
components for leaks, bends, kinks, interference, etc.
3. Check for air in the hydraulic system. Erratic machine
performance and/or spongy cylinder operation are
signs of air in the hydraulic system.
If air in the hydraulic system is suspected, you will
hear air leakage when hydraulic fittings are loosened
and see air bubbles in the hydraulic fluid.
Loose fittings, faulty o-rings or seals, trapped oil,
leaks, system opened for service, etc., can cause air
in the system. Determine what is causing air to enter
the system and correct it. Bleed air from the system.
8.4.1 Hydraulic Pressures MAP0550
a. Checking Pressure 5. The Load Sense (LS) Pressure Adjustment Plug (1)
adjusts the swashplate angle (and therefore, the
1. Start the machine and warm the hydraulic system to
system flow) to maintain a constant pressure delta
operating temperature.
(or Margin Pressure) across an external control
2. Shut off the machine and install a digital or a valve.
5000 psi (345 bar) gauge to the appropriate test port
6. The Pressure Compensator (PC) Adjustment Plug
on the hydraulic manifold.
(2) maintains the system pressure in the hydraulic
3. Start the machine, run the engine at idle and bottom circuit at or below the PC setting by varying the
the appropriate hydraulic function. Refer to Section output flow of the pump if needed. The pump
8.4.1, c. Pressure Specifications, for the correct remains at maximum displacement until the LS
pressure rating. control has enough margin pressure for the flow
command, or the system pressure exceeds the PC
b. Adjusting Hydraulic Pressure setting.
1. Shut the machine off. Remove the cap on the relief
(if necessary).
2. Start the machine and loosen the jam nut on the
relief. Turn the relief clockwise to increase pressure
or counter-clockwise to decrease pressure. Set to
the correct pressure.
3. Tighten the jam nut and recheck the pressure at full
throttle. If the reading is within specification, shut the

Hydraulic System
c. Pressure Specifications
Hydraulic Circuit Test Port Adjustment Function Used to Pressure Range

Location Test
System Relief G1 Refer to Section Tilt Forward 3550-3700 psi
8.4.1, Hydraulic (245-255 Bar)
Pressures.
Priority Relief GLS 1 Steering 2950-3050 psi
(Steering) (203-210 Bar)
Brake BV1 2 Steering 1050-1150 psi
(72-79 Bar)
Park Brake PBG Not Adjustable No Function 450-550 psi
(31-38 Bar)
Note: Bring engine to high idle and bottom out designated function to test the hydraulic pressures.
GLS PBG
G1
2
1
BV1
MAP0410

Hydraulic System
8.5 HYDRAULIC SYSTEM SCHEMATICS AND DIAGRAMS
8.5.1 Chassis Schematic
MAP0310 D

Hydraulic System
8.5.2 Boom Schematic
MAP0320 D

Hydraulic System
8.5.3 Hydraulic Diagram
MAP0600 F

Hydraulic System
8.5.3 Hydraulic Diagram (Continued)
MAP0610 F

Hydraulic System
8.5.3 Hydraulic Diagram (Continued)
MAP0620 F

Hydraulic System
8.6 HYDRAULIC RESERVOIR 8.6.3 Hydraulic Oil Reservoir Removal/

Installation
The hydraulic reservoir (1) is located on the frame
If it is determined that the hydraulic oil reservoir must be
between the engine compartment and the cab.
removed, the hydraulic oil must be drained before the
2 reservoir is removed. Always dispose of hydraulic oil
1 properly.
a. Reservoir Removal
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
3 2. Place a Do Not Operate Tag on both the ignition key
MAP0210 switch and the steering wheel, stating that the
8.6.1 Hydraulic Oil Reservoir Draining 3. Open the engine cover. Allow the system fluids to
cool.
machine, fully retract the boom, lower the boom, 4. Disconnect the battery negative (-) cable from the
place the transmission control lever in battery negative (-) terminal.
(N) NEUTRAL, engage the park brake and shut the 5. Drain the hydraulic oil reservoir. Refer to Section
engine OFF. 8.6.1, Hydraulic Oil Reservoir Draining.
2. Place a Do Not Operate Tag on both the ignition key 6. Label, disconnect and cap all hydraulic hoses
switch and the steering wheel, stating that the attached to the hydraulic oil reservoir. Cap all fittings
machine should not be operated. and openings to keep dirt & debris from entering the
3. Open the engine cover. Allow the system fluids to hydraulic system.
cool. 7. Remove the bolts securing the hydraulic oil reservoir
4. Disconnect the battery negative (-) cable from the to the frame.
battery negative (-) terminal. 8. Remove the hydraulic oil reservoir.
5. Open the filler cap (2) on the hydraulic oil reservoir.
Remove the drain plug (3) on the side of the b. Disassembly
hydraulic oil reservoir. The hydraulic oil reservoir is a one-piece unit and cannot
6. Transfer the used hydraulic oil into a suitable be disassembled. The hydraulic oil level sight- glass and
covered container, and label as "Used Oil". Dispose hydraulic oil filler cap can be removed and reused on the
of used oil at an approved recycling facility. Clean new replacement reservoir. Dispose of the old reservoir
and reinstall the drain plug. according to local regulations concerning hazardous
7. Wipe up any hydraulic fluid spillage in, on, near and materials disposal.
around the machine and the work area.
c. Cleaning and Drying
8.6.2 Hydraulic Oil Reservoir Filling If contaminated hydraulic oil or foreign material is in the
1. Be sure the reservoir is clean and free of all debris. tank, the tank can usually be cleaned.
2. Install a new hydraulic oil filter. Note: If a leak is suspected in the hydraulic oil reservoir,
contact JLG Service Department.
3. Fill the reservoir with Mobilfluid 424 (ISO Grade 46)
oil. Refer to Section 2.4, Fluid and Lubricant
Capacities.

Hydraulic System
To clean the hydraulic oil reservoir: 8.7 ENGINE IMPLEMENT PUMP

1. Have a dry chemical (Class B) fire extinguisher near
the work area. 8.7.1 Pump Description
2. Remove the hydraulic oil reservoir drain plug, and For internal service instructions contact your local JLG
safely drain any hydraulic oil into a suitable distributor.
container. Dispose of hydraulic oil properly.
3. Clean the hydraulic oil reservoir with a high-pressure 8.7.2 Pump Failure Analysis
washer, or flush the tank with hot water for five
The pump (1) is the heart of the hydraulic system, and
minutes and drain the water. Dispose of
whenever there is a problem in the system, the pump
contaminated water properly.
often is blamed. However, pump failure is seldom due to
failure of pump components. Pump failure usually
d. Inspection
indicates another problem in the hydraulic system.
Note: If a leak is suspected in the fuel or hydraulic oil tank, According to pump manufacturer statistics, 90-95 percent
contact JLG Service Department. of pump failures are due to one or more of the following
1. Inspect the hydraulic oil reservoir thoroughly for any causes:
cracks, slices, leaks or other damage. Aeration
2. With the hydraulic oil reservoir removed from the Cavitation
machine, plug all openings except one elbow fitting. Contamination
Install the elbow fitting, and apply approximately Excessive Heat
1-1.5 psi (7-10 kPa) of air pressure through the Over-Pressurization
elbow. Check the reservoir for leaks by applying a
Improper Fluid
soap solution to the exterior and look for bubbles to
appear at the cracked or damaged area. In the event of pump failure, investigate further to
determine the cause of the problem.
e. Reservoir Installation
1. Place the hydraulic oil reservoir into its original 8.7.3 Pump Replacement
orientation.
a. Pump Removal
2. Secure the hydraulic oil reservoir to the frame with
the previous mounting hardware. 1. Park the machine on a firm, level surface, level the
3. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations.
4. Install the hydraulic fluid level sight-glass using
special designed and drilled capscrews and gaskets.
5. Install hydraulic filter bracket and hydraulic filter. machine should not be operated.
6. Fill the hydraulic oil reservoir according to 3. Open the engine cover. Allow the system fluids to
specifications. Refer to Section 2.4, Fluid and cool.
4. Disconnect the battery negative (-) cable from the
7. Check the hydraulic oil reservoir for leaks. battery negative (-) terminal.
8. Connect the battery negative (-) cable to the battery 5. Drain the hydraulic reservoir. Refer to Section 8.6.1,
negative (-) terminal. Hydraulic Oil Reservoir Draining.
9. Close and secure the engine cover. 6. Thoroughly clean the pump and surrounding area,
including all hoses and fittings before proceeding.
Note: Cap all hoses as you remove them to prevent
unnecessary fluid spillage.

Hydraulic System
7. Label, disconnect and cap the hydraulic hoses 8. Connect a hose to the P1 port on the pump. Direct
attached to the pump. the open end of the hose into a fluid drip pan.
9. Turn the machine ignition switch to START and back
1
OFF in 3 to 5 second intervals. Monitor the open end
of the drain hose for a constant flow of fluid (no air)
while engine is cranking.
10. Once a constant flow is achieved at the open end of
the drain hose, disconnect the hose and reinstall the
10 amp fuse to location F3 in the power distribution
2 unit.
11. Inspect for leaks and check all fluid levels. The
hydraulic reservoir oil level must be to the middle of
the sight gauge.
3
c. Pump Test
MAP0220
Refer to Section 8.3.1, Pressure Checks and
8. Remove the four bolts and lockwashers securing the Adjustments.
pump to the transmission (2). Remove the four bolts
securing the hydraulic manifold (3) to the pump. 8.8 CONTROL VALVES
Remove the o-ring located between the transmission
and the pump. Wipe up any hydraulic oil spillage.
8.8.1 Lift Valve
Note: DO NOT disassemble the operating pump. The
pump is pre-set from the manufacturer. Any adjustments a. Lift Valve Removal
or repairs performed by anyone other than an authorized
dealer could void the warranty.
3
b. Pump Installation 2
1
1. Place the pump and a new, oiled o-ring into position
on the transmission. Align the pump shaft with the
internal transmission gear, so that the machined
teeth mesh together.
2. Align the bolt holes with the pump mount holes.
Secure the pump to the transmission with the four
bolts and washers. Secure the hydraulic manifold to
the pump with the four bolts. MY2810
SHOWN WITHOUT ACCUMULATOR
hoses to their appropriate locations. 1. Park the machine on a firm, level surface, level the
4. Fill the hydraulic reservoir. Refer to Section 8.6.2, machine, fully retract the boom, raise and support the
Hydraulic Oil Reservoir Filling. boom, place the transmission control lever in (N)
5. Prime the pump by filling the case drain port with fresh, NEUTRAL, engage the park brake and shut the
filtered hydraulic oil from a clean container before engine OFF.
installing the case drain connector and hose. 2. Place a Do Not Operate Tag on both the ignition key
6. Check all routing of hoses and tubing for sharp switch and the steering wheel, stating that the
bends or interference with any rotating members. All machine should not be operated.
tube and hose clamps must be tight. 3. Open the engine cover. Allow the system fluids to
cool.
7. Remove the 10 amp fuse from location F3 in power
distribution unit located in the engine compartment. 4. Disconnect the battery negative (-) cable from the
This will allow the engine to crank, but not start while battery negative (-) terminal.
air is worked out of the new pump.

Hydraulic System
5. Thoroughly clean the valve and surrounding area, 8.8.2 ISP Valve
6. Label, disconnect and cap the hydraulic hoses a. ISP Valve Removal
attached to the lift valve (1) and lift manifold (2). Cap
all fittings to prevent dirt & debris from entering the
hydraulic system.
7. Label and disconnect the electrical connectors from
4
the lift valve.
8. Support the underside of the lift valve and remove
the bolts (3) securing the lift manifold and lift valve to
the bracket. Carefully remove the lift valve and lift
manifold from the bracket.
9. If necessary, remove the hardware securing the
bracket to the machine frame.
MAP0240
10. If necessary, remove the lift valve controller from the
lift valve.
b. Lift Valve Installation machine, fully retract the boom, lower the boom,
1. If necessary, install the lift valve controller to the lift engage the park brake and shut the engine OFF.
valve with the previously used hardware. Refer to
Section 8.8.11, Valve Controllers, for proper torque
values and sequence.
2. If necessary, Install the bracket onto the machine
frame with the previously used hardware.
cool.
3. Place the lift manifold on the top of the bracket and
insert the previously removed bolts. Place the lift
valve on the underside of the bracket and secure
with the four bolts. 5. Thoroughly clean the valve and surrounding area,
hoses to their appropriate locations. 6. Label, disconnect and cap the hydraulic hoses
attached to the ISP valve (4). Cap all fittings to
5. Connect the previously labeled electrical connectors
prevent dirt & debris from entering the hydraulic
to the lift valve.
system.
7. Label and disconnect the electrical connector from
the ISP valve controller.
7. Before starting the machine, check fluid level of the
8. Remove the hardware securing the ISP valve to the
hydraulic fluid reservoir and if necessary fill to full
engine compartment.
mark with Mobilfluid 424 (ISO 46).
9. If necessary, remove the ISP valve controller from
8. Start the machine and run at low idle for about one the ISP valve.
minute. Test the functions of the lift valve.
9. Inspect for leaks and check level of hydraulic fluid in b. ISP Valve Installation
reservoir. Add hydraulic fluid if needed. Shut the
1. If necessary, install the ISP valve controller to the
engine OFF.
ISP valve with the previously used hardware. Refer
10. Close and secure the engine cover. to Section 8.8.11, Valve Controllers, for proper
torque values and sequence.
2. Install the ISP valve to the engine compartment with
3. Connect the previously labeled electrical connector
to the ISP valve controller.
Hydraulic System
4. Uncap and connect the previously labeled hydraulic 8. Label and disconnect the electrical connectors from
hoses to their appropriate locations. the stabilizer valve.
5. Connect the battery negative (-) cable to the battery 9. Remove the hardware securing the stabilizer valve
negative (-) terminal. to the machine frame.
hydraulic fluid reservoir and if necessary fill to full b. Stabilizer Valve Installation
mark with Mobilfluid 424 (ISO 46). 1. Install the stabilizer valve to the machine frame with
7. Start the machine and run at low idle for about one the previously used hardware.
minute. Test the functions of the ISP valve. 2. Connect the previously labeled electrical connectors
8. Inspect for leaks and check level of hydraulic fluid in to the stabilizer valve.
reservoir. Add hydraulic fluid if needed. Shut the 3. Uncap and connect the previously labeled hydraulic
engine OFF. hoses to their appropriate locations.
9. Close and secure the engine cover. 4. Connect the battery negative (-) cable to the battery
8.8.3 Stabilizer Valve 5. Before starting the machine, check fluid level of the
a. Stabilizer Valve Removal
6. Start the machine and run at low idle for about one
5 minute. Test the functions of the stabilizer valve.
7. Inspect for leaks and check level of hydraulic fluid in
engine OFF.
c. Stabilizer Valve Adjustment

If slow motion is experienced on one of the stabilizers/
outriggers after one of the two stabilizers/outriggers hits
MAP0240
end of stroke, use the following procedure to adjust the
stabilizer valve:
1. Park the machine on a firm, level surface, level the 7
6
cool.
5. Thoroughly clean the valve and surrounding area, MAP0730
including all hoses and fittings before proceeding. 1. Extend one stabilizer/outrigger to end of stroke.
6. Remove the valve protective cover from the machine 2. Measure the pressure at the valve LS port (7).
frame.
3. Adjust the load sense relief valve screw (6) until the
7. Label, disconnect and cap the hydraulic hoses measured pressure is 325 psi (22 bar) below system
attached to the stabilizer valve (5). Cap all fittings to pressure (nominally 3300 psi (228 bar)) as read via
prevent dirt & debris from entering the hydraulic the analyzer under DIAGNOSTICS/ISP.
system.

Hydraulic System
Note: This will ensure that there is approximately a 325 3. Uncap and connect the previously labeled hydraulic
psi (22 bar) margin between the valve LS and pump hoses to their appropriate locations.
output. 4. Connect the battery negative (-) cable to the battery
8.8.4 Auxiliary Valve
a. Auxiliary Valve Removal hydraulic fluid reservoir and if necessary fill to full
8 6. Start the machine and run at low idle for about one
minute. Test the functions of the auxiliary valve.
engine OFF.
8. Install the protective cover on the boomhead.
8.8.5 Telescope Valve
a. Telescope Valve Removal

MAP0250
10
1. Remove any attachment from the boom. Park the
machine on a firm, level surface, level the machine,
fully retract the boom, lower the boom, place the
the park brake and shut the engine OFF.
machine should not be operated. MAP0710
3. Open the engine cover. Allow the system fluids to 9

cool.
5. Remove the protective cover from the boomhead. engage the park brake and shut the engine OFF.
6. Thoroughly clean the valve and surrounding area, 2. Place a Do Not Operate Tag on both the ignition key
including all hoses and fittings before proceeding. switch and the steering wheel, stating that the
7. Label, disconnect and cap the hydraulic hoses machine should not be operated.
attached to the auxiliary valve (8). Cap all fittings to 3. Open the engine cover. Allow the system fluids to
prevent dirt & debris from entering the hydraulic cool.
system.
8. Label and disconnect the electrical connectors from battery negative (-) terminal.
the auxiliary valve.
5. Label, disconnect and cap the hydraulic hoses
9. Remove the hardware securing the auxiliary valve to attached to the telescope valve (9). Cap all fittings to
the boomhead. prevent dirt & debris from entering the hydraulic
system.
b. Auxiliary Valve Installation
1. Install the auxiliary valve to the boomhead with the the telescope valve.
previously used hardware. 7. Support the telescope valve and remove the bolts on
2. Connect the previously labeled electrical connectors the clamps (10) securing the telescope valve to the
to the auxiliary valve. extend cylinder.

Hydraulic System
8. If necessary, remove the telescope valve controller 8. Label and disconnect the electrical connectors from
from the telescope valve. the tilt valve (12).
b. Telescope Valve Installation

1. If necessary, install the telescope valve controller to
the telescope valve with the previously used
hardware. Refer to Section 8.8.11, Valve
Controllers, for proper torque values and sequence.
2. Install the telescope valve to the extend cylinder with 12
3. Connect the previously labeled electrical connectors
to the telescope valve.
hoses to their appropriate locations.
6. Before starting the machine, check fluid level of the 11
minute. Test the functions of the telescope valve.
engine OFF. MAP0260
9. Close and secure the engine cover. 9. Attach a suitable sling to an appropriate lifting device
and to the tilt cylinder. Make sure the device used is
8.8.6 Tilt Valve capable of supporting the cylinder.
10. Remove the lock bolt and/or any retaining clips
a. Tilt Valve Removal
securing the cylinder pins. Remove the cylinder pins.
1. Park the machine on a firm, level surface, level the 11. Lower the cylinder from the boom.
place the transmission control lever in (N) NEUTRAL, 12. Remove the hardware securing the Tilt valve to the
engage the park brake and shut the engine OFF. tilt cylinder. Remove the tilt valve.
2. Place a Do Not Operate Tag on both the ignition key 13. If necessary, remove the tilt valve controller from the
switch and the steering wheel, stating that the tilt valve.
b. Tilt Valve Installation
cool. 1. If necessary, install the tilt controller to the tilt valve
with the previously used hardware. Refer to Section
8.8.11, Valve Controllers, for proper torque values
and sequence.
5. Remove the protective cover from the boomhead.
2. Install the tilt valve to the tilt cylinder with the
6. Thoroughly clean the valve and surrounding area, previously used hardware.
3. Grease the bushings at the ends of the tilt cylinder.
7. Label, disconnect and cap the hydraulic hoses Using an appropriate sling, lift the cylinder into its
attached to the tilt cylinder (11). Cap all fittings to mounting position.
prevent dirt & debris from entering the hydraulic
4. Align the cylinder bushing and install pin and
system.
retaining clips.

Hydraulic System
5. Uncap and connect the previously labeled hydraulic 4. Disconnect the battery negative (-) cable from the
hoses to their appropriate locations. battery negative (-) terminal.
6. Connect the previously labeled electrical connectors 5. Label, disconnect and cap all hoses attached to the
to the tilt valve. Service Brake valve (13).
7. Connect the battery negative (-) cable to the battery 6. Remove the service brake pedal. Refer to Section
negative (-) terminal. 4.3.2, Service Brake Pedal.
8. Before starting the machine, check fluid level of the 7. Remove the capscrews, nuts and lockwashers
hydraulic fluid reservoir and if necessary fill to full mounting the service brake valve to the service
mark with Mobilfluid 424 (ISO 46). brake bracket.
9. Start the machine and run at low idle for about one Note: DO NOT disassemble the service brake valve.
minute. Test the functions of the tilt cylinder. The service brake valve is not serviceable and must be
10. Inspect for leaks and check level of hydraulic fluid in replaced in its entirety, if defective.
engine OFF. b. Service Brake Valve Installation
11. Close and secure the engine cover. 1. Install the service brake valve with the capscrews,
lockwashers and nuts onto the service brake
8.8.7 Service Brake Valve bracket.
2. Install the service brake pedal. Refer to Section
4.3.2, Service Brake Pedal.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
13
operation. Lubricate seals and o-rings with clean
hydraulic oil.
3. Use new oiled o-rings as required. Uncap and
connect the previously labeled hoses to the service
brake valve.
4. Check the routing of all hoses, and tubing for sharp
bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps.
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.
MAP0270
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
a. Service Brake Valve Removal reservoir. Shut the engine OFF.
1. Park the machine on a firm, level surface, level the Note: Check for leaks, and repair as required before
machine, fully retract the boom, lower the boom, continuing. Add hydraulic fluid to the reservoir as
place the transmission control lever in (N) NEUTRAL, needed.
engage the park brake and shut the engine OFF. 8. Wipe up any hydraulic fluid spillage in, on, near and
2. Place a Do Not Operate Tag on both the ignition key around the machine, work area and tools.
machine should not be operated. 8.8.8 Brake Test
3. Open the engine cover. Allow the system fluids to Carefully bleed the brake lines as soon as the brake valve
cool. is installed in the machine. Air in the system will not allow
Hydraulic System
the brakes to apply properly. There are four brake

bleeder locations on the axles. Work with an assistant to
perform this procedure. 15
1. Place the travel select lever in (N) NEUTRAL,
engage the park brake, and start the engine.
2. Remove the plastic cap from the brake bleeder (14).
Attach one end of a length of transparent tubing over
the brake bleeder. Place the other end of this tubing
in a suitable transparent container that is partially MZ0370
filled with hydraulic oil. The end of the tubing must be
below the oil level in the container.
3. DO NOT open the brake bleeder without holding the 8.8.10 Steer Select Valve
tubing firmly on the bleeder. There is pressure at the
brakes. Carefully open the bleeder with a 12 mm The machine can be used in the front-wheel, four-wheel
wrench. Have the assistant depress the brake pedal. or crab steering mode. The steer select valve (16)
Close the brake bleeder when air bubbles no longer controls the direction of hydraulic fluid flow to the steering
appear in the oil. Release the brake pedal. Remove cylinder mounted on each axle. The steer select valve is
the tubing from the brake bleeder. attached to a mounting plate on the underside of the
frame near the transmission.
4. Repeat Steps 2 and 3 for the remaining brake
bleeders.
5. Install a vacuum pump on the brake reservoir and
remove the remainder of the trapped air from the
brake system.
6. Check brake fluid level and add fluid if necessary.
7. Conduct a pressure and function check of the
service brake. Refer to Section 8.4.1, Hydraulic
Pressures.
16
14
MAP0280
Verify the correct operation of the steer select valve

solenoids before considering replacement of the valve.
Refer to Section 9.6, Electrical System Schematics And
Diagrams, and Section 9.12, Display Monitor and
MY0150 Gauges. The housing of the steer select valve is not
serviceable and must be replaced if defective.
8.8.9 Steering Orbitrol Valve
a. Steer Select Manifold and Valve Removal
The steering orbitrol valve (15) is located at the base of
the steering wheel shaft, concealed by the lower dash 1. Park the machine on a firm, level surface, level the
cover. The valve is not serviceable and must be replaced machine, fully retract the boom, lower the boom,
in its entirety if defective. For detailed information refer to place the transmission control lever in (N) NEUTRAL,
Section 4.3.1, Steering Column and Orbitrol Valve. engage the park brake and shut the engine OFF.

Hydraulic System
3. Open the engine cover. Allow the system fluids to c. Steer Select Valve and Manifold Installation
cool.
1. Install the steer select valve to the mounting plate on
4. Disconnect the battery negative (-) cable from the the underside of the frame near the transmission
battery negative (-) terminal. using the two bolts.
5. Label, disconnect and cap the hydraulic hoses and 2. Connect all the hydraulic hoses, fittings, solenoid
the electrical plugs connected to the steering select wire terminal leads, etc., to the steer select valve
valve.
3. Check the routing of all hoses, wiring and tubing for
6. Remove the bolts holding the steer select valve to sharp bends or interference with any rotating
the mounting plate on the frame. members, and install tie wraps and/or protective
7. Remove the steer select manifold with the attached conduit as required. Tighten all hose clamps.
steer select valve from the machine. Wipe up any 4. Start the engine and run at approximately 1/3-1/2
hydraulic fluid spillage in, on, near and around the throttle for about one minute without moving the
machine. machine or operating any hydraulic functions.
5. Inspect for leaks and check the level of the hydraulic
b. Steer Select Manifold and Valve Disassembly,
fluid in the reservoir. Shut the engine OFF.
Cleaning, Inspection and Assembly
Note: Check for leaks and repair as required before
1. Place the steer select assembly on a suitable work
continuing. Add hydraulic fluid to the reservoir as
surface.
needed.
2. Separate the steer select valve from the manifold by
removing the four socket head capscrews. Discard 6. Wipe up any hydraulic fluid spillage in, on, near and
the four o-rings. around the machine, work area and tools.
3. Remove the solenoid valves and cartridges from the 7. Close and secure the engine cover.
steer select housing.
d. Steering Test
4. Clean all components with a suitable cleaner before
inspection. Refer to Section 8.4.1, Hydraulic Pressures.
5. Inspect the solenoid cartridges for proper operation. 1. Conduct a pressure check of the steering hydraulic
Check by shifting the spool to ensure that it is circuit.
functioning properly. Check that the spring is intact. 2. Check each steering mode for proper function.
Inspect the cartridge interior for contamination.
6. Inspect internal passageways of the steer select
manifold and 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 secondary function manifold.
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
four new, oiled o-rings and the four socket head
capscrews.

Hydraulic System
8.8.11 Valve Controllers 2. Place a Do Not Operate Tag on both the ignition key
CAUTION 3. Open the engine cover. Allow the system fluids to
HIGH OIL PRESSURE WITHIN VALVE AND cool.
CONTROLLER. Removing the controller may cause 4. Disconnect the battery negative (-) cable from the
cylinder leakage. Brace and block the boom before battery negative (-) terminal.
removing lift valve and telescope valve controllers.
5. Thoroughly clean the accumulator and surrounding
Valve controllers (7) are located on the following valves: area, including all hoses and fittings before
Lift Valve, ISP Valve, Telescope Valve and Tilt Valve. proceeding.
When installing the valve controller onto the valve, ensure 6. Discharge the pressure in the accumulator.
transducer gaskets are in place and torque the bolts to 4 Note: Attaching the charging assembly to the gas valve
lb-ft (5 Nm) in the following sequence: on the accumulator will relieve any residual pressure in
the accumulator. Refer to Section 8.9.2, Accumulator
Pre-Charge & Check Procedure.
Valve 7. Place a suitable container under the hydraulic hose
6 fittings on the accumulator and lift manifold to catch
5 hydraulic oil.
8. Label, disconnect and cap the hydraulic hose
Valve Controller attached to the accumulator (1) and lift manifold (2).
Cap all fittings to prevent dirt & debris from entering
3 2
the accumulator.
1 4
MAP0630
10. Remove the hardware securing the accumulator to
8.9 HYDRAULIC PISTON the bracket. Attach a suitable sling to the
ACCUMULATOR accumulator. Remove the accumulator from the
machine.
8.9.1 Accumulator Removal Note: Accumulator weighs approximately

128 lbs (58 kg).
1
2 e. Accumulator Installation
Note: New accumulators are precharged.
1. Install the accumulator to the bracket with the
previously used hardware.
2. If necessary, charge the accumulator. Refer to
Section 8.9.2, Accumulator Pre-Charge & Check
Procedure.
hose to the appropriate locations on the accumulator
MAP0430
and lift manifold.
1. Park the machine on a firm, level surface, level the 4. Connect the previously labeled electrical connectors
machine, fully retract the boom, raise and support the to the accumulator.
boom, place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the 5. Connect the battery negative (-) cable to the battery
engine OFF. negative (-) terminal.

Hydraulic System
6. Before starting the machine, check fluid level of the 3. Open the engine cover. Allow the system fluids to
hydraulic fluid reservoir and if necessary fill to full cool.
Note: Attaching the charging assembly to the
7. Start the machine and run at low idle for about one accumulator will relieve any residual pressure in the
minute. Test the functions of the accumulator and lift accumulator.
valve.
4. If applicable, discharge all the oil from the
8. Inspect for leaks and check level of hydraulic fluid in accumulator by placing a suitable container under
reservoir. Add hydraulic fluid if needed. Shut the the hydraulic hose connection on the accumulator
engine OFF. and removing the hose attached to the accumulator
9. Close and secure the engine cover. The piston must bottom against the hydraulic end
cap. Transfer the used hydraulic oil into a suitable
8.9.2 Accumulator Pre-Charge & Check covered container, and label as "Used Oil". Dispose
Procedure of used oil at an approved recycling facility. Clean
and reinstall the drain plug.
WARNING 5. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
Use an inert gas such as nitrogen for pre-charging the 6. Make sure nitrogen supply is shut off.
piston accumulator. DO NOT use oxygen or shop air. 7. Attach the nitrogen fitting adapter (5) on the charging
Note: If water pumped nitrogen is not available, oil- assembly to a proper hose attached to the nitrogen
pumped nitrogen may be used. bottle.
Use the Accumulator Fill Kit (JLG P/N 10268992) 8. Remove the gas valve guard (8) and gas valve cap
when charging and checking the pressure in the from the accumulator (9).
accumulator. Refer to the illustration below.
7
6
3
4
5
9 10 8
MAP0200
9. Back the handle (4) all the way out (counter-

clockwise) before attaching the fill kit assembly to
accumulator gas valve (10).
10. Close the bleed valve (7).
MAP0720 11. Making sure not to loop or twist the hose, attach the
gas valve on the fill kit (3) to the gas valve on the
Note: If equipment other than the above listed is used, accumulator.
make sure it is compatible with the gas valve assembly. 12. Slowly turn the handle until the regulator (6) starts
1. Park the machine on a firm, level surface, level the showing the pressure in the accumulator. Do not turn
machine, fully retract the boom, lower the boom, the handle all the way down, as it will damage the
place the transmission control lever in (N) NEUTRAL, valve core.
engage the park brake and shut the engine OFF. 13. Crack open the nitrogen bottle valve and slowly fill
2. Place a Do Not Operate Tag on both the ignition key the accumulator. Shut off when gauge indicates 600
switch and the steering wheel, stating that the psi (41 bar).
machine should not be operated. 14. Let the pre-charge set for 10 to 15 minutes. This will
allow the gas temperature to stabilize. If the desired
pre-charge is exceeded, close the nitrogen bottle
Hydraulic System
valve, then slowly open the bleed valve. Do not

reduce the pre-charge by depressing the valve core
with a foreign object. High pressure may rupture the
rubber valve seat.
15. When finished pre-charging the accumulator, turn
the handle all the way out on the gas chuck, then
open the bleed valve.
16. Remove the fill kit assembly from the gas valve on
the accumulator. Check for precharge leak using a
common leak reactant.
17. Replace the gas valve cap and valve guard. Torque
to 10-15 in-lbs (11.5-17 cm kg).
MZ0400
8.10 HYDRAULIC CYLINDERS
8.10.1 General Cylinder Removal a. General Cylinder Disassembly

Instructions
1. Clean the cylinder with a suitable cleaner before
1. Remove any attachment from the machine. Park the
disassembly. Remove all dirt, debris and grease
machine on a firm level surface and fully retract the
from the cylinder.
boom. Allow sufficient work space around the
hydraulic cylinder being removed. Support the boom 2. Clamp the barrel end of the cylinder in a soft-jawed
if the lift/lower cylinder is being removed. Place the vise or other acceptable holding equipment if
travel select lever in (N) NEUTRAL, engage the park possible.
brake, shut the engine OFF and chock wheels.
WARNING
machine should not be operated. Significant pressure may be trapped inside the cylinder.
Exercise caution when removing a counterbalance valve
or a pilot-operated check valve from a cylinder. Escaping
cool.
hydraulic fluid under pressure could penetrate the skin.
4. Label, disconnect and cap or plug hydraulic hoses in
relation to the cylinder. Note: Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
Note: Prior to removing the extend/retract cylinder, cylinder securely. Excessive force can damage the
remove the telescope valve assembly attached to the cylinder tube.
cylinder to prevent damage to the valve. Refer to Section
8.8.5, Telescope Valve. 3. If applicable, remove the counterbalance valve from
the side of the cylinder barrel.
5. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Ensure the device used can Note: DO NOT tamper with or attempt to adjust the
actually support the cylinder. counterbalance valve cartridge. If adjustment or
replacement is necessary, replace the counterbalance
6. Remove the lock bolt and/or any retaining clips
valve with a new part.
securing the cylinder pins. Remove the cylinder pins.
7. Remove the cylinder. 4. Extend the rod as required to allow access to the
base of the cylinder.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools. Note: Protect the finish of 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 from the tube. A considerable amount of force
will be needed to remove the head gland. Carefully

Hydraulic System
slide the head gland down along the rod toward the Note: If a white powdery residue is present on threads
rod eye, away from the cylinder barrel. or parts, it can be removed by using a soft brass wire
brush. Wipe clean with Loctite Cleaner prior to
Note: When sliding the rod and piston assembly out of
reassembly.
the barrel, prevent the threaded end of the barrel from
damaging the piston. Keep the rod centered within the
c. Cylinder Inspection
barrel to help prevent binding.
1. Inspect internal surfaces and all parts for wear,
6. Carefully pull the rod assembly along with the head
damage, etc. If the inner surface of the cylinder
gland out of the cylinder barrel.
barrel does not display a smooth finish, or is scored
7. Fasten the rod eye in a soft-jawed vise, and place a or damaged in any way, replace the barrel.
padded support under and near the threaded end of
2. Remove light scratches on the piston, head gland,
the rod to prevent any damage to the rod.
rod or inner surface of the cylinder barrel with a 400-
8. Remove the set screw from the piston head. 600 grit emery cloth. Use the emery cloth in a rotary
Note: It may be necessary to apply heat to break the motion to polish out and blend the scratch(es) into
bond of the sealant between the piston and the rod the surrounding surface.
before the piston can be removed. 3. Check the piston rod assembly for run-out. If the rod
is bent, it must be replaced.
Some cylinder parts are sealed with a special organic
d. General Cylinder Assembly Instructions
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals 1. Use the proper tools for specific installation tasks.
from the area of the bonded parts. Wipe off any hydraulic Clean tools are required for installation.
oil, then heat the part(s) uniformly to break the bond. A 2. Install new seals, back-up rings and o-rings on the
temperature of 300-400 F (149-204 C) will destroy the piston and new seals, back-up rings, o-rings and
bond. Avoid overheating, or the parts may become bearing on the head gland.
distorted or damaged. Apply sufficient torque for removal
while the parts are still hot. The sealant often leaves a Note: The extend/retract cylinder has a spacer that
white, powdery residue on threads and other parts, which MUST be installed over the rod AFTER the head gland
must be removed by brushing with a soft brass wire brush and BEFORE the piston head.
prior to reassembly.
3. Fasten the rod eye in a soft-jawed vise, and place a
9. Remove the piston head from the rod and carefully padded support under and near the threaded end of
slide the head gland off the end of the rod. the rod to prevent any damage to the rod.
10. Remove all seals, back-up rings and o-rings from the Note: Protect the finish on the cylinder rod at all times.
piston head and all seals, back-up rings and o-rings Damage to the surface of the rod can cause seal failure.
from the head gland.
4. Lubricate and slide the head gland over the cylinder
Note: The head gland bearing will need to be inspected rod. Install the piston head on to the end of the
to determine if replacement is necessary. cylinder rod. Loctite and install the set screw in the
DO NOT attempt to salvage cylinder seals, sealing rings piston head. Refer to Section 8.10.4, Cylinder
or o-rings. ALWAYS use a new, complete seal kit when Torque Specifications for torque specifications for
rebuilding hydraulic components. Consult the parts the piston head and the set screw.
catalog for ordering information. Note: Avoid using excess force when clamping the
cylinder barrel in a vise. Apply only enough force to hold
b. Cylinder Cleaning Instructions the cylinder barrel securely. Excessive force can damage
1. Discard all seals, back-up rings and o-rings. Replace the cylinder barrel.
with new items from seal kit to ensure proper 5. Place the cylinder barrel in a soft-jawed vise or other
cylinder function. acceptable holding devise.
2. Clean all metal parts with an approved cleaning
Note: When sliding the rod and piston assembly into the
solvent such as trichlorethylene. Carefully clean
cylinder barrel, prevent the threaded end of the cylinder
cavities, grooves, threads, etc.
barrel from damaging the piston head. Keep the cylinder
rod centered within the barrel to prevent binding.

Hydraulic System
6. Carefully insert the cylinder rod assembly into the 8.10.3 Steering Cylinders
cylinder barrel.
The steer cylinder is attached to each axle center
7. Screw the head gland into the cylinder barrel and housing.The steer cylinder assembly can be found in
tighten with a spanner wrench. Refer to Section Section 5.3, Axle Assemblies. The steer cylinder is
8.10.4, Cylinder Torque Specifications for torque covered in the appropriate manufacturers axle literature.
specifications for the head gland.
8. If applicable, install new counter balance valve into Steering Cylinder
block on the cylinder barrel.
e. General Cylinder Installation

1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder
into its mounting position.
2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
3. Connect the hydraulic hoses in relation to the labels
or markings made during removal.
hydraulic fluid reservoir and if necessary fill to full Axle Center Section
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic
oil.
engine OFF.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8.10.2 Cylinder Pressure Checking

Attach a 5000 psi (345 bar) gauge to the test ports on the
hydraulic pump manifold to check the system pressure.
For more information, refer to Section 8.3.1, Pressure
Checks and Adjustments, and Section 8.4.1, Hydraulic
Pressures.

Hydraulic System
8.10.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Model Head Nut Valve Valve Screw

G10-55A 275 lb-ft min 1600-2000 lb-ft 45-50 lb-ft 28-30 lb-ft
(373 Nm) (2169-2712 Nm) (54-61 Nm) (38-41 Nm)
G12-55A 300 lb-ft min 1600-2000 lb-ft 45-50 lb-ft 28-30 lb-ft
(407 Nm) (2169-2712 Nm) (54-61 Nm) (38-41 Nm)
b. Extend/Retract Cylinder
Head Nut Valve (Large) Valve (Small)

250 lb-ft min 1898-2305 lb-ft 110 lb-ft (149 Nm) 35 lb-ft (47 Nm)
(339 Nm) (1400-1700 Nm)
c. Tilt Cylinder
Head Nut Set Screw

500-600 lb-ft (678-814 Nm) 2400-2600 lb-ft (3254-3525 Nm) 4-4.5 in-lbs (0.45-0.51 Nm)
use Loctite 271 use Loctite 243
d. Frame Level Cylinder
Head Nut
200 lb-ft min (271 Nm) 1125-1375 lb-ft (1525-1864 Nm)
e. Stabilizer Cylinder
Head Nut Cartridge Cartridge Nut

200 lb-ft 1125-1375 lb-ft 22 lb-ft 2.5 lb-ft
(271 Nm) (1525-1864 Nm) (30 Nm) (3,3 Nm)
f. Outrigger Cylinder
Head Nut Valve Mount

hand tight 1100 lb-ft 30-35 lb-ft
(1491 Nm) (41-47 Nm)

Hydraulic System

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4.1 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4.2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4.3 Power Distribution Unit (VEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.4.4 Optional Power Distribution Unit (VEC). . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.5 Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5.1 CAN Distribution Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5.2 Universal Ground Control Module (UGM) . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
9.5.3 Frame Level, Auxiliary Hydraulic and Outrigger Joysticks Module . . . . . . 9.13
9.6 Electrical System Schematics And Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.6.1 Cab Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.6.2 Options Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.6.3 CAN Distribution Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.6.4 Chassis Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.6.5 Power Unit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.6.6 Boom Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9.6.7 CAN Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.8.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.9.1 Windshield/Rear Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . 9.25
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.10.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.11 Solenoids, Senders and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.11.1 Intelligent Control Valves (INCOVA) Solenoids . . . . . . . . . . . . . . . . . . . . . 9.27
9.11.2 Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.11.3 Sway Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.11.4 Pump Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.11.5 Boom Ride Control Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.11.6 Lift Isolation Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.11.7 Steer Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
9.11.8 Transmission Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31

Electrical System
9.11.9 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31

9.11.10 Engine Coolant Temperature Sender / Switch . . . . . . . . . . . . . . . . . . . . . 9.32
9.11.11 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
9.11.12 Boom Angle Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
9.11.13 Boom Length Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34
9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35
9.12.1 3-N-1 Digital Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
9.13.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
9.13.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
9.14 Engine Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38
9.15 Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.39
9.15.1 Analyzer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.39
9.15.2 Debug Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.40
9.15.3 Personality Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41
9.15.4 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46
9.15.5 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.47
9.15.6 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 9.48
9.15.7 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.49
9.15.8 Diagnostic Trouble Code (DTC) Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.59

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
the operator/mechanic be familiar with the name and
location of the electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.
9.1.1 General Overview
IGNITION & DASH

SWITCHES
OPTIONAL POWER
DISTRIBUTION UNIT
(under dash panel)
UGM & FRAME LEVEL, AUXILIARY

HYDRAULIC AND OUTRIGGER
JOYSTICKS MODULE
MAP0570
POWER DISTRIBUTION UNIT

(in engine compartment)
ALTERNATOR
(backside of engine)
COOLANT TEMPERATURE
SENDER
ECU
50 AMP FUSE
GLOW PLUG
RELAY
STARTER RELAY
STARTER MAP0420
MY1850

Electrical System
9.2 SPECIFICATIONS 9.4 FUSES AND RELAYS

Electrical system specifications are listed in Section 2,
General Information and Specifications.
9.4.1 Engine Compartment
The starter relay (1), glow plug relay (2), 50 amp fuse (3)
9.3 SAFETY INFORMATION and power distribution unit (4) are located on the power
distribution unit bracket in the engine compartment.
WARNING 4

3
2 1
MAP0420
9.4.2 Cab
The optional power distribution unit is located in the cab.
For access, remove the screws securing the load chart
panel (5) to the dash.
MAP0290

Electrical System
9.4.3 Power Distribution Unit (VEC)
F8 F3
IGN1
CB3 F4
CB4 CB2 CB1 F1
F9 F7
IGN3
F10
ACCY1
F11 F2
F12 F5
ACCY2
F6
MY1250
Connector Legend
No. Function Amp Rating
CB1 Options Power 3 20
F1 Trans/Park Brake Power 15
F2 Alternator Excite 5
F3 Engine ECU Ignition Power 10
F4 Gauge (Instrument Panel) Power 10
F5 Spare Accessory Power 1 15
F6 Auxiliary Electric Power 10
F7 Horn Power 15
F8 Battery Power 1 25
F9 Engine ECU Battery Power 25
F10 Steer/Sway Power 10
F11 Spare Accessory Power 2 10
F12 Key Battery Power 15
IGN1 Ignition 1
IGN 2 Ignition 2
ACCY1 Accessory 1
ACCY2 Accessory 2

Electrical System
9.4.4 Optional Power Distribution Unit (VEC)
F1
R1 R5
F2
F3
R2 R6
F4
F5
R3 R7
F6
F7
R4 R8
F8
MY1260
Connector Legend
No. Function Amp Rating
F1 Wiper 20
F2 Option 1 15
F3 Option 2 15
F4 Option 25
F5 Heater/Blower 20
F6 Lights 20
F7 Beacon 10
F8 Dash Fan 10
R1 Wiper
R2 Heater/Blower
R3 Aux Elec 1
R4 Aux Elec 2
R5 Option 15
R6 Option 25
R7 Lights
R8 Beacon/Fan

Electrical System
9.5 CONTROL MODULES b. Disassembly

DO NOT disassemble the CAN Module other than
9.5.1 CAN Distribution Module removing the cover. The module is not serviceable.
Replace the module if found to be defective.
The CAN Distribution Module (1) is located at the rear of
the machine between the boom masts. c. CAN Module Installation
1 2 1. If removed, install the cover on the CAN Module.
2. Attach the CAN Module to the mounting bracket with
the appropriate hardware.
3. Reconnect the electrical harnesses to the CAN
Module.
4. Connect the negative (-) battery cable to the negative
(-) battery terminal.
5. Close and secure engine cover.
MAP0520
a. CAN Module Removal

engine OFF.
cool.
5. Remove the bolts attaching the CAN Module to the
mounting bracket (2) and remove the CAN Module.
6. Disconnect the electrical harnesses attached to the
CAN Module.
7. If needed, remove the four screws on the CAN
Module cover and remove the cover to gain access
to the terminals.

Electrical System
d. CAN Module Connections
MAP0530
CAN Module Harness Connector Legend

No. Description
1 Lift Valve Cable Connector
2 Tele-Valve Cable Connector
3 Boom Angle Sensor Cable Connector
4 Boom Length Cable Connector
5 Chassis Harness Connector
6 Not Used
CAN Module Terminal Connector Legend

No. Amp Rating
V+ 8
V+ 4 (additional as power splice)
V- 8
V- 4 (additional as power splice)
CANS 3.2
CANL 3.2
CANH 3.2
V+P3 3.2
V+P4 3.2
V+P5 3.2
V+P6 3.2
J1 3.2
J2 3.2
J3 3.2
J4 3.2

Electrical System
9.5.2 Universal Ground Control Module b. Disassembly

(UGM) DO NOT disassemble the UGM. The module is not
The UGM is located behind the right hand side panel (3) serviceable. Replace the module if found to be defective.
where the joysticks are located.
c. Inspection and Replacement
Inspect the module terminals for continuity. Replace the
module if continuity is not found.
d. UGM Installation
1. Attach the UGM to the cab with the previously
removed hardware.
3 2. Reconnect the electrical harnesses to the UGM.
3. Install the right hand side panel to the cab with the
previously removed hardware. Refer to Section
4.3.5, Frame Level, Auxiliary Hydraulic and
Outrigger Joysticks.
MAP0580 (-) battery terminal.
a. UGM Removal
engine OFF.
cool.
5. Remove the hardware securing the right hand side
panel to the cab. Refer to Section 4.3.5, Frame
Level, Auxiliary Hydraulic and Outrigger Joysticks.
UGM.
7. Remove the bolts securing the UGM to the cab and
remove the UGM.

Electrical System
e. UGM Connections
J8
J1
J7
J12
J2
J3
J4
MAP0540
a. UGM Inputs
UGM Description Description/Purpose

Connector/Pin
J3-2 Sway Valve Return Current feedback return for Sway Left and Right Solenoids
J3-6 Right Stabilizer Valve Current feedback return for Right Up and Down Solenoids
Return
J3-13 Boom Angle Right Analog Input Signal Range: 0.5 4.5V
Sensor Signal 0.5V = 0
4.5V = 90
J3-14 Left Stabilizer Valve Current feedback return for Left Up and Down Solenoids
Return
J4-6 AccuPlace Mode Fault High Sensing Closed = Vbat = Request to Reset Fault to
Reset Switch Digital Input Continue Motion
J4-10 Sway Joystick Out of High Sensing Closed = Vbat = Out of Neutral
Neutral Digital Input
J4-11 Aux Joystick Out of High Sensing Closed = Vbat = Out of Neutral
Neutral Digital Input
J4-18 Boom Ride Enable Closed = Vbat = Request for Boom Ride Mode
Switch
J4-23 Right Stabilizer Joystick Closed = Vbat = Out of Neutral
Out of Neutral
J4-30 Continuous Auxiliary Closed = Vbat = Request for Boom Ride Mode
Hydraulics Switch

Electrical System

Connector/Pin
J4-35 Left Stabilizer Joystick Closed = Vbat = Out of Neutral
Out of Neutral
J7-4 Aux Joystick Signal Signal Range: 0.5 4.5V (2.5V = neutral)
0.5V = -100% = Aux1
4.5V = +100% = Aux2
J7-7 Sway Joystick Signal Signal Range: 0.5 4.5V (2.5V = neutral)
0.5V = -100% = Sway Left
4.5V = +100% = Sway Right
J7-8 Left Stab Joystick Signal Signal Range: 0.5 4.5V (2.5V = neutral)
0.5V = -100% = Left Down
4.5V = +100% = Left Up
J7-20 Right Stab Joystick Signal Range: 0.5 4.5V (2.5V = neutral)
Signal 0.5V = -100% = Right Down
4.5V = +100% = Right Up
b. UGM Outputs

Connector/Pin
J1-2 Rear Stab Valve Signal 2 Current Capacity = 3A Digital Output; Coil
Driver
J1-11 Circulation Valve Current Capacity = 3A Digital Output; Coil
Driver
J1-13 Rear Stab Valve Signal 1 Current Capacity = 3A Digital Output; Coil
Driver
J2-8 Right Stabilizer Up Valve Current Capacity = 3A Proportional
Output; Coil Driver
J2-9 Left Stabilizer Up Valve Current Capacity = 3A Proportional
Output; Coil Driver
J2-11 Sway Left Valve Current Capacity = 3A Proportional
Output; Coil Driver
J2-19 Right Stabilizer Down Valve Current Capacity = 3A Proportional
Output; Coil Driver
J2-20 Left Stabilizer Down Valve Current Capacity = 3A Proportional
Output; Coil Driver
J2-22 Sway Right Valve Current Capacity = 3A Proportional
Output; Coil Driver
J4-26 Boom Ride Mode Lamp Current Capacity = 350ma Digital Output;
Lamp driver
J4-28 AccuPlace Mode Fault Reset Lamp Current Capacity = 350ma Digital Output;
Lamp driver
J4-29 AccuPlace Mode Lamp Current Capacity = 350ma Digital Output;
Lamp driver

Electrical System
c. UGM Communications/Power/Ground
UGM Description Signal Level Description/Purpose

Connector/Pin
J1-4 Rear Stab Valve Gnd Common ground for the two rear stabilizer
coils; no current feedback
J1-28 Analyzer PWR Analyzer Power
J1-29 Analyzer RS232 Receive Analyzer Communication
J1-30 Analyzer RS232 Transmit Analyzer Communication
J1-31 Analyzer Return Analyzer Ground
J3-3 Boom Angle Right Sensor B- Analyzer Ground
Ground
J3-12 Boom Angle Right Sensor +5V
Power regulated
J4-24 Vbat for Panel Switches B+ (Vbat) UGM provides power for panel switch inputs
J4-25 Mini Joystick Switch Power B+ (Vbat) UGM provides power to Mini Joysticks to
confirm out-of-neutral state
J4-32 Lamp Gnd GND Common lamp return
J7-3 Controller Power Enable B+ ( Power Enable for UGM Logic Circuitry
J7-6 CAN1 Terminator 1 Jumper to J7-17 for 120 ohm termination
J7-13 CAN1 HI
J7-17 CAN1 Terminator 2 Jumper to J7-6 for 120 ohm termination
J7-18 CAN1 Shield
J7-19 Cab Joystick Ground B-
J7-24 CAN1 LO
J7-25 Mini Joystick Ground B-
J7-27 Mini Joystick Power +5V
regulated
J7-34 Cab Joystick Power B+ (Vbat)
J8-1 B- B- Ground for UGM
J8-2 Switched B+ B+ (Vbat) Power to UGM; fused to 25A via F8
J8-4 INCOVA Power B+ (Vbat) Power Enable for UGM Logic Circuitry
J12-3 CAN2 HI Cab Joystick on CAN2
J12-4 CAN2 LO
J12-5 CAN2 Shield
J12-6 CAN2 Terminator 1
J12-7 CAN2 Terminator 2

Electrical System
9.5.3 Frame Level, Auxiliary Hydraulic and b. Disassembly

Outrigger Joysticks Module DO NOT disassemble the module. The module is not
The frame level, auxiliary hydraulic and outrigger serviceable. Replace the module if found to be defective.
joysticks module is located on the inside of the right hand
side panel (4) where the joysticks are located. c. Inspection and Replacement
Inspect the module terminals for continuity. Replace the
module if continuity is not found.
d. Module Installation
1. Attach the module to the right hand side panel with
the previously removed hardware.
2. Reconnect the electrical harnesses to the module.
4
3. Install the right hand side panel to the cab with the
previously removed hardware. Refer to Section
4.3.5, Frame Level, Auxiliary Hydraulic and
Outrigger Joysticks.
MAP0580
a. Module Removal
engine OFF.
cool.
5. Remove the bolts securing the right hand side panel
to the cab. Refer to Section 4.3.5, Frame Level,
Auxiliary Hydraulic and Outrigger Joysticks.
module.
7. Remove the hardware securing the module to the
right hand side panel and remove the module.

Electrical System
e. Frame Level, Auxiliary Hydraulic and Outrigger

Joysticks Module Connections
A (GREY)
B (BLACK) MAP0560
TERMINAL FUNCTION CHART

B (BLACK) CAB HARNESS A (GREY) JOYSTICKS HARNESS
1 SWITCH PWR IN (+V 13-16V) 1 JOYSTICK COMMON OUT (0V)
2 JOYSTICK COMMON IN (0V) 2 JOYSTICK POWER OUT (+5V)
3 JOYSTICK POWER IN (+5V) 3 JOYSTICK IN 1
4 JOYSTICK OUTPUT 1 4 JOYSTICK IN 2
7 JOYSTICK OUTPUT 4 7 OFF CENTER IN (TIED DIRECTIONAL)
SWITCH 1
8 OUT OF NEUTRAL OUT (TIED DIRECTIONAL) 8 OUT OF NEUTRAL IN (TIED DIRECTIONAL)
SWITCH 1 SWITCH 2
SWITCH 2 SWITCH 3
SWITCH 3 SWITCH 4
11 OUT OF NEUTRAL OUT (TIED DIRECTIONAL) 11 SWITCH PWR OUT (+V -0.7V)
SWITCH 4
12 PLUGGED 12 PLUGGED

Electrical System
9.6 ELECTRICAL SYSTEM SCHEMATICS AND DIAGRAMS
9.6.1 Cab Schematic
MAP0340 C

Electrical System
9.6.1Cab Schematic (Continued)
MAP0350 C

Electrical System
9.6.2 Options Schematic
MAP0360 C

Electrical System
9.6.3 CAN Distribution Schematic
MAP0370 C

Electrical System
9.6.4 Chassis Schematic
MAP0380 C

Electrical System
9.6.5 Power Unit Schematic
MAP0390 C

Electrical System
9.6.6 Boom Schematic
MAP0400 C

CAB
9.22
9.6.7
JOYSTICK
LEFT BOOM
DIAGNOSTIC ANGLE SENSOR
CONNECTOR
CAN Diagram
Electrical System
LIFT VALVE
Dash/
CAN2
3-N-1
Gauge TO BOOM
CAN
UGM DISTRIBUTION
CAN1
TELE VALVE
ISP BOOM LENGTH

SENSOR
ENGINE
FORK VALVE
BOOM
TERMINATION
SENSOR
MAP0650

Electrical System
9.7 ENGINE START CIRCUIT 2. If a whirring noise is heard but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
9.7.1 Starter the drive forward to engage the flywheel may be
The starter (1) is located on the left side of the engine. defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
engine.
3. If the starter only clicks it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit, refer
to Section 9.6, Electrical System Schematics And
Diagrams.
c. Starter Removal
1
Remove the starter only if it fails. To remove the starter:
1. Open the engine cover.
MY1850
2. Disconnect the battery negative (-) cable at the
a. Testing the Starter on the Engine
3. Remove the wires from the solenoid stud. Remove
If the starter does not engage when the ignition key the positive (+) battery cable from the starter. Label
switch is turned, check the following: and disconnect the wire from the starter solenoid
1. The main fuse may be blown, requiring replacement. housing stud. Record how the wires are installed to
Check for the cause of the blown fuse. ensure correct installation later.
2. There may be a defect in the ignition key switch, 4. Loosen, but DO NOT remove, the three fasteners
ignition wiring or starter solenoid. securing the starter to the flywheel housing. Support
the starter securely, as it is relatively heavy and will
3. Check battery condition. Clean the battery posts and
fall if not supported.
the connectors at each end of the battery cables.
5. Support the starter and remove the fasteners
4. Check for broken wiring and damaged insulation on
securing the starter to the engine. Remove the
the wiring. Replace all broken or damaged wiring.
negative (-) ground cable from its starter mounting
5. Check all connections at the starter solenoid, key bolt.
switch and wiring harness plugs. Clean and tighten
6. Remove the starter from the machine.
all connections.
6. If the starter still does not operate after these checks d. Starter Installation
have been performed, check the starting circuit.
1. Position the starter in its mounting opening on the
b. Starter Circuit Checks flywheel housing. Position the ground cable over the
correct starter mounting bolt. Secure the starter with
1. Check wires and connections for looseness, the three fasteners.
corrosion, damage, etc.
2. Connect the positive (+) battery cable to the upper
solenoid stud. Install the wires to the upper solenoid
stud, and secure with lock washer and nut.
3. Connect the wire to the solenoid mounting stud.

Electrical System
9.8 CHARGING CIRCUIT b. Alternator Installation
Before using a battery charger, an attempt can be made 2

to recharge the battery by jump-starting the machine
(Refer to the appropriate Operation & Safety Manual).
Allow the engine to run, which will enable the
alternator (2) to charge the battery.
If the engine alternator charging warning indicator
illuminates, perform the following checks:
1. Check all battery cable connections at the battery,
and verify that they are clean and tight.
2. Check the external alternator wiring and
connections, and verify that they are in good
condition.
3. Check the fan belt condition and tension.
4. Run the engine and check the alternator for noise. A
MY0370
loose drive pulley, loose mounting hardware, worn or
dirty internal alternator bearings, a defective stator 1. Position the alternator and align with the upper
or defective diodes can cause noise. Replace a worn alternator mount on the engine bracket. Insert the
or defective alternator. upper (longer) mounting hardware through the
alternator mount. Thread the longer capscrew into
9.8.1 Alternator the alternator front mount. DO NOT tighten
completely at this time.
a. Alternator Removal
2. Align the lower alternator mount hole with the lower
1. Open the engine cover. Allow the system fluids to mounting bracket on the engine, and insert the lower
cool. mounting capscrew. Tighten the lower capscrew and
2. Disconnect the battery negative (-) cable at the upper capscrew securely.
battery negative (-) terminal. 3. Place a drive ratchet into the square hole on the
3. Install a drive ratchet into the square hole in the serpentine belt tensioner bracket. Apply pressure
serpentine belt tensioner bracket. against the tensioner bracket and route the
serpentine belt onto the alternator and engine
4. While lifting the automatic belt tensioner away from
pulleys. Release and check the tensioner pulley to
the belt, remove the fan serpentine belt.
verify that it is pivoting freely in order to provide the
Note: Record how the alternator is installed to ensure proper tension on the belt. Check for proper belt
correct installation later. alignment. (Refer to the appropriate Operation &
Safety Manual.)
5. Label and disconnect the wire leads attached to the
alternator. 4. Connect the previously labeled wire leads to the
alternator.
6. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine. 5. Connect the battery negative (-) cable to the battery
7. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware from 6. Close and secure the engine cover.
the upper alternator mount. Remove the alternator
from the machine.

Electrical System
9.9 WINDOW WIPER/WASHER 9. Remove the motor from the inside of the cab.
WINDSHIELD WIPER MOTOR
b. Disassembly
a. Removal DO NOT disassemble the motor. The motor is not

serviceable. Replace motor if found to be defective.
Note: It may be necessary to remove several hydraulic
hoses from behind the dash in order to remove and c. Inspection and Replacement
install the wiper motor housing. (Refer to Section 4.3.1,
Steering Column and Orbitrol Valve.) Inspect the motor terminals for continuity. Replace motor
if continuity is not found.
machine, fully retract the boom, lower the boom, d. Installation and Testing
(N) NEUTRAL, engage the park brake and shut the 1. Install all required hardware to the motor assembly.
engine OFF. 2. Align motor with the mounting holes and bolt the
2. Place a Do Not Operate Tag on both the ignition key motor to the mounting bracket.
switch and the steering wheel, stating that the 3. Connect the wiper linkage to the wiper motor shaft.
Note: Align the wiper linkage arm with the flat on the
3. Open the engine cover. Allow the system fluids to motor shaft to ensure wiper stroke covers window area,
cool. and it does not swipe passed the glass area.
4. Disconnect the battery negative (-) cable from the 4. Connect the cab harness connectors to windshield
battery negative (-) terminal. wiper motor connectors.
5. Remove the screws that secure the main dash 5. Replace the main dash panel to its original
panel. Pull out the dash panel to gain access to the orientation. Secure with the previously used screws.
wiper motor (3).
6. Disconnect the cab harness connectors from the negative (-) terminal.
wiper motor.
7. 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.
8. If previously removed, install hydraulic hoses under
the dash. (Refer to Section 4.3.1, Steering Column
and Orbitrol Valve.)
9.9.1 Windshield/Rear Window Washer

Reservoir
The windshield washer motor and reservoir (4) is located
in the cab behind the seat. It is labeled as a unit and
cannot be serviced separately.
3
a. Removal
MY0440 1. Park the machine on a firm, level surface, level the
7. Remove the linkage attached to the wiper motor. place the transmission control lever in
8. Loosen and remove the four bolts holding the wiper (N) NEUTRAL, engage the park brake and shut the
motor to the mounting bracket. engine OFF.
Note: Retain all hardware removed from the wiper 2. Place a Do Not Operate Tag on both the ignition key
assembly for possible reuse on the replacement motor switch and the steering wheel, stating that the
housing. machine should not be operated.

Electrical System
3. Open the engine cover. Allow the system fluids to 9.10 CAB HEATER AND FAN
cool.
4. Disconnect the battery negative (-) cable from the 9.10.1 Cab Heater Controls
Note: If the suspect component is found to be within the
5. Remove the nuts and the lock washers from the heater box, the heater box must be removed as a
washer mounting bolts. complete unit and replaced.
6. Pull the washer reservoir out and away from the
mounting bracket. a. Cab Heater Controls Removal
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. 5
b. Disassembly
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective.
MAP0590

4 machine, fully retract the boom, lower the boom,
engine OFF.
MY1220
cool.
c. Installation and Testing
1. Connect the windshield washer hoses to the 5. Remove the screws securing the left cab dash panel
reservoir. (5).
2. Connect the cab wiring harness connectors to the 6. Pull out the panel to gain access to the heater
reservoir connectors. control electrical connections. Disconnect the
3. Install the reservoir tank onto the mounting bracket. harnesses.
4. Install the lock washers and nuts and secure. 7. Remove the heater control knobs.
5. Fill the washer fluid reservoir with washer fluid. 8. Remove the necessary hardware securing the
6. Connect the battery negative (-) cable to the battery heater control from the dash panel. Remove the
negative (-) terminal. control from the panel.
7. Turn the ignition key switch to the RUN position and b. Disassembly
press the washer switch. Verify that fluid is sprayed
on both the windshield and rear glass. DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.

Electrical System
c. Installation and Testing 4. Disconnect the battery negative (-) cable from the
1. Check that the variable speed fan control is in the
OFF position. 5. Disconnect the wiring connector at the park brake
solenoid lead.
2. Install the heater controls to the dash panel with the
previously used hardware. 6. Remove the nut on the end of the park brake coil (1).
3. Connect the cab electrical harness connector to the 7. Remove the park brake coil.
controls. 8. Remove the park brake solenoid (2). (Remove only if
4. Install the control knobs. the electrical coil is found to not be faulty.)
5. Install the screws securing the dash panel to the
cab.
6. Connect the battery negative (-) cable to the battery 1
2
7. Turn the ignition key to the ON position and check
the fan speeds. If further repair is needed, refer to
Section 9.6, Electrical System Schematics And
Diagrams.
8. Start the machine and allow engine to warm to
operating temperature. Check heat control at
different levels.
9.11 SOLENOIDS, SENDERS AND MAP04101
SENSORS
b. Disassembly
9.11.1 Intelligent Control Valves (INCOVA) DO NOT disassemble the solenoid. The solenoid is not
Solenoids serviceable. Replace solenoid if found to be defective.
Note: INCOVA valves include the lift valve, telescope
valve and fork tilt valve. c. Park Brake Solenoid Valve Installation
DO NOT remove the solenoids on the INCOVA valves. Note: ALWAYS replace seals, o-rings, gaskets, etc.,
Replace the valve assemblies if found to be defective. with new parts to help ensure proper sealing and
Refer to Section 8.8, Control Valves, for valve removal operation. Lubricate seals and o-rings with clean
procedures. hydraulic oil.
1. If necessary, install the park brake solenoid in its
9.11.2 Park Brake Solenoid Valve original orientation.
a. Park Brake Solenoid Valve Removal 2. Slide the park brake coil over the solenoid. Tighten
the nut to secure the solenoid. DO NOT overtighten.
3. Connect the wiring connector to the park brake coil
lead.
(N) NEUTRAL, engage the park brake and shut the 4. Connect the battery negative (-) cable at the battery
engine OFF. negative (-) terminal.
2. Place a Do Not Operate Tag on both the ignition key 5. Close and secure the engine cover.
machine should not be operated. 9.11.3 Sway Solenoid Valve
a. Sway Solenoid Valve Removal
cool.
Electrical System
place the transmission control lever in 4. Connect the battery negative (-) cable at the battery
(N) NEUTRAL, engage the park brake and shut the negative (-) terminal.
engine OFF. 5. Close and secure the engine cover.
switch and the steering wheel, stating that the 9.11.4 Pump Solenoid Valve
3. Open the engine cover. Allow the system fluids to a. Pump Solenoid Valve Removal
cool. 1. Park the machine on a firm, level surface, level the
4. Disconnect the battery negative (-) cable from the machine, fully retract the boom, lower the boom,
battery negative (-) terminal. place the transmission control lever in
5. Disconnect the two wiring connectors at the sway
engine OFF.
solenoid leads.
6. Remove the nut on the end of the sway coil (3).
7. Remove the sway coil. machine should not be operated.
8. Remove the sway solenoid (4). (Remove only if the 3. Open the engine cover. Allow the system fluids to
electrical coil is found to not be faulty; cold cool.
resistance approximately 6 ohm.)
3 battery negative (-) terminal.
4 5. Disconnect the wiring connector at the pump
solenoid lead.
6. Remove the nut on the end of the pump coil (5).
7. Remove the pump coil.
8. Remove the pump solenoid (6). (Remove only if the
electrical coil is found to not be faulty; cold
resistance approximately 3.7 ohm.)
5
MAP04101
b. Disassembly
DO NOT disassemble the solenoid. The solenoid is not
serviceable. Replace solenoid if found to be defective.
c. Sway Solenoid Valve Installation

MAP04101
hydraulic oil.
b. Disassembly
1. If necessary, install the sway solenoid in its original
orientation. DO NOT disassemble the solenoid. The solenoid is not
2. Slide the sway coil over the solenoid. Tighten the nut
to secure the solenoid. DO NOT overtighten.
3. Connect the two wiring connectors to the sway coil
leads.

Electrical System
c. Pump Solenoid Valve Installation 8. Remove the boom ride control solenoid (8).
(Remove only if the electrical coil is found to not be
faulty.)
hydraulic oil.
1. If necessary, install the pump solenoid in its original
orientation.
2. Slide the pump coil over the solenoid. Tighten the
nut to secure the solenoid. DO NOT overtighten. 7
3. Connect the wiring connector to the pump coil lead.

4. Connect the battery negative (-) cable at the battery
9.11.5 Boom Ride Control Solenoid Valve

8
a. Boom Ride Control Solenoid Valve Removal MAP0450

b. Disassembly
place the transmission control lever in DO NOT disassemble the solenoid. The solenoid is not
(N) NEUTRAL, engage the park brake and shut the serviceable. Replace solenoid if found to be defective.
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key c. Boom Ride Control Solenoid Valve Installation
switch and the steering wheel, stating that the Note: ALWAYS replace seals, o-rings, gaskets, etc.,
machine should not be operated. with new parts to help ensure proper sealing and
3. Open the engine cover. Allow the system fluids to operation. Lubricate seals and o-rings with clean
cool. hydraulic oil.
4. Disconnect the battery negative (-) cable from the 1. If necessary, install the boom ride control solenoid in
battery negative (-) terminal. its original orientation.
5. Disconnect the wiring connector at the boom ride 2. Slide the boom ride control coil over the solenoid.
control solenoid lead. Tighten the nut to secure the solenoid. DO NOT
6. Remove the nut on the end of the boom ride control overtighten.
coil (7). 3. Connect the wiring connector to the boom ride
7. Remove the boom ride control coil. control coil lead.
4. Connect the battery negative (-) cable at the battery
9.11.6 Lift Isolation Solenoid Valves
a. Lift Isolation Solenoid Valve Removal

engine OFF.

Electrical System
2. Place a Do Not Operate Tag on both the ignition key 5. Close and secure the engine cover.
machine should not be operated. 9.11.7 Steer Solenoid Valves
cool. a. Steer Solenoid Valve Removal
4. Disconnect the battery negative (-) cable from the 1. Park the machine on a firm, level surface, level the
battery negative (-) terminal. machine, fully retract the boom, lower the boom,
5. Disconnect the wiring connector at the lift isolation
solenoid lead.
engine OFF.
6. Remove the nut on the end of the lift isolation coil
(9).
7. Remove the lift isolation coil. machine should not be operated.
8. Remove the lift isolation solenoid (10). (Remove only 3. Open the engine cover. Allow the system fluids to
if the electrical coil is found to not be faulty.) cool.
10
5. Disconnect the wiring connector at the two steer
solenoid leads.
6. Remove the nut on the end of the steer coil (11).
10 7. Remove the lift isolation coil.
9 8. Remove the steer solenoid (12). (Remove only if the
electrical coil is found to not be faulty.)
9 11
MAP0450
12
b. Disassembly
DO NOT disassemble the solenoid. The solenoid is not
c. Lift Isolation Solenoid Valve Installation

Note: ALWAYS replace seals, o-rings, gaskets, etc., 11
12
MAP0460
hydraulic oil.
b. Disassembly
1. If necessary, install the lift isolation solenoid in its
original orientation. DO NOT disassemble the solenoid. The solenoid is not
2. Slide the lift isolation coil over the solenoid. Tighten
the nut to secure the solenoid. DO NOT overtighten.
c. Steer Solenoid Valve Installation
3. Connect the wiring connector to the lift isolation coil
lead. Note: ALWAYS replace seals, o-rings, gaskets, etc.,
4. Connect the battery negative (-) cable at the battery operation. Lubricate seals and o-rings with clean
negative (-) terminal. hydraulic oil.

Electrical System
1. If necessary, install the lift isolation solenoid in its 9.11.9 Transmission Temperature Sender
original orientation.
2. Slide the steer coil over the solenoid. Tighten the nut a. Transmission Temperature Sender Removal
to secure the solenoid. DO NOT overtighten. The transmission temperature sender (14) is located at
3. Connect the two wiring connectors to the steer coil the bottom left side of the transmission housing.
leads. 1. Park the machine on a firm, level surface, level the
4. Connect the battery negative (-) cable at the battery machine, fully retract the boom, lower the boom,
negative (-) terminal. place the transmission control lever in
engine OFF.
9.11.8 Transmission Solenoid Valves 2. Place a Do Not Operate Tag on both the ignition key
13 cool.
5. Unplug the transmission temperature sender
14
connector from the wiring harness connector.
6. The sender is threaded into the transmission
housing. Remove the sender.
b. Transmission Temperature Sender Inspection and

Replacement
MY0980
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
Note: If the transmission is not shifting properly, the sender with a new part.
transmission shift control switch (travel select lever),
wiring harness or transmission shift solenoids (13) c. Transmission Temperature Sender Installation and
should be checked in order to determine which Testing
component is defective. Specific information to
determine which travel position and corresponding 1. Thread the transmission temperature sender into the
component is not responding can be found in the transmission housing snugly, then connect the sender
detailed transmission service instructions (covering connector to the wiring harness connector.
repair, disassembly, reassembly and adjustment 2. Connect the battery negative (-) cable to the battery
information) are provided in the ZF Powershift negative (-) terminal.
Transmission 4WG-92/98 TSC Repair Manual, (JLG P/N
3. Check for proper fluid level.
31200241) and can be obtained by calling your local JLG
Service distributor or ZF Service Center. 4. Start the engine, allow it to reach operating
temperature and observe the operators display
The transmission should be checked, serviced and cluster for warning indication. If the sender is not
repaired only by experienced service technicians who are defective, the problem could be elsewhere; possibly
aware of all safety instructions and particular component in a shorted wire, damaged transmission, improper
features. or low fluid, etc.
Note: Contact the JLG Service Department if internal 5. Close and secure the engine cover.
transmission repair is required during the warranty
period.

Electrical System
9.11.10 Engine Coolant Temperature 4. Start the engine, allow it to reach operating
Sender / Switch temperature and observe the operators instrument
cluster for warning indication. If the sender is not
a. Engine Coolant Temperature Sender Removal defective, the problem could be elsewhere; possibly
1 in a shorted wire, improper-running engine, improper
or low coolant, obstructed or faulty radiator, coolant
pump, loose fan belt, defective instrument display,
etc.
9.11.11 Fuel Level Sender
a. Fuel Level Indicator Testing

1. The fuel level sender wiring harness leads can be
accessed from the top of the fuel tank. Disconnect
the fuel level sender wiring harness leads. With the
MY2830
help of an assistant, touch both harness leads
1. Park the machine on a firm, level surface, level the together.
machine, fully retract the boom, lower the boom, 2. From the operators cab, have the assistant turn the
place the transmission control lever in ignition key switch to the RUN position. DO NOT
(N) NEUTRAL, engage the park brake and shut the start the engine. Observe the fuel level indicator
engine OFF. needle on the operators instrument cluster. The
2. Place a Do Not Operate Tag on both the ignition key reading must be at the FULL mark.
switch and the steering wheel, stating that the 3. Turn the ignition key switch to the OFF position. The
machine should not be operated. fuel level indicator needle should return to the
3. Open the engine cover. Allow the system fluids to EMPTY position.
cool.
battery negative (-) terminal. Unplug the engine
coolant temperature sender /switch connector from
the wiring harness connector.
5. Unplug the engine coolant temperature sender
connector from the wiring harness connector.
6. The engine coolant temperature sender (1) is 2
threaded into the engine block. Remove the sender.
b. Engine Coolant Temperature Sender / Switch

Inspection and Replacement
Inspect the sender/switch and the wiring harness
connector terminals for continuity. Replace a defective or
faulty sender with a new part.
c. Engine Coolant Temperature Sender Installation

and Testing MAP0440
1. Thread the engine coolant temperature sender into

the engine block snugly, then connect the sender b. Fuel Level Circuit Tests
connector to the wiring harness connector.
If the fuel level sender (2) is suspected of giving a false
2. Connect the battery negative (-) cable to the battery reading, perform the following checks:
3. Check for proper coolant level.
Electrical System
1. If the fuel level indicator needle does not move, 4. Disconnect the negative (-) battery cable at the
check the fuel tank for fuel. negative (-) battery terminal.
2. Check for loose or defective wiring, faulty ground
connections, and corrosion on the fuel tank sender
and wiring lead.
3. If the fuel level indicator needle does not move after
the ignition key switch is turned to the RUN position,
use a test lamp to determine whether current is
flowing from the ignition switch to the fuel level 2
sender.
4. If the fuel level indicator does not move and a faulty 1
or defective fuel level sender in the fuel tank has
been ruled out, and in addition, wiring and
connectors have been checked and ruled out, the
fuel level indicator is defective and must be replaced.
5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown.
MAP0470
6. Check for broken, shorted, frayed, disconnected or 5. Remove the screw attaching the crank arm (2) to the
damaged wiring between the fuel level indicator sensor shaft and remove the crank arm.
wiring at the cab, fuse and relay panel, ignition key 6. Remove the sensor cover by removing the bolts.
switch, and from the fuel level sender on the fuel
7. Unplug the wiring harness from the boom angle
tank through the wiring in the cab.
sensor (1).
7. Check the fuel level sender. A defective fuel level
8. Remove the bolts holding the sensor to the mounting
sender in the fuel tank may also prevent the fuel
bracket.
level indicator from moving. Refer to Section 9.6,
Electrical System Schematics And Diagrams, for 9. Remove the boom angle sensor.
further information.
b. Disassembly
9.11.12 Boom Angle Sensors 1. Inspect the sensor and the wiring harness connector
The sensors located on both sides at the rear of the boom terminals for continuity. Replace a defective or faulty
are used to measure the boom angle. The sensor on the sensor with a new sensor.
left side of the boom is CAN-based and is the primary
sensor. The sensor on the right side of the boom is a c. Installation
backup or check of the primary sensor. 1. Install the bolts holding the sensor to the mounting
Left Side: bracket.
2. Align the holes on the crank arm and sensor shaft
a. Left Side Boom Angle Sensor Removal
and install the screw to secure crank arm in place.
1. Park the machine on a firm, level surface, level the Apply Loctite 222 and torque to 16 lb-in (18.4 cm
machine, fully retract the boom, lower the boom, kg).
3. Connect the boom angle sensor to the wiring
harness.
engine OFF.
machine should not be operated. 5. Close and secure engine cover.
3. Open engine cover. Allow system fluids to cool. The sensor must be calibrated after installation. Refer to
Section 9.15.5, Calibrations.

Electrical System
Right Side: 2. Align the holes on the crank arm and sensor shaft
and install the screw to secure crank arm in place.
a. Right Side Boom Angle Sensor Removal
3. Connect the boom angle sensor to the wiring
1. Park the machine on a firm, level surface, level the harness.
place the transmission control lever in 4. Connect the negative (-) battery cable to the negative
(N) NEUTRAL, engage the park brake and shut the (-) battery terminal.
engine OFF. 5. Close and secure engine cover.
2. Place a Do Not Operate Tag on both the ignition key The sensor must be calibrated after installation. Refer to
switch and the steering wheel, stating that the Section 9.15.5, Calibrations.
3. Open engine cover. Allow system fluids to cool. 9.11.13 Boom Length Sensor
4. Disconnect the negative (-) battery cable at the The boom length sensor is a CAN-based cable reel that
negative (-) battery terminal. measures the combined distance in which the extend/
retract cylinder and boom section three have moved.
The sensor is mounted at the rear of the boom.
a. Boom Length Sensor Removal
4 1. Park the machine on a firm, level surface, level the
engine OFF.
3. Open engine cover. Allow system fluids to cool.
3
4. Disconnect the negative (-) battery cable at the
MAP0480 negative (-) battery terminal.
5. Unplug the wiring harness from the boom angle
sensor (3).
6. Remove the screw attaching the crank arm (4) to the
sensor shaft.
7. Remove the bolts holding the sensor to the sensor 5
cover.
8. Remove the boom angle sensor.
9. If necessary, remove the sensor cover from the
mounting bracket by removing the bolts.
b. Disassembly
1. Inspect the sensor and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sensor with a new sensor.
MAP0490
c. Installation 5. Unplug the wiring harness from the boom length

sensor (5).
1. Install the bolts holding the sensor to the sensor
cover. 6. Unhook the cable latch from the boom.

Electrical System
7. Remove the bolts holding the sensor to the sensor fault symbol (12) and the numeric DTC value above the
mount. symbol.
8. Remove the boom length sensor. Note: For detailed machine DTC listings, refer to
9. If necessary, remove the sensor cover from the Section 9.15.8, Diagnostic Trouble Code (DTC) Table.
mounting bracket by removing the bolts. Note: For engine fault codes, contact a local Perkins
Engine Distributor.
b. Disassembly
1. Inspect the sensor and the wiring harness connector
terminals for continuity. Replace a defective or faulty XXXXXX.X 10
sensor with a new sensor.
XX.X V
9
c. Installation RPM XXXX XXX.XX
1. Install the bolts holding the sensor to the sensor
mount.
2. Connect the cable latch to the appropriate point on XXXXXX.X XXXX
the third boom section. 11
XX.X V
3. Connect the boom length sensor to the wiring
harness. RPM XXXX 12
MAP0640
5. Close and secure engine cover. a. Gauge Removal
The sensor must be calibrated after installation. Refer to 1. Park the machine on a firm, level surface, level the
Section 9.15.5, Calibrations. machine, fully retract the boom, lower the boom,
9.12 DISPLAY MONITOR AND GAUGES (N) NEUTRAL, engage the park brake and shut the
engine OFF.
9.12.1 3-N-1 Digital Gauge 2. Place a Do Not Operate Tag on both the ignition key
7
cool.
5. Remove the screws (7) securing the dash panel.
6. Label and disconnect the wires from the gauge,
remove the gauge bracket.
7. Pull the gauge out from the dash.
8 b. Disassembly
MAP0300
DO NOT disassemble the gauge. The gauge is not

The 3-N-1 gauge (8) is located on the center dash panel. serviceable. Replace the gauge if found to be defective.
The digital display in the center of the gauge displays the
operating hours, voltmeter and engine speed on the left c. Gauge Installation and Testing
hand side and engine fault codes or machine diagnostic
trouble codes (DTCs) on the right hand side. Engine fault 1. Install the gauge in the dash. Install the gauge
codes (9) will be displayed with the engine fault symbol bracket.
(10) and the numeric fault code value below the symbol. 2. Connect the previously labeled wires to the gauge.
Machine DTCs (11) will be displayed with the machine

Electrical System
3. Install the dash panel with the previously used

hardware. BA C
13 T AC
ACC
BAT
5. Turn the ignition to the ON position to check the
gauge values. ST
9.13 DASH SWITCHES IG

N N
IG
MY0830
Note: For information on the front windshield wiper, rear
window wiper and washer systems, refer to Section 9.9,
Window Wiper/Washer Windshield Wiper Motor. d. Ignition Switch Installation
1. Connect the ignition key switch to the previously
9.13.1 Ignition Key Switch labeled wires.
a. Ignition Switch Removal 2. Align the ignition switch in the dash so that when it is
in the OFF position, the key slot is positioned vertically
1. Park the machine on a firm, level surface, level the (straight up and down). Install the hex nut securing
machine, fully retract the boom, lower the boom, the ignition switch to the dash. DO NOT overtighten.
3. Install the dash panel with the previously used
hardware.
engine OFF.
machine should not be operated. 5. Close and secure the engine cover.
3. Open the engine cover. Allow the system fluids to Note: If further information is needed, refer to Section
cool. 9.6, Electrical System Schematics And Diagrams.
battery negative (-) terminal. 9.13.2 Dash Switches
5. Remove the screws securing the dash panel. a. Switch Removal
6. Remove the hex nut securing the ignition key switch
to the dash.
7. Label and disconnect the ignition switch wires and place the transmission control lever in
remove the switch from the machine. (N) NEUTRAL, engage the park brake and shut the
engine OFF.
b. Disassembly
DO NOT disassemble the ignition switch. Replace a switch and the steering wheel, stating that the
defective switch with a new part. machine should not be operated.
c. Inspection and Replacement cool.
To determine the proper operation of the ignition key 4. Disconnect the battery negative (-) cable from the
switch, test the terminals on the back of the switch for battery negative (-) terminal.
continuity with an ohmmeter.
5. There are three frames with three switches in each
Test the ignition key switch for continuity, by checking frame.
from the BAT terminal (13) to each of the remaining
6. Pull the frame out of the dash, disconnect the
terminals in their corresponding switch position.
harness connector to the switch in question and
If all terminals do not show proper continuity, replace the push the switch out of the frame.
ignition switch.

Electrical System
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 and shorting in
both the engaged and disengaged positions. Replace a
defective or faulty switch with a new switch.
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.
4. Start the machine and check the replaced switch for
proper function.

Electrical System
9.14 ENGINE INDICATOR LAMPS
Warning Shutdown Lamp State Lamp Indication Engine State

Lamp Lamp
ON ON Bulb Check When the ignition is turned on, the Key on, but engine has
EMS shall illuminate each bulb for yet to be cranked
2 seconds and extinguish them
afterwards
OFF OFF No Faults Present With both lamps off whilst engine is Engine is running with no
running then are no currently active detected faults
warnings, diagnostics or events
ON OFF Active Diagnostic Should the warning lamp illuminate Engine is running
during engine running, this normally, but has one or
indicates that an Active diagnostic more faults with engine
(Electrical fault) is present management system
ON FLASH Derate (Invoked by Should the warning lamp illuminate Engine is running, but has
Active Diagnostic) and the shutdown lamp flash one or more Active
during engine running, this diagnostic events that
indicates that an Active diagnostic have initiated engine
(Electrical fault) is present. The derate
diagnostic is sufficiently serious to
invoke engine derate
FLASH OFF Warning (Warning Should the warning lamp flash Engine is running
only) during engine running, this normally, but has one or
indicates that one or more of the more monitored engine
engine protection strategy warning parameters outside of the
values have been exceeded, but acceptable range
not to a level that will invoke Derate
or Shutdown
FLASH FLASH Derate (Warning and Should both the Warning Lamp Engine is running, but
Derate) and Shutdown Lamp flash during one or more of the
engine running, this indicates that monitored engine
one, or more of the engine parameters has gone
protection strategy values have beyond that of warning
been exceeded beyond the level only and has now
required to invoke engine derate exceeded those set for
engine derate
ON ON Engine Shutdown Should both the Warning Lamp Engine is either shutdown
and Shutdown Lamp illuminate or shutdown is imminent,
during engine running this one of more monitored
indicates that either: engine parameters have
1. One or more of the engine gone beyond that of
protection strategy shutdown warning or derate and
values has been exceeded have now exceeded
those set for engine
2. A serious Active diagnostic shutdown, or a serious
has been detected Active diagnostic has
Shortly after (time duration to be agreed) been detected
engine will shutdown

Electrical System
9.15 HAND HELD ANALYZER last 25 Help (fault) messages. This menu can be
viewed at access Levels 2 and 3.
The hand held analyzer can be used in place of the cab
Note: The Help Messages are prioritized according to
analog gauge.
DTC/Service Code (9-9 is highest, No Flash Code is
lowest). For detailed DTC listings, refer to Section
9.15.8, Diagnostic Trouble Code (DTC) Table.
Note: Machine and engine DTCs (numeric values only)
1 are also displayed on the 3-N-1 gauge. Refer to Section
9.12.1, 3-N-1 Digital Gauge.
2. DIAGNOSTICS
This menu provides real-time status information
about the control system as a diagnostic aid. This
2 menu can be viewed at access Levels 2 and 3.
3. SYSTEM TEST
4 This menu is used to activate and then interact with
3 the control systems self-test functionality. Invoking
the System Test will cause the functionality of each
5 6 device to be exercised. Outputs are energized to
detect short or open circuit conditions and digital
inputs are stimulated to simulate switching
conditions. This menu can be viewed at access
Levels 2 and 3.
MAP0510
4. ACCESS LEVEL
This menu allows the user to navigate between
1. Cable Connector.
access levels. To enter Level 2, the five-digit code
2. Analyzer Display Screen. 33271 must be entered. Powering down returns the
3. Escape Key: To return home or access previous Analyzer to Level 3 security. This menu can be
menu. viewed at access Levels 2 and 3.
4. Enter Key: Stores and selects Top Level, Sub Level 5. PERSONALITIES
and Items Menus. This menu contains performance settings that are
specific to machine models. These settings are
5. Up/Down Arrow Keys: Change adjustable values.
necessary to maintain critical specifications such as
6. Left & Right Arrow Keys: Used to move between Top solenoid breakpoints and joystick engagement
Level, Sub Levels and Item Menus. percentages. This menu can be viewed at access
Levels 2 and 3. Some items are hidden to avoid
9.15.1 Analyzer Description confusion based on Machine Setup menu entries.
The JLG Analyzer is a service tool used to diagnose These settings may be edited in access Level 2.
electrical/electronic problems and serves as the 6. MACHINE SETUP
configuration, diagnostic, and visual interface between This menu contains vehicle configuration data for the
the machine and user. control system. The choices contained can alter
There are 7 menu levels within the Analyzer structure: interlock functionality and trigger some Personality
and Machine Setup entries to be visible or hidden.
1. HELP:PRESS ENTER This menu can be viewed at access Levels 2 and 3.
This is the default menu, that menu which appears These settings may be edited in access Level 2.
upon power up of the Analyzer each time. This menu
displays the current Help (fault) message. This 7. CALIBRATIONS
message is intended to quickly guide a user in the This menu allows the user to interact with critical
event of a fault in the control system. This menu is sensors on the vehicle. This menu can be viewed
also intended to display functional interlocks. and edited at access Level 2.
Pressing ENTER views Logged Help records of the The Analyzer cable plugs into the port located on the
underside of the dash.

Electrical System
9.15.2 Debug Functionality

The JLG Analyzer can be used to override the cab
joystick commands and hydraulic pump commands. This
feature can be accessed under DIAGNOSTICS/DEBUG
menu.
a. Cab Joystick Simulation

In the event of joystick failure, the analyzer can be used
to initiate signals that replicate joystick commands. Only
one functional direction is enabled at a time and when the
analyzer is being used, all commands from the cab
joystick are disregarded.
The Analyzer allows the following functions to be
simulated: Lift Up, Lift Down, Tele In, Tele Out, Fork Tilt
Up, or Fork Tilt Down. After selecting the function, use the
UP and DOWN arrow keys to provide the COMMAND
VALUE. The command range corresponds to that of the
joystick: 0-100%.
Note: Simulation of the joystick S1 button is not required
and Coordinated mode is prohibited.
b. Hydraulic Pump Override

The analyzer can be used to provide increased pump
flow for troubleshooting purposes. Use the UP arrow key
to increase pump flow. Use the DOWN arrow key to
decrease pump flow.
Note: A time limit of 5 minutes is imposed on this
feature. Unattended full volume pump flow can degrade
the oil and components. Therefore, after five minutes,
boom motion is disabled and the pump command is set
to 0% until power is cycled.
Machine power must be recycled for boom and pump
controls to be re-enabled.

Electrical System
9.15.3 Personality Settings

The following parameters are given to define how each
function shall perform when accessed. All parameters
can be viewed from Access Level 3, but can only be
modified in Access Level 2. Access Level 2 Code: 33271.
Function Personality Default Setting Adjustment Range
FRAME SWAY Acceleration 0.1 second 0.1-1.0 second

ACCEL
Deceleration 0.1 second 0.1-0.5 second

DECEL
Min Left Sway Duty Cycle 550ma 400-1000ma

MIN LEFT
Max Left Sway Duty Cycle 1700ma 1000-2000ma

MAX LEFT
Min Right Sway Duty Cycle 550ma 400-1000ma

MIN RIGHT
Max Right Sway Duty Cycle 1700ma 1000-2000ma

MAX RIGHT
Reduced sway function speed 1000ma 600-1400ma

CREEP RT
Reduced sway function speed 1000ma 600-1400ma

CREEP LT
STABILIZER Left acceleration up 0.1 second 0.1-1.0 second
Left deceleration up 0.1 second 0.1-0.5 second
Right acceleration dn 0.1 second 0.1-1.0 second
Right deceleration dn 0.1 second 0.1-0.5 second
Min Left Stabilizer Up Duty Cycle 600ma 400-1000ma

LT STABILIZER UP MIN
Max Left Stabilizer Up Duty Cycle 1300ma 1000-2000ma

LT STABILIZER UP MAX
Min Left Stabilizer Down Duty Cycle 600ma 400-1000ma

LT STABILIZER DN MIN
Max Left Stabilizer Down Duty Cycle 1300ma 1000-2000ma

LT STABILIZER DN MAX
Min Right Stabilizer Up Duty Cycle 600ma 400-1000ma

RT STABILIZER UP MIN

Electrical System
Max Right Stabilizer Up Duty Cycle 1300ma 1000-2000ma

RT STABILIZER UP MAX
Min Right Stabilizer Down Duty Cycle 600ma 400-1000ma
RT STABILIZER DN MIN
Max Right Stabilizer Down Duty Cycle 1300ma 1000-2000ma

RT STABILIZER DN MAX
Reduced left stabilizer function speed 800ma 600-1400ma
LT STABILIZER CREEP
Reduced right stabilizer function speed 800ma 600-1400ma

RT STABILIZER CREEP
SWAY JOYSTICK Low Center Deadband Voltage (5V supply) 2.3V 1.90-2.50V
DEADBAND LOW
High Center Deadband Voltage (5V supply) 2.7V 2.20-3.00V

DEADBAND HIGH
Low End Voltage 0.5V 0.30-0.70V

(min command; 5V supply)
MIN VOLTAGE
High End Voltage 4.4V 4.00-4.60V

(max command; 5V supply)
MAX VOLTAGE
Low End Fault Voltage (5V supply) 0.25V 0.10-0.40V

FAULT LOW
High End Fault Voltage (5V supply) 4.75V 4.40-4.90V

FAULT HIGH
AUX JOYSTICK Low Center Deadband Voltage (5V supply) 2.3V 1.90-2.50V
DEADBAND LOW

DEADBAND HIGH
Low End Voltage (min command; 5V supply) 0.5V 0.30-0.70V

MIN VOLTAGE
High End Voltage (max command; 5V 4.4V 4.00-4.60V

supply)
MAX VOLTAGE

FAULT LOW

Electrical System

FAULT HIGH
LEFT STABILIZER Low Center Deadband Voltage (5V supply) 2.3V 1.90-2.50V
JOYSTICK DEADBAND LOW

DEADBAND HIGH
MIN VOLTAGE

MAX VOLTAGE

FAULT LOW

FAULT HIGH
RIGHT STABILIZER Low Center Deadband Voltage (5V supply) 2.3V 1.90-2.50V
JOYSTICK DEADBAND LOW

DEADBAND HIGH

MIN VOLTAGE

MAX VOLTAGE

FAULT LOW

FAULT HIGH
BOOM Acceleration up 0.1000 kph 0.001-0.2 kph

LIFT UP ACCEL
Deceleration up 0.0500 kph 0.006-0.2 kph

LIFT UP DECEL
Acceleration down 0.0200 kph 0.001-0.2 kph

LIFT DN ACCEL

Electrical System
Deceleration down 0.0500 kph 0.006-0.2 kph

LIFT DN DECEL
Acceleration in 0.0200 kph 0.01-1.0 kph
TELE IN ACCEL
Deceleration in 0.0500 kph 0.02-1.0 kph

TELE IN DECEL
Acceleration out 0.0200 kph 0.01-1.0 kph
TELE OUT ACCEL
Deceleration out 0.0500 kph 0.02-1.0 kph

TELE OUT DECEL
Acceleration up 1.000 kph 0.01-1.0 kph

FORK UP ACCEL
Deceleration up 0.100 kph 0.02-1.0 kph

FORK UP DECEL
Acceleration down 1.000 kph 0.01-1.0 kph

FORK DN ACCEL
Deceleration down 0.100 kph 0.02-1.0 kph

FORK DN DECEL
Low Standard Speed 0.400 0.2-0.5

LOW SPEED MLTPR
Medium Speed 0.800 0.5-0.9

MED SPEED MLTPR
End of Stroke Slowdown Speed Multiplier (to 0.400 0.2-0.9

be used for all function soft stops)
SOFT ZONE MLTPR
Lift Up End of Stroke Slowdown Threshold 65.0 DEG 55.0-75.0 DEG

LIFT UP SOFT ZN
Lift Down End of Stroke Slowdown -2.0 DEG -8.0 - (+2.0) DEG
Threshold
LIFT DN SOFT ZN
Tele Out End of Stroke Slowdown Threshold 11.48 FT 10.16-12.13 FT

TELE CYL OUT SFT ZONE (3500mm) (3097-3697mm)
Tele In End of Stroke Slowdown Threshold 0.49FT 0-1.96FT

TELE CYL IN SFT ZONE (150mm) (0-597mm)

Electrical System
Fork Up End of Stroke Threshold 23.0 DEG 0.0 -50.0 DEG

FORK UP SOFT ZN
Fork Down End of Stroke Threshold -115.0 DEG -125.0 - (-90.0) DEG
FORK DN SOFT ZN
Fork Tilt Flow Priority False True/False

FORK FLOW PRIOR
Auxiliary Hydraulics Flow Priority False True/False
AUX FLOW PRIOR
Lift Down Derating When Telescoped Out 0.5 0.2-0.9

LIFT DN DERATE
Lift Down Derating When Telescoped Out 4.26 FT 1.64-9.18 FT

Begin Point (1300mm) (500-2798mm)
LIFT DN DERATE START
Lift Down Engine Speed Dependency RPM BASED RPM BASED/NOT

LIFT DOWN SPEED RPM BASED
AccuPlace Vertical Height Limit 52.7 FT 44.9-59.9 FT

ACCUPLACE MAX HEIGHT
Allow Difference Between Boom Angle 8 DEG 4 to 10 DEG

Readings
ALLOWED BM ANGLE DIFF

Electrical System
9.15.4 Machine Setup

The Machine Setup menu contains the following entries
to define how each item shall perform when accessed.
Parameters marked with a no asterisk can be viewed
from Access Level 3, but can only be modified in Access
Level 2. Parameters with single asterisk (*) can be
viewed and modified only from Access Level 2.
Access Level 2 Code: 33271.
Menu Item Choices
MODEL NONE (default initially; requires model to be selected)

G12
G10
ENGINE PERKINS (default)
MODE STARTUP STANDARD (default)

ACCUPLACE
BOOM RIDE YES (default)

NO
EMERGENCY LOWER* DISABLED (default at each machine startup)

ENABLED

Electrical System
9.15.5 Calibrations Note: Ensure the boom end/quick switch is not in

contact with the ground.
Machine calibrations are required to initialize
components and to account for mechanical mounted 2. With the hand held analyzer, put the machine into
offsets (i.e., zero the components). If the ESC key is access level 2 (Access Level 2 Code: 33271).
pressed during the calibration procedure, the calibration a. Under the CALIBRATION menu, enter the
will be aborted and "CAL FAILED" will be displayed on BOOM ANGLE calibration.
the bottom line of the analyzer and the previous
b. When calibrating the boom angle sensors, the
calibration values will be used.
analyzer will display BOOM CAL POS 1 on the
Initial conditions: top line and BOOM DOWN? on the bottom line.
Ensure the forks are unloaded and boom is fully c. Press the ENTER key on the analyzer.
retracted.
All four tires are the same size/inflation. BOOM POS 1
Left Boom Angle Raw Counts = 32000 4000
The machine is on an even and level surface
(within 0.3) and ensure the boom is level side- Right Boom Angle Raw Counts = 180 50
ways (0.3).
The Boom and Fork appear visually level. d. If the boom angle is within the acceptable range,
the first calibration point will be accepted and the
analyzer will display BOOM CAL POS 2 on the
a. Chassis Tilt Sensor Calibration top line and BOOM UP? on the bottom line.
1. Park the machine on a firm, level surface, level the e. Lift the boom to the end of stroke then press the
machine, fully retract the boom, lower the boom, ENTER key on the analyzer.
(N) NEUTRAL and engage the park brake. BOOM POS 2
2. With a digital level, ensure the machine is on an Left Boom Angle Raw Counts = POS 1 + 27490
even and level surface (within 0.3) and the boom is 1100
level sideways (0.3). Right Boom Angle Raw Counts = 910 60
a. If angle is not within 0.1 tolerance, relocate the
machine or use the outriggers to make the f. If the boom angle is within the acceptable range,
necessary adjustments to reach the tolerance. the calibration point will be accepted and the
3. With the hand held analyzer, put the machine into analyzer will display CAL COMPLETE;
access level 2 (Access Level 2 Code: 33271). otherwise CAL FAIL LT ANGL or CAL FAIL RT
ANGL.
a. Under the CALIBRATION menu, enter the
CHASSIS TILT calibration. g. If CAL FAILED, make necessary adjustments
and repeat the calibration process.
b. The analyzer will display LEVEL VEHICLE on
the top line and the angle reading on the bottom Note: The calibration procedure will simultaneously
line. calibrate both the left and right boom angle sensors.
c. Press the ENTER key on the analyzer. If both tilt
sensor angles are acceptable, the analyzer will c. Boom Length Sensor Calibration
display CAL COMPLETE. 1. Park the machine on a firm, level surface, level the
Note: If the initial sensor angle conditions are not met, machine, fully retract the boom, lower the boom,
the analyzer will display CAL FAILED. Adjust the place the transmission control lever in
machine position and repeat the tilt sensor calibration. (N) NEUTRAL and engage the park brake.
2. With the hand held analyzer, put the machine into
b. Boom Angle Sensor Calibration access level 2 (Access Level 2 Code: 33271).
1. Park the machine on a firm, level surface, level the a. Under the CALIBRATION menu, enter the
machine, fully retract the boom, lower the boom to BOOM LENGTH calibration.
the machine stop, place the transmission control b. When calibrating the boom length sensor, the
lever in (N) NEUTRAL and engage the park brake. analyzer will display BM LNGTH CAL POS 1 on
the top line and BOOM RETRACTED? on the
bottom line.

Electrical System
c. Verify the boom is fully retracted and press the up) then press the ENTER key on the analyzer.
ENTER key on the analyzer.
FORK CAL POS 2
BM LNGTH POS 1 Fork Length Raw Counts = 4100 100
Boom Length Raw Counts = 800 500
f. If the fork length is within the acceptable range,
d. If the boom length is within the acceptable range, the calibration point will be accepted and the
the first calibration point will be accepted and the analyzer will display CAL COMPLETE;
analyzer will display BM LNGTH CAL POS 2 on otherwise CAL FAILED.
the top line and BOOM EXTENDED? on the g. If CAL FAILED, make necessary adjustments
bottom line. and repeat the calibration process.
e. Extend the boom to the end of stroke then press
the ENTER key on the analyzer. 9.15.6 Emergency Boom Lowering
Procedure
BM LNGTH POS 2
1. Turn keyswitch on, but ensure the engine is off.
Boom Length Raw Counts = 63500 1500
2. With the hand held analyzer, put the machine into
access level 2 (Access Level 2 Code: 33271).
f. If the boom length is within the acceptable range,
the calibration point will be accepted and the 3. Under the MACHINE SETUP menu, enter the
analyzer will display CAL COMPLETE; EMERGENCY LOWER submenu.
otherwise CAL FAILED.
4. Use the UP ARROW on the analyzer to select
g. If CAL FAILED, make necessary adjustments ENABLE and press the ENTER key of the
and repeat the calibration process. analyzer.
d. Fork Sensor Calibration 5. Using the boom joystick, fully retract the boom
(telescope in) if the boom is extended.
machine, fully retract the boom, place the Note: The emergency boom lowering procedure is
transmission control lever in (N) NEUTRAL and achieved by gravity, therefore it is important to fully
engage the park brake. retract the boom prior to lowering the boom.
2. With the hand held analyzer, put the machine into 6. After boom is fully retracted, use the boom joystick to
access level 2 (Access Level 2 Code: 33271). completely lower the boom.
a. Under the CALIBRATION menu, enter the
FORK LENGTH calibration.
b. When calibrating the fork length sensor, the
WARNING
analyzer will display FORK CAL POS 1 on the Ensure the forks remain relatively level as the boom is
top line and FORKS DOWN? on the bottom lowered to prevent losing any load on the forks.
line.
c. Fully retract the fork cylinder (i.e. forks moved
down) then press the ENTER key on the
analyzer.
FORK CAL POS 1

Fork Length Raw Counts = 320 40
d. If the fork length is within the acceptable range,

the first calibration point will be accepted and the
analyzer will display FORK CAL POS 2 on the
top line and FORKS UP? on the bottom line.
e. Fully extend the fork cylinder (i.e. forks moved

Electrical System
9.15.7 Diagnostics Note: All items are available in Access Level 3, unless
designated with a superscript of the lowest access level
The table below lists Diagnostic Help Messages that the
in which the items can be displayed (i.e., "PUMP
Control System shall communicate to the Analyzer. The
MANFLD CMD2" denotes that this parameter is available
goal is to help locate the source of any problem which
in Access Levels 1, and 2).
occurs on the vehicle. #
Indicates that parameter should be displayed only if the
machine is configured to utilize the component.
Diagnostics Parameter Parameter Value Description

Submenu (Displayed on (Displayed on
(Displayed on Analyzer 1st Line) Analyzer 2nd Line)
Analyzer 1st Line)
GROUND: AP FLT RST SW: CLOSED/OPEN Displays status of AccuPlace Fault Reset switch.
CONT AUX HYD SW: CLOSED/OPEN Displays status of Continuous Auxiliary
Hydraulics switch.
BOOM RIDE SW:# CLOSED/OPEN Displays status of Boom Ride Mode Enable
switch.
AP MODE LAMP: ON/OFF Displays status of AccuPlace Mode Lamp.
AP FLT RST LAMP: ON/OFF Displays status of User Fault Lamp.
BOOM RIDE LAMP:# ON/OFF Displays status of Boom Ride Mode Lamp.
LIFT CMD: UP/DOWN XXX.X% Displays reprocessed joystick lift direction &
demand.
TELE CMD: IN/OUT XXX.X% Displays reprocessed joystick telescope switch
direction & demand.
FORK CMD: UP/DOWN XXX.X% Displays reprocessed joystick fork lift direction &
demand.
AUX CMD: AUX 1/AUX 2 Displays reprocessed joystick Auxiliary
XXX.X% Hydraulics direction & demand.
SWAY OUTPUT LEFT/RIGHT Displays UGM sway output command direction &
XXX.X% demand.
SWAY CMD: LEFT/RIGHT Displays UGM sway output current command
XXXXmA direction & demand.
SWAY FDBK: XXXXmA Current feedback measured on Sway Valve
Return.
LT STAB OUTPUT: UP/DOWN XXX.X% Displays UGM Left Stabilizer output command
direction & demand.
LT STAB CMD: UP/DOWN XXXXmA Displays UGM Left Stabilizer output current
command direction & demand.
LT STAB FDBK: XXXXmA Current feedback measured on Left Stabilizer
Valve Return.
RT STAB OUTPUT: UP/DOWN XXX.X% Displays UGM Right Stabilizer output command
direction & demand.
RT STAB CMD: UP/DOWN XXXXmA Displays UGM Right Stabilizer output command
direction & demand.

Electrical System

Analyzer 1st Line)
RT STAB FDBK: XXXXmA Current feedback measured on Right Stabilizer
Valve Return.
REAR AXLE OUT1: ON/OFF Displays UGM Rear Oscillating Axle Lock output
state for Coil 1.
REAR AXLE OUT2: ON/OFF Displays UGM Rear Oscillating Axle Lock output
state for Coil 2.
CIRC OUTPUT: ON/OFF Displays the UGM Circulation Valve output state.
CAB JOYSTICK: JOYSTICK X: XXX% Displays position in percentage for this axis.
X NEUTRAL: NEUTRAL, NOT Indicates whether joystick is in neutral position for
NEUTRAL, ERROR this axis.
JOYSTICK Y: XXX% Displays position in percentage for this axis.
Y NEUTRAL: NEUTRAL, NOT Indicates whether joystick is in neutral position for
NEUTRAL, ERROR this axis.
JOYSTICK AR: XXX% Displays position in percentage for the analog
rocker.
AR NEUTRAL: NEUTRAL, NOT Indicates whether analog rocker is in neutral
NEUTRAL, ERROR position.
JOYSTICK S1: ON/OFF Displays status of S1 pushbutton.
MINI JOYSTICKS: SWAY JOY CMD: XXX% Displays position in percentage for this axis;
positive is lower voltages and negative is higher
voltages.
SWAY JOY SIGNAL: X.XV Provides voltage signal output for joystick.
SWAY NEUTRAL SW: NEUTRAL/OUT OF Indicates whether joystick switches designate out-
NEUTRAL of-neutral position.
AUX JOY CMD: XXX% Displays position in percentage for this axis;
voltages.
AUX JOY SIGNAL: X.XV Provides voltage signal output for joystick.
AUX NEUTRAL SW: NEUTRAL/OUT OF Indicates whether joystick switches designate out-
LT STAB JOY CMD: XXX% Displays position in percentage for this axis;
voltages.
LT STAB SIGNAL: X.XV Provides voltage signal output for joystick.
LT STAB NEUT SW: NEUTRAL/OUT OF Indicates whether joystick switches designate out-

Electrical System

Analyzer 1st Line)
RT STAB JOY CMD: XXX% Displays position in percentage for this axis;
voltages.
RT STAB SIGNAL: X.XV Provides voltage signal output for joystick.
RT STAB NEUT SW: NEUTRAL/OUT OF Indicates whether joystick switches designate out-
BOOM BOOM ANGLE LEFT: XX.X DEG Displays boom angle of left-mounted CAN sensor
COMPONENTS: with negative degrees below horizontal; 90
means invalid reading.
BOOM ANGLE LEFT: XXXXX COUNTS Displays raw counts of left-mounted CAN sensor.
BOOM ANGLE RT: XX.X DEG Displays boom angle of right-mounted analog
sensor with negative degrees below horizontal;
90 means invalid reading.
BOOM ANGLE RT: XXXXX COUNTS Displays raw counts of right-mounted analog
sensor.
TELE LENGTH: XXX.X INCHES Displays total boom length reading; 900 means
invalid reading.
TELE LENGTH: XXXXX COUNTS Displays raw counts of boom length sensor.
FORK ANGLE: XXX.X DEG Displays fork angle with negative angles below
horizontal. This calculation uses Attachment F to
relate Fork Angle to Cylinder Length (displayed
only if MTS configured).
FORK LENGTH: XXXXX.X INCHES Displays calibrated length in inches of Fork
Length sensor.
FORK LENGTH: XXXXX COUNTS Displays raw counts of Fork Length sensor.
2
ISP BOOM ANGLE: XXX.X DEG Displays Boom Angle computed by ISP.
ISP BOOM LENGTH:2 XXX.X INCHES Displays Boom Length computed by ISP.
2
ISP FORK ANGLE: XXX.X DEG Displays Boom Angle computed by ISP.

Electrical System

Analyzer 1st Line)
SYSTEM POWER: ENGINE RPM: XXXX Engine RPM reported from engine controller.
ENGINE STATE: OFF/CRANKING/ Reports state of engine depending on RPM value.
RUNNING/
UNKNOWN
ENGINE OIL PRESS: XXX PSI Engine oil pressure reported from engine
controller.
ENGINE TEMP: XXX DEG C Engine temperature reported from engine
controller.
UGM V BAT: XX.XV UGM battery voltage.
ISP V BAT: XX.XV Battery voltage reported from ISP.
LIFT V BAT: XX.XV Battery voltage reported from Lift valve.
TELE V BAT: XX.XV Battery voltage reported from Tele valve.
FORK V BAT: XX.XV Battery voltage reported from Fork valve.
SYSTEM: CHASSIS TILT X: XX.X DEG Displays X side-to-side tilt angle.
CHASSIS TILT Y: XX.X DEG Displays Y fore-to-aft tilt angle.
BOOM MODE STANDARD/ Displays whether joystick is mapped to provide
ACCUPLACE boom motion as a standard Telehandler or
coordinated AccuPlace.
ELEV STATUS: ABOVE/BELOW Displays Elevation status.
TRANSPORT MODE: IN TRANSPORT/ Displays whether Boom is in Transport Mode.
OUT OF
TRANSPORT
BOOM RIDE MODE:# ON/OFF If configured, displays status of Boom Ride Mode.
BOOM SPEED: LOW, MED, Boom speed set via INCOVA configuration
NORMAL, message.
EMERGENCY
LOWER, DISABLED
INCOVA CFG LSB: 2 XX XX XX XX Bytes 1-4 of INCOVA Configuration Message.
INCOVA CFG MSB: 2 XX XX XX XX Bytes 5-8 of INCOVA Configuration Message.
2
RETRIEVAL LOCK: ACTIVE/NOT Displays status of boom Retrieval Lock.
ACTIVE

Electrical System

Analyzer 1st Line)
ISP: ISP SUPPLY PRESS: XXXX.X PSI System Pressure at Pump Manifold (PS).
ISP LS PRESS: 1 XXXX.X PSI Load Sense Pressure at Pump Manifold (PCLS).
ISP SUPPLY TEMP: XXXDEG C Hydraulic Supply Oil Temperature reported at
Pump Manifold.
ISP LS TEMP: 1 XXXDEG C Hydraulic LS Oil Temperature reported at Pump
Manifold.
PUMP MANFLD CMD: XXXXmA Current command going to Coil 1/Pump Manifold
Valve.
PUMP MANFLD XXXXmA Current returning from Coil 1/Pump Manifold
FDBK 2 Valve.
RT LIFT ISOL CMD: 2 XXXXmA Current command going to Coil 2/Right Lift
Isolation Valve.
RT LFT ISOL FDB: 2 XXXXmA Current returning from Coil 2/Right Lift Isolation
Valve.
LT LIFT ISOL CMD: 2 XXXXmA Current command going to Coil 3/Left Lift Isolation
Valve.
LT LFT ISOL FDB: 2 XXXXmA Current returning from Coil 3/Left Lift Isolation
Valve.
BOOM RIDE CMD: 2# XXXXmA Current command going to Coil 4/Boom Ride
Mode Valve.
BOOM RIDE FDB: 2# XXXXmA Current returning from Coil 4/Boom Ride Mode
Valve.
ISP LIFT VEL: 2 XX.XX kph Velocity command from ISP for Lift Valve.
ISP TELE VEL: 2 XX.XX kph Velocity command from ISP for Telescope Valve.
2
ISP FORK VEL: XX.XX kph Velocity command from ISP for Fork Valve.
ISP AUX VEL: 2 XX.XX kph Velocity command from ISP for Auxiliary
Hydraulics part of Fork Valve.

Electrical System

Analyzer 1st Line)
LIFT VALVE: LIFT DPLOAD: 2 XXXX.X PSI Lift cylinder load pressure differential.
LIFT PRESS-ROD: XXXX.X PSI Pressure reported from Work Port 1 (Rod).
LIFT PRESS-HEAD: XXXX.X PSI Pressure reported from Work Port 2 (Head).
LIFT TEMP-ROD: XXXDEG C Temperature reported from Work Port 1 (Rod).
LIFT TEMP-HEAD: 2 XXXDEG C Temperature reported from Work Port 2 (Head).
LIFT COIL 1 CMD: 2 XXXXmA Current commanded to Lift Coil 1.
2
LIFT COIL 1 FDBK: XXXXmA Current returning from Lift Coil 1.
2
2
2
LIFT COIL 4 FDBK: XXXXmA Current returning from Lift Coil 4;.
TELE VALVE2 TELE DPLOAD: XXXX.X PSI Tele cylinder load pressure differential.
TELE PRESS-HEAD: XXXX.X PSI Pressure reported from Work Port 1 (Head).
TELE PRESS-ROD: XXXX.X PSI Pressure reported from Work Port 2 (Rod);.
TELE TEMP-HEAD: XXXDEG C Temperature reported from Work Port 1.
TELE TEMP-ROD: XXXDEG C Temperature reported from Work Port 2.
TELE COIL 1 CMD: XXXXmA Current commanded to Tele Coil 1.
TELE COIL 1 FDBK: XXXXmA Current returning from Tele Coil 1.

Electrical System

Analyzer 1st Line)
FORK VALVE2 FORK PRESS-HEAD: XXXX.X PSI Pressure reported from Work Port 1 (Head).
FORK PRESS-LS: XXXX.X PSI Pressure reported from Fork Shuttle Valve.
FORK TEMP-HEAD: XXXDEG C Temperature reported from Work Port 1.
FORK TEMP-LS: XXXDEG C Temperature reported from Fork Shuttle Valve.
FORK COIL 1 CMD: XXXXmA Current commanded to Fork Coil 1.
FORK COIL 1 FDBK: XXXXmA Current returning from Fork Coil 1.
FORK COIL 2 CMD: XXXXmA Current commanded to Fork Coil 2.
FORK COIL 2 FDBK: XXXXmA Current returning from Fork Coil 2.
AUX COIL 1 CMD: XXXXmA Current commanded to Fork Coil 3.
AUX COIL 1 FDBK: XXXXmA Current returning from Fork Coil 3.
AUX COIL 2 CMD: XXXXmA Current commanded to Fork Coil 4.
AUX COIL 2 FDBK: XXXXmA Current returning from Fork Coil 4.
CALIBRATION BOOM ANGLE LT: CAL LOW XXXXX Calibration offset for Boom Down of Boom Angle
DATA2 Left Sensor (CAN).
BOOM ANGLE LT: CAL HIGH XXXXX Calibration offset for Boom Up of Boom Angle Left
Sensor (CAN).
BOOM ANGLE RT: CAL LOW XXXXX Calibration offset for Boom Down of Boom Angle
Right Sensor (Analog).
BOOM ANGLE RT: CAL HIGH XXXXX Calibration offset for Boom Up of Boom Angle
Right Sensor (Analog).
TELE SENSOR CAL: RET XXXXX Calibration offset for Boom Retracted of Tele
Length Sensor.
TELE SENSOR CAL: EXT XXXXX Calibration offset for Boom Extended of Tele
Length Sensor.
FORK SENSOR CAL: LOW XXXXX Calibration offset for Fork Down of Fork Angle
Sensor.
FORK SENSOR CAL: HIGH XXXXX Calibration offset for Fork Up of Fork Angle
Sensor.

Electrical System

Analyzer 1st Line)
CAN CAN1 RX/S: XXXXX CAN1 Receptions per second by UGM.
STATISTICS2
CAN1 TX/S: XXXXX CAN1 Transmissions per second by UGM.
CAN1 BUS PASS: XXXXX CAN1 passive messages; rolls over at 65535.
CAN1 ERR F/S: XXXXX CAN1 errors frames per second.
CAN2 RX/S: XXXXX CAN2 Receptions per second by UGM.
CAN2 TX/S: XXXXX CAN2 Transmissions per second by UGM.
CAN2 BUS PASS: XXXXX CAN2 passive messages; rolls over at 65535.
CAN2 ERR F/S: XXXXX CAN2 errors frames per second
DATALOG: DATALOG: ON XXXXH XXM Displays total controller on (power) time.
DATALOG: ENGINE XXXXH Displays time engine running.
XXM
DATALOG: LIFT XXXXH XXM Displays total controller lift operation time.
DATALOG: TELE XXXXH XXM Displays total controller telescope operation time.
DATALOG: FORK XXXXH XXM Displays total controller for operation time.
DATALOG: AUX HYD XXXXH Displays total auxiliary hydraulics 1 and 2
XXM operation time.
DATALOG: UGM MAX VOLTS XX.XV Displays maximum measured battery voltage for
DATALOG: ISP UGM, ISP, and all INCOVA modules.
DATALOG: LIFT
DATALOG: TELE
DATALOG: FORK
DATALOG: ISP MAX OIL XXXC Maximum oil temp measured on INCOVA Valve
DATALOG: LIFT with associated valve name (i.e., Lift, Tele, Fork,
etc.).
DATALOG: TELE
DATALOG: FORK
DATALOG: LIFT CYCLES XXXXXX Number of cycles on Lift; Lift cycle defined as Lift
Up knowing that complementary Lift Down must
naturally happen as part of a cycle.
DATALOG: TELE CYCLES XXXXXX Number of cycles on Tele; Tele cycle defined as
Tele Out knowing that complementary Tele In
must naturally happen as part of a cycle.
DATALOG: FORK CYCLES XXXXXX Number of cycles on Fork; Fork cycle defined as
Fork Tilt Up knowing that complementary Fork Tilt
Down must naturally happen as part of a cycle.

Electrical System

Analyzer 1st Line)
DATALOG: AUX CYCLES XXXXXX Number of cycles on Aux; Aux cycle defined as
Aux Left knowing that complementary Aux Right
must naturally happen as part of a cycle.
DATALOG: RENTAL XXXXH Displays total time on with engine running. NOTE:
XXM can be reset.
DATALOG: ERASE RENTAL? 2 ENTER resets rental data log time to zero.
DEBUG2 CAB JOYSTK SIM: LIFT UP LIFT UP COMMAND
-XXX%
LIFT DOWN LIFT DOWN
+XXX%
TELE IN TELE IN
-XXX%
TELE OUT TELE OUT
+XXX%
FORK TILT UP FORK TILT UP
-XXX%
FORK TILT DOWN FORK TILT DOWN
+XXX%
HYD PMP OVERRIDE PUMP OVERRIDE? PUMP OVERRIDE
ACTIVATE: ENT XXX%
CAN1 MSG TO CAN2 ACTIVATE: ENT FOR 1 PWR CYCLE?
NO/YES

Electrical System

Analyzer 1st Line)
VERSIONS: VERSIONS: UGM SW XX.X Displays UGM software version.
VERSIONS: UGM HW REV XX Displays UGM hardware revision.
VERSIONS: UGM SN XXXXXX Displays UGM serial number.
VERSIONS: UGM PN XXXXXX Displays UGM part number.
VERSIONS: UGM CD REV XX.X Displays Constant Data software version.
VERSIONS: JOY SW XX.X Displays joystick software version.
VERSIONS: ISP SW XX.X Displays ISP software version.
VERSIONS: LIFT SW XX.X Displays Lift function software version.
VERSIONS: TELE SW XX.X Displays Tele function software version.
VERSIONS: FORK SW XX.X Displays Fork function software version.
VERSIONS: BOOM LENGTH SN Displays Boom Length sensor serial number.
XXXXXX
VERSIONS: FORK SENS SN Displays Fork Length sensor serial number.
XXXXXXXX
VERSIONS: ANALYZER Displays Analyzer software version.
VX.XXXX

Electrical System
9.15.8 Diagnostic Trouble Code (DTC) Table operating in Standard mode and a fault occurs, pushing
AccuPlace Mode Fault Reset button is never required.
Note: The column labeled Fault Requires AccuPlace
Reset indicates whether the AccuPlace Mode Fault Note: 1All faults disregarded during engine crank except
Reset button is required to be pushed if a fault occurs those annotated.
while operating in AccuPlace mode (Y = Yes, N = No). In 2Fault/Check applies during Power Up/System
addition to pressing the Reset button if in AccuPlace
Initialization period.
mode even if not explicitly stated, the conditions under
the Action description are required. Motion is permitted
after AccuPlace Fault Reset button is pushed. If
Help Message1 DTC Fault Condition Fault Action(s)

(for configurable items, Requires
fault applies only if AccuPlace
configured) Reset?
EVERYTHING OK 001 None N For information only; system fully

functional. Not stored in Fault Log or sent
to 3-N-1 gauge.
ENVELOPE LIMIT 0026 AccuPlace function limit has N Normal condition; for information only.
REACHED been reached. Not stored in Fault Log or sent to 3-N-1
gauge.
POWER CYCLE2 211 None N Normal operation. Used as a marker to
denote the end of the Fault Log for the
faults logged during the current power
cycle.
JOYSTICK AXES 215 Main Joystick X and Y axes N Center joystick and normal operation
NOT IN NEUTRAL not in neutral during system should resume. If not, check that the X and
AT POWER UP2 startup. Y axis commands = 0% and In-Neutral
under Diagnostics/Main Joystick on the
Analyzer when the joystick is centered.
If the readings display ???, this indicates
that the CAN Bus is not communicating or
Main joystick power is lost.
Check joystick signal and continuity of its
wiring connections. The joystick should
read 120 ohms across CAN2H and
CAN2L when disconnected from the
machine harness. When disconnected
from the joystick, the machine harness
should also have 120ohms between
CAN2H and CAN2L.

Electrical System

configured) Reset?
SWAY JOYSTICK 2126 The sway joystick is not N Center joystick and normal operation
NOT IN NEUTRAL centered or one of the should resume. If not, check that the
AT POWER UP2 joystick directional switches command is 0% and the neutral switch
is closed during system state is In-Neutral under Diagnostics/Mini
startup. Joystick/Sway Joystick on the Analyzer
when the joystick is centered. A command
= -100% and signal voltage = 0.0V
indicates that the Joystick Power or Signal
wire has an open circuit. A command =
100% and signal voltage > 4.75V indicates
the Joystick Ground wire has an open
circuit. If the Neutral state always
indicates Neutral, then either the
directional switch or the Joystick Switch
Power wire has an open circuit.
If neutral voltage is near 2.4V or 2.5V
when centered, check that the joystick
voltage is still within the allowed deadband
detailed in the Personalities section. If
outside the deadband, adjust the
Personality setting for the Deadband.
If not, swap connector between Sway
joystick and an adjacent Mini Joystick to
determine whether the Sway joystick is
faulty. If the joystick is fine, focus
troubleshooting efforts on the connector
and wiring. If this is fine and the Joystick
Interface Module is suspected to be faulty,
verify by temporarily interchanging wiring
on the Joystick Interface Module between
joysticks for troubleshooting purposes.

Electrical System

configured) Reset?
AUX 2127 The Aux Hydraulic joystick is N Center joystick and normal operation
HYDRAULICS not centered or one of the should resume. If not, check that the
JOYSTICK NOT joystick directional switches command is 0% and the neutral switch
IN NEUTRAL AT is closed during system state is In-Neutral under Diagnostics/Mini
POWER UP2 startup. Joystick/Aux Joystick on the Analyzer
when the joystick is centered. A command
= -100% and signal voltage = 0.0V
indicates that the Joystick Power or Signal
wire has an open circuit. A command =
100% and signal voltage > 4.75V indicates
the Joystick Ground wire has an open
circuit. If the Neutral state always
indicates Neutral, then either the
If not, swap connector between Aux
determine whether the Aux joystick is
and wiring. If this is fine and the Joystick
Interface Module is suspected to be faulty,
verify by temporarily interchanging wiring
on the Joystick Interface Module between
joysticks for troubleshooting purposes.

Electrical System

configured) Reset?
LEFT 2128 The Left Stabilizer joystick is N Center joystick and normal operation
STABILIZER not centered or one of the should resume. If not, check that the
POWER UP2 startup. Joystick/Left Stabilizer Joystick on the
Analyzer when the joystick is centered. A
command = -100% and signal voltage =
0.0V indicates that the Joystick Power or
Signal wire has an open circuit. A
command = 100% and signal voltage >
4.75V indicates the Joystick Ground wire
has an open circuit. If the Neutral state
always indicates Neutral, then either the
If not, swap connector between Left
Stablilizer joystick and an adjacent Mini
Joystick to determine whether the Left
Stablilizer joystick is faulty. If the joystick is
fine, focus troubleshooting efforts on the
connector and wiring. If this is fine and the
Joystick Interface Module is suspected to
be faulty, verify by temporarily
interchanging wiring on the Joystick
Interface Module between joysticks for
troubleshooting purposes.

Electrical System

configured) Reset?
RIGHT 2129 The Right Stabilizer joystick N Center joystick and normal operation
STABILIZER is not centered or one of the should resume. If not, check that the
POWER UP2 startup. Joystick/Right Stabilizer Joystick on the
Analyzer when the joystick is centered. A
command = -100% and signal voltage =
0.0V indicates that the Joystick Power or
Signal wire has an open circuit. A
command = 100% and signal voltage >
4.75V indicates the Joystick Ground wire
has an open circuit. If the Neutral state
always indicates Neutral, then either the
If not, swap connector between Right
Stablilizer joystick and an adjacent Mini
Joystick to determine whether the Right
Stablilizer joystick is faulty. If the joystick is
connector and wiring. If this is fine and the
Joystick Interface Module is suspected to
be faulty, verify by temporarily
interchanging wiring on the Joystick
Interface Module between joysticks for
troubleshooting purposes.

Electrical System

configured) Reset?
JOYSTICK 216 Joystick AR axis not in N Center joystick and normal operation
ROLLER NOT IN neutral during system should resume. If not, check that the AR
NEUTRAL AT startup. axis commands = 0% and In-Neutral
POWER UP2 under Diagnostics/Main Joystick on the
Analyzer when the joystick is centered.
If the readings display ???, this indicates
that the CAN Bus is not communicating or
power is lost.
Check joystick signal and continuity of its
wiring connections. The joystick should
read 120 ohms across CAN2H and
CAN2L when disconnected from the
machine harness. When disconnected
from the joystick, the machine harness
should also have 120ohms between
CAN2H and CAN2L.
CAB JOYSTICK - 2323 Joystick senses and reports N Center joystick and check to see if a power
X AXIS FAULT fault for X axis. cycle will clear DTC. If not, replace
joystick.
Y AXIS FAULT fault for Y axis. cycle will clear DTC. If not, replace
joystick.
ROLLER FAULT fault for AR axis. cycle will clear DTC. If not, replace
joystick.
CAB JOYSTICK - 2326 S1 engaged for more than 7 Y Fault clears when S1 signal returns to
S1 BUTTON seconds with joystick in zero. Press button to confirm that button is
FAULT neutral. functional. If fault persists, check under
Diagnostics/Main Joystick to verify that S1
changes state. Check to determine
whether a power cycle will clear the DTC.
BOOM ANGLE 2343 A Boom Angle sensor N Calibrate boom angle sensor. Refer to
SENSOR - NOT calibration has not been Section 9.15.5, Calibrations.
CALIBRATED performed since a new UGM
was installed. UGM still has
default calibration data in
memory.

Electrical System

configured) Reset?
BOOM RIDE 2355 Boom Ride Mode Switch N Turn Boom Ride Mode switch off (open
MODE SWITCH read by UGM as closed state), then back on (closed state).
CLOSED AT during system startup. Press button to confirm that button is
POWER UP2 functional. If fault persists, check under
Diagnostics/Ground to verify that the
switch changes state. Check to determine
whether a power cycle will clear the DTC.
Check continuity of wiring connections.
AUXILIARY 2356 The Aux Hydraulic joystick is N Center joystick and check to see if a power
HYDRAULICS within its centered deadband cycle will clear DTC.
JOYSTICK and one of the out-of-neutral If not, swap connector between Aux
NEUTRAL directional switches is closed Hydraulics joystick and an adjacent Mini
DISAGREEMENT or the joystick is outside its Joystick to determine whether the Aux
deadband and the Hydraulics joystick is faulty. If the joystick
respective directional switch is fine, focus troubleshooting efforts on the
is not closed. connector and wiring as detailed in DTC
2127.
AUXILIARY 2357 The Aux Hydraulic joystick N Center joystick and check to see if a power
HYDRAULICS voltage has reached the high cycle will clear DTC.
JOYSTICK OUT error limit defined in If not, swap connector between Auxiliary
OF RANGE HIGH Personalities. Hydraulics joystick and an adjacent Mini
Joystick to determine whether the
Auxiliary Hydraulics joystick is faulty. If the
joystick is fine, focus troubleshooting
efforts on the connector and wiring as
detailed in DTC 2127.
AUXILIARY 2358 The Aux Hydraulic joystick N Center joystick and check to see if a power
HYDRAULICS voltage has reached the low cycle will clear DTC.
JOYSTICK OUT error limit defined in If not, swap connector between Auxiliary
OF RANGE LOW Personalities. Hydraulics joystick and an adjacent Mini
Joystick to determine whether the
Auxiliary Hydraulics joystick is faulty. If the
joystick is fine, focus troubleshooting
efforts on the connector and wiring as
detailed in DTC 2127.

Electrical System

configured) Reset?
SWAY JOYSTICK 2359 The Sway joystick is within N Center joystick and check to see if a power
NEUTRAL its deadband and one of the cycle will clear DTC.
DISAGREEMENT directional switches is closed If not, swap connector between Sway
or the joystick is outside its joystick and an adjacent Mini Joystick to
deadband and the determine whether the Sway joystick is
respective directional switch faulty. If the joystick is fine, focus
is not closed; debounce 2 troubleshooting efforts on the connector
seconds. and wiring as detailed in DTC 2126.
SWAY JOYSTICK 2360 The Sway joystick voltage N Center joystick and check to see if a power
OUT OF RANGE has reached the high error cycle will clear DTC.
HIGH limit defined in Personalities. If not, swap connector between Sway
and wiring as detailed in DTC 2126.
SWAY JOYSTICK 2361 The Sway joystick voltage N Center joystick and check to see if a power
OUT OF RANGE has reached the low error cycle will clear DTC.
LOW limit defined in Personalities. If not, swap connector between Sway
and wiring as detailed in DTC 2126.
LEFT 2362 The Left Stabilizer joystick is N Center joystick and check to see if a power
STABILIZER within its deadband and one cycle will clear DTC.
JOYSTICK of the directional switches is If not, swap connector between Left
NEUTRAL closed or the joystick is Stabilizer joystick and an adjacent Mini
DISAGREEMENT outside its deadband and the Joystick to determine whether the Left
respective directional switch Stabilizer joystick is faulty. If the joystick is
is not closed; debounce 2 fine, focus troubleshooting efforts on the
seconds. connector and wiring as detailed in DTC
2128.

Electrical System

configured) Reset?
LEFT 2363 The Left Stabilizer joystick N Center joystick and check to see if a power
STABILIZER voltage has reached the high cycle will clear DTC.
JOYSTICK OUT error limit defined in If not, swap connector between Left
OF RANGE HIGH Personalities. Stabilizer joystick and an adjacent Mini
Stabilizer joystick is faulty. If the joystick is
connector and wiring as detailed in DTC
2128.
LEFT 2364 The Left Stabilizer joystick N Center joystick and check to see if a power
STABILIZER voltage has reached the low cycle will clear DTC.
JOYSTICK OUT error limit defined in If not, swap connector between Left
OF RANGE LOW Personalities. Stabilizer joystick and an adjacent Mini
2128.
RIGHT 2365 The Right Stabilizer joystick N Center joystick and check to see if a power
STABILIZER is within its deadband and cycle will clear DTC.
JOYSTICK one of the directional If not, swap connector between Right
NEUTRAL switches is closed or the Stabilizer joystick and an adjacent Mini
DISAGREEMENT joystick is outside its Joystick to determine whether the Left
deadband and the Stabilizer joystick is faulty. If the joystick is
respective directional switch fine, focus troubleshooting efforts on the
is not closed; debounce 2 connector and wiring as detailed in DTC
seconds. 2129.
STABILIZER voltage has reached the high cycle will clear DTC.
JOYSTICK OUT error limit defined in If not, swap connector between Right
OF RANGE HIGH Personalities. Stabilizer joystick and an adjacent Mini
2129.

Electrical System

configured) Reset?
STABILIZER voltage has reached the low cycle will clear DTC.
JOYSTICK OUT error limit defined in If not, swap connector between Right
OF RANGE LOW Personalities. Stabilizer joystick and an adjacent Mini
2129.
FUNCTIONS 2520 UGM constant data version N Requires reprogramming of UGM.
LOCKED OUT is incompatible.
CONSTANT
DATA VERSION
IMPROPER2
MULTIPLE LIFT 2540 A Lift Valve fault coexists Y Multiple faults have occurred.
VALVE FAULTS with either a Left or Right Begin by first troubleshooting fault
LIFT MOTION Isolation Valve fault. associated with Isolation Valve Faults
PREVENTED (DTCs 4549 or 4551).
MODEL 259 Machine model has been N Cycle power.
CHANGED changed.
HYDRAULICS
SUSPENDED
CYCLE EMS?
LEFT 33222 Voltage on UGM pin J2-20 N Check for continuity through this circuit.
STABILIZER indicates solenoid Inspect wiring for physical damage.
DOWN VALVE disconnected.
OPEN CIRCUIT2 Note: An open circuit voltage of nearly
8.0V exists on this UGM pin for circuit
diagnostic purposes.
STABILIZER indicates STB fault. Inspect wiring for physical damage.
DOWN VALVE
SHORT TO Note: The wire on the low side of the coil
BATTERY provides current feedback to J3-14 and
can open circuit the electrical path to
ground to prevent current flow through the
coil (to prevent function movement).
LEFT 33224 Loss of current feedback on N Check for coil damage or a shorting
STABILIZER UGM pin J3-14 while driving condition in this circuit.
DOWN VALVE coil via UGM pin J2-20. Inspect wiring for physical damage.
SHORT TO
GROUND

Electrical System

configured) Reset?
STABILIZER UP indicates solenoid Inspect wiring for physical damage.
VALVE OPEN disconnected.
CIRCUIT2 Note: An open circuit voltage of nearly
STABILIZER UP indicates STB fault. Inspect wiring for physical damage.
VALVE SHORT
TO BATTERY Note: The wire on the low side of the coil
provides current feedback to J3-14 and
LEFT 33227 Loss of current feedback on N Check for continuity through this circuit.
STABILIZER UP UGM pin J3-14 while driving Inspect wiring for physical damage.
VALVE SHORT coil via UGM pin J2-9;
TO GROUND assessed at startup.
LEFT 3334 Current feedback on UGM N Check for continuity through this circuit.
STABILIZER pin J3-14 > 250ma; but Inspect wiring for physical damage.
CURRENT difference from commanded
FEEDBACK current while driving coil via Check the current on the Feedback wire
READING TOO UGM pin J2-9 > 125ma for 1 returning to UGM pin J3-14. This current
LOW second. should read within 20ma of the value
commanded as read on the Analyzer
under Diagnostics/Ground for either Left
Stabilizer Up or Down functions;
otherwise, there is a degraded
connection. If the value does not track,
temporarily swap connections to assess
whether and how the fault follows the
wiring.
RIGHT 33228 Voltage on UGM pin J2-19 N Check for continuity through this circuit.
STABILIZER indicates solenoid Inspect wiring for physical damage.
DOWN VALVE disconnected.
OPEN CIRCUIT2
STABILIZER indicates STB fault. Inspect wiring for physical damage.
DOWN VALVE
SHORT TO Note: The wire on the low side of the coil
BATTERY provides current feedback to J3-14 and

Electrical System

configured) Reset?
RIGHT 33230 Loss of current feedback on N Check for continuity through this circuit.
STABILIZER UGM pin J3-6 while driving Inspect wiring for physical damage.
DOWN VALVE coil via UGM pin J2-19.
SHORT TO
GROUND
STABILIZER UP indicates solenoid Inspect wiring for physical damage.
VALVE OPEN disconnected.
CIRCUIT2 Note: An open circuit voltage of nearly
STABILIZER UP indicates STB fault. Inspect wiring for physical damage.
VALVE SHORT
TO BATTERY Note: The wire on the low side of the coil
RIGHT 33233 Loss of current feedback on N Check for continuity through this circuit.
STABILIZER UP UGM pin J3-6 while driving Inspect wiring for physical damage.
VALVE SHORT coil via UGM pin J2-8.
TO GROUND
RIGHT 33335 Current feedback on N Check for continuity through this circuit.
STABILIZER UGM pin J3-6 > 250ma; but Inspect wiring for physical damage.
CURRENT difference from commanded
FEEDBACK current while driving coil via Check the current on the Feedback wire
READING TOO UGM pin J2-8 > 125ma for 1 returning to UGM pin J3-14. This current
LOW second. should read within 20ma of the value
wiring.
Note: The wire on the low side of the coil
will measure an open circuit when a STB
condition exists because the UGM has
open circuited the electrical path to

Electrical System

configured) Reset?
FRAME LEVEL 33234 Voltage on UGM pin J2-11 N Check for continuity through this circuit.
LEFT VALVE indicates solenoid Inspect wiring for physical damage.
OPEN CIRCUIT disconnected.
Note: An open circuit voltage of nearly
LEFT VALVE indicates STB fault. Inspect wiring for physical damage.
SHORT TO
BATTERY
FRAME LEVEL 33236 Loss of current feedback on N Check for continuity through this circuit.
LEFT VALVE UGM pin J3-2 while driving Inspect wiring for physical damage.
SHORT TO coil via UGM pin J2-11.
GROUND
RIGHT VALVE - indicates solenoid Inspect wiring for physical damage.
OPEN CIRCUIT disconnected.
RIGHT VALVE indicates STB fault. Inspect wiring for physical damage.
SHORT TO
BATTERY Note: The wire on the low side of the coil
FRAME LEVEL 33239 Loss of current feedback on N Check for continuity through this circuit.
RIGHT VALVE UGM pin J3-2 while driving Inspect wiring for physical damage.
SHORT TO coil via UGM pin J2-22.
GROUND
FRAME LEVEL 33336 Current feedback on UGM N Check for continuity through this circuit.
CURRENT pin J3-2 > 250ma; but Inspect wiring for physical damage.
FEEDBACK difference from commanded
READING TOO current while driving coil via Check the current on the Feedback wire
LOW UGM pin J2-22 > 125ma for returning to UGM pin J3-14. This current
1 second. should read within 20ma of the value
wiring.

Electrical System

configured) Reset?
CIRCULATION 3337 Feedback voltage on UGM N Check for continuity through this circuit.
VALVE SHORT pin J1-11 indicates STB Inspect wiring for physical damage.
TO BATTERY fault.
With the engine off but controller power
on, and with the circulation valve
disconnected, the open circuit voltage at
the valve connector should be around
8.0V or less. If not, continue tracing the
circuit back toward the cab wall (rear of
boom, cab wall, UGM connectors, etc.)
and making measurements to determine
where the STB exists. Once isolated,
perform continuity check to narrow source
of problem.
CIRCULATION 33346 Voltage on UGM pin J1-11 N Check for coil damage or a shorting
VALVE SHORT while driving coil indicates condition in this circuit.
TO GROUND STG condition. Inspect wiring for physical damage. The
low side of this coil should be within 1ohm
resistance to the negative battery
terminal.
CIRCULATION 33347 Feedback voltage on UGM N Check for continuity through this circuit.
VALVE OPEN pin J1-11 indicates STB Inspect wiring for physical damage.
CIRCUIT fault.
REAR 33348 Feedback voltage on UGM N Check for continuity through this circuit.
STABILIZER ONE pin J1-13 indicates STB Inspect wiring for physical damage.
VALVE SHORT fault.
TO BATTERY With the engine off but controller power
on, and with the valve disconnected, the
open circuit voltage at the valve connector
should be around 8.0V or less. If not,
continue tracing the circuit back toward
UGM, making measurements to
determine where the STB exists. Once
isolated, perform continuity check to
narrow source of problem.
REAR 33349 Voltage on UGM pin J1-13 N Check for continuity through this circuit.
STABILIZER ONE while driving coil indicates Inspect wiring for physical damage. The
VALVE SHORT STG condition. low side of this coil should be within 1ohm
TO GROUND resistance to the negative battery
terminal.

Electrical System

configured) Reset?
STABILIZER ONE pin J1-13 indicates STB Inspect wiring for physical damage.
VALVE OPEN fault.
CIRCUIT Note: An open circuit voltage of nearly
STABILIZER TWO pin J1-2 indicates STB fault. Inspect wiring for physical damage.
VALVE SHORT
TO BATTERY With the engine off, but controller power
on, and with the valve disconnected, the
open circuit voltage at the valve connector
should be around 8.0V or less. If not,
continue tracing the circuit back toward
UGM, making measurements to
determine where the STB exists. Once
isolated, perform continuity check to
narrow source of problem.
REAR 33352 Voltage on UGM pin J1-2 N Check for continuity through this circuit.
STABILIZER TWO while driving coil indicates Inspect wiring for physical damage. The
VALVE SHORT STG condition. low side of this coil should be within 1ohm
TO GROUND resistance to the negative battery
terminal.
STABILIZER TWO pin J1-2 indicates STB fault. Inspect wiring for physical damage.
VALVE OPEN
CIRCUIT Note: An open circuit voltage of nearly
ENGINE 437 Engine reports fault and N This fault provides an Suspect Parameter
TROUBLE CODE UGM initiates display of Number/Failure Mode Identifier to be used
SPN/FMI. in conjunction with the engine
manufacturer's instructions.
BATTERY 441 UGM measures battery Y Recharge batteries or check for damaged
VOLTAGE TOO voltage < 9V for more than 3 batteries.
LOW SYSTEM seconds (excluding during
SHUTDOWN engine cranking).
BATTERY 442 UGM measures battery Y May be due to improper battery charging
VOLTAGE TOO voltage > 16V for more than or incorrect voltage batteries being used.
HIGH SYSTEM 3 seconds (excluding during
SHUTDOWN engine cranking).

Electrical System

configured) Reset?
BATTERY 445 UGM measures battery N Recharge batteries or check for damaged
VOLTAGE LOW voltage < 11V for more than batteries.
3 seconds (excluding during Also, wiring to UGM may be faulty.
engine cranking). Confirm voltage reading with a multimeter
at UGM connector J8.
LIFT VALVE 449 Lift valve controller detects Y Recharge batteries or check for damaged
VOLTAGE TO supply voltage < 9V for 1 batteries.
LOW second. Verify consistent voltage readings at other
control modules via the Analyzer under
Diagnostics/System Power. If the module
is providing an inconsistent reading, check
for faulty wiring to the module using a
multimeter.
LIFT VALVE 4410 Lift valve controller detects Y May be due to improper battery charging
VOLTAGE TOO supply voltage > 17V for 1 or incorrect voltage batteries being used.
HIGH second. Verify consistent voltage readings at other
Diagnostics/System Power. If
inconsistent, check voltage going into
module. If inconsistent with other modules
or reading on Analyzer, module
replacement may be required.
TELESCOPE 4411 Tele valve controller detects Y Recharge batteries or check for damaged
VALVE supply voltage < 9V for 1 batteries.
VOLTAGE TOO second. Verify consistent voltage readings at other
LOW control modules via the Analyzer under
multimeter.
TELESCOPE 4412 Tele valve controller detects Y May be due to improper battery charging
VALVE supply voltage > 17V for 1 or incorrect voltage batteries being used.
VOLTAGE TOO second. Verify consistent voltage readings at other
HIGH control modules via the Analyzer under

Electrical System

configured) Reset?
FORK VALVE 4413 Fork valve controller detects Y Recharge batteries or check for damaged
VOLTAGE TOO supply voltage < 9V. batteries.
LOW Verify consistent voltage readings at other
multimeter.
FORK VALVE 4414 Fork valve controller detects Y May be due to improper battery charging
VOLTAGE TOO supply voltage > 17V for 1 or incorrect voltage batteries being used.
HIGH second. Verify consistent voltage readings at other
ISP VOLTAGE 4415 ISP controller detects supply Y Recharge batteries or check for damaged
TOO LOW voltage < 9V for 1 second. batteries.
Verify consistent voltage readings at other
multimeter.
ISP VOLTAGE 4416 ISP controller detects supply Y May be due to improper battery charging
TOO HIGH voltage > 17V for 1 second. or incorrect voltage batteries being used.
Verify consistent voltage readings at other
LIFT VALVE COIL 4546 Lift valve controller detects Y Inspect wiring for physical damage.
1 SHORT TO too large of an error between Check for continuity through this circuit.
GROUND OR coil drive current and
OPEN CIRCUIT feedback. Detection shall On the 12-pin valve controller connector,
occur during Startup and verify that the LIFT V1 wire in pin 3 and
Powered Down (into object) LIFT V1 RTN in pin 8 are properly seated,
only. as well as the connections on the V1 coil.
Current Command and Feedback values
may be monitored via the Analyzer under
Diagnostics/Lift Valve to help with the
assessment.

Electrical System

configured) Reset?
TELESCOPE 4554 Tele valve controller detects Y Inspect wiring for physical damage.
VALVE COIL 1 too large of an error between Check for continuity through this circuit.
SHORT TO coil drive current and
GROUND OR feedback. Detection shall On the 12-pin valve controller connector,
OPEN CIRCUIT occur during Startup and verify that the TELE V1 wire in pin 3 and
Tele Out. TELE V1 RTN in pin 9 are properly seated,
as well as the connections on the V1 coil.
Diagnostics/Tele Valve to help with the
assessment.
FORK VALVE 4562 Fork valve controller detects Y Inspect wiring for physical damage.
COIL 1 SHORT too large of an error between Check for continuity through this circuit.
TO GROUND OR coil drive current and
occur during Startup and verify that the FORK V1 wire in pin 3 and
Fork Tilt Up. FORK V1 RTN in pin 7 are properly
seated, as well as the connections on the
FORK V1 coil.
Diagnostics/Fork Valve to help with the
assessment.
AUX VALVE COIL 4566 Fork valve controller detects Y Inspect wiring for physical damage.
FAULT occur during Startup and verify that the AUX V1 wire in pin 5 and
Aux 1. AUX V1 RTN in pin 9 are properly seated,
as well as the connections on the AUX V1
coil.
assessment.
occur during Startup Lift Up/ verify that the LIFT V2 wire in pin 4 and
Down. LIFT V2 RTN in pin 7 are properly seated,
assessment.

Electrical System

configured) Reset?
Tele Retract. TELE V2 RTN in pin 8 are properly seated,
assessment.
FORK VALVE 4564 Fork valve controller detects Y Inspect wiring for physical damage.
COIL 2 SHORT too large of an error between Check for continuity through this circuit.
TO GROUND OR coil drive current and
occur during Startup and verify that the FORK V2 wire in pin 4 and
Fork Tilt Down. FORK V2 RTN in pin 10 are properly
FORK V2 coil.
assessment.
AUX VALVE COIL 4568 Fork valve controller detects Y Inspect wiring for physical damage.
occur during Startup and verify that the AUX V2 wire in pin 6 and
Aux 2. AUX V2 RTN in pin 8 are properly seated,
as well as the connections on the AUX V2
coil.
assessment.
occur during Startup and Lift verify that the LIFT V3 wire in pin 5 and
Up. LIFT V3 RTN in pin 9 are properly seated,
assessment.

Electrical System

configured) Reset?
Tele Retract. TELE V3 RTN in pin 7 are properly seated,
assessment.
occur during Startup and Lift verify that the LIFT V4 wire in pin 6 and
Down. LIFT V4 RTN in pin 10 are properly
V4 coil.
assessment.
Tele Extend. TELE V4 RTN in pin 10 are properly
V4 coil.
assessment.

Electrical System

configured) Reset?
PUMP MANIFOLD 4570 ISP detects too large of an Y Inspect wiring for physical damage.
VALVE SHORT error between coil drive Check for continuity through this circuit.
TO GROUND OR current and feedback.
OPEN CIRCUIT Detected during startup or On the 12-pin ISP controller connector,
during pump command. verify that the PUMP MAN VLV wire in pin
3 and PUMP MAN VLV RTN in pin 10 are
properly seated, as well as the
connections on the Pump Manifold Valve
coil.
Diagnostics/ISP to help with the
assessment.
LIFT RIGHT 4572 ISP detects too large of an Y Inspect wiring for physical damage.
ISOLATION error between coil drive Check for continuity through this circuit.
VALVE SHORT current and feedback.
TO GROUND OR Detected during startup or On the 12-pin ISP controller connector,
OPEN CIRCUIT Lift Down. verify that the RT LIFT ISOL VLV wire in
pin 4 and RT LIFT ISOL VLV RTN in pin 9
are properly seated, as well as the
connections on the Right Lift Isolation
Valve coil.
assessment.
LIFT LEFT 4574 ISP detects too large of an Y Inspect wiring for physical damage.
ISOLATION error between coil drive Check for continuity through this circuit.
VALVE SHORT current and feedback.
TO GROUND OR Detected during startup or On the 12-pin ISP controller connector,
OPEN CIRCUIT Lift Down. verify that the LT LIFT ISOL VLV wire in
pin 5 and LT LIFT ISOL VLV RTN in pin 8
are properly seated, as well as the
connections on the Left Lift Isolation Valve
coil.
assessment.

Electrical System

configured) Reset?
BOOM RIDE 4577 ISP detects too large of an N Inspect wiring for physical damage.
VALVE SHORT error between coil drive Check for continuity through this circuit.
TO GROUND OR current and feedback.
OPEN CIRCUIT Detected during startup or On the 12-pin ISP controller connector,
when entering Boom Ride verify that the BOOM RIDE VLV wire in pin
Mode. 6 and BOOM RIDE VLV RTN in pin 7 are
properly seated, as well as the
connections on the Boom Ride Valve coil .
assessment.
LIFT VALVE COIL 4547 Lift valve controller detects Y Check for continuity through this circuit.
1 SHORT TO uncommanded current in Inspect wiring for physical damage.
BATTERY feedback circuit.
Disconnect Lift V1 coil connection, cycle
power, and verify that fault changes to
DTC 4546 (open circuit); then check the
V1 coil connector/pins and wiring. If the
fault remains, remove the 12-pin
connector and verify the integrity of the
connector pins of both the controller and
harness, then dislodge LIFT V1 RTN pin
from the connector, reconnect the 12-pin
connector, and cycle power. If the fault still
remains, dislodge the LIFT V1 pin,
reconnect, and cycle power. If the fault
persists, continue this pattern until all the
wires are dislodged. If the only wires
remaining are power and CAN Bus and a
STB fault still exists, then the fault lies
within the valve controller and
replacement is necessary.

Electrical System

configured) Reset?

Electrical System

configured) Reset?
TELESCOPE 4555 Tele valve controller detects Y Check for continuity through this circuit.
VALVE COIL 1 uncommanded current in Inspect wiring for physical damage.
SHORT TO feedback circuit.
BATTERY Disconnect TELE V1 coil connection,
cycle power, and verify that fault changes
to DTC 4554 (open circuit); then check the
harness, then dislodge TELE V1 RTN pin
remains, dislodge the TELE V1 pin,

Electrical System

configured) Reset?

Electrical System

configured) Reset?
FORK VALVE 4563 Fork valve controller detects Y Check for continuity through this circuit.
COIL 1 SHORT uncommanded current in Inspect wiring for physical damage.
TO BATTERY feedback circuit.
Disconnect FORK V1 coil connection,
FORK V1 coil connector/pins and wiring.
If the fault remains, remove the 12-pin
harness, then dislodge FORK V1 RTN pin
remains, dislodge the FORK V1 pin,

Electrical System

configured) Reset?
FORK VALVE 4565 Fork valve controller detects Y Check for continuity through this circuit.
COIL 2 SHORT uncommanded current in Inspect wiring for physical damage.
TO BATTERY feedback circuit.
Disconnect FORK V2 coil connection,
FORK V2 coil connector/pins and wiring.
If the fault remains, remove the 12-pin
harness, then dislodge FORK V2 RTN pin
remains, dislodge the FORK V2 pin,
AUX VALVE COIL 4567 Fork valve controller detects Y Check for continuity through this circuit.
Disconnect AUX V1 coil connection, cycle
AUX V1 coil connector/pins and wiring. If
the fault remains, remove the 12-pin
harness, then dislodge AUX V1 RTN pin
remains, dislodge the AUX V1 pin,

Electrical System

configured) Reset?
AUX VALVE COIL 4569 Fork valve controller detects Y Check for continuity through this circuit.
Disconnect AUX V2 coil connection, cycle
AUX V2 coil connector/pins and wiring. If
the fault remains, remove the 12-pin
harness, then dislodge AUX V2 RTN pin
remains, dislodge the AUX V2 pin,
PUMP MANIFOLD 4571 ISP controller detects Y Check for continuity through this circuit.
VALVE SHORT uncommanded current in Inspect wiring for physical damage.
TO BATTERY feedback circuit of the Pump
Manifold coil. Disconnect PUMP MAN VLV coil
connection, cycle power, and verify that
fault changes to DTC 4570 (open circuit);
then check the PUMP MAN VLV coil
connector/pins and wiring. If the fault
remains, remove the 12-pin connector and
verify the integrity of the connector pins of
both the controller and harness, then
dislodge PUMP MAN VLV RTN pin from
the connector, reconnect the 12-pin
remains, dislodge the PUMP MAN VLV
signal pin, reconnect, and cycle power. If
the fault persists, continue this pattern
until all the wires are dislodged. If the only
wires remaining are power and CAN Bus
and a STB fault still exists, then the fault
lies within the controller and replacement
is necessary.

Electrical System

configured) Reset?
LIFT RIGHT 4573 ISP controller detects Y Check for continuity through this circuit.
ISOLATION uncommanded current in Inspect wiring for physical damage.
VALVE SHORT feedback circuit on the right
TO BATTERY Lift Isolation valve coil. Disconnect RT LIFT ISOL VLV coil
then check the RT LIFT ISOL VLV coil
dislodge RT LIFT ISOL VLV RTN pin from
remains, dislodge the RT LIFT ISOL VLV
is necessary.
LIFT LEFT 4575 ISP controller detects Y Check for continuity through this circuit.
ISOLATION uncommanded current in Inspect wiring for physical damage.
VALVE SHORT feedback circuit on the left
TO BATTERY Lift Isolation valve coil. Disconnect LT LIFT ISOL VLV coil
then check the LT LIFT ISOL VLV coil
dislodge LT LIFT ISOL VLV RTN pin from
remains, dislodge the RT LIFT ISOL VLV
is necessary.

Electrical System

configured) Reset?
BOOM RIDE 4577 ISP controller detects N Check for continuity through this circuit.
VALVE SHORT uncommanded current in Inspect wiring for physical damage.
TO BATTERY feedback on the Boom Ride
Mode valve coil. Disconnect BOOM RIDE VLV coil
then check the BOOM RIDE VLV coil
dislodge BOOM RIDE VLV RTN pin from
remains, dislodge the BOOM RIDE VLV
is necessary.
LIFT VALVE 4578 Lift valve controller detects N Cycle power to clear DTC; if DTC is still
PRESSURE too low or high voltage from present, replace controller (Refer to
SENSOR Pressure Sensor 1 or 2. Section 8.8.11, Valve Controllers.).
VOLTAGE OUT CAUTION: HIGH OIL PRESSURE
OF RANGE WITHIN VALVE AND CONTROLLER.
Removing controller may cause cylinder
leakage. Brace/block boom before
removing controller.
TELESCOPE 4579 Tele valve controller detects N Cycle power to clear DTC; if DTC still
VALVE too low or high voltage from present, replace controller (Refer to
PRESSURE Pressure Sensor 1 or 2. Section 8.8.11, Valve Controllers.).
SENSOR CAUTION: HIGH OIL PRESSURE
VOLTAGE OUT WITHIN VALVE AND CONTROLLER.
OF RANGE
FORK VALVE 4580 Fork valve controller detects N Cycle power to clear DTC; if DTC still
PRESSURE too low or high voltage from present, replace controller (Refer to
SENSOR Pressure Sensor 1 or 2. Section 8.8.11, Valve Controllers.).
VOLTAGE OUT CAUTION: HIGH OIL PRESSURE
OF RANGE WITHIN VALVE AND CONTROLLER.

Electrical System

configured) Reset?
ISP PRESSURE 4581 ISP controller detects too N Cycle power to clear DTC; if DTC still
SENSOR low or high voltage from present, replace controller (Refer to
VOLTAGE OUT Pressure Sensor 1 or 2. Section 8.8.11, Valve Controllers.).
OF RANGE CAUTION: HIGH OIL PRESSURE
WITHIN VALVE AND CONTROLLER.
LIFT VALVE 4582 Lift valve controller detects N Cycle power to clear DTC; if DTC still
PRESSURE TOO too high pressure from present, remove controller and clean
HIGH Pressure Sensor 1 or 2. around pressure transducers. Ensure
transducer gaskets are in place and
reinstall/torque in sequence (Refer to
Section 8.8.11, Valve Controllers.). If
fault is still present, controller replacement
is required.
CAUTION: HIGH OIL PRESSURE
VALVE too high pressure from present, remove controller and clean
PRESSURE TOO Pressure Sensor 1 or 2. around pressure transducers. Ensure
HIGH transducer gaskets are in place and
is required.
PRESSURE TOO too high pressure from present, remove controller and clean
HIGH Pressure Sensor 1 or 2. around pressure transducers. Ensure
is required.

Electrical System

configured) Reset?
ISP PRESSURE 4585 ISP controller detects too N Cycle power to clear DTC; if DTC still
TOO HIGH high pressure from Pressure present, remove controller and clean
Sensor 1 or 2. around pressure transducers. Ensure
is required.
TEMPERATURE too low or high voltage from present, controller replacement required.
SENSOR Temperature Sensor 1 or 2. Ensure transducer gaskets are in place
VOLTAGE OUT and reinstall/torque in sequence (Refer to
OF RANGE Section 8.8.11, Valve Controllers.).
VALVE too low or high voltage from present, controller replacement required.
TEMPERATURE Temperature Sensor 1 or 2. Ensure transducer gaskets are in place
SENSOR and reinstall/torque in sequence (Refer to
VOLTAGE OUT Section 8.8.11, Valve Controllers.).
OF RANGE CAUTION: HIGH OIL PRESSURE
TEMPERATURE too low or high voltage from present, controller replacement required.
ISP 4589 ISP controller detects too N Cycle power to clear DTC; if DTC still
TEMPERATURE low or high voltage from present, controller replacement required.

Electrical System

configured) Reset?
TEMPERATURE both Temperature Sensors 1 present, controller replacement required.
DISAGREEMENT and 2 out of range or their Ensure transducer gaskets are in place
readings differ by more than and reinstall/torque in sequence (Refer to
20 C. Section 8.8.11, Valve Controllers.).
VALVE both Temperature Sensors 1 present, controller replacement required.
TEMPERATURE and 2 out of range or their Ensure transducer gaskets are in place
DISAGREEMENT readings differ by more than and reinstall/torque in sequence (Refer to
TEMPERATURE both Temperature Sensors 1 present, controller replacement required.
DISAGREEMENT and 2 out of range or their Ensure transducer gaskets are in place
ISP 4593 ISP controller detects both N Cycle power to clear DTC; if DTC still
TEMPERATURE Temperature Sensors 1 and present, controller replacement required.
DISAGREEMENT 2 out of range or their Ensure transducer gaskets are in place
LIFT VALVE 4594 Lift valve controller detects N Oil is near highest recommended
TEMPERATURE oil temperature greater than operating temperature; slightly reduced
TOO HIGH 100 C machine duty cycle is recommended.
TELESCOPE 4595 Tele valve controller detects N Oil is near highest recommended
VALVE oil temperature greater than operating temperature; slightly reduced
TEMPERATURE 100 C machine duty cycle is recommended.
TOO HIGH

Electrical System

configured) Reset?
FORK VALVE 4596 Lift valve controller detects N Oil is near highest recommended
TEMPERATURE oil temperature greater than operating temperature; slightly reduced
TOO HIGH 100 C. machine duty cycle is recommended.
ISP 4597 ISP controller detects oil N Oil is above highest recommended
TEMPERATURE temperature greater than operating temperature; reduced machine
TOO HIGH 100 C. duty cycle is required. Machine boom
motion is reduced to Medium speed until
temperature decreases.
LIFT VALVE 4598 Lift valve controller detects N Oil is above highest recommended
TEMPERATURE oil temperature greater than operating temperature; reduced machine
MACHINE AT motion is reduced to Medium speed until
CUTBACK temperature decreases.
TELESCOPE 4599 Tele valve controller detects N Oil is above highest recommended
VALVE oil temperature greater than operating temperature; reduced machine
TEMPERATURE 105 C. duty cycle is required. Machine boom
TOO HIGH motion is reduced to Medium speed until
MACHINE AT temperature decreases.
CUTBACK
FORK VALVE 45100 Fork valve controller detects N Oil is above highest recommended
TEMPERATURE oil temperature greater than operating temperature; reduced machine
MACHINE AT motion is reduced to Medium speed until
CUTBACK temperature decreases.
ISP WIRING 45102 The order of the ISP current Y Verify that the proper signal wires are
NOT MAPPED feedback wiring in the 12-pin connected in terminations 3-6 and the
PROPERLY connector does not match proper current feedback wires are
what the controller expects. connected in terminations 7-10 of the 12-
pin connector. Next, check the integrity of
the controller pins and the harness
terminations by removing each socket,
inspecting, and reinserting.
Verify that the proper controller is
installed. Disconnect the Lift, Tele, and
Fork Valve controllers and cycle power.
Under Diagnostics/Versions, verify that
only the UGM, Joystick and ISP are
reporting a software version (??? for the
other controllers).

Electrical System

configured) Reset?
LIFT VALVE 45103 The order of the Lift Valve Y Verify that the proper signal wires are
WIRING NOT current feedback wiring in connected in terminations 3-6 and the
MAPPED the 12-pin connector does proper current feedback wires are
PROPERLY not match what the controller connected in terminations 7-10 of the 12-
expects. pin connector. Check the integrity of the
controller pins and the harness
installed. Disconnect the ISP, Tele Valve,
and Fork Valve controllers and cycle
power. Under Diagnostics/Versions, verify
that only the UGM, Joystick and Lift Valve
are reporting a software version (??? for
the other controllers).
TELESCOPE 45104 The order of the Tele Valve Y Verify that the proper signal wires are
VALVE WIRING current feedback wiring in connected in terminations 3-6 and the
NOT MAPPED the 12-pin connector does proper current feedback wires are
installed. Disconnect the ISP, Lift Valve,
and Fork Valve controllers and cycle
that only the UGM, Joystick and Tele
Valve is reporting a software version (???
for the other controllers).
FORK VALVE 45105 The order of the Fork Valve Y Verify that the proper signal wires are
WIRING NOT current feedback wiring in connected in terminations 3-6 and the
MAPPED the 12-pin connector does proper current feedback wires are
installed. Disconnect the ISP, Lift Valve,
and Tele Valve controllers and cycle
that only the UGM, Joystick and Fork
Valve is reporting a software version (???
for the other controllers).

Electrical System

configured) Reset?
ISP 45401 ISP controller detects oil N Machine is being run with a high duty cycle
TEMPERATURE temperature greater than and the hydraulic oil is hotter than
TOO HIGH 105 C. permitted. Operator should reduce
MACHINE AT machine duty cycle to cool oil. Machine
CUTBACK boom speed will automatically be derated.
CANBUS 666 UGM does not received CAN Y Engine controller not transmitting CAN
FAILURE Bus message from engine Bus messages. Cycle power to see if fault
ENGINE controller within 60ms. clears.
CONTROLLER With power off, disconnect boom cable at
rear of machine. The resistance between
CAN-H and CAN-L should be
approximately 120ohms. Reconnect
boom cable.
Check continuity of connection near
engine controller and at round Deutsch
connector at the interface of engine pod
and chassis.
Check continuity of each power and CAN
Bus wire going to engine controller from
cab area. Conduct a visual check of the
pin and socket terminations for each wire
to ensure good integrity.
CANBUS 6613 More than 22 error frames N CAN Bus faults are excessive.
FAILURE per second for 4 seconds or Degradation and intermittent machine
EXCESSIVE more than 500 Buss Off operation is likely. CAN Bus connections
CANBUS conditions since last power need to be checked thoroughly. To assist
ERRORS cycle. with the troubleshooting efforts, the
Terminator in the Boom Head can be
removed and inserted at the engine
controller connection. This will cause CAN
loss errors for the boom controllers, but
will enable the machine to be divided to
determine whether this improves the
number of CAN Bus errors.

Electrical System

configured) Reset?
CANBUS 6617 UGM has not received a Y Cycle power to see if fault clears.
FAILURE CAB Main Joystick CAN Bus With engine off but power on, verify with a
JOYSTICK message within 60ms. multimeter that approximately 12V is
present across power and ground
connections of the cab harness pins.
With power off, verify with a multimeter
that the resistance between CAN-H and
CAN-L wire of the joystick is
approximately 120ohms.
Verify the integrity of the joystick
connector pins.
Reconnect joystick and cycle power to see
if fault clears. If fault is still present and
boom needs moved, use the Analyzer to
command boom functions under
DIAGNSTICS/DEBUG/CAB JYSTK SIM.
CANBUS 6621 UGM has not received Left Y Cycle power to see if fault clears. If
FAILURE BOOM Boom Angle Sensor CAN multiple CAN Bus faults are occurring, the
ANGLE SENSOR Bus message within 60ms. integrity of connections and continuity of
the entire CAN Bus must be checked.
Otherwise, plug and unplug each end of
the Boom Angle cable, both at the sensor
and CAN Distribution module. Verify
integrity of pins and that none are bent
within the small round M12 connector. If
fault still exists after cycling power,
disconnect cable at Boom Length sensor
end and connect to Left Boom Angle
sensor. If Boom Angle CAN Bus fault still
exists (Boom Length CAN Bus fault will
also be present since that sensor is
disconnected), then Boom Angle sensor
can be considered suspicious. If fault
clears, then try Boom Length cable at
connection occupied by Boom Angle
sensor to verify the integrity of CAN
Distribution module. If successful, replace
Boom Angle cable.
Check sensor for damage.

Electrical System

configured) Reset?
FAILURE BOOM Boom Angle Sensor CAN multiple CAN Bus faults are occurring, the
LENGTH Bus message within 120ms. integrity of connections and continuity of
SENSOR the entire CAN Bus must be checked.
Otherwise, plug and unplug each end of
the Boom Length cable, both at the sensor
and CAN Distribution module. Verify
integrity of pins and that none are bent
within the small round M12 connector. If
fault still exists after cycling power,
disconnect cable at Boom Angle sensor
and connect to Boom Length sensor (may
need to unbolt length sensor). If Boom
Length CAN Bus fault still exists (Boom
Angle CAN Bus fault will also be present
since that sensor is disconnected), then
Boom Length sensor can be considered
suspicious. If fault clears, then try Boom
Angle cable at connection occupied by
Boom Length sensor to verify the integrity
of CAN Distribution module. If successful,
replace Boom Length cable.
Check sensor for damage.
FAILURE FORK Boom Angle Sensor CAN multiple CAN Bus faults are occurring, the
SENSOR Bus message within 60ms. integrity of connections and continuity of
the entire CAN Bus must be checked.
Otherwise, unplug the Fork sensor and
with a multimeter verify approximately
60ohms between CAN-H and CAN-L in
the machine harness. Turn power on a
verify +12V between power and ground
pins. Also, verify that the ground pin has
less than 1.0ohms resistance to a good
chassis (B-) connection. Turn power off,
reconnect Fork sensor and power on. If
fault still exists, check connections for
Fork sensor. Remove the 4 screws
holding the sensor and firmly, but gently
wiggle the connector forward to get to the
back of the 4-pin Deutsch connector.
Remove each pin and check the integrity
of the terminations. Prior to reinserting into
cylinder, sealant must be applied in back
of connector flange to prevent water
intrusion.

Electrical System

configured) Reset?
CANBUS 6626 ISP communicates Y Cycle power to see if fault clears.

FAILURE LIFT SPN/FMI: 2161/11 If multiple CAN Bus faults are occurring,
VALVE the integrity of connections and continuity
of the entire CAN Bus must be checked.
Otherwise, with power off, unplug the Lift
Valve and with a multimeter verify
approximately 60ohms between CANH
and CANL in the machine harness. Turn
power on a verify +12V between power
and ground pins. Also, verify that the
ground pin has less than 1.0ohms
resistance to a good chassis (B-)
connection. Turn power off, reconnect Lift
Valve, and power on. If fault still exists,
unplug connector to Lift Valve and verify
the connectivity in the 12-pin Deutsch
connector. Remove the wedge and pull
each termination back past the rubber
seal. Lightly tug on each wire and inspect
the crimp.
Check the integrity of the M12 connector
termination at the green CAN Distribution
module. Disconnect, clean, and
reconnect. Do not add dielectric grease,
as the pins may not engage properly. The
spare connection in the CAN Distribution
module may also be used as a means to
verify connectivity of the M12 connector.
The functionality of the system will remain
unchanged if the spare M12 connection is
used.
Note: Although similar, the Lift Valve and
Tele Valve harnesses are not directly
interchangeable for troubleshooting
purposes because the current feedback
wires populate different connector pins.

Electrical System

configured) Reset?

FAILURE SPN/FMI: 2162/11 If multiple CAN Bus faults are occurring,
TELESCOPE the integrity of connections and continuity
VALVE of the entire CAN Bus must be checked.
Otherwise, with power off, unplug the Tele
power on a verify +12V between power
connection. Turn power off, reconnect
Tele Valve, and power on. If fault still
exists, unplug connector to Tele Valve and
verify the connectivity in the 12-pin
Deutsch connector. Remove the wedge
and pull each termination back past the
rubber seal. Lightly tug on each wire and
inspect the crimp.
Check the integrity of the M12 connector
termination at the green CAN Distribution
module. Disconnect, clean, and
reconnect. Do not add dielectric grease,
as the pins may not engage properly. The
spare connection on the CAN Distribution
module may also be used as a means to
verify integrity of the M12 connection. The
functionality of the system will remain
unchanged if the spare M12 connection is
used.
Note: Although similar, the Lift Valve and
Tele Valve harnesses are not directly
interchangeable for troubleshooting
purposes because the current feedback
wires populate different connector pins.

Electrical System

configured) Reset?

FAILURE FORK SPN/FMI: 2163/11 If multiple CAN Bus faults are occurring,
VALVE the integrity of connections and continuity
Otherwise, with power off, unplug the Fork
power on and verify +12V between power
connection. Turn power off, reconnect
Fork Valve, and power on. If fault still
exists, unplug connector to Fork Valve
and verify the connectivity in the 12-pin
Deutsch connector. Remove the wedge
inspect the crimp.
CANBUS 6629 An excessive number of N This fault may cause an inoperable
FAILURE messages are being joystick. Disconnect the Telematics
TELEMATICS broadcast from the Control Unit from CAN2. If fault still exists,
LOADING TOO Telematics Control Unit. check power and CAN connections within
HIGH CAN2 cab harness.
CANBUS 6630 UGM has not received a Y Cycle power to see if fault clears.
FAILURE ISP CAN Bus message from the If multiple CAN Bus faults are occurring,
ISP within 60ms. the integrity of connections and continuity
Otherwise, with power off, unplug the ISP
and with a multimeter verify approximately
60ohms between CANH and CANL in the
machine harness. Turn power on and
pins. Also, verify that the ground pin has
less than 1.0ohms resistance to a good
chassis (B-) connection. Turn power off,
reconnect ISP, and power on. If fault still
exists, unplug connector to ISP and verify
the connectivity in the 12-pin Deutsch
connector. Remove the wedge and pull
each termination back past the rubber
seal. Lightly tug on each wire and inspect
the crimp.

Electrical System

configured) Reset?
CHASSIS TILT 813 Out-of-range default offset Y Calibrate tilt sensor.

SENSOR NOT value not overwritten. Refer to Section 9.15.5, Calibrations.
CALIBRATED
CHASSIS TILT 814 Sensor reads outside range Y Fault will occur if machine is physically
SENSOR OUT OF of -25 < X < 25 for 2 angled beyond its permitted ranges.
RANGE seconds. Otherwise, the tilt sensor located within
the UGM may be suspect.
Cycle power to see if fault clears.
Calibrate tilt sensor, if necessary. Refer to
CHASSIS TILT 815 (Sensor 1 reading Sensor Y Fault may occur if operating under
SENSOR 2 reading) >= 3.0 for 5 extremely rough conditions.
DISAGREEMENT seconds. Cycle power to see if fault clears.
Otherwise, calibrate tilt sensor.
BOOM ANGLE 841 Boom Angle Left and Right Y Check that sensors are securely mounted
SENSOR sensors disagree by more and not damaged or bent. Verify all
DISAGREEMENT than the allowed amount set hardware is tight. Lift boom through range
in Personalities for more to verify tracking of sensors via Analyzer
than 2 seconds or greater under Diagnostics/Boom Components..
than 10 degrees for 40ms. If tracking appears to be slightly off,
calibrate Boom Angle sensor. Refer to
BOOM ANGLE 8455 Calibrated Left Boom Angle Y Check that sensors are securely mounted
SENSOR LEFT less than -15 for more than and not damaged or bent. Verify all
OUT OF RANGE 2 seconds. hardware is tight. Lift boom through range
LOW to verify Left Boom Angle tracks smoothly
via Analyzer under Diagnostics/Boom
Components.
If tracking appears to be slightly off,
calibrate boom angle sensors. Refer to
BOOM ANGLE 8456 Calibrated Left Boom Angle Y Check that sensors are securely mounted
SENSOR LEFT greater than +85 for more and not damaged or bent. Verify all
OUT OF RANGE than 2 seconds. hardware is tight. Lift boom through range
HIGH to verify Left Boom Angle tracks smoothly
via Analyzer under Diagnostics/Boom
Components.
9.100 G10-55A & G12-55A AccuPlace

Electrical System

configured) Reset?
BOOM ANGLE 8457 Calibrated Right Boom Y Check that sensors are securely mounted
SENSOR RIGHT Angle less than -15 for more and not damaged or bent. Verify all
OUT OF RANGE than 2 seconds. hardware is tight. Lift boom through range
LOW to verify Right Boom Angle tracks
smoothly via Analyzer under Diagnostics/
Boom Components.
Disconnect sensor, turn power on, and
pins. Also, with power off, verify that the
unplug connector to Right Boom Angle
sensor and verify the connectivity in the 3-
pin AMP connector. Remove the wedge
inspect the crimp.
BOOM ANGLE 8458 Calibrated Right Boom Y Check that sensors are securely mounted
SENSOR RIGHT Angle greater than +85 for and not damaged or bent. Verify all
OUT OF RANGE more than 2 seconds. hardware is tight. Lift boom through range
HIGH to verify Right Boom Angle tracks
Boom Components.
Disconnect sensor, turn power on, and
pins. Also, with power off, verify that the
unplug connector to Right Boom Angle
sensor and verify the connectivity in the 3-
pin AMP connector. Remove the wedge
inspect the crimp.
G10-55A & G12-55A AccuPlace 9.101

Electrical System

configured) Reset?
BOOM LENGTH 8459 Absolute Telescope Length Y Check that sensor is securely mounted
SENSOR OUT less than 218 counts (approx and not damaged. Verify all hardware is
OF RANGE LOW 1) for more than 2 seconds. tight. Extend boom through range to verify
Tele Length tracks smoothly via Analyzer
under Diagnostics/Boom Components.
calibrate boom length sensor. Refer to
BOOM LENGTH 8460 Absolute Telescope Length Y Check that sensor is securely mounted
SENSOR OUT greater than 65098 counts and not damaged. Verify all hardware is
OF RANGE HIGH (approx 298) for more than tight. Extend boom through range to verify
2 seconds. Tele Length tracks smoothly via Analyzer
calibrate boom length sensor. Refer to
FORK POSITION 8461 Calibrated Fork Angle less Y A cylinder that has been bent or
SENSOR OUT than -120 for more than 2 undergone severe shock may exhibit this
OF RANGE LOW seconds. error.
Move forks through range to verify Fork
Length tracks smoothly via Analyzer
calibrate fork sensor. Refer to Section
9.15.5, Calibrations.
FORK POSITION 8462 Calibrated Fork Angle Y A cylinder that has been bent or
SENSOR OUT greater than +30 for more undergone severe shock may exhibit this
OF RANGE HIGH than 2 seconds. error.
Move forks through range to verify Fork
Length tracks smoothly via Analyzer
calibrate fork sensor. Refer to Section
9.15.5, Calibrations.
9.102 G10-55A & G12-55A AccuPlace

Electrical System

configured) Reset?
BOOM ANGLE 8463 Controls determine the Y Fault may occur from a stalled boom.
SENSOR NOT boom has a slow response Cycle power to see if fault clears.
DETECTING to commands.
CHANGE Check that sensors are securely mounted
and not damaged or bent. Verify all
hardware is tight.
Lift boom through range to verify Left and
Right Boom Angle sensors are tracking
Boom Components.
If not tracking well, calibrate boom angle
sensors.
Refer to Section 9.15.5, Calibrations.
BOOM LENGTH 8464 Out-of-range default offset N Check that boom length sensor is securely
SENSOR NOT value not overwritten. mounted and undamaged.
CALIBRATED Calibrate boom length sensor. Refer to
FORK POSITION 8465 Out-of-range default offset N Calibrate fork sensor. Refer to Section
SENSOR NOT value not overwritten. 9.15.5, Calibrations.
CALIBRATED
NEW BOOM 8466 UGM determines that Boom N Calibrate boom length sensor. Refer to
LENGTH Length Sensor serial number Section 9.15.5, Calibrations.
SENSOR differs from the sensor used
DETECTED for last calibration.
NEW FORK 8467 UGM determines that Fork N Calibrate fork sensor. Refer to Section
POSITION Sensor serial number differs 9.15.5, Calibrations.
SENSOR from the sensor used for last
DETECTED calibration.
BOOM LENGTH 8468 Controls determine slow Y Fault may occur from a stalled boom.
SENSOR - NOT response to commands. Not Cycle power to see if fault clears.
DETECTING reported if cab joystick not
CHANGE commanding motion. Check that boom length sensor is securely
mounted and undamaged. Verify all
hardware is tight.
Extend boom through range to verify Tele
Length sensor is tracking smoothly via
Analyzer under Diagnostics/Boom
Components.
If not tracking well calibrate boom length
sensor.
Refer to Section 9.15.5, Calibrations.
G10-55A & G12-55A AccuPlace 9.103

Electrical System

configured) Reset?
FORK POSITION 8469 Controls determine slow Y If not tracking well calibrate fork sensor.
SENSOR - NOT response to commands. Not Refer to Section 9.15.5, Calibrations.
DETECTING reported if cab joystick not
CHANGE commanding motion.
BOOM LIFT 8470 Controls determine too fast Y Fault generally occurs for an overrunning
OVERSPEED boom motion for commands. load or when the machine is used outside
Not reported if cab joystick of its intended operating parameters.
not commanding motion. Cycle power to see if fault clears.
If fault still exists after motion is
commanded, check integrity of Boom
Angle sensors.
TELESCOPE 8471 Controls determine too fast Y Fault generally occurs for an overrunning
OVERSPEED Telescope motion for load or when the machine is used outside
commands. Not reported if of its intended operating parameters.
cab joystick not commanding Cycle power to see if fault clears.
motion.
commanded, check integrity of Boom
Length sensor.
FORK 8472 Controls determine too fast Y Fault generally occurs for an overrunning
OVERSPEED boom motion for commands. load or when the machine is used outside
Not reported if cab joystick of its intended operating parameters.
not commanding motion. Cycle power to see if fault clears.
commanded, check integrity of Fork
Position sensor.
WRONG LIFT 8414 Controls determine motion Y Fault may indicate improper electrical or
RESPONSE direction opposite the hydraulic connections after a repair.
commanded direction for Cycle power to see if fault clears.
more than 1 second. Not
reported if cab joystick not If fault still exists after motion is
commanding motion. commanded, check connections and
integrity of Boom Angle sensors.
WRONG 8413 Controls determine motion Y Fault may indicate improper electrical or
TELESCOPE direction opposite the hydraulic connections after a repair.
RESPONSE commanded direction for Cycle power to see if fault clears.
reported if cab joystick not If fault still exists after motion is
integrity of Boom Length sensor.
9.104 G10-55A & G12-55A AccuPlace

Electrical System

configured) Reset?
WRONG FORK 8473 Controls determine motion Y Fault may indicate improper electrical or
RESPONSE direction opposite the hydraulic connections after a repair.
commanded direction for Cycle power to see if fault clears.
reported if cab joystick is not If fault still exists after motion is
integrity of Fork Position sensor.
FORK POSITION 8474 Fault indicates that the Fork Y Cycle power to see if fault clears.
SENSOR Position sensor has
EEPROM FAULT observed an internal error
with its stored memory.
SENSOR Position sensor can not Move forks through range, cycling power
MAGNET NOT detect the presence of its periodically, to determine whether sensor
DETECTED positioning magnet. This can detect magnet at any cylinder
FAULT may occur if the magnet position.
inside the cylinder has been
damaged.
SENSOR Position sensor is having Move forks through range, cycling power
MULTIPLE problems with the sensing of periodically, to determine whether sensor
MAGNETS its positioning magnet. This can properly detect a single magnet at any
may occur if the magnet cylinder position.
inside the cylinder has been
damaged.
FORK POSITION 8477 Fault indicates that the Y Cycle power to see if fault clears.
SENSOR positioning magnet of the This fault may be exhibited on rare
MAGNET BELOW Fork Position sensor is near occasions when exchanging carriages.
WORKING LIMIT the low limit of its linear
sensing range.
SENSOR positioning magnet of the
MAGNET ABOVE Fork Position sensor is near
WORKING LIMIT the high limit of its linear
sensing range.
SENSOR positioning magnet of the Move forks through range, cycling power
MAGNET BELOW Fork Position sensor is periodically, to determine whether sensor
LOWEST outside of its linear sensing can properly detect position magnet at any
WORKING LIMIT range. cylinder position.
G10-55A & G12-55A AccuPlace 9.105

Electrical System

configured) Reset?
SENSOR positioning magnet of the Move forks through range, cycling power
MAGNET ABOVE Fork Position sensor is periodically, to determine whether sensor
HIGHEST outside of its linear sensing can properly detect position magnet at any
WORKING LIMIT range. cylinder position.
FORK POSITION 8481 Fault occurs if Fork Position Y Cycle power to see if fault clears.
SENSOR DATA sensor reports invalid data or If fault is present while no command
INVALID UGM computes an exists, then move forks through range,
abnormally large rate of cycling power periodically, to determine
change in the Fork Position whether sensor can properly detect the
sensor reading. position magnet at any cylinder position.
If fault exists while joystick command is
present, the UGM is computing larger than
expected changes in Fork velocity. Move
the forks through the range and observe
how the reported position tracks via the
Analyzer under DIAGNOSTICS/BOOM
COMPONENTS.
BOOM ANGLE 8489 UGM computes an Y Cycle power to see if fault clears.
SENSOR DATA abnormally large rate of Lift the Boom through the range and
INVALID change in the Left Boom observe how the reported angular position
Angle sensor reading. tracks via the Analyzer under
DIAGNOSTICS/BOOM COMPONENTS.
The Left Boom Angle sensor reading
should track the Right Boom Angle
reading, as well as, roughly tracking the
Boom Angle Indicator pointer.
BOOM LENGTH 8490 UGM computes an Y Cycle power to see if fault clears.
SENSOR DATA abnormally large rate of Extend the Boom through the range and
INVALID change in the Boom Length observe how the reported length tracks via
sensor reading. the Analyzer under DIAGNOSTICS/
BOOM COMPONENTS.
9.106 G10-55A & G12-55A AccuPlace

Electrical System

configured) Reset?
CHASSIS TILT 9915 Gain calibrations not Y Cycle power to see if fault clears.
SENSOR NOT properly set at factory. Calibrate tilt sensor. Refer to Section
GAIN 9.15.5, Calibrations. If tilt sensor will not
CALIBRATED calibrate, record all Machine Setup and
Personality parameters. Next, toggle
model from existing model to another
machine model and back. This will
effectively set EEPROM values to default.
Adjust the Machine Setup and Personality
parameters to previous values. If fault
persists, UGM replacment is required.
If Chassis Tilt sensor will not calibrate or
fault still exists after calibration and
resetting of EEPROM, UGM replacement
is required.
CHASSIS TILT 9916 Gain calibration at factory Y Cycle power to see if fault clears.
SENSOR GAIN outside acceptable range. Calibrate tilt sensor. Refer to Section
OUT OF RANGE 9.15.5, Calibrations. If tilt sensor will not
calibrate, record all Machine Setup and
Personality parameters. Next, toggle
model from existing model to another
If Chassis Tilt sensor will not calibrate or
fault still exists after calibration and
resetting of EEPROM, UGM replacement
is required.
FUNCTIONS 9981 Lift valve controller has N Software update required.
LOCKED OUT incompatible software
LIFT VALVE version.
SOFTWARE
VERSION
IMPROPER2
FUNCTIONS 9982 Telescope valve controller N Software update required.
LOCKED OUT has incompatible software
TELESCOPE version.
VALVE
SOFTWARE
VERSION
IMPROPER2
G10-55A & G12-55A AccuPlace 9.107

Electrical System

configured) Reset?
FUNCTIONS 9983 Fork valve controller has N Software update required.

FORK VALVE version.
SOFTWARE
VERSION
IMPROPER2
FUNCTIONS 9984 ISP controller has N Software update required.
ISP SOFTWARE version.
VERSION
IMPROPER2
FUNCTIONS 9985 Joystick software version N Verify proper UGM software; then replace
LOCKED OUT improper. joystick.
CAB JOYSTICK
SOFTWARE
VERSION
IMPROPER2
CAB JOYSTICK 9976 Joystick has observed an N Cycle power to see if fault clears.
INTERNAL internal hardware fault or If faults persists, replace joystick.
FAILURE inconsistency.
EEPROM 998 Controls have detected Y Cycle power to see if fault clears.
FAILURE corruption in the UGM If fault persists, record all Machine Setup
CHECK ALL EEPROM settings. and Personality parameters. Next, toggle
SETTINGS model from existing model to another
parameters to previous values.
GROUND 9986 VLow FET determined to N Cycle power to see if fault clears.
MODULE VLOW have failed on startup. UGM This fault indicates internal hardware
FET FAILURE is unable to read high- failure and may require UGM
sensing digital inputs. replacement.
INCOVA 9987 The UGM to INCOVA Setup N This fault may occur when the CAN Bus
MACHINE SETUP data was not successfully communications are of poor quality.
DATA NOT written to ISP, Lift, Tele, and Cycle power to see if fault clears.
WRITTEN Fork Valves at startup.
Check the amount of CAN1 traffic and
errors via the Analyzer under
DIAGNOSTICS/CAN STATISTICS.
Expected ranges of values are CAN1 Rx/
s ~ 600-700; CAN1 Tx/s ~ 100-150; CAN1
ERR F/S = 0. Troubleshoot CAN Bus if
errors are present or transmit/receive
values are suspect.
9.108 G10-55A & G12-55A AccuPlace

Electrical System

configured) Reset?
INCOVA 9988 The UGM to ISP Calibration Y This fault may occur when the CAN Bus
CALIBRATION data was not successfully communications are of poor quality.
DATA NOT written to ISP. Cycle power to see if fault clears.
WRITTEN
s ~ 600-700; CAN1 Tx/s ~ 100-150; CAN1
values are suspect.
INCOVA 9989 The UGM to ISP Y This fault may occur when the CAN Bus
PERSONALITIES Personalities data was not communications are of poor quality.
NOT WRITTEN successfully written to ISP. Cycle power to see if fault clears.
s ~ 600-700; CAN1 Tx/s ~ 100-150; CAN1
values are suspect.
G10-55A & G12-55A AccuPlace 9.109

Electrical System

configured) Reset?
INCOVA 9990 INCOVA Parameter/Data N This fault is a result of system controllers

PARAMETER Check not successful. computing different boom positions or
CHECK NOT velocities. This fault may occur when the
SUCCESSFUL CAN Bus communications are of poor
quality, if suspect sensor values are being
transmitted, or if the machine has
experienced abnormally rapid or
unexpected boom movements.
s ~ 600-700; CAN1 Tx/s ~ 100-150; CAN1
values are suspect.
Verify the controllers are computing
similar sensor values via the Analyzer
under DIAGNOSTICS/BOOM
COMPONENTS. Check that the ISP
BOOM ANGLE, ISP BOOM LENGTH,
AND ISP FORK ANGLE correlate well
(angles +/-4deg; length +/-8") with the
BOOM ANGLE LEFT, TELE LENGTH,
and FORK ANGLE respectively.
CURRENT 9944 The UGM factory set current Y Cycle power to see if fault clears.
FEEDBACK feedback gains are out of If fault persists, record all Machine Setup
GAINS OUT OF range. and Personality parameters. Next, toggle
RANGE model from existing model to another
CURRENT 9945 The factory set current Y Cycle power to see if fault clears.
FEEDBACK feedback check sum is not If fault persists, record all Machine Setup
CALIBRATION correct. and Personality parameters. Next, toggle
CHECKSUM model from existing model to another
INCORRECT machine model and back. This will
persists, UGM replacement is required.
9.110 G10-55A & G12-55A AccuPlace

31200452
An Oshkosh Corporation Company
JLG Industries, Inc.

1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: +1-717-485-5161
Customer Support Toll Free: 1-877-554-5438
Fax: +1-717-485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester Phone: +33 (0)5 53 88 31 70
Australia Phone: +55 193 295 0407 M24 2GP Fax: +33 (0)5 53 88 31 79
Phone: +61 265 811 111 Fax: +55 193 295 1025 England
Fax: +61 265 810 122 Phone: +44 (0)161 654 1000
Fax: +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude-lhlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Germany Sheung Shui N.T. Italy The Netherlands
Phone: +49 (0)421 69 350 20 Hong Kong Phone: +39 029 359 5210 Phone: +31 (0)23 565 5665
Fax: +49 (0)421 69 350 45 Phone: +852 2639 5783 Fax: +39 029 359 5845 Fax: +31 (0)23 557 2493
Fax: +852 2639 5797
JLG Polska JLG Industries (Scotland) Plataformas Elevadoras JLG Sverige AB

UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
Poland Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 176 27 Jarfalla
Phone: +48 (0)914 320 245 Scotland 08755Castellbisbal, Barcelona Sweden
Fax: +48 (0)914 358 200 Phone: +44 (0)141 781 6700 Spain Phone: +46 (0)850 659 500
Fax: +44 (0)141 773 1907 Phone: +34 93 772 4 700 Fax: +46 (0)850 659 534
Fax: +34 93 771 1762

Service - JLG Telehandler Service Manual - English

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service - JLG Telehandler Service Manual - English

Uploaded by

Copyright:

Available Formats

Service Manual

An Oshkosh Corporation Company

January 20, 2009 - A - Original Issue Of Manual

31200452 G10-55A & G12-55A AccuPlace i

-ii G10-55A & G12-55A AccuPlace 31200452

G10-55A & G12-55A AccuPlace i

5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

ii G10-55A & G12-55A AccuPlace

PARAGRAPH TITLE PAGE

G10-55A & G12-55A AccuPlace 1.1

1.1 INTRODUCTION 1.2 DISCLAIMER

1.2 G10-55A & G12-55A AccuPlace

1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

1.6.2 Equipment Hazards

G10-55A & G12-55A AccuPlace 1.3

1.6.3 General Hazards appropriate container and dispose of in accordance with

1.4 G10-55A & G12-55A AccuPlace

PARAGRAPH TITLE PAGE

G10-55A & G12-55A AccuPlace 2.1

2.1 REPLACEMENT PARTS AND

Note: The replacement of any part on this machine with

2.2 G10-55A & G12-55A AccuPlace

G10-55A & G12-55A AccuPlace

Note: These torque values do not apply to cadmium plated fasteners.

14 0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104

Note: These torque values do not apply to cadmium plated fasteners.

G10-55A & G12-55A AccuPlace

2.2.3 Metric Fastener Torque Chart

Note: These torque values do not apply to cadmium plated fasteners.

METRIC CLASS 8.8 METRIC CLASS 10.9

G10-55A & G12-55A AccuPlace 2.5

2.3.1 Travel Speeds

2.3.2 Electrical System

2.3.3 Engine Performance Specifications

Description G10-55A G12-55A

2.6 G10-55A & G12-55A AccuPlace

Size Tire Type Minimum Ply/ Fill Type Pressure

Size Tire Type Minimum Ply/ Fill Type Pressure

G10-55A & G12-55A AccuPlace 2.7

2.4 FLUID AND LUBRICANT CAPACITIES

Engine Crankcase Oil

2.8 G10-55A & G12-55A AccuPlace

2.5 SERVICE AND MAINTENANCE

2.5.1 10, 1st 100 & 50 Hour

Check Check Hydraulic Check Auto-

Change Change Wheel Change Engine Change Change

Check Wheel Check Boom

Drain Fuel/ Check Engine Check Lubrication

G10-55A & G12-55A AccuPlace 2.9

2.5.2 250, 500, 1000 & 1500 Hour

Change Engine Check Axle Check Wheel Air Filter Check

Check Boom Check Boom Check Transfer Check Rear Axle

Change Fuel Check Wheel

Change Change Change Change Wheel

Change Change Change

2.10 G10-55A & G12-55A AccuPlace

2.6 LUBRICATION SCHEDULES

G10-55A & G12-55A AccuPlace 2.11

2.12 G10-55A & G12-55A AccuPlace

PARAGRAPH TITLE PAGE

G10-55A & G12-55A AccuPlace 3.1

3.1 BOOM SYSTEM COMPONENT

ATTACHMENT BOOM HYDRAULIC